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Can BMW’s Large Cylindrical Batteries Overcome Tesla’s Challenges?

2025-02-28

Can BMW’s Large Cylindrical Batteries Overcome Tesla’s Challenges? Tesla’s 4680 battery technology was meant to revolutionize EVs, yet production challenges have stalled its success. Meanwhile, BMW is betting big on its large cylindrical batteries. But can it succeed where Tesla struggles? And how crucial is thermal management in this race? Battery technology is more than just higher energy density—thermal management and safety are critical. Heat buildup reduces battery lifespan, impacts charging speed, and can even cause thermal runaway. Efficient cooling solutions, like liquid cooling plates and battery enclosures, are essential for maintaining performance and longevity. Companies specializing in EV battery thermal management, such as XDTHERMAL, provide advanced cooling solutions that help maximize battery efficiency and safety. Table of Contents Tesla vs. BMW: A Comparison of Large Cylindrical Battery Strategies To better understand why BMW may succeed where Tesla struggles, we can compare their approaches to large cylindrical batteries: Feature Tesla (4680 Battery) BMW (4695 & 46120 Batteries) Manufacturing Process Dry electrode coating (causing high production failure rates) Wet electrode coating (more stable, proven technology) Energy Density Increase 5x higher than older Tesla batteries 20% higher than BMW’s previous generation Charging Speed Claimed to be significantly faster, but lacks real-world results 30% faster charging than BMW’s previous batteries Thermal Management Approach Uses a cell-to-chassis (CTC) design, limiting cooling options Uses a pack-to-open-body (PTOB) design, allowing more effective cooling Production Challenges Struggles with high failure rates in dry-coating and cell expansion issues Collaborates with CATL & EVE Energy, ensuring stable production Battery Safety Concerns High heat buildup due to compact battery integration Focus on long-term thermal stability and safe energy output Scalability Production is significantly behind schedule Already ramping up for 2025 mass production Supply Chain Heavy internal production reliance Outsources to major battery suppliers for efficiency From this table, it’s clear…

Lightweight EV Battery Casing - XD THERMAL

How Can Lightweight Battery Cases Improve Electric Vehicle Performance?

2025-02-21

How Can Lightweight Battery Cases Improve Electric Vehicle Performance? The rise of electric vehicles (EVs) has sparked a rapidly growing global market that revolves around sustainable mobility, reduced emissions, and innovative technology. As governments introduce stricter emission regulations and consumers demand cleaner transportation, automakers are racing to develop EVs that strike the perfect balance between range, cost, and driving experience. Amid this drive toward electrification, every kilogram counts, and one of the most pivotal components affecting overall vehicle weight is the battery enclosure. A battery in an electric vehicle typically consists of numerous cells arranged to form modules, which then combine into a complete battery pack. These modules require protection from external elements, including impact, moisture, and extreme temperatures. This protective shell—commonly known as a battery casing or EV battery enclosure—plays a fundamental role in ensuring the safety and longevity of an electric car’s power source. However, conventional metal casings, often made of steel, can add significant mass to an EV. Heavier enclosures negatively affect driving range, overall efficiency, and even handling. It is for this reason that manufacturers and materials scientists alike are researching lighter yet sturdy alternatives. The pursuit of an optimal balance between lightweight construction and robust protection has spawned a new generation of enclosures. These innovations employ materials such as aluminum alloys, carbon fiber composites, and thermoplastic composites that aim to reduce weight without compromising critical performance factors like crashworthiness and thermal management. This article explores the essentials of what is the battery casing for EV, why its weight matters, and how modern materials can dramatically enhance performance. We will also discuss what EV batteries are encased in, who the EV battery enclosure manufacturers are, various design strategies, real-world examples, and future directions. Whether you are curious about EV battery pack casing Tesla solutions, searching for…

Why Does Liquid Seepage Occur in Liquid Cold Plates

2025-02-14

Why Does Liquid Seepage Occur in Liquid Cold Plates High repair costs, compromised thermal performance, and potential safety hazards—liquid seepage in cold plates threatens system stability. Understanding its causes is key to preserving reliable cooling solutions. Leakage frequently results from fabrication defects, material fatigue, and weakened seals. To counteract these issues, implement robust welding, use corrosion-resistant alloys, and adopt high-quality sealing materials. Crucially, if a seepage issue emerges during final inspection, the cold plate is scrapped rather than repaired—underscoring the importance of meticulous manufacturing and early detection. Let us now examine the primary factors that contribute to seepage and proven methods to prevent it. Table of Contents What Are the Primary Triggers for Liquid Seepage in Cold Plates Liquid cold plates, when subjected to tiny cracks or exposed to corrosive coolants, become more prone to leakage. Recognizing these triggers early on helps maintain operational stability and prolong component life. Core drivers include flawed welding, subpar material selection, Thermal Expansion issues, and chemical incompatibility. Even minute weaknesses can develop into full-blown leaks under continual stress. Since final checks cannot salvage a defective plate, enforcing precise engineering standards from the outset is crucial. Engineers often overlook minor deviations in weld quality or micro-fissures in brazed joints. Over time, continuous temperature fluctuations and mechanical stresses worsen these defects. Additionally, corrosive coolant additives can eat away at the surface, allowing seepage through eroded pathways. Being vigilant from design through production is cost-effective and safeguards against scrapping entire batches when a leak is finally discovered. Implementing real-time imaging or ultrasonic testing helps detect vulnerabilities at an earlier stage. In-Depth Analysis: Design Defects Insufficient structural strength Liquid-cooling plate runner walls thinner than 1 mm, or an inadequate reinforcement layout, can deform under pressure fluctuations above 0.3 MPa. (Example: One liquid cooling plate experienced weld cracking after 50,000 pressure…

prismatic battery manufacuturer in US top 10

Mainstream Prismatic Battery Types and their Manufacturer in USA TOP 10

2025-01-21

Mainstream Prismatic Battery Types and their Manufacturer in USA TOP 10+ As the demand for sustainable energy solutions and electric vehicles accelerates, the importance of effective battery management cannot be overlooked. Innovations such as battery liquid cooling plates are paving the way for improved efficiency and reliability, showcasing the progress being made in battery technology. The Americas, as a hub of innovation, is leading this charge, particularly in the development of advanced prismatic batteries. In this article, I’ll detail the top ten manufacturers of mainstream prismatic batteries in the U.S.—whose technologies are powering the future of energy storage and electric vehicles. I hope you find this list helpful. Table of Contents Clarios Location: USA Company type: Design, Manufacturing The number of employees: 16000＋ Main products: Mainstream Prismatic Battery, Lead Acid Battery, Adsorbed Glass Mat (AGM) Battery, EFB Battery Website: https://www.clarios.com/ The company’s Mainstream Prismatic Battery solution manages many high power loads and usage demands while also effectively meeting regulatory requirements. A global network of power storage expertise helps them achieve and maintain a leadership position and also enables their customers to anticipate and respond to market and consumer trends. Recently, I learned that CLARIOS and OPTIMA BATTERIES announced a partnership with the FORD PERFORMANCE DAKAR RALLY program, and that Clarios and Optima Batteries will be providing battery support to Ford Performance to help its entry teams excel in the challenging Dakar Rally. Dakar Rally. Tesla Location: USA Company type: R&D, Design, Manufacturing The number of employees: 10000＋ Main products: Solar Panels, Mainstream Prismatic Battery, Solar Roofs, Electric Vehicles, Battery Storage Systems Website: https://www.tesla.com/ While Tesla’s battery technology is focused on cylindrical cells (such as the 2170 and 4680 cells) and future solid-state battery technology, it has also excelled in prismatic cells. For example, one of Tesla’s prismatic LFP batteries, which…

FSW in battery cooling industry - XD THERMAL

Why Should You Use Aluminium FSW in the Battery Cooling Industry?

2025-01-15

Why Should You Use Aluminium FSW in the Battery Cooling Industry? Struggling to balance durability, efficiency, and cost in your battery cooling components? Friction stir welding (FSW) offers a game-changing solution for manufacturers seeking robust thermal management in electric vehicle (EV) and energy storage system (ESS) applications. Aluminium FSW ensures high-strength, defect-free joints, minimizing leaks and improving heat dissipation—two critical factors in battery cooling. By merging components without melting, FSW preserves material properties for optimal performance. Curious about why so many innovators are turning to friction stir welding for better battery cooling? Let’s explore each aspect in detail. Table of Contents Understanding the Friction Stir Welding Process Friction stir welding is a solid-state joining technique that merges metals without reaching their melting point. Using a rotating, non-consumable tool, FSW generates frictional heat, softening the material so it can be stirred together. Unlike fusion welding, FSW avoids creating a molten pool, significantly reducing defects like cracks and porosity. This solid-state approach is particularly beneficial for aluminium—common in battery cooling—because it preserves the base metal’s mechanical and thermal properties, ensuring joints stay strong under demanding conditions. Traditional welding methods melt the edges of metals, often causing thermal distortion, micro-cracks, or a weakened heat-affected zone (HAZ). The friction stir welding process, however, operates below the melting temperature of aluminium, producing a fine-grained, homogenous weld. This results in better fatigue resistance and less shrinkage. Such features are pivotal in battery cooling plates and enclosures that must endure frequent thermal cycling while maintaining fluid-tight seals. Key Advantages of FSW in Battery Cooling FSW is more than just a novel welding technique—its unique benefits tackle critical challenges in the battery cooling industry. From enhancing joint integrity to lowering environmental impact, FSW stands out as a superior option compared to both fusion welding and brazing. High-strength, leak-proof…

Mainstream Cylindrical Battery Types and their Manufacturer in USA TOP 10+

2025-01-08

Table of Contents Mainstream Cylindrical Battery Types and their Manufacturer in USA TOP 10+ The U.S. battery market is a battleground where innovation meets demand, driving the evolution of dominant battery models and shaping the strategies of key suppliers. For manufacturers, staying ahead means understanding not just what powers the future, but who provides it. At XD THERMAL, we bring precision and expertise to the forefront of thermal management solutions. As a manufacturer of cutting-edge liquid-cooled components, we understand the pulse of the industry and the critical role advanced cooling plays in unlocking battery potential. By sharing this LIST, we hope to empower manufacturers and industry professionals to make informed decisions in this dynamic market. 18650 / 21700 cell Panasonic Company Name: Panasonic Contact Info : Email: secsales@us.panasonic.com, Phone: (469) 362-5600 Website Address: https://energy.panasonic.com/na/business/products/lithium-ion/models/NCR18650GA Samsung SDI Company Name: Samsung SDI Contact Info : Phone: +82-31-288-4115/ +1-248-912-6848 (USA Office) Website Address: https://www.samsungsdi.com/ EVE Energy Company Name: EVE Energy Contact Info (26V/35V) : Email: Anna.Gu@evebattery.com, Phone: +86 18819982208 Contact Info (33V) : Phone: +86-18688-788968, Email: michael@ancoo-battery.com Website Address: https://www.evebattery.com/en A123 Systems Company Name: A123 Systems Contact Info : Sales Hotline: +1-734-772-0300; Email: info@a123systems.com Website Address: https://www.a123systems.com/ SK Battery America Company Name: SK Battery America Contact Info : info@skbatteryamerica.com Website Address: https://www.skbatteryamerica.com/ Molicel Company Name: Molicel Contact Info : eservice@molicel.com, +886 6 505 0666 Website Address: https://www.18650batterystore.com/products/molicel-p28a Efest Power Company Name: Efest Power Contact Info : 1-888-501-1846, support@epochbatteries.com Website Address: https://www.efestpower.com/ Epoch Batteries Company Name: Epoch Batteries Contact Info : 1-888-501-1846, support@epochbatteries.com Website Address: https://www.epochbatteries.com/ EnerSys Company Name: EnerSys Contact Info : sales@enersys.com Website Address: https://www.enersys.com/ Toshiba Company Name: Toshiba Contact Info : +81-3-6871-3404 Website Address: https://www.toshiba.com/tai/ Tenergy Corporation Company Name: Toshiba Contact Info : Phone: (510) 687-0388; Email: sales@tenergybattery.com Website Address: https://www.murata.com/ EnerSys Company Name: EnerSys Contact Info: Phone: +82 31-8006-3100, Email:…

Which process improvements have the greatest impact on cost reduction in battery liquid cold plate manufacturing?

2024-12-31

Which process improvements have the greatest impact on cost reduction in battery liquid cold plate manufacturing? Faced with rising production costs for your battery liquid cooled plate? Feeling the pressure to stay competitive? Here’s how to optimize your processes and significantly cut expenses without compromising quality. Cost savings stem from three core strategies: careful material selection, innovative design, and streamlined manufacturing. By choosing stamped aluminum or advanced alloys, optimizing plate geometry, and embracing automated workflows, cold plate manufacturers can reduce expenses while improving performance. In a competitive market, these steps help secure profitability and maintain technical leadership. Table of Contents Let’s explore the questions engineers and buyers frequently ask when aiming for cost-efficient cold plate cooling solutions. 1. Focusing on cost reduction in battery liquid cold plate production? Balancing performance and cost is crucial in battery applications. Every dollar saved in manufacturing can be funneled into innovation, quality improvements, or competitive pricing. When liquid cooling solutions are produced efficiently, you gain an edge in pricing without sacrificing product reliability. This balance draws more customers while ensuring profitability. By streamlining costs, you can also invest in R&D, positioning your business at the forefront of EV and ESS thermal management innovations. Lowering production costs for liquid cooled plate assemblies involves strategic planning from the earliest design stages. Material procurement, tooling, and workflow processes are areas where overheads can quickly inflate. Choosing the right cold plate manufacturers who understand IATF 16949 requirements and have proven engineering support helps ensure smooth, cost-effective operations at every stage of production. 2. material selection and optimization can lower manufacturing costs Material decisions directly influence production complexity and overheads. High thermal conductivity and affordability both matter when selecting metals and insulators. Stamped aluminum offers an excellent balance between heat conduction and material cost. Dielectric materials and thermal pads…

Meeting the Demands of Liquid Cooling in New Energy Mining Trucks

2024-12-23

Meeting the Demands of Liquid Cooling in New Energy Mining Trucks The mining industry is going through a major shift. Tightening environmental laws, higher fuel costs and world-wide efforts to reduce carbon emissions are driving the change. Mining companies, and the makers of heavy-duty equipment they use, are all talking about the new energy mining trucks. These are the big trucks that don’t have a traditional diesel engine. Instead, they’re powered by electric or hybrid-electric systems. These trucks promise better gas mileage, lower greenhouse gas emissions and big money saved over time. However, the switch to battery-powered mining vehicles has added a big problem to the engineer’s to-do list. You have to figure out how to keep the high-capacity battery packs at the right temperature. Of course, battery cooling is critical to all electric vehicle (EV) designs. However, the harsh conditions in mining—where the trucks work hard, climb big hills and have to go out in all sorts of weather—mean your thermal management system has to be a lot more bulletproof than a typical consumer electric vehicle, or EV. This article will explain the unique liquid cooling needs of these new energy mining trucks. I’ll also address the hot topics in the minds of people in this industry about this issue. Table of Contents The Rising Trend of New Energy Mining Trucks Over the past ten years or so, the mining industry has gotten a lot of pressure to buy cleaner, more efficient equipment. The diesel trucks that have always been the heart of the mining business now have some problems. First, fuel costs are sky-high. Second, the maintenance you need to do on diesel trucks is taking more time and getting more expensive. Finally, everybody around the mine wants more sustainability by the mining companies. The trouble is, the…

Common Aluminum Sheets Used for Stamped Liquid Cold Plates: Production, Minimum Order Quantity, and Lead Time

2024-12-16

Common Aluminum Sheets Used for Stamped Liquid Cold Plates: Production, Minimum Order Quantity, and Lead Time Stamped liquid cold plates are vital components in industries such as electronics, automotive, and renewable energy. They serve as an effective thermal management solution, dissipating heat efficiently in applications where high-performance cooling is essential. Among the materials used in their construction, aluminum stands out as a preferred choice due to its exceptional thermal conductivity, light weight, and versatile processing characteristics. In this article, we will explore the types of aluminum sheets commonly used for liquid cold plates, their production process, the minimum order quantities required, and the typical lead times for procurement. This comprehensive overview will provide manufacturers and stakeholders with valuable insights into optimizing their material selection and supply chain management. Table of Contents Importance of Aluminum in Liquid Cold Plates The primary function of a liquid cold plate is to transfer heat from critical components, such as power electronics or battery modules, to a liquid coolant circulating through internal channels. To achieve this, the material of the cold plate must offer a combination of high thermal conductivity, light weight, and structural strength. Aluminum fulfills these criteria better than most alternatives, such as copper or composite materials. Specifically: -Thermal Conductivity: While copper has a slightly higher thermal conductivity than aluminum, the latter provides a more balanced solution in terms of cost, weight, and manufacturability. – Weight-to-Strength Ratio: Aluminum’s low density (around 2.7 g/cm³) makes it ideal for lightweight designs, particularly in electric vehicles and aerospace applications. – Cost Efficiency: Aluminum is more affordable than copper and widely available in various grades suitable for different requirements. These characteristics make aluminum the most commonly used material in liquid cold plate manufacturing. Common Aluminum Sheets for Stamped Liquid Cold Plates Different applications require specific aluminum grades…

XD Group

Can BMW’s Large Cylindrical Batteries Overcome Tesla’s Challenges?

How Can Lightweight Battery Cases Improve Electric Vehicle Performance?

Why Does Liquid Seepage Occur in Liquid Cold Plates

Mainstream Prismatic Battery Types and their Manufacturer in USA TOP 10

Why Should You Use Aluminium FSW in the Battery Cooling Industry?

Mainstream Cylindrical Battery Types and their Manufacturer in USA TOP 10+

Which process improvements have the greatest impact on cost reduction in battery liquid cold plate manufacturing?

Meeting the Demands of Liquid Cooling in New Energy Mining Trucks

Common Aluminum Sheets Used for Stamped Liquid Cold Plates: Production, Minimum Order Quantity, and Lead Time

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