Mahle HeatX Range+ Boosts EV Driving Range by 20% in Winter Conditions

On February 10, Mahle GmbH announced the development of Mahle HeatX Range+, a next-generation cabin heating solution engineered to improve EV driving range during winter. The company stated that the system can lower the electrical energy required for cabin air conditioning by up to 20%, directly contributing to extended range on a single charge in cold climates. By optimizing how thermal energy is reused inside the vehicle, the innovation addresses one of the most persistent challenges affecting electric vehicle winter performance.

Mahle HeatX Range+ Enhances EV Driving Range in Cold Weather

Mahle HeatX Range+ is designed to recover thermal energy from the cabin’s exhaust air and reuse it to warm incoming outside air. This intelligent heat recovery approach reduces the load on the battery electric vehicle’s heating system, thereby preserving stored energy for propulsion. In winter conditions, where EV efficiency typically declines due to higher heating demands, this thermal management system plays a critical role in stabilizing performance and improving overall range.

How the Refrigerant Preheating Technology Works

The system utilizes refrigerant preheating technology to transfer heat from the outgoing cabin air to the fresh air entering the vehicle. Before the air is reintroduced into the cabin, it is preheated using the captured thermal energy, minimizing the need for additional electrical heating. This process ensures a steady supply of fresh air while maintaining cabin comfort and optimizing electric vehicle winter performance without increasing power consumption.

Test Validation and Performance Benefits

Mahle confirmed that the extended EV driving range was validated through tests conducted on a mid-size battery electric vehicle. According to the company, the system demonstrated measurable improvements in efficiency under cold-weather conditions. Importantly, Mahle HeatX Range+ maintains airflow performance and acoustic comfort, ensuring that enhanced thermal efficiency does not compromise cabin experience or noise levels.
The system offers several practical benefits:

• Continuous intake of fresh external air for improved cabin air quality.

• Reduced risk of window fogging in cold environments.

• No negative impact on airflow dynamics or acoustic behavior.

• Compatibility with minimal adjustments when integrated with alternative refrigerants.

Future Adoption Across Electrified Platforms

Mahle expects broader deployment of Mahle HeatX Range+ across electric vehicles and other electrified platforms in the coming years. As automakers focus on extending EV efficiency and addressing cold weather EV range concerns, advanced thermal management systems are becoming central to product strategy. By lowering auxiliary power consumption without affecting comfort, the technology supports the wider adoption of sustainable mobility solutions while reinforcing performance standards in challenging climates.
With winter range remaining a key consumer concern, Mahle HeatX Range+ positions itself as a practical, scalable solution that strengthens electric vehicle winter performance and supports the continued evolution of energy-efficient battery electric vehicles.