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The cooling plate is the critical component that ensures battery safety in BESS cabinets. With tightly packed cells generating significant heat during charge and discharge cycles, liquid cooling provides the solution—but only when the plate maintains uniform contact with cell surfaces.
Our CNC milling process achieves flatness under 0.1mm across 600x400mm plates, eliminating hot spots that can lead to battery failure. Aluminum 5052 offers superior corrosion resistance for long-term glycol-water cooling applications, while our precision channel designs optimize thermal performance and flow distribution.
Key Features
Flatness Control: <0.1mm across full plate surface—CMM verified on every production lot
Leak Testing on Every Unit: Comprehensive testing prevents costly failures in battery cabinet installations
Channel Machining Experience: Expertise in serpentine, parallel, pin-fin, and hybrid channel designs
Brazing Partner Network: Coordination with qualified vacuum brazing vendors with full quality documentation
Flatness Priority: Fixturing and machining processes designed around flatness as primary quality metric
Thermal Cycling Validation: Test data from previous projects available to support qualification processes
Manufacturing Process
Design Review: Analysis of channel pattern for machining access, wall thickness, and brazing clearance
Material Preparation: 5052-H32 plate stock verified for flatness, with pre-stress-relieving as needed
CNC Milling: 3-axis and 4-axis CNC with custom vacuum fixtures and fresh tooling
CMM Inspection: Comprehensive measurement of flatness, channel depth, and wall thickness
Surface Treatment: Nickel plating for corrosion protection or chromate conversion for brazing
Leak Testing & Packaging: Helium leak test or pressure decay test with custom protective packaging
Frequently Asked Questions
What's the minimum channel width you can machine?
2mm with standard tooling. We can go down to 1mm with custom tools, but tool life decreases and per-unit cost increases. Most designs use 3-5mm channels.
Can you machine both sides of the plate?
Yes. We flip the plate in a dedicated fixture for the second side, maintaining alignment between sides for proper inlet/outlet port alignment.
Do you offer vacuum brazing for the cover plate?
We coordinate vacuum brazing through qualified partners. We machine both halves and manage the brazing process with full quality documentation.
What coolant is compatible with 5052-H32?
Standard glycol-water mix (ethylene or propylene glycol). 5052 resists corrosion well in these environments. Avoid straight water due to chloride content.
How do you prevent warpage during machining?
Low-stress machining strategies, symmetric roughing passes, vacuum fixtures supporting full plate area, and stress-relieving before final finishing when needed.
What's the typical thermal resistance of your cooling plates?
Depends on design, but a well-optimized serpentine channel plate typically achieves 0.05-0.15 C/W depending on flow rate. We machine to the tolerances that make your thermal design work.
