Product Overview
Aluminum's liquid cold plate is a production-optimized thermal component engineered to meet the demanding requirements of today's utility-scale and commercial battery energy storage projects. The core of our design philosophy is simple: deliver consistent, measurable thermal performance at a cost structure that works for high-volume BESS deployment. We achieve this by precision-stamping flow channel geometry into 3003 aluminum sheet, a process that ensures uniform channel depth and exceptional surface flatness for optimal module-to-plate contact. The cooling circuit is sealed using a flux-free, solid-state bonding technique that creates a permanent, homogeneous structure, backed by a 100% helium leak test (<1×10⁻⁷ mbar·L/s). Available in custom dimensions up to 2400mm, with integrated mounting bosses and a choice of surface treatments, this cold plate is built for project developers who need a reliable, scalable, and fully documented thermal solution from pilot to mass production.
Key Features at a Glance
- Stamped Channels: Complex flow paths formed in seconds at low cost, ideal for high-volume scaling.
- Leak-Proof Construction: Solid-state sealed for permanent, maintenance-free operation with no internal contaminants.
- Custom Configurable: Size, port locations, mounting bosses, and surface treatments can be tailored to your module layout.
- Fast Sample Turnaround: Functional prototypes delivered in weeks, using the same production-ready process.
- Certification Support: Full documentation and material traceability to assist with UL 1973 and UL 9540A compliance.
Parameter Details
| Item |
Parameter / Description |
| Main Material |
3003 / 3003MOD / 6061 Aluminum Alloy |
| Tray Forming Process |
High-Precision Progressive Die Stamping |
| Cooling Plate Joining |
Vacuum Brazing (CAB – Controlled Atmosphere Brazing) |
| Structural Assembly |
Self-Piercing Riveting (SPR) & Flow Drill Screws (optional) |
| Insulation & Damping |
Closed-Cell Polyurethane (PU) In-Situ Foaming |
| Surface Finish |
Electrostatic Powder Coating (Insulating, RAL options) |
| Ingress Protection |
IP67 / IP6K9K (Powder coating + Foam seal design) |
| Coolant Compatibility |
Water-Glycol, Dielectric fluids |
| Cooling Channel Integrity |
Helium Mass Spectrometry Leak Test, <1*10⁻⁷ mbar·L/s |
| Salt Spray Resistance |
≥1,500 hours (per ASTM B117, with powder coat) |
| Dielectric Strength |
3000V DC (Coating + Foam combined insulation) |
| Customization |
Connector openings, cell array mounting holes, sloped drainage |
| Compliance |
Designed to UL 1973, UL 9540A, UN 38.3 test profiles |
Solution – Trumony's Application-First Approach
Trumony's cold plate is designed to solve supply chain challenges without cutting corners on performance:
· Speed of Stamping: Once the progressive die is set, channels are formed in seconds per plate. This allows us to ship thousands of identical, high-quality plates per month, keeping your assembly line moving.
· Predictable Cost Trajectory: Because stamping is a fast, low-labor process, unit economics improve naturally with volume. We pass this structure through with transparent, tiered pricing.
· Single-Process Validation: We use the exact same stamping tooling and sealing method for prototype samples as for volume production. The thermal performance data you gather from a sample is identical to what every production plate will deliver.
· Scalable Customization: We work with you to finalize channel routing and port placement before committing to the stamping die. Once the die is qualified, scaling up is simply a matter of scheduling production runs.
How To Choose Your Stamped Cooling Plate
- · Project Timelines First: Tell us your first article and volume delivery dates. We build the production schedule backwards from your milestones.
· Thermal Design Lock-In: Our team will finalize channel layout and simulate performance before any tooling is cut, ensuring the design is right the first time.
· Logistics Planning: We offer flexible shipping solutions from our manufacturing base, including consolidated air freight for prototypes and cost-optimized ocean freight for volume runs.
FAQ
Q1: I don’t have a finalized design. Can you help from the concept stage?
Absolutely. That is the core of our one-stop service. Share your heat load, space envelope, and target thermal performance. Our engineers will propose an initial flow channel design, run CFD simulations for your approval, and then move to prototype. We guide you from idea to serial production.
Q2: What is the minimum order quantity (MOQ) for custom liquid cooling plates?
We have no fixed MOQ for the prototype and NPI (New Product Introduction) stage. For mass production, we work flexibly with your volumes. As a factory serving global clients, we comfortably handle everything from small pilot runs to millions of pieces annually.
Q3: How do you ensure zero leaks in a water-cooled battery pack?
Quality is built in from the start. We use vacuum brazing for high-integrity joints and 100% test every single plate with a helium mass spectrometer, achieving leak rates tighter than 1*10⁻⁹ Pa·m³/s. Additionally, we conduct pressure cycling and thermal shock tests on pre-production samples validated according to customer durability requirements.
Q4: Do you hold certifications for the North American and Asian markets?
Yes. Our manufacturing is certified to ISO 9001 and IATF 16949. Our materials and components comply with RoHS, REACH, and UL standards as required by your product. We are also experienced in supporting customers through final system-level UL 9540A or UN 38.3 certification by providing detailed design and material documentation.
Q5: What kind of warranty and after-sales support do you offer for your cooling plates?
We stand behind our workmanship. Our standard product warranty is 5 years when properly operated within specified parameters. In the rare event of an issue, our engineering team provides root cause analysis and works to resolve it immediately. For ongoing production, we maintain complete traceability records tied to each batch.
