US EV Battery Cooling Market - Strategic Insights and Forecasts (2025-2030)

Description

US EV Battery Cooling Market is anticipated to expand at a high CAGR over the forecast period.

US EV Battery Cooling Market Key Highlights

• The increasing adoption of high-energy-density lithium-ion batteries directly elevates demand for sophisticated cooling solutions to manage heightened thermal loads, particularly during rapid charging.
• Government safety initiatives and regulations from agencies like the National Highway Traffic Safety Administration (NHTSA) mandate improved battery safety, driving demand for advanced thermal management systems that mitigate the risk of thermal runaway.
• The rise of Battery Electric Vehicles (BEVs) as the dominant vehicle type amplifies the demand for high-performance liquid cooling systems due to the large, energy-dense battery packs these vehicles utilize.
• Automakers and suppliers are increasingly investing in and launching new liquid-based cooling technologies, including immersive and two-phase systems, to meet the performance and safety requirements of next-generation EVs.

The US market for EV battery cooling systems is expanding, driven by fundamental shifts in both vehicle technology and consumer expectations. As electric vehicles transition from a niche segment to a mainstream automotive category, the performance and longevity of their battery systems become paramount. This imperative directly translates to a heightened focus on thermal management. The industry is responding with a move toward more complex and efficient cooling solutions, moving beyond basic air cooling to advanced liquid and dielectric systems. These developments are integral to enabling the increased range, faster charging, and extended battery life that consumers now demand, simultaneously addressing critical safety concerns. The evolving landscape of battery chemistry and vehicle applications necessitates a continuous evolution of cooling technologies.

US EV Battery Cooling Market Analysis

• Growth Drivers

The primary catalyst for market growth is the technological evolution of EV batteries themselves. As manufacturers strive to increase driving range and reduce charging times, they utilize higher-energy-density lithium-ion chemistries. These batteries, particularly those in the 4680 format, generate significant heat during operation and especially during fast-charging cycles. Efficiently dissipating this heat is an engineering imperative to prevent performance degradation and thermal runaway. Consequently, the need for high-performance liquid cooling systems, which offer superior heat transfer capabilities compared to air cooling, has surged. This trend is further fueled by consumer demand for faster charging, which places extreme thermal stress on battery packs, necessitating robust thermal management. The Department of Energy’s Vehicle Technologies Office sets goals to reduce charge time to 15 minutes or less, a target that cannot be met without advanced cooling solutions.

• Challenges and Opportunities

A significant challenge facing the market is the technical complexity and high initial cost of integrating advanced thermal management systems into vehicle architectures. The integration of complex fluid circuits, pumps, and heat exchangers adds weight and engineering overhead. This can act as a constraint on adoption in more budget-conscious vehicle segments. However, this challenge presents a clear opportunity for innovation. The industry can develop modular, lightweight, and cost-effective cooling systems that are easier to integrate. The push for next-generation battery technologies, such as solid-state batteries, also introduces new thermal challenges, creating a long-term opportunity for new cooling solutions.

• Raw Material and Pricing Analysis

The US EV battery cooling market is a physical product market, with systems composed of coolants, heat exchangers, pumps, and piping. Coolants are typically ethylene glycol-based or mineral-oil-based dielectric fluids. The pricing of these materials is subject to fluctuations in the broader chemical and oil markets. The supply chain for these raw materials is largely global, and their costs are influenced by commodity price volatility. As demand for specialized, non-conductive dielectric fluids rises, pricing may become more competitive, though their superior performance justifies a higher cost.

• Supply Chain Analysis

The global EV battery cooling supply chain is complex and involves multiple tiers of suppliers. It originates with chemical companies that produce the base coolants and plastic manufacturers that provide the components for coolant channels and casings. These are supplied to Tier-2 and Tier-1 automotive component manufacturers, such as Valeo and Hanon Systems, who engineer and assemble the complete cooling systems. The finished systems are then delivered to automotive OEMs for integration into the EV assembly line. Major production hubs are located in Asia and Europe, creating logistical dependencies that can be susceptible to global supply chain disruptions. The US is increasing its domestic manufacturing capacity for EV components, which may alleviate some of these dependencies over time.

Government Regulations

In-Depth Segment Analysis

• By Vehicle Type: Battery Electric Vehicles (BEVs)

The BEV segment is the primary growth driver for the US EV battery cooling market. Unlike Hybrid Electric Vehicles (HEVs) or Plug-in Hybrid Electric Vehicles (PHEVs), BEVs rely exclusively on a large, high-capacity battery pack for propulsion. These larger battery packs generate significantly more heat during both driving and DC fast-charging. The imperative for long-range travel requires larger, more energy-dense batteries, which inherently require more robust and efficient thermal management. Consequently, the BEV segment exhibits a strong and growing demand for advanced liquid cooling systems, as air cooling is insufficient for the thermal load of modern BEV battery packs. This segment’s growth is also being propelled by the proliferation of electric trucks and SUVs, which feature even larger battery capacities and place greater thermal demands on cooling systems than passenger sedans.

• By Cooling Type: Liquid Cooling

Liquid cooling has become the dominant technology in the US market, a direct result of the increasing performance requirements of modern EV batteries. Liquid coolants possess a higher heat capacity and thermal conductivity than air, enabling them to absorb and transfer heat far more efficiently. This capability is critical for maintaining a uniform temperature across the battery pack, which is essential for maximizing battery lifespan and performance. The liquid cooling segment is bifurcated into indirect and direct (or immersion) cooling. While indirect systems with cooling plates are the industry standard, the emergence of high-power-density batteries is propelling interest and investment in direct immersion cooling, where battery cells are submerged in a non-conductive dielectric fluid. This technology promises even greater thermal control and is becoming a key area of research and development.

Geographical Analysis

• US Market Analysis

The US market for EV battery cooling is concentrated in states with high EV adoption and strong manufacturing bases. California holds a commanding position, with the largest number of registered EVs nationwide, creating a massive installed base for service and aftermarket demand. The state's strong ZEV regulations and consumer-centric policies propel this growth. Other states like Texas and Florida, while having fewer total registrations, are experiencing rapid growth in EV sales. The growing domestic battery manufacturing capacity in states like Kansas and Nevada further solidifies the US as a key market for cooling system suppliers.

Competitive Environment and Analysis

The US EV battery cooling market is defined by a mix of specialized thermal management companies and major automotive component suppliers. The competitive landscape is intensely focused on innovation, particularly in liquid cooling and new materials. Companies differentiate through product performance, system integration capabilities, and supply chain resilience.

• Valeo

Valeo is a major Tier-1 automotive supplier with a strong presence in thermal systems. The company offers a range of EV battery cooling solutions, including its Immersive EV Battery Cooling System, which utilizes a dielectric coolant. This product’s strategic positioning focuses on high-performance EVs, where its ability to mitigate thermal runaway and optimize battery life is a key selling point.

• Hanon Systems

Hanon Systems is a global supplier of automotive thermal and energy management solutions. The company's portfolio includes a variety of heat exchangers, fluid transport components, and integrated thermal systems for EVs. Their strategic focus is on providing comprehensive, end-to-end solutions to automakers, leveraging their long-standing relationships with global OEMs to secure new contracts for EV platforms.

Recent Market Developments

• September 2025: Shell Lubricants announced a new EV thermal management fluid, Shell EV-Plus Thermal Fluids. This product is a high-performance, electrically non-conductive liquid designed for immersion cooling systems. The company claims it can significantly reduce EV charging times, enabling sub-10-minute charging by efficiently managing the high heat generated during rapid charging. The fluid improves thermal stability, safety, and battery lifespan by ensuring direct contact with battery cells and consistent temperature control across the pack.
• August 2025: A study published by scientists from Chungbuk National University showcased an innovative cooling system for Tesla batteries. The system, combining heat pipes and two-phase immersion cooling, removes heat efficiently without active elements like pumps, relying instead on the natural circulation of a cooling liquid.

US EV Battery Cooling Market Segmentation

BY COOLING TYPE

• Air Cooling
• Liquid Cooling
• Fan Cooling

BY BATTERY TYPE

• Lead Acid
• Lithium Ion
• Others

BY VEHICLE TYPE

• Battery Electric Vehicles
• Hybrid Electric Vehicles
• Plug-In Hybrid Electric Vehicle

Table Of Contents

1. EXECUTIVE SUMMARY 

2. MARKET SNAPSHOT

2.1. Market Overview

2.2. Market Definition

2.3. Scope of the Study

2.4. Market Segmentation

3. BUSINESS LANDSCAPE 

3.1. Market Drivers

3.2. Market Restraints

3.3. Market Opportunities 

3.4. Porter’s Five Forces Analysis

3.5. Industry Value Chain Analysis

3.6. Policies and Regulations 

3.7. Strategic Recommendations 

4. TECHNOLOGICAL OUTLOOK 

5. UNITED STATES EV BATTERY COOLING MARKET BY COOLING TYPE  

5.1. Introduction

5.2. Air Cooling

5.3. Liquid Cooling

5.4. Fan Cooling

6. UNITED STATES EV BATTERY COOLING MARKET BY BATTERY TYPE  

6.1. Introduction

6.2. Lead Acid

6.3. Lithium Ion

6.4. Others

7. UNITED STATES EV BATTERY COOLING MARKET BY VEHICLE TYPE  

7.1. Introduction

7.2. Battery Electric Vehicles

7.3. Hybrid Electric Vehicles

7.4. Plug-In Hybrid Electric Vehicle

8. COMPETITIVE ENVIRONMENT AND ANALYSIS

8.1. Major Players and Strategy Analysis

8.2. Market Share Analysis

8.3. Mergers, Acquisitions, Agreements, and Collaborations

8.4. Competitive Dashboard

9. COMPANY PROFILES

9.1. Gentherm Inc.

9.2. Dana Limited 

9.3. BorgWarner Inc.

9.4. Modine Manufacturing Company 

9.5. 3M 

9.6. Boyd 

9.7. Grayson Thermal Systems 

9.8. RIGID Technology  

9.9. Valeo 

9.10. Dober 

9.11. Onegene USA 

10. APPENDIX

10.1. Currency 

10.2. Assumptions

10.3. Base and Forecast Years Timeline

10.4. Key benefits for the stakeholders

10.5. Research Methodology 

10.6. Abbreviations 

LIST OF FIGURES

LIST OF TABLES

Companies Profiled

Gentherm Inc.
Dana Limited
BorgWarner Inc.
Modine Manufacturing Company
3M
Boyd
Grayson Thermal Systems
RIGID Technology
Valeo
Dober
Onegene USA

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