MAHLE Introduces HeatX Range+ to Cut EV Heating Energy Use and Boost Winter Range

MAHLE Introduces HeatX Range+ to Cut EV Heating Energy Use and Boost Winter Range

(IN BRIEF) MAHLE has developed HeatX Range+, a new heat recovery system that reduces the energy demand for cabin heating in electric vehicles by up to 20 percent, helping to extend driving range in winter conditions while maintaining high interior air quality. By capturing heat from outgoing cabin air and using it to preheat incoming fresh air via the air conditioning evaporator, the system can add nearly 10 kilometres of range in cold-weather testing on a mid-size EV, all while preserving normal airflow and acoustic performance. Designed for easy integration into existing vehicle platforms and compatible with R1234yf and other refrigerants, HeatX Range+ builds on MAHLE’s long history in efficient climate control and supports the broader adoption of electric mobility.

(PRESS RELEASE) STUTTGART, 9-Feb-2026 — /EuropaWire/ — MAHLE has introduced a new heat recovery system designed to make cabin heating in electric vehicles significantly more energy-efficient, directly contributing to longer driving range and improved passenger comfort. The technology, called HeatX Range+, tackles one of the key limitations of battery-electric vehicles in cold weather by reducing the energy required for climate control while maintaining high interior air quality.

Heating the cabin can account for a substantial share of total energy consumption in electric vehicles during winter, often leading to noticeable reductions in range. With HeatX Range+, MAHLE has developed a solution that lowers the energy demand for air conditioning by up to 20 percent compared with conventional exhaust air systems. This efficiency gain translates into more usable range per charge, making electric vehicles more practical in everyday winter conditions.

According to Martin Wellhoeffer, Member of the MAHLE Group Management Board responsible for Thermal and Fluid Systems, the new system strengthens the appeal of electric mobility by addressing real-world usability. He highlighted that the modular design of HeatX Range+ allows vehicle manufacturers to integrate it into existing platforms without major redesigns, keeping implementation both technically and commercially attractive.

Testing carried out on a representative mid-size electric vehicle demonstrated that the system can extend driving range by nearly 10 kilometres under typical winter conditions, with an outside temperature of -7°C and a cabin temperature maintained at 20°C. At the same time, the system ensures a continuous supply of fresh, oxygen-rich air, helping to prevent window fogging and maintaining a comfortable interior environment for occupants.

The core principle behind HeatX Range+ is the intelligent reuse of thermal energy that would otherwise be lost. Instead of simply expelling warm cabin air to the outside, the system routes this exhaust air through the air conditioning evaporator. As the air passes through, it transfers heat to the refrigerant before leaving the vehicle. This captured energy is then used to preheat incoming fresh air before it enters the cabin, reducing the amount of additional heating required.

Importantly, the new heat recovery concept does not negatively affect air flow performance or noise levels in the vehicle’s climate control system. MAHLE’s extensive experience in developing and manufacturing thermal management solutions played a key role in achieving this balance between efficiency and comfort.

Dr. Uli Christian Blessing, Vice President R&D Thermal and Fluid Systems at MAHLE, noted that the company has been working on cabin heat recovery for decades. He pointed to the introduction of the “Economizer” in the 1990s as an early milestone that laid the groundwork for today’s advanced systems. HeatX Range+ builds on this legacy, using refrigerant R1234yf as its standard working fluid while remaining adaptable to alternative refrigerants with only minor modifications.

Overall, MAHLE’s latest innovation reflects the company’s broader commitment to improving the efficiency, sustainability, and everyday usability of electric vehicles through advanced thermal management technologies.

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SOURCE: MAHLE