By ATN
Summary: MAHLE has developed HeatX Range+, a heat recovery system that significantly reduces the energy demand of cabin heating in electric vehicles, particularly in winter conditions. By recovering heat from cabin exhaust air, the system cuts HVAC energy use by around 20 percent and can extend driving range by nearly 10 km in cold-weather testing. Its modular design allows OEMs to integrate it into existing vehicle architectures with minimal cost and complexity.
Key engineering takeaway: HeatX Range+ uses the air conditioning evaporator to capture thermal energy from exhaust air and transfer it to incoming fresh air via the refrigerant circuit. This preheats cabin air without compromising airflow or acoustic performance, while maintaining high interior air quality and reducing window fogging. The system is compatible with R1234yf and can be adapted to alternative refrigerants with minor changes.
Why it matters: Cabin heating remains a major drain on EV range in winter, directly affecting real-world usability. A relatively simple, cost-effective heat recovery solution offers OEMs a practical way to improve cold-weather range without increasing battery size. This strengthens the everyday appeal of electric vehicles, particularly in colder markets where range anxiety remains a barrier to adoption.
MAHLE develops HeatX Range+
MAHLE has developed an innovative heat recovery system for efficient cabin heating in electric vehicles. Heating has a significant impact on EV range, particularly during winter. MAHLE HeatX Range+ reduces the energy demand for air conditioning in electric vehicles by approximately 20 percent compared to conventional exhaust air systems. As a result, drivers benefit from extended range per battery charge and first-class interior air quality. “Our HeatX Range+ heat recovery concept maximizes the everyday practicality of electric vehicles in winter and makes a decisive contribution to further increasing the attractiveness of electric mobility,” explained Martin Wellhoeffer, Member of the MAHLE Group Management Board, responsible for the business unit Thermal and Fluid Systems. Thanks to its modular design, manufacturers can easily and cost-effectively integrate the new system into existing vehicle architectures.
MAHLE has succeeded in extending driving range by nearly 10 kilometers with an innovative and economical solution – as testing with a typical mid-size electric vehicle at an outside temperature of -7°C and an interior temperature of 20°C demonstrated. At the same time, the continuous supply of oxygen-rich air ensures high interior air quality and minimizes the risk of fogging on vehicle windows.
The new heat recovery system uses the air conditioning evaporator to extract and utilize heat energy from the vehicle cabin’s exhaust air. As the air directed outside passes through the evaporator, it heats the refrigerant while leaving the cabin. The refrigerant then transfers the stored energy to the fresh air intake before it enters the vehicle interior. This efficiently preheats the fresh air and reduces heating power demand at winter temperatures compared to conventional exhaust air systems.
The new heat recovery system has no adverse effect on the air flow performance or acoustic behavior of the vehicle air conditioning system. In implementing this innovative energy recovery technology, MAHLE drew on its extensive experience developing and manufacturing vehicle climate control systems. “As early as the 1990s, MAHLE introduced the ‘Economizer’, the first cabin heat recovery system concept for passenger and commercial vehicles, thereby pioneering today’s trend toward efficient cabin climate control,” said Dr. Uli Christian Blessing, Vice President R&D Thermal and Fluid Systems at MAHLE. The current heat recovery layout is designed for refrigerant R1234yf and can be adapted to all alternative refrigerants with only minor modifications.
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