Sourcing the most effective means of keeping vehicle batteries cool is a task explored extensively in IDTechEx's latest report, "Thermal Management for Electric Vehicles 2025-2035: Materials, Markets, and Technologies". The report covers many thermal management approaches for electric vehicles, including immersion cooling, and the respective players aiming to make their uptake more widespread.
Immersion cooling could be considered a more direct approach to battery cooling when compared to alternatives, as the dielectric fluid used in the process comes into contact with the cells, potentially without the need for cooling channels, thermal interface materials, or fire protection materials. The nature of the dielectric fluid being flame retardant means that it can, to an extent, prevent thermal runaway propagation and improve safety. Employing immersion cooling may also mean that other components within the vehicle, such as cold plates, condenser, and chiller, are no longer necessary for battery cooling.
The main coolant requirements
In addition to being dielectric, immersion coolants also need to possess other performance qualities in order to achieve optimal efficiency. High thermal conductivity, high specific heat, and low viscosity are amongst the desired traits of coolant, as well as a low freezing and high ignition point, a high atmospheric boiling point, and good chemical and thermal stability to ensure a long life. The coolant also needs to be non-corrosive to other pack materials and meet potential regulatory requirements that are concerned with environmental factors such as non-toxic makeup, biodegradability, and a low global warming impact. Lastly, cost is one of the most important factors to consider for automotive applications because it could be the difference between OEMs opting for immersion cooling or a cheaper alternative.
IDTechEx's report covers the main players within the immersion fluids for EVs market, from newer companies like Engineered Fluids to large established materials suppliers such as Total, 3M, and Solvay.
Single-phase vs two-phase
The two types of immersion cooling include single-phase and two-phase, both offering individual benefits for consideration. Single-phase immersion coolant is pumped through the battery and a heat exchanger and is the most popular approach for immersion cooling in electric vehicles. Despite offering better thermal qualities, two-phase cooling can see the fluid requiring refills after potential evaporation, with the design proving trickier to get right, especially for use in electric vehicles.
Barriers to EV adoption for immersion cooling
Immersion cooling sees the most popularity in cooling for servers, data centers, and transformers, and is not yet widely used within the automotive sector. The weight of the immersion cooling fluid could potentially be difficult to navigate for EVs, as well as the costs associated with this method and its lack of maturity. There is also the potential need for a chiller and the need for effective battery module sealing, which also prevents the uptake of immersion cooling within the automotive sector despite its effectiveness. However, with the benefits of reduced components and direct cooling effectiveness considered, its usage may become more popular as EV types grow and differentiate. Early adopters are applications like high-performance hybrids and construction equipment.
To find out more, please see the IDTechEx report, "Thermal Management for Electric Vehicles 2025-2035: Materials, Markets, and Technologies". Downloadable sample pages are available for this report.
For the full portfolio of related market research available from IDTechEx, please see:
About IDTechEx
IDTechEx provides trusted independent research on emerging technologies and their markets. Since 1999, we have been helping our clients to understand new technologies, their supply chains, market requirements, opportunities and forecasts. For more information, contact research@IDTechEx.com or visit www.IDTechEx.com.
