Energy Storage / BESS Cold Plate
TC-1P104S BESS Liquid Cold Plate
A stamped-brazed aluminium liquid cold plate for 1P104S battery modules in grid-scale and container battery energy storage. Bottom liquid cooling, parallel flow channels, cell-top ΔT 6.2 °C, 100% leak-tested — engineered and manufactured by ToneCooling (ISO 9001 / IATF 16949-aligned).
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Cooling technology
The TC-1P104S sits beneath the 1P104S battery module and draws heat from the cell base through a sealed coolant loop — targeted, even cell-base cooling without exposing cells to coolant.
Internal channels (~12–15 mm wide × 3–3.5 mm deep) are arranged in parallel for balanced flow distribution, holding cell-top ΔT to 6.2 °C across all 104 cells at 15 W per cell.
Top and channel plates are AL3003MOD with an AL4045 brazing-clad layer (1.3–1.5 mm), giving a metallurgically bonded, leak-tight body optimised for thermal conductivity and weight.
An SPCC / Q235 steel frame carries module load (< 750 kg over the installation area) and keeps the assembly flat (≤ 1 mm under load) for reliable cell contact.
Manufacturing process
The aluminium cold-plate body is formed by stamping and joined by controlled-atmosphere brazing — the same Tier-1 automotive process family, delivering durable, leak-tight channels.
The steel structural frame is laser-welded to the cold plate, then electrophoretically coated for corrosion resistance.
The plate surface receives an insulating epoxy powder coating (200±50 µm) rated to 2700 V DC with V0 flame-retardant insulation — protecting against electrical fault and supporting BESS fire-safety design.
Testing & validation
Every unit is leak-tested — pressure-decay 4 Pa measured against a 30 Pa specification per QC/T 468-2010, with helium-grade integrity.
Burst pressure 4 MPa; rated maximum working pressure 0.35 MPa — a wide safety margin for grid-scale loops.
CFD simulation confirms cell-top ΔT 6.2 °C across 104 cells at 15 W/cell on 50% EGW, 10 L/min, 20 °C inlet.
Flatness ≤ 3 mm overall / ≤ 1.8 mm module area / ≤ 1 mm under load; surface insulation 2700 V DC, ≥ 1 GΩ; RoHS 2.0 compliant.
Full technical specifications
| Application | 1P104S battery module — grid-scale & container BESS |
|---|---|
| Outline size (L × W × H) | 2180 × 790 × 42 mm |
| Internal volume | 1.95 L |
| Total weight | 39.1–40.3 kg |
| Load-bearing (module area) | < 750 kg |
| Coolant medium | 50% ethylene glycol aqueous (EGW) |
| Recommended flow rate | 10 L/min (8–10 L/min operating) |
| Total pressure drop | 24.6 kPa at 10 L/min (< 25 kPa; max 30 kPa) |
| Cell-top ΔT | 6.2 °C across 104 cells at 15 W/cell (CFD) |
| Recommended inlet temperature | 20 °C |
| Max working pressure | 0.35 MPa |
| Burst pressure | 4 MPa |
| Air-tightness | 4 Pa measured vs 30 Pa spec (QC/T 468-2010); 100% tested |
| Top & channel plate | AL3003MOD + AL4045 brazing alloy (1.3–1.5 mm) |
| Structural frame | SPCC / Q235 steel |
| Joining process | Stamped brazing (CAB, aluminium) + laser welding (steel) |
| Surface treatment | Insulating powder coating (epoxy, 200±50 µm); frame electrophoretic |
| Flow channel | Parallel layout, ~12–15 mm width × 3–3.5 mm depth |
| Flatness | ≤ 3 mm overall; ≤ 1.8 mm module area; ≤ 1 mm under load |
| Quick-connect fitting | CQC14 / CQC16 / CQC18 |
| Compatible cell | 0.5C, 280 Ah / 314 Ah |
| Compliance | RoHS 2.0; V0 flame-retardant insulation |
Values are validated at the stated working point; final values are confirmed per drawing, heat load, flow rate and pressure-drop limit. Designed, engineered and manufactured at ToneCooling’s ISO 9001:2015 / IATF 16949-aligned-aligned facility in Huizhou, Guangdong, China.
Applications
The TC-1P104S is engineered for grid-scale and container battery energy storage systems (BESS) built on 1P104S prismatic modules (0.5C, 280 Ah / 314 Ah). Its bottom liquid-cooling architecture keeps cell-to-cell temperature uniform, protecting cycle life and supporting safe operation. For other module formats, ToneCooling also supplies custom EV-battery and energy-storage cold plates — see cold plates for energy storage systems.
Frequently asked questions
What is the TC-1P104S BESS cold plate?
A 2180 × 790 × 42 mm stamped-brazed aluminium liquid cold plate for 1P104S battery modules in grid-scale and container battery energy storage (BESS). It uses bottom liquid cooling with parallel flow channels for uniform cell temperature.
How does it keep cells uniform?
Parallel internal channels (~12–15 mm × 3–3.5 mm) balance coolant flow so cell-top ΔT stays at 6.2 °C across all 104 cells at 15 W per cell (CFD-validated, 50% EGW, 10 L/min, 20 °C inlet).
What manufacturing process is used?
Stamped aluminium body joined by controlled-atmosphere brazing (CAB), with a laser-welded SPCC/Q235 steel frame and an insulating epoxy powder coating (200±50 µm, 2700 V, V0).
How is quality validated?
100% air-tightness testing (4 Pa measured vs 30 Pa spec, QC/T 468-2010), 4 MPa burst / 0.35 MPa working pressure, CFD thermal validation, flatness and insulation checks, RoHS and REACH declarations on request.
Which cells and connectors are supported?
0.5C 280 Ah / 314 Ah prismatic cells; quick-connect CQC14 / CQC16 / CQC18. Custom footprints, channels and connectors per project.
Where is it manufactured?
ToneCooling manufactures the TC-1P104S at its ISO 9001:2015 / IATF 16949-aligned facility in Huizhou, Guangdong, China, with full lot traceability.
Request a TC-1P104S quote
Send your module layout, cell format, flow rate and pressure-drop limit. ToneCooling responds with a thermal review and quotation.
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