Immersion cooling in three steps
Every battery makes heat as it charges and discharges. Heat that is not removed wears cells out faster and, in the worst case, can lead to a fire. Immersion cooling solves this at the source.
1. Submerge
Cells and electronics sit fully immersed in a dielectric coolant. With a dielectric strength of at least 60 kV, the fluid cannot carry a spark or cause a short circuit.
2. Absorb
The coolant touches every surface of every cell, so it draws heat away evenly. It is around 1 600 times more thermally efficient than air.
3. Contain
If a single cell fails, the fluid absorbs the heat and floods any void, stopping thermal runaway from spreading. The surrounding cells keep their voltage, and the failed cell can be replaced without special tools.
The coolant is biodegradable, non-toxic and has zero global warming potential. It needs no special handling, works from −60 °C to +200 °C and has a 10-year operating life.
Why our blade cells leave the egg uncooked
The nail penetration test is one of the toughest in the battery industry. A nail is driven through a cell to force an internal short circuit, the same fault that causes thermal runaway in real life.
In the version of the test known as the egg test, an egg is placed on each battery. On a conventional NCM cell the surface temperature rose so fast that the cell exploded and the egg was blown away. On a conventional block cell the egg was charred.
On the blade cell, the surface stayed between 30 and 60 °C. There was no fire and no smoke, and the egg stayed uncooked.
Tested beyond the nail
The blade cell was also crushed, bent, heated in a furnace to 300 °C and overcharged by 260%, without fire or explosion. It was even driven over by a 46-ton truck and came out without leakage, deformation or smoke.
The reason is its chemistry and shape. Lithium iron phosphate stays stable at temperatures above 500 °C and releases no oxygen when it breaks down. The long, thin blade gives a large surface for shedding heat.
Star-Energy patents its immersion-cooled blade battery
In 2024 Star-Energy patented its immersion-cooled blade battery. The design submerges every working component, from the cells to the electronics, in a dielectric coolant inside a single sealed unit.
The patent builds on two foundations. The first is the blade cell, a lithium iron phosphate cell for which Star-Energy holds exclusive distribution rights across Africa and Sub-Saharan Africa. The second is a strategic partnership to integrate liquid immersion cooling across our range.
Why it matters
Conventional batteries rely on air, fans or cold plates to remove heat. Immersion cooling surrounds every cell instead, carrying heat away evenly and stopping a single failing cell from setting off its neighbours.
Together with registered intellectual property covering our designs, the patent is a cornerstone of what makes a Star-Energy system different.