CP005 Stamped & Brazed Cold Plate Large-Format Liquid Cooling for EV Battery Packs

Product Overview

The CP005 is a large-format liquid cold plate engineered for lithium-ion battery thermal management in electric vehicles and energy storage systems. Built with a stamping + brazing dual-process, it delivers cost-effective, high-volume-ready battery cooling with a footprint large enough to cover entire battery module areas.

With dimensions of 1152 × 810 × 37.5 mm, the CP005 is among the largest cold plates in its class, capable of providing uniform liquid cooling across substantial battery module surfaces. The stamped aluminum construction forms precise internal flow channel geometries, while high-temperature aluminum brazing creates a leak-free, metallurgically bonded enclosure — no gaskets, no O-rings, no age-related seal degradation. A degreasing surface treatment ensures a clean, contamination-free finish ready for direct contact with battery cells or thermal interface materials.

The stamping process enables rapid, repeatable plate forming at automotive-tier production volumes. Combined with batch aluminum brazing, the CP005 achieves a cost structure that scales favorably with quantity — making it a practical liquid cooling solution for EV platform programs where thermal performance, manufacturing scalability, and unit economics must all be optimized simultaneously.

How Stamping and Brazing Work Together

The CP005 leverages two complementary manufacturing processes to achieve both thermal performance and production cost efficiency:

Stamping creates precise flow channel patterns in aluminum sheet stock at high throughput rates. A single stamping die, once qualified, produces consistent plate components with minimal material waste — fundamentally different from CNC machining where each cold plate requires individual tool-path processing. For high-volume EV programs, this translates into lower per-unit cost and shorter lead times as production quantities increase.

Aluminum brazing joins the stamped upper and lower plate shells into a single, leak-proof assembly through a controlled high-temperature furnace cycle. The brazing process creates a metallurgical bond — the aluminum components fuse at the molecular level without melting the base material. The result is a chemically and mechanically homogeneous seal across the entire plate perimeter and all internal channel divider walls.

This process combination is particularly well-suited for high-volume EV production, where cost control and manufacturing scalability are as critical as thermal performance. Neither process requires filler metals, eliminating material compatibility concerns while keeping raw material costs low. Compared to individually welded or CNC-machined cold plates, the stamping + brazing approach delivers structural cost advantages that compound with production volume.

Battery Thermal Management Challenge

Lithium-ion battery packs present a uniquely demanding cooling environment:

• Temperature Uniformity: Cell-to-cell temperature differences exceeding 3–5°C accelerate degradation and reduce pack lifespan. A large-format cold plate like the CP005 must maintain even cooling across its entire 1152 × 810 mm contact surface.

• Large-Area Coverage: Modern EV battery modules and ESS racks pack substantial cell counts across wide footprint areas. The cold plate must cover these extensive surfaces without creating thermal dead zones between inlet and outlet regions.

• High-Volume Manufacturing: EV and ESS programs routinely produce tens of thousands to hundreds of thousands of units per year. The cold plate production process must scale without sacrificing quality or cost competitiveness.

• Cleanliness Requirements: Battery assembly environments demand strict contamination control. Cold plates must arrive clean, oil-free, and ready for integration — no secondary cleaning steps in the production line.

• Long-Term Reliability: Battery packs are expected to perform for 8–15 years. The cooling system must maintain leak integrity and thermal performance over the full vehicle or system service life.

Key Features

Stamping + Brazing Dual-Process Manufacturing

The CP005 combines two proven high-volume metal fabrication processes into a single, efficient manufacturing flow. Stamping rapidly forms the upper and lower plate halves from aluminum sheet stock, creating precise internal flow channel geometries at automotive-tier cycle rates. Aluminum brazing then seals the two halves into a single, leak-proof cold plate assembly through a controlled high-temperature furnace cycle — with batch processing capability that allows multiple cold plates to be brazed simultaneously.

The result is a manufacturing flow optimized for repeatability at scale: consistent quality from the first unit to the hundred-thousandth, with lead times that shorten as order quantities increase. Neither process requires filler metals, eliminating material compatibility concerns while keeping raw material costs low.

Large-Format 1152 × 810 mm Coverage

The CP005's 1152 × 810 mm footprint provides approximately 933,120 mm² of cooling contact area — large enough to cover entire battery module baseplates or substantial ESS rack sections in a single cold plate. This large format reduces the number of individual cold plates, plumbing connections, and potential leak points in the overall thermal management system.

The 37.5 mm total thickness accommodates the internal flow channel profiles, inlet/outlet port structures, and structural rigidity requirements for a plate of this scale — while remaining compact enough for integration into standard battery pack enclosure dimensions.

Leak-Free Brazed Seal Architecture

The brazing process creates a metallurgical bond between the upper and lower plate shells — fundamentally different from gasketed or O-ring sealed designs. There are no elastomeric seals to age, relax, or degrade over a 10+ year vehicle service life. The aluminum-to-aluminum bond is chemically and mechanically homogeneous, ensuring consistent leak integrity across the entire perimeter and internal channel divider walls. This is particularly critical for large-format cold plates where a single seal failure could compromise an entire battery module.

Clean, Integration-Ready Surface

The degreasing treatment removes all stamping lubricants, handling residues, and surface contaminants from the aluminum surfaces. CP005 cold plates arrive at the customer's assembly line in a clean, oil-free state — compatible with direct application of thermal interface materials (TIMs), gap fillers, or thermal pads without additional pre-cleaning steps. This reduces process complexity and quality risk at the battery module assembly station.

Scalable for Volume Production

The stamping + brazing process pair is inherently scalable. Stamping tooling, once qualified, produces consistent plate components at high throughput rates. Batch brazing furnaces process multiple cold plates simultaneously. For EV platform programs producing 50,000 to 500,000+ battery packs per year, this manufacturing approach delivers unit costs that decrease meaningfully with volume — a structural cost advantage over CNC-machined or individually welded cold plate designs.

Technical Specifications

Thermal Performance & Design

The CP005's internal flow channel geometry is formed through the stamped plate profile — a design approach that supports a range of channel configurations to match different heat flux and flow rate requirements across its large 1152 × 810 mm surface:

• Parallel channel patterns for uniform cooling across wide rectangular cell footprints

• Serpentine channel routing for higher convective heat transfer coefficients in hot-spot zones

• Multi-zone channel designs to independently address different thermal load regions within a single module

• Custom inlet/outlet positioning to match existing pack plumbing architectures

The 1152 × 810 mm plate footprint provides a contact area of approximately 933,120 mm² — suitable for baseplate-level cooling of large prismatic cell modules, distributed cylindrical cell arrays, or ESS rack-level thermal management.

The aluminum construction offers excellent thermal conductivity (approximately 160–180 W/m·K for typical brazing-grade aluminum alloys at operating temperatures), ensuring low conductive thermal resistance from the cell contact surface to the internal channel walls across the full plate area.

For precise thermal performance values (thermal resistance, pressure drop, cooling capacity) specific to a given coolant, flow rate, and cell configuration, Greatminds provides application engineering support with CFD simulation and experimental validation.

Applications

Why Choose CP005?

OEM & Customization Services

Greatminds provides full application engineering support for CP005-based liquid cooling solutions:

• Channel Geometry Customization: Adjust internal flow channel pattern, width, depth, and routing to match specific heat flux distributions and pressure drop budgets across the 1152 × 810 mm surface

• Port Configuration: Custom inlet/outlet nipple types (barbed, threaded, quick-connect), positions, and orientations

• Mounting Features: Integrate mounting tabs, bolt holes, or bracket interfaces into the stamped plate profile

• Surface Treatments: Available upgrades including anodizing, passivation, and corrosion-resistant coatings for demanding electrolyte-exposure environments

• Thermal Simulation & Testing: CFD thermal-hydraulic simulation and in-house thermal testing to validate performance against customer requirements

• Scaled Delivery: From prototype quantities to series production volumes — the CP005 stamping + brazing process scales with your program

Contact Us

Discuss your battery thermal management requirements with our engineering team. Whether you need a single prototype for evaluation or are planning a high-volume EV platform program, we can provide the right liquid cooling solution.

• Email: info@greatminds.com.cn

• Website: www.greatminds-cn.com

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