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Cooling Solution for Prismatic Cells: BESS/EV Battery Module on FSW Liquid Cold Plate

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EV Battery Cooling & E‑Mobility

Engineered Battery Thermal Management Systems (BTMS) for high‑voltage EV traction battery packs in passenger electric vehicles (BEV, PHEV), e‑buses, and heavy‑duty commercial vehicles. Six modular cooling architectures maintain the cell stack within the optimal 20 °C to 35 °C operating window at a cell‑to‑cell uniformity of ΔT ≤ 2.5 K even during 2C–6C HPC fast charging.

Combining dry intercellular two‑phase ALVC/PHP heat spreaders with external Liquid Cold Plates (FSW, vacuum brazing, roll‑bond) eliminates internal coolant leak risks and reduces automotive thermal hardware weight by up to 70% compared to copper.

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System Engineering & Benchmarks

Technical Specifications & Performance Metrics (BESS / ESS / EV)

Target Systems

BESS · ESS · E‑Mobility (EV)

19" racks, 20/40 ft containers, BEV, e‑bus & marine

Cell Formats & Chemistry

Prismatic · Cylindrical · Pouch

LFP, NMC, 18650 / 21700 / 4680 (MTP & CTP)

Cell‑to‑Cell Uniformity

ΔT ≤ 2,5 K

Homogeneous thermal profile across the entire cell stack

Operating Window & HPC

20 °C – 35 °C (2C–6C)

Hotspot suppression during fast charging & peak shaving

Manufacturing Processes

FSW · Vacuum Brazed · Roll‑Bond

Extrusion, hydroforming & precision CNC machining

Cell Stack Safety

100% Dry Separation

Zero liquid coolant inside the cell stack (intercellular ALVC/PHP cooling)

Testing & Protection

100 % Helium · IP67 / IP68

Burst pressure > 35 bar, pressure‑drop & flow tested

Lightweight Advantage

Up to −70% Weight vs. Cu

EN AW‑3003 / 6061 / 6063 for maximum pack energy density

6 Modular Battery Cooling Solutions by Cell & Pack Format

ALVC Battery Cooling Architectures for BESS, ESS & E‑Mobility

Engineered for your specific cell format, pack envelope, and heat‑rejection loop, ALVC provides six production‑ready thermal architectures. Click any card to inspect the 3D assembly in the gallery.

For Prismatic CellsBottom LCP · BESS/EV

Bottom Liquid Cold Plate (FSW / Roll‑Bond)

Direct bottom cooling of prismatic LFP/NMC battery modules via a serpentine multi‑channel aluminum Liquid Cold Plate with thermal interface pad (TIM) coupling and front coolant ports.

Minimal Z‑height for 19" BESS rack trays
FSW, vacuum‑brazed & roll‑bond series production
High structural rigidity in Cell‑to‑Pack floors

For Prismatic & Pouch CellsIntercellular · L‑Profile

Intercellular L‑Profile PHP/ALVC + LCP

Ultra‑thin L‑shaped Pulsating Heat Pipes (PHP) or ALVC phase‑change sheets between cells transfer core heat dryly downward into the external bottom Liquid Cold Plate.

Large‑area heat extraction across cell side faces
100% dry intercellular space with zero leak risk
Eliminates vertical temperature gradients under HPC

For Heavy‑Duty BESS ModulesHousing‑Integrated · Dual‑Path

Housing‑Integrated ALVC Fins + LCP

Full‑height intercellular ALVC/PHP spreaders interlock structurally with the extruded side housing walls and couple to the bottom Liquid Cold Plate for dual‑path heat rejection.

Dual heat path via side housing & bottom LCP
Structural cell clamping & vibration resistance
Thermal barrier against thermal runaway

For Low‑Profile Battery PacksSide LCP · Low Z‑Height

Side‑Mounted Liquid Cold Plate + L‑ALVC

Intercellular ALVC/PHP plates feature 90° side L‑flanges thermally coupled to a side‑mounted vertical Liquid Cold Plate — ideal when vertical pack height is strictly constrained.

Zero vertical height penalty underneath cells
Easy side‑access maintenance of coolant manifolds
No liquid coolant routed beneath the cell stack

For Autonomous BESS CabinetsClosed‑Loop HVAC · Off‑Grid

Two‑Phase ALVC/PHP + Closed‑Loop HVAC

Dual‑stack prismatic array with curved intercellular ALVC/PHP sheets, top fin heat exchangers, and top‑mounted closed‑loop HVAC module (centrifugal blower + evaporator + TXV) with U‑ducts.

100% waterless architecture without external CDU
Hermetic closed air loop against dust & humidity
Scalable for 19" cabinets & outdoor ESS

For Cylindrical Cell Packs18650 · 21700 · 4680

Cylindrical Pack + Serpentine ALVC Ribbon

Contoured serpentine ALVC Vapor Chamber and micro‑channel ribbons wrap around cylindrical cells (18650, 21700, 4680) and reject heat into an end‑mounted fin cooler or cold plate.