Trumony 60S Solar ESS Battery Tray Enclosure: In-House FSW R&D and Manufacturing up to 250V

Jiangsu, China — Trumony Aluminum Limited has released its aluminum battery tray bottom enclosure for 60S battery packs, a 900 x 560 x 130 mm structural base designed for solar and residential energy storage systems rated up to 250 V.  it illustrates a capability that has become central to Trumony's business: end-to-end enclosure research, development and manufacturing under one roof.

Most enclosure suppliers assemble a box from purchased extrusions and outsourced welding. Trumony works differently. The company controls the full chain — aluminum material, profile extrusion, machining, friction stir welding, surface treatment and final leak testing — inside its own facility. That vertically integrated model is what allows a 3.0 mm wall, 10.4 kg enclosure with IP65 sealing to move from drawing to shipped sample in weeks rather than quarters.

• Material capability: in-house supply of 6061-T6 and 6005A aluminum alloy sheet, plate and tube, with traceable heat and lot control
• Extrusion capability: custom profile development for battery housing frames, bottom trays and cooling channels
• FSW welding capability: dedicated friction stir welding equipment and tooling for long, leak-tight seam welds on aluminum housings
• Machining and finishing: CNC machining, powder coating and passivation performed to the same drawing revision
• Validation capability: dimensional inspection, leak and ingress protection testing before packing
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Trumony's engineering team engages at the concept stage. Using customer CAD data, the team runs design and simulation review to check structural stiffness, weld line placement, module mounting interfaces and cooling integration, then produces prototypes for fit and sealing verification. Only after validation does the part move to molding and serial production. For enclosure programs, this front-loaded engineering work is what prevents the costly re-tooling cycle that follows a late-discovered interference or an unsealable weld joint.

Energy storage cabinets are installed outdoors for a decade or more, exposed to thermal cycling, humidity and mechanical vibration. Fusion welding of thin aluminum introduces porosity and heat distortion that compromise both sealing and flatness. Friction stir welding is a solid-state process: the alloy is stirred and consolidated below its melting point, producing a fine-grain joint with high efficiency and minimal distortion. Applied to a 3.0 mm wall enclosure, the result is a bottom tray that stays flat for automated module assembly, resists fatigue under continuous cycling, and holds IP65 sealing without relying on sealant alone.

The TR-BT60S-900 is a proven, already-tooled design, which is why no mold or development fee applies. For programs that need a different envelope, Trumony adapts the same engineering base: custom overall dimensions, wall thickness, mounting interfaces, cable entry positions and cooling architecture — including integrated liquid cold plates for higher-power packs. The same team that designed the standard part carries the custom variant, so tolerances and weld parameters remain under one responsible owner.

Trumony Aluminum Limited specializes in aluminum materials and thermal management solutions, including aluminum sheets, plates, tubes, cooling plates and battery pack housings. Serving the new energy vehicle and energy storage industries, the company supports customers from design and simulation through molding, prototyping and serial delivery — shortening development cycles and keeping enclosure design, welding process and quality control under a single engineering roof.

Quotations, technical drawings and samples for the TR-BT60S-900 60S aluminum battery tray bottom enclosure are available on request, together with engineering discussion on custom enclosures for solar ESS, residential storage and commercial battery cabinets.