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Castrol ON e-thermal fluid

Castrol has launched an advanced new ‘direct’ battery e-thermal fluid that will enable future generations of EVs to be charged more rapidly and offer increased performance, protection, and sustainability.

Castrol launches innovative Electric Vehicle (EV) battery e-thermal fluid that cuts charge times and boosts performance, safety and longevity.

  • Advanced Castrol ON e-thermal fluid developed for ‘direct’ battery cooling applications in next-generation EVs 
  • The low-viscosity dielectric fluid provides enhanced thermal management and efficiency gains 
  • Part of new Castrol ON e-Fluids range which also include e-Transmission Fluids and e-Greases 

Castrol has launched an advanced new ‘direct’ battery e-thermal fluid that will enable future generations of EVs to be charged more rapidly and offer increased performance, protection, and sustainability.  

 

Almost all of today’s EVs feature batteries using water / glycol-based coolants contained within a ‘jacket’ that surrounds the battery module. In line with technology demands of the future, the new Castrol ON e-thermal fluid is an innovative dielectric fluid formulated specifically for ‘direct’ cooling, where the fluid circulates within the module and in direct contact with individual battery cells. The result is a significant improvement in thermal management in all operating conditions1, at high and low ambient temperatures, for a longer battery life2.   

 

The use of Castrol ON e-thermal fluid allows EV batteries to be charged more rapidly. For example, when compared against existing water / glycol fluids in an independently conducted modelling study with the same variables, Castrol ON e-thermal fluid allowed for 41% faster charging3. In addition, during discharge the cells remain at their optimum operating temperature maximising efficiency and performance. In independent tests, during discharge the Castrol ON e-thermal fluid reduced peak cell temperatures by 28°C compared to test water / glycol coolant, and by 11°C compared to an existing dielectric fluid4.  

 

The new Castrol ON e-thermal fluid also ensures potential technical problems within the battery module can be better managed. For example, overcharging or short-circuiting in an EV powertrain can lead to ‘thermal runaway’, where high temperatures cause irreversible failure to individual battery cells. Thermal runaway can also lead to thermal propagation, where heat from the damaged cell is transferred via convection and conduction to adjacent cells. This process can ultimately result in the catastrophic failure of the entire battery module. However, with the Castrol ON e-thermal fluid, temperature spikes within individual cells are less likely, and if they occur, they can be quenched at source – unlike coolants used in indirect cooled systems.  

 

A further benefit of the new Castrol product comes from how it behaves within an EV’s coolant circulatory system. It is of a lower viscosity than existing dielectric transformer oils and so delivers reduced pumping losses, optimising the efficiency and effectiveness of the temperature management process.  

 

“We’re undertaking extensive testing of the new direct Castrol ON e-thermal fluid to ensure it provides high levels of performance, protection and sustainability, throughout the life of the battery,” comments Dr Marc Payne, Castrol’s EV fluids research manager. “The increased power density that can be enabled through the application of direct battery cooling will allow manufacturers to develop EVs with even greater performance and much improved fast-charging capabilities. While direct e-thermal fluids currently only feature in high-profile hybrid and battery-EV (BEV) hypercars, we expect the technology to ‘trickle down’ and be widely adopted in future generations of volume-selling EVs.” 

 

 The Castrol ON e-thermal fluid is part of a family of Castrol ON products, which include Castrol ON e-Transmission fluids and Castrol ON e-Greases.   

Castrol’s high-performance e-Mobility team is optimising thermal management performance through joint co-engineering programmes with partners. For further information, please contact Castrol at evfluids@castrol.com

 

Notes to editors 

1: Independent tests have shown that Castrol ON e-thermal fluid provides increased thermal management performance against water glycol indirect coolants and existing dielectric direct coolants. Source explaining the benefits of thermal management: Thermal management of lithium‐ion batteries for electric vehicles; G. Karimi X. Li; International Journal of Energy Research; Volume37, Issue1; January 2013; pages 13-24.  

 

2: Effective thermal management of cells (keeping temperature within their ideal operating range) reduces premature aging through loss of ‘state of health’, and therefore maintains battery capacity for longer. Source: Capacity vs days data: Calendar aging of commercial graphite/LiFePO4 cell e. Predicting capacity fade under time-dependent storage conditions, Sébastien Grolleau, Arnaud Delaille, Hamid Gualous, Philippe Gyan, Renaud Revel, Julien Bernard, Eduardo Redondo-Iglesias, Jérémy Peter; on behalf of the SIMCAL Network Journal of Power Sources 255 (2014) 450-458 LFP cells.  

 

3: When compared against water glycol in an independently conducted modelling study with the same variables, Castrol ON e-thermal fluid demonstrated 41% faster charging (10 mins to 80% charge for Castrol ON e-thermal fluid, compared to 14.1 mins for existing water glycol fluids).  

 

4: When compared against water glycol in an independently conducted modelling study during cell discharge, Castrol ON e-thermal fluid reduced peak cell temperatures by 28°C, and reduced cell temperature variation by 8°C. When compared against existing dielectric fluids, Castrol ON e-thermal fluid reduced peak cell temperatures by 11°C, and reduced cell temperature variation by 2°C. These improvements enabled higher performance at a given maximum temperature.  

When compared against water glycol during cell charging, Castrol ON e-thermal fluid reduced peak cell temperatures by 17°C, and reduced cell temperature variation by 2°C. When compared against existing dielectric fluids, Castrol ON e-thermal fluid reduced peak cell temperatures by 11°C, and reduced cell temperature variation by 3°C during charging. Just like cell discharge, these improvements enabled higher performance at a given maximum temperature. 

 

About Castrol 

Castrol, one of the world’s leading lubricant brands, has a proud heritage of innovation and fuelling the dreams of pioneers. Our passion for performance, combined with a philosophy of working in partnership, has enabled Castrol to develop lubricants and greases that have been at the heart of numerous technological feats on land, air, sea and space for over 100 years.   

 

Castrol is part of the BP group and serves customers and consumers in the automotive, industrial, and marine and energy sectors in over 120 countries. Our branded products are recognized globally for innovation and high performance through our commitment to premium quality and cutting-edge technology.