ZF TherMaS Launches Thermal Management System to Boost EV Range by Up to 10 Percent

ZF TherMaS to Extend EV Range by Up to 10 Percent

In a significant advancement for electric vehicles, ZF has introduced its innovative thermal management system, TherMaS, which can enhance the range of battery-electric and plug-in hybrid vehicles by up to 10 percent. This development, announced on June 4, 2025, showcases ZF’s expertise in vehicle technology without necessitating costly upgrades to drivetrains or larger batteries.

TherMaS is designed as a highly integrated system that is both lighter and smaller compared to existing alternatives, while also being more efficient and cost-effective. By utilizing propane as a refrigerant, it achieves superior cooling performance, leading to a more compact system design. Testing has shown that this optimized thermal management, combined with improved utilization of waste heat from the drivetrain, can significantly increase the electric range during challenging winter conditions by up to 10 percent, and even up to 30 percent under extreme circumstances.

A crucial challenge for electric vehicles is managing the energy consumed for heating and cooling the vehicle’s interior, which can vary depending on weather and operating conditions. According to Dr. Otmar Scharrer, Senior Vice President R&D, Electrified Powertrain Technology at ZF, “The battery of an electric car is particularly sensitive to its operating temperature, with optimal conditions being between 15 and 25°C.” Extreme temperatures can strain the thermal management system, leading to increased power consumption and potentially halving the vehicle’s range. Thus, enhancing thermal management is beneficial for both manufacturers and drivers.

ZF’s pursuit of developing TherMaS stemmed from the need for an effective thermal management solution. The company previously showcased a central thermal management system in 2023, and since then, has made notable technological advancements. “Thanks to superior capabilities and an easy-to-integrate design, our customers can expect improved e-drivetrain performance and longer electric ranges without sacrificing comfort,” Scharrer emphasized.

TherMaS boasts cooling and heating capacities of at least 10 kW across a temperature range of -25°C to +35°C, ensuring the battery remains within its optimal operating range while minimizing noise and vibrations. ZF’s holistic approach integrates all thermal management functions into a complete subsystem, including the design of its first in-house heat pump. This allows TherMaS to be simpler, lighter, and more efficient compared to market alternatives.

A standout feature of TherMaS is its compact, propane-based heat pump refrigeration circuit, which integrates components based on specific temperature, heating, and cooling needs. Additionally, it includes two separately controlled cooling circuits carrying frost-protected water: one for the electric motor and another for the power and charging electronics, including the battery. The use of propane allows for a reduction in the size of these circuits while maintaining high performance.

The streamlined design not only conserves installation space and assembly time but also reduces heat and cooling losses by positioning the system closer to the cabin, leading to shorter lines. This high level of integration is expected to lower maintenance efforts and enhance the cost-benefit ratio for vehicle manufacturers.

ZF has rigorously tested TherMaS in real-world scenarios, demonstrating its ability to provide up to 10 percent more electric range in challenging winter conditions and even achieving a 30 percent increase in extreme situations. The new thermal management system will be offered in three performance classes to cater to a diverse array of applications and vehicle platforms. Automotive manufacturers have expressed significant interest, confirming the prototype’s high level of maturity.