Thermal management systems could be likened to the glue holding operations together, to ensure systems can run smoothly in optimal conditions. IDTechEx‘s portfolio of Thermal Management Research Reports and Subscriptions, showcases the importance of method and material developments for thermal management across multiple sectors, including two of the largest industries: battery energy storage systems and electric vehicles.
Active and passive thermal management for stationary energy storage
Battery energy storage systems (BESS) have been subject to concerns around the thermal runaway that can occur with Li-ion batteries. The large increase in scale of projects and the use of BESS for grid-scale, commercial, industrial, and residential applications, highlights thermal management systems as being more necessary than ever to ensure safety remains a top priority. Thermal incidents, as described by IDTechEx, have the potential to release toxic chemicals, alongside simply the fire and explosion risks. These could have detrimental impacts on health and the environment, as well as potentially resulting in asset loss and increased insurance costs.
BESS thermal management can be categorized into active and passive approaches, with passive including deflagration venting or materials choices, such as cell spacers, thermal interface materials, fire protection materials, and phase change materials. Active thermal management systems include the use of different cooling types, sensors for gas, heat, and smoke, fire suppressants such as aerosols and water sprinklers, and ventilation. IDTechEx’s report, “Thermal Management, Fire and Explosion Protection for BESS 2026-2036: Materials, Technologies and Players“, goes into more detail on established and emerging methods, as well as exploring some of the global regulations surrounding BESS safety. With expected growth, IDTechEx predicts the BESS thermal management and fire protection material and system market to surpass US$25 billion by 2036.
Advancing electric vehicle thermal management
With the evolvement of battery packs and drivetrains for electric vehicles comes a need for thermal management approaches past the initial trends of active cooling which have now become standard across the EV industry. The development of cell-to-pack designs, directly oil-cooled motors, and silicon carbide power electronics, are a few trends that will affect the approach to thermal management going forward, according to IDTechEx.
Creating materials that serve multiple purposes, including fire protection, compression, and thermal insulation, is one approach to thermal management for material suppliers, which also helps to meet the energy density requirements of EV battery packs. Another up-and-coming trend outlined by IDTechEx is immersion cooling, as this method could allow for faster charging and increased safety within batteries due to enhanced thermal performance. This approach would see a number of different potential fluids, which are benchmarked alongside suppliers in the report, “Thermal Management for Electric Vehicles 2026-2036: Materials, Markets, and Technologies“.
Thermal management is required in all areas of a vehicle powertrain, including for the motor, where the magnets need an optimal temperature maintained to ensure efficient operation. One recent trend has been the eradication of the cooling jacket and instead using the method of direct oil cooling, which would also allow for the motor size to be minimized. The two methods can however be used in conjunction also, to increase the efficacy of thermal management, though there was a clear increase in the use of oil as an electric motor thermal management strategy between 2015 and 2024, and a simultaneous reduction in the use of water-glycol.
