Hanon Systems is supplying a highly integrated thermal management module for electric vehicles, combining seven refrigerant-circuit components into a single 16 kg (35 lb) assembly. The module has been deployed in BMW’s fully electric iX3 SUV.

The unit integrates an eCompressor, electronic expansion valve block, water-cooled condenser, internal heat exchanger, chiller, A/C lines, and pressure and temperature sensors into one package. It dynamically regulates refrigerant flow and temperature to manage thermal demands across multiple vehicle subsystems simultaneously, including fast charging, high-performance driving and extreme weather operation. Hanon says the design reduces system complexity and packaging requirements while improving thermal performance and energy utilization, contributing to extended driving range.

EV thermal management is more demanding than in ICE vehicles because the battery introduces a third thermal system alongside cabin comfort and powertrain cooling—and all three interact. Fast charging and aggressive driving push significant heat into the battery that the refrigerant circuit has to handle in real time, while cold weather requires heating the battery efficiently without draining range. Consolidating the refrigerant-side components into a single module reduces the number of connections (each a potential refrigerant leak point) and shrinks the packaging footprint.

“Our solution transforms thermal management into an efficient and intelligent system. By unifying all critical refrigerant thermal management functions into one exceptionally compact module, we achieve savings in both packaging and materials,” said Soo Il Lee, CEO of Hanon Systems.

Source: Hanon Systems