The electric vehicle (EV) market is growing. From 2020 to 2023, their share of total sales grew from 4% to 18%, and as early numbers roll in, experts estimate that 17 million EVs will be sold in 2024 alone.
With increased adoption, there is also an imperative for innovation.
For example, a limited driving range is a major concern for many potential EV buyers, especially given that EV infrastructure and charging points are still sparser than gas stations.
EV engineers are creating new technologies to overcome challenges like these. Read on to learn why the next big breakthrough may come from new immersion cooling oils.
Suzanne Kingsbury, Director of Quality
Immersion Cooling Oils and the Mission to Increase Driving Range
EV engineers have two main methods to attack the problem of increasing driving range.
One is to improve battery performance. Batteries that charge faster, waste less energy, and hold their charge longer settle buyers’ unease about driving range.
The other is to improve efficiency. Eliminating every aspect of energy waste from the vehicle is important in making sure the battery is optimized for speed and range.
Addressing Efficiency Loss
Although the top cause of efficiency loss, aerodynamic drag, may be hard to ever get rid of in the automotive industry, there are opportunities for significant advancements in energy consolidation.
The second biggest cause of efficiency losses is electrical drive units (EDUs), which make up 24% of total inefficiencies.
- Mechanical energy loss. Part of the problem is the loss of energy from highly viscous lubricants. The fluid drag that occurs in EDUs is a problem for vehicles with internal combustion engines and EVs alike.
- Heat-influenced energy loss. The other major source of inefficiency is in the resources it takes to control heat generated by batteries and electrical components in the EDU.
Energy loss from battery-generated heat is one issue that immersion cooling can address. Dielectric fluids present a more efficient alternative to air cooling.
But new EDU configurations that combine electrical and mechanical components present the need for fluids that not only insulate but have excellent lubrication properties as well.
New EDU Configurations and Immersion Cooling Oil Needs
Pioneering engineers face a sort of catch-22. In their efforts to develop drivelines that are better at harnessing mechanical energy to travel further per kilowatt hour, they are trying to make them smaller to save weight and space.
The Challenge of EDU Compression
But these efforts are also increasing power density and raising temperatures within the EDU, creating an increased need for immersion cooling (in addition to battery cooling). Heat management lowers efficiency, undercutting the gains achieved by shrinking the unit.
EDU compression involves housing the components together in various configurations. Gearboxes, electric motors, and electrical converters are stored together in different two-in-one and even three-in-one combinations.
Checking All the Boxes with Immersion Cooling and Lubrication
Each component requires a unique set of properties to ensure consistent performance. Cooling properties have to be balanced with lubrication needs to achieve optimal performance and longevity.
For example, low viscosity lubricants will be crucial to reduce mechanical loss, but immersion cooling oils must also effectively transfer out heat generated from electronics and mechanical friction with corrosion protection, a low pour point, and other key characteristics.
As engineers continue to opimize EDUs, they will need specialty oils engineered with all these characteristics combined — with attention given to the precise application.
“Electric drive fluids are not off-the-shelf products, and rather bespoke fluids must be developed for each unique design.” — Troy Muransky, Lead Organic Materials Engineer, American Axle & Manufacturing
That’s a tall order, but a capable partner with experience in specialty oil innovation like Renkert Oil can help.
Immersion Cooling Oils from Renkert Oil: Your Partner in Innovation
At Renkert Oil, we specialize in helping businesses achieve their goals, including entering new markets and supporting innovation in emerging markets, such as EVs.
- Oil Solutions Consultants. With four decades of experience, our team has the consultative expertise to determine whether existing products will meet your needs or help you develop new solutions.
- Extensive Product Selection. Our extensive selection of specialty oils meets a wide variety of industry needs. For example, our Shell GTL Isoparaffins are suitable for some immersion cooling applications because of their very low viscosity, low volatility and excellent thermodynamic properties.
- Commitment to Sustainability. Also, as an Ecovadis bronze medal recipient, our sustainable practices and products make us an excellent vendor partner for green companies and industries such as EVs.
- Excellence in Supply Security. Deep inventories on select products, redundant supply points, and an extensive logistics network across the U.S. and Europe allow us to work around supply chain disruptions and keep you consistently supplied.
To learn more about making Renkert Oil your partner in solving your specialty oil challenges, contact us today.