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Battery Cooling Tubes

Battery cooling tubes are widely used in cylindrical cells thermal management. They are also called serpentine tubes or liquid cooling tubes. Battery cooling tubes are developed with highly refined manufacturing quality, to make sure they can fit with cylindrical cells side curves, hence large contact surface between cooling tube and cells can be guaranteed .
With their large internal surface area, they can achieve more efficient heat transfer and are well adapted to different forms to work with 1865, 2170, 4680, 4695 and many other dimensions of cylindrical cells.
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Battery cooling tubes
The reliable thermal management solution for cylindrical cells and even prismatic cells.
XD Thermal battery cooling tubes use automotive standard technology, deliver excellence and performance in battery heat dissipation.
  • Optimal internal structure to achieve increased heat dissipation efficiency.
  • Multiple forms of external structure to fit into different types of battery packs.
  • Accurate workmanship to guarantee sufficient contact surface with cells.
  • Dichtheitsprüfung mit Heliumtest 100%.
  • Über 10 Jahre Garantie auf die Lebensdauer.
  • Korrosionsschutz mit hoher Mn-Aluminiumlegierung.
  • Leichtgewichtig und einfach zu installieren.
  • Recycelbar und umweltfreundlich.
  • Vibration resistant frequncy 0-200Hz.
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Typical Applications For Battery cooling tubes
Kühlplatte in Elektrofahrzeugen - XD THERMAL
Elektrische Fahrzeuge
Kühlplatte in Energiespeichersystemen - XD THERMAL
Energiespeichersysteme
Kühlplatte in schwerer Ausführung - XD THERMAL
Schwere Aufgaben
Kühlplatte in eVTOL - XD THERMAL
eVTOL
Kühlplatte in Marinen - XD THERMAL
Marinesoldaten
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Meistverkaufte Produkte
XD Thermal verwendet die unterschiedlichsten Verarbeitungsmethoden, um Ihren technischen Anforderungen gerecht zu werden.
Liquid cooling tube2 - XD THERMAL
C2P Battery Cooling Tubes
Most preferred type of battery cooling tubes so far in automotive industry. Giants like Tesla or BMW use the same concept. Both U turn structure and Straight structure are available. Very good compatibility for 4680, 4695 and 46125 cylindrical cells.
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C2M Liquid Cooling Tube-XDTHERMAL
C2M Bended Battery Cooling Tubes
Bended cooling tubes can be modified as per module layout, making cells deployment flexible. In order to utilize every single corner in the battery module, such cooling tubes can have inlets and outlets at the same side or different sides.
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liquid cooling tube 3 - XD THERMAL
Tri-way Battery Cooling Tubes
3 parallel cooling ribbons provide sufficient contact and heat transfer performance for cylindrical cells. Excellent compacted build, reduce the connection numbers to 1/3 of it’s original requirement. Faster and easier for assembly, make smaller battery module dimensions possible!
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Type of Product

Number of Connections

Tooling

Lead Time for OTS

Cell Compatibility

Ideal für

C2P Cooling Tube
Normal
Needed
35days
1865,2170,
32140,4680,
60160
EVs, Heavy Duties, Marines, eVTOL
C2M Cooling Tube
Less
Needed
40days
1865,2170,
32140,4680
EVs, Residence ESS, eVTOL
Tri-way Cooling Tube
Less
Needed
35days
1865,2170,
32140,4680
EVs, Heavy Duties, Marines
XD Thermal is a professional battery cooling tubes manufactuer in China, with rich experience in supplying cooling components for automotive OEMs and other fields which run Li-ion battery packs. We not only produce cooling parts, but also provide engineering service, including design, simulation and validation tests.
  • Cell Size
  • 18650
  • 21700
  • 32700
  • 4680
  • 4695
  • 46120
  • 60160
  • Extrusion Height
  • 2,2~3,2mm
  • 2,2~3,2mm
  • 2,2~3,2mm
  • 2,2~3,6mm
  • 2,2~3,8mm
  • 2,2~3,8mm
  • 2,6~4,0mm
  • Extrusion Width
  • 48~50mm
  • 50~60mm
  • 50~60mm
  • 65~75mm
  • 75~85mm
  • 95~110mm
  • 130~148mm
  • Extrusionsrippe
  • 0,28~0,43mm
  • 0,28~0,43mm
  • 0,28~0,45mm
  • 0,3~0,6mm
  • 0,35~0,6mm
  • 0,35~0,6mm
  • 0,4~0,8mm
  • Wandstärke des Strangpressprofils
  • 0,25~0,8mm
  • 0,25~0,8mm
  • 0,25~0,8mm
  • 0,25~0,8mm
  • 0,25~0,8mm
  • 0,25~0,8mm
  • 0,25~0,8mm
  • R-Winkel
  • 1.1~1.6
  • 1.1~1.6
  • 1.1~1.6
  • 1.1~1.8
  • 1.1~1.9
  • 1.1~1.9
  • 1.3~2
Zu verpaarende Partner for Your Cooling Tubes
Es gibt mehrere zusammenpassende Teile, die mit Kühlplatten und Batteriezellen zusammenarbeiten. Jedes Teil wird in jedem Akkupack zusammengefügt und montiert.
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Schnellkupplungen - XD THERMAL

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Thermische Schnittstelle - XD THERMAL

Thermische Schnittstelle

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Bewertungen von Kunden

Was haben unsere Kunden zu sagen?
From the get-go, they really got what we're about and what we need. Their team is on the ball and super helpful, always touching base to make sure any questions or worries we have are sorted out. So great!
Graham SterlingChief Mechanical Engineer
Graham Sterling-Chief Mechanical Engineer
Every suggestion they make shows they're not just thinking about sales but about pushing boundaries and creating something new and valuable together.
Benedict HawthorneStrategic Sourcing Manager
Benedict Hawthorne
Their transparency during the course of the liquid cooling tube projects enhanced our trust and respect for them.
Leo GrantEV Cooling Solutions Procurement Engineer
Leo Grant-EV Cooling Solutions Procurement Engineer
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FAQs
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Normally 35 days, including tooling development and sample production.
Aluminium Serie 3 und Serie 6. Ausgezeichnete Eigenschaft in Anti-Korrosion und mechanische Festigkeit.
It is suitable for cylindrical cells. The specs of 18650, 21700, 32140, 4680, 4695, 60160 can be compatible for XD Thermal’s cooling tubes. Customized solutions can be available as well.
XD Thermal bietet Validierungstests an. Durch die Durchführung mehrerer Tests können Kunden quantifizierbare Daten über Berstdruck, Korrosionsschutzleistung, Durchflusswiderstand usw. erhalten.
Each battery cooling pipe manufactured by XD Thermal will be tested with helium tester, which is a very accurate and sensitive testing method over water test.
C2P straight cooling tubes are getting more popular among EV OEMs. It has very good compatibility with 4680 series battery cells, by using such solution, number of welding can be reduced, power density can be lifted up to a higher level. C2P cooling tubes can be used in automated assembly in GA line in OEM place. So it is getting a much bigger share.
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Battery Liquid Cooling Tubes:
Der umfassende Leitfaden (2024)
At XD THERMAL, our liquid cooling plates are essential for efficient battery thermal management, ensuring optimal performance and safety. Engineered to automotive-grade standards, these plates prevent overheating, enhance durability, and maintain consistent temperature distribution across battery packs. With our commitment to quality, certified by IATF 16949, we guarantee products that meet strict industry requirements, delivering significant benefits to your battery systems. Choose XD THERMAL for superior protection and performance.

Inhaltsübersicht

What is battery cooling tubes?

Battery cooling tube is also called liquid cooling ribbon, it can be seen in Tesla model 3 and model Y. It deployed with curved surface, so cylindrical cells, such 4680 cells, can be well adated to its geometric structure. Battery cooling tube is considered as an active cooling component for battery packs, especially for Li-ion battery packs. Heat generated and accumulated while battery go through charging and discharging. Without heat management, battery life and performance would be seriously impacted. Thus liquid cooling plates is commonly deployed in today’s Li-ion battery packs.

Was ist Flüssigkeitskühlung?

Bei der Flüssigkeitskühlung wird hauptsächlich ein Wasser-Glykol-Gemisch oder ein freonähnliches Kühlmittel verwendet. Diese Flüssigkeiten fließen im Inneren von Kühlkomponenten und absorbieren Wärme von der Schnittstelle, durch die sie fließen. Funktionsweise der Flüssigkeiten: Kühlflüssigkeiten werden über die Einlässe in die Komponenten geleitet -> nehmen Wärme auf -> verlassen die Komponenten über die Auslässe -> werden über externe Kühler abgekühlt -> werden wieder in die Komponenten geleitet.

Welche Vorteile hat die Flüssigkeitskühlung?

Die Größe des Batteriepakets kann kompakter sein; die Kühleffektivität ist viel höher als bei Luftkühlung; höhere IP-Schutzart; Möglichkeit der Abwärmerückgewinnung; Kompatibilität mit einer größeren Bandbreite an Klimabedingungen.

Welches Material wird bei der Herstellung von Batteriekühlplatten verwendet?

Aluminum is the most preferred material, because aluminum is lighter and recyclable. 3003, 3005, 6061, 6063 are some of the common aluminum alloys used. 3 series enjoy excellent anti-corrosion performance, in most 3 series coolign plates proejcts, it can withstand over 1000 hours of salt spray test. 6 series material is usually used in higher strength solution, or act as connectors.
PROFIL-EXTRUSION1_540

How many kinds of cylindrical cooling pipe are there?

a) C2P cooling pipe. The most preferred type of cooling pipe so far for automotive and heavy duty battery packs. It has very good compatibility with 4680 Li-on battery cells.
b) C2M cooling pipe. It is usually used in smaller battery modules, or used in fields where the use of space needs optimal.
c) Tri-way cooling pipe. This three-in-one solution can reduce the number of connectors, so it is efficient in pack assembly, and cost-saving.

How a cooling tube is been made?

There are multiple types of cooling tubes. However, there might be several steps which are in common.
  • Schritt 1 , Material preparation. For example shearing.
  • Schritt 2 , Flow channel/internal structure. For example extrusion.
  • Schritt 3 , Connector/accessories processing. For example, inlet & outlet.
  • Schritt 4 Schweißen. Zum Beispiel, Hartlöten, FSW, CMT.
  • Schritt 5 Oberflächenbehandlung. Zum Beispiel, Politur, Isolationsbeschichtung.
  • Schritt 6 , Test und Überprüfung.
serpentine tube structure design considerations- XD THERMAL2

Was ist Hartlöten und wie wird es bei der Herstellung von Kühlplatten eingesetzt?

Yes, brazing is used for joinning cooling tube body with spigots. The brazing process will make the aluminum material stay in a semi-melded condition, then mating parts will attach to each other, and a strong joint between them will be created.

How many types of brazing will be used in Tesla-like cooling ribbon production?

There are two popular brazing ways.
Erste ist das kontinuierliche Löten, auch Korridorlöten genannt. Es wird in einem langen und offenen Ofen durchgeführt.
The second one ist das Induktionslöten. Es wird in der Nähe eines Heizkreises durchgeführt.

Welche Lötmethode sollte ich verwenden?

  1. Wenn Sie höchste Produktivität und kürzere Zykluszeiten anstreben, ist das kontinuierliche Löten die richtige Lösung für Sie.
  2. Wenn eine höhere Festigkeit erforderlich ist und die Kühlplatten in ihren Abmessungen dicker sind, sollten Sie sich für das Vakuumlöten entscheiden.
  3. Wenn auf engstem Raum geklebt werden muss, sollte das Induktionslöten auf Ihrer Liste stehen.

What kind of connectors/inlets & outlets are recomended?

Connectors, sometimes also called inlets & outlets, are the places where cooling tubes connecting to pipeline systems. Since connectors play the role of mating, so its dimension and shape should match its mating parts. We suggest following SAE, VDA or CQC standards. Under these standards’ connectors, pipelines can be easily assembled.

Wie werden Steckverbinder hergestellt?

Normalerweise werden Steckverbinder durch CNC, Stanzen und Druckguss hergestellt.

How to make insulation on the surface of cooling tubes?

Nachstehend sind die beliebten Wege of cooling tube insulation.
  1. Do insulation coating on the external surface of cooling tubes.
  2. Attach insulation films on top of cooling tubes.
  3. Verwenden Sie Materialien für thermische Schnittstellen, um sowohl die Wärmeübertragung als auch die Isolierung zu gewährleisten.

What is the thermal interface material between cylindrical cooling plates and cells?

Thermal interface material called TIM for short, it is a silicon based material which aims to fill invisible gap between cells and cylindrical cooling plates. TIM could guarantee sufficient contact between cylindrical cooling plates and cells, and at the same time TIM also become an efficient conductor of heat transfer.

Things you should know before designing a battery cooling tube

In order to make a robust cooling tubes. There are certain ABCs to follow. For example, choose the right wall thickness of micro channel tube when running pressure is at the higher side; When maintaining mechanical strength is at top priority, then try to avoid heat treatment in the production of cooling plates.

What is common running pressue for serpentine tubes?

Meistens bleibt es between 1-3 bars für die meisten Kühlplatten und deren Systeme für Personenkraftwagen. Für schwere Aufgaben oder andere Versorgungsunternehmen wäre der Betriebsdruck höher.

Sollte ich mich immer für einen möglichst geringen Strömungswiderstand entscheiden?

The answer is no. Cooling pipe’s job is do proper heat dissipation inside of battery packs. When flow resistance is way low, it will make fluid run much faster than it should be. Too fast speed means less time of heat exchange, heat transfer could not be sufficiently done.

Welche Dämmstufe sollte ich einstellen?

2U+1K is the design guideline for most projects. Find nominal voltage of your battery pack, make it two times more then plus 1000 V. This standard suits most scenarios. Currently, most cylindrical cooling tubes have insulation level around 3Kv.

What ultimate pressure can cylindrical cooling plates withstand?

With proper wall thickness, battery cooling tubes can withstand over 100 bars.

The tests might required for a cooling tube project

Apart from regular product tests, cooling tubes will have to go through a series of validation tests.

Korrosionsschutz-Tests

Anti-corrosion tests will verify cooling tubes’ durability in corrosion environment. External tests will be done with salt spray chamber. Internal tests will be done in circulation stations. Based on the materials’ selection, XD Thermal’s cooling tubes will be durable mehr als 1000 Stunden in Korrosionstests.

Berstdruck

Burst pressure tests will help designers to locate cooling tube’s ultimate pressure resistance. One of the inlets or outlets will be sealed before testing, pressure with liquid will be injected from another port till cooling tube start cracking. Normally, cooling tubes can withstand 60-140 bars pressure.

Strömungswiderstand

Too much flow resistance will add unnecessary burden to the cooling system’s pump. At the same time, higher flow resistane means reduced flow speed, in most of the cases, cooling tubes could not reach to heat dissipation target with too high flow resistance. So get flow resistance optimized and tested in development period if very important. Such tests can be done in a liquid circulation station.

How to install a cooling tube?

Inserting Installation

First get all cylindrical cells sit in right position, insert the cooling tube into the space between each two rows of battery cells.

Horizontal installation

Cooling tube will be brushed by glues, then one row of battery cells will be pushed to the cooling plate, then another around glue brushing will be done to cells, afterwards one cooling tube after another row of cells.
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  • HQ-Adresse: 211 Changjiang Rd, SND, Suzhou China
  • Whatsapp: (+86) 193-5550-1188
  • E-Mail: info@xdthermal.com
  • Arbeitszeiten: Montag bis Freitag, 08:30-17:30

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