• New e-axle cooler for the Chinese smart electric vehicles manufacturer
• Optimal thermal behaviour through water-cooled vacuum brazed aluminium technology
• Recognition of the UFI’s advanced engineering and customer relations.

UFI Filters has been pioneering products in thermal management since 2010 and is now one of the industry leaders in an area of high growth. Testimony of this is the latest project awarded by NIO to the UFI Group for the e-axle cooler of a new upcoming Battery Electric Vehicle (BEV).

The e-axle is a core part of BEVs. It works by integrating an e-motor, transmission and power electronics into a compact, modular package that sits between a vehicle’s wheels. As a key element of a BEV, it is essential that the e-axle operates within an optimal range of temperature. UFI Filters technology in water-cooled vacuum brazed aluminium, plays a key role in maintaining the best thermal conditions.

The project has been awarded to UFI in recognition of the company’s advanced engineering and customer relations. For UFI, it represents the beginning of a partnership with a multinational smart vehicle manufacturer headquartered in Shanghai, with branches and R&D departments all around the world. NIO is not just a vehicle manufacturer, it also embodies a new way of conceiving mobility, which is centred on sustainability and the creation of a community of users.

NIO Inc. is a pioneer and leading company in the premium smart electric vehicle market. Founded in November 2014, NIO’s mission is to shape a joyful lifestyle. NIO aims to build a community that starts with smart electric vehicles, in order to share joy and grow together with users. NIO designs, develops, jointly manufactures and sells premium smart electric vehicles and is driving innovations in next-generation technologies in autonomous driving, digital technologies, electric powertrains and batteries. NIO differentiates itself through its continuous technological breakthroughs and innovations, such as its industry-leading battery swapping technologies, Battery as a Service, or BaaS, as well as its proprietary autonomous driving technologies and Autonomous Driving as a Service, or ADaaS. NIO’s product portfolio consists of the ES8, a six-seater smart electric flagship SUV, the ES7 (or the EL7), a mid-large five-seater smart electric SUV, the ES6, a five-seater all-round smart electric SUV, the EC7, a five-seater smart electric flagship coupe SUV, the EC6, a five-seater smart electric coupe SUV, the ET7, a smart electric flagship sedan, and the ET5, a mid-size smart electric vehicle.

Rinaldo Facchini, CEO UFI Filters Group, comments: “Being chosen by one of the leading manufacturers of smart electric vehicles makes us particularly proud. This demonstrates we are paving the way towards 360° mobility. Starting with our know-how gained from the traditional engine, we have been able to develop technologies for vehicles powered by new energies, all thanks to the reactivity and industrial footprint of our Group. The new thermal management business unit and dedicated production sites are therefore able to meet the growing demand for alternative technological innovations.”

UFI Filters boasts its know-how as original equipment on one of the most awaited, beloved and awarded cars of 2022: the Alfa Romeo Tonale, elected “Auto Europa 2023” by UIGA (Unione Italiana Giornalisti Automotive) journalists, and “Best New Design 2022” by German magazine “auto motor und sport”!

UFI Filters is not just a filtration leader, it also innovates the engine on its way to electrification, insomuch so that the Casa del Biscione has chosen UFI thermal management systems as original equipment for the mild and plug-in hybrid versions of their newcomer – the Tonale Suv.

Already present with the Gen2plus filter – ensuring the best filtration and water/diesel separation – and with the oil filter in the Diesel version, UFI Filters provides all-around solutions to several drives mounted on the Tonale. Indeed, the Group has already been entrusted with the two thermal management systems as original equipment, for the new plug-in hybrid model and the heat exchanger for the mild hybrid version. Thermal management systems are an essential part of modern engines to keep the temperature under control and within the limits set by manufacturers, not just for the car’s proper operation, but also to reduce consumption, limit emissions and increase the engine or ePowertrain’s (for the Tonale Electric Drive Module – EDM) life span.

To back the high-performing 1.5 Lt mild hybrid engine, UFI Filters provides the heat exchanger manufactured in one of its plants entirely devoted to thermal management systems – the Opole factory, in Poland. The coolant coupling on the UFI exchanger is held in place by a support obtained directly on the exchanger upper portion, during the component moulding phase. This allows for a sturdier structure, and prevents any possible deformation.

For the plug-in hybrid version with 280 CV 1.3 engine, apart from the engine heat exchanger, UFI Filters also supplies the Electric Drive Module oil exchanger. Made of a vacuum brazed aluminium alloy, it features two quick oil couplings and two coolant couplings, for easier mounting.

Innovation and passion have always guided the UFI Group, and have contributed to the success of this compact SUV that won everyone over: from UIGA (Unione Italiana Giornalisti Automotive), which awarded it the prestigious “Auto Europa 2023” Award, to the readers of the German magazine “auto motor und sport”, who voted for the Tonale as the “Best New Design 2022”.

The OE Pedigree of UFI Filters, a leader in filtration and in the production of heat exchangers for combustion, hybrid and electric vehicles, includes the multi heat exchanger for the transmission oil of Daimler Truck AG’s multi-award-winning electric truck.

In 2022, the German manufacturer’s commitment to developing electrified heavy vehicles received dual awards: the first mass-produced zero-emissions truck won the Truck Innovation Award 2023 and the Sustainable Truck of the Year 2023 in the Distribution category.

UFI Filters made its own significant contribution to the development of this vehicle by providing its know-how in the design and production of heat exchangers. For optimum operation of the e-axle, which incorporates two electric motors able to provide a continuous 300 kW, with peak power of up to 400 kW, UFI Filters developed a dual cooling system alongside the manufacturer. This is a module composed of two pairs of heat exchangers operating in parallel, installed in a single aluminium housing. The module is perfectly integrated with the transmission circuit, providing optimisation of the temperature of the fluid in the circuit.

The entire UFI Filters module is manufactured in the dedicated plant in Opole, Poland, and manufactured from aluminium using vacuum brazing techniques to provide high levels of durability and cleanliness. As well as increasing the lifespan of the entire transmission system, the heat exchanger contributes at the same time to reducing vehicle consumption.

The two major European awards won by the electric truck speak to how important investing in e-mobility development is for the manufacturers of heavy vehicles, too.

For the last five years, the Truck Innovation Award has been awarded by the International Truck of the Year jury to vehicles incorporating the most advanced technologies on vehicles with gross weight of over 3.5 tonnes and equipped with alternative fuel or drive systems. The Truck Innovation Award 2023 jury, composed of 25 expert sector journalists, recognised the advanced technology used in the German truck: the fast-charging, long-lifetime lithium iron phosphate (LFP) cells and the speed of the manufacturer’s R&D process.

The Sustainable Truck of the Year award is also decided using very similar parameters: since 2016, the prestigious European award announced by the specialist magazine “Vado e Torno”, has marked a sustainability index by recognising the “greenest” vehicles in terms of emissions, safety, comfort, as well as the manufacturer’s commitment to sustainability matters.

The technology offered by UFI contributes to raising the performance of all types of motors, thereby reconfirming itself as a manufacturer of premium technologies, including for the electric motors used on heavy vehicles.

• Heat exchanger for the Renault Megane E-Tech and Nissan Ariya ePT-160 front e-motor
• Additional heat exchanger for Ariya e-4ORCE 4WD rear e-motor
• Vacuum-brazing aluminum manufacturing technology

UFI Filters is not only a leader in filtration, but also in thermal management. Indeed, the company is able to provide 360-degree solutions for the mobility of the future. Its innovative capabilities have once again been demonstrated by its providing of Original Equipment heat exchangers for Renault-Nissan-Mitsubishi Alliance’s electric motors.

UFI Filters has been chosen to supply the heat exchanger for the new ePT-160 front electric motor, 160kW, mounted on the new Renault Megane E-Tech and Nissan Ariya. The e-motor will also equip other C-segment model vehicles that will be launched by 2024 within the Franco Japanese alliance and has the potential to become very popular in Europe in the next few years.

The heat exchanger for the ePT-160 is of an aluminum plate type and produced according to vacuum brazing technology that allows for a very robust and clean product. The UFI heat exchanger is made up of four layers dedicated to oil and four to coolant. The oil enters through the base plate fixed directly on the outside of the electric motor. The heat exchanger configuration is diagonal counter-flows. It means that the liquids (oil and coolant) flow in opposite directions, oil and coolants cross their path into alternating layers.

For the 4×4 version available on Nissan Ariya e-4ORCE 4WD, UFI Filters supplies an additional heat exchanger for the rear electric motor. Also made of aluminum and featuring vacuum brazing technology, it has seven layers for oil and six for coolant. The oil and coolant liquid enter through the base plate fixed directly on the outside of the electric motor. The heat exchanger configuration is parallel counter-flows. The two liquids flow in opposite directions but remaining on the same side of the plates layer.

With these two applications, UFI Filters is strengthening its position as leader in electric motor thermal management for Renault, Nissan and Mitsubishi.

Rinaldo Facchini, CEO of the UFI Filters Group, comments: “The collaboration with the Renault-Nissan-Mitsubishi Alliance represents a milestone for UFI Filters. It testifies that the UFI Filters Group is a technology leader in the area of electric mobility. Being present on an electric motor that goes from 120,000 pieces a year – aiming to reach 300,000 – shows that thermal management of battery-powered vehicles is one of the company’s strengths.”

• Strong commitment by UFI Filters to addressing the ongoing shift in the automotive industry towards vehicle electrification.
• Intended further development of (currently) seven thermal management product lines for all types of vehicles
• Dedicated team based in UFI Innovation Center in Italy

UFI Filters, a leading company in the filtration and production of heat exchangers for combustion, hybrid and electric vehicles, announces a major extension to its organisation and with the creation of a new Business Unit dedicated to Thermal Management Systems.

The Thermal Management Business Unit will be operationally flexible and independent and will benefit from a dedicated Research and Development team. It will be based in Italy, at the UFI Innovation Center in Ala di Trento.

Thanks to this new Business Unit (TBU), UFI Filters is demonstrating a strong commitment to addressing the ongoing shift in the automotive industry towards vehicle electrification. In this way, the company intends to further develop technological innovation more quickly, to better meet the requirements of the high-performance product market.

The new TBU will be headed by Ivano Cordioli, who holds a degree in Mechanical Engineering and an EMBA masters. Ivano boasts 15 years of experience in the Group and has held various positions of increasing responsibility, ranging from Project Engineer to Business Development Director.

Rinaldo Facchini, CEO of the UFI Filters Group, says: “The increasing electrification of vehicles is leading us to focus more on this segment, which is why we have created a team dedicated to one of the key factors for electric vehicles: thermal management. I am pleased to entrust this job to Ivano Cordioli, who has long experience, and a proven track record at UFI Filters of bringing innovation directly to the OE customer.”

The UFI Filters Group has been present in the automotive OEM heat exchanger sector since 2010. In particular, investment in research and innovation has led to specialisation in the design, development and production of aluminium heat exchangers produced by vacuum brazing and water-cooling. This process allows for the obtainment of a more robust, efficient and clean product compared to traditional steel systems.

Today the UFI Group provides seven product lines dedicated to thermal management, covering the needs of all types of vehicles. They feature sophisticated products from the stand-alone or the integrated engine oil cooler (for combustion vehicles), the transmission oil cooler and liquid-cooled condenser (both for combustion, hybrid and electric vehicles), the battery chiller and coolant battery heater or the coolant flow valve (for hybrid and electric vehicles) up to the heat exchanger for e-axles for electric vehicles that can be supplied as single heat exchanger or as integrated module that reflects the company’s complete range of capabilities.

“I am extremely proud of this task and of the trust placed in me,” comments Ivano Cordioli, Thermal Management Business Unit Director. – “The new Business Unit will be able to count on a specialised and cross-functional team at our Innovation Center, so that we can better focus on the mobility technologies of the future. I am convinced that this motivated and highly skilled team will be able to give the right contribution and the best push to this sector both in terms of innovation and research and business development.”

UFI Filters, specialist in filtration and thermal management, supplies the heat exchanger for the innovative 9HP transmission designed for vehicles with transverse and hybrid engines and produced by ZF Friedrichshafen AG, a world leader in technological solutions for the automotive and industrial sector.

Optimum fluid management is essential to ensure the maximum efficiency and functionality of modern transmissions, and thus offer the best driving comfort. UFI Filters technology was chosen because of the Group’s ability to produce lighter, stronger and more efficient aluminium heat exchangers with vacuum brazing technology.

One of the main technological advantages offered by the UFI Filters exchanger for the nine-speed transmission is the thermostatic bypass valve (engineered and produced by UFI itself) which allows better thermal management of the oil in all driving conditions. The oil bypasses the exchanger when the temperature is low, so as not to jeopardise the operation of the transmission gears, but when it exceeds a critical temperature threshold it’s sent directly to the exchanger for cooling. The valve seat is integrated in the exchanger body itself during the vacuum brazing process.

The lightweight, compact solution defined by UFI Filters makes a significant contribution to ensuring the maximum efficiency of ZF’s 9-speed transmission, which stands apart from standard 6-speed transmissions as it enables fuel savings of 16% in a small space.

Rinaldo Facchini, CEO of the UFI Filters Group, says: “We’re very proud that our technology has been chosen for one of the transmissions that will have numerous applications in the automotive market. This once again confirms the Group’s OE vocation, not only in filtration. In fact, UFI Filters can boast more than ten years’ experience in the thermal management sector and today has 3 industrial centres – one in Europe, one in China and the last in the Americas (dedicated entirely to the production of coolers). UFI Filters’ aluminium heat exchangers are used not only on traditional engines but also electric ones, for which we produce state-of-the-art battery coolers and battery chillers.”