New fluids coming for EV thermal management

Balancing low conductivity, corrosion resistance and optimum heat transfer in next-generation EV coolants while meeting new EV safety regulations.

Managing the heating and cooling of electric vehicle propulsion systems may seem to be an easy task compared with combustion engines. After all, ICEs run much hotter-the thermal optimum for a gasoline engine is around 212 F (100 C). By comparison, EV batteries normally generate (as a function of current during charge/discharge cycles) a relatively cool 59-86 F (15-30 C). And while motors and power electronics operate hotter, typically 140-176 F (60-80 C), they still run cooler than ICEs.

But among the myriad complexities of EV thermal management are batteries' dislike for temperature extremes, new cell chemistries, heat-generating high-voltage electrical architectures and 800V fast charging. All are putting greater focus on maintaining stable EV battery thermal performance and safety. Experts note that compatibility among the cell chemistry, hardware, and coolant fluid is the key to a balanced systems solution.