Battery Thermal Management: Thick Film Heaters for EV & Storage Systems
As electric vehicles (EVs) and off-grid energy storage systems become ubiquitous, one critical engineering challenge often overlooked is battery thermal management. Properly controlling battery temperature—especially in cold climates—is vital for safety, performance, and lifespan. At Datec Coating, our thick-film heaters deliver precise thermal control, ensuring lithium-ion batteries function at their peak, even below freezing. In this post, we’ll explore EV battery heating, energy storage thermal management, and how thick-film solutions help optimize performance and sustainability.
Why Temperature Control Matters in EV & Storage Batteries
Lithium-ion batteries perform best within a narrow temperature range—typically 25–35 °C. Deviations can lead to:
- Reduced charge acceptance in the cold, resulting in slower charging or refusal to charge
- Capacity loss and decreased driving range
- Safety risks like lithium plating or thermal runaway
Battery Thermal Management Systems (BTMS) often focus on cooling—via air, liquid coolant, or phase-change materials (PCMs). However, heating capabilities are equally essential, especially during preconditioning and cold starts. Datec’s IntegrAL® thick-film heaters, operable on a wide range of voltage sources, ranging from 12V to 800V, are ideal for managing these critical thermal tasks effectively.
What Sets Datec's Thick-Film Heaters Apart?
Datec’s IntegrAL® aluminum-base heater features heating elements screen-printed directly onto aluminum substrates , delivering:
- Uniform, integrated heat—no cold spots across battery surfaces
- Fast thermal response—ideal for rapid preconditioning
- Precise temperature control—minimizes energy waste
- Low-profile, space-efficient design—perfect for OEM constraints
- Compatibility with EV battery systems—directly powered by battery or auxiliary circuits
Compared to alternatives like silicone heating mats or conventional wire-wound heaters, thick-film heaters offer superior surface coverage, thermal uniformity, and durability—all while conserving energy and space.
Applications in EV & Off Grid Energy Storage
EV Battery Pack Preconditioning
Low-temperature charging hurts lithium-ion battery chemistry. Using thick-film heaters embedded in battery enclosures allows quick pre-heating, preventing voltage drops and optimizing charge acceptance—even when ambient temperatures are well below freezing.
Learn more about the IntegrAL® aluminum-base heater on our product page.
Off‑Grid & Home Energy Systems
Stand-alone solar-plus-storage systems often rely on 12 V DC (smaller) or 24/48V DC (larger) subsystems. In cold weather, thick-film heaters ensure the energy storage batteries remain within optimal temperature ranges, preventing power loss and prolonging battery lifespan—without drawing excessive energy.
Auxiliary Thermal Management in Hybrid BTMS
Most BTMS focus on cooling, but intelligent systems include integrated heaters. Thick-film elements can be embedded into cooling heat exchangers, enabling bi-directional thermal control (heating and cooling). This mirrors research efforts like ecoEII’s “Development of Thick Film Electric Heaters for Thermal Modulation of Battery Systems” in partnership with Dana Canada and Datec.
A Real-World Collaboration: Datec & A Tier 1 OEM Supplier
In a pioneering collaboration, Datec in conjunction with a Tier 1 Automotive OEM supplier developed thick-film heaters laminated onto aluminum heat exchangers for EV battery systems. Funded through Canada’s ecoEII, this project advanced performance in cold conditions and passed demanding lifecycle trials—underscoring thick-film’s industrial viability.
Why Engineers Prefer Thick-Film Heaters
✅ Even Heat Distribution
Unlike point-heating pads, thick-film heaters can be designed as continuous, printed circuits covering the full battery surface.
✅ Fast, Efficient Heating
Low heat capacity means rapid warm-up, ideal for preconditioning or standby heating.
✅ Custom Design Flexibility
Screen-printing allows custom heater shapes that seamlessly fit into battery modules and cooling plates—especially on aluminum substrates that aid thermal conduction.
✅ Safety & Reliability
Engineered for even thermal distribution and controlled heating like PTC behavior, they minimize hot spots and energy waste—all backed by rigorous lifecycle testing.
Comparing Heating Technologies
| Technology | Heat Uniformity | Response Time | Integration Ease | Typical Use Cases |
|---|---|---|---|---|
|
Silicone Heating Pads |
Medium |
Moderate |
Adhesive |
DIY battery heaters |
|
Wire Wound Heaters |
Point-based |
Slow |
Bulky |
Industrial preheating |
|
Thick Film Heaters |
Excellent |
Fast |
Thin and custom |
EV modules, energy storage |
Thick-film heaters excel in uniformity, speed, and custom integration—critical factors in EV and storage BTMS designs.
Tips for Integrating Thick Film Heaters in Battery Systems
- Select the Right Substrate
Choosing aluminum substrates enhances thermal conduction. Explore our Thick Film Heating Technology page for technical insights. - Embed in Cooling Plates
Place heaters in direct contact with battery cells or modules, ideally integrated into existing cooling surfaces. - Implement Smart Control
Use thermostats or BMS signals to control heaters, ensuring activation at target thresholds (e.g., <5 °C) without wasting battery power. - Validate Through Life Cycle Testing
Simulate real-world cold cycles to confirm heater performance and durability under extreme scenarios. - Design for Low and High-Voltage Operation
Thick film heaters can be configured for low-voltage systems, such as 12 V DC in off-grid solar or auxiliary EV circuits. They also support high-voltage platforms, including 800 V EV battery packs, making them adaptable across a wide range of battery applications.
Supporting Studies & Industry Best Practices
NREL research highlights performance improvements in cold climates with intelligent battery preconditioning systems—reinforcing the critical role of heating in stored-energy systems. (Check it out here)
Webasto’s electrical Battery Thermal Management (eBTM) system shows EV range gains of up to ~9%, combining active heating and liquid cooling—showcasing segment-wide benefits of integrated thermal solutions
Closing Thoughts: Charge Ahead with Confident Thermal Control
As the EV and off-grid storage markets scale, battery heating solutions are no longer optional—they’re essential. Datec’s low-voltage thick-film heaters merge energy efficiency, design flexibility, and performance reliability for next-gen BTMS solutions.
Whether you’re designing EV battery packs or stand-alone energy storage units, our heaters:
- Ensure fast recovery in cold weather
- Maintain safe and efficient temperature ranges
- Integrate seamlessly into custom, space-constrained modules
Ready to Start?
👉 Explore IntegrAL® heaters to find the right fit.
👉 Need help designing a custom thermal solution? Contact our engineering team today.
👉 Request a Free Sample to evaluate performance.
By integrating temperature control into your energy systems—especially using thick-film resistive heaters—you’re reinforcing battery safety, efficiency, and longevity. Let’s power the future, one temperature-controlled battery at a time.