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

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메인 애플리케이션 배터리 냉각판용

For Standard Battery Case

XD Thermal은 전문가입니다. aluminum liquid cooling battery case manufactuer in China, with rich experience in supplying cooling components for automotive OEMs 그리고 other fields which run Li-ion battery packs. We not only produce cooling parts, but also provide 설계, 시뮬레이션 및 검증 테스트를 포함한 엔지니어링 서비스입니다.

짝짓기할 짝 for Your Cooling Plate

냉각판 및 배터리 셀과 함께 작동하는 여러 결합 부품이 있습니다. 각 부품은 모든 배터리 팩에서 결합 및 조립됩니다.

스피곳

(냉각수 주입구 및 배출구)

빠른 커넥터

열 인터페이스

파이프 라인

고객 리뷰

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

자주 묻는 질문

여기에 질문이 없는 경우 언제든지 이메일을 보내주세요!

개발 리드 타임은 어떻게 되나요?

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.

냉각판이 설계 목표에 도달하는지 확인하는 방법은 무엇인가요?

XD Thermal은 여러 테스트를 수행하여 고객이 파열 압력, 부식 방지 성능, 흐름 저항 등에 대한 정량화 가능한 데이터를 확보할 수 있도록 검증 테스트를 제공합니다.

XD Thermal은 어떻게 누출을 방지하나요?

XD Thermal에서 제조하는 각 냉각 부품은 수중 테스트보다 훨씬 정확하고 민감한 테스트 방법인 헬륨 테스터로 테스트합니다.

오늘날 리튬 이온 배터리 팩에서 가장 인기 있는 공법은 무엇인가요?

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

Battery Pack Enclosure

종합 가이드(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 액체 냉각판 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.

액체 냉각이란 무엇인가요?

액체 냉각은 주로 물-글리콜 혼합물 또는 프레온 계열 냉각수를 사용합니다. 이러한 유체는 냉각 구성 요소 내부를 흐르며 구성 요소가 통과하는 인터페이스에서 열을 흡수합니다. 유체 작동 모드: 냉각 유체가 입구를 통해 구성 요소로 들어가고-> 열 흡수-> 출구를 통해 구성 요소 밖으로 나가고-> 외부 냉각기를 통해 냉각된 유체-> 다시 구성 요소로 들어갑니다.

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.

1단계 , Material preparation. For example shearing.
2단계 , bottom plate/liquid cooling plate manufacturing. Flow channel/internal structure processing, for example extrusion, stamping.
3단계 , Connector/accessories processing. For example, beam, inlet & outlet.
4단계 , 용접. 예를 들어, 브레이징, FSW, CMT.
5단계 , 표면 처리. 예를 들어, 광택, 단열 코팅.
6단계 테스트 및 확인을 클릭합니다.

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?

인렛 & 아웃렛이라고도 하는 커넥터는 냉각판이 파이프라인 시스템에 연결되는 곳입니다. 커넥터는 결합 역할을 하므로 커넥터의 치수와 모양이 결합 부품과 일치해야 합니다. SAE, VDA 또는 CQC 표준을 따르는 것이 좋습니다. 이러한 표준의 커넥터를 사용하면 파이프라인을 쉽게 조립할 수 있습니다.

커넥터는 어떻게 만들어지나요?

일반적으로 커넥터는 CNC, 스탬핑 및 다이캐스팅으로 만들어집니다.

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

어떤 단열 수준을 설정해야 하나요?

2U+1K는 대부분의 프로젝트의 설계 지침입니다. 배터리 팩의 공칭 전압을 찾아 두 배 더한 다음 1000V를 더하면 대부분의 세나리오에 적합한 표준이 됩니다.

냉각판 프로젝트에 필요할 수 있는 테스트

냉각판은 일반 제품 테스트와는 별도로 일련의 검증 테스트를 거쳐야 합니다.

부식 방지 테스트

부식 방지 테스트는 부식 환경에서 냉각판의 내구성을 검증합니다. 외부 테스트는 염수 분무 챔버에서 진행됩니다. 내부 테스트는 순환 스테이션에서 수행됩니다. 재료 선택에 따라 다릅니다, XD Thermal의 냉각판은 내구성이 뛰어납니다. 1000시간 이상 부식 테스트에서

파열 압력

파열 압력 테스트는 설계자가 냉각판의 최종 압력 저항을 찾는 데 도움이 됩니다. 테스트 전에 입구 또는 출구 중 하나를 밀봉하고 냉각판이 균열이 시작될 때까지 다른 포트에서 액체를 주입하여 압력을 가합니다. 일반적으로 하이드로포밍 냉각판은 12바~20바의 압력을 견딜 수 있지만 압출 냉각판은 50바 이상의 압력을 견딜 수 있습니다.

흐름 저항

유량 저항이 너무 크면 냉각 시스템의 펌프에 불필요한 부담이 가중됩니다. 동시에 유량 저항이 높으면 유속이 감소하며, 대부분의 경우 너무 높은 유량 저항으로 냉각판이 방열 목표에 도달할 수 없습니다. 따라서 유동 저항이 매우 중요한 경우 개발 기간에 유동 저항을 최적화하고 테스트해야 합니다. 이러한 테스트는 액체 순환 스테이션에서 수행할 수 있습니다.

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.