MAHLE GmbH products

Our HVAC modules are tailor-made to the specifications of vehicle manufacturers. Continuous improvements in efficiency, reductions in weight and pressure loss, as well as the further optimization of acoustics are among our key development objectives. Standardized components and design features help us to economically develop and produce robust and high-performance HVAC modules.

Our flat tube evaporators deliver high performance in spite of their compact and lightweight design. Our patented BehrOxal® coating technology modifies the aluminum surface such that it assumes hydrophilic properties. As a result, water runs off more easily, enabling the evaporator to dry more quickly. This makes the evaporator more resistant to corrosion and less prone to unpleasant odors.

As the processes in the engine become ever more complex, the demands on the intake system also increase. Emissions regulations and consumption specifications, shorter model cycles, and rising expectations for performance in shrinking packages are the cornerstones of modern development. For example, MAHLE was recently able to take another substantial step forward in the development for modern combustion engines with the integration of charge air cooling in the air intake module.

Crankcase ventilation systems reliably remove the gases from the crankcase that are contaminated with oil mist. The oil mist separator integrated into the ventilation separates gaseous and liquid components. The separated oil is recirculated into the oil circuit and the residual air is recirculated into the intake system. The oil mist separator must ensure a high level of oil separation for all engine-specific requirements that lead to varying volume flow rates and fluctuating amounts of oil. Active oil mist separation achieves this at a consistently high level, regardless of the engine operating conditions. This solution also enables active management of gases and testing of the ventilation system to ensure its integrity and proper operation.

Indirect charge air cooling systems use extremely compact coolers that are cooled by the coolant of the separate low-temperature cooling circuit. Since the low-temperature radiator has a large front surface and is swept by the cold cooling air flow, very low charge air temperatures can be achieved. Due to their superior efficiency (as compared to a charge air/air cooler), they can be designed with very compact dimensions and mounted onto the engine. In transient driving conditions, they provide for a much more stable intake air temperature and thus help reduce fuel consumption.