Research & development highlights

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.

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

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

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.

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.

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.

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.