High Precision Stamping CAB Brazing Liquid Cooling Tray With PU Foam Insulation Helium Leak Test Battery Thermal Management Cold Plate

Trumony Aluminum's Liquid Cold Plate is engineered for the precise thermal management needs of modern Battery Energy Storage Systems. We utilize high-precision progressive die stamping to form complex flow channel geometries directly from high-quality 3003 aluminum sheet, ensuring consistent depth, flatness, and surface quality for maximum contact with battery modules. The cooling circuit is then sealed using a proprietary, flux-free joining process that creates a homogeneous, maintenance-free structure without the weaknesses of gaskets or welded joints. Every single plate undergoes a 100% helium mass spectrometry leak test, achieving a tightness better than 1×10⁻⁷ mbar·L/s. The result is a compact, lightweight cold plate that maintains cell temperature uniformity within ±1.5°C, effectively extending battery life and preventing the safety risks of coolant ingress. Fully customizable and designed for high-volume scalability, it provides a reliable thermal foundation for C&I and utility-grade storage systems.

Poorly designed or manufactured cold plates introduce significant risks into battery packs:

• Fluid Leaks: Gasketed or traditionally welded plates are susceptible to thermal fatigue and aging, causing dangerous coolant leakage onto high-voltage components.
• Hot Spots: Inconsistent channel depth or flatness creates uneven thermal contact, leading to cell degradation and potential thermal runaway triggers.
• Production Limitations: Many high-precision plates rely on slow CNC machining, limiting throughput and raising costs for large-scale BESS deployments.

Solution – Trumony's Stamped & Sealed Cold Plate
We address these challenges with a design optimized for both performance and production:

• Stamped Precision: Progressive stamping forms channels in seconds, guaranteeing repeatable geometry, excellent surface flatness, and low manufacturing cost at scale.
• Monolithic Sealing: Our solid-state joining technique eliminates gaskets and filler metals, creating a continuous bond that permanently prevents external leaks and internal channel bypass.
• Proven Leak Integrity: 100% helium leak testing verifies that every plate meets or exceeds a leak rate of <1×10⁻⁷ mbar·L/s, ensuring a life cycle of 15+ years without maintenance.

High Precision Stamping CAB Brazing Liquid Cooling Tray With PU Foam Insulation Helium Leak Test Battery Thermal Management Cold Plate

Heat from the battery cells passes through a thermal interface material to the flat top surface of the cold plate. Coolant circulates through the precision-stamped, hermetically sealed internal channel, absorbing thermal energy and carrying it away to the system’s chiller or radiator. The sealed structure physically separates the coolant from all electrical elements, eliminating any leakage risk.

• For high-volume programs, stamped construction ensures the best unit economics without sacrificing thermal performance.
• For corrosive or coastal environments, select the optional trivalent chromium conversion coating.
• Share your module’s 3D model and thermal requirements, and our team will provide a simulated design and production-ready prototype in just a few weeks.