Custom Powder Coated Aluminum Liquid Cooling Plate For Battery Module Packs

Our Custom Powder Coated Aluminum Liquid Cooling Box is a high-integrity thermal management solution engineered for electric vehicle battery module assemblies. It leverages a reliable manufacturing process that combines precision stamping with a proprietary epoxy powder coating, delivering a durable, electrically insulated, and corrosion-resistant enclosure for volume manufacturing.

Manufactured from high-grade aluminum, the main body of this cooling box is formed using our established precision stamping tooling, which efficiently creates the structural housing and integrated flow channels. After assembly and sealing, each unit undergoes a specialized electrostatic powder coating process, followed by a thermal cure. Critically, 100% of finished units are subjected to a stringent high-voltage withstand test. This proven process eliminates the need for new tooling investment, making it a cost-effective solution for large-scale production. Each unit is validated for both leak-tight integrity and electrical insulation performance.

This powder-coated liquid cooling box is designed as a robust thermal and structural component for modern electric vehicle battery systems. Its primary application is:

• Integrated Cooling for Prismatic Cell Battery Modules:​ Functions as both the structural lower housing and the active cooling element for battery modules utilizing large-format prismatic cells. It provides direct cooling to the cell base while offering mechanical support and electrical isolation.

• Certified High-Voltage Insulation:​ Every single cooling box is 100% tested to withstand a minimum of 2.5 kV AC, providing a verified, thick dielectric barrier. This is critical for preventing electrical leakage or short circuits to the vehicle chassis, ensuring pack-level safety.

• Superior Corrosion & Chemical Resistance:​ The thermally cured epoxy powder coating forms a tough, continuous film that is highly resistant to corrosion from coolants, road salts, and harsh automotive environments, ensuring long-term reliability.

• Cost-Effective Volume Manufacturing:​ Utilizing existing stamping dies allows for rapid production startup and excellent economies of scale, eliminating customer tooling costs and minimizing per-unit pricing for high-volume orders.

• Robust, Sealed Enclosure Design:​ The design integrates cooling functionality into a structural box, providing a protective housing for the battery cells. The manufacturing process ensures robust, leak-proof seams and joints.

• Customizable for Module Integration:​ While based on proven stamping tooling, we offer customization in overall box dimensions (within limits), port and connector locations, mounting flange details, and coating color to suit specific module designs and OEM requirements.

Our powder-coated aluminum liquid cooling boxes are the ideal integrated solution for high-volume production of prismatic cell-based EV battery modules, where electrical safety, corrosion protection, structural integrity, and manufacturing cost are paramount. We provide full support from design for manufacturability to serial production delivery.