As the electric vehicle landscape continues to evolve, so does the technology.
BorgWarner developed its advanced High-voltage Coolant Heater (HVCH) technology to meet the demand for fast-acting solutions as the thermal management systems of vehicles increasingly become decoupled from the internal combustion engine, permanently in the case of electric vehicles (EVs) and for longer parts of the drive cycle in hybrid electric vehicles (HEVs).
By offering consistent temperature distribution inside the battery pack and its cells, BorgWarner’s coolant heaters can be used for improving battery energy performance in EVs and HEVs.
In addition it allows comfortable cabin temperatures to be generated in a short time enabling a better driving and passenger experience.
With high thermal power density and fast response time due to their low thermal mass, these heaters also extend pure electric driving range as they use less power from the battery.
“We are excited to offer our innovative heater technology, which solves two problems in a single device . . . Our High-voltage Coolant Heater will help improve battery-operated range by controlling the battery temperature at an optimal level while also increasing passenger comfort through delivering an ideal interior climate,” said Joe Fadool, President and General Manager, BorgWarner Emissions, Thermal and Turbo Systems.
“BorgWarner’s extensive range of advanced battery and cabin heater systems are widely recognized by global OEMs as they improve the efficiency of their cars and help them meet the latest clean mobility trends.”
BorgWarner’s latest High Voltage Coolant Heater features a thick film heating element (TFE).
A compact contour enables flexible sizes and shapes while low thermal mass results in fast response times. The innovative technology not only offers high thermal power density, it also allows for direct temperature sensing.
Different designs of BorgWarner’s High Voltage Coolant Heater are suitable for application with supply voltages between 180 and 800V, offer a power range of between 3 and 10 kW, and are suitable for a broad range of applications.
In addition, an intelligent safety concept prevents the High Voltage Coolant Heater from overheating during high electricity flow.
The system recognizes various situations and can react to each.
The High Voltage Coolant Heater is available in two versions: Single Plate and Dual Plate. Compared to its Single Plate version which is responsible for either the thermal management of the battery or the heating of the cabin, the Dual Plate Heater manages both tasks at the same time.
In addition, it provides up to 80 percent more heat transfer surface as it has two heater plates. Both versions are integrated into a robust aluminum housing that allows for excellent electromagnetic shielding.
As the heat packages within this application are covered by the coolant, the heat power losses are minimized providing higher efficiency and extending the battery-powered driving range.
The devices are protected from overheating, as the system switches off automatically in the event a failure occurring.