Coolants Critical: Why are Coolants Important for Electric Vehicles?

Thermal management is the process of heating and cooling vehicle systems to ensure that they remain between operating limits – safe, efficient, and at optimum performance. While this is true of Internal Combustion Engine (ICE) vehicles, the same can be said about Electric vehicles (EVs) – including BEVs, PHEVs, and FCEVs. In fact, thermal management is one of the most important considerations when designing an EV. 

Powertrain EVolution 

Unlike an ICE vehicle, many types of EVs do not have combustion or hot exhaust gases to manage. Nor do they need to keep an engine block cool to prevent catastrophic damage. Instead, they must manage a new set of challenges – controlling the temperature of e-motors, batteries, and a myriad of auxiliary systems. 

For certain types of hybrids with a combustion engine or range extender, traditional ICE cooling considerations are also present.

Cooling System Requirements 

So, what cooling requirements do EVs have? A typical EV will have one or two high-torque e-motors. While they don’t generate anywhere near the heat of a combustion engine, there is waste heat associated with their operation, a by-product of converting electrical energy into kinetic energy. Effective cooling helps to prevent overheating, which can cause wear and degrade performance. 

To keep the motors supplied with sufficient electrical energy, the e-motors require a large battery pack. Today, these are almost exclusively made using lithium-ion batteries. The battery must be kept within a precise operating temperature range to maximize the efficiency of chemical reactions within and extend the battery’s lifetime. 

EVs are also packed with electrical components and sub-systems. Keeping inverters, converters, and other components operating at safe temperatures is critical for long-term reliability. 

EV Performance 

Thermal management allows EVs to operate more efficiently and in adverse weather conditions. For example, in colder weather, the battery must be warmed, and in hot weather, it must be cooled. This is particularly important when it comes to range. Have you noticed that your phone battery doesn’t seem to work as well when it’s cold? The same principle applies to EVs, with many incorporating a battery heating system to counteract this issue. 

Longevity and durability are two of the most desirable traits for vehicle systems. In EVs, effective thermal management can reduce wear, tear, and degradation. This means longer component lifespans, including the battery, which can be expensive to replace. 

Need for Specialist Coolants 

When considering EV coolant, it is important to use a fluid that can safely be used in high-voltage environments. Most EVs operate at 360-450 Volts with some as high as 800 Volts, making electrical safety a high priority for any material or fluid selection. Just like in ICE vehicles, thermal conductivity and thermal capacity are also  

important to maximize heat transfer. Given the sustainable nature of EVs, it is logical to use a coolant with minimal environmental impact. 

Champion’s advanced solution for EV Cooling 

Champion Lubricants’ E-PULSE range is a specialised, comprehensive suite of products formulated for today’s electric and hybrid vehicles, including BEVs, FCEVs, and PHEVs. E-PULSE Coolants, specifically formulated for electric powertrains, combines Organic Additive Technology (OAT) with mineral-based (silicate) corrosion inhibitors—known as Si-OAT technology. This advanced blend provides extended drain intervals of up to six years or 250,000 km, delivering excellent heat transfer and dispersion alongside robust anti-corrosion and anti-freeze protection. E-PULSE Coolant also meets SAE J1034, ASTM D3306, D4985, and D6210 standards, ensuring top-tier performance and reliability for EV applications. 

Optimise your electric drive: Champion’s E-PULSE Coolants deliver the performance and protection your electric and hybrid vehicles need.

Explore the full range today and ensure you are equipped with the best in e-mobility.