High-Performance Liquid Cold Plate | 3003 Aluminum with Continuous Brazing

Engineered for the rigorous thermal demands of North American electrification, our liquid cold plates utilize aerospace-grade 3003 aluminum alloy. Through advanced stamping and continuous brazing technologies, we deliver a leak-proof, lightweight solution that maximizes heat dissipation for prismatic and cylindrical cells. This cooling plate ensures uniform temperature distribution across your battery pack, eliminating hotspots that degrade battery life. Designed for high-volume EV and Energy Storage System (ESS) production, it offers an optimal balance of thermal conductivity, corrosion resistance, and structural integrity, keeping your energy systems operational at peak performance

• Stamped Channels: Complex flow paths formed in seconds at low cost, ideal for high-volume scaling.
• Leak-Proof Construction: Solid-state sealed for permanent, maintenance-free operation with no internal contaminants.
• Custom Configurable: Size, port locations, mounting bosses, and surface treatments can be tailored to your module layout.
• Fast Sample Turnaround: Functional prototypes delivered in weeks, using the same production-ready process.
• Certification Support: Full documentation and material traceability to assist with UL 1973 and UL 9540A compliance.

Trumony's cold plate is designed to solve supply chain challenges without cutting corners on performance:

· Speed of Stamping: Once the progressive die is set, channels are formed in seconds per plate. This allows us to ship thousands of identical, high-quality plates per month, keeping your assembly line moving.
· Predictable Cost Trajectory: Because stamping is a fast, low-labor process, unit economics improve naturally with volume. We pass this structure through with transparent, tiered pricing.
· Single-Process Validation: We use the exact same stamping tooling and sealing method for prototype samples as for volume production. The thermal performance data you gather from a sample is identical to what every production plate will deliver.
· Scalable Customization: We work with you to finalize channel routing and port placement before committing to the stamping die. Once the die is qualified, scaling up is simply a matter of scheduling production runs.

• The continuous brazed cold plate operates as a high-efficiency counterflow heat exchanger integrated directly into the heat source. Here is the thermal pathway in sequence:

  1. Thermal Collection: Heat generated by the semiconductor junction or battery cell surface migrates through a thin, high-conductivity thermal interface material (TIM) into the cold plate's precision-ground top face.
  2. Spreading & Conduction: The solid aluminum lid conducts heat downward into the internal fin field, where the continuous brazed joints ensure no thermal constriction occurs at the bond interface.
  3. Fluid-Side Convection: Coolant entering the inlet manifold is evenly distributed across hundreds of micro-channels or pin arrays. As the fluid velocity increases within these constricted pathways, the flow transitions from laminar to turbulent — dramatically increasing the convective heat transfer coefficient.
  4. Heat Rejection Loop: The heated coolant exits through the outlet manifold and travels to a remote Cooling Distribution Unit (CDU), where a liquid-to-air or liquid-to-liquid heat exchanger rejects the thermal energy to the ambient environment.
  5. Closed-Loop Return: Cooled fluid returns to the pump and reservoir, completing the circuit. The entire system operates under slight positive pressure to prevent air ingestion and cavitation.

 Application

1. Passenger EV Battery Trays
Our large-format stamped plates integrate directly beneath prismatic or cylindrical cell modules in skateboard chassis designs. The low-profile stamped channels minimize coolant volume while maximizing contact area, enabling ultra-fast charging without exceeding safe cell temperature limits.

2. Commercial & Utility-Scale ESS Racks
For containerized megawatt-hour storage systems, we supply rack-mount side-cooling plates that maintain precise temperature control across thousands of cycles. The 3003 alloy’s inherent corrosion resistance ensures decades of service in unconditioned outdoor enclosures, from desert solar farms to coastal frequency regulation sites.

3. Blade Cell Inter-Cooling
Ultra-thin double-sided plates (as thin as 4mm) are inserted directly between blade or pouch cells. This doubles the effective cooling surface area per cell and eliminates the thermal gradient across the cell thickness — a requirement for high-energy-density packs exceeding 200 Wh/kg.

4. Power Electronics Cold Plates
Beyond batteries, our plates cool IGBT modules, DC-DC converters, and onboard chargers where concentrated heat fluxes demand high-efficiency liquid cooling in a compact envelope.