Following successful development of an immersively-cooled battery pack, extensive testing has now proven that Shell EV-Plus Thermal Fluid with PurePlus Technology, can act as an all-in-one thermal management solution for the entire BEV power train. This enables a simplified battery and powertrain design, supporting reduction in the number of components and vehicle weight, and helping to drive operational economy and cost-efficiency.
Shell, supported by HORIBA MIRA, has demonstrated that its specialised thermal fluid not only promotes outstanding thermal control in the battery pack during high-speed charging conditions, but is also effective at cooling the motor and power electronics whilst driving. The ultra-low viscosity Shell EV-Plus Thermal Fluid proved efficacious across a wide range of replicated conditions, from the extreme cold of an arctic winter to the scorching heat of a Saharan summer. This opens the door to an elegant single-fluid, single-circuit system design that can reduce component inventory and promotes enhanced vehicle performance and economy.
“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 drive train 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,” said Jason Wong, Global Executive Vice President, Shell Lubricants. “Previously, we announced how Shell’s thermal fluid technology has facilitated sub-10-minute battery charging without compromising cell integrity or lifetime via enhanced thermal management. Through clever co-engineering, we have now shown the potential to unlock greater system-wide benefits.”
Shell’s EV-Plus Thermal Fluid features proprietary Shell PurePlus Technology which uses a crystal-clear 99.5% pure base oil[1] made from natural gas with stronger molecular bonds, to improve BEV battery cooling. It opens the door to charging from 10% to 80% capacity in under 10 minutes through direct contact between the battery cells and the dielectric fluid. Today’s announcement demonstrates that the same fluid is effective at transferring the heat from other electrical components even when the fluid and heat source are not in direct contact.
“Having managed the heat generated during brisk battery charging with an immersive fluid, the challenge was extended to cover all other electric components in the powertrain, ” 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 of HORIBA MIRA, commented, “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 power train 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’, covers details of the full power train testing, and is available for download here.
For more information, please visit www.shell.com/ev-plus
For more news: https://designsolutionsmag.co.uk/category/news/
