#China #Suzhou #Electric Bus #Cooling System #XD THERMAL

Introduction

In a significant advancement for the electric vehicle sector, XD THERMAL has unveiled a cutting-edge dual-sided liquid cooling architecture specifically designed for a European electric bus platform. This innovative system is tailored to manage the thermal demands of high-performance battery technology effectively. The initiative marks a crucial step toward enhancing the efficiency and longevity of electric bus operations, aligning with the growing demand for sustainable transport solutions across Europe.

The Cooling Architecture

The newly designed cooling system integrates dual-faced liquid cooling to efficiently dissipate heat from the 35.3 kWh battery modules used in the buses. By utilizing liquid cooling jackets combined with stamped top plates, this architecture manages heat from both sides of the battery packs. The development of the first prototype was surprisingly swift, taking only about six weeks. Within two months, the design progressed to a production-ready phase, showcasing the team's expertise and dedication.

Reducing Complexity and Improving Efficiency

One of the standout features of this design is its ability to reduce the number of cooling-related components by approximately 25%. This reduction simplifies the assembly process and contributes to a more streamlined manufacturing workflow. The new architecture also benefits from a multi-interface configuration, which enhances heat distribution within the battery system, thus prolonging the lifespan of lithium-ion batteries.

The engineering team faced a significant technical challenge in validating the system's overall sealing. Rather than assessing each component in isolation, they had to evaluate multiple interfaces and sealing paths collectively. This required the development of precise fastening devices and conducting extensive airtightness tests using both air and helium to ensure the integrity of the seals and detect any potential micro-leaks prior to commercial rollout.

Challenges and Innovative Solutions

Another challenge encountered was the creation of a reliable manufacturing process for this multifunctional coating system. Different surfaces demanded various thermal and insulating materials, making uniform application difficult. Customized masking and suspension techniques were devised to achieve sharp coating boundaries and ensure consistent application across complex geometries.

"Once cooling is an integral part of the battery casing, design constraints significantly shift," explained Xu, the Chief Technology Officer at XD THERMAL. "The focus moves from merely optimizing a cooling plate to ensuring that the entire structure provides stable thermal performance while remaining manufacturable."

The collaborative efforts of the thermal, structural, process, quality, and manufacturing teams were crucial throughout the development phase. Their ability to integrate insights from prototype testing directly into design and process revisions helped ensure a rapid transition from concept to production.

Scalability and Future Applications

This scalable architecture is adaptable for varying vehicle platforms, battery sizes, and capacity requirements without necessitating a complete redesign of the cooling concept. Since early 2025, XD THERMAL has been expanding its focus on thermal management solutions tailored for commercial vehicles. They have established dedicated production capabilities for large-format battery cooling components, preparing for mass production by the year's end.

Presently, this production facility supports programs encompassing electric buses and heavy-duty vehicles, consolidating engineering, validation, and production resources within a shared workflow suited for various battery sizes and structural specifications.

Participation in IAA TRANSPORTATION 2026

As part of its commitment to innovation in the electric vehicle sector, XD THERMAL will showcase its new cooling architecture at IAA TRANSPORTATION 2026 in Hanover this September. Visitors can find them at stand C23 in hall 22, where they will engage with industrial partners on topics related to battery integration, manufacturing feasibility, and transitioning from prototype to mass production.

Conclusion

The dual-sided liquid cooling architecture developed by XD THERMAL is a promising advancement in electric bus technology, setting a new standard for battery cooling solutions. As electric vehicle adoption grows, innovations like these will play a critical role in ensuring efficient and sustainable transportation options for the future.