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.
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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
 
integrated battery enclosure-XD THERMAL
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Main Application For Battery Cooling Plate
cooling plate in Electrical vehicles- XD THERMAL
Electrical Vehicles
cooling plate in Energy storage systems - XD THERMAL
Energy Storage Systems
cooling plate in solar system of battery cooling plate - XD THERMAL
Solar System
cooling plate in Heavy duties - XD THERMAL
Heavy Duties
cooling plate in Marines - XD THERMAL
Marines
Hot Selling Products
XD Thermal uses all different workmanship to fit in with your engineering needs.
Housing case - XD THERMAL
Housing Case
The cold plate design can be optimized for certain local heat dissipation
Standard battery case- XD THERMAL
Standard Battery Case
It is usually made by one-piece brazing or die-casting of extruded runner plates
lightweight battery case
Lightweight Battery Case
It is especially suitable for lightweight and low-cost solutions for energy storage

For Standard Battery Case

48S low battery enclosures - XD THERMAL
48S Liquid Cooling Battery Case
Standard battery case- XD THERMAL
52S Standard Battery Case
104S liquid cooling battery trays - XD THERMAL
104S Liquid Cooling Low Battery Case
XD Thermal is a professional aluminum liquid cooling battery case 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.
Mates to be mated for Your Cooling Plate
There are multiple mating parts that work together with cooling plates and battery cells. Each part mated and assembled in every battery pack.
Bulkhead fitting

Spigots

(coolant inlet & outlet)

Quick Connectors - XD THERMAL

Quick Connectors

thermal interface - XD THERMAL

Thermal interface

pipe system

Pipe lines

Customers reviews

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
FAQs
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Lead time 45 days including mold development and sample production.
Aluminum 3 series and 6 series. Excellent property in anti-corrosion and mechanical strength
Prismatic cells, cylindrical cells, pouch cells, and prismatic cells are all suitable, compatible with C2P and C2M configurations.
XD Thermal provides validation tests, by doing multiple tests, clients can have quantifiable data about burst pressure, anti-corrosion performance, flow resistance and so on.
Each cooling components manufactuered by XD Thermal will be tested with helium tester, which is a much accurate and sensitive testing method over water test.
In EV applications,the most popular workmanship is welded extrusion with FSW and CMT.
Battery Pack Enclosure
The Comprehensive Guide (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.

Table of Contents

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 liquid cooling plate 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.

What is liquid cooling?

Liquid cooling mainly uses water-glycol mixture or freon-like coolant. These fluids runs inside of cooling components, absorb heat from the interface where they run through. Fluids working mode: cool fluids go into components via inlets–> absorb heat –> go out of components via outlets–> fluids cooled down via external chiller –> again go into components.

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.
PROFILE EXTRUSION1_540

How many kinds of liquid cooling battery trays are there?

Housing case - XD THERMAL

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.

Standard battery case- XD THERMAL

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

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.
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.
XD THERMAL CMT TECHNOLOGY

What kind of connectors/inlets & outlets are recomended?

Connectors, sometimes also called inlets & outlets, are the places where cooling plates 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.

How connectors are made?

Usually connectors are made from CNC, stamping and die casting.

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

What insulation level should I set?

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 of the senarios.

The tests might required for a cooling plate project

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

Anti-corrosion tests

Anti-corrosion tests will verify cooling plates’ 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 plate will be durable more than 1000 hours in corrosion tests.

Burst pressure

Burst pressure tests will help designers to locate cooling plate’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 plate start cracking. Normally, hyroformed cooling plate will withstand 12bars – 20bars pressure; extruded cooling plate could withstand over 50 bars.

Flow resistance

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 plates 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 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.
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