Advanced Thermal Management in Electric Vehicles
Electric vehicles face critical challenges, including battery range, charging time, and cabin comfort. Optimized thermal management is crucial to overcoming these, especially by leveraging electrical high-voltage technologies. Eberspaecher is expanding its product line with two 800-volt system heating solutions: a coolant heater using thick film technology and an air heater based on PTC technology. These heaters target passenger cabin comfort and battery conditioning, addressing key EV adoption barriers such as cold-weather performance and charging efficiency. The growing number of battery-powered vehicles emphasizes the importance of such innovations in achieving climate-friendly mobility.
Challenges in EV Battery Range, Charging, and Comfort
Despite rising EV sales, users still demand better driving range and comfort, especially in cold climates where heat pumps underperform. Advanced thermal management systems that regulate battery and cabin temperature can stabilize system efficiency and user experience. Eberspaecher’s high-voltage electrical heaters provide fast, reliable heating, crucial for improving battery longevity and reducing charging periods.
Coolant Heater with Thick Film Technology: Compact, Powerful, and Safe
Eberspaecher’s coolant heater presents a high-output, compact heating solution using thick film technology. Its core thick film element is screen-printed onto a metal substrate, enabling up to 12 kW heat output at 800 volts. This heater efficiently conditions EV batteries, extending life and reducing charging times. Designed to work with both 800-volt and 400-volt infrastructure, it ensures compatibility with global charging networks. Safety is paramount, featuring multiple sensors and a secondary shutdown path to monitor and control thermal processes. Suitable for passenger cars and trucks, production is scheduled for 2027, with several automakers already incorporating it.
Multi-Zone Air Heater with PTC Technology: Enhanced Cabin Comfort and Performance
The air heater, integrated within the air conditioning system, supports multi-zone cabin temperature control for up to four zones, customizing comfort for driver and passengers. Utilizing PTC technology, the heater offers a power range of 3-8 kW and supports both 400- and 800-volt architectures. Its self-regulating nature provides safe operation with overheating protection. Adhesive-free construction reduces passenger compartment emissions. This air heater will be introduced to markets in Asia, Europe, and North America starting in 2028.
Modular Design Compatible with 400-Volt Infrastructure
Though many electric vehicles are adopting an 800-volt architecture for performance benefits, compatibility with the widely-used 400-volt charging infrastructure remains essential. Eberspaecher’s heating solutions achieve this by delivering sufficient heat even at the lower voltage, increasing their versatility and appeal to diverse market segments.
Upcoming Market Availability and Manufacturer Adoption
Eberspaecher’s coolant heater production will start in 2027, followed by the air heater’s availability in 2028 across major regions. These technologies have been selected by several automobile manufacturers for series production, highlighting confidence in their efficiency and safety. The company’s innovations promise to improve electric vehicle thermal management, aiding the broader adoption of EVs through enhanced battery health and occupant comfort.
