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At CSTHEATEXCHANGER, we design and manufacture high-efficiency Aluminum Roll Bond Evaporators (Roll Band / Inflated Plate Evaporator Panels) engineered specifically for household refrigerators, commercial beverage coolers, under-counter bar fridges, chest freezers, ice-box compartments, and medical cold storage appliances (standard cooling capacities engineered from 50 W to over 850 W). Fabricated from high-purity aluminum alloy sheets (AA1050 / AA1060 / AA1070) through precision screen-printed stop-weld patterns, hot-roll diffusion bonding, and high-pressure pneumatic channel inflation (>12 MPa), our roll bond evaporators are available in Single-Side Inflated (flat on one side for intimate liner contact), Double-Side Inflated, and custom U/C/Box-bent configurations. Equipped with integrated liquid accumulators, friction-welded copper-aluminum transition connector stubs, and food-grade anti-corrosion powder coating / anodic oxidation finishes, CSTHEATEXCHANGER roll bond evaporators deliver burst pressures >4.5 MPa, ultra-clean internal channels (<15 mg/m2) optimized for R600a Isobutane, R290 Propane, and R134a, and rapid pull-down freezing with zero hot spots.
Roll bond evaporators provide the highest contact thermal conductivity in appliance refrigeration by embedding the refrigerant flow circuit directly inside a solid aluminum plate:
ROLL BOND EVAPORATOR INFLATION & THERMAL ARCHITECTURE
================== ROLL BOND DIFFUSION BONDING PROCESS ==================
[ AA1050/AA1060 Aluminum Sheet ] + [ Screen-Printed Stop-Weld Ink Circuit ]
│
▼
┌────────────────────────────────────────────────────────────────────────────┐
│ HIGH-TEMPERATURE ROLLING MILL (SOLID-STATE MOLECULAR DIFFUSION WELDING) │
│ Sheets bond metallurgically under intense rolling force except printed ink │
└────────────────────────────┬───────────────────────────────────────────────┘
│
▼
┌────────────────────────────────────────────────────────────────────────────┐
│ HIGH-PRESSURE HYDRAULIC / PNEUMATIC INFLATION BLOWING (> 12 - 16 MPa) │
│ Non-welded ink channels inflate into smooth, aerodynamically curved paths │
└────────────────────────────┬───────────────────────────────────────────────┘
│
▼
┌────────────────────────────────────────────────────────────────────────────┐
│ PRECISION CNC FORMING & SURFACE FINISHING │
│ ┌────────────────────────┐ ┌────────────────────────┐ ┌──────────────────┐ │
│ │ SINGLE-SIDE FLAT PANEL │ │ DOUBLE-SIDE INFLATED │ │ BENT FREEZER BOX │ │
│ │ Flat back for liners │ │ High surface area flow │ │ U / C / O Shaped │ │
│ └────────────────────────┘ └────────────────────────┘ └──────────────────┘ │
└────────────────────────────────────────────────────────────────────────────┘Two high-purity aluminum alloy sheets are chemically cleaned. The customized refrigerant flow pattern is screen-printed onto one sheet using high-precision stop-weld graphite ink. The sheets are heated and passed through heavy-duty rolling mills where extreme mechanical pressure fuses the aluminum at a molecular level, except where the stop-weld pattern isolates the metal.
The bonded composite plate is placed inside a hydraulic press die, and pressurized dry air or fluid (>12 to 16 MPa>12 to 16 MPa) is injected into the inlet port. The non-bonded circuit inflates outwards, forming continuous, leak-free refrigerant channels with smooth internal radii that eliminate flow dead-zones and minimize pressure drops.
CSTHEATEXCHANGER manufactures roll bond evaporator panels in multiple structural styles to suit diverse refrigerator cabinet architectures:
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ROLL BOND EVAPORATOR STYLES & APPLICATION ENVELOPES
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Evaporator Configuration Structural Feature Typical Refrigerator Application
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Single-Side Inflated (Flat Back)One face 100% flat; channels Direct-contact foaming inside refrigerator
protrude exclusively on front cabinet rear liners & hidden cooling walls.
Double-Side Inflated Channels inflate symmetrically Free-hanging cold room plates, beverage coolers,
on both front and rear faces and multi-shelf freezer contact evaporators.
Formed Box / U-Shape / C-Shape Pre-bent into 3D box or U-curve Integrated 4-sided freezer compartments, ice
with seamless corner flow lines maker boxes, and mini-bar freezer chambers.
Integrated Accumulator Panel Enlarged suction volume bulb Prevents liquid refrigerant floodback to
roll-bonded into the return leg compressor during rapid pull-down cycles.
================================================================================ SINGLE-SIDE FLAT VS. DOUBLE-SIDE EXPANDED ROLL BOND PROFILES
[1] SINGLE-SIDE INFLATED (FLAT REAR FOR LINER ADHESION)
═══════════════════════════════════════════════════════════ <-- 100% Flat Rear
───┐ ┌───────┐ ┌───────┐ ┌───────┐ ───
│ │ │ │ │ │ │
└───────┘ └───────┘ └───────┘ └─────── <-- Inflated Front Channels
[2] DOUBLE-SIDE INFLATED (MAXIMIZED HEAT TRANSFER SURFACE)
┌───────┐ ┌───────┐ ┌───────┐ ┌───────
───┘ └───┬───┘ └───┬───┘ └───┬───┘ ─── <-- Symmetrical
───┐ ┌───┴───┐ ┌───┴───┐ ┌───┴───┐ ─── Bilateral Flow
└───────┘ └───────┘ └───────┘ └───────================================================================================
CSTHEATEXCHANGER ROLL BOND PANELS VS. GENERIC ROLL BOND EVAPORATORS
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Engineering Parameter Generic Roll Bond Evaporators CST Heavy-Duty Roll Bond Evaporators
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Aluminum Base Metallurgy Low-Grade Recycled Alloy (AA1030) High-Purity Virgin Alloy AA1050 / AA1060
Bonding Rolling Ratio < 50% Reduction (Delamination) > 60% Extreme Reduction (Molecular Bond)
Channel Inflation Burst Press. 2.0 - 2.5 MPa > 4.5 to 6.5+ MPa (High Burst Margin)
Cu-Al Connection Joint Type Adhesive Glue or Mechanical Swage Friction-Welded / Ultrasonic Metallurgical Joint
Cu-Al Joint Corrosion Seal Bare Joint (Galvanic Pitting) Multi-Layer Polyolefin Heat-Shrink Sleeve
Internal Tube Cleanliness > 30 mg/m² Residual Impurities Ultra-Clean < 15 mg/m² (R600a Capillary Safe)
Surface Coating Quality Thin Spray Paint (< 30 µm) High-Adhesion White Epoxy Powder (> 60 µm)
Salt Spray Rating (ASTM B117) < 72 Hours > 150 to 240+ Hours (Zero Blistering)
================================================================================Connecting aluminum evaporators to copper refrigeration system piping creates galvanic corrosion risks. CSTHEATEXCHANGER integrates metallurgically bonded, friction-welded copper-aluminum (Cu-Al) connector tubes protected by double-walled polyolefin heat-shrink sleeves, allowing field technicians to solder copper-to-copper joints with zero risk of joint embrittlement.
Every evaporator undergoes multi-stage chemical pre-treatment and electrostatic powder coating or anodic oxidation. The non-toxic, food-safe white or silver epoxy layer (60 to 90 μm60 to 90 μm) resists mechanical scratching, food acid spills, and withstands >240\text{ hours of ASTM B117 salt spray testing.
(Note: The following engineering parameters represent standard manufacturing design envelopes. Sheet dimensions, channel circuits, bending radiuses, and connector stubs are custom-tooled to OEM refrigerator drawings.)
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CSTHEATEXCHANGER REFRIGERATOR ROLL BOND EVAPORATOR (CST-RBE SERIES)
================================================================================
Engineering Parameter Standard Manufacturing & Design Range
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Cooling Capacity Rating Typical: 50 W to 850+ W per plate (Customizable)
Target Refrigeration Appliance Household Refrigerators, Freezers, Ice Boxes, Beverage Fridges
Refrigerant Compatibility R600a (Isobutane), R290 (Propane), R134a, R513A, R1234yf
Raw Material Base Sheets High-Purity Virgin Aluminum AA1050, AA1060, or AA1070
Raw Material Sheet Thickness Pre-Rolling: 1.5 - 2.5 mm | Finished Plate: 1.1 mm to 2.0 mm
Inflated Channel Height 2.5 mm to 4.5 mm (Optimized for Low Refrigerant Charge)
Channel Inflation Pattern Single-Side Inflated (Flat Back), Double-Side, or Partially Flat
Bending & Forming Options Flat Plate, U-Shaped, C-Shaped, O-Shaped 4-Sided Freezer Boxes
Copper-Aluminum Connector Stubs Solid Friction-Welded Cu-Al Joints (Ø 6.0 mm or 6.35 mm [1/4"])
Surface Finish Options Electrostatic Epoxy Powder (White/Silver), Anodized, or Bare Mill
Coating Thickness & Adhesion 60 to 90 µm (Cross-Hatch Adhesion ISO 2409 Class 0)
Salt Spray Corrosion Rating > 150 to 240+ Hours ASTM B117 Neutral Salt Spray (No Blisters)
Internal Residual Cleanliness < 15 mg/m² Residual Impurities; Residual Moisture < 10 mg/m²
Operating & Burst Pressures Operating Pressure: 1.5 - 2.5 MPa | Burst Pressure: > 4.5 MPa
Leakage Verification Standard 100% Mass Spectrometer Helium Leak Testing (< 1x10⁻⁶ mbar·l/s)
Quality & Environmental Codes RoHS, REACH, FDA / LFGB Food Contact Safe, ISO 9001:2015
================================================================================A single-side inflated roll bond evaporator features one completely flat surface. This allows the evaporator to be mounted flush against the plastic cabinet liner of a refrigerator or foamed directly into the polyurethane insulation wall, maximizing cabinet storage space while preventing frost build-up behind the cooling plate.
R600aR600a refrigeration systems use ultra-low refrigerant charges and very narrow capillary expansion tubes (<0.6 mm<0.6 mm inner diameter). Even minute quantities of residual lubricating oil, graphite dust, or moisture inside the roll bond channels will cause immediate capillary clogging or ice-plugging. CSTHEATEXCHANGER guarantees internal contamination below 15 mg/m2 with sealed nitrogen pressurization.
Yes. We can design and inflate an enlarged bulbous chamber directly into the outlet circuit of the roll bond pattern. This integrated accumulator traps unevaporated liquid refrigerant during rapid compressor startup, protecting the compressor from liquid slugging without requiring an external steel accumulator canister.
Achieve rapid cooling pull-down, zero hot spots, and leak-free reliability with CSTHEATEXCHANGER:
Custom Roll Bond Evaporators (Single-Side Flat, Double-Side & Formed 3D Boxes)
High-Purity Virgin Aluminum Sheets (AA1050 / AA1060) with Solid Diffusion Bonding
Integrated Accumulator Reservoirs & Friction-Welded Copper-Aluminum (Cu-Al) Stubs
Food-Safe Non-Toxic White Epoxy Powder Coating (>240 Hours>240 Hours Corrosion Protection)
100%100% Helium Vacuum Leak Tested & Optimized for R600aR600a and R290R290 Hydrocarbons
Custom Screen-Printing Tooling, 2D/3D CAD Engineering & Factory-Direct Global Supply
Contact our specialized appliance refrigeration engineering team today with your refrigerator cabinet dimensions, target heat load (WW), bending geometry, and capillary connection requirements for customized engineering drawings and factory-direct quotations.
Website: https://www.cstheatexchanger.com/
Technical Inquiries: info@cstheatexchanger.com
