Chinese thermal management specialist XD Thermal has, according to its own statements, developed a new battery cooling system for an unspecified European electric bus platform. The platform uses battery modules with a capacity of 35.3 kWh, and XD Thermal contributes liquid-cooled battery housings with stamped cover plates. This design enables heat dissipation from both sides of the battery modules.
Unlike solutions with separate cooling plates, parts of the thermal management system are directly integrated into the housing structure. According to XD Thermal, this reduces the number of components required for cooling by around 25 per cent while eliminating several assembly steps.
The configuration with multiple thermal interfaces also ensures more uniform heat distribution within the battery system, thereby contributing to the lifespan of the lithium-ion batteries. However, XD Thermal has not published specific figures on cooling performance, temperature distribution, or battery lifespan, and independent tests to verify the stated advantages are not yet available.
Integrated cooling increases demand on sealing
According to the manufacturer, integrating the cooling system into the battery housing introduces additional requirements for design and production. A central challenge was sealing the entire system. Due to multiple interfaces, joints, and sealing paths, these had to be tested not only individually but also in interaction with each other.
