From electric vehicles (EVs) to aerospace and industrial systems, a battery is the foundation of modern energy storage. But its performance is also highly dependent on temperature fluctuations. In cold environments, lithium-ion batteries experience increased internal resistance for example, and slower charge rates. Conversely, excessive heat can lead to thermal runaway, which poses serious safety risks.
While traditional heating solutions (rigid resistive elements, passive insulation) often fail to deliver efficient heat, flexible heaters have become a go-to alternative for precise thermal management. Let’s find out why, and how they can help you solve your own challenges!
Heating a battery is about unlocking its full potential, ensuring efficiency, and powering the future safely.
Understanding Battery Heating Challenges
Battery performance is highly temperature dependent. A 2018 study linked environmental conditions and their impact on lithium-ion batteries.
The acceptable temperature region for LIBs normally is −20 °C ~ 60 °C.
Temperature effect and thermal impact in lithium-ion batteries, Progress in Natural Science: Materials International, Volume 28, Issue 6
Understanding Battery Heating Challenges – ohmvo.comUnderstanding these challenges is essential to designing effective thermal management solutions.
Temperature Sensitivity of Batteries
- Cold Temperature Effects
- Higher internal resistance from lithium-ion and other battery chemistries, reducing power output.
- Capacity loss, as electrolyte viscosity increases.
- Charging at low temperatures can cause lithium plating, leading to irreversible capacity loss and potential short circuits.
- High Temperature Effects
- Decomposition of electrolytes, which can reduce battery lifespan.
- Thermal runaway can lead to fires or explosions, especially in high-energy applications like EVs and aerospace.
- Thermal gradients in case of uneven heating, leading to imbalanced performance and early degradation.
Traditional Heating Solutions & Their Limitations
- Resistive Heating Elements
- Traditional rigid heaters struggle to maintain uniform heating. Hot spots and inefficiencies appear regularly.
- Their fixed shape makes integration difficult, particularly in compact or irregularly shaped battery packs.
- Passive Insulation
- While insulation helps retain heat, it does not actively generate or regulate temperature.
- In extreme cold, insulation alone is insufficient to maintain optimal battery function.
Traditional Heating Solutions & Their Limitations – ohmvo.com- Air and Liquid Heating Systems
- Forced-air heating is inefficient. This requires significant energy consumption with delayed thermal response.
- Liquid heating systems add weight and complexity. That’s why they are unsuitable for lightweight applications.
Precision & Uniform Heating With Flexible Heaters
Thin-film heaters (such as polyimide and silicone rubber heaters) provide uniform thermal coverage that prevents localized overheating or underheating. They also feature customized power densities, for precise control of heat output that ensures each section of the battery receives the right amount. Ideal for eliminating thermal gradients that cause performance imbalances and premature aging of individual cells!
On the other hand, flexible heaters have a low thermal mass that allows them to heat up quickly and provide near-instantaneous temperature stabilization. This rapid response is essential in cold-start conditions, such as in electric vehicles or aerospace applications. Meanwhile, integrated sensors (thermistors or RTDs) provide real-time temperature monitoring and feedback control. This ensures that the battery remains within its optimal operating range. This allows for dynamic heating adjustments depending on the conditions, and a significant reduction in energy waste !
Learn more about Thermal Behavior Modeling of Lithium-Ion Batteries.
Material & Design Advantages Of Flexible Heaters
Flexible heaters combine durability, efficiency and seamless integration into battery systems, thanks to advanced materials. These can be :
- Polyimide (Kapton®) Heaters
- Ultra-thin (as low as 0.13 mm), lightweight, and highly flexible.
- Excellent dielectric strength and resistance to chemicals and extreme temperatures (-200°C to 200°C).
- Ideal for space-constrained applications where weight and size are critical (drones, satellites, and EV battery modules).
- Silicone Rubber Heaters
- Flexible yet durable, it offers high mechanical strength and resistance to moisture, vibration, and chemicals.
- Temperature range of -60°C to 230°C, suitable for harsh environments (industrial battery packs, outdoor energy storage).
- Provides shock absorption.
Material & Design Advantages Of Flexible Heaters – ohmvo.com- Carbon-Based & Printed Heaters
- Innovative printed heating elements using conductive carbon or metal-based inks.
- Offers low power consumption with customizable heating profiles.
- Ideal for thin-film battery applications.
Customizable Design for Any Battery Shape
No rigid constraints with flexible heaters ! Simply cut to size to fit cylindrical, prismatic or pouch cell batteries, ensuring complete thermal coverage. Laser cutting & etching for ultra-thin heaters enables production of micron-level precision heating elements.
Pressure sensitive adhesives (PSA) or laminated encapsulation also ensure a secure bond to battery surfaces. This reduces heat loss and maximizes efficiency by ensuring direct thermal contact. They seamlessly integrate with Battery Management Systems (BMS) to provide real-time temperature regulation, adaptive power control, and enhanced battery safety.
A battery management system typically is an electronic control unit that regulates and monitors the operation of a battery during charge and discharge. In addition, the battery management system is responsible for connecting with other electronic units and exchanging the necessary data about battery parameters.
Renewable and Sustainable Energy Reviews, 2021
Communication with External Systems
- CAN Bus & I2C Communication. Flexible heaters can integrate with EV powertrains, aerospace control systems, or industrial battery controllers via standardized communication protocols.
- Allows remote monitoring and predictive maintenance, which improves reliability in mission-critical applications.
Energy Efficiency & Sustainability
In terms of energy efficiency, as we have seen, flexible heaters are also flawless.
Unlike air or liquid heating systems, flexible heaters provide direct surface heating, optimized power densities and a fast response time. Adaptive power regulation prevents overuse, activating the heaters only when necessary. There is also the pulse width modulation (PWM) technology that allows precise adjustments, in order to boost the efficiency and runtime of the battery. This helps preserve the entire cycle life.
Of course, flexible heaters can also be powered by solar, wind or hybrid energy systems, which makes them ideal for off-grid and sustainable energy storage solutions. Advances in recent years contribute to the sustainability goals of electric vehicles by improving efficiency, reducing energy consumption and overall emissions.
Energy Efficiency & Sustainability – ohmvo.com
Compliance Of Flexible Heaters With Industry Standards
For seamless reliability and compliance, adherence to international safety and performance standards must be carefully considered.
UL 499 – Electric Heating Appliances
- Scope: Covers the safety of electric heating elements, including flexible heaters.
- Key Requirements:
- Electrical insulation must prevent short circuits and leakage currents.
- Surface temperatures must remain within safe limits to avoid fire hazards.
- Thermal cutoffs or overheat protection mechanisms are required to prevent excessive heating.
- Relevance to Flexible Heaters:
- Ensures heaters are designed with safe watt densities and proper electrical insulation to prevent overheating or electrical faults in battery packs.
IEC 62133 – Battery Safety for Portable Applications
- Scope: Covers safety requirements for rechargeable batteries, including lithium-ion and nickel-based chemistries.
- Key Requirements:
- Batteries must operate within safe temperature limits to prevent thermal runaway.
- Tests for overcharging, short-circuiting, and mechanical abuse ensure heaters do not create hazardous conditions.
- Requires integration of thermal protection to prevent excessive heating.
- Relevance to Flexible Heaters:
- Flexible heaters must integrate temperature sensors and fail-safe mechanisms to comply with safe battery operation.
- Heating elements must be designed to avoid damaging battery chemistry and prevent overheating scenarios.
ISO 16750-4 – Environmental Testing for Automotive Batteries
- Scope: Defines testing conditions for electrical and electronic components in road vehicles, including battery systems.
- Key Requirements:
- Thermal cycling tests to ensure heaters function in extreme cold and high temperatures.
- Vibration and shock resistance testing for durability in automotive environments.
- Resistance to humidity, chemicals, and dust exposure.
- Relevance to Flexible Heaters:
- Automotive battery heaters must withstand harsh environmental conditions, requiring durable materials like silicone rubber or polyimide (Kapton®).
- Flexible heaters must be shock and vibration-resistant.
ISO 9001 & IATF 16949 Certification
- Guarantees consistent, high-quality production for automotive, aerospace, and industrial applications.
- Ensures traceability and compliance with global manufacturing standards.
Flexible Heaters : The Future of Battery Thermal Management
There is no challenge that can’t be met with flexible heaters! In fact, we are now seeing new emerging trends in battery thermal management. Here graphene-based heaters, there AI-driven thermal management, all to further improve energy efficiency and extend the life of your batteries.
Looking for the perfect flexible heating solution for your applications? Discover Ohmvo’s range of advanced thermal management products designed to improve the performance, safety and longevity of your batteries.
Let us help you stay ahead of the curve with innovative, reliable and efficient heating solutions. Do not hesitate to contact us for any questions !