What is Air Tightness Testing for EV Battery Cold Plates
2026-05-25
.gtr-container-7x9y2z {
font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif;
color: #333;
line-height: 1.6;
padding: 15px;
box-sizing: border-box;
overflow-x: auto;
}
.gtr-container-7x9y2z * {
box-sizing: border-box;
}
.gtr-container-7x9y2z .gtr-title-main {
font-size: 18px;
font-weight: bold;
color: #0E49BB;
margin-top: 25px;
margin-bottom: 15px;
text-align: left;
}
.gtr-container-7x9y2z .gtr-title-sub {
font-size: 16px;
font-weight: bold;
color: #333;
margin-top: 20px;
margin-bottom: 10px;
text-align: left;
}
.gtr-container-7x9y2z p {
font-size: 14px;
margin-bottom: 15px;
text-align: left !important;
line-height: 1.6;
}
.gtr-container-7x9y2z ul,
.gtr-container-7x9y2z ol {
margin-bottom: 15px;
padding-left: 20px;
}
.gtr-container-7x9y2z ul {
list-style: none !important;
padding-left: 25px;
}
.gtr-container-7x9y2z ul li {
position: relative;
margin-bottom: 8px;
font-size: 14px;
text-align: left !important;
line-height: 1.6;
list-style: none !important;
}
.gtr-container-7x9y2z ul li::before {
content: "•" !important;
color: #0E49BB;
font-size: 18px;
position: absolute !important;
left: -20px !important;
top: -2px;
}
.gtr-container-7x9y2z ol {
list-style: none !important;
counter-reset: list-item;
padding-left: 25px;
}
.gtr-container-7x9y2z ol li {
position: relative;
margin-bottom: 8px;
font-size: 14px;
text-align: left !important;
line-height: 1.6;
list-style: none !important;
counter-increment: none;
}
.gtr-container-7x9y2z ol li::before {
content: counter(list-item) "." !important;
color: #0E49BB;
font-weight: bold;
position: absolute !important;
left: -25px !important;
width: 20px;
text-align: right;
}
.gtr-container-7x9y2z img {
display: block;
margin: 20px auto;
height: auto;
}
.gtr-container-7x9y2z .gtr-advantages,
.gtr-container-7x9y2z .gtr-disadvantages {
margin-bottom: 10px;
font-size: 14px;
text-align: left !important;
line-height: 1.6;
}
.gtr-container-7x9y2z .gtr-advantages strong,
.gtr-container-7x9y2z .gtr-disadvantages strong {
color: #0E49BB;
}
@media (min-width: 768px) {
.gtr-container-7x9y2z {
padding: 25px 40px;
}
.gtr-container-7x9y2z .gtr-title-main {
margin-top: 30px;
margin-bottom: 20px;
}
.gtr-container-7x9y2z .gtr-title-sub {
margin-top: 25px;
margin-bottom: 15px;
}
.gtr-container-7x9y2z p {
margin-bottom: 18px;
}
.gtr-container-7x9y2z ul,
.gtr-container-7x9y2z ol {
margin-bottom: 18px;
}
.gtr-container-7x9y2z ul li,
.gtr-container-7x9y2z ol li {
margin-bottom: 10px;
}
}
Introduction
Power batteries serve as the core energy component for electric vehicles and energy storage systems. Massive heat generates during charging and discharging cycles. Insufficient heat dissipation will trigger battery performance degradation, shortened service life, and even severe thermal runaway hazards. Liquid cooling stands out as a mainstream thermal management solution thanks to its efficient and uniform heat dissipation performance.
Aluminum cold plates, commonly fabricated from 3003, 5052 and other aluminum alloys via stamping, brazing and friction stir welding, are critical heat transfer components inside liquid cooling systems. Internal intricate flow channels allow circulating coolant to absorb heat from battery modules steadily. Therefore, cold plates must maintain complete airtightness and pressure resistance. Even tiny leaks will cause severe consequences:
Coolant loss leads to sharply reduced heat dissipation and battery overheating
Conductive ethylene glycol coolant may contact high-voltage terminals and cause short circuits
Overall battery pack failure and failure to meet IP67 dustproof and waterproof standards
Air tightness testing acts as an indispensable final inspection procedure in cold plate manufacturing, safeguarding product quality and operational safety.
Mainstream Air Tightness Testing Methods
2.1 Pressure Decay Method
This is the most widely adopted and highly automated testing solution. Dry compressed air or nitrogen is injected into sealed cold plates until preset pressure such as 250kPa is reached. The system then enters pressure holding phase. High-precision sensors monitor real-time pressure fluctuations. Pressure drop within designated holding duration, typically 30 seconds, determines leakage status.
Advantages: Fast testing speed, quantitative results, non-destructive inspection, easy integration into automated production lines, objective judgment
Disadvantages: Unable to pinpoint leakage locations; testing accuracy affected by ambient temperature and workpiece deformation
Direct Pressure Type: Measures internal pressure variation directly with low equipment cost
Differential Pressure Type: Compares pressure difference between tested workpiece and standard reference part. It eliminates interference from ambient temperature and pressure fluctuation, delivering superior detection precision for high-standard requirements.
2.2 Water Immersion Bubble Test
A traditional intuitive testing approach. Pressurized cold plates are fully submerged in water. Operators observe bubble generation to identify exact leakage positions.
Advantages: Simple operation, low cost, accurate leak positioning
Disadvantages: Low testing efficiency, subjective judgment, mandatory post-test drying process, incapable of detecting micro leakage. Mainly applied for random inspection, laboratory verification and leak troubleshooting.
2.3 Helium Mass Spectrometer Leak Detection
It features top-tier detection accuracy in the industry. Helium gas owns tiny molecular size, strong penetration and extremely low natural atmospheric concentration, serving as ideal tracer gas.
Vacuum Chamber Method: Place cold plate into vacuum chamber. Inject helium internally after vacuum pumping. Escaped helium is captured and analyzed by spectrometer.
Sniffer Probe Method: Fill cold plate with helium and scan welding seams and joints with sniffer probe to locate micro leakage points precisely.
Advantages: Ultra-high sensitivity up to 10⁻⁹ Pa·m³/s, accurate leak rate quantification, micro leak positioning
Disadvantages: High equipment and operational cost, complicated operation. Suitable for aerospace, high-end energy storage products and standard calibration verification.
2.4 Thermal Cycle Shock Test
This method verifies long-term sealing reliability rather than conventional leakage inspection. Cold plates are placed in temperature alternating chamber under extreme working conditions ranging from -40°C to 85°C. Repeated thermal expansion and contraction generates mechanical stress on welding seams and sealing joints. Secondary air tightness tests are conducted after cycling to check sealing durability.
It evaluates potential cracking risks caused by material fatigue under long-term temperature fluctuation.
Core Industry Specifications & Standards
Standard testing pressure: 200kPa to 250kPa, 2 to 2.5 times actual working pressure for sufficient safety margin
Qualification criteria: Pressure drop shall be less than 100 Pa within 30-second pressure holding period
IP Rating Matching: Automotive battery packs are required to reach IP67 protection grade. Qualified cold plate airtightness lays solid foundation for overall waterproof and dustproof performance of battery packs. Unqualified leakage will directly result in IP67 certification failure.
Standard Testing Procedures
Pre-treatment: Clean workpiece and seal all ports with customized fixtures
Gas charging and pressure stabilization: Inject testing gas and stabilize pressure to eliminate temperature impact
Pressure holding and real-time monitoring: Execute formal detection and record pressure variation data
Automatic qualification judgment and product sorting
Leak positioning: Apply water immersion or helium detection for defective products to optimize manufacturing process
Conclusion
Air tightness testing for power battery cold plates integrates precision machinery, sensor technology and strict quality control. Pressure decay method dominates online mass production for its high efficiency, stability and automation compatibility. Helium mass spectrometry provides ultra-precision inspection for high-end products and research validation. Water immersion test and thermal cycle test serve as auxiliary means for leak location and durability assessment.
As stricter safety and reliability requirements are raised in new energy industry, cold plate air tightness inspection will develop toward higher precision, efficiency and intelligent operation.
View More
Trumony’s Successful Participation in CIBF 2026
2026-05-14
.gtr-container-x7y8z9 {
font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif;
font-size: 14px;
line-height: 1.6;
color: #333;
padding: 15px;
margin: 0 auto;
max-width: 100%;
box-sizing: border-box;
overflow-x: auto;
border: none !important;
outline: none !important;
}
.gtr-container-x7y8z9 p {
margin-bottom: 1em;
text-align: left !important;
}
.gtr-container-x7y8z9 strong {
font-weight: bold;
color: #0E49BB;
}
.gtr-container-x7y8z9 .gtr-heading {
font-size: 18px;
font-weight: bold;
color: #0E49BB;
margin-top: 1.5em;
margin-bottom: 1em;
text-align: left !important;
}
.gtr-container-x7y8z9 ul {
list-style: none !important;
margin: 0;
padding: 0;
margin-bottom: 1em;
}
.gtr-container-x7y8z9 ul li {
position: relative;
padding-left: 1.5em;
margin-bottom: 0.5em;
text-align: left !important;
list-style: none !important;
}
.gtr-container-x7y8z9 ul li::before {
content: "•" !important;
position: absolute !important;
left: 0 !important;
color: #0E49BB;
font-size: 1.2em;
line-height: 1;
top: 0;
}
.gtr-container-x7y8z9 img {
display: inline;
vertical-align: middle;
height: auto;
}
@media (min-width: 768px) {
.gtr-container-x7y8z9 {
padding: 25px;
}
.gtr-container-x7y8z9 .gtr-heading {
font-size: 20px;
}
}
Shenzhen, May 13–15, 2026 — Trumony Aluminum Limited (“Trumony”), a leading provider of thermal management solutions for new energy vehicles (NEVs) and energy storage systems, is thrilled to announce its successful participation in the 18th China International Battery Fair (CIBF 2026). Held at the Shenzhen World Exhibition & Convention Center, CIBF 2026 is the world’s largest and most influential battery industry event, gathering over 3,200 global exhibitors and 350,000+ professional attendees across the entire battery value chain. This year, Trumony not only showcased its comprehensive thermal management portfolio but also highlighted its core product — high-performance liquid cooling plates, which became a key focus of discussions with global clients.
A Key Platform for Industry Exchange & Collaboration, Highlighting Liquid Cooling Plate Advantages
As a pivotal player in EV battery cooling components, liquid cooling plates, and advanced thermal materials, Trumony centered its exhibition around its innovative liquid cooling plates, complemented by its full range of thermal management solutions. The booth became a vibrant hub for in-depth discussions with global clients, industry partners, and technical experts, focusing on thermal management challenges in power batteries, energy storage systems, and electric mobility applications — with particular attention to how Trumony’s liquid cooling plates can optimize battery performance and safety.
Trumony’s liquid cooling plates, a core product on display, stand out for their outstanding performance and broad applicability, tailored specifically for the new energy battery industry:
Superior Thermal Conductivity: Adopting high-purity aluminum materials and advanced integral forming technology, the liquid cooling plates feature excellent heat transfer efficiency, effectively dissipating heat generated by battery modules during charging and discharging, ensuring stable battery operation within the optimal temperature range (20-40℃).
Lightweight & Compact Design: With a thin-walled structure and optimized flow channel design, the liquid cooling plates are lightweight yet durable, saving installation space and reducing the overall weight of battery packs — a key advantage for NEV range improvement.
Strong Compatibility & Customization: Compatible with various battery types (lithium-ion, solid-state, etc.) and battery pack designs, Trumony offers fully customized liquid cooling solutions, including flow channel layout, size, and connection methods, to meet the unique needs of different clients and application scenarios.
High Reliability & Durability: Undergoing strict pressure testing, high-low temperature cycle testing, and corrosion resistance testing, the liquid cooling plates feature excellent sealing performance and long service life, adapting to harsh working environments such as high temperature, low temperature, and vibration in automotive and energy storage applications.
We are delighted to share meaningful moments from face-to-face meetings with valued clients at CIBF 2026, where our team had in-depth exchanges about liquid cooling plate applications, technical parameters, and customization needs:
Strengthened partnerships with long-term clients through in-depth discussions on liquid cooling plate optimization, project progress, and future cooperation plans for NEV and energy storage projects.
Explored new cooperation opportunities with potential clients from Europe, Southeast Asia, and other regions, introducing the advantages of Trumony’s liquid cooling plates and aligning on customized solution directions.
Gathered valuable market insights and client feedback on liquid cooling plate performance, cost, and application requirements, laying a solid foundation for product iteration and optimization.
*(Insert your client meeting photos here: e.g., group photos at the booth, discussion scenes with clients, close-up photos of liquid cooling plates displayed at the booth)*
Trumony: Committed to Thermal Management Innovation, Leading Liquid Cooling Technology
Founded in 2017 and headquartered in Suzhou, China, Trumony specializes in the R&D, production, and sales of high-performance thermal management products, with liquid cooling plates as its core competitive product. The company’s product portfolio also includes aluminum heat exchangers, battery thermal management assemblies, and advanced thermal interface materials.
With a 100,000㎡ standardized production base, advanced production equipment (including CNC machining, laser welding, and integral forming lines), and ISO 9001/IATF 16949 quality management system certifications, Trumony has built a complete R&D and production system for liquid cooling plates. Our technical team, composed of industry experts with over 10 years of experience, is dedicated to developing more efficient, lightweight, and cost-effective liquid cooling solutions, supporting the global green energy transition.
Looking Ahead: Innovate Together, Win Together with Advanced Liquid Cooling Solutions
CIBF 2026 has been a remarkable journey for Trumony, providing an invaluable platform to connect with clients, showcase the strength of our liquid cooling plates, and explore in-depth cooperation. We sincerely thank all clients and partners who visited our booth, engaged in fruitful discussions, and showed trust in Trumony’s products and solutions.
Moving forward, Trumony will remain committed to its mission — “Helping technology get off the ground and helping customers succeed”. We will continue to invest in R&D of liquid cooling technology, optimize product performance, expand global cooperation, and strive to become your most trusted partner in thermal management solutions, especially in the field of battery liquid cooling.
Let’s join hands to drive innovation in the battery industry, leverage advanced liquid cooling technology to enhance battery safety and efficiency, and contribute to a sustainable, low-carbon future!
View More
What’s Inside an Energy Storage Battery PACK? A Complete Guide
2026-05-12
.gtr-battery-pack-comp-789abc {
font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif;
color: #333;
line-height: 1.6;
padding: 15px;
box-sizing: border-box;
max-width: 100%;
overflow-x: hidden;
}
.gtr-battery-pack-comp-789abc-heading {
font-size: 18px;
font-weight: bold;
margin-top: 25px;
margin-bottom: 15px;
color: #0E49BB;
text-align: left;
}
.gtr-battery-pack-comp-789abc p {
font-size: 14px;
margin-bottom: 10px;
text-align: left;
word-break: normal;
overflow-wrap: normal;
}
.gtr-battery-pack-comp-789abc ul,
.gtr-battery-pack-comp-789abc ol {
list-style: none !important;
padding-left: 25px;
margin-bottom: 10px;
}
.gtr-battery-pack-comp-789abc ul li {
position: relative;
padding-left: 15px;
margin-bottom: 5px;
font-size: 14px;
text-align: left;
word-break: normal;
overflow-wrap: normal;
list-style: none !important;
}
.gtr-battery-pack-comp-789abc ul li::before {
content: "•" !important;
position: absolute !important;
left: 0 !important;
color: #0E49BB;
font-size: 1.2em;
line-height: 1;
}
.gtr-battery-pack-comp-789abc ol {
counter-reset: list-item;
}
.gtr-battery-pack-comp-789abc ol li {
position: relative;
padding-left: 25px;
margin-bottom: 5px;
font-size: 14px;
text-align: left;
word-break: normal;
overflow-wrap: normal;
counter-increment: none;
list-style: none !important;
}
.gtr-battery-pack-comp-789abc ol li::before {
content: counter(list-item) "." !important;
position: absolute !important;
left: 0 !important;
color: #333;
font-weight: bold;
width: 20px;
text-align: right;
}
.gtr-battery-pack-comp-789abc img {
max-width: 100%;
height: auto;
margin-top: 15px;
margin-bottom: 15px;
}
.gtr-battery-pack-comp-789abc-table-wrapper {
width: 100%;
overflow-x: auto;
margin-top: 20px;
margin-bottom: 20px;
}
.gtr-battery-pack-comp-789abc table {
width: 100%;
border-collapse: collapse !important;
border-spacing: 0 !important;
min-width: 300px;
}
.gtr-battery-pack-comp-789abc th,
.gtr-battery-pack-comp-789abc td {
border: 1px solid #d0d0d0 !important;
padding: 10px 12px !important;
text-align: left !important;
vertical-align: top !important;
font-size: 14px;
word-break: normal;
overflow-wrap: normal;
}
.gtr-battery-pack-comp-789abc th {
font-weight: bold !important;
background-color: #f0f0f0;
color: #333;
}
.gtr-battery-pack-comp-789abc tr:nth-child(even) {
background-color: #f9f9f9;
}
.gtr-battery-pack-comp-789abc-sub-heading {
font-size: 18px;
font-weight: bold;
margin-top: 20px;
margin-bottom: 10px;
color: #333;
text-align: left;
}
@media (min-width: 768px) {
.gtr-battery-pack-comp-789abc {
padding: 25px 50px;
}
.gtr-battery-pack-comp-789abc-heading {
margin-top: 35px;
margin-bottom: 20px;
}
.gtr-battery-pack-comp-789abc p {
margin-bottom: 12px;
}
.gtr-battery-pack-comp-789abc ul,
.gtr-battery-pack-comp-789abc ol {
padding-left: 30px;
}
.gtr-battery-pack-comp-789abc ul li {
padding-left: 20px;
}
.gtr-battery-pack-comp-789abc ol li {
padding-left: 30px;
}
.gtr-battery-pack-comp-789abc ol li::before {
width: 25px;
}
}
1. What is a Battery PACK?
Lithium-ion battery PACK, also known as a battery module, is a core manufacturing process for lithium-ion batteries. It refers to integrating multiple lithium-ion single cells through series and parallel connections, while comprehensively solving system issues such as mechanical strength, thermal management, BMS matching, and structural protection.
The core technologies are reflected in: overall structural design, welding and processing technology control, protection level, and active thermal management system. Simply put, combining battery cells into a battery pack with specific voltage, capacity, and shape according to customer needs is called PACK.
2. Composition of a Battery PACK (Five Core Components)
Battery Module: The "energy heart" of the PACK, composed of single cells connected in series and parallel, responsible for energy storage and release, and is the core energy storage unit.
Electrical System: The "blood vessels and neural network" of the PACK, consisting of connecting copper bars, high-voltage wiring harnesses, low-voltage wiring harnesses, and protective devices (fuses, relays, etc.); high-voltage wiring harnesses transmit large currents, while low-voltage wiring harnesses transmit detection and control signals.
Thermal Management System: The "temperature control air conditioner" of the PACK, mainly including air cooling and liquid cooling (cold plate/immersion liquid cooling), which controls the working temperature difference of the battery to ≤5℃ to ensure service life and safety.
Case: The "protective skeleton" of the PACK, composed of the case body, cover plate, bracket, and fasteners, undertaking the functions of support, impact resistance, vibration prevention, and sealed environmental protection.
BMS (Battery Management System): The "control brain" of the PACK, which real-time monitors voltage, current, and temperature, and realizes cell balancing, data upload, and safety protection.
3. Core Characteristics of Battery PACK
Extremely high requirements for cell consistency (minimal differences in capacity, internal resistance, voltage, discharge curve, and service life).
The cycle life of the battery pack is lower than that of single cells.
Must be used under limited conditions (charging/discharging current, charging method, temperature range).
After assembly, the voltage and capacity are greatly improved, and overcharge, over-discharge, over-current, and over-temperature protection and balancing functions must be configured.
Must accurately meet the designed rated voltage and rated capacity indicators.
4. Grouping Methods of Battery PACK
Series-Parallel Rules
Series Connection: Voltage superposition, capacity remains unchanged; example: 15 pieces of 3.2V cells in series = 48V.
Parallel Connection: Capacity superposition, voltage remains unchanged; example: 2 pieces of 50Ah cells in parallel = 100Ah.
Cell Matching Requirements: Same model, same specification, same batch, with capacity/internal resistance/voltage difference ≤2% to ensure consistency.
Connection Technology
Welding Technology: Laser welding, ultrasonic welding, pulse welding, with reliable connection and low internal resistance; laser welding is the industry's mainstream choice.
Elastic Contact: Welding-free and easy to replace, but prone to poor contact and high internal resistance, with low reliability.
5. Complete PACK Production Line (Six Core Links)
Cell Manufacturing: Including positive and negative electrode preparation, cell formation (winding/lamination/stamping), electrolyte injection, and formation; cell formation determines performance and service life.
Cell Testing: Full-item testing such as capacity, internal resistance, and temperature to screen out defective products.
Cell Grading: Grouping by parameter consistency to ensure assembly quality.
Cell Assembly: Series-parallel connection, module integration, electrical connection, thermal management and case assembly.
Quality Inspection: Full inspection of electrical performance, safety, insulation, temperature control, and BMS functions.
Packaging and Shipping: Encapsulation, labeling, and warehousing of qualified products.
6. Future Prospects of Lithium-Ion Battery PACK (Four Technical Directions)
Intelligence: AI + Internet of Things to realize automated, information-based, and flexible production, improving efficiency and yield.
Greenization: Environmentally friendly materials, energy conservation and emission reduction, low-carbon manufacturing, in line with the dual carbon goals.
Personalization: Customize voltage, capacity, structure, and interface according to scenarios/customer needs to improve adaptability.
Safety: Strengthen thermal runaway protection, multi-level safety interlock, and full-process risk control to ensure safe use.
7. How to Understand Battery PACK Technical Parameters
Item Name
Parameter Index
Configuration
1P24S
Rated Capacity
280Ah
Rated Voltage
76.8V
Rated Energy
21.504kWh
Max Charge/Discharge Rate
0.5C Continuous
Weight
138±3 kg
1. Combination Method: For example, "1P24S" = 1 parallel and 24 series; S = series, P = parallel; rated voltage = single cell voltage × number of series (3.2V × 24 = 76.8V).
2. Rated Capacity: Unit is Ah, representing the continuous discharge capacity under standard working conditions; example: 280Ah ≈ 0.5C discharge can last for 2 hours.
3. Rated Energy: Unit is Wh/kWh, calculation formula: Rated Energy = Rated Voltage × Rated Capacity; example: 76.8V × 280Ah = 21504Wh = 21.504kWh.
About Trumony
Trumony aluminum limited is a leading global supplier specializing in high-performance liquid cooling solutions for energy storage and new energy applications. With over a decade of expertise in thermal management systems, we design and manufacture custom liquid cold plates, cooling manifolds, and integrated thermal solutions that are critical to the safety, efficiency, and longevity of battery PACK systems.
Our core offerings include high-precision aluminum liquid cold plates, engineered to meet the most demanding requirements of energy storage, EV, and industrial battery systems. We support clients worldwide with end-to-end services: from initial thermal simulation and design optimization, through CNC machining, friction stir welding, and laser welding, to full performance and leak testing.
Contact Us
If you are looking for high-quality liquid cold plates or custom thermal solutions for your battery PACK projects, please feel free to reach out to us anytime.
Sherry
View More
Liquid Cooling Plate Manufacturing Process: From Materials to Precision Testing
2026-05-08
As new energy vehicles, data centers, and energy storage systems experience explosive growth, the thermal performance of liquid cooling plates directly determines equipment stability and service life. A well-designed flow channel structure significantly improves temperature uniformity of battery modules, while advanced manufacturing processes ensure optimal flow path design, pressure resistance, and cost efficiency. This article provides a comprehensive overview of mainstream fabrication technologies, key techniques, and quality control points for liquid cooling plates.
1. Material Selection & Pre-Treatment
1.1 Mainstream Materials
Aluminum Alloys: The dominant choice for EV battery cooling plates, balancing thermal conductivity, light weight, strength, processability, and cost. 3003 aluminum alloy is widely used due to its mature technology and excellent comprehensive performance.
Copper Alloys: Pure copper (thermal conductivity: 401 W/m·K) is ideal for high-power scenarios (e.g., 800V high-voltage platforms), requiring nickel plating or anodization to prevent corrosion.
Composite Materials: High-strength aluminum alloy composites (3-layer structure: core + brazing layer + sacrificial layer) are used for applications demanding superior mechanical strength.
1.2 Pre-Treatment Process
Surface Degreasing: Ultrasonic cleaning (28–80 kHz) removes oil contaminants to ensure reliable welding and passivation.
Passivation: Chromate or chromium-free passivation (e.g., titanium salt solution) forms a nano-scale protective film, achieving 1,000+ hours of salt spray resistance.
2. Flow Channel Forming Technologies
2.1 Stamping Forming: High-Volume Production Core
Process Features: Servo presses deliver 60 strokes/min high-speed stamping with flow channel depth tolerance of ±0.05 mm. Ideal for medium/small cooling plates with 70%+ material utilization.
Case: BYD Seal CTB batteries adopt stamping plate direct cooling, boosting heat exchange efficiency by 40% via large-area flow channels.
2.2 Hydroforming: Complex Flow Channel Expert
Process Steps: Aluminum blank cutting (±0.1 mm) → hydraulic expansion (30–50 MPa, 2–10 seconds hold) → water jet trimming → vacuum brazing assembly.
Advantages: High design flexibility (serpentine, branched structures) with 20% lower pressure loss than stamped plates.
Case: CATL Kirin battery uses hydroformed large plates (1,200×800×50 mm), increasing cooling area by 4×.
2.3 Extrusion Forming: Cost-Effective Standard Solution
Process: Extrusion of aluminum profiles with preformed flow channels (e.g., harmonica tubes), followed by cutting and header welding.
Limitations: 30% lower cost than stamping but restricted to straight flow channels, suitable for energy storage container cooling plates.
2.4 3D Printing: Structural Innovation Breakthrough
Technology: Direct Metal Laser Sintering (DMLS) produces monolithic cooling plates without weld seams, withstanding 6+ bar pressure.
Case: Singapore’s CoolestDC’s 3D-printed plates use oblique fins to improve cooling efficiency by 20%, deployed in NVIDIA H100 GPU cooling systems.
3. Flow Channel Machining: Core of Thermal Performance
3.1 Mainstream Methods
Embedded Tube Process: Copper tubes are pressed into milled aluminum grooves (depth/diameter ratio ≤3:1) and fixed via brazing.
Pros: Zero leakage risk (seamless tubing), mature and cost-effective.
Cons: Limited flow channel flexibility; risk of galvanic corrosion between copper and aluminum.
Applications: Server liquid cooling, industrial inverter heat sinks.
Electrical Discharge Machining (EDM): Wire cutting (±0.01 mm precision) creates micro-channels in hard alloy molds for prototyping.
Chemical Etching: Photolithography + NaOH etching produces micro-scale channels for ultra-thin plates (≤0.5 mm).
3.2 Innovative Designs
Bionic Flow Channels: Valeo’s shark fin-shaped channels enhance coolant turbulence, increasing heat transfer coefficient by 15%.
Branched Structures: Tesla 4680 battery modules use side-branched plates with 15° sub-branches to minimize temperature differentials.
4. Welding Technologies: Sealing & Strength Challenges
4.1 Vacuum Brazing: Mass Production Preferred
Principle: Aluminum-silicon brazing filler melts in a vacuum furnace, bonding flow channel plates and covers metallurgically.
Advantages: Supports complex micro-channels/fin structures (30%+ efficiency gain); lightweight aluminum construction withstands 10+ bar pressure.
Case: CATL CTP battery plates use vacuum brazing with deformation 500V).
PTFE Coating: 50–100 μm polytetrafluoroethylene layers reduce friction coefficient to 0.1, minimizing coolant flow resistance.
5.2 Full-Process Testing
Leak Detection:
Helium mass spectrometry (1×10⁻⁹ mbar·L/s): EV battery plates, leakage rate ≤0.1 sccm.
Hydrostatic testing (1.5× working pressure, 30 min hold): Energy storage plates.
Internal Quality:
Ultrasonic C-SAM (50–200 MHz): Detects brazing defects (voids >5%) with 50 μm resolution.
CMM (±0.002 mm): Verifies channel dimensions and cell contact accuracy.
Conclusion
Liquid cooling plate manufacturing integrates material science, precision machining, and advanced welding technologies. From 3003 aluminum substrate preparation to helium leak testing, every process directly impacts cooling performance and reliability. As high-density thermal management demands grow, innovations like 3D-printed bionic channels and FSW monolithic structures will further enhance efficiency while reducing costs.
View More
Battery Pack Side Cooling or Bottom Cooling, Which Is Better?
2026-04-27
.gtr-container-b7c9d2 {
font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif;
color: #333;
line-height: 1.6;
padding: 16px;
max-width: 100%;
box-sizing: border-box;
}
.gtr-container-b7c9d2 p {
margin-bottom: 1em;
text-align: left !important;
font-size: 14px;
}
.gtr-container-b7c9d2 .gtr-section-title {
font-size: 18px;
font-weight: bold;
color: #0E49BB;
margin-top: 2em;
margin-bottom: 1em;
text-align: left;
}
.gtr-container-b7c9d2 .gtr-subsection-title {
font-size: 14px;
font-weight: bold;
color: #333;
margin-top: 1.5em;
margin-bottom: 0.5em;
text-align: left;
}
.gtr-container-b7c9d2 img {
margin: 1em 0;
}
.gtr-container-b7c9d2 ul {
list-style: none !important;
padding-left: 0;
margin-left: 0;
}
.gtr-container-b7c9d2 ul li {
position: relative !important;
padding-left: 1.5em !important;
margin-bottom: 0.5em !important;
font-size: 14px;
text-align: left !important;
list-style: none !important;
}
.gtr-container-b7c9d2 ul li::before {
content: "•" !important;
position: absolute !important;
left: 0 !important;
color: #0E49BB !important;
font-size: 1.2em !important;
line-height: 1.6 !important;
}
.gtr-container-b7c9d2 a {
color: #0E49BB;
text-decoration: none;
}
.gtr-container-b7c9d2 a:hover {
text-decoration: underline;
}
@media (min-width: 768px) {
.gtr-container-b7c9d2 {
padding: 24px 40px;
max-width: 960px;
margin: 0 auto;
}
}
Thermal management is a critical cornerstone of battery pack performance, safety, and service life, especially as electric vehicles (EVs) and energy storage systems (ESS) continue to develop towards higher power density, faster charging speeds, and more diverse operating scenarios. The efficient dissipation of heat generated by battery cells during charging and discharging directly determines the stability of energy output, the risk of thermal runaway, and the long-term reliability of the entire battery system. Among the various thermal management technologies currently in practical application, side cooling and bottom cooling are two mature and widely adopted solutions, each with distinct working principles, performance characteristics, and applicable scenarios. This article will systematically compare the two methods in terms of principle, advantages, disadvantages, and application scope, providing a clear reference for the selection of battery pack thermal management solutions.
1. Side Cooling
Principle:
Liquid cooling plates or heat conduction structures are installed on the sides of the battery pack. Coolant or heat-conducting materials transfer heat generated by cells from the sides, expanding the heat dissipation area and improving cooling efficiency.
Advantages:
It provides a large heat dissipation area and effectively reduces cell surface temperature, making it highly suitable for high-power and high-rate charging and discharging scenarios such as ultra-fast charging battery packs.
It optimizes internal temperature uniformity of the battery pack, minimizes temperature differences between cells, and reduces the risk of thermal runaway.
For both cylindrical and prismatic cells, side cooling enables better coverage of core heat-generating areas.
Disadvantages:
The structure is relatively complex, requiring strict consideration of liquid cooling plate installation, sealing and close contact with cells, resulting in higher costs.
It occupies lateral space inside the pack, restricting the overall layout design when the battery pack dimension is limited.
Application Scenarios:
Widely adopted in high-end electric vehicles, energy storage systems and other high-power applications, represented by CATL Qilin Battery and some Tesla models.
2. Bottom Cooling
Principle:
A liquid cooling plate or heat-conducting base plate is arranged at the bottom of the battery pack. Heat is conducted outwards through direct contact between the bottom structure and cooling media.
Advantages:
It features a simple structure and lower cost, facilitating mass production and standardized manufacturing.
It meets basic heat dissipation demands for low-power and low-rate operating conditions with minimal space occupation.
Disadvantages:
The limited heat exchange area leads to low cooling efficiency, failing to support high-power operation and high-rate fast charging.
It easily causes uneven internal temperature distribution; the bottom remains cool while heat accumulates at the top, impairing overall battery performance and service life.
Application Scenarios:
Applied to low-power devices, entry-level electric vehicles and battery packs with low heat dissipation requirements, including cost-effective EVs and general energy storage battery modules.
Summary
Side cooling delivers high cooling efficiency and superior temperature consistency, ideal for high-power and high-rate working conditions at a higher structural cost. Bottom cooling boasts a simple structure and cost advantages, which is applicable to low-power and low-demand scenarios. In practical engineering, hybrid solutions combining side cooling and bottom cooling are commonly adopted to achieve comprehensive thermal management performance.
In the global transition towards green energy and carbon neutrality, electric vehicles (EVs) and energy storage systems (ESS) have become the core driving forces of the new energy revolution. Among the key components that determine the performance, safety, and lifespan of EV battery packs and ESS modules, thermal management systems stand out as a critical technology—directly affecting charging efficiency, battery cycle life, and even preventing thermal runaway risks. Trumony Aluminum Limited (referred to as "Trumony"), founded in 2017 and headquartered in Suzhou, Jiangsu Province, China, has emerged as a fast-growing, innovative manufacturer and one-stop solution provider specializing in high-performance battery thermal management systems, liquid cooling solutions, and aluminum heat exchangers, dedicated to supporting the global new energy industry with reliable, cost-effective, and customized thermal management technologies.
Whether you are an EV OEM, battery manufacturer, ESS integrator, or enterprise in need of high-quality battery thermal management solutions, Trumony is your reliable long-term partner. We are committed to strengthening cooperation with global partners, jointly promoting the development of the new energy industry, and achieving win-win results. If you are interested in our side cooling, bottom cooling, or integrated liquid cooling solutions, want to customize thermal management products for your specific needs, or have any questions about our products and services, please do not hesitate to contact us immediately—our professional team will respond to you promptly and provide you with tailored solutions.
Headquarters Address: Jindi Weixin Wuzhong Intelligent Manufacturing Park, Wuzhong District, Suzhou City, Jiangsu Province, China
Factory Address: Suqian Economic & Technological Development Zone, Jiangsu Province, China
Email:sales4@trumony.com
Contact Trumony today, and let us work together to create a greener, more sustainable future with advanced battery thermal management technology!
View More
