High Performance Microchannel Liquid Cooling Tube For EV Thermal Management

Introduction:

Our Aluminum Micro-Channel Liquid Cooling Plate for Battery Cooling Systems is a highly efficient thermal management solution specifically designed for modern energy storage and EV battery applications. It integrates advanced extrusion and brazing technologies to deliver superior heat dissipation performance and structural reliability.

Crafted from high-grade aluminum, the core of this plate features extruded micro-channel tubes, which provide exceptionally high surface-area-to-volume ratios for maximum heat transfer. These tubes are seamlessly integrated onto a base plate through a high-precision brazing process, creating a robust, leak-proof monolithic assembly. Every unit undergoes rigorous helium leak testing and burst pressure validation, ensuring complete integrity under demanding thermal and pressure conditions.

Introduction:

Our High-Performance Micro-Channel Liquid Serpentine Cooling Tube is an advanced thermal management solution specifically engineered for the demanding cooling requirements of modern electric vehicle battery packs. It combines state-of-the-art extrusion, precision bending, and high-frequency welding technologies to deliver superior, direct-contact heat dissipation for high-density battery configurations.

Fabricated from high-grade aluminum alloys, the core of this solution is a precisely extruded, multi-port micro-channel flat tube. This tube is then shaped into complex serpentine layouts via CNC bending to match specific battery module designs. Critical connections are sealed using high-frequency welding, ensuring robust, leak-proof joints. Each assembly undergoes stringent helium leak testing and burst pressure validation, guaranteeing reliable performance under the vibration, pressure, and thermal cycling of automotive environments.

This high-efficiency serpentine cooling tube is a specialized thermal solution designed for high-power EV battery packs, particularly for applications requiring compact, direct cooling of cylindrical cell arrays. Its primary application is:

• Direct Cooling for Cylindrical Cell Battery Packs:​ Specifically engineered to contour around and effectively cool high-density arrays of cylindrical cells (e.g., 21700, 4695 formats), managing heat generation during fast charging and high-power discharge to ensure pack safety, performance, and longevity.

• Optimized Serpentine Layout for Cylindrical Cells:​ The tube can be bent into precise serpentine patterns that maximize contact surface area with cylindrical cells, providing targeted and uniform cooling. The layout is fully customizable to match the cell diameter, pitch, and module arrangement (e.g., 8S, 10S).
• Efficient Micro-Channel Extruded Tube:​ The extruded flat tube features multiple internal micro-channels, offering a high surface-area-to-volume ratio for exceptional heat transfer efficiency from the cell to the coolant, all within a minimal space envelope.
• Robust, Welded Construction:​ The use of high-frequency welding for critical joints (e.g., to headers or manifolds) ensures strong, metallurgically sound, and hermetic seals. This construction is highly resistant to the mechanical stresses and thermal cycling found in EV applications.
• Compact and Flexible Integration:​ The design provides a highly compact cooling solution that can be directly integrated into the interstitial spaces of a battery module, minimizing impact on overall pack energy density and allowing for versatile pack layout options.
• Fully Customizable Geometry:​ We offer complete customization of the tube's serpentine path, bend radii, header/port locations, and micro-channel geometry to fit your specific cell type (21700, 4695, etc.), module dimensions, and thermal load requirements.

Our micro-channel serpentine cooling tubes are an ideal solution for next-generation electric vehicle battery packs utilizing cylindrical cells, where direct, efficient cooling is critical for performance and safety. We provide end-to-end support from thermal and mechanical design simulation to prototyping and high-volume production.