800-volt heating solutions from Eberspächer: Efficient thermal management for electric vehicles

– 800-volt products complement product portfolio

– Ensuring comfort and battery conditioning

– Integration into a wide variety of vehicle architectures

The biggest challenges facing electromobility include battery range requirements, charging times, and comfort. Optimized thermal management plays an important role here—especially through the use of high-voltage electrical technologies. With two new solutions for 800-volt electrical systems, Eberspächer is expanding its portfolio to include coolant and air heaters.

The increasing popularity of battery-powered electric vehicles is a key component on the road to climate-friendly mobility. Technological challenges such as range, driver comfort, and charging times are still influencing widespread acceptance. Overcoming these challenges requires advanced thermal management systems that improve efficiency, comfort, and system stability in equal measure. As an experienced system developer and supplier to the automotive industry, Eberspächer has been manufacturing key components for temperature control in electric vehicles for many years, including high-voltage electric heaters. These ensure fast and reliable temperature control, especially in cold conditions, where heat pump systems often reach their performance limits. With two new solutions for 800-volt electrical systems—a coolant heater with thick-film technology and an air heater with PTC technology—Eberspächer offers targeted, demand-based heat output for the interior and battery conditioning. Both systems can be integrated into OEM systems in a modular fashion.

Coolant heater: High performance, compact, and safe
With its coolant heater based on thick-film technology, Eberspächer offers a compact and powerful alternative to classic PTC technology. At its heart is a thick-film element (TFE) that is applied to a metal plate using a screen printing process. This design enables high heating performance in a minimum of space. The component conditions the vehicle battery and achieves up to 12 kW of power at 800 volts – a key contribution to extending battery life and reducing charging times. Another advantage is voltage flexibility: many BEV platforms rely on an 800-volt architecture, but must also be compatible with
400-volt charging infrastructure – because this currently accounts for the majority of the global charging network. The coolant heater is designed precisely for this scenario and delivers sufficient power even at 400 volts. Maximum operational reliability is ensured by a safety concept based on multiple sensors with a second, independently operating shutdown path. This reliably monitors and controls thermal processes. The thick-film heater is suitable for both passenger cars and trucks, and several automobile manufacturers have already nominated it for series projects. Production is scheduled to start in 2027.

Air heater with multi-zone function: comfort and performance for the cabin
The portfolio is complemented by the air heater, which is installed directly in the air conditioning system. The multi-zone function allows separate temperature control of up to four zones in the interior, for example for the driver and passenger sides. Since the air heaters are located close to the passengers and partly within the firewall, PTC technology is used. Thanks to a system-inherent self-regulating effect, this ensures reliable protection against overheating. With a power range of 3 to 8 kW, the heater is designed for both
400- and 800-volt architectures. Eberspächer has largely dispensed with adhesives in the construction of the heating element, thus minimizing the risk of unwanted emissions in the vehicle interior. The product will be in use in Asia, Europe, and North America from 2028.

Pictures: Eberspächer

About Eberspächer:
With around 10,700 employees at 80 locations worldwide, the Eberspächer Group is one of the leading system developers and suppliers to the automotive industry. The family-owned company, based in Esslingen am Neckar, stands for innovative solutions in exhaust technology, vehicle electronics, and air conditioning for various types of vehicles. Eberspächer components and systems ensure greater comfort, higher safety, and a cleaner environment in everyday mobile life. Eberspächer is a pioneer in future technologies for mobile and stationary fuel cell applications, synthetic fuels, and the use of hydrogen as an energy source. In 2024, the group generated sales of around 5.3 billion euros. Adjusted for transitory items, net sales amounted to 2.7 billion euros.