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the battery popular heat exchange solution - xd thermal

What Are the Popular Battery Heat Exchange Solutions in the Market ?

2024-10-12

What are the popular battery heat exchange solutions in the market? Are you encountering difficulties in effectively managing heat within your battery systems? Is it challenging to identify the optimal heat exchange solution tailored for your battery needs? Explore the leading battery heat exchange solutions currently available in the market. As new energy technologies advance, liquid cooling has become the top choice for battery heat management. Air cooling is no longer adequate for high-load and compact systems. The two leading liquid cooling options are liquid cooling plates and serpentine tubes, each designed for specific battery pack configurations. Now, let’s dive into the different Battery Thermal Management Systems (BTMS) available, specifically focusing on liquid cooling technology. Table of Contents What Are the Different Types of Battery Thermal Management Systems? Understanding the multitude of Battery Thermal Management Systems (BTMS) available on the market is key to making an informed decision for your specific application. Broadly speaking, BTMS can be divided into two types: active BTMS and passive BTMS. There are also hybrid BTMS that combine elements of both types to optimize performance. Active Thermal Management Systems Active systems use external resources (e.g., fans, liquid coolers) to regulate battery temperature. They are more complex systems but offer precise control over the operating conditions of the battery. Table of Contents Liquid Cooling Systems Liquid cooling is one of the most effective methods for managing battery temperatures in electric vehicles (EVs). The coolant, usually a mixture of water and glycol, flows through channels or plates in direct or indirect contact with the battery cells. Indirect Liquid Cooling: The coolant flows through a closed-loop system of pipes or plates that contact the battery cells. The battery cells conduct heat to the coolant. This method prevents the coolant from coming into direct contact with the electrical components,…

price range micro-channel liquid cooling plates - XD THERMAL

What is the price range of high-quality micro-channel liquid cooling plates?

2024-10-05

What is the price range of high-quality micro-channel liquid cooling plates? Having trouble figuring out how much these premium micro-channel liquid cooling plates cost? It can be frustrating because a lot of these companies don’t give the pricing upfront, and you want to know how much this stuff costs, especially when quality is important and performance is required for the projects you’re doing. High-quality micro-channel liquid cooling plates typically range from $30 to $150 per unit. This price varies based on materials used, manufacturing processes, order quantities, and the expertise of the supplier. The bottom line is you need to know how much it’s going to cost. So, we need to dive further into what all leads to these costs. Table of Contents What are the key factors influencing the price of micro-channel liquid cooling plates? Multiple factors contribute to the price of this stuff. It’s not going to be the same every single time, and talking about “Hey, what do these things cost?” is not a one-size-fits-all answer. Factors such as material selection, production techniques, order volume, and supplier capabilities significantly impact the overall cost of these advanced cooling solutions. The choice of materials—aluminum or copper—makes a big difference in the price. How you build it—vacuum brazing, hydro forming, special processes for Micro Channel Heat Exchangers (also called Micro Channel cold plates)—all those things make a difference in the price. The quantity you order also makes a difference in the price because of economies of scale. What is the quality control process for micro-channel plates? Quality control is critical for the reliability, performance, and safety of micro-channel cold plates in applications like electric vehicles (EVs) and energy storage systems (ESS). You perform a variety of different quality control inspections all along the way including inspection of all the material coming in, inspection of runners, production of all of the different…

Battery Heat Sink Assembly -XD THERMAL

How Can a Battery Heat Sink Assembly Improve Performance and Longevity?

2024-09-29

How Can a Battery Heat Sink Assembly Improve Performance and Longevity? Battery systems really struggle with overheating, and you know what happens when a battery system gets hot? It doesn’t work so well. Also, the longevity of the battery degrades significantly if the system gets too hot. This is a big problem in terms of safety and efficiency. The battery heat sink assembly is the solution to this. A battery heat sink assembly improves performance and longevity by effectively dissipating excess heat, maintaining optimal temperatures, and preventing thermal degradation of battery components. To understand this a little bit better, I’ll explain how the battery heat sink assembly helps with battery thermal management. Table of Contents What Is a Battery Heat Sink Assembly? A battery heat sink assembly is a device used to absorb and remove heat from a battery system to keep it at a stable operating temperature. In these battery heat sink assemblies, we’re using materials that have a very high thermal conductivity to take the heat away from the battery cells to keep them from overheating. In the grand scheme of the BTMS (Battery Thermal Management System), the battery heat sink assembly is the critical part. It’s the piece that helps keep the battery at the right temperature to make sure it works well and it is safe. Battery thermal management is about making sure your batteries can always perform the way they’re supposed to at all different temperatures and conditions. How Does a Battery Heat Sink Assembly Improve Battery Performance? When a battery gets hot, it doesn’t work as well, and it often fails. How does the heat sink assembly fix that?g temperature. It does that by getting rid of the heat as fast as it’s coming in. This way, you don’t end up with a whole bunch of heat in the battery that…

Cooling Plates for Heavy-Duty Use: Procurement Challenges & Success-XD THERMAL

Cooling Plates for Heavy-Duty Use: Procurement Challenges & Success

2024-09-25

How Can You Overcome Procurement Challenges for Heavy-Duty Cooling Plates and Achieve Success? Are procurement roadblocks holding up your heavy-duty projects? Are you struggling to pick the right electrical cooling plates solutions to buy? Let’s talk about how to solve those problems everything you need to know to make that problem go away right now. This article outlines the top procurement risks for buying it using a real-world example of a success story. It shows you how XD THERMAL worked with a structural engineer to eliminate these risks and make heavy-duty equipment perform better. Procurement of electrical cooling plates for heavy-duty applications faces key risk points such as unclear technical specifications, supply chain disruptions, and quality control during manufacturing. These risks can lead to delays, increased costs, and suboptimal cooling performance. Addressing these procurement risks early ensures more reliable thermal management for heavy-duty equipment, reducing downtime and enhancing operational efficiency. Table of Contents Initial Communication: Clarifying Needs Unclear technical specs is a risk you have to address at the very beginning. Especially when dealing with the high-performance needs of heavy-duty equipment. I was approached by a structural engineer who works on this heavy-duty equipment. This particular engineer came to us with some preliminary specs regarding the cooling plates and enclosures he needed for thermal protection of his applications. He also had some preliminary ideas about the thermal exchange he needed from our plates. While the customer had some design parameters, they were not so concrete about exactly what they needed as far as thermal performance. By having some conversations with them, we were able to make sure there wasn’t going to be some huge disconnect between what they thought they were going to get and what we delivered to them. Proposal Development: Technical Coordination Design space limitations and manufacturing constraints…

Liquid Cooling Plate Stamping Mould - XDTHERMAL

The Crucial Role of Molds in Battery Liquid Cooling Component Manufacturing

2024-09-20

The Crucial Role of Molds in Battery Liquid Cooling Component Manufacturing As battery liquid cooling technology advances rapidly, the importance of precision manufacturing techniques becomes paramount, with molds playing a central role in the production of key components. Whether you’re a procurement professional or a structural/technical engineer, understanding molds is essential when dealing with battery liquid cooling products. This article explores the types of molds, their features, manufacturing methods, and key considerations for designing or procuring products. Molds are critical tools in the manufacturing of battery liquid cooling components, determining the shape, precision, and consistency of each part. From extrusion dies used for cooling tubes to stamping molds for cooling plates, molds ensure that the products meet the necessary thermal management standards. Without precise molds, the final components may lack the dimensional accuracy required for efficient heat dissipation, directly impacting the performance of the battery cooling system. The precision of molds is essential, particularly for high-volume production where even the slightest deviation in dimensions can lead to product failure or inefficiencies. Molds must be designed to ensure that the parts produced meet tight tolerances, guaranteeing both functionality and cost efficiency. Table of Contents Main Types of Molds and Their Applications Extrusion Molds Extrusion molds are used to manufacture extruded profiles, such as cooling tubes. These molds consist of a male and female die, where the male die shapes the internal structure, and the female die forms the outer surface. During the extrusion process, materials like aluminum are heated and forced through the mold, producing continuous lengths of cooling tubes. For example, a typical extrusion mold weighing 1.5 tons can extrude around 1 ton of finished product. After each extrusion run, the mold requires maintenance to ensure that the next batch meets the required precision and quality. The female die, which…

The Origins of Serpentine Tubes: The Aluminum Profile Manufacturing Process -XDTHERMAL

The Origins of Serpentine Tubes: The Aluminum Profile Manufacturing Process

2024-09-13

The Origins of Serpentine Tubes: The Aluminum Profile Manufacturing Process In recent years, the demand for serpentine cooling tubes has grown significantly, especially in the electric vehicle (EV) industry. These tubes play a critical role in thermal management for battery packs, ensuring that lithium-ion batteries are kept at optimal temperatures to prevent overheating and improve performance. But how exactly are these essential components made? The journey of a serpentine tube begins with the aluminum extrusion process, an advanced technique that has been refined over centuries. I will concisely explain the aluminum extrusion process, emphasizing the role of serpentine tubes in thermal management for batteries. The explanation will include details on the extrusion process and its significance in battery cooling solutions Table of Contents What is the process of making aluminum profiles? The manufacturing of aluminum profiles, including those used for serpentine cooling tubes, consists of several key stages. The process begins with the adjustment of the shrinkage rate. Each extrusion machine has unique characteristics that influence how much the aluminum shrinks during the process. This step requires precise calibration and testing, depending on the tonnage of the machine and the brand of equipment used. The next step involves heating and slicing the aluminum. A round bar of aluminum, typically from the 3-series or 6-series materials, is heated to a high temperature using a furnace. The heating softens the metal, making it more malleable and ready for extrusion. Once heated, the aluminum bar is sliced into smaller sections that are suitable for the extrusion machine. Following this, the sliced aluminum bars are transferred to the extruder using a transfer machine. This ensures that the material moves smoothly to the next stage without any delays or inefficiencies What is the history of extrusion? The extrusion process has a long history, dating back…

XD THERMAL- Top 10 Battery Liquid Cooling System Companies in Europe

Top 10 Battery Liquid Cooling Systems Companies in Australia

2024-09-12

Top 10 Battery Liquid Cooling Systems Companies in Australia Australia is a leader in renewable energy innovation, driving advances in areas as diverse as energy storage, green technology and cooling solutions. The country’s strong infrastructure and focus on sustainability has fuelled the growth of several forward-looking companies. In exploring the battery liquid cooling systems market, I have written a list of Australian companies that are excelling in this field. I hope this list serves as a useful guide and provides valuable insights. Table of Contents XD THERMAL TECHNOLOGY CO.,LTD Location: Suzhou, China Company type: Manufacturer, R&D, Design, Production The number of employees: 500＋ Main products: Prismatic cooling plate, Cylindrical cooling pipe, Battery enclosure, Design& simulation Main application: Electrical vehicles, Energy storage systems, Solar systems, Heavy duties, eVTOL, Marines Website: https://www.xdthermal.com XD THERMAL serves over 55 countries and has a wealth of experience in international OEM projects, with proprietary profile extrusion lines and machining centres, and of course experience in battery liquid cooling systems, all of which are essential for a first class supplier. Liquid Cooling Systems in Australia, so there really should be a place for this company on this list. SCHNEIDER ELECTRIC Location: Australia Company type: R&D, Design, Production The number of employees: 150000 Main products: Electrification, Smart industry, Resilient infrastructure, Liquid cooling systems for future data centres, Smart buildings, Intuitive homes Website: https://www.se.com/ww/en/ As I understand it, Schneider Electric has a wide range of solutions for liquid-cooling systems, mainly for data centres and edge computing. The company offers a wide range of liquid cooling technologies, including direct chip cooling, positive pressure cooling and precision cooling. They are a global industrial technology leader, bringing world-leading expertise in electrification, automation and digitisation to smart industry, resilient infrastructure, future-proof data centres, smart buildings and intuitive homes.Schneider Electric has always been a…

How to Choose Battery Liquid Cooling Plate Insulation ？-xd thermal

How to Choose Battery Liquid Cooling Plate Insulation ？

2024-09-09

How to Choose Battery Liquid Cooling Plate Insulation? Selecting insulation materials for battery liquid cooling plates is crucial to ensuring the safety, efficiency, and longevity of electric vehicle (EV) battery systems. Given the increasing performance demands and higher operational voltages in modern EVs, traditional insulation methods such as PET films (“blue film”) are now being replaced by more advanced solutions, including UV-coated insulation materials. In this guide, we explore the benefits and challenges of using UV-coated insulation, comparing it with other commonly used materials. Additionally, we’ll discuss critical considerations such as application process, spray thickness, and the unique advantages of UV coatings in the context of electric vehicle battery systems. Table of Contents From PET to UV Coatings Historically, PET-based insulation films (often referred to as “blue films”) were the industry standard for battery insulation. However, with the advent of higher energy densities and voltages—especially with the emergence of 800V platforms—these traditional materials have started to fall short in several key performance areas, including adhesion and electrical breakdown. Why Are PET “Blue Films” Falling Behind? The widespread use of “blue films” for insulating battery cells stems from their chemical resistance, insulation properties, and tensile strength. However, there are significant limitations: Adhesion Issues: Blue films have limited adhesion strength, especially in high-vibration environments like automotive applications. The adhesive layers (PSA) used in blue films can easily undergo cohesive failure, which weakens the overall structural integrity of the battery pack. As a result, battery cells are more likely to detach, leading to potential short-circuiting. High-Voltage Platforms: With the push for faster charging times and higher energy outputs, battery systems are moving to 800V platforms. The limited dielectric strength and adhesion properties of blue films make them increasingly inadequate for these high-voltage applications. UV-Coated Insulation: The New Standard In response to these limitations,…

XD THERMAL- Top 10 Battery Liquid Cooling System Companies in Europe

Top 10 Battery Liquid Cooling System Companies in Europe

2024-09-06

Top 10 Battery Liquid Cooling System Companies in Europe With the growing demand for electric vehicles and energy storage solutions, efficient battery thermal management is becoming increasingly important. Battery liquid cooling systems are critical to maintaining optimal battery performance and lifetime. At the forefront of automotive innovation and renewable energy, Europe is home to several leading companies specialising in battery liquid cooling solutions. Below is a list of the top 10 companies in Europe in this important field, which we hope will be useful to you. Table of Contents XD THERMAL TECHNOLOGY CO.,LTD   Location: Suzhou, China Company type: Manufacturer, R&D, Design, Production The number of employees: 500＋ Main products: Prismatic cooling plate, Cylindrical cooling pipe, Battery enclosure, Design& simulation Main application: Electrical vehicles, Energy storage systems, Solar systems, Heavy duties, eVTOL, Marines Website: https://www.xdthermal.com Although XD THERMAL is not from Europe, we are recognized in the field of thermal management technology and in the field of liquid cooling systems for batteries, especially in the production of liquid cooling plates. Our specialty is the design of advanced liquid cooling panels that provide a comprehensive thermal management solution for power batteries. We are pleased to enter the European market, while recognizing and appreciating the fierce competition in the European market. We understand and respect the tireless efforts of our competitors, whose constant innovation may soon propel them to join this list. VALEO Location: France Company type: Research and development, Design, Production, manufacturing The number of employees: 113600 Main products: Battery cooling systems, Thermal management systems, Aautomatic driver assistance systems, Lighting systems, Electrical systems Website: https://www.valeo.com/en/?s=+liquid+cooling+system As a global leader in the electrification of powertrain systems and the second largest player in thermal management systems and battery liquid cooling systems that ensure the performance and range of electric vehicles, Valeo has a…

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