Lightweight Aluminum Liquid Cooling Plate for EV Battery Pack, ESS, GPU Server, Industrial IGBT Cooling

The booming market of new energy vehicles, grid energy storage and AI computing hardware has brought unprecedented high heat flux challenges, exposing obvious defects of traditional cooling solutions:

First, air cooling cannot cope with high-power fast charging batteries and dense GPU clusters. Limited heat dissipation leads to equipment overheating derating, reduced runtime efficiency and accelerated component aging. Second, low-quality generic cold plates use rough internal flow paths, causing severe temperature imbalance among battery cells, which raises thermal runaway risks and fails strict regional safety codes in US, Germany and Japan. Third, heavy copper cooling plates bring extra load to EV battery packs and push up overall project costs, which is not friendly for mass vehicle manufacturing. Fourth, many cooling plate suppliers lack stable mass production capacity, leading to delayed delivery and inconsistent product quality for overseas importers and system integrators. Fifth, most cooling manufacturers only supply standard sizes without flexible customization, forcing buyers to carry out secondary machining and waste labor & production cycles.

• The liquid cold plate functions as a compact heat exchanger integrated directly into the battery pack structure.

  Thermal Interface: Battery cells transfer waste heat through a thermal interface material to the cold plate's flat contact surface. The high thermal conductivity of 3003 aluminum rapidly conducts this heat into the channel walls.

  Fluid Dynamics: Coolant enters through the inlet port and is distributed into the stamped channel network. The channel geometry is designed via computational fluid dynamics to induce controlled turbulence at the target flow rate — typically 2–10 L/min per plate. This turbulent flow disrupts the thermal boundary layer that would otherwise insulate the channel walls, dramatically increasing heat transfer efficiency.

  Heat Rejection: As coolant flows through the serpentine or parallel channel matrix, it absorbs thermal energy and exits at an elevated temperature through the outlet port. The heated fluid travels to an external radiator, chiller, or heat exchanger where the thermal energy is dissipated to ambient air before the cooled fluid recirculates.

  Structural Integrity: The continuous brazed bond between the stamped top plate and the flat bottom plate forms a pressure vessel capable of withstanding pump pressures, thermal expansion stresses, and vibration loads encountered in automotive and stationary storage environments. Unlike gasketed or O-ring sealed plates, there are no elastomeric elements to deteriorate or relax over time.