IGBT cold plates and liquid-cooled heat sinks remove heat from power modules in converters, traction inverters, wind and industrial drives, keeping baseplates below their limits at full load. ToneCooling designs custom IGBT cold plates to each module layout and coolant.
IGBT Cold Plates and Liquid Cooled Heatsinks | ToneCooling
Custom IGBT cold plates and liquid cooled heatsinks for high-power converters, traction inverters, wind power and industrial drives. ToneCooling designs and manufactures vacuum-brazed and FSW cold plates with reliable leak-tight performance. For an overview of designs and standard kits, see our liquid cold plates page.
IGBT Cold Plates and Liquid Cooled Heatsinks for Power Electronics
IGBT power modules and high-power converters operate at high currents, high voltages and demanding duty cycles. Efficient thermal management is critical to ensure reliability, lifetime and safe operation of traction inverters, wind power converters, industrial drives and HVDC systems.
ToneCooling is a specialized manufacturer of custom IGBT cold plates and liquid cooled heatsinks. We support customers from concept to mass production, providing robust, leak-tight cooling solutions for high-power electronics in harsh environments.
Thermal Challenges in IGBT Power Modules
Typical power electronics applications face several cooling challenges:
High continuous and transient losses
Large current and switching losses in IGBT and freewheel diodes
Thermal cycling due to load variations and start/stop conditions
High reliability and safety requirements
Railway traction, metro systems, wind power and grid applications
Long service life and low failure rates required
Limited space and complex module layouts
Multi-chip modules, stacked assemblies, laminated busbars
Electrical isolation and creepage/clearance constraints
Without proper liquid cooling, junction temperatures may exceed safe limits, leading to accelerated aging, derating or even catastrophic failure. A well-designed IGBT cold plate keeps module temperatures under control and improves overall system reliability.
ToneCooling IGBT Liquid Cooled Heatsink Solutions
We design and manufacture a wide range of liquid cooled heatsinks and cold plates for IGBT power modules:
Direct-mount IGBT cold plates
Custom cold plates matching your IGBT module footprint and bolt pattern
Optimized flow paths under chip locations for uniform temperature distribution
Flatness and surface quality controlled for low thermal resistance
AlSiC pin-fin heatsinks with liquid base
AlSiC (aluminum silicon carbide) pin-fin or baseplate structures on the module side
Integrated liquid cooling channels on the opposite side
Combines high thermal conductivity with good CTE matching to reduce stress
Multi-module cold plates
Cold plates designed to cool multiple IGBT modules in a single assembly
Manifolded inlet/outlet design for even flow distribution
Suitable for larger converters, inverter cabinets and power stacks
Our engineering team can support both standard module sizes and fully custom designs.
Typical Applications
ToneCooling IGBT cold plates are used or suitable for:
Railway and metro traction inverters
Traction motor control for metro, light rail and mainline trains
Wind power converters and pitch systems
High power converters in onshore and offshore wind turbines
Industrial motor drives and soft starters
Variable frequency drives for heavy industry and mining applications
HVDC, STATCOM and other grid applications
High power conversion and reactive power compensation systems
High-power rectifiers and test benches
Electrolysis, plating and industrial rectification equipment
Each application may have specific requirements on coolant, ambient conditions, vibration and mounting – we can adapt the design accordingly.
Design and Manufacturing Capabilities
We combine thermal design, mechanical engineering and reliable manufacturing processes to provide robust IGBT cooling solutions.
Design capabilities
Channel and manifold layout according to module hotspots
Balancing heat transfer performance and pressure drop
Material selection (e.g. copper, aluminum, AlSiC combinations)
Electrical isolation considerations (e.g. interface with insulation sheets or substrates)
Manufacturing processes
Vacuum brazing
For complex internal channels and high integrity joints
Suitable for both copper and aluminum cold plates
Friction Stir Welding (FSW)
High-strength hermetic welds for aluminum cold plates
Good for larger, thicker plates that require mechanical robustness
CNC machining and finishing
Precision machining for flatness and mounting holes
Surface treatment and corrosion protection where needed
Testing, Reliability and Documentation
Power electronics systems demand high reliability. We can support:
Leak and pressure testing
100% pressure test at agreed test pressure
Helium leak test upon request
Dimensional and flatness control
Controlled surface flatness for good thermal contact
Tolerances suitable for module mounting and sealing
Cleanliness and coolant compatibility
Cleanliness levels appropriate for closed-loop coolant systems
Material compatibility with water-glycol and other coolants
Documentation
Basic inspection records and test reports
PPAP Level 2 or similar documentation packages, if agreed in advance
Our goal is to deliver production-ready IGBT cold plates that can be used confidently in long-life, safety-critical systems.
How to Start an IGBT Cooling Project with ToneCooling
To evaluate a custom IGBT cold plate or liquid cooled heatsink, you can start with the following information:
IGBT module type and manufacturer
Power dissipation (continuous and peak)
Coolant type, inlet temperature and allowable pressure drop
Mechanical drawings (module outline, bolt pattern, isolation requirements)
Environment and application (railway, wind, industrial, grid, etc.)
Expected annual volume and project schedule
Based on this information, we can provide:
An initial cooling concept and layout suggestion
A quotation for prototypes and mass production
Recommendations on materials and test levels
Please contact sales@tonecooling.com and share your project details.
Frequently Asked Questions
Can you design cold plates for specific IGBT module types?
Yes. We can design cold plates for specific module outlines, including mounting hole patterns and clearance areas. 3D or 2D drawings are very helpful.
Do you support AlSiC or other advanced base materials?
We can integrate AlSiC pin-fin or baseplate parts with liquid cooling structures, depending on your design and supply chain. Details can be discussed case by case.
What coolants do you support for IGBT cold plates?
Typical coolants include water-glycol mixtures and treated water. If your application uses other coolants, we will review material compatibility and adjust the design accordingly.
How do you ensure leak-tightness over long-term operation?
We use vacuum brazing or FSW processes for hermetic joints and perform 100% pressure testing according to agreed standards. Helium leak testing is available when required.
Do you offer prototypes before mass production?
Yes. We usually build prototype or pilot batches for validation in your system. After successful testing, we can scale up to mass production. Custom samples are available from a single piece and typically take 4–6 weeks.
Can you provide documentation such as PPAP?
For automotive or other highly regulated applications, we can provide documentation support such as PPAP Level 2 if this is defined in the project scope.
Get a Custom Thermal Solution from ToneCooling
ToneCooling is a professional liquid cooling solution provider specializing in custom cold plates, AIO coolers, and advanced thermal management systems. With ISO 9001 quality management and our own manufacturing facility in Huizhou, China, we deliver prototype samples typically within 4–6 weeks. Contact ToneCooling today for a free consultation and quote. An engineer reviews every RFQ and replies by email with next steps.
For industry standards and best practices, refer to IEEE.
References: ASHRAE thermal standards
Engineering review and prototype planning are based on the project requirements. Custom prototype lead time is normally 4–6 weeks after drawing approval and order confirmation; confirm the production schedule in the quotation.
Need a Custom Liquid Cold Plate?
ToneCooling engineers review your drawings and requirements and reply by email with next steps.
Last updated: 2026-10-02
