IDTechEx outlines thermal trends for batteries and EVs

The battery energy storage system (BESS) thermal management and fire protection market will surpass US$25bn by 2036 as project scale increases and safety concerns drive adoption of both active and passive thermal management solutions, according to research firm IDTechEx. Thermal incidents in lithium-ion BESS installations can release toxic chemicals alongside fire and explosion risks, potentially resulting in health impacts, environmental damage, asset loss and increased insurance costs.

BESS thermal management approaches can be categorised into passive methods, including deflagration venting, cell spacers, thermal interface materials and phase change materials, and active systems encompassing cooling, gas and heat sensors, fire suppressants and ventilation. The growing use of BESS for grid-scale, commercial, industrial and residential applications is increasing demand for thermal management systems, according to IDTechEx.

Electric vehicle thermal management is also evolving beyond the active cooling approaches that have become standard across the industry. Cell-to-pack battery designs, directly oil-cooled motors and silicon carbide power electronics are among the trends affecting thermal management requirements, IDTechEx said.

Immersion cooling is emerging as a method that could enable faster charging and improved safety through enhanced thermal performance, while material suppliers are developing multi-purpose materials that combine fire protection, compression and thermal insulation. Direct oil cooling for electric motors has gained traction, with IDTechEx noting a clear increase in oil-based thermal management strategies between 2015 and 2024 alongside a reduction in water-glycol cooling.

Source: IDTechEx