High-voltage coolant heater increases range of HEVs and BEVs

September 12, 2018 // By Christoph Hammerschmidt
Vehicles with hybrid (HEVs) and battery electric drive (BEVs) are becoming increasingly popular. For this reason, BorgWarner presents an innovative high-voltage coolant booster heater as part of its battery and cabin heater families. The technology optimizes battery performance by maintaining the operating temperature of the battery in the optimum temperature window and ensuring even temperature distribution within the battery pack and its cells.

Due to its low thermal mass, the coolant heater has a high thermal power density with short response times. As a result, the technology draws less power from the battery than from comparable systems, resulting in an increase in range for purely electric driving. In addition, the technology generates comfortable vehicle interior temperatures within a very short time.

The new high-voltage coolant booster heater contains a long-life thick film heating element (TFE). A compact contour allows flexible sizes and shapes, while a low thermal mass results in short response times. The innovative technology not only offers high thermal power density, but also enables direct temperature measurement. The different versions of the heater are suitable for applications with voltages between 180 and 800V. In addition, they offer a power range between 3 and 10 kW and are therefore suitable for a wide range of applications. A safety concept prevents overheating of the auxiliary heater at high power output. The system detects different operating states and can react accordingly.

The high-voltage auxiliary coolant heater is available in two versions: Single Plate and Dual Plate. In contrast to the Single Plate version, which is responsible either for heat management of the battery or for heating the vehicle interior, the Dual Plate version performs both tasks simultaneously. In addition, it offers up to 80 percent more heat transfer surface as it has two heating plates. Both variants are integrated in a robust aluminium housing, which provides optimum electromagnetic shielding. Since the heating packages are covered with coolant, only minimal heat loss is generated, which ensures higher efficiency and increases the battery-powered range.

More information at www.borgwarner.com


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