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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.

Heaters

Heaters play a key role in any vehicle, allowing liquids and air to be heated for optimal engine operation and passenger comfort – even more so in hybrid and electric vehicles than in internal combustion cars.
BorgWarner offers efficient and powerful air and liquid heating solutions for a variety of applications.

High Voltage Air Heaters

BorgWarner’s high voltage air heater delivers a comfortable interior and safety through quick window defrosting for applications with limited waste heat such as electric vehicles.
Thanks to its very compact and modular design, it can easily be integrated into existing structures within the vehicle.

High Voltage Air Heater
HV-Air-Heater
High Voltage Air Heater

Features

  • Dual Zone cabin heating capability
  • Acoustic comfort
  • Dielectric strength 4.3kV design
  • IP67 Product
  • Core temperature sensing
  • Low pressure drop
  • Robust design over lifetime
  • Problem free integration in existing HVAC systems
  • Odorless heating – no usage of glue or pastes in mfg processes

Benefits

  • Replace heat source (IC engine)
  • High thermal power density
  • Fast response times
  • Low pressure drop

Product Sheet

High Voltage Coolant Heaters

Batteries have a narrow optimal temperature range. BorgWarner’s specially developed high voltage coolant heaters have been developed to keep the core components of hybrid and pure electric vehicles at temperatures that facilitate maximum charging efficiency, durability and driving range. It delivers heat to the interior quickly and clears the ice from windows in short order.

HV-Coolant-Heater
High Voltage Coolant Heater

Features

  • Compact modular design with high thermal power density
  • Clean room manufacturing approach – safety and reduced manufacturing cost

Benefits

  • Battery Management for EV platforms
  • Fast response times (heating up/cooling down) due to low thermal mass and high efficiency
  • Reduced package size and weight compared to competitors
  • Long lifetime: Thick Film Heating Elements 15,000 hours and above
  • Voltage Range: Up to 1000V

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

Thermostats & Coolant Control Valves

For optimal management and control of heat flows within and around the engine, BorgWarner offers a wide range of products from fixed- and variable-temperature wax thermostats to electrical coolant control valves. 

Electrical Heated Thermostats

Characterized by a broader working range than conventional wax thermostats featuring a fixed opening temperature,
BorgWarner’s electrically heated thermostats adjust the internal engine temperature as needed in response to signals from the
engine control unit, thereby reducing fuel consumption.

Features

  • Broad working range
  • Adjust the internal engine temperature as needed in response to control signals from engine management

Benefits

  • Fast and accurate coolant flow control for improved engine performance
  • Zero flow capability to support fast engine warm up and reduce fuel consumption
  • Optionally with integrated wax thermostat for fail safe
  • Low pressure loss to enable reduced coolant pump power
  • Competitive product due to modular design
Wax_Thermostat

Wax Thermostats

Wax thermostats are proven million times and still in use to control and regulate the coolant temperature. Conventional wax thermostats are regulating just with the wax liquefying when the coolant temperature is rising or falling.
Electrically heated wax thermostats offer a wider operating range and can be triggered when  the engine is exposed to specific load conditions.

ECCV

Electric Coolant Control Valves

These valves feature rotary sleeve valve with an electrical DC-actuator and position feed back, temperature-independent control of coolant flows and are usable for both inlet and outlet control.

Our valves help improve engine performance with fast and accurate coolant control, provide zero-flow capability for fast engine warm-up and improved fuel economy and reduce coolant pump power required through low pressure losses.

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.

48V Electric Fans

Making full use of the additional power available from a 48V power supply, BorgWarner’s 48V eFan family is based on a scalable BLDC motor design with integrated and actively cooled electronics. Primarily designed for the Off-Highway and SUV/LCV segments, our electric fans provide trouble-free operation as well as optimal airflow and cooling performance even under severe conditions.

48V_eFan
48V e Fan

Features

  • Modular 48V eFan family in the power range of 0.7kW up to 3.2kW
  • Fully integrated motor and controller designs
  • Superior airflow performances up to 75% above current 12V-fan systems
  • Robust, durable assembly suitable for rough environments
  • Expertise available to allow trouble free operation of >10.000h
  • Optimized packaging and light weight design

Benefits

  • Airflow meets market demands at very high efficiency levels
  • Modular, flexible system arrangements possible
  • Immediate response to fan speed demand
  • Superior durability
  • Low noise
  • Engine speed independent airflow
  • Possibility of reversible rotating direction

Product Sheet

Fan Drives

Combining the advantages of an electrical fan and mechanical fan drive regarding fuel efficiency, performance, noise and system integration, BorgWarner’s Dual Mode Visctronic® fan drive achieves best-in-class efficiency in all operating modes by driving the fan either electrically or mechanically.

FanDrive
Fan Drive

Features

  • Robust design using proven Visctronic® technology and a highly efficient BLDC motor
  • Fan Drive Performance
  • Torque Capacity up to 35 Nm
  • Slip Heat Capacity typically 2.5 kW
  • Efficient fan designs
  • Electrical Interface and integrated Electronics
  • ECU Supply Voltage 12V, 850W
  • LIN or PWM communication protocol

Benefits

  • Compact System Layout
  • Improved Fuel Economy
  • Auxiliary pusher fans can be eliminated
  • Reduced system restriction
  • Low noise

Spec it Right

When it is time to place the order for new trucks, Spec it Right with BorgWarner.

Spec it right

Combustion
Combustion
Hybrid
Hybrid
Electric
Electric