Thermal Management Innovations for Electrification at CES 2025

Thermal management isn’t just a buzzword; it’s the backbone of efficient e-mobility. At CES 2025, MAHLE is putting this critical technology front and center. Located at Booth 5652, MAHLE is showcasing a suite of innovations designed to optimize the performance and sustainability of electric vehicles. From bionic-inspired cooling solutions to wireless charging advancements, MAHLE is demonstrating how thermal management drives the evolution of electrification.

Efficiency in Motion: The Heart of MAHLE’s Strategy

Thermal management and electrification are at the core of MAHLE’s mission. According to Peter Lynch, Vice President of Sales & Application Engineering and President of MAHLE North America, “Electrification and thermal management are two major strategy fields for MAHLE, as we continue to position ourselves as a systems expertise champion in e-mobility.”

Efficient thermal management is essential for the success of electric mobility. At CES 2025, MAHLE is presenting cutting-edge solutions that demonstrate their commitment to pushing boundaries:

• A new technology kit for electric motors
• A bionic battery cooling plate
• A high-performance bionic fan
• A groundbreaking wireless charging positioning system

Let’s dive into the details of these innovations.

The “Perfect Motor”: Combining Power and Precision

MAHLE’s new technology kit for electric motors is a game-changer. By combining their Superior Continuous Torque (SCT) and Contactless Transmitter (MCT) motor technologies, they’ve created an electric motor that delivers:

• Permanently high peak power
• Wear-free, contactless power transmission
• Rare-earth-free construction
• Maximum efficiency

This motor is designed to meet the demands of next-generation electric vehicles, offering both performance and sustainability.

Wireless Charging: Aligning for a Seamless Future

One of MAHLE’s standout innovations is its wireless charging positioning system. This technology allows electric vehicles to align effortlessly over a charging coil embedded in the ground. Recognized by SAE International as the global standard for wireless charging, this system eliminates the hassle of cables and ensures precise alignment every time. The result? A more convenient and reliable way to charge electric and hybrid vehicles.

Nature-Inspired Designs for Quieter and More Efficient Vehicles

MAHLE’s engineers have turned to nature for inspiration in two of their most innovative thermal products: the bionic fan and the bionic cooling plate.

• The Bionic Fan: Taking cues from the wings of an owl, one of nature’s quietest creatures, the bionic fan reduces noise by up to 4 dB(A). That’s more than a 50% reduction in sound output, making it ideal for demanding fuel cell and battery electric vehicles. The fan also boasts:
  • 10% reduction in power consumption
  • 10% lighter design
• The Bionic Cooling Plate: Designed to extend battery life and enhance performance, this cooling plate improves cooling efficiency by 10% while reducing pressure loss by 20%. By keeping lithium-ion batteries within an optimal temperature range, it supports faster charging and longer cruising ranges.

Next-Generation Thermal Management

In addition to their bionic designs, MAHLE is unveiling advanced thermal management technologies:

• Refrigerant Thermal Management Module: A plug-and-play solution for vehicle installation, compatible with PFAS-free R290 refrigerant. This module enables megawatt-level battery charging while maintaining precise temperature control.
• MAHLE e-Compressor: Compact and efficient, this e-compressor reduces charging time and extends battery range, ensuring optimal performance in electric vehicles.

The Big Picture: Efficiency Meets Innovation

MAHLE’s showcase at CES 2025 highlights their commitment to advancing e-mobility through innovative engineering. From wireless charging to nature-inspired thermal solutions, they are addressing critical challenges in the electric vehicle industry. With their strategic focus on efficiency and sustainability, MAHLE is setting a high bar for the future of electrification.

Visit MAHLE at Booth 5652 during CES 2025 (January 7-10) to experience these innovations firsthand. As the industry moves toward a more electrified future, MAHLE is leading the charge with efficiency in motion.