XD THERMAL Enhances Industrial Cooling Solutions for Cylindrical Cell Packs

In a significant industry advancement, XD Thermal Technology, a China-based manufacturer specializing in thermal management solutions, has announced enhancements to its side cooling solutions designed specifically for cylindrical cell-to-pack battery systems. With an increasing demand for efficient battery management, the company stands out as a leading supplier in this competitive market, thanks to its robust production capabilities and quality process control comparable to automotive standards.

Innovations in Battery Cooling

The challenge faced by manufacturers of high-speed chargeable cylindrical batteries is the heat generation that occurs during charging and discharging at high currents and voltages. XD THERMAL’s latest side cooling design utilizes serpentine tubes aligned along the cell walls. This innovative configuration significantly increases the effective contact area when compared to conventional bottom cooling plates. The augmented vertical contact area effectively addresses heat gradients along the Z-axis, ensuring that each cell maintains a balanced temperature range. This balanced thermal condition is essential, as it contributes positively to the overall lifespan of lithium-ion batteries.

To complement these advancements, XD THERMAL has developed a family of side-cooled modules and packs that are founded on robust structures and reliable quality assurance processes. The cooling tubes are specifically optimized for cylindrical cell layouts and can be flexibly integrated with various distributors, brackets, and piping systems. Furthermore, validated flow path structures and internal design guidelines ensure that heat transfer performance remains consistent and predictable, from prototype to mass production.

Guo, a technical engineer at XD THERMAL, emphasized the advantages of their platform-based design, stating, "This approach reduces development costs and timelines, supporting agile development for our customers. With proven solutions for piping connectors, electrical insulation, and geometric combinations, we have successfully aided numerous clients in seamlessly completing their developments for side-cooled batteries."

Expanding Production Capabilities

In 2024, XD THERMAL launched a high-performance serpentine tube production line capable of achieving a daily output of 30,000 units. This automated line integrates molding, welding, cleaning, and comprehensive leak tests, enhancing the overall productivity and reliability of the cooling solutions. The quality of the welds is meticulously monitored through a 360-degree 3D scan inspection of the pipes, distributors, and associated components, guaranteeing complete weld coverage and performance integrity.

"Boosting production capacity and industrialization is as vital as product development," stated Sun, the head of manufacturing technology at XD THERMAL. "We offer a repeatable, scalable production system backed by a validated development roadmap and SOP timeline, allowing us to maintain proven capabilities for expanding manufacturing lines. Typically, production lines and tools can be completed 6 to 8 weeks prior to PPAP."

The industrialization and supply capacities of XD THERMAL have also garnered recognition from customers at the system level. In November 2025, OP Mobility, a global Tier-1 automotive supplier, officially designated XD THERMAL as a supplier of thermal management components within its supply chain, showcasing the company’s growing influence and acceptance in the market.

With cylindrical cell-to-pack (C2P) battery systems rapidly gaining market share in electric vehicle applications, XD THERMAL anticipates an increasing demand for side cooling solutions. This demand will likely be met by suppliers that possess adequate capabilities, highly automated production lines, and mature design platforms. The company’s commitment to innovation and excellence positions it well for future success in the battery cooling technology landscape.

XD THERMAL Cooling Technology

In conclusion, XD THERMAL’s latest innovations enhance the performance and longevity of cylindrical battery packs, making it a key player in the sustainable energy landscape. As electric vehicle technology continues to evolve, the demand for sophisticated thermal management solutions will only increase, reaffirming the importance of companies like XD THERMAL in the progression toward efficient battery technology.