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Adopting new energy vehicle water-cooled radiator shell [specific material] is sturdy and durable, effectively resisting external impact and impurity invasion, ensuring the safety of the radiator core components and prolonging the service life, carefully designing the thermal structure and layout, combining with high-quality thermal conductivity of materials to achieve rapid heat dissipation and maintain a stable operating temperature of the power system of the new energy vehicle, customized in strict accordance with the model of the new energy vehicle and the thermal demand, seamlessly connecting the vehicle Thermal management system, easy to install, to ensure the cooling effect, improve the performance of the whole vehicle; after a number of strict quality inspection process, in line with the high standard industry norms, for the reliable operation of new energy vehicles provides a solid guarantee.
| Product Name: | New energy battery box shell |
| Mounting Location. | Packaging new energy vehicle batteries |
Application Scenarios:
1. High-Energy Fast-Charging Scenarios for Passenger Vehicles
Product Name: One-Piece Die-Cast Aluminum Alloy Liquid-Cooled Battery Tray
Installation Location: CTP Battery System for All-Electric/Plug-in Hybrid Passenger Vehicle Chassis
To meet the extreme demands on thermal management and space utilization posed by 800V high-voltage fast charging and ultra-long range, the design employs a single-piece die-casting process using a high-strength, high-toughness aluminum-silicon alloy that requires no heat treatment. This integrates the base plate, side beams, liquid-cooling channels, and module mounting points into a single unit. This design reduces weight by more than 20% compared to traditional stamping and welding solutions. The meandering liquid-cooling channels inside the housing closely follow the bottoms of each row of battery cells, rapidly dissipating the instantaneous high temperatures generated during fast charging and maintaining a temperature difference of less than 5°C across the entire pack. The entire battery pack features IP68-rated sealing and bottom impact protection, ensuring cell safety during water fording and gravel impact operations, making it the ideal platform for a new generation of highly integrated battery packs.
2. Commercial Vehicles and High-Safety Energy Storage Applications
Product Name: High-Load-Capacity, Flame-Retardant Die-Cast Aluminum Alloy Energy Storage Battery Enclosure
Installation Location: Battery frames for electric heavy-duty trucks; enclosures for energy storage container modules
To meet the stringent safety standards for commercial vehicles and energy storage systems, the housing features thickened reinforcing ribs and a multi-chamber flame-retardant design capable of withstanding mechanical compression, vibration, impact, and internal thermal runaway pressures. The aluminum alloy housing acts as a natural heat sink, rapidly distributing heat evenly and preventing localized heat propagation. The surface combines an insulating powder coating with a fire-retardant membrane to ensure full compliance with insulation resistance, dielectric strength, and flame-retardant ratings. The high-seal design, coupled with anti-corrosion treatment, prevents rust and water ingress during years of outdoor operation, providing robust protection for high-value battery cells throughout their entire lifecycle.
3. Battery Swapping and Modular Quick-Swap Scenarios
Product Name: Quick-Swap Die-Cast Aluminum Alloy Battery Frame Housing
Installation Location: Battery Pack Housing for Quick-Swap Battery Models
To meet the demands of repeated assembly and disassembly, as well as automated docking in the battery-swapping model, the housing is assembled from high-precision, modular die-cast aluminum components. The positioning pin holes and locking interfaces are precision-machined, achieving a repeat positioning accuracy of ±0.3 mm. The structure of the locking mechanism area has been reinforced to ensure no deformation or fatigue even after thousands of quick-swap operations. With built-in quick-connect cooling interfaces and electrical connection mounts, the body’s integrated air ducts or fluid channels can accommodate various cooling strategies. Through extreme lightweight design and precise switching, it supports the efficient flow and round-the-clock operation of the battery-swapping network.
Product Specifications
| Parameter Categories | Key Indicators |
|---|---|
| material (that sth is made of) | AlSi10MnMg heat-treatment-free alloy / A356 / AlSi9Cu3 (upon request) |
| Molding process | 3,500T–5,000T Large-Scale Cold-Chamber Vacuum Die Casting + CNC Precision Machining |
| tensile strength | ≥250 MPa (main body) |
| yield strength | ≥120 MPa |
| elongation | ≥5% (as-forged condition) |
| protection class | IP67 / IP68 / IP6K9K (depending on design) |
| airtight | Total leakage rate ≤ 5 cc/min @ 50 kPa (dry test) |
| Flatness | Sealing surface flatness ≤ 0.5 mm / 1,000 mm |
| Liquid-Cooled Flow Channel | Integrated water cooling, operating pressure ≥ 300 kPa, burst pressure ≥ 1.2 MPa |
| Insulation Resistance | ≥500 MΩ @ 1000 V DC |
| Dielectric Withstand Test | 2700 V DC, 60 s, leakage current < 1 mA |
| weights | Typically 60–120 kg (depending on size), 30%–50% lighter than steel |
| Dimensional accuracy | Critical mounting hole positions: ±0.15 mm; locating pin holes: H7 |
| surface treatment | Chromium-free passivation + insulating epoxy powder coating (150–300 μm); dielectric strength meets vehicle requirements |
| Flame Retardancy Rating | UL 94 V-0 (Coatings and Seals) |
| application scenario | CTP/CTC Chassis for Passenger Cars, Electric Commercial Vehicles, Energy Storage Systems |
Product Advantages
- Highly Integrated, Ultra-Simple Design
Single-piece die casting reduces more than 100 parts to just 1 or 2 large components, eliminating welding distortion and leak points, improving the overall rigidity and sealing consistency of the tank, while significantly shortening production line cycle times and reducing capital investment. - Security by Design, Layered Protection
The aluminum alloy frame withstands severe impacts and crushing forces, while the underbody protection structure and energy-absorbing ribs mitigate underbody penetration. Combined with a multi-layer sealing and insulation design, it fully complies with regulatory requirements such as GB 38031 and ECE R100. - Efficient Thermal Management to Protect Battery Cells
The enclosure features integrated liquid-cooling channels that leverage aluminum’s superior thermal conductivity to rapidly equalize cell temperatures, eliminate hot spots, minimize temperature variations, extend cell lifespan, and ensure the safe implementation of fast-charging strategies. - Lightweight and highly rigid, extending battery life
Compared to traditional steel-aluminum hybrid designs, it reduces weight by more than 30%, directly contributing to an increase in the vehicle’s overall range. At the same time, the body’s high modal stiffness suppresses structural resonance and optimizes the vehicle’s NVH performance. - Corrosion- and aging-resistant, worry-free throughout its entire service life
The aluminum substrate’s inherent corrosion resistance, combined with a protective coating, allows it to withstand road salt spray, moisture and condensation, and acid rain. Designed for 12 years of corrosion protection, it eliminates the risk of rust-through in the battery pack housing.
Manufacturing & Services
Ningbo Hexin Molding Co., Ltd. is deeply committed to the new energy lightweighting sector. Building on two decades of expertise in aluminum alloy precision casting, the company has introduced a cluster of ultra-large, intelligent die-casting islands ranging from 3,500T to 5,000T, establishing a one-stop, full-process production system that spans from mold flow analysis and mold design, high-pressure vacuum die-casting, heat treatment, five-axis CNC precision machining, to airtightness testing, cleaning, and insulating coating. The factory is IATF 16949 certified and possesses capabilities in structural topology optimization for battery enclosures, validation of heat-treatment-free materials, and integrated design of liquid-cooled runners. It offers customized development solutions for various technical routes, including CTP and CTC. With our flexible production lines, we can accommodate everything from prototype parts to large-scale deliveries of hundreds of thousands of sets annually. We strictly enforce 100% inspection of cleanliness, dielectric strength, and airtightness, providing safe and reliable lightweight battery enclosure solutions for global OEMs and battery manufacturers.
