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Enhancing the range of battery-electric vehicles (BEV) and plug-in hybrid vehicles (PHEVs) no longer requires costly drivetrains or larger batteries. German automotive technology leader ZF has developed a highly efficient thermal management system called TherMaS, which helps maintain optimal temperatures for the vehicle battery and cabin, significantly reducing energy consumption.
TherMaS is a compact, integrated, and lightweight system that is more efficient and cost-effective than conventional alternatives. It uses propane as a refrigerant, which enhances cooling performance and allows for a more compact system design. According to ZF, this system can increase electric vehicle range by up to 10% during cold weather and up to 30% under extreme conditions.
Dr. Otmar Scharrer, Senior Vice President (R&D) for Electrified Powertrain Technology at ZF, explains, “An EV battery operates best between 15 to 25 degrees Celsius. In extreme temperatures, keeping the battery warm or cool demands high energy, which can nearly halve the available range. An efficient thermal management system is, therefore, beneficial for both manufacturers and drivers.”
TherMaS also includes ZF’s first in-house-developed heat pump technology. It will be available in three performance classes, making it adaptable to a wide range of vehicle types and platforms.
The propane-based heat pump system is supported by two independently controlled water-cooling circuits—one for the electric motor and another for the battery and charging electronics—making the system highly effective. Its compact design allows easier installation, reduced heat/cooling losses, and space savings in the vehicle layout.
ZF has confirmed that TherMaS is now ready for the market, and several leading automotive manufacturers have already shown strong interest. This technology has the potential to redefine energy efficiency, reliability, and range for electric vehicles globally.
