MAHLE HeatX Range+ is a new heat‑recovery system that tackles one of the biggest practical challenges of electric vehicles. Reduced range in winter. In cold climates, heating the cabin can sharply increase energy demand. Often cutting real‑world driving distance by a noticeable margin. With HeatX Range+, MAHLE reduces the air‑conditioning system’s power draw by about 20 percent compared with conventional exhaust‑air systems. Which translates into more kilometers per battery charge and smoother winter usability for drivers.
How HeatX Range+ Works
The system taps into the existing air‑conditioning evaporator to capture heat energy from the cabin exhaust air. When used air is sent outside, it passes through the evaporator and transfers its remaining warmth to the refrigerant inside the loop. This heated refrigerant then joins the normal AC circuit. And delivers the recovered energy back to the incoming fresh‑air stream. As a result, the outside air entering the vehicle is preheated. So the vehicle’s heater does not need to work as hard. In tests at around −7 °C outside temperature with a target interior temperature of 20 °C, MAHLE showed that the device can extend the driving range by nearly 10 kilometers in a mid‑size EV, without compromising driver comfort.
Compared with older, purely resistive heating units, which consume direct electrical power like a space heater, HeatX Range+ functions more like a heat pump plus a smart air‑to‑air recovery loop. That approach is in line with broader industry efforts to limit the impact of HVAC loads on battery capacity and to bring EVs closer to their official range figures under realistic winter conditions.
Higher Range and Better Air Quality
By lowering the energy demand of cabin heating, HeatX Range+ contributes to both longer range and more consistent range estimates in cold weather. This is especially important because many consumers still worry about “range anxiety” when temperatures drop. A 20‑percent reduction in HVAC energy use can significantly change the perceived practicality of an EV. Particularly on short‑ to medium‑distance daily routes where a few extra kilometers matter.
Beyond efficiency, the system also improves interior air quality. Because the recovered heat supports continuous circulation of fresh, oxygen‑rich air, the interior remains well ventilated even in low‑temperature environments. At the same time, the warmer intake air reduces the likelihood of window fogging, which improves visibility and safety. These user‑centric benefits align with MAHLE’s broader strategy of turning thermal‑management innovations into tangible everyday advantages for drivers.
Scalable Design and Compatibility
HeatX Range+ has been engineered with a modular structure. So that OEMs can integrate it into existing vehicle architectures without extensive redesign. Instead of requiring a full‑scoop climate‑control overhaul, the added heat‑recovery unit fits into the current air‑handling assembly and connects to the refrigerant loop used for cooling. This cost‑effective integration helps manufacturers boost winter range across different EV platforms without adding major complexity to production.
The current layout uses the widely adopted refrigerant R1234yf and can be adapted to alternative refrigerants with only minor engineering changes. This flexibility is important as the automotive industry explores low‑global‑warming‑potential options and new global regulations tighten. MAHLE’s focus on adaptability positions HeatX Range+ as a near‑term upgrade path, alongside longer‑term trends such as advanced integrated thermal systems that manage battery, powertrain, and cabin heat in a single loop.
Noise, Airflow, and Brand Heritage
A critical concern with any cabin‑ventilation add‑on is airflow performance and noise. MAHLE emphasizes that HeatX Range+ does not have a negative effect on fan‑flow behavior or the acoustic output of the air‑conditioning system. Which means passengers experience standard‑level quietness and acceptable airflow even in heavy‑snow or high‑humidity conditions. This practical balance between efficiency gains and comfort perception is key to real‑world adoption.
HeatX Range+ also builds on more than three decades of MAHLE experience in thermal systems. The company points to its “Economizer” line from the 1990s as one of the first cabin heat‑recovery concepts for passenger and commercial vehicles, laying the groundwork for today’s recovery‑and‑recirculation strategies. That legacy of innovation underlines MAHLE’s role as a long‑standing supplier capable of evolving traditional HVAC know‑how for the electrified future.
