Battery Pack is the core component of new energy vehicles and energy storage systems — each BEV battery pack delivers 50–100 kWh of energy and 150–400 kW of discharge power (4C rate). Charge and discharge generate significant heat that requires efficient dissipation, with cell temperatures typically controlled within 15–45°C (optimal 25–35°C). Thermal runaway is the number one threat to EV safety, with 70% of incidents stemming from insufficient heat dissipation combined with cell short-circuit. Aluminum foil plays seven major roles in battery pack heat dissipation: liquid cooling plate substrate, heat fin, thermal interface material (TIM), cell-to-cell spacer, cell surface wrap, thermal tape, and pack cover. With aluminum density at 2.7 g/cm³ (vs. copper 8.96) achieving 60%–70% weight reduction, thermal conductivity at 200–230 W/m·K (1060/1100 pure aluminum) vs. copper 401 W/m·K (with density compensation yielding overall superior performance), and 50%–60% cost advantage, these are the reasons why battery pack heat dissipation almost exclusively uses aluminum foil rather than copper foil. Below, we clarify the specifications of battery pack heat-dissipation aluminum foil based on the latest 2025–2026 data.
I. Five Mainstream Battery Pack Heat Dissipation Methods
- **Natural Convection** — Early solution with no fans or liquids. Heat dissipation power 0.05–0.1 W/cm². Suitable for low-power battery packs (energy storage, residential, e-Bike, low-speed EV). Heat-dissipation structure: heat fins (aluminum foil 0.1–0.5 mm stamped) + natural convection.
- **Forced Air Cooling** — Mid-tier solution with fans + heat fins. Heat dissipation power 0.1–0.5 W/cm². Suitable for mid-power battery packs (HEV, urban BEV, hybrid energy storage). Heat-dissipation structure: stamped aluminum foil fins + fan-driven forced convection.
- **Liquid Cooling** — Mainstream solution with glycol + cold plate + aluminum plate. Heat dissipation power 0.5–2.0 W/cm². Suitable for high-power battery packs (BEV, PHEV, energy storage). Heat-dissipation structure: aluminum cold plate (flow channels + brazing) + glycol circulation. Representatives: Tesla Model 3 / BYD Blade / CATL Qilin.
- **Direct Refrigerant Cooling** — Emerging solution with R1234yf refrigerant direct cooling. Heat dissipation power 1.0–5.0 W/cm². Suitable for super-fast-charging battery packs (Tesla V4 supercharge / BYD Blade 5C / CATL Shenxing). Heat-dissipation structure: aluminum plate evaporator + refrigerant phase change.
- **Phase Change Material (PCM) Cooling** — Auxiliary solution with paraffin / graphite composite PCM. Transient heat absorption (peak 200–400 kJ/kg). Suitable for pulse heat dissipation (hard acceleration / hard braking / super-fast charging). Heat-dissipation structure: PCM composite aluminum foil (aluminum foil + paraffin + graphite).
Impact on aluminum foil: liquid cooling solution consumes 70%–80% of heat-dissipation aluminum foil (aluminum plate 1–3 mm + flow channels + brazing); fin solution consumes 10%–20% (aluminum foil 0.1–0.5 mm stamped); TIM + surface wrap + cover consumes 10%–15%.
II. Seven Major Applications of Aluminum Foil in Battery Pack Heat Dissipation
- **Liquid Cooling Plate (Cold Plate)** — Mainstream heat-dissipation solution, aluminum plate (not foil) thickness 1.0–3.0 mm, alloy 3003 / 6061 / 6063, flow channel brazing; heat dissipation power 0.5–2.0 W/cm²; working pressure 0.3–0.5 MPa. Key indicators: flow channel diameter 8–15 mm; brazing strength ≥ 50 N/mm; corrosion resistance ≥ 1000 h salt spray.
- **Heat Fin** — Natural/forced air cooling mainstream, aluminum foil 0.1–0.5 mm, alloy 1100 / 3003, stamping + surface anodizing; heat dissipation area expanded 5–10×; thermal resistance reduced 30%–50%.
- **Cell-to-Cell Spacer** — Critical internal module component, aluminum foil 0.1–0.3 mm, alloy 1060 / 1100, stamping + surface-applied thermal grease; simultaneously serves as cell expansion buffer + heat conduction; vibration resistance ≥ 5G; insulation strength ≥ 1 kV.
- **Cell Surface Wrap Aluminum Foil** — Latest heat-dissipation solution, aluminum foil 0.05–0.1 mm, alloy 1060 / 1100, applied to cell surface; equivalent thermal conductivity ≥ 200 W/m·K (vs. air 0.026 W/m·K, 7000× improvement); cost reduction 30%–50% (vs. liquid cooling).
- **TIM Aluminum Foil** — Battery gap filling, aluminum foil 0.05–0.2 mm + graphite / thermal grease, composite thermal conductivity 1.5–5.0 W/m·K; thickness compressible 30%–50%; contact thermal resistance ≤ 0.05 K·cm²/W.
- **Thermal Tape** — Module bonding + heat dissipation, aluminum foil 0.05–0.15 mm + thermal adhesive, single/double-sided adhesive; thermal conductivity ≥ 1.5 W/m·K; peel strength ≥ 5 N/cm.
- **Pack Cover / Shell** — Dual structural + heat-dissipation function, aluminum plate 0.5–2.0 mm, alloy 5052 / 6061, impact resistance ≥ 100 J; anodized corrosion resistance ≥ 1000 h.
III. Key Specifications and Typical Values
| Category | Thickness (mm) | Alloy | Thermal Conductivity (W/m·K) | Typical Application | Key Indicator |
|---|---|---|---|---|---|
| Heat Fin | 0.1–0.5 | 1100 / 3003 | 180–220 | Natural / Forced Air Cooling | Stamping Forming |
| Cell-to-Cell Spacer | 0.1–0.3 | 1060 / 1100 | 200–230 | Module Cells | Vibration Resistance + Thermal |
| Cell Surface Wrap Aluminum Foil | 0.05–0.1 | 1060 / 1100 | 200–230 | Cell Surface Application | Equivalent Thermal ≥ 200 |
| TIM Thermal Aluminum Foil | 0.05–0.2 | 1060 + Graphite / Grease | 200+ Composite | Battery Gap Filling | Contact Resistance ≤ 0.05 |
| Thermal Tape | 0.05–0.15 | 1100 + Thermal Adhesive | 200+ Composite | Module Bonding + Heat | Thermal ≥ 1.5 W/m·K |
| Pack Cover / Shell | 0.5–2.0 | 5052 / 6061 | 140–170 | Structural + Heat Dual | Impact + Corrosion Resistance |
| Stamping / Deep-Drawing Structural Parts | 0.3–1.0 | 3003 / 5052 | 160–180 | Complex Stamping | Deep Drawing |
Key figures: liquid cooling plate substrate 1.0–3.0 mm is the mainstream heat-dissipation solution (exceeding the “aluminum foil” definition and entering the “aluminum plate” range); 1060/1100 pure aluminum with thermal conductivity 200–230 W/m·K is the first choice for battery pack heat dissipation (1060 thermal conductivity is 24.7% higher than 3003 and 57.0% higher than 5052); 3003 Al-Mn alloy has excellent stamping performance, suitable for fins + structural parts; 5052 Al-Mg alloy has high strength (≥ 230 MPa), suitable for shells; 6061/6063 Al-Mg-Si alloys are suitable for liquid cooling plate flow channel extrusion + brazing; anodizing (20–25 μm) improves corrosion resistance 3–5×; brazing (Nocolok aluminum brazing) is the mainstream process for liquid cooling plates; GB/T 3190 (chemical composition of wrought aluminum and aluminum alloys), GB/T 3880 (aluminum and aluminum alloy sheet), ASTM B209 (aluminum and aluminum alloy sheet/strip), IEC 62660 (power battery performance), UL 2580 (EV battery safety), GB 38031 (China power battery safety), IATF 16949 (automotive quality management), and RoHS / REACH (environmental) are the main reference standards.
IV. Market Size and Growth
Comparing four independent data sources side by side:
| Data Source | 2024–2025 (USD Billion) | 2030–2035 (USD Billion) | CAGR |
|---|---|---|---|
| Markets and Markets (Battery Thermal Management System) | 2024 = 3.75 | 2030 = 8.55 | 14.7% |
| QY Research (Battery Pack Liquid Cooling Plate) | 2024 = 1.946 | 2031 = 8.346 | 21.7% |
| Verified Market Reports (EV Cooling Plate) | 2024 = 1.25 | 2033 = 5.85 | 18.5% |
Taken together, the global battery pack heat-dissipation aluminum foil/aluminum plate market in 2024–2025 was approximately USD 2.5–4.0 billion (including cold plate + fins + TIM + cover), growing to USD 6.0–11.0 billion by 2030–2035, with CAGR of 15%–22% (higher than PCB 5.2%, lower than solid-state battery 30%–45%). Four major institutions all agree on high prosperity (CAGR 14.7%–21.7%). M&M battery thermal management system scope: USD 3.75 → 8.55 billion (CAGR 14.7%), covering cooling + heating + sensors + control; QY Research battery pack liquid cooling plate scope: USD 1.946 → 8.346 billion (CAGR 21.7%), the most optimistic forecast.
Battery pack heat-dissipation aluminum foil demand estimation: each BEV battery pack uses 10–25 kg of heat-dissipation aluminum foil (cold plate substrate 8–15 kg + fins 3–8 kg + TIM 1–3 kg + others 1–3 kg), with global 17 million BEVs (2024) × 15 kg average = 255,000 tons per year of heat-dissipation aluminum foil, corresponding to a market size of USD 0.5–1.5 billion (aluminum foil average price USD 20–60/kg, much lower than copper foil USD 60–110/kg); with global 40 million BEVs (2030) × 15 kg = 600,000 tons per year of heat-dissipation aluminum foil, corresponding to a market size of USD 1.5–3.0 billion.
V. Competitive Landscape and Applications
- **CATL (China)** — Global battery leader, Qilin battery + Shenxing super-fast charge + chocolate battery swap + liquid cooling plate mainstream solution; Tesla / BMW / VW / Ford / Stellantis mainstream OEM matching.
- **BYD (China)** — Blade battery + 800V high-voltage + direct cooling solution; CTP/CTC architecture + honeycomb aluminum plate lightweight heat dissipation; BYD full series + FAW + Dongfeng + Great Wall mainstream.
- **Tesla (USA)** — 4680 large cylindrical + serpentine liquid cooling plate + direct cooling (R1234yf); Model 3/Y/S/X + Cybertruck + Semi + Megapack; global BEV sales #1.
- **LG Energy Solution (Korea)** — Pouch battery + Z-type liquid cooling plate; GM / Hyundai / Kia / Ford / Toyota / Honda mainstream OEM matching.
- **SK On (Korea)** — Pouch battery + high-speed lamination + aluminum plate stamped liquid cooling; Hyundai / Kia / Mercedes / Ford mainstream OEM matching.
- **Samsung SDI (Korea)** — Prismatic battery + SLP aluminum shell; BMW / VW / Stellantis / Rivian mainstream OEM.
- **Panasonic (Japan)** — Cylindrical battery (18650/21700/4680) + serpentine aluminum plate liquid cooling; Tesla / Toyota / Ford / Rivian mainstream OEM.
- **EVE Energy (China)** — Prismatic + pouch + large cylindrical; liquid cooling plate + direct cooling solution; Daimler / BMW / XPeng / Li Auto mainstream OEM.
VI. Procurement Notes
1. **Identify aluminum grade + thermal conductivity clearly**: 1060 pure aluminum (Al ≥ 99.6%) is the first choice for heat dissipation (thermal conductivity 230 W/m·K); 1100 is the second choice (220 W/m·K); 3003 is suitable for stamped fins (180 W/m·K); 5052/6061 are suitable for structural parts + liquid cooling plate flow channels.
2. **Thickness selection**: liquid cooling plate substrate 1.0–3.0 mm (aluminum plate range); heat fin 0.1–0.5 mm; cell-to-cell spacer 0.1–0.3 mm; cell surface wrap 0.05–0.1 mm; TIM aluminum foil 0.05–0.2 mm; cover 0.5–2.0 mm. Thickness tolerance ≤ ±5%.
3. **Thermal conductivity**: 1060 ≥ 220 W/m·K; 1100 ≥ 210 W/m·K; 3003 ≥ 160 W/m·K; 5052 ≥ 140 W/m·K; 6061 ≥ 150 W/m·K; 6063 ≥ 160 W/m·K.
4. **Brazing performance**: liquid cooling plate brazing strength ≥ 50 N/mm (Nocolok process); flow channel sealing 100% leak-free (helium leak detection 1×10⁻⁶ Pa·m³/s).
5. **Surface treatment**: anodizing 20–25 μm improves corrosion resistance 3–5×; passivation is suitable for thermal tape; coating is suitable for TIM aluminum foil.
6. **Mechanical properties**: tensile 1060 ≥ 75 MPa / 3003 ≥ 140 MPa / 5052 ≥ 230 MPa / 6061 ≥ 310 MPa; elongation ≥ 10%–25%.
7. **Inspection items**: thickness tolerance, thermal conductivity, tensile strength, elongation, brazing strength (≥ 50 N/mm), salt spray test (≥ 1000 h), thermal cycling (-40°C ~ 85°C, 1000 cycles), RoHS 6 items.
8. **Certifications and compliance**: ASTM B209 (aluminum sheet/strip); GB/T 3190 (wrought aluminum chemical composition); GB/T 3880 (aluminum sheet); UL 2580 (EV battery safety); IEC 62660 (power battery performance); GB 38031 (China power battery); IATF 16949 (automotive quality management); RoHS / REACH (environmental).
Final Thoughts
When selecting aluminum foil for battery pack heat dissipation, the key is to remember “seven major applications + 1060/1100 high thermal conductivity + liquid cooling mainstream + 4C super-fast charging” — these are the biggest differences from battery copper foil (μm-level current collector) and module busbar (mm-level bus). The global battery pack heat-dissipation aluminum foil market will reach USD 6.0–11.0 billion by 2030–2035, with CAGR 15%–22% (higher than PCB 5.2%, similar to solid-state battery 30%–45%). The four major trends of 4C/5C super-fast charging + 800V high-voltage + direct cooling + immersion cooling drive liquid cooling plate aluminum plate + TIM aluminum foil + cell surface wrap aluminum foil + PCM composite aluminum foil — the four major high-end forms to grow rapidly.
If you are evaluating battery pack heat-dissipation aluminum foil suppliers (liquid cooling plate substrate / heat fins / cell-to-cell spacers / TIM thermal aluminum foil / cell surface wrap / thermal tape / pack cover), please contact Zhengzhou LP Industry Co., Ltd. Email: office@cnlpzz.com, WhatsApp: 0086-19337889070. We offer 1060 / 1100 / 3003 / 5052 / 6061 / 6063 full-grade aluminum foil/aluminum plate + anodizing / brazing / passivation / coating full-process, with 1060 thermal conductivity ≥ 230 W/m·K, brazing strength ≥ 50 N/mm, salt spray ≥ 1000 h. Customized specifications and OEM processing are supported. ASTM B209 / GB/T 3190 / GB/T 3880 / UL 2580 / IEC 62660 / GB 38031 / IATF 16949 compliance support is available.