Shell and FAW Trucks have developed and tested a battery pack that uses an immersion-cooling system to better manage battery heat, improve vehicle performance and durability, Shell announced.
The battery pack uses an electrically insulating fluid that surrounds the battery cells, allowing heat to be transferred away from the cells more effectively during operation. Managing battery temperature is particularly important for commercial vehicles, which can place significant demands on their batteries during acceleration, heavy loads and charging.
By keeping the cells at more consistent temperatures, the companies said the technology can improve the truck’s energy efficiency and performance while potentially extending battery life.
Shell and FAW Trucks developed the system as part of their ongoing work regarding hybrid and electrified commercial vehicle technology. Both companies are continuing to validate the battery pack for potential use in future FAW hybrid trucks.
“As commercial vehicles continue to evolve, so do the technologies needed to support them. By working closely with original equipment manufacturers (OEMs) like FAW TRUCKS, we’re developing advanced fluid solutions designed to support evolving vehicle technologies, including electrification powertrains and thermal management systems,” Cara Tredget, vice president of Mobility & Lubricants Technology at Shell, said. “The Shell Starship Hybrid vehicle demonstrates what’s possible when collaboration and innovation come together.”
What the tests showed
Initial vehicle validation showed potential improvements in several areas, including an up to 98% increase in maximum gradability, a 0.8% improvement in vehicle-level energy efficiency and a potential battery life improvement of up to 32%, according to Shell. The results came from testing the battery pack under specific vehicle conditions, including sustained high-power charging and discharging.
The battery pack also underwent industry-standard testing and vehicle evaluations, with the results verified by the China Automotive Technology and Research Center, according to Shell. The company also said the reported data is based on joint testing conducted by Shell and FAW Trucks under specific test conditions, and final performance data will be released after the validation process is completed.
How immersion cooling works
Immersion cooling is designed to remove heat from battery cells by surrounding them with an electrically insulating fluid. Instead of transferring heat through a separate cooling plate or system, the fluid comes into direct contact with the cells, allowing heat to move away from a larger portion of the battery. This can help keep temperatures more consistent across the battery pack, which is important as batteries generate more heat during high-power charging and discharging.
Shell’s system uses this approach on the Starship 3.0 Hybrid. Shell said conventional battery cooling systems primarily cool the battery from the bottom, while its immersion fluid surrounds the cells and is designed to improve heat transfer and maintain more consistent temperatures across the pack.
From concept to commercial use
For commercial trucks, better thermal management could help manufacturers increase power output and charging capabilities without sacrificing battery durability. But the Shell and FAW testing has so far been conducted on a concept vehicle under specific test conditions, rather than across a production fleet.
The battery pack has not been announced as a production system. Shell and FAW Trucks said it is being evaluated for potential use in future FAW hybrid commercial vehicles, while Shell plans to continue developing immersion-cooling fluids for broader commercial vehicle applications.
The technology is part of the Shell Starship program, a technology demonstration platform focused on improving commercial vehicle efficiency and reducing emissions. The Starship 3.0 Hybrid was developed by Shell and FAW Trucks as a platform for testing technologies including hybrid powertrains and battery thermal management under commercial vehicle operating conditions.
FAW Trucks is a majority-owned subsidiary of China FAW Group and is headquartered in Changchun, China. Shell brings its work in lubricants and thermal-management fluids to the partnership, while FAW contributes commercial vehicle engineering and development expertise.
The companies will showcase the latest validation progress and the Shell Starship Hybrid equipped with the immersion-cooled battery pack at the FAW Trucks booth during IAA Transportation 2026 in Hannover, Germany, beginning Sept. 14.
For now, the technology remains in the validation stage. Whether the performance seen in the Starship concept truck can translate into a battery system suitable for production hybrid commercial vehicles remains to be determined.
Why this matters
Battery thermal management is becoming increasingly important as commercial vehicle manufacturers look to improve power, charging capability and battery life. Immersion cooling could give truck manufacturers another way to manage the heat generated by batteries under demanding operating conditions.
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