EV Batteries Feel the Heat

Automakers and suppliers invest in thermal systems as fast charging, safety, and hot climates pressure EV performance

7 Apr 2025

As heatwaves sweep across the United States, electric vehicles face a quieter but growing challenge: keeping their batteries from getting too hot. Managing battery temperature is becoming one of the most important issues in EV design.

Battery thermal management systems, once a minor feature, are now central to how EVs perform. As vehicles charge faster, travel longer distances and operate in hotter climates, temperature control is critical for safety, battery life and overall reliability. Overheating can reduce performance, shorten battery lifespan and, in extreme cases, cause fires.

Modine, a thermal systems supplier, is among those adapting. Its new chassis-integrated cooling modules aim to offer strong thermal control without taking up too much space. These designs reflect a broader shift. As batteries move from traditional packs to cell-to-chassis layouts, thermal systems must become more compact, efficient and precise.

The stakes are rising. Research and Markets, a consultancy, valued the global battery thermal management market at $3.7 billion in 2024, and expects strong growth as EV adoption expands. Safety regulations, consumer expectations and fast-charging infrastructure are all adding pressure.

Suppliers and automakers are responding by filing patents on advanced materials and new cooling designs. But such innovation is not without cost. More complex systems raise production expenses and can limit design flexibility. Yet the benefits are clear: greater safety, longer battery life and fewer warranty claims.

For consumers, range and charging speed still matter. But as EVs go mainstream, trust in their ability to withstand heat is becoming just as important. Those who can keep batteries cool may end up leading the market. In the electric age, managing heat could matter more than horsepower.