Batteries & Fuel Cells
density variations under thermal load, heat transfer coefficients at cell surfaces and internal pack thermal gradients. This modelling ensures that heat extraction is balanced across the entire pack. The result is tighter thermal control, reduced cell-to-cell variation and a broader safe operating window.
Intelligent control
Thermal management does not end with fl uid fl ow. Each cell is monitored via integrated printed circuit boards (PCBs) that continuously track temperature and performance parameters. This data is fed back to the vehicle control systems in real time, enabling dynamic management of discharge rates and load profi les. The battery management system (BMS) therefore operates not just as a safety mechanism, but as a performance optimiser. Continuous feedback ensures that cells remain within defi ned thresholds while extracting maximum output. By reducing thermal stress and maintaining balance across all cells within the pack, we preserve long-term health while enabling higher short-term power delivery.
More usable performance The cumulative impact of immersion cooling, fl uid optimisation, CFD-driven design and intelligent monitoring is substantial. On our latest technology, we have demonstrated that our immersion-cooled powerpack achieves the following performance goals: 1 10-80 per cent charge in less than 10 minutes on existing charge infrastructure
2 Cell electrochemical properties held within safe parameters
3 Module temperature variation kept within 5°C By controlling temperature more precisely and reducing internal resistance under load, we can sustain higher discharge rates for longer durations. In high performance applications, this
translates to increasing the average charge and discharge
power that can be maintained by the battery over other cooling technologies. This means we can achieve more usable performance from the same lithium-ion cell
technology without altering the underlying chemistry and whilst minimizing the size and mass of the battery.
Where this technology goes next Until now, high volume automotive manufacturers have focused on longer range and lower cost, to widen the potential customer base for electric vehicles. As the market and infrastructure matures, the necessity for long range BEVs diminishes; most consumers need only a modest range with the ability to fast charge on very occasional longer drives. RML in collaboration with Shell have demonstrated that immersion cooling can enable 10-80 per cent charging in less than ten minutes on readily available 175kW charge infrastructure. As increased EV uptake puts
a greater demand on natural resources
(Above) Keeping up to 400 of these cells cool at the same time is the key to better battery performance, says RML Group’s Denis Gorman.
for construction then lower mass, greater effi ciency and reduced environmental impact will come to the fore, and immersion cooling could be a key player in enabling this. In parallel the potential in niche sectors is considerable. We see huge potential for this immersion cooling application in high- performance and hypercar programmes, defence vehicle electrifi cation, eVTOL aircraft platforms and Unmanned Aerial Vehicles (UAVs).
In these sectors, power density, reliability and repeatable performance outweigh cost- per-kilowatt-hour considerations. Battery chemistry innovation – whether lithium-ion refi nement, sodium-ion maturation or solid-state breakthroughs – will undoubtedly shape the long-term future of electrifi cation. But in the near term, performance gains will come from engineering the system around the cell.
At RML Group, our work in immersion cooling demonstrates that meaningful performance improvements are achievable today. By treating thermal management as a primary performance enabler rather than a secondary constraint, we have unlocked hidden potential in usable battery capability.
https://www.rmlgroup.com/
A little ‘support’ to help with the biggest projects
In addition to the regular users of the CIE website we get 12,500 new users every year across the globe from Japan to the USA, from China to Germany and many more.
Want to be part of the action? From concept to completion, ATC Semitec is your
go-to partner for all your temperature monitoring needs. With over 25 years technical expertise and cutting edge solutions – trust us to provide the extra support that makes the difference in your biggest projects.
Then contact
Tony Patman | 01622 687031 |
tpatman@cieonline.co.uk Sophie Scott | 01622 699193 |
sscott@cieonline.co.uk
www.cieonline.co.uk 01606 871680
smart@atcsemitec.co.uk atcsemitec.co.uk
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