Composite liquid cold plates integrate high-conductivity base plates with internal micro-channels, embedded tubing, or vacuum-brazed fin structures. Engineered for high-heat-flux electronics where standard extruded heat sinks fail to meet thermal dissipation thresholds. Designed for direct compliance with strict industrial, automotive, and medical reliability standards under certified quality frameworks (ISO 9001 / IATF 16949).
Technical Specifications
|
Parameter |
Standard Capability / Range |
|
Base Material |
Aluminum (6061-T6, 6063-T5), Copper (C11000) |
|
Tubing Material |
Copper, Stainless Steel (304/316), Aluminum |
|
Max. Operating Pressure |
Up to 1.0 MPa (Factory tested to 1.5 MPa) |
|
Thermal Resistance |
Down to 0.02 °C/W (dependent on flow rate and fluid type) |
|
Coolant Compatibility |
Water-Glycol (EG/PG), Dielectric Fluids, Mineral Oils |
|
Surface Treatment |
Anodizing (Type II / III), Chemical Conversion (RoHS & REACH compliant), Nickel Plating |
|
Flatness Tolerance |
Up to ±0.05 mm across contact surface |
Key Features
Direct-Contact Cooling:
Minimizes thermal resistance interfaces between high-dissipation components and fluid paths.
Corrosion Mitigation:
Isolated fluid paths via embedded seamless tubing prevent galvanic corrosion in mixed-metal systems.
Custom Flow Path Topology:
Optimized manifold and serpentine channel designs minimize pressure drop while maximizing turbulent flow.
Leak-Free Joint Integrity:
Vacuum brazing and friction stir welding create metallurgical bonds exceeding parent material strength.
Materials & Options
Baseplates:
Aluminum 6061-T6 (balanced weight, thermal conductivity, and mechanical strength)
Copper C11000 (maximum thermal conductivity for extreme heat fluxes)
Internal Structures:
Vacuum-brazed aluminum fin stock (louvered, offset, or plain fins)
Pressed-in or friction-stir-welded copper/stainless steel tubing
Interface Finishes: Unplated raw milled, clear/hardcoat anodized, or immersion silver/nickel plated for electrical isolation and corrosion resistance.
Manufacturing Process
Our facility executes complete in-house manufacturing workflows to control dimensional tolerances and structural integrity:
CNC Machining: High-precision milling of fluid channels, manifolds, and mounting holes on 5-axis vertical machining centers.
Tubing Integration: Automated tube bending, mechanical expansion, or friction stir welding (FSW) for embedded-tube cold plates.
Vacuum Brazing: Controlled atmosphere brazing (CAB) furnaces for multi-layer fin-and-plate assemblies without flux residue clogging.
Surface Finishing & Cleaning: Ultrasonic degreasing and passivation to remove machining oils and particulate contamination.
Quality Control
Operated under strict quality management systems compliant with ISO 9001 and IATF 16949:
Pressure & Leak Testing: 100% pneumatic pressure decay testing followed by helium mass spectrometer leak testing (< 1 × 10⁻⁹ Pa·m³/s).
Dimensional Inspection: CMM (Coordinate Measuring Machine) verification for critical mounting datums, hole patterns, and flatness.
Thermal Performance Verification: In-house thermal test benches evaluate real-world thermal resistance and pressure drop curves against simulation models.
Customization
OEM engineering teams can specify custom geometric envelopes, specialized port configurations (G-threads, NPT, SAE, or quick-disconnect fittings), and integrated temperature sensors. Submit 3D CAD models (STEP/IGES) alongside operating parameters (heat load Q, coolant type, maximum allowable pressure drop, and volumetric flow rate) for engineering evaluation and DFM (Design for Manufacturability) review.
Applications
EV Powertrains:
Traction inverter cooling, on-board charger (OBC) modules, and battery thermal management systems (BTMS).
Power Electronics:
High-power IGBT and Silicon Carbide (SiC) semiconductor module cooling.
Renewable Energy:
Wind turbine converters and utility-scale energy storage system (ESS) racks.
Industrial Lasers:
High-power diode and fiber laser resonator thermal stabilization.
Data Centers:
Direct-to-chip liquid cooling cold plates for high-density server blades.
Packaging & Delivery
Packaging: Individually sealed in anti-static, moisture-barrier vacuum bags with desiccant; secured in custom high-density polyethylene (HDPE) foam cutouts within corrugated export cartons or fumigation-free wooden crates.
Port Protection: Ports sealed with threaded plastic plugs to prevent particulate ingress during transit.
Compliance Documentation: Shipments include Material Test Reports (MTRs), dimensional inspection sheets, pressure test certificates, and Certificate of Conformance (CoC) documents.
Lead Time: Prototypes delivered in 3 to 4 weeks; volume production schedules established via Kanban or scheduled blanket orders.
FAQ
Q: What is the typical lead time for custom prototype cold plates?
A: Prototypes generally require 3 to 4 weeks from drawing approval, including CNC machining, joining, pressure testing, and dimensional inspection reports.
Q: How do you prevent galvanic corrosion between copper tubing and aluminum baseplates?
A: When liquid paths require copper while base structures use aluminum, we utilize engineered barrier layers, dielectric isolation seals, or direct mechanical bonding with inhibited coolants to eliminate galvanic interaction.
Q: What is your standard helium leak test threshold?
A: Standard production testing verifies helium leak rates below 1 × 10⁻⁹ Pa·m³/s, ensuring zero fluid migration over multi-year operating lifecycles.
Q: Can you accommodate complex internal fin geometries?
A: Yes. Vacuum brazing allows us to integrate internal offset, louvered, or wavy aluminum fins to augment turbulence and heat transfer coefficient at acceptable pressure drop penalties.
Q: What file formats do you accept for engineering review?
A: We accept STEP, IGES, Parasolid, and SolidWorks files alongside 2D PDF drawings detailing critical tolerances, flatness specifications, and pressure test requirements.
Q: What quality documentation is supplied with production shipments?
A: Shipments include Material Test Reports (MTRs), CMM dimensional inspection sheets, helium leak test certificates, and CoC documentation aligned with ISO/IATF standards.
Request a Quote
To initiate an engineering review and quotation, provide your operating specifications and 3D models via our secure RFQ portal.
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