Innovation - the engine of success

Our core themes rest upon a solid bedrock of perennial factors that have shaped our company since it was founded: a relentless quest to respond to new challenges, the, and, above all, a love for the automobile and its technology. These factors drive us to find even better solutions that continuously take our customers to the next level while continually exciting and inspiring them.

Battery concept for 90-second charging

Battery concept for 90-second charging

One highlight is a new lithium-carbon battery concept developed by MAHLE Powertrain, the Group’s engineering division. It is designed to enable ultrafast charging of lightweight two-wheeled and small vehicles in under 90 seconds for applications such as urban distribution transport. The concept is particularly sustainable because it does not require rare raw materials and is fully recyclable.

The heart of the Air Conditioning System: the Electric Air Conditioning Compressor

The heart of the Air Conditioning System: the Electric Air Conditioning Compressor

The Air Conditioning Compressor delivers the output needed to cool the battery, making it fundamental to a long service life for the air conditioning system as a whole. As the only manufacturer offering ultrapowerful 800 V compressors, MAHLE is paving the way for fast charging and full-load operation of heavy-duty, electrified commercial vehicles.

Magnet-free traction motor

Magnet-free traction motor

This new traction motor for electric vehicles with 140 kW power is wear-free, particularly efficient and requires no rare earths.

Immersion-cooled battery module

Immersion-cooled battery module

By immersing battery cells directly into a dielectric fluid, we prevent overheating during fast charging and ensure uniform temperature distribution.

Intelligent air conditioning

Intelligent air conditioning

MAHLE makes the air conditioning system intelligent by moving the sensors directly into the HVAC. There, in the middle of the main air flow, they allow the system to be regulated in real time. Combined with the right MAHLE filter media, this approach reliably keeps harmful influences away from the interior.

Modular air filters for fuel cells

Modular air filters for fuel cells

Fuel cells need clean air. Modular air filters from MAHLE are available off-the-shelf. They reliably keep ammonia and harmful gases away from the cell, enabling an economical use of catalysts and protecting the cell from damages.

Systemically integrated: the Cooling Module

Systemically integrated: the Cooling Module

Cooling Modules protect batteries and power electronics by releasing much of the heat built up in the system into the environment. Depending on the cooling strategy, the modules could include additional radiators. For over 100 years, MAHLE has been playing a crucial role in advancing development, from simple coolers to complex thermal management

Modular bodyguard for the battery: the High-Voltage Heater

Modular bodyguard for the battery: the High-Voltage Heater

During the cold season, the High-Voltage Heater actively raises the coolant temperature and ensures the optimal working temperature and a long service life for the lithium-ion battery. The battery can only function optimally within a narrow temperature range of approx. 10 °C to 40 °C. Only a small amount of waste heat is generated in vehicles with a battery electric drive. While this does increase efficiency and cruising range, it also poses a challenge during the winter months. An additional High-Voltage Heater with an output of up to 8 kW ensures a comfortable cabin temperature by heating the coolant.

Complex system for efficiency and comfort: the Air Conditioning System

Complex system for efficiency and comfort: the Air Conditioning System

MAHLE’s highly efficient Air Conditioning System ensures the cabin is perfectly climate-controlled while minimizing energy consumption. Working in a pleasant temperature, drivers can focus better and safely navigate the traffic. In addition, the CareMetix® Cabin Filter keeps the cabin free of fine particulates and pollutants, thus protecting the driver’s health.

Interface between the systems: the Chiller

Interface between the systems: the Chiller

MAHLE’s Chiller is designed to keep the lithium-ion battery optimally cooled, even at high outside temperatures. This is essential, as the lithium-ion battery is temperature-sensitive and must be kept below 40 °C at all times. This cannot be achieved using coolant alone, especially during the summer months. Therefore, the Air Conditioning System’s refrigerant circuit takes on this important task. In the Chiller, heat is transferred from the battery cooling circuit to the refrigerant circuit to produce the desired effect.

Protecting the power electronics: the Electronics Cooling Plate

Protecting the power electronics: the Electronics Cooling Plate

MAHLE’s many years of development experience in lithium-ion battery cooling is incorporated into its Electronics Cooling Plate Design. In addition to the electric powertrain, other electronic components such as the inverter also have to be cooled. These are protected against overheating by the Electronics Cooling Plates and coolant circuit.

Energy-efficient and powerful: the 24 V Coolant Pump

Energy-efficient and powerful: the 24 V Coolant Pump

The 24 V Coolant Pump drives the coolant circuits. A pumping performance of up to 700 W can be delivered if required. In other words, the pump only ever runs as quickly as the conditions necessitate in order to save electrical energy. In MAHLE Coolant Pumps, the coolant also actively cools the pump drive, thereby reducing wear and tear and extending their service life.

Highly integrated systems competence: the Oil Management Module

Highly integrated systems competence: the Oil Management Module

The traction motor is a “powerhouse” that has to be protected against overheating. MAHLE’s integrated and compact Oil Management Module cools the motor, with a Heat Exchanger transferring the heat from the oil to the coolant circuit. The Oil Pump needed for this is already integrated into the module.

Humidifier for fuel cells

Humidifier for fuel cells

Fuel cells need pre-moistened air. The MAHLE humidifier removes the water from the exhaust air line and feeds it into the supply air in a cross flow. This ensures a long life of the cell through optimal humidification.

Battery cooling plate

Battery cooling plate

Vehicle electrification poses new challenges for thermal management. A temperature below 40 degrees Celsius is needed in order to cool the lithium-ion batteries in hybrid and electric vehicles.

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