A new non conductive thermal fluid developed by Shell shows how a single cooling circuit can manage batteries, motors, and power electronics, potentially reshaping next generation EV design.
How a thermal fluid for electric vehicles can manage batteries, motors, and power electronics
A new thermal fluid for managing battery temperature during high speed charging, and for cooling the motor and power electronics during driving, is emerging as a potential shift in electric vehicle engineering. Shell Lubricants has introduced a solution that could redefine how EV powertrains are designed. With its EV Plus thermal fluid, the company shows that a single cooling circuit can handle the thermal needs of an entire electric propulsion system.
What thermal fluids do in EVs
Electric vehicles have specific thermal management needs. The demanding environmental conditions in which they operate require fluids that protect both electrical and mechanical components.
Fast charging generates significant heat, and controlling it is essential. Excess thermal energy can accelerate cell degradation, shorten battery life, and in certain cases create serious safety risks. EV specific thermal fluids are formulated to work under extreme conditions, maintain stability and safety, and deliver consistent performance while helping dissipate heat. This applies not only to battery packs. Motors and power electronics must also operate within a narrow temperature range to ensure safety and stable performance.
Shell’s innovation
Traditionally, each EV subsystem, the battery, inverter, and motor, relies on its own cooling loop, often using different thermal fluids. Shell’s approach changes this model.
The company has developed a new electrically non conductive thermal fluid with strong thermodynamic properties in which battery cells are directly immersed. The fluid fills all gaps, ensuring uniform heat transfer. Its performance and low viscosity allow it to replace conventional glycol based coolants while remaining compatible with standard hardware. This means that through a single circuit, Shell EV Plus can also cool other essential parts of the electric powertrain.
In collaboration with Horiba Mira, an engineering and advanced testing firm, Shell tested the fluid under extreme conditions ranging from arctic cold to Sahara level heat. Results show that EV Plus maintains stable thermal control during ultra fast charging, from 10 percent to 80 percent in under 10 minutes, while effectively cooling both the motor and the power electronics during operation.
Thermal fluid, efficiency, and sustainability in one formula
The environmental benefit is twofold. With fewer components and cooling circuits, vehicles can reduce weight, energy consumption, and materials use. A unified and more efficient thermal system also improves range and extends battery life.
According to David Bridge, chief engineer at Horiba Mira, integrated thermal management is essential to unlocking the full potential of battery electric vehicles. It allows faster charging, greater safety, and longer component life. He describes this innovation as a decisive step toward a fully electrified and sustainable transport future.
A simpler path to electrification
With this technology, Shell aims to provide a universal thermal platform for next generation EV manufacturers, reducing development time and costs. Simplifying cooling systems also opens the door to lighter, more efficient, and more affordable vehicles, strengthening the case for widespread electric mobility.
