Shell has announced the successful development of an immersively-cooled battery pack, confirming that its EV-Plus Thermal Fluid with PurePlus Technology can serve as a comprehensive thermal management solution for the entire BEV powertrain. This advancement enables a more streamlined battery and powertrain design, reducing the number of components and overall vehicle weight, thereby driving operational efficiency and cost-effectiveness.
Supported by HORIBA MIRA, Shell demonstrated the fluid’s superior thermal control capabilities during high-speed charging and its effectiveness in cooling motors and power electronics during operation. The ultra-low viscosity Shell EV-Plus Thermal Fluid proved effective across a range of conditions, from arctic cold to Saharan heat, allowing a single-fluid, single-circuit system design. This innovation reduces component inventory and enhances vehicle performance and economy.
Jason Wong, Global Executive Vice President of Shell Lubricants, stated, “Today’s announcement marks an important milestone in demonstrating that a specialised Shell Thermal Fluid operating in a single circuit can manage the thermal needs of all electrical drivetrain components. This eagerly anticipated ‘all-in-one’ concept is crucial in supporting both reduced cost and complexity in BEV design and manufacturing for our partners.”
Shell’s EV-Plus Thermal Fluid incorporates proprietary Shell PurePlus Technology, using a 99.5% pure base oil derived from natural gas, which enhances BEV battery cooling. It enables charging from 10% to 80% capacity in under 10 minutes through direct contact between the battery cells and the dielectric fluid. The fluid also efficiently transfers heat from other electrical components, even without direct contact.
Robert Mainwaring, Shell’s lead engineer on the project, commented, “Our Shell EV-Plus Thermal Fluid’s ability to entirely replace traditional glycol-based coolants and work with existing hardware is a game-changer. It shows that you don’t need a patchwork of cooling systems; one fluid can do it all, enabling ultra-fast charging and facilitating optimal drivetrain performance.”
Dr. David Bridge, Chief Engineer – Thermal at HORIBA MIRA, added, “The development of advanced thermal management solutions is a critical enabler for the future of electric vehicles. The ability to manage heat effectively across the entire powertrain is fundamental to unlocking the full potential of BEV technology, enabling faster charging, improved safety, and longer component life. This is a significant step forward in the journey towards a fully electrified and sustainable transport future.”
The full white paper, ‘Cooling an entire BEV drivetrain with Shell’s Thermal Fluid for simplicity, operational economy and cost-efficiency,’ is available for download and provides comprehensive details on the powertrain testing. For more information, visit Shell’s official site.
