Our Thermal Systems
Integrated Solutions for Battery Thermal Management
From water-glycol based cold plates to full plastic design and novel heat transfer fluids, we have the thermal management solutions our customers need.
Thermal+
Foil cooler solution
Our Thermal+ heat exchangers represent a next‑generation approach to battery cooling, engineered to deliver high performance within the tight packaging constraints of electric vehicles. Fully customizable to a wide range of battery pack architectures, they are designed to conform precisely to the shape of the pack, ensuring efficient, uniform heat removal across the entire cell array.
Compatible with both prismatic and cylindrical cells, thermal+ heat exchangers leverage an adaptable geometry to effectively manage asymmetric heat loads. The result is excellent temperature homogeneity, supporting consistent performance and long‑term battery reliability.
This technology is currently being advanced through multiple customer development programs, where thermal+ heat exchangers are integrated into next‑generation battery systems.
These programs highlight the solution’s scalability and its potential to support future electric vehicle platforms. Compared with conventional cooling solutions such as cold plates, which are widely used in today’s automotive applications, thermal+ heat exchangers offer clear system‑level advantages, such as reduced weight and overall system cost, elimination of thermal interface material, and 100% tolerance compensation for improved integration.
Immersion Cooling
General Overview
Immersion cooling represents one of the most advanced concepts in battery thermal management. In this approach, the battery cells are directly surrounded by a non‑conductive dielectric fluid that picks up heat at the source. Because the fluid is in direct contact with the cell surface, thermal resistance is minimized and temperature can be controlled more effectively than with conventional cold plate solutions.
Integrating cooling channels directly into the composite housing enables highly efficient coolant distribution for the immersion cooling system, ensuring excellent temperature homogeneity even under high load conditions.
Single- and Two-Phase Immersion cooling
Single‑phase immersion cooling relies on the specific heat capacity of a liquid phase of a dielectric fluid. This approach offers efficient and consistent heat removal while maintaining a predictable thermal profile. It provides a balance of performance and system complexity, making it suitable for many EV applications, and adds the possibility to actively cool busbars and terminals.
Two‑phase immersion cooling harnesses the latent heat of evaporation. This mechanism allows extremely high heat‑pickup rates at a nearly constant fluid temperature, providing exceptional cooling performance even for very high‑power battery systems. Two‑phase immersion cooling offers the highest thermal performance potential among current immersion technologies while maintaining uniform and stable cell temperatures.
Traditional Solutions
Aluminum Cooling Systems
Kautex offers proven aluminum‑based liquid cooling solutions as part of a flexible thermal‑management portfolio. Using cold‑plate designs with integrated flow channels, these systems provide reliable heat removal and uniform temperature control across the battery pack.
Depending on performance and cost requirements, we support both roll‑bonded cold plates and higher‑performance brazed designs with enhanced internal features—allowing customers to select the right solution for their application.
While our focus is on advancing next‑generation thermal technologies, Kautex seamlessly integrates established aluminum cooling systems when required, giving customers confidence and continuity as they transition toward future‑ready battery platforms.