Photo: Freepik
On September 9, 2025, Shell Lubricants (“Shell”) announced a significant breakthrough that could reshape the future of electric vehicle (EV) charging. The company has successfully formulated and demonstrated a high-performance EV thermal management fluid that can dramatically reduce charging times while maintaining battery safety, thermal stability, and lifespan. This innovation could play a critical role in accelerating the adoption of battery electric vehicles (BEVs)
Working in collaboration with the UK-based RML Group, one of the leading names in automotive innovation, Shell developed a 34 kWh battery pack that incorporates its new EV-Plus Thermal Fluid. Built on proprietary Shell Gas-to-Liquid (GTL) Technology, the system has achieved charging speeds from 10% to 80% in under 10 minutes, a milestone that positions it well ahead of current industry norms. By reducing thermal stresses, the fluid enables much higher charging currents to be handled safely.
“As we celebrate World EV Day, we are thrilled to demonstrate that Shell EV-Plus Thermal Fluids can help to significantly improve battery thermal performance, paving the way towards higher charging efficiencies, enhanced safety, convenience and cost-effectiveness— to support the widespread adoption of BEVs demanded by legislative initiatives around the world,” said Jason Wong, Global Executive Vice President, Shell Lubricants.
“This evolution is a testament to our commitment to collaborative innovation towards enabling more value with less emissions – building on our experience in high-performance transformer oils, proprietary Gas-to-Liquid (GTL) technology, and single-phase immersion cooling fluids for data centres,” Wong continued.
When applied to a lightweight, aerodynamic car capable of 10 km per kWh, the system could deliver a charging rate equivalent to 24 km of range per minute spent charging. That is nearly five times faster than the 5 km per minute achieved by many existing BEVs, a leap forward that promises greater convenience for drivers while simplifying vehicle design by reducing component count and weight.
At the heart of this technology are Shell EV-Plus Thermal Fluids, which are electrically non-conductive and designed to maximize heat transfer. The fluid fills the interstitial spaces inside the battery pack, ensuring direct contact with each cell. This setup efficiently manages the immense heat generated during rapid charging, maintaining consistent temperatures across the pack while providing enhanced protection against thermal events.
The result is a compact, cost-effective, and reliable battery pack design that demonstrates how advanced thermal management can unlock both performance and safety. Shell plans to showcase this innovation at The Battery Show North America in Detroit, running October 6–9, 2025, offering a closer look at how EV-Plus Thermal Fluids could help redefine what’s possible for the next generation of EVs.
Source: msn
