JSW Introduces Dual-Plate Battery Cooling Technology for Heavy EVs

Key highlights

• Dual-plate liquid cooling for heavy EV batteries.

• Cooling plates placed above and below LFP cells.

• Designed to reduce battery thermal gradients.

• 0.4 mm PTED coating protects welded chassis areas.

• Focus on durability under heat, heavy loads and harsh roads.

JSW Group is developing a new dual-plate liquid cooling architecture for heavy electric commercial vehicles (EVs), aimed at reducing battery temperature differences, improving performance and slowing battery degradation under demanding operating conditions.

Why JSW Is Moving Beyond Single-Plate Cooling

Most commercial EV battery packs in India use LFP (Lithium Iron Phosphate) cells with a single cooling plate positioned below the battery module. However, high Indian ambient temperatures combined with sustained heavy payloads can create a significant temperature gap between the top and bottom of individual battery cells.

Sumit Mittal, Chief Executive Officer of JSW Greentech, explained that bottom-only cooling can cause a thermal lag, as one side of the cell receives direct cooling while the other side takes longer to cool. This temperature difference can reduce battery life and affect overall battery performance.

How JSW’s Dual-Plate Cooling System Works

JSW’s ground-up EV platform places active liquid cooling plates on both the top and bottom of the LFP cells. The cells are effectively sandwiched between two cooling surfaces, allowing heat to be managed more evenly across the battery.

The company says this architecture is designed to eliminate thermal gradients within the cells and maintain more stable operating temperatures. This can be particularly important during heavy acceleration and uphill haulage, when electric commercial vehicles experience high loads and greater thermal stress.

By reducing the temperature differential between the two sides of the cells, the dual-surface cooling architecture is intended to help prevent rapid battery degradation while supporting consistent battery performance.

JSW Adds PTED Coating for Better Chassis Protection

JSW is also focusing on chassis durability for heavy commercial EVs operating on Indian roads. Conventional commercial vehicle frames often use spray-painted primers, which can leave welded joints vulnerable to oxidation and corrosion.

Following frame welding, JSW applies Pre-Treatment Electro-Deposition (PTED), which deposits a uniform 0.4 mm electro-plated layer across the entire chassis assembly. The coating seals high-energy welded areas against moisture, helping prevent structural rust.

According to JSW, the approach also helps eliminate the frame noise commonly associated with older commercial vehicle fleets, adding another layer of durability for vehicles exposed to harsh road conditions and severe overloading.

Also Read: JSW Greentech Enters Electric Commercial Vehicle Segment with AMPSTAR

CMV360 Says

JSW’s dual-plate liquid cooling system addresses a key challenge in heavy electric commercial vehicles by cooling LFP cells from both sides. The company is also strengthening chassis durability through PTED coating. Together, these technologies focus on battery life, consistent performance, corrosion protection and long-term reliability under India’s demanding commercial vehicle operating conditions.