MAHLE International GmbH

Novel designs and configurations for heat exchangers that improve heat transfer efficiency, compactness, or enable specific phase change or separation processes within refrigeration and heat pump cycles.

Utilization of heat pump cycles, often with natural refrigerants, for efficient heating and cooling of the vehicle cabin and/or thermal conditioning of high-voltage components like battery modules.

Systems designed to manage the temperature of multiple components in electric or hybrid vehicles, such as batteries, electric motors, power electronics, and the passenger cabin, often using shared or interconnected cooling/heating circuits.

Development of novel motor architectures beyond traditional radial flux designs, including linear, axial, or multi-armature configurations, often to optimize for specific performance characteristics like torque density or form factor.

Methods and components for optimizing the performance, efficiency, and control of electric motors, inverters, and power converters within electric vehicle and hybrid vehicle drivetrains.

Technologies for efficiently delivering power to electric vehicles, encompassing fast charging, wireless charging, and smart grid integration, alongside vehicle-side control and management of the charging process.

Systems and methods for transferring electrical energy without physical contact, often utilizing inductive or resonant coupling, including antenna design, resonance tracking, and control mechanisms for efficient power delivery.

Specific heat exchanger designs and auxiliary components tailored for integration into refrigeration, air conditioning, or heat pump systems, often involving gas-liquid separation or rotary mechanisms.

Design and optimization of fin structures, baffles, and surface textures within heat exchangers to increase heat transfer area, promote turbulence, or manage fluid flow for improved thermal performance.

Techniques and mechanisms to optimize the performance, energy consumption, and operational range of compressors in refrigeration and heat pump systems, often involving variable control of compression parameters like volume ratio or speed.

Advanced systems for maintaining passenger comfort and air quality within the vehicle cabin, including features like condensation prevention, remote control, after-blow functions, and air purification.

Manufacturing processes and techniques for producing stator cores, windings, and coils, including lamination, impregnation, hairpin winding, and segment coil bending, to improve motor efficiency, power density, or reliability.

Design and control strategies for improving the efficiency, stability, and operational flexibility of refrigerant circuits, including component integration, flow management, phase separation, and pressure regulation.

Pumps and blowers specifically adapted or designed for unique fluid types, challenging environments, or particular industrial, medical, or consumer applications, often involving debris, specific gas mixtures, or precise delivery requirements.

Engineering and diagnostic aspects of individual heating, ventilation, and air conditioning components, such as PTC heaters, air ducts, flow control valves, and compressor monitoring.

Innovations in the design, materials, and maintenance of seals, valves, and related components to improve durability, reduce leakage, and enable specific pump functions like high-pressure operation or automated seal replacement.

Heat transfer devices that utilize the phase change of a working fluid (evaporation and condensation) to efficiently move heat, often incorporating capillary structures, heat pipes, or vapor chambers.

Methods and components for converting power into mechanical motion to drive pump mechanisms, encompassing electric motors, hydraulic actuators, and specialized motion converters like ball screws or solenoids.

Focuses on the structural integrity, housing, mounting, and physical integration of battery cells into robust and protected packs within electric vehicles, including manufacturing considerations.

Techniques for designing and manufacturing compact, multi-functional magnetic components, such as inductors, transformers, and coils, often involving embedded structures, multilayer designs, or shared magnetic circuits to achieve higher power density or smaller form factors.

Focuses on optimizing the geometry, structure, and internal flow channels of impellers, blades, and housings to improve fluid dynamics, efficiency, or specific performance characteristics of centrifugal pumps and fans.

Membrane and depth filtration for industrial separation, gas purification, and bioprocess clarification including cross-flow, dead-end, tangential flow filtration, and oil/water separation.

Software, algorithms, and associated hardware for monitoring, controlling, and optimizing battery performance, safety, and lifespan, including charge/discharge cycles, thermal regulation, and system integration.

Systems and methods for monitoring, regulating, and diagnosing the performance and health of pumps and fans, including speed control, flow rate management, abnormality detection, and safety mechanisms like overspeed safeguards.

Specialized refrigeration systems for temperature-sensitive cargo in vehicles or containers, focusing on power management, energy storage (e.g., swappable batteries), and environmental sensing for cargo preservation.

Design and assembly of power conversion, distribution, and protection modules, focusing on compact form factors, efficient electrical connections, and robust protective measures for electronic systems, often in high-power applications.

Systems and devices that utilize controlled magnetic fields, often generated by electromagnets, to produce mechanical motion, precise positioning, or manipulate physical phenomena like plasma distribution.

Methods and structures for integrating and enclosing electronic components into compact, multi-functional modules, often involving embedded components, multi-layer substrates, and electromagnetic shielding for performance and miniaturization.

Integration of electric motors into larger systems (e.g., vehicles, power tools) and safety features for high-voltage components, including control interfaces, mechanical integration, and environmental protection (e.g., waterproofing).

Technologies and systems for removing unwanted components or separating desired gases from a mixed gas stream, including adsorption, absorption, and membrane-based methods.

Processes and apparatus for disassembling spent batteries and recovering valuable materials (e.g., metals, electrolytes, plastics) through mechanical, chemical, or electrochemical methods for reuse or sustainable disposal.

Integration of power converters with energy storage devices (batteries, supercapacitors) or grid interfaces, often involving AC/DC conversion, power flow management, and fault handling for hybrid power systems or specific applications like EVs or PV.

Non-traditional refrigeration and heat pump systems that utilize principles other than vapor compression, such as magnetocaloric effects, thermoelectric effects, absorption cycles, or thermochemical reactions.

Methods and materials used to construct robust and protective enclosures for electronic devices, focusing on structural integrity, impact resistance, thermal dissipation, and specialized material properties for enhanced durability.

Process and equipment for producing solid-state battery cells, including solid electrolyte synthesis (sulfide/oxide/polymer), thin-film deposition, lamination, sintering, dry-electrode fabrication, and stacking under controlled atmosphere.

Development of materials with tailored porosity, surface chemistry, or structure, such as metal-organic frameworks (MOFs), zeolites, or superficially porous particles, for selective adsorption, ion exchange, or chromatographic separations.

Systems and methods specifically engineered for removing pollutants and impurities from water sources, ranging from groundwater decontamination to point-of-use filtration, often employing adsorption, membrane, or distillation techniques.

Slurry compositions and coating processes for battery electrodes, including binder/active-material slurries, surface coating layers, and electrode-to-foil adhesion for cathode and anode.

Systems and components designed to store thermal energy, often using sensible, latent (phase change material), or thermochemical reactions, for later release and utilization in various applications.

Equipment and processes for separating solid particles from liquid or gas phases in industrial settings, encompassing mechanical screening, filtration of molten materials, and various filter media designs.