Thyssenkrupp Dynamic Components, a division of German manufacturer thyssenkrupp Automotive Technology, has launched a CO₂ (R744) compressor designed for battery-powered electric vehicles (EVs).

Engineered for high efficiency in “all climate conditions,” the compact unit delivers advanced thermal management, enhancing both heating and cooling performance with a capacity exceeding 12kW (3.4TR), explained the manufacturer.

The company said the R744 compressor’s efficiency stems from a robust design optimized for continuous operation over a broad range of conditions. Unlike traditional start-stop compressors, thyssenkrupp’s technology is capable of steady operation, significantly boosting efficiency for EV thermal management.

“For decades we have been working with our customers to develop relevant and innovative solutions for the automotive industry,” explained Volkmar Dinstuhl, CEO of thyssenkrupp Automotive Technology. “In a dynamic market environment, we, like the entire industry, are facing new challenges. To remain a market leader, it is essential that we continue to develop our product portfolio.”

The compressor is the first technology to be developed under thyssenkrupp’s new thermal management product portfolio and was introduced at the International Suppliers Fair (IZB), which took place October 22–24 in Wolfsburg, Germany.

It was also showcased by Sebastian Wappler, Head of Product Platform Development at thyssenkrupp Dynamic Components, at the ATMOsphere (ATMO) MAC Summit 2024 × TU Berlin in September, which was co-organized by ATMOsphere, publisher of NaturalRefrigerants.com. It was the first ATMOsphere event dedicated solely to air-conditioning and heat pump systems for mobile applications.

Supporting the transition to natural refrigerants

As the automotive sector increasingly shifts away from traditional chemical refrigerants, thyssenkrupp has said that it is supporting the move toward sustainable options like CO₂.

“The environmental impact of chemical refrigerants is widely recognized and is driving a shift to natural refrigerants like R744,” the company states on its website.

Compared to other natural refrigerants such as propane (R290), R744 offers higher efficiency in heat pump applications and is non-flammable. However, its higher operational pressure – approximately five times that of R290 and synthetic refrigerants – presents a significant engineering challenge.

To address this, thyssenkrupp said it designed the compressor to handle the high-pressure demands of R744 systems. The OEM said the compressor’s low inner leakage and minimal lubrication needs contribute to its efficiency, durability and ability to support high mass flows without relying on start-stop cycles. It added that the design allows for compactness, yet it remains powerful and efficient, covering a full range of operating conditions with low energy consumption.

“The environmental impact of chemical refrigerants is widely recognized and is driving a shift to natural refrigerants like R744.”

thyssenkrypp Automotive Technology

Thyssenkrupp began developing this technology in 2018, and comprehensive testing has confirmed the compressor’s technical maturity and readiness for commercial application, explained Wappler during his ATMO MAC Summit presentation.

“This isn’t just a prototype,” he said, underscoring the compressor’s practical readiness for the market.

“With this new development, thyssenkrupp Dynamic Components is continuing to drive the transformation towards e-mobility,” noted the company.