Stamped Aluminum Liquid Cooling Plate with Continuous Brazing for Energy Storage, EV Battery & IGBT

Product Overview

Trumony provides stamped aluminum liquid cooling plates manufactured with continuous brazing for high-volume battery and power electronics cooling. Our factory delivers fully custom designs — from channel pattern to surface finish — backed by one-stop service from prototyping to mass production.

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Cause

High-power battery packs and IGBT modules generate concentrated heat that passive cooling cannot handle. Without effective liquid cooling, cells degrade rapidly, charging slows, and power electronics risk thermal failure.

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Solution

Our precision stamping process forms consistent, optimized flow channels at low cost and high speed. Continuous brazing creates a uniform, leak-proof metallurgical bond across every plate. The result: dependable thermal performance at any production scale.

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Application

1. Electric Vehicle Traction Battery Packs
Our stamped cold plates are installed between prismatic or pouch cell modules to maintain optimal temperatures during highway driving and DC fast charging. The high flatness ensures maximum contact with cell surfaces, while robust brazed joints withstand years of vibration and thermal cycling.

2. Commercial & Utility-Scale Energy Storage (BESS)
For containerized and cabinet-type storage systems using high-capacity cells. Stamped plates with multi-parallel channels keep dozens of cells within a 2°C temperature band, extending system life beyond 10,000 cycles and meeting UL 9540A safety test requirements.

3. IGBT & SiC Power Module Cooling
Power inverters, motor controllers, and renewable energy converters demand compact cold plates that handle extreme heat flux. Our pin-fin stamped designs maximize surface area directly beneath semiconductor substrates, reducing junction temperatures and preventing thermal throttling.

4. Automotive Ancillary Electronics
On-board chargers, DC-DC converters, and ADAS compute units also benefit from our lightweight stamped plates, which integrate easily into tight vehicle packaging envelopes.

How It Works

Stamped aluminum liquid cooling plates operate on a closed-loop liquid circulation principle. Coolant enters through an inlet fitting, flows through the stamped channel network beneath the heat-generating components, absorbs waste heat, and exits through an outlet to an external heat exchanger. The stamping process forms the intricate channel geometry directly into the aluminum sheet — creating raised features like dimples or chevrons that disturb the fluid boundary layer and enhance convective heat transfer. The cover plate is then joined via continuous brazing, where the assembly passes through a furnace with precisely controlled temperature and inert atmosphere. The brazing filler metal (typically a clad layer on the sheet) melts and forms a metallurgical bond along every contact point, creating a single, leak-proof structure. Because every plate undergoes identical automated processing, thermal performance is exceptionally consistent from the first unit to the millionth.

How To Choose Your Stamped Cooling Plate

1. Heat Load & Flow Rate: Determine total watts to dissipate and available coolant flow (L/min). Our engineers use this to calculate required channel cross-section and plate size.
2. Stamped vs. Machined Design: For high volumes (>5,000 units/year), stamping offers dramatic cost and speed advantages. We help you decide if your geometry is suitable for stamping or requires a hybrid approach.

3. Channel Pattern Selection: Serpentine for simple, low-cost designs; multi-parallel for low pressure drop; dimpled or pin-fin for maximum turbulence and heat transfer. We recommend the pattern based on your thermal simulation inputs.

4. Surface Protection: Choose based on your coolant chemistry and environment. E-coat provides excellent corrosion resistance for water-glycol systems; hard anodizing adds electrical insulation for direct cell contact.

5. Project Timeline & Volume: Share your expected annual quantities and target SOP date. Our stamping die development lead-time is typically 4-6 weeks, with samples following shortly after. We manage everything in-house to keep your program on track.

Simply reach out with your requirements. We return a comprehensive proposal including die design feasibility, CFD thermal report, and transparent cost breakdown for prototype, pilot, and mass production phases.