Why thermal loads matter more for EVs
In an internal combustion engine vehicle, waste heat from the engine provides cabin heating essentially for free, and the AC compressor draws power from the engine with negligible impact on fuel economy. In an EV, every thermal watt comes directly from the battery. Heating and cooling combined can reduce EV range by 20 to 40% in extreme conditions.
The AC compressor is the single largest parasitic electrical load after the drivetrain. On a sunny day at 28 degrees Celsius ambient with 600 W per square metre solar radiation, a baseline cabin requires 1.44 kW of continuous AC power to maintain 20 degrees Celsius interior. That energy comes directly from the propulsion battery, reducing range kilometre for kilometre.
AC power as range competitor
Using Kriya's Calculation Model 887 (validated at r-squared = 0.999 against field measurements), the impact of solar heat control on AC power is:
- Baseline AC power: 1.44 kW
- With Kriya ATO solar heat control: 0.93 kW
- AC power reduction: 35%
- Interior temperature reduction: 9 degrees Celsius (from 58.9 to 49.9 degrees Celsius before AC intervention)
The 0.51 kW saving is continuous during sun exposure. Over a typical driving hour, this saves 0.51 kWh — energy that remains available for propulsion.
Range extension by EV segment
Kriya has calculated the range extension from solar heat control for two representative EV segments:
| Parameter | Premium EV | Compact EV |
|---|---|---|
| Average battery capacity | 85.6 kWh | 39.3 kWh |
| WLTP range | 442 km | 227 km |
| Range extension | up to 16 km | up to 7 km |
| Battery weight saving | 8.5 kg | 4.6 kg |
| Battery cost saving | ~325 EUR | ~159 EUR |
Battery weight saving and cascading cost benefit
The AC power reduction from solar heat control allows the battery to be downsized while maintaining the same range. This creates a cascading benefit:
- Direct battery savings — 4.6 to 8.5 kg of battery cells can be removed while maintaining equivalent range, saving 159 to 325 euros in cell cost
- Vehicle weight reduction — lighter battery reduces structural requirements, suspension load, and brake sizing
- Manufacturing cost — smaller battery pack simplifies assembly and reduces module complexity
- Carbon footprint — fewer battery cells means less embodied carbon in manufacturing
For an OEM producing 200,000 EVs per year, the battery cost saving alone represents 32 to 65 million euros annually.
Integration pathways for EV manufacturers
Kriya's ATO solar heat control is available in three formats:
- PVB masterbatch — for OEMs and glass Tier-1s integrating solar heat control into laminated windshields and side glass during manufacturing
- Window film — for aftermarket and fleet retrofit applications
- Sol-gel coating — for specialty lightweight glazing applications
The PVB masterbatch route is the most scalable for new vehicle platforms. A Tier-1 PVB interlayer partner has validated the format, and a 1,000,000 kg annual capacity plant is fully engineered and execution-ready.
Eco-innovation credit eligibility
Solar heat control glazing qualifies for eco-innovation credits under EU Regulation 2019/631. AC power efficiency improvements are eligible from 2025 onwards, with up to 6 g CO2 per km credit per manufacturer until 2029. For details on the EU CO2 penalty context, see the EU CO2 penalty impact page.