ألواح تبريد البطاريات المصنوعة من الصفائح المعدنية ： تصميم دقيق للإدارة الحرارية للمركبات الكهربائية

Aluminum dominates EV cooling systems because it offers light weight, excellent corrosion resistance, and cost-effective formability. Copper, while providing nearly double the thermal conductivity, is heavier and more expensive — used mainly where high heat flux or space constraints demand extreme performance.

Surface Treatments and Corrosion Protection

Cooling plates continuously contact glycol-based coolants, so corrosion protection is critical to prevent internal leakage and particle contamination. The most effective surface treatments combine chemical stability with bonding compatibility for thermal interface materials (TIMs).

Common treatments include:

• أنودة: Forms a hard, oxide layer on aluminum that resists corrosion and enhances heat spreading.
• Nickel or Chromate Plating: Adds a barrier layer that protects against galvanic corrosion when paired with dissimilar metals.
• Epoxy or Passivation Coatings: Used in extreme humidity or marine applications for additional protection.

Testing shows anodized aluminum plates retain over 95% of their thermal conductivity after 1,000 hours of salt-spray exposure — far outperforming untreated plates. Well-applied coatings not only extend service life but also improve coolant purity, thereby reducing maintenance costs in the long term.

Flow Channel and Plate Structure Design

The internal channel geometry defines how effectively the coolant absorbs and distributes heat across the plate. Designers use Computational Fluid Dynamics (CFD) simulations to optimize this balance between temperature uniformity, pressure drop, and coolant velocity.

Serpentine Flow Channels

• A single continuous path that ensures complete coverage of the surface.
• Delivers excellent thermal uniformity but higher pressure loss.
• Ideal for compact EV modules and battery packs under fast-charging cycles.

Parallel Flow Channels

• Multiple flow paths allow lower pressure drop and faster flow.
• Simpler manufacturing and scalability.
• Requires careful balancing to prevent uneven flow distribution.

Pin-Fin or Dimple Structures

• Small 3D protrusions inside channels increase turbulence, boosting heat transfer by 10–15%.
• Typically formed by hydroforming or CNC embossing.
• Best for high-power-density applications where surface area is crucial.

In EV applications, target flow rates typically range from 2–4 L/min per module, with a temperature rise of less than 3 °C between the inlet and outlet. CFD analysis also ensures the pressure drop remains below 20 kPa, minimizing pump energy consumption while achieving uniform cooling.

Design Parameters and Thickness Optimization

Cooling plates are generally built from two sheets, 1.0–3.0 mm thick. Thinner plates provide better heat transfer but risk deformation under pressure, while thicker plates increase stiffness but add weight.

Engineers use Finite Element Analysis (FEA) to simulate internal pressure loads — often up to 0.3 MPa — and identify areas requiring reinforcement ribs or adjustments to weld spacing.

A well-optimized plate achieves:

• Flatness tolerance: within ±0.05 mm
• Burst pressure: over 1 MPa
• Thermal resistance: below 0.20 °C/W

This precision ensures the plate stays flat and leak-free even after 10,000+ pressure cycles, critical for high-voltage battery modules where sealing integrity is non-negotiable.

Manufacturing Tolerances and Surface Flatness

Effective heat transfer relies on tight control of surface flatness and channel geometry. Even small irregularities can increase thermal resistance and reduce efficiency.

تتضمن أفضل الممارسات ما يلي:

• Controlling flatness within ±0.05 mm using precision clamping during welding.
• Minimizing weld bead distortion through controlled heat input and cooling rates.
• Applying thermal interface materials (TIMs) like gap fillers or pads to bridge microscopic air gaps.

Improving surface flatness from 0.10 mm to 0.05 mm can reduce interface resistance by nearly 25%, enhancing overall temperature uniformity.

عمليات تصنيع ألواح التبريد بالصفائح المعدنية

Transforming a digital design into a durable, leak-proof, and thermally efficient cooling plate demands precision at every stage. From sheet forming to welding, each step must preserve geometry, prevent distortion, and ensure consistent performance across thousands of units.

Forming and Channel Creation

The process begins with two sheets of aluminum or copper, typically 1–3 mm thick. Depending on production volume and design complexity, manufacturers use several forming methods:

Precision Stamping

• مثالية للإنتاج بكميات كبيرة.
• Provides consistent depth and channel curvature within ± 0.1 مم tolerance.
• Works best for simple serpentine or parallel flow layouts.

التصنيع باستخدام الحاسب الآلي

• Suitable for prototyping or low-volume runs.
• Allows full design flexibility with channel depths up to 3 مم and complex geometries.
• Ensures high repeatability for early-stage validation or design customization.

التشكيل المائي

• Uses high-pressure fluid to form evenly spaced channels across the sheet.
• Reduces residual stress and delivers smooth internal surfaces for better coolant flow.
• Preferred in EV applications requiring compact, high-density plates.

Joining and Sealing Processes

Once the channel layer is formed, the two sheets are joined to create a sealed internal network. The choice of joining process affects thermal efficiency, weight, and production cost.