LAS VEGAS—Engineers at Mahle have developed new thermal management technology that was inspired by nature, including a battery cooling plate and a bionic fan.

The latter reduces loud noises from fans under full load and when charging vehicles. It was developed for demanding fuel cell and battery electric vehicle applications. Engineers were inspired by the wings of an owl. One of the quietest birds in the world, an owl’s plumage has a noise-reducing effect.

The bionic fan blades can reduce the fan noise of a truck by up to 4 dB(A), which is equal to more than halving the sound output,” says Peter Lynch, vice president of sales and application engineering at Mahle North America. “The fan demonstrates a rule of 10s—reduction potential of 10 percent in consumed electrical power and a unique fan design that is 10 percent lighter. 

“Electrification and thermal management are two major strategy fields for Mahle, as we continue to position ourselves as a systems expertise champion in e-mobility,” explains Lynch.

The bionic cooling plate is designed to ensure fast charging, long cruising range and long service life for sensitive lithium-ion batteries. According to Lynch, the complete thermal management system is “significantly more efficient, with up to 20 percent battery life.”

Mahle engineers were able to increase cooling performance by 10 percent and reduce pressure loss by 20 percent. “As a result, the battery can be reliably and homogeneously kept within the necessary temperature window,” claims Lynch.