Microchannel Aluminum Flat Tubes for BESS Separators

Why integrate microchannel aluminum flat tubes into BESS separators?

BESS separator = structure + cooling + safety

Embedding MPE (Multi Port Extruded) microchannel aluminum flat tubes directly into the separator delivers.

Thermal management

High surface area channels + high thermal conductivity aluminum → ~30% better heat transfer vs traditional cold plates.

TRP (Thermal Runaway Propagation) blocking

Works with flame-retardant/insulation layers to conduct heat and block fire—providing component-level data for UL9540A certification.

Weight reduction & assembly simplification

Eliminates separate cold plates and complex piping; the BESS separator cooling channel becomes part of the structure, speeding up assembly.

Standardization + fast customization

Common 11/13/19-port profiles in stock, cut to drawing/vacuum brazed; CAD/CFD feedback within 24h.

integrate microchannel aluminum flat tubes into BESS separators

Specifications & Technical Parameters (Standard Profiles)

Dimensions & Structure Parameters

Model Code	W (mm)	H (mm)	Ports N	Dh (mm)	t (mm)	Zn Coating (g/m²)	Stock Lengths (mm)
MPE-20×2.0-11	20	2	11	1.1	1.2	5±2	3000 / 6000
MPE-22×1.8-13	22	1.8	13	0.95	1.1	7±2	3000 / 6000
MPE-25×2.2-19	25	2.2	19	0.85	1.4	7±2	3000 / 6000
MPE-28×2.5-19H	28	2.5	19	0.9	1.6	10±2	4000 / 6000
MPE-18×1.5-11L	18	1.5	11	1.2	1	5±2	3000
MPE-32×3.0-19R	32	3	19	1	1.6	10±2	4000 / 6000
MPE-24×2.0-13A	24	2	13	1.05	1.3	7±2	3000 / 6000
MPE-30×2.2-19S	30	2.2	19	0.88	1.5	10±2	4000 / 6000

Performance & Processing

Model Code	Burst Pressure (MPa)	ΔP @ 60 L·min⁻¹ Single Plate (MPa)	Min Bend Radius Rmin (mm)
MPE-20×2.0-11	4.8	0.015	≥10
MPE-22×1.8-13	5.2	0.014	≥9
MPE-25×2.2-19	5.6	0.013	≥11
MPE-28×2.5-19H	6	0.012	≥13
MPE-18×1.5-11L	4.5	0.017	≥8
MPE-32×3.0-19R	6.2	0.011	≥15
MPE-24×2.0-13A	5	0.014	≥10
MPE-30×2.2-19S	5.8	0.012	≥12

Special Requirements for Flat Tubes in Energy Storage Baffle Applications

Requirement Point	Background Reason	Flat Tube Requirements	Our Solution
Thermal Runaway Blocking (UL9540A)	Large single-cell capacity with concentrated heat generation	Wall thickness 1.0–1.6 mm; redundant weld design	Rounded weld seams, burst/leak test reports, flame-retardant layer bonding compatibility tests
Large-Area Flatness (≤0.3 mm/m)	Large cell contact surface; warping = poor thermal contact	Symmetrical tube layout, aspect ratio w/t ≤ 25	FEM pre-compensation, anti-deformation fixtures, brazing process control documentation
Low ΔP & Low Pump Power	Long-term operational energy efficiency sensitivity	Dh 0.8–1.2 mm, 11/13/19-hole cross section	ΔP–Q test curves, CFD optimization recommendations, pump selection reference table
Corrosion/Environmental Resistance	EG water/insulating oil, salt spray conditions	Zinc spray 5±2 / 7±2 / 10±2 g·m⁻² + coating	1,000 h NSS test report, compatibility charts, surface treatment options
Complete Certification Documentation	PED, UL1973/9540A, IEC62619	Full burst, fatigue, ΔP–Q, corrosion documentation	Master report templates + project-specific variation tests, shipment-ready documentation package

Selecting Section & Key Parameters

Parameter	Recommended Range (BESS)	Impact Indicators	Design Notes
Number of holes N	11 / 13 / 19	ΔP, temperature uniformity	Increasing N → reduces flow velocity → lowers ΔP; excessive holes raise cost and clogging risk. 11/13/19 covers most application needs.
Hydraulic diameter Dh	0.8–1.2 mm	ΔP, Re, heat transfer	Re ≈ 300–1200 (laminar/transitional) for controllable pump power; locally >2000 to enhance heat transfer.
Wall thickness t	1.0–1.6 mm	Burst strength, fatigue, safety factor	Greater t improves safety but slightly reduces thermal conductivity; select based on TRP/pressure requirements.
Overall dimensions w×h	18–32 mm × 1–3 mm	Flatness, stiffness	Keep w/t ≤ 25 to prevent buckling; match thickness to total baffle thickness.
Zinc spray weight	5±2 / 7±2 / 10±2 g·m⁻²	Brazing wetting, corrosion resistance	For coastal/salt spray projects, select 10±2; clean surface after brazing to aid subsequent flame-retardant coating.
Surface treatment	Anodizing / Nano-coating / Bare tube	Bonding, corrosion protection	Choose treatment compatible with bonding/flame-retardant processes to avoid peeling or contamination.

Quick selection: Send ΔT target, allowed ΔP, coolant, and plate size → CFD/ΔP–Q preliminary in 24h.

Six Key Procurement Criteria for BESS Separators

UL9540A support: ≥4× burst margin, >10⁷ fatigue cycles, leak/fire data.

30%+ higher heat transfer & lower ΔP.

2-week shipment for standard profiles, ≤5 free samples by DHL in 3–5 days.

CAD/CFD files within 24h for internal review.

Full documentation: CE, PED, UL, IEC62619, RoHS/REACH/SDS, MTC, PQR/WPS.

Flatness ≤0.3 mm/m & w/t ≤25.: Ensure close contact with the electrode and smooth assembly.

Four Processes for Integrating Flat Tubes into Baffles

CNC Slotting + Vacuum Brazing (Embedded Type): Slot width allowance of +0.05–0.15 mm; ensure uniform zinc spray; use anti-deformation fixtures. Apply a brazing layer at the slot bottom to prevent cold joints.

Sandwich Structure: Upper and lower plates with intermediate flat tubes/ribs; control the brazing curve to prevent bulging or collapse; match flat tube wall thickness with rib dimensions to increase stiffness.

Extruded Profile + Flat Tube Insert Welding: Extrude ribs into the main profile and locally insert/weld flat tubes; reserve a weld seam buffer zone and perform post-weld heat treatment to avoid fatigue weak points in the heat-affected zone (HAZ).

One-Piece Bending: Minimum bending radius Rmin ≥ 3–5× t; use internal mandrels or segmented bending when necessary. Verify via FEM analysis that the inner wall at the bend does not collapse.