Large Size 1000mm Length Aluminum Extrusion Enclosures for New Energy Charger Module

Introduction Of Large Size 1000mm Length Aluminum Extrusion Enclosures:

Designed specifically for high-power new energy charger systems, these large-size aluminum extrusion enclosures feature a standard 1000mm length (customizable) and are crafted from premium 6063-T5/6061-T6 aluminum alloy. The extrusion structure integrates robust load-bearing capacity with exceptional thermal conductivity, addressing the core needs of new energy charger modules—stable heat dissipation for high-voltage components and reliable protection against environmental hazards. Compliant with IP65/IP67 waterproof/dustproof standards and RoHS, IEC 61851 certifications, these enclosures ensure long-term operational safety for AC/DC chargers in residential, commercial, and industrial settings, making them a trusted housing solution for electric vehicle (EV) charging stations, energy storage systems, and renewable energy charging equipment.

Specification Table Of Large Size 1000mm Length Aluminum Extrusion Enclosures:

Parameter	Details
Material	6063-T5/6061-T6 aluminum alloy (thermal conductivity: 201–218 W/(m·K))
Standard Length	1000 mm (customizable range: 800 mm – 3000 mm; cuttable to exact size)
Cross-Section Dimensions	80×120 mm / 100×150 mm / 120×180 mm (custom profiles available)
Wall Thickness	2.5–5.0 mm (optimized for structural stability and heat transfer)
Protection Grade	IP65 (standard) / IP67 (sealed version with silicone gaskets)
Surface Treatment	Black anodization (15–30μm), electrostatic powder coating (anti-UV), or conductive oxidation
Operating Temperature	-40℃ ~ 140℃ (resists high heat from charger components)
Installation Type	Floor-mount, wall-mount, pole-mount (with reinforced mounting brackets)
Load-Bearing Capacity	≤50 kg (supports internal charger modules and wiring harnesses)
Dimensional Tolerance	±0.1 mm (extrusion precision) / ±0.05 mm (CNC machining)
Certifications	RoHS, IEC 61851, UL 94 V-0, ISO 9001, CE
Weight	4.5–8.2 kg (varies by cross-section and wall thickness)
Heat Dissipation	Integrated extrusion fins (heat dissipation efficiency: 30% higher than flat enclosures)

Application Scenarios Of Large Size 1000mm Length Aluminum Extrusion Enclosures:

• Electric vehicle (EV) DC fast charging stations (50kW–350kW)
• Residential/commercial AC wall-mounted chargers (7kW–22kW)
• Energy storage system (ESS) charging/discharging modules
• Solar/wind power renewable energy charger units
• Electric bus/truck fleet charging stations
• Industrial new energy equipment charger housings
• Portable EV charging station modules
• Off-grid new energy charging systems (remote areas)

Surface Treatment & Product Advantages Of Large Size 1000mm Length Aluminum Extrusion Enclosures:

Surface Treatment Of Large Size 1000mm Length Aluminum Extrusion Enclosures:

Three specialized options tailored to new energy charger requirements:

1. Black Anodization: 15–30μm oxide layer formed via electrochemical process, offering excellent corrosion resistance (500+ hours salt spray test) and heat dissipation efficiency—ideal for high-temperature charger environments.
2. Anti-UV Powder Coating: Thermoset coating with UV inhibitors, resisting fading and cracking under outdoor sunlight (1000+ hours accelerated weathering test) while enhancing impact resistance (IK08 rating).
3. Conductive Oxidation: Thin conductive layer (5–10μm) maintaining electrical continuity for grounding, suitable for charger modules requiring EMI shielding.

Product Advantages Of Large Size 1000mm Length Aluminum Extrusion Enclosures：

1. Ample Internal Space: 1000mm length + customizable cross-sections accommodate large charger components (transformers, capacitors, PCBs) and wiring harnesses, simplifying assembly.
2. Superior Heat Dissipation: Aluminum alloy’s high thermal conductivity + integrated fins reduce internal temperature by 25–40℃, preventing overheating of high-power charger modules and extending component lifespan.
3. Rugged Structural Stability: 2.5–5.0mm wall thickness + extrusion molding ensures the enclosure resists deformation and impact (IK08) in outdoor/industrial settings, supporting heavy internal loads.
4. Reliable Environmental Protection: IP65/IP67 rating blocks dust, rain, and water jets, enabling safe operation in outdoor charging stations, coastal areas, and high-humidity environments.
5. Custom Flexibility: Supports custom length cutting, CNC-machined cutouts (for connectors, vents, displays), and personalized mounting brackets—no mold fees for orders over 50 units.
6. Compliance for Global Markets: Meets IEC 61851 (EV charging safety), UL 94 V-0 (flame retardancy), and RoHS standards, facilitating market access in Europe, North America, and Asia.
7. Easy Installation & Maintenance: Multiple mounting options (floor/wall/pole) with pre-drilled holes; removable end caps simplify module inspection and repair.
8. Cost-Effective Production: Extrusion process enables mass production with consistent quality, reducing unit costs for bulk orders while maintaining performance.

Frequently Asked Questions (FAQ) Of Large Size 1000mm Length Aluminum Extrusion Enclosures

Q: What is the lead time for bulk orders, and do you provide sample testing?

A: Prototypes (sample units) are ready in 7–10 days; bulk orders (500+ units) have a 15–20 day lead time. We provide free sample testing (thermal performance, IP rating) and custom certification support (e.g., UL, TUV) for global markets.s an option) enhances shielding by redirecting EMI to the ground, recommended for high-noise environments.

Q: Can the 1000mm length be customized to fit my specific charger module size?

A: Yes. The enclosure is fully customizable—length can be adjusted from 800mm to 3000mm, and cross-section dimensions (e.g., 90×130mm) can be tailored to your module’s footprint, with no mold fees for custom profiles (MOQ: 100 units).

Q: Why is 6063-T5/6061-T6 aluminum alloy used for new energy charger enclosures?

A: These alloys balance three critical needs: high thermal conductivity (dissipates charger heat efficiently), structural rigidity (supports heavy components in large enclosures), and extrusion feasibility (enables complex finned designs for heat dissipation).

Q: How does the enclosure handle the high heat generated by fast-charging modules?

A: The integrated extrusion fins + aluminum’s thermal conductivity (201 W/(m·K)) boost heat dissipation by 30% vs. standard enclosures. For 350kW fast chargers, optional thermal pads or built-in heat sinks can be added to further enhance cooling.

Q: Is the enclosure suitable for outdoor EV charging stations in harsh weather?

A: Absolutely. With IP67 protection (sealed silicone gaskets) and anti-UV surface treatment, it resists rain, dust, extreme temperatures (-40℃~140℃), and UV radiation—ideal for outdoor use in all climates.

Q: Can the surface treatment withstand coastal high-salt environments?

A: Yes. Black anodization (≥20μm) or powder coating with anti-corrosion additives achieves 500+ hours salt spray resistance, preventing rust and corrosion in coastal charging stations.

Q: What mounting options are available for different installation scenarios?

A: Standard options include floor-mount (reinforced base brackets), wall-mount (flange tabs), and pole-mount (adjustable straps). Custom mounting solutions (e.g., ceiling-mount) can be designed for unique setups.

Q: Does the enclosure support EMI shielding for sensitive charger electronics?

A: Yes. Opt for conductive oxidation surface treatment + conductive gaskets (Ni-Cu-Ni plated foam) to achieve 80–90 dB shielding effectiveness (30 MHz–1 GHz), protecting charger modules from electromagnetic interference.

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Vanway Tech – Premium Quality Custom Aluminum Extrusions Manufacturing

Vanway Precision Materials Tech Co.,Ltd is a trusted leader in premium aluminum extrusion profiles. It offers custom, industrial, architectural options, angle, channels, tubes and precision extruded products for industrial, infrastructure and downstream sectors.

Contact Vanway Tech today for tailored one-stop aluminium extrusion solutions.

Tel: +86 – 188 6143 8114 Chloe.Xue @ WeChat

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Email: info@vanway-tech.com

Address: No. 588, Wuyi South Road, CSJ Moldware