Custom EV Battery Liquid Cooling Plate Progressive Stamping CAB Vacuum Brazing Aluminum Cooling Tray With PU Foam Insulation

Trumony Aluminum Limited supplies high-performance liquid cooling plates for battery modules in commercial and utility-scale energy storage. We combine progressive die stamping and controlled atmosphere vacuum brazing to deliver thermally efficient, leak-proof plates that are ideal for volume production.

Flow channels are precision-stamped into 3003 aluminum sheet, ensuring consistent geometry and flatness for optimal cell contact. The stamping route provides uniform quality and avoids the high cost of machining. A cover plate is then vacuum-brazed to the base, forming a continuous metallurgical bond with no flux or residue. Every plate passes a 100% helium leak test (<1×10⁻⁷ mbar·L/s), providing a permanent, maintenance-free seal.

The brazed aluminum construction offers low thermal resistance and maintains cell-to-cell temperature variation within ±1.5°C. The plates work with water-glycol, up to 3 bar pressure, and across -40°C to +85°C. This tight temperature control extends battery life and reduces thermal risk. An optional trivalent chromium coating adds corrosion protection without impacting heat transfer.

Plates are fully customizable—mounting bosses, tie-rod clearances, connector ports, and coolant fittings are integrated to match your module layout. Trumony provides full material certifications and test reports supporting UL 1973 and UL 9540A compliance. We deliver functional prototypes in weeks using the same production-ready process, and scale smoothly to annual volumes in the multi-gigawatt-hour range.

In mission-critical energy storage, common failures often start from the bottom. Inferior lower enclosures lead to three major risks:

· Thermal runaway propagation: Without integrated cooling, heat builds up between cells, accelerating degradation and creating safety hazards.
· Environmental ingress: Dust, salt spray, and standing water corrode steel housings and cause ground faults, especially in coastal or desert utility sites.
· Structural fatigue: Constant vibration during transportation and seismic events can crack conventional welded steel trays, compromising pack integrity.
  A standard battery housing simply cannot meet the demanding life cycle of 10+ years expected by North American project developers and asset owners.

· Built-in Liquid Cooling Gallery: Serpentine flow channels are CNC-machined into the thick aluminum baseplate, allowing direct contact with the module thermal interface. This ensures cell temperatures stay within a tight ±2°C band.
· Monolithic Sealing via FSW: Friction stir welding creates a solid-state bond stronger than the parent material itself, with no filler metals or porosity. This enables a true, maintenance-free IP67 seal across the entire tray.
· Lightweighting without Sacrifice: Using 6061-T6 aluminum, we deliver the same mechanical strength as steel at less than half the weight, reducing shipping costs and easing installation.
· Corrosion-Free Lifecycle: With a chromate conversion coating and optional electrophoretic paint finish, the enclosure withstands over 1,000 hours of salt spray testing, perfect for marine and humid continental climates.
· Custom Engineering Support: Send us your module layout, and we will optimize the cooling circuit, mounting bosses, and cable entry positions. Whether you need a prototype or volume supply, Trumony’s aluminum manufacturing ensures a consistent, premium product.