Battery Pack Cooling Block

Name: EV Cooling Block for Battery Heat Safety - Frigate
Price: 249.00 USD
Availability: InStock

Battery Pack Cooling Block ensures minimal thermal gradient across cells by incorporating optimized microchannel geometry for homogeneous coolant flow. This maintains uniform surface temperatures critical for lithium-ion cell stability during high C-rate charging and discharging. Controlled temperature distribution improves electrochemical efficiency and reduces capacity fade over thermal cycles.

Material Grade & Specification

Aluminum 6061-T6 (or equivalent for thermal conductivity and corrosion resistance), ASTM B221 for aluminum extrusions

Dimensional Tolerances

±0.005 inches (±0.13 mm) for critical dimensions, ±0.002 inches (±0.05 mm) for flow channels and mounting holes

Surface Finish Requirement

Ra ≤ 1.6 µm (63 µin) for internal contact and flow channels, Ra ≤ 3.2 µm (125 µin) for external surfaces

Thermal Conductivity Requirement

≥ 150 W/m·K (for Aluminum 6061); or as per custom specifications for optimal heat dissipation from the battery pack

Flatness and Straightness Tolerances

Flatness ≤ 0.005 inches (0.13 mm), Straightness ≤ 0.01 inches (0.25 mm) for alignment and integrity of surfaces

Product Description

Battery Pack Cooling Block is manufactured using high-thermal-conductivity aluminum alloys (typically 6xxx or 1xxx series), selected for their ability to rapidly conduct heat away from battery cells. The material’s isotropic conduction properties support fast transient response to thermal spikes, helping to regulate localized heat zones in dense pack configurations.

Heat Treatment Specification

Solution heat-treated and artificially aged (T6 temper) to enhance strength and thermal conductivity

Hardness Requirement

70-80 HRB (for Aluminum 6061-T6), or as specified for the component’s wear and thermal cycling resistance

Non-Destructive Testing (NDT) Requirement

Ultrasonic Testing (UT), Dye Penetrant Testing (DPT), or Radiographic Testing (RT) for internal voids and defects

Flow Channel Design Specifications

Channels with ≤ 1.5 mm deviation in width or height, designed for efficient coolant flow (considering pressure drop and flow uniformity)

Certification Standard

ISO 9001:2015, IEC 62133 (for batteries), UL 94 (for flame retardancy if applicable), RoHS compliance (if required)

Technical Advantages

Battery Pack Cooling Block is designed with internal channels tuned through CFD analysis to achieve low hydraulic resistance. This minimizes pressure drop across the coolant circuit while maintaining turbulent or transitional flow regimes necessary for high heat transfer coefficients. The geometry supports both water-glycol and dielectric fluid compatibility.

Battery Pack Cooling Block is CNC-machined to tolerances within ±0.05 mm to support precise alignment with cell structures and thermal interface materials. Consistent flatness across contact surfaces enhances thermal coupling with minimal gap resistance. This dimensional stability is essential for modular battery designs requiring repeatable thermal interface behavior.

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Industry Applications

Electric Vehicles (EVs)

Used to maintain uniform cell temperature during acceleration and regenerative braking, improving thermal stability in compact EV battery modules.

Energy Storage Systems (ESS

Regulates heat in high-capacity stationary battery arrays operating under continuous charge-discharge cycles in grid-level power management systems.

Hybrid Electric Vehicles (HEVs)

Controls cell temperatures under frequent engine-battery switching, supporting thermal consistency in automotive hybrid traction battery configurations.

Uninterruptible Power Supplies (UPS)

Dissipates heat generated during extended backup operations in high-density lithium-ion battery racks used in critical power supply systems.

Aerospace Auxiliary Power Units (APUs)

Manages thermal loads in onboard battery systems exposed to wide ambient temperature swings and varying power demands during flight cycles.

Telecom Base Station Batteries

Enables effective heat dissipation in compact enclosures where telecom battery packs face prolonged high-load operation and elevated ambient conditions.

Leakage Resistance Under Dynamic Load

Battery Pack Cooling Block is validated for pressure integrity under thermal cycling and vibration loads common in mobile and stationary battery systems. Helium leak detection and burst testing verify sealing under pressures exceeding 2.5 bar. Structural design accounts for differential expansion between block material and housing.

Battery Pack Cooling Block includes surface treatments such as hard anodizing or chemical conversion coating to resist galvanic corrosion and coolant degradation. Surface passivation layers maintain long-term dimensional stability and prevent particulate contamination in closed-loop cooling systems, ensuring coolant quality and thermal performance over service life.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure leak-proof performance in Battery Pack Cooling Blocks during thermal and mechanical stress?

Frigate uses helium leak detection to validate sealing performance under simulated thermal cycling and pressure fluctuations. Each block is pressure-tested above 2.5 bar. We account for thermal expansion mismatches between materials using compliant sealing geometries. This ensures long-term integrity under automotive and industrial load profiles.

What design features does Frigate include to optimize coolant flow in complex battery layouts?

Frigate uses CFD modeling to shape internal channels for low pressure drop and uniform flow distribution. We design for both series and parallel coolant circuits. Flow velocity and Reynolds number are tuned for optimal heat transfer while avoiding turbulence-induced vibration. This helps stabilize thermal performance even in multi-module systems.

How does Frigate handle custom pack geometries when designing Battery Pack Cooling Blocks?

Frigate offers modular cooling block platforms that adapt to cylindrical, pouch, or prismatic cell formats. Each design is parametric, allowing quick changes in channel spacing and interface layout. CNC machining tolerances are held within ±0.05 mm to match customer pack specifications. Customization ensures thermal contact quality is maintained across cell arrays.

What surface treatments does Frigate apply to prevent corrosion inside the Battery Pack Cooling Block?

Frigate applies Type II or Type III anodizing based on coolant chemistry and system voltage class. For systems with dielectric fluids, internal surfaces remain chemically inert. We also offer chemical conversion coatings where galvanic compatibility is needed. These treatments increase service life and maintain internal cleanliness.

How does Frigate verify the thermal performance of its Battery Pack Cooling Blocks?

Frigate conducts thermal resistance measurements using controlled cell simulators and precision thermocouples. We validate steady-state and transient cooling response across operating ranges. Results are compared against simulation data for thermal model calibration. This ensures accurate prediction of in-vehicle or in-system performance.

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10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

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9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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