Temperature Challenges and Heating Needs of Battery Thermal
Multiple Impacts of Low Temperatures on Lithium-ion Batteries
- Decreased Electrochemical Performance: Low temperatures reduce electrolyte conductivity and slow lithium-ion diffusion.
- Sharp Reduction in Usable Capacity: Some charge is "locked" and cannot be released.
- Increased Charging Risk: Lithium metal precipitation (lithium dendrites) may lead to internal short circuits.
- Battery Lifespan Degradation: Frequent low-temperature operation accelerates battery aging.
Heating Strategies in Thermal Management Systems
- Preheating Stage: Warming the battery from a low temperature to a suitable operating temperature (typically 10-25°C) before vehicle start-up.
- In-driving Temperature Insulation: Maintaining the battery's optimal operating temperature range in cold environments.
- Preheating Before Charging: Ensuring fast charging conditions and protecting battery health.
OEM Custom Heating Element Solutions
1. Silicone Heating Sheet/Heating Film
Application Scenarios: Directly bonded to the surface of battery modules or cooling plates
OEM Customization Advantages:
- Precisely matches complex internal curves and installation space limitations of battery packs
- Thickness can be as thin as 0.8mm, minimizing impact on battery pack energy density
- Excellent thermal conductivity and electrical insulation (breakdown voltage up to 4000V)
- Waterproof and shockproof, suitable for automotive-grade vibration and humidity environments
2. PTC Heating Element
Application Scenarios: Air-cooled thermal management systems, heating the air entering the battery pack
OEM Customization Advantages:
- Self-regulating temperature control prevents overheating and ensures high safety
- Integrates with temperature sensors and control systems for intelligent temperature control
- Customizable power density to meet the heating power requirements of different battery packs
JAYE's OEM Customization Capabilities Demonstrated in Battery
Case Study: Customized Battery Pack Heating Solution for a New Energy Brand
Client Requirements:
- Battery pack operating temperature: -30°C to 55°C
- Batteries need to be preheated from -20°C to above 10°C within 15 minutes.
- The heating system weight should not exceed 1.5% of the total battery pack weight.
- Meets automotive-grade vibration, waterproof, and insulation requirements.
JAYE Customized Solution:
Design Phase:
- Determine heating element layout and power distribution through thermal simulation analysis.
- Develop non-standard shaped silicone heating films to perfectly fit the curved surfaces of each module.
- Design an integrated solution incorporating temperature sensors and fuses.
Material Selection:
- Use automotive-grade silicone material with a temperature range of -60°C to 250°C.
- Employ thick-film heating technology for rapid response and uniform heating.
- Electrical insulation layer meets a withstand voltage test of 3000V AC/1 minute.
Performance Results:
- Preheating target achieved in 12 minutes at -20°C.
- System weight accounts for only 1.2% of the total battery pack weight.
- Passed IP67 protection rating test and 200-hour salt spray test.
- Heating temperature uniformity deviation < ±3°C.
JAYE's Silicone rubber heater
Conclusion
More Than Just Heating, It's an Enabling Force for Battery Performance
In today's increasingly competitive new energy vehicle market, battery thermal management has evolved from an "additional function" to a "core performance indicator." An excellent OEM-customized heating solution can not only solve the performance degradation problem in low-temperature environments, but also extend battery life and improve safety limits through intelligent temperature control, ultimately enhancing the overall vehicle's competitiveness.
