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Thermal Management

A keen market sense coupled with tightly aligned processes, manufacturing excellence and fast implementation makes BorgWarner a market and product leader. Our thermal management systems are designed to meet the needs of our global customers while also improving fuel economy and reducing emissions.

Intercell eCoolers

Cold plates intended to cool down battery cells.

Intercell eCoolers 1
Intercell eCoolers 2
    • Material: aluminum
    • Wall thickness ≥ 0,3 mm
    • I-flow & U-flow versions
    • Single-sided & double-sided cooling versions
    • Stack-up concept: different battery pack sizes may be cooled down using the same part numbers
    • Connection between different profiles optimized to compensate large misalignments if needed
    • Excellent coolant distribution (homogeneity) and pressure drop
  • Intercell eCoolers Product Sheet

​eCoolers for Power Electronics

Cold plate to cool down power modules.

eCoolers Power Electronics 1
eCoolers Power Electronics 2
eCoolers Power Electronics 5
eCoolers Power Electronics 6

High Voltage Coolant Heaters (HVCH)

BorgWarner’s high-voltage coolant heaters optimize charging, durability, and range in hybrid and electric vehicles, while quickly heating the cabin and defrosting windows.

High Voltage Coolant Heater 1
High Voltage Coolant Heater 2
High Voltage Coolant Heater 3
High Voltage Coolant Heater 4
High Voltage Coolant Heater 5
High Voltage Coolant Heater 6
High Voltage Coolant Heater 7
    • Coolant Heater for Battery and Cabin heating in xEV vehicles

    • System Benefits

      • Full Range Platform Portfolio: Air / Coolant - 400 / 800V - 3…10kW
      • Straightforward Voltage scalability
      • Extreme power density -> Brazed fins
      • Easy to manufacture for fast market entry
      • Modular in-house developed Power Electronics
      • Almost no restrictions in shape
      • Plug and play replacement possible
      • New low conductivity coolant compatibility
      • Self-regulating for dry run, no flow, low flow, misuse conditions
      • ASPICE / FuSa / Cybersecurity Capable

       

      Semi Conductor

      • Reliable delivery in a volatile market

       

      Platform approach

      • Reduced testing effort
      • Fast to market
      • D/P FMEA, Design rules, Checklist and standards available
      • Customer support with specification definition possible
      • Application guides available

       

      Simulation

      • Boiling, efficiency, pressure drop, burst pressure, pressure pulsation, stress and strain, stress, heat source temperature, coolant contact temperature and many more

       

    • High Voltage Coolant Heaters (HVCH) Product Sheet

    High Voltage Air Heater

    BorgWarner’s High Voltage Air Heater achieves outstanding cabin heating performances and includes up to 4 independently controlled heating zones (controlled and control zones linked to PCBA complexity).

    High Voltage Air Heater 1
    High Voltage Air Heater 2
    High Voltage Air Heater 3
      • Voltage - 400 and 800 V
      • Heater performance  for the 800 V heater - ~8 kW @ 800 V, 480 kg/h, –20°C 
      • Heater Core /  Electronic - 198x192x37mm / 203x91x58mm
      • Heating Zones - up to 4
      • Temperature  Sensors - Outlet air temperature sensors  are optional 
      • IP - IP6K9K
      • Weight - ~3,1 kg
      • Pressure Drop - <50 Pa @ 0°C, 300 kg/h
      • Control - via LIN
      • Voltage up to 800 V
      • Tier 1 / Tier 2 approach
      • Validation complete: Deep understanding of materials and design, as well as system interaction
      • 5 different protection mechanisms against overtemperature:
        • Core derating
        • PCBA derating
        • IGBT temperature monitoring
        • High Ohmic Protection
        • Intrinsic PTC stones behaviour
      • High efficiency Aluminum Tube heat sink
    • High Voltage Air Heater Product Sheet

    Secondary Air Systems

    Secondary air systems are important for gas cold-engine starts when the majority of hydrocarbon emissions are created. The complete system (including pump, valve, bracket, relay and hoses) provides additional advantages such as low noise and vibration. Air pump flows can be tailored to meet specific customer requirements. BorgWarner has a diverse list of global electric air pump (EAP) customers.

    Fans

    Airflow management plays a key role in cooling the engine. Our polymer cooling fans range from optimized axial flow fans and ring-fans for specific installations, to new hybrid designs to cover future cooling demands. New features include improved aerodynamics and durability in the same light-weight package. Using technology-focused design methods such as FEA, CFD and MoldFlow™, performance and reliability are optimized.
    BorgWarner’s Guide Vane design provides optimized air-flow potential through its world-class efficiency improvements and unique diffuser design. This unique design requires lower torque than fans operating in a traditional shroud, translating into more power to the wheels.

    High Voltage eFan System

    BorgWarner offers a complete 800 V system solution consisting of Cooling Fan, Electric Motor and Inverter.

    The high voltage 800V electric driven eFan system for Battery Electric Vehicles (BEV), Plug-in Hybrid Electric Vehicles (PHEV) and Fuel Cell Electric vehicles (FCEV) offers a cooling system for a vehicle with highest cooling requirements during braking, uphill with full load or megawatt charging. Designed to provide air flow to radiators/condensers in cooling circuits for components such as fuel cell stacks, traction motors, electric brakes (high power resistor), or battery packs in BEV or FCEV. 


    Low-Power 3-20kW (max. ~70 Nm at 2600 rpm)

    High-Power 40kW (max. ~160 Nm at 2350 rpm)

    eFan 1
    eFan 4
    eFan 5
    eFan 6
      • High torque and efficiency with low noise and fan speeds up to 3500 rpm
      • Operating voltage range 430V to 970V DC
      • Fully encapsulated design to meet IP67 and IP6k9k requirements
      • Air and liquid cooled components for ease of implementation and stable operation
      • Scalable electric motor platforms with a power range from 3 kW up to 40 KW
      • Modular system solution with integrated or remote inverter
      • Customer specific connectors can be used
      • Series proven fan portfolio with best-in-class performance, efficiency and low noise level
      • Compact & flexible design for installation in challenging installation spaces
      • Highly efficient and robust High Voltage electric motors
      • Customized inverter and software developed according to ASPICE / Functional Safety (ISO 26262) requirements
      • Fulfills Asil A
    • High Voltage eFan System Product Sheet

    Visctronic® Fan Drives

    Visctronic Fan Drives utilize BorgWarner’s proven viscous technology with precise electronic control.

    The fan drive is controlled by the engine’s control module for precise fan speed modulation. Visctronic fan drives provide better engine cooling and improved fuel economy with minimum parasitic loss.

    Fan Drive

    Fan Drive

    Features

    • For 711mm to 813mm diameter fans
    • Crankshaft pulley mounting possible
    • Hex input shaft with internal thread or flange shaft are available
    • Clockwise and counterclockwise rotation versions available
    • Broad scope for light-, medium- and heavy-duty applications (On- and Off-Highway)
    • Controlled by the engine ECU through PWM signal
    • Closed-loop fan speed control and excellent electronics environmental robustness
    • High-speed reservoir and patented fluid distribution

    Benefits

    • Improved efficiency – fan operates when required and at the appropriate speed – allowing for possible fuel and horsepower savings of up to 6-10%
    • Maintenance free – self contained unit, nothing to service or maintain
    • Improved temperature control – for extended engine & component life

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