The Key Role and Customized Solutions of OEM Heating Elements in Thermal Management of New Energy Vehicle Batteries

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.

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

 

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.

 

 

 

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.