EV Battery Enclosure

Whether you refer to them as battery boxes, trays, or housing, which are essentially components used to the contain and protect electric vehicle (EV) battery cells and their associated electrical and thermal-management systems ,and they are critical elements within the automotive industry. These enclosures are vital for maintaining the batteries’ performance and safety.

Integrated Liquid Cooling EV Battery Case

This case enhances battery life, improves performance, and increases safety compared to traditional air-cooled systems. It is particularly well-suited for automotive and energy storage systems that are high-performance and operate in extreme weather conditions.

XD Thermal utilizes a variety of advanced manufacturing techniques, such as aluminum extrusion, roll forming, and die casting, to meticulously select the optimal materials and processes for your battery housing and structural needs

Light weighted and easy to recycle
Highly durable, Over 10 years lifetime guaranteed
IP68, Meet the rigorous standards of the automotive industry
Exhibit exceptional high-temperature resistance and electrical properties
Integrated high-efficiency liquid-cooling system, with the temperature difference in the container limited to 5℃
Length from 500mm-2900mm, width from 200mm-1600mm

Índice de esta página

Portales rápidos para esta página

Haga clic en la información que quieres abajo, llegas.

Principal Aplicación Para la placa de refrigeración de la batería

Productos más vendidos

XD Thermal utiliza todo tipo de mano de obra para adaptarse a sus necesidades de ingeniería.

Housing Case

The cold plate design can be optimized for certain local heat dissipation

Standard Battery Case

It is usually made by one-piece brazing or die-casting of extruded runner plates

Lightweight Battery Case

It is especially suitable for lightweight and low-cost solutions for energy storage

For Standard Battery Case

XD Thermal es un profesional aluminum liquid cooling battery case manufactuer in China, with rich experience in supplying cooling components for automotive OEMs y other fields which run Li-ion battery packs. We not only produce cooling parts, but also provide servicio de ingeniería, que incluye pruebas de diseño, simulación y validación.

Parejas que se aparean for Your Cooling Plate

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.

Grifos

(entrada y salida de refrigerante)

Enchufes rápidos

Interfaz térmica

Tuberías

Opiniones de los clientes

What people say?

Our collaboration with XD THERMAL feels more like a partnership than a typical supplier relationship. They take the time to understand our specific needs and work with us to find the best solutions. This collaborative spirit has led to several successful projects and innovations.

Rohan Patel

battery engineer

Safety is paramount in our industry, and it is truly reassuring to receive fast and high-quality proofing products from the start. I am very optimistic about our future development with XD THERMAL.

John Anderson

procurement manager

Preguntas frecuentes

Si su pregunta no está aquí, no dude en enviarnos un correo electrónico.

¿Cuál es el plazo de desarrollo?

Lead time 45 days including mold development and sample production.

What is material used for cooling plates?

Aluminum 3 series and 6 series. Excellent property in anti-corrosion and mechanical strength

What kind of cells fit for XD Thermal battery case?

Prismatic cells, cylindrical cells, pouch cells, and prismatic cells are all suitable, compatible with C2P and C2M configurations.

¿Cómo saber si las placas de refrigeración alcanzan el objetivo de diseño?

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.

¿Cómo evita XD Thermal las fugas?

Cada componente de refrigeración fabricado por XD Thermal será probado con un probador de helio, que es un método de prueba mucho más preciso y sensible que la prueba de agua.

¿Qué fabricación es la más popular en las baterías de iones de litio actuales?

In EV applications,the most popular workmanship is welded extrusion with FSW and CMT.

Battery Pack Enclosure

La guía completa (2024)

At XD THERMAL, our LIQUID COOLING BATTERY ENCLOSURE 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.

What is integrated liquid cooling battery case?

It is a standard EV/ESS battery enclosure that we are all familiar with. This design integrates a placa de refrigeración líquida at the bottom of the battery pack. Not only does it facilitate heat exchange for the battery, but it also serves a structural role, providing support, especially for square batteries.

¿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.

What advantages does liquid cooling battery boxes have?

Aluminum alloy liquid cooling EV battery cases are lighter and more efficient, enhancing range extension, safety, cost-effectiveness, and thermal management, thereby outperforming traditional materials. These cases also excel in extreme temperatures, both hot and cold, ensuring reliable battery operation across a broad spectrum of environmental conditions.

What material is used in making battery boxes?

3 series and 6 series aluminum materials are the most commonly used.

3 Series aluminum profiles are Al-Mn alloys. Its manganese content is between 1.0-1.5. It has good anti-rust function, that is, corrosion resistance. It can survive in humid environments and has high strength, such as 3003, 3004, 3104, 3105, 3203.
6 Series aluminum profiles are Al-Mg-Si alloys, of which 6061 and 6063 are the most representative. And after T6 treatment, the product has stronger ductility and can better realize the production of some boxes with complex structures.

How many kinds of liquid cooling battery trays are there?

Battery Housing Case

The flow channel of the liquid cooling plate can be flexibly designed according to the heat exchange requirements, supplemented by reinforcement ribs. It also meets the load-bearing requirements and is mostly used in EV.

52S Standard Battery Case

The use of extruded profile cold plates and brackets eliminates the need for traditional battery pack lower shell structures, while CMT and FSW welding ensure the sealing of the battery box.

Lightweight Battery Case

1. Simple structure, light weight and low cost

2. All parts are stamped and blanked with high efficiency

3. The spot welding process is simple and can be used by ordinary operators.

How a battery trays is been made?

There are multiple types of battery trays. However, there might be several steps which are in common.

Primer paso , Material preparation. For example shearing.
Paso 2 , bottom plate/liquid cooling plate manufacturing. Flow channel/internal structure processing, for example extrusion, stamping.
Paso 3 , Connector/accessories processing. For example, beam, 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.

Welding is one of the most critical processes in battery enclosure production. Mainly FSW will be used in joinning extrusions; CMT will be used in joinning lower case with cooling plates.

What kind of connectors/inlets & outlets are recomended?

Los conectores, a veces también llamados entradas y salidas, son los lugares donde las placas de refrigeración se conectan a los sistemas de tuberías. Dado que los conectores desempeñan la función de acoplamiento, sus dimensiones y forma deben coincidir con las de las piezas de acoplamiento. Sugerimos seguir las normas SAE, VDA o CQC. Con los conectores de estas normas, las tuberías se pueden montar fácilmente.

¿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 battery enclosures?

Below are the three popular ways of battery enclosures insulation.

Things you should know before designing a battery trays

In fact, the overall requirements of new energy vehicles are consistent with ordinary vehicles, but more attention is paid to safety issues and high-voltage protection in the system.

In order to prevent the occurrence of thermal runaway, focus on the selection of box materials and the heat exchange area and type of the box, choose the bottom heat exchange for prismatic batteries, and choose the side heat exchange for cylindrical batteries. Either way, the space between the liquid-cooled line and the battery cell needs to be designed to prevent the liquid from coming into contact with the high-pressure components in the event of a leak.

Secondly, choose the right high-voltage insulation material. Polyimide (Kapton), polytetrafluoroethylene (PTFE), and silicone pads are more compliant, as they have excellent electrical insulation properties and high temperature and chemical resistance, and PC film is not recommended.

In addition, highly efficient insulation and isolation technology (epoxy coating) is used to prevent electric shocks and electrical short circuits. Overvoltage, overcurrent, and short-circuit protection devices can be installed to respond quickly to electrical anomalies. Products need to undergo strict safety testing and industry-standard certification (hi-pot test) before leaving the factory to ensure the stability and safety of high-voltage systems in various environments

¿Qué nivel de aislamiento debo fijar?

2U+1K es la pauta de diseño para la mayoría de los proyectos. Busca el voltaje nominal de tu batería y multiplícalo por dos más 1000 V. Esta norma se adapta a la mayoría de los casos.

Las pruebas podrían ser necesarias para un proyecto de placa de refrigeración

Además de las pruebas habituales de los productos, las placas de refrigeración tendrán que pasar una serie de pruebas de validación.

Pruebas anticorrosión

Las pruebas anticorrosión verificarán la durabilidad de las placas de refrigeración en entornos corrosivos. Las pruebas externas se realizarán con cámara de niebla salina. Las pruebas internas se realizarán en estaciones de circulación. Basado en la selección de materiales, La placa de refrigeración de XD Thermal será duradera más de 1000 horas en las pruebas de corrosión.

Presión de rotura

Las pruebas de presión de rotura ayudarán a los diseñadores a localizar la resistencia máxima a la presión de la placa de refrigeración. Una de las entradas o salidas se sellará antes de la prueba, se inyectará presión con líquido desde otro puerto hasta que la placa de refrigeración empiece a agrietarse. Normalmente, la placa de refrigeración hyroformada soportará una presión de entre 12 y 20 bares; la placa de refrigeración extruida podría soportar más de 50 bares.

Resistencia al flujo

Una resistencia al flujo demasiado alta añadirá una carga innecesaria a la bomba del sistema de refrigeración. Al mismo tiempo, una mayor resistencia al flujo significa una velocidad de flujo reducida, en la mayoría de los casos, las placas de refrigeración no podrían alcanzar el objetivo de disipación de calor con una resistencia al flujo demasiado alta. Por lo tanto, es muy importante optimizar y probar la resistencia al flujo durante el periodo de desarrollo. Estas pruebas pueden realizarse en una estación de circulación de líquidos.

How to install a battery trays?

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.

If you are using prismatic batteries, you need to arrange the cells in order, fix the ends with end plates, and place them neatly on the liquid cold plate

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

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

Positioning the Battery Tray

Identify the designated location for the battery tray. This is usually at the bottom of the vehicle for lower center of gravity but can vary based on vehicle design. Ensure the tray is properly aligned with the mounting points.