On November 6, 2025, LION E-Mobility AG announced that its subsidiary, LION Smart Production GmbH, has entered into a partnership with Castrol to develop a next-generation battery module featuring direct cooling for plug-in hybrid and electric vehicle applications. This collaboration combines LION Smart’s patented immersion-cooling architecture with Castrol’s expertise in advanced thermal fluids and battery thermal management.
The new module immerses individual cells in a lightweight, dielectric fluid—Castrol ON EV Thermal Fluid—to enable rapid heat removal and maintain uniform temperature distribution. Its modular design maximizes contact between coolant and cell surfaces while minimizing temperature gradients. In addition, an integrated single-cell fuse mechanism helps contain thermal events and reduce the risk of propagation in the event of an internal short circuit.
According to internal testing, this approach to direct cooling can significantly enhance charging and discharging rates compared to conventional indirect systems. Improved heat dissipation boosts power density, extends battery life, and enhances operational safety. For plug-in hybrids, the technology also supports greater energy recuperation, higher output at lower system cost, and more consistent performance under varying environmental conditions.
Matthias Donner, VP Advanced Mobility and Industrial products at Castrol, commented: “Direct battery cooling is a transformative technology for EV performance and safety, and this collaboration is a significant step towards real-world deployment. Partnering with LION Smart allows us to demonstrate the full potential of Castrol ON EV Thermal Fluids in advanced battery systems. Together, we’re shaping a future where electric vehicles can charge faster and last longer** whilst operating more efficiently, even under extreme conditions.”
Michael Geppert, Head of Engineering at LION Smart, added: “Our battery system architecture is designed to push the boundaries of electrical performance in high-power applications, and Castrol’s direct battery cooling expertise is a perfect match. This partnership reinforces our commitment to delivering next-generation solutions that meet the growing demands of the electric mobility sector.”
This strategic alliance reflects Castrol’s ongoing investment in direct-cooling technologies and underscores LION E-Mobility’s focus on scalable, high-performance energy storage solutions for automotive and stationary applications.
Source: Lion e-Mobility News
