Shell Lubricants has succeeded in developing thermal management for battery electric vehicles (BEVs), thanks to its EV-Plus thermal fluid with PurePlus technology. In collaboration with the specialized firm HORIBA MIRA, Shell validated that this dielectric fluid is capable of effectively cooling all the electrical components of the propulsion system with a single-circuit, single-fluid design.
The creation and implementation of thermal fluid
Traditionally, electric vehicles rely on multiple fragmented cooling systems to maintain optimal temperatures in the battery, motor and power electronics. Shell’s proposal, however, unifies that entire process into a simpler, lighter thermal architecture that also improves energy efficiency and reduces manufacturing costs.
The EV-Plus thermal fluid, derived from natural gas and highly pure, was tested in simulated extreme conditions: from arctic temperatures to hot environments comparable to the Sahara desert. In all cases, the fluid maintained exceptional thermal performance without compromising safety or component life.
One of the most relevant tests was the validation of fast battery charging from 10% to 80% in less than 10 minutes, without affecting the structural integrity of the cells. The same fluid that cools the batteries by immersion is also effective in regulating heat in the inverter, motor and power electronics, even without direct contact with the heat sources.
This represents a key technical advantage for original equipment manufacturers (OEMs), who will be able to reduce weight and complexity in powertrain design. By dispensing with multiple traditional coolants such as glycol, developers also gain physical space inside the vehicle.
HORIBA MIRA, the project’s development partner, supported the performance tests and confirmed that Shell EV-Plus thermal fluid can be integrated with existing hardware. This flexibility paves the way for wider adoption in the automotive industry without the need to redesign current systems.
Robert Mainwaring, Shell’s chief engineer, emphasized that this solution completely replaces conventional cooling systems and offers ultra-fast charging along with thermal stability. For his part, Dr. David Bridge of HORIBA MIRA underlined the importance of this technology as a firm step towards more efficient and sustainable electric mobility.
The success of Shell EV-Plus thermal fluid is not only limited to the automotive sector. Shell has already applied it in environments such as data centers, where it was officially certified by
Source and photo: Shell
