In the demanding world of industrial electronics, electric vehicles, renewable energy systems, and high-frequency power conversion, managing extreme heat dissipation is no longer optional—it’s critical. Introducing our next-generation Liquid-Cooled Resistor, engineered to handle power loads from 20kW to 30kW with unmatched thermal efficiency, reliability, and compact design. Built around robust Thick Film Power Resistors mounted on high-performance AlN substrates and integrated with precision-engineered Pinfin liquid cooling technology, this solution redefines what’s possible in high-density power management.
Engineered for Extreme Power: Thick Film Power Resistors on AlN Substrate
At the heart of our liquid-cooled resistor module are multiple thick film power resistors, strategically arranged in parallel and series configurations to distribute the massive 20–30kW thermal load evenly across the substrate. These resistors are not standard components—they are custom-designed for high-temperature stability, low inductance, and long-term durability under continuous high-power operation.
Each resistor is precisely soldered onto a high-purity Aluminum Nitride (AlN) ceramic substrate—a material chosen for its exceptional thermal conductivity (~170–220 W/mK), excellent electrical insulation, and near-perfect CTE match with silicon devices. This ensures minimal thermal stress during temperature cycling and maximizes heat transfer from the resistive element to the cooling system below.
The AlN substrate features a fully metallized copper backside, bonded using advanced Active Metal Brazing (AMB) technology. This creates an ultra-low thermal resistance interface between the resistor and the cooling structure—critical for maintaining junction temperatures well below 120°C even at full power.
Pinfin cooler
Superior Cooling Performance: Precision Pinfin Liquid Cooling Technology
What sets our liquid-cooled resistor apart is its proprietary Pinfin liquid cooling architecture. Unlike conventional flat-plate or microchannel coolers, our Pinfin design utilizes thousands of microscopic copper pins arranged in optimized staggered patterns within a sealed flow chamber. This dramatically increases the surface area exposed to the coolant, enhancing convective heat transfer by up to 3x compared to traditional designs.
Coolant—typically deionized water or a water-glycol mixture—is channeled through the pin matrix via a manifold inlet/outlet system, ensuring uniform flow distribution and eliminating hot spots. Computational Fluid Dynamics (CFD) simulations guide every aspect of the pin geometry—height, diameter, spacing, and arrangement—to balance maximum heat dissipation against acceptable pressure drop, allowing seamless integration into existing liquid cooling loops.
The entire assembly is housed in a rugged, leak-proof aluminum enclosure with quick-connect fluid fittings, making installation and maintenance effortless. The modular design allows scalability for higher power applications by simply adding more resistor modules in parallel.
Why Choose Our Liquid-Cooled Resistor?
✅ Unmatched Thermal Management: Handles 20–30kW continuously without overheating. ✅ High Reliability: AMB-bonded AlN substrate + thick film resistors ensure >100,000 hours MTBF. ✅ Compact & Lightweight: Achieves high power density without bulky heatsinks. ✅ Low Thermal Resistance: Optimized Pinfin design reduces Rth(junction-to-fluid) to <0.05°C/W. ✅ Versatile Integration: Ideal for EV inverters, solar string combiners, motor drives, and grid-tied energy storage systems.
Designed for Real-World Demands
Our engineers have tested this liquid-cooled resistor under real-world conditions—from automotive vibration cycles to rapid thermal shock testing—from -40°C to +125°C ambient. Every unit undergoes rigorous burn-in and leakage testing before shipment.
Whether you’re developing a next-gen EV traction inverter, designing a utility-scale solar farm controller, or building a high-efficiency UPS system, our liquid-cooled resistor delivers the performance, safety, and longevity your application demands.
Upgrade your power system today. Experience the future of thermal management with our cutting-edge liquid-cooled resistor featuring thick film power resistors on AlN substrates with Pinfin cooling technology. Contact us for custom configurations, thermal simulations, and volume pricing.
