#China #Suzhou #Thermal Management #XD THERMAL #Battery Cooling

XD THERMAL Expands Its Cooling Solutions

XD Thermal Technology, a prominent thermal management manufacturer based in Suzhou, China, has announced significant enhancements to its cooling solutions tailored for cylindrical Cell-to-Pack (C2P) battery packs. This development is in response to the growing demand for advanced thermal management in the electric vehicle (EV) industry, particularly as high-capacity batteries necessitate efficient cooling mechanisms during rapid charging and discharging cycles.

Innovative Cooling Technology

The crux of XD THERMAL's innovation lies in its unique side liquid-cooling concept. Instead of traditional bottom cooling plates, the new design employs serpentine tubes positioned along the sidewalls of the batteries. This approach not only increases the effective contact area for cooling but also addresses the challenge of heat accumulation in batteries during high current and voltage operations. By expanding the vertical contact surface, XD THERMAL has successfully mitigated the heat gradients typically observed along the Z-axis of cylindrical cells, thereby ensuring a more uniform temperature distribution across individual cells. This uniformity is crucial for enhancing the lifespan and reliability of Lithium-ion batteries.

Platform Solutions for Scalability

XD THERMAL's strategy involves the creation of a platform family of side-cooled modules and packs that are designed with robustness and reliability in mind. The cooling tubes are engineered to match cylindrical cell layouts and can be flexibly combined with various manifold designs, brackets, and pipelines. This versatility is underscored by validated flow-path structures and strict internal design guidelines that guarantee consistent heat-transfer performance from the prototype stage through to mass production.

"Our platformized design minimizes development costs and duration, while also facilitating agile adaptations based on customer needs," explains Guo, a technical engineer at XD THERMAL. "With our proven pipeline connections, electrical insulation solutions, and geometric combinations, we have assisted various clients in seamlessly developing side-cooled batteries."

Production Capacity and Quality Assurance

In alignment with the growing market for side-cooling solutions, XD THERMAL has commissioned high-volume serpentine-tube production lines capable of manufacturing 30,000 units daily. This facility integrates state-of-the-art automation including forming, welding, cleaning, and comprehensive leak testing processes. To ensure top-notch quality, welds undergo rigorous 360-degree 3D scanning inspection across components like tubes and manifolds, confirming full coverage and preventing potential failures.

"The ramp-up of production capabilities is as critical as the product development phase itself," mentions Sun, the Head of Manufacturing Engineering at XD THERMAL. "Our established production system is not only repeatable but also scalable, supported by a well-defined development roadmap and Standard Operating Procedures (SOPs). Typically, the preparation for production lines and tooling can be completed 6-8 weeks prior to the start of Part Production Approval Process (PPAP)."

Recognized by Industry Leaders

The company’s commitment to industrialization and delivery precision has been acknowledged by major industry players. In November 2025, OP Mobility, a global tier-1 automotive supplier, officially named XD THERMAL as a supplier of thermal-management components within its supply chain. This recognition highlights XD THERMAL's capability to meet high standards and needs of the automotive sector, particularly in the burgeoning electric vehicle market.

As the adoption of cylindrical C2P battery packs accelerates in EV applications and beyond, XD THERMAL is poised to capture rising demand for advanced side-cooling solutions, leveraging its extensive production capacity and mature design platforms to remain at the forefront of battery technology innovation.


Source: XD Thermal Technology