MORTON · ENERGY STORAGE SYSTEMS

Thermal Management for Energy Storage Systems

Custom cold plates, PCS heat sinks and thermal interfaces engineered around your heat load, site conditions and production needs.

Bring your operating conditions into the design.

Discuss Your ESS Cooling Project

Battery modules · Power conversion systems · Auxiliary electronics

When Heat Becomes a System Constraint

Temperature variation and PCS overheating can limit usable energy, charge/discharge power and availability. Define cooling limits at the module and converter interfaces before system integration.

Uneven module temperatures

Temperature gradients can accelerate uneven cell aging and constrain pack operation around the hottest or most degraded cells.

PCS derating under load

Concentrated semiconductor losses consume thermal headroom when ambient and coolant temperatures rise.

Leakage and corrosion risks

Incompatible wetted materials, trapped air and poorly defined interfaces create avoidable maintenance exposure.

Late integration changes

Unclear flow, mounting and test requirements lead to repeated prototypes and delayed project milestones.

Turn the constraint into a clear engineering requirement.

Review Your Thermal Challenges

Open stationary BESS rack with enclosed battery drawers, protected coolant distribution and separated electrical routing

Cooling components matched to the battery, conversion and control zones.

Follow the Heat Through Your ESS

Battery modules, PCS stages and controls have different temperature limits and heat paths. Define each interface so one subsystem does not constrain the platform.

Battery modules

Engineered cold plates distribute contact cooling across the approved module footprint. Channel layout, mounting and TIM compression are reviewed together.

PCS and DC/DC stages

Liquid cold plates or air-cooled heat sinks remove concentrated IGBT and SiC losses within the available flow or airflow budget.

Controls and auxiliary electronics

Compact heat sinks, thermal enclosures and interface materials complete the lower-power thermal paths.

Define the thermal path before freezing the mechanical layout.

Map Your Heat Sources

Cooling Components Matched to the Job

Every thermal architecture balances cooling medium, pressure allowance, and mechanical tolerances. We fabricate targeted components tailored to your system boundary limits.

Precision CNC machined aluminum liquid cold plate with fluid ports and mounting holes

Liquid cold plates

Tube-in-plate, vacuum-brazed, friction-stir-welded and microchannel structures provide direct conductive cooling for battery modules and PCS power devices.

Channel geometry matched to heat distribution
Ports coordinated with the coolant loop
Flat contact faces and controlled sealing

Large industrial bonded-fin aluminum heat sink with straight dense cooling fins and mounting plate

PCS heat sinks

Extruded, skived and bonded-fin structures use the installed airflow effectively for power conversion stages that favor an air-cooled architecture.

Fin spacing matched to the fan working point
Machined semiconductor mounting faces
Practical access for assembly and cleaning

Precision thermal interface materials, phase-change gap pads, and spring-loaded retention hardware

Thermal interfaces and mounting

Die-cut pads, spring fasteners and brackets help maintain the intended contact path through assembly tolerances and service cycles.

Gap and compression matched to the stack
Device load limits considered
Controlled positioning and fastening

Build a cooling package around your approved platform.

Select Your Cooling Route

A Design Envelope You Can Engineer Against

Engineering an ESS thermal architecture requires rigorous alignment across heat loads, fluid circuits, and mechanical constraints before freezing specifications.

Design input	What we define
Heat load and footprint	Losses across charge/discharge and PCS duty cycles, source layout, maximum cell or device contact temperature, and allowed temperature spread across the battery module.
Fluid circuit	Coolant formulation, inlet temperature, flow rate and cold-plate pressure drop.
Mechanical integration	Envelope, contact-face flatness, mounting pattern, port orientation and service access.
Installed airflow	Actual flow through the heat sink, air pressure drop, fan curve and inlet-air temperature.
Acceptance conditions	Measurement positions, steady-state criteria, drawing revision and agreed test limits.

Cold-plate heat load: typically 0.3–5 kW per component, depending on construction and defined conditions.
Coolant flow: 0.5–20 L/min across different component designs.
Standard industrial rated pressure: 0.3 MPa gauge; selected designs can be engineered to 0.5 MPa.
Precision contact faces: typical flatness ≤0.05 mm over 100 mm, where specified on the approved drawing.

Share the boundary conditions that matter to your design.

Define Your Cooling Specification

Designed Around the Site, Not Just the Bench

Real-world ESS deployments expose cooling hardware to harsh ambient profiles, diverse fluid chemistries, and strict enclosure constraints that lab benches rarely replicate.

High ambient operation

Review the inlet-air and inlet-coolant temperatures expected at the site, including the equipment derating strategy.

Coolant compatibility

Coordinate aluminum, copper, stainless steel, seals and the inhibited coolant formulation to manage corrosion risks.

Flow and cleanliness

Check pump working point, trapped-air removal, channel cleanliness and filtration against the smallest passages.

Outdoor integration

Consider condensation, surface protection, connection access and the system-level enclosure requirements.

Commercial and industrial BESS outdoor installation in hot dry environment

Make the field conditions part of the first design review.

Review Your Operating Environment

A PCS Cooling Challenge, Made Measurable

Defined prototype tests give engineering and procurement a shared basis for comparing cold-plate performance before tooling commitment.

Thermal laboratory test bench with mounted liquid cold plate and electrical dummy heater

Direct verification of cold-plate pressure drop and baseplate thermal resistance under calibrated thermal loads.

Case Record

Project: UAE energy-storage PCS power module

Challenge: Remove 1,000 W from an 80 × 80 mm heat source inside a 250 × 200 × 20 mm cold plate, with internal pressure drop below 30 kPa.

Design response: Aluminum microchannels, an inlet distribution region, controlled contact faces and a defined cleanliness and coolant specification.

49 °C

Base hot spot

0.024 K/W

Base-to-inlet thermal resistance

23 kPa

Cold-plate pressure drop

240 units

In the first delivery

Test conditions: 25 °C inlet water at 10 L/min; 1,000 W applied heat load. Pressure drop measured at the cold-plate ports.

Field operating point: Qualify the specified 40 °C inlet and inhibited water-glycol coolant as a separate operating point; the water-test result does not establish field performance.

Use defined test conditions to make your next decision.

Discuss a Comparable PCS Project

From Prototype to Repeatable Supply

A disciplined four-stage engineering and quality route from initial DFM through full production traceability.

Define and review

Freeze the heat sources, operating limits, interfaces and drawing revision through DFM and thermal review.

Build and correlate

Produce engineering samples and compare simulation with thermal and pressure-drop measurements.

Verify and release

Check critical dimensions, contact faces, cleanliness and the approved pressure and leak-test requirements.

Control and deliver

Link material batches, work orders, inspection results and packing labels; approve changes before implementation.

Documentation line: 2D / 3D drawings · FAI and dimensional reports · Thermal and pressure-drop curves · Pressure and leak-test records · Material and batch traceability

Liquid-cooling inspection: Each standard industrial cold plate receives hydrostatic proof testing, cleaning and drying, followed by a final gas leak check to the approved specification.

Make qualification evidence part of the supply plan.

Plan Your Sample and Validation Route

Engineering Questions, Answered

Direct technical clarification on cooling medium selection, interface boundaries, qualification testing, and production supply.

When should an ESS use liquid cooling rather than air cooling?

Compare heat density, available airflow, coolant infrastructure, ambient conditions, noise and service strategy. We review both routes against the actual thermal and packaging limits.

Can you support battery cold plates as well as PCS cooling?

We develop cooling components around the approved module interface and power-device layout, including cold plates, PCS heat sinks, thermal interfaces and mounting parts.

What information is needed for a first review?

Send the heat load, source footprint, available space, allowed temperatures, airflow or coolant conditions, connection requirements and expected annual volume.

Can a 25 °C water test predict hot-climate glycol performance?

It provides a reference point. The field coolant, inlet temperature, viscosity, flow distribution and pressure drop need their own evaluation before the specification is approved.

How are coolant leakage and material compatibility addressed?

Wetted materials, seals, coolant formulation, pressure limits and cleaning are reviewed together. Production checks follow the approved proof-pressure and leak-test criteria.

Can you supply samples before series production?

Yes. Engineering samples, validation quantities and production releases are planned around the drawing maturity, construction method and project milestones.

Bring the remaining questions to an engineering review.

Ask About Your ESS Cooling Design

Bring Your ESS Cooling Requirements to the Table

Engage our thermal engineering team directly with your boundary conditions, module heat dissipation budgets, and packaging constraints.

Cold plates and heat sinks matched to the real heat load

Coolant, mounting and service interfaces reviewed together

Prototype testing with clearly defined conditions

Controlled drawings and traceable production records

One project contact from review to delivery

Tell Us About Your Project

Start with the essentials. Detailed drawings can follow during the engineering review.