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XD THERMAL TECHNOLOGY CO.,LTD

Top 10 Battery Liquid Cooling System Companies in USA

2024-08-22

Top 10 Battery Liquid Cooling System Companies in USA With the rapid growth of the electric vehicle (EV) and renewable energy storage markets, the importance of battery liquid cooling systems is growing. These systems not only effectively manage battery temperature and extend battery life, but also improve charging speed and overall performance.  The U.S., being at the forefront of technological innovation, has seen a number of companies emerge in this field. Through continuous technological innovation, they provide advanced battery liquid cooling solutions that help electric vehicles and energy storage systems run efficiently. In this article, I will introduce you to the top 10 battery liquid cooling system companies in the US. 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 based in the United States, we have earned recognition for our commitment to innovation and quality in the field of battery liquid cooling systems, particularly for the manufacture of liquid cooling panels. We specialise in cutting-edge liquid cooling solutions, providing comprehensive thermal management solutions for power batteries. We are honoured to enter the US market and become their benchmark, and we acknowledge the potential of our competitors, whose tireless efforts may put them on the list. VERTIV Location: United States Company type: Design, Production, Manufacturing, R&D The number of employees: 27,000 Main products: Uninterruptible power supplies, Rack coolin, Battery storage systems, Switcharge and switchboards, Bus bars、DC power systems Website: https://www.vertiv.com/en-us/ This company is a publicly traded company with 22 manufacturing and assembly locations, 19 customer experience centres, 750,000+ customer site connections, 2,740 patents issued globally, 240+…

Cooling Plate Manufacturing: Case Studies and Engineering Insights -XD THERMAL

Cooling Plate Manufacturing: Case Studies and Engineering Insights

2024-08-19

Cooling Plates Manufacturing: Engineering Insights and Case Studies In the rapidly evolving industries of energy storage systems (ESS) and electric vehicles (EVs), the importance of thermal management cannot be overstated. Cooling plates play a pivotal role in ensuring the efficiency, safety, and longevity of high-power battery systems. However, the manufacturing process of these components is intricate, involving multiple advanced techniques to meet the specific requirements of different applications. This article delves into the step-by-step process of how cooling plates are made, highlighting the materials and methods used. Whether you’re a mechanical engineer, procurement manager, or involved in the high-voltage battery industry, this guide is tailored to provide you with insights into the production process of cooling plates, focusing on the needs and expectations of professionals . Table of Contents Material Preparation: The Foundation of Cooling Plate Manufacturing The first step in the manufacturing of cooling plates is material preparation. The choice of materials directly influences the performance, durability, and efficiency of the cooling plates. Shearing: This process involves cutting raw materials, typically metals like aluminium or copper, into the desired size and shape. Precision in shearing is essential to ensure that the cooling plate meets the specific dimensions required for its application. Extrusion: In cases where complex cross-sectional shapes are needed, extrusion is employed. This process involves forcing the material through a die to create long sections with consistent profiles. Extruded materials are often used in the production of channels or fins within the cooling plate. Benefits: Aluminum offered a good balance between performance and cost. The extrusion process enabled the production of channels that optimized fluid dynamics, reducing the overall size and weight of the cooling plates. Challenges: The extrusion process, while effective, introduced complexities in maintaining tight tolerances during subsequent machining steps, which could potentially impact the flow…

Extrusion liquid cold plates2 - XDTHERMAL

Understanding Liquid Cold Plates: Types and Selection Guide

2024-08-12

Understanding Liquid Cold Plates: Types and Selection Guide Liquid cold plate is a critical component in thermal management systems, offering efficient cooling solutions by transferring heat through a circulating liquid within the plate. They are widely used in various applications, including electronics, data centers, electric vehicles, and ESS. This article will explore the different types of liquid cold plates and provide a comprehensive guide on selecting the right type for your specific needs. Table of Contents Types of Liquid Cold Plates Liquid cold plates can be categorized based on their structure and operating principles. The primary types include: Embedded Tube Cold Plates Embedded tube cold plates consist of a metal base (typically copper or aluminum) with tubes embedded within. The coolant flows through these tubes, absorbing and dissipating heat. This type of cold plate is relatively simple in construction and manufacturing, making it cost-effective. However, due to the longer heat conduction path, the thermal resistance is higher, making it suitable for applications with moderate cooling requirements. Advantages   Simple construction Cost-effective Suitable for moderate cooling requirements Brazed Cold Plates Brazed cold plates are constructed by stacking multiple thin metal sheets (usually copper or aluminum) and brazing them together to form intricate liquid channels. This design allows for greater flexibility in channel layout, resulting in improved thermal performance due to shorter heat conduction paths. Brazed cold plates are ideal for high-performance applications, such as power electronics and high-performance computing, where superior cooling is essential. Advantages High thermal performance Flexible channel design Suitable for high-performance applications Extruded Cold Plates Extruded cold plates are manufactured by extruding aluminum or copper into specific shapes with internal channels for the coolant. These cold plates offer good thermal conductivity and lower manufacturing costs, making them suitable for medium-demand cooling applications, such as servers and communication equipment. Advantages…

Battery Pack

Why Are Liquid Cooling Battery Packs Essential?

2024-08-05

Why Are Liquid Cooling Battery Packs Essential? As the demand for efficient and reliable energy storage systems continues to rise, advancements in battery technology are crucial. One such advancement is the liquid cooling battery pack. This innovative system offers significant advantages over traditional air-cooled systems, providing superior thermal management, improved safety, and enhanced performance. In this article, we will delve into the workings of a liquid cooling battery pack and explore why it is becoming increasingly important in various applications, especially in electric vehicles (EVs). Table of Contents What is a Liquid Cooling Battery Pack? A liquid cooling battery pack utilizes a liquid coolant to regulate the temperature of the batteries. This system comprises several key components, including the coolant, heat exchanger(liquid cooling plate or tube), pumps, and temperature sensors. Unlike air-cooled systems, which rely on air to dissipate heat, liquid cooling systems use a fluid—typically a mixture of water and glycol—to absorb and transfer heat away from the battery cells. This method is more efficient, especially in high-performance applications where rapid and consistent cooling is required. How Does a Liquid Cooling Battery Pack Work? The operation of a liquid cooling battery pack involves several key components and processes: Coolant Circulation: A liquid coolant, typically a mixture of water and glycol, is circulated through the battery pack. This coolant absorbs heat generated by the battery cells during operation. Heat Exchangers: The heated coolant is then passed through a heat exchanger, where the heat is transferred from the coolant to the outside environment. This can be achieved through various methods, such as using a radiator or a chiller. Pumps and Sensors: Pumps are used to maintain the flow of the coolant, while temperature sensors monitor the temperature of the battery cells and the coolant. These sensors ensure that the system operates…

CNC liquid cooling plate machine factory -XD THERMAL

CNC and FSW: Game-Changers in Battery Liquid Cooling

2024-07-23

CNC and FSW: Game-Changers in Battery Liquid Cooling Thermal management is crucial in modern industries and electronics, where efficient heat dissipation significantly impacts the performance and longevity of various devices. CNC (Computer Numerical Control) and FSW (Friction Stir Welding) liquid cooling plates are emerging as effective solutions for thermal management, offering exceptional heat dissipation and flexible design options. This article will explore these technologies’ characteristics, benefits, applications, and future trends. Table of Contents Understanding CNC and FSW Technologies EV batteries generate significant amounts of heat during operation and charging. This heat, if not managed properly, can lead to a decrease in battery performance, reduced lifespan, and even safety hazards like thermal runaway. Thus, an effective EV battery cooling system is indispensable for maintaining optimal battery performance and ensuring safety. Overheating can result in thermal runaway, a dangerous chain reaction that can cause fires or explosions. Proper cooling helps maintain the battery within its optimal temperature range, ensuring consistent performance and longevity. CNC Technology CNC technology utilizes digital information to control the movement and machining of tools, allowing for the precise and efficient production of complex parts. The CNC process involves a computer that precisely controls machine tools via programmed commands, reducing manual intervention and ensuring high consistency and repeatability. This technology is indispensable in industries requiring high accuracy. FSW Technology FSW involves a rotating tool that frictionally heats and mechanically agitates material joints, creating a dense and robust weld without melting the base material. This process is particularly beneficial for joining metals with different melting points or those difficult to weld using traditional methods. FSW is widely used in aerospace, automotive, and shipbuilding industries. CNC Liquid Cooling Plates CNC liquid cooling plates are advanced heat dissipation devices created through precise machining of cooling channels in metal sheets. These channels allow…

How Does an EV Battery Cooling System Work?

How Does an EV Battery Cooling System Work?

2024-07-19

How Does an EV Battery Cooling System Work? Electric vehicles (EVs) have revolutionized the automotive industry by offering a cleaner and more sustainable mode of transportation. One of the critical components that ensure the efficient operation of EVs is the battery cooling system. Understanding how these systems work and why they are essential is crucial for anyone interested in EV technology. Table of Contents Why EV Battery Cooling is Crucial EV batteries generate significant amounts of heat during operation and charging. This heat, if not managed properly, can lead to a decrease in battery performance, reduced lifespan, and even safety hazards like thermal runaway. Thus, an effective EV battery cooling system is indispensable for maintaining optimal battery performance and ensuring safety. Overheating can result in thermal runaway, a dangerous chain reaction that can cause fires or explosions. Proper cooling helps maintain the battery within its optimal temperature range, ensuring consistent performance and longevity. Types of EV Battery Cooling Systems There are primarily two types of cooling systems used in EV batteries: air cooling and liquid cooling. Air Cooling Systems: Passive Air Cooling: Uses natural airflow to cool the battery. It is simple and cost-effective but limited in its cooling capacity. This method relies on the surrounding air to dissipate heat, which means it is less efficient in extreme temperatures or during high-demand scenarios. Active Air Cooling: Involves using an air conditioner to regulate the battery temperature. It is more effective than passive air cooling but also more complex and energy-intensive. This system uses fans and blowers to circulate air over the battery pack, improving heat dissipation but consuming more power. Application Case: Nissan Leaf’s Air Cooling Systems The Nissan Leaf initially employed a passive air cooling system. While effective in moderate climates, this system struggled in extreme temperatures, leading to…

TRADITIONAL VS NEW THERMAL MANAGEMENT

”Traditional” vs “New ” Thermal Management

2024-07-12

“Traditional” vs “New” Thermal Management The transition from traditional fuel vehicles to modern new energy vehicles has significantly impacted the complexity of vehicle thermal management systems. Originally simple, these systems have evolved into intricate structures, progressing from standalone modules to integrated systems engineering. Traditional thermal management primarily involves air conditioning and powertrain systems. In contrast, new energy vehicles incorporate the power battery system into the thermal management scope, marking a shift towards ‘new’ thermal management. This article focuses on key components within both traditional and new thermal management systems. In traditional systems, we highlight the condenser, evaporator, radiator, oil cooler, and intercooler. For new thermal management, the spotlight is on the battery cooling plate. The distinction between ‘traditional’ and ‘new’ does not imply that traditional thermal management is ineffective. Instead, it underscores that new thermal management technologies are advancing at an unprecedented pace. This rapid development is driven by the unique demands and challenges posed by new energy vehicles, necessitating more sophisticated and efficient thermal management solutions. Table of Contents Traditional Thermal Management Condenser The condenser is an integral component of the vehicle’s air conditioning (A/C) refrigerant circuit. It connects to the A/C compressor and the receiver-drier via copper and aluminium pipes. Typically installed in front of the car’s radiator, it often shares a cooling fan with the radiator. Based on the type of coolant used, condensers can be classified into four types: water-cooled, air-cooled, water-air cooled (including evaporative and spray types), and those cooled by refrigerant evaporation or other process media. During operation, the condenser cools high-pressure, high-temperature refrigerant into a high-pressure, low-temperature liquid. This liquid then passes through a capillary tube, vaporising into the evaporator to continue the cooling cycle. As this process releases heat, the condenser usually operates at a high temperature, categorising it as a type…

Thermal Interface Materials

How Do Thermal Interface Materials Enhance Liquid Cooling in Battery Packs?

2024-07-04

How Do Thermal Interface Materials Enhance Liquid Cooling in Battery Packs? In today’s world, where electronic devices are becoming increasingly powerful and compact, managing heat is critical for ensuring reliable operation, optimal performance, and longer lifespans. Thermal interface materials (TIMs) play a pivotal role in enhancing heat transfer between heat-generating components and heat dissipation systems. This is especially crucial in modern battery pack design, particularly for liquid cooling components in electric vehicles (EVs) and high-performance batteries. Effective thermal management, facilitated by TIMs, is essential for maintaining the optimal operating temperature of battery packs, directly impacting their performance, safety, and longevity. Table of Contents Types of Thermal Interface Materials Thermal interface materials (TIMs) come in various forms, each designed for specific applications and requirements, including thermal adhesives, thermal pads, thermal pates/grease, and thermal tapes. Thermal Adhesives They are known for their bonding properties and thermal conductivity, providing strong bonds between surfaces while facilitating efficient heat transfer. Advantages： Thermal adhesives are useful for securing components while effectively cooling them, providing both mechanical bonding and thermal management. Disadvantages： Once applied, they can be difficult to remove, making them less suitable for situations requiring reworkability. Thermal pads They made from materials like silicone or graphite, are pre-formed TIMs offering flexibility and ease of application. They fill gaps between surfaces, ensuring a uniform thermal interface, and their compressibility makes them ideal for battery packs with surface irregularities. Advantages: Thermal pads are user-friendly and maintain consistent thickness, making them ideal for applications where ease of use and reworkability are crucial. They are also more durable over time compared to pastes. Disadvantages: They may not conform as well as pastes to microscopic surface irregularities, potentially resulting in slightly lower thermal performance. Thermal Pastes Thermal pastes, also known as thermal paste, is a viscous substance applied between surfaces to…

Exploring Lithium Battery Packaging: Square, Cylindrical, and Soft Pack - XD THERMAL

How Does Lithium Battery Packaging Affect Heat Dissipation in Square, Cylindrical, and Pouch Cells?

2024-06-27

How Does Lithium Battery Packaging Affect Heat Dissipation in Square, Cylindrical, Pouch Cells? In the ever-evolving world of lithium batteries, the packaging form plays a crucial role in determining the performance, efficiency, and safety of these energy storage devices. Whether you’re driving an electric vehicle, using a smartphone, or working with industrial equipment, the type of lithium battery inside significantly impacts your experience. Let’s delve into the fascinating world of lithium battery packaging and explore the three primary forms: square, cylindrical, and soft pack. Square batteries provide high efficiency but face heat dissipation challenges. Cylindrical batteries offer good heat dissipation and consistency but have lower energy density. Soft pack batteries are flexible and high in energy density but more costly. Table of Contents Square Lithium Batteries Structure and Composition Square lithium batteries, often referred to as prismatic batteries, are encased in a rectangular shell, usually made of aluminum or steel. These batteries can be produced using either winding or lamination processes, depending on the specific requirements of the application. Manufacturing Processes The manufacturing process for square batteries involves either winding the cells into a compact form or stacking layers of cells to create the final structure. This method allows for greater flexibility in the design and size of the battery, making it suitable for various applications. Advantages & Disadvantages Advantages： High Group Efficiency Square batteries can be packed tightly together, maximizing the use of space and improving the overall efficiency of the battery pack. Large Single Capacity Due to their design, square batteries often have a larger single cell capacity compared to cylindrical batteries, making them ideal for applications requiring high power output. Simple Structure The straightforward design of square batteries simplifies the manufacturing process and reduces potential points of failure. Disadvantages： Low Consistency Achieving consistent performance across all cells…

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