Automobile & EVPune EV Belt
EV Battery Pack Thermal Housing Enclosure
Client PartnerElectroDrive Mobility
TechnologyCNC Milling
Material GradeAluminum 6061-T6 & Thermal Pad
Turnaround Time8 Working Days
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Project Execution & Background
Client Objectives & Background
ElectroDrive needed a thermal housing to prevent battery cell thermal runaway during 150kW fast charging.
Design & Prototyping Methodology
Friction-stir welded aluminum cooling plates with internal serpentine fluid channels.
Quality Control & Inspection Protocol
Verified zero coolant leakage using helium mass spectrometer leak detection.
Engineering Specifications Table
| Engineering Parameter | Specification & Standard |
|---|---|
| Tolerance | ±0.05 mm |
| Material Grade | Aluminum 6061-T6 & Liquid Cold Plate |
| Thermal Conductivity | 205 W/m·K Dissipation |
| Surface Finish | Anodized & Thermal Barrier Coating |
| Quality Inspection | Helium Leak Test & AIS-048 Crash Test |
| Standards Compliance | AIS-048 & UN 38.3 EV Battery |
| Production Volume | 100 Battery Enclosures |
The Challenge
High-current fast charging generated extreme heat hotspots, causing thermal throttling and battery cell degradation.
Engineering Solution
Designed friction-stir-welded aluminum cooling plates embedded into the structural bottom chassis plate.
Key Technical Features
Friction-stir-welded liquid cooling plate
High impact structural aluminum frame
Integrated cell compression pads
Flame-retardant silicone sealing perimeter
Integrated high-voltage busbar channels
Pressure relief safety vent valve
Measurable Impact
Project Performance & Results
35% Cooler
Thermal Isolation
22% Reduced
Enclosure Weight
IP67 Certified
Waterproof Rating
AIS-048 Compliant
Crash Test Rating
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