MAHLE Showcases a New Lithium-Carbon Battery for EVs

November 07, 2021 by Antonio Anzaldua Jr.

MAHLE, an international developer in electric vehicles (EVs) and fuel cell solutions, brings a new EV battery concept to the renewable energy table with a 90-second charging capability at 20 kW.

With range anxiety still lingering in the minds of EV consumers, it is refreshing to read about competing solutions for faster charging devices. MAHLE recently introduced a new battery concept for ultrafast charging of small electric vehicles in urban distribution transport. This battery will be composed of lithium-carbon and will enable fast charging for lightweight, two-wheeled, and small vehicles in under a couple of minutes.


MAHLE’s innovative cooling system involves immersion cooling that helps shorten charging time for the battery concept. Image used courtesy of MAHLE.


Ultra-Fast 90-Second EV Charging

MAHLE’s powertrain transmission specialists have created a shiftable high-speed electric drive module that led to the ultra-fast charger. This module delivers high power density not susceptible to runaway events or any uncontrolled overheating. MAHLE’s thermal management group is also making strides for the new EV batteries by developing an integrated system. The battery avoids failures such as thermal degradation that are brought on by lithium-based batteries. Combining the advantages of supercapacitors and conventional lithium-ion batteries, the lithium-carbon battery concept targets compact delivery vehicles in inner-city areas with ultrafast charging. 

An electrically non-conductive coolant flows around the cells, thereby ensuring that the maximum temperature of the battery drops markedly during charging and that the overall temperature is distributed much more homogeneously. Allowing for the size of EV batteries to go down in size, letting costs go down while still remaining efficient. 

Currently MAHLE’s 90-second charger is still under development and is withholding further details on design specifications however, the Vice President of Corporate Research and Advanced Engineering at MAHLE, Dr. Martin Berger, shared that MAHLE was on track to become a large contributor to removing CO2 emissions. “MAHLE’s portfolio today is as varied as the future mobility requirements. With the topics we’re presenting in Aachen, we’re once again demonstrating that we are targeting those areas where zero-carbon mobility needs good ideas.”


MAHLE’s chargeBIG Project

Other developments from MAHLE is its chargeBIG, an e-mobility division dedicated to finding new ways of establishing fast EV charging for large scale airport, parking garages, and fleet operators infrastructures. These charging cabinets can house up to 36 charging points and wall mounts. This technology will enable a network of charging stations, complete with dynamic and phase individual load management.


A look behind the immersion cooling for the battery concept to ensure ultrafast charging without additional coolers. Image used courtesy of MAHLE.


MAHLE supplies systems for high-voltage capacitor discharge ignition (CDI) as well as transistor-controlled ignition (TCI). In CDI units, the discharge of a high-voltage capacitor is used. TCI ignition involves a steady current flowing through the ignition coils. If the contact is interrupted, the self-induction in the ignition coil gives rise to a voltage surge that generates the ignition spark in the spark plug.


MAHLE’ Newest 3D Printing Center

In the city of Stuttgart, Germany, MAHLE will continue to develop automotive products and solutions for next generation EVs with a new 3D printing center that will manufacture power components with a new range of possibilities.

The new facility will allow MAHLE to speed up the development of climate neutral mobility solutions, increase process validation by automotive standards, and boost performance of existing automotive products.The unique printing process utilizes a software to 3D render solutions and easily integrate several functions into one product. Design engineers can create very complex designs at the click of a mouse. The printing center will lead to future developments of heat exchangers, thermoelectric generators, cooling plates, low temperature coolers, rapid prototyping,  and pre-charge air cooler for electric vehicles.