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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.
  • A prueba de fugas con la prueba de helio 100%.
  • Más de 10 años de garantía de por vida.
  • Anticorrosión con aleación de aluminio de alto Mn.
  • Ligero y fácil de instalar.
  • Reciclable y respetuoso con el medio ambiente.
  • Vibration resistant frequncy 0-200Hz.
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Typical Applications For Battery cooling tubes
placa de refrigeración en vehículos eléctricos- XD THERMAL
Vehículos eléctricos
placa de refrigeración en sistemas de almacenamiento de energía - XD THERMAL
Sistemas de almacenamiento de energía
placa de refrigeración en Heavy duties - XD THERMAL
Tareas pesadas
placa de refrigeración en eVTOL - XD THERMAL
eVTOL
placa de refrigeración en Marines - XD THERMAL
Marines
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Productos más vendidos
XD Thermal utiliza todo tipo de mano de obra para adaptarse a sus necesidades de ingeniería.
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 para

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
  • 2,2~3,2 mm
  • 2,2~3,2 mm
  • 2,2~3,2 mm
  • 2,2~3,6 mm
  • 2,2~3,8 mm
  • 2,2~3,8 mm
  • 2,6~4,0 mm
  • Extrusion Width
  • 48~50mm
  • 50~60mm
  • 50~60mm
  • 65~75mm
  • 75~85mm
  • 95~110mm
  • 130~148mm
  • Costilla de extrusión
  • 0,28~0,43 mm
  • 0,28~0,43 mm
  • 0,28~0,45 mm
  • 0,3~0,6 mm
  • 0,35~0,6 mm
  • 0,35~0,6 mm
  • 0,4~0,8 mm
  • Espesor de la pared de extrusión
  • 0,25~0,8 mm
  • 0,25~0,8 mm
  • 0,25~0,8 mm
  • 0,25~0,8 mm
  • 0,25~0,8 mm
  • 0,25~0,8 mm
  • 0,25~0,8 mm
  • Ángulo R
  • 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
Parejas que se aparean for Your Cooling Tubes
Hay múltiples piezas de acoplamiento que trabajan juntas con las placas de refrigeración y las celdas de la batería. Cada pieza se acopla y ensambla en cada paquete de baterías.
Pasamuros xdtérmico

Grifos

(entrada y salida de refrigerante)

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Conectores rápidos - XD THERMAL

Enchufes rápidos

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interfaz térmica - XD THERMAL

Interfaz térmica

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sistema de tuberías

Tuberías

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Opiniones de los clientes

¿Qué dicen nuestros clientes?
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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Preguntas frecuentes
Si su pregunta no está aquí, no dude en enviarnos un correo electrónico.
Normally 35 days, including tooling development and sample production.
Aluminio serie 3 y serie 6. Excelentes propiedades anticorrosión y resistencia mecánica.
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 proporciona pruebas de validación, realizando múltiples pruebas, los clientes pueden tener datos cuantificables sobre la presión de rotura, el rendimiento anticorrosión, la resistencia al flujo, etc.
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:
La guía completa (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.

Índice

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.

¿Qué es la refrigeración líquida?

La refrigeración líquida utiliza principalmente una mezcla de agua y glicol o un refrigerante similar al freón. Estos fluidos circulan por el interior de los componentes de refrigeración y absorben el calor de la interfaz por la que circulan. Modo de funcionamiento de los fluidos: los fluidos fríos entran en los componentes a través de las entradas-> absorben el calor -> salen de los componentes a través de las salidas-> los fluidos se enfrían a través de un refrigerador externo -> vuelven a entrar en los componentes.

¿Qué ventajas tiene la refrigeración líquida?

El tamaño del paquete de baterías puede compactarse más; la eficacia de la refrigeración es mucho mayor que la de la refrigeración por aire; mayor nivel de proyección IP; posibilidad de reciclar el calor residual; compatible en una gama más amplia de climas.

¿Qué material se utiliza para fabricar las placas de refrigeración de las baterías?

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.
EXTRUSIÓN DE PERFILES1_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.
  • Primer paso , Material preparation. For example shearing.
  • Paso 2 , Flow channel/internal structure. For example extrusion.
  • Paso 3 , Connector/accessories processing. For example, inlet & outlet.
  • Paso 4 Soldadura. Por ejemplo, soldadura fuerte, FSW, CMT.
  • Paso 5 Tratamiento de superficies. Por ejemplo, pulido, revestimiento aislante.
  • Paso 6 Prueba y verificación.
serpentine tube structure design considerations- XD THERMAL2

¿Qué es la soldadura fuerte y para qué sirve en la producción de placas de refrigeración?

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.
Primero es la soldadura fuerte continua, o llamada soldadura fuerte de pasillo. Se realiza en un horno largo y abierto.
The second one es la soldadura por inducción. Se realiza cerca de un circuito calentado.

¿Qué método de soldadura debo utilizar?

  1. Si lo que busca es la máxima productividad y un tiempo de ciclo más corto, la soldadura continua es la opción que más le conviene.
  2. Cuando se requiera una mayor resistencia y las placas de refrigeración sean más gruesas en sus dimensiones, opte por la soldadura fuerte al vacío.
  3. Cuando se requiere una unión en un área pequeña, la soldadura por inducción debe estar en su lista.

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.

¿Cómo se fabrican los conectores?

Normalmente, los conectores se fabrican mediante CNC, estampación y fundición a presión.

How to make insulation on the surface of cooling tubes?

A continuación las formas populares 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. Utilizar materiales de interfaz térmica para realizar tanto la transferencia de calor como el trabajo de aislamiento.

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?

La mayoría se queda between 1-3 bars para la mayoría de las placas de refrigeración y sus sistemas para turismos. Para trabajos pesados u otras utilidades, la presión de funcionamiento sería mayor.

¿Debo buscar siempre una resistencia al flujo lo más baja posible?

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.

¿Qué nivel de aislamiento debo fijar?

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.

Pruebas anticorrosión

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 más de 1000 horas en las pruebas de corrosión.

Presión de rotura

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.

Resistencia al flujo

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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  • Dirección de la sede central: 211 Changjiang Rd, SND, Suzhou China
  • Whatsapp: (+86) 193-5550-1188
  • Correo electrónico: info@xdthermal.com
  • Horario de trabajo: Lunes a viernes, 08:30-17:30

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