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Battery heating for lithium-ion batteries: Heating mats for OEMs
High-performance batteries form the basis for electromobility, industrial applications and modern logistics systems. However, lithium-ion batteries only operate reliably when they are used within the correct temperature range. Therefore, product developers, engineers, and OEM partners face the question: how batteries can be temperature-controlled efficiently, safely and for a long time.
Embro develops and manufactures for this purpose individual battery heaters in the form of textile resistance heating mats. This proven technology ensures a constant and reliable temperature control and can flexibly adaptable to different geometries and production processes. PTC systems can also be integrated upon request if variable environmental conditions require it.
Why is temperature control crucial for lithium-ion batteries?
Lithium-ion batteries They are now the standard technology in electromobility, industrial applications, and logistics. They are characterized by a high energy density, good charging behavior and long lifetime However, lithium-ion cells only operate within a narrow range. Temperature range of approximately 0 to 40 °C efficient.
✔ At Cold The available capacity decreases significantly, charging processes slow down, and the risk of cell damage increases.
✔ At Heat The cells age faster and the safety of the entire battery system may be compromised.
A targeted one thermal management Batteries are therefore indispensable. Embro develops for this purpose. textile battery heaters, keeping the battery cells in their optimal range and thus ensuring consistent performance, safety and durability to care.
Do you want to reliably protect your batteries and prepare them for performance?
Resistance heating mats: Proven technology for lithium-ion batteries
Resistance heating mats are the most commonly used solution for temperature control in batteries. They work with electrical conductors that generate heat when current flows through them. This principle ensures a uniform and constant temperature maintenance and is particularly suitable for applications where batteries need to be operated reliably within a fixed temperature range.
Features
✔ Constant heating power thanks to conductive wires or yarns
✔ Even heat distribution across the entire surface
✔ Flexible and malleable, even for complex geometries
Benefits
✔ cost-effective and robust
✔ Ideal for applications with a defined temperature window
✔ Reliable heating without complicated controls
Typical areas of application
✔ Electric cars and hybrid vehicles: Reliable operation even in cold weather
✔ Electric commercial vehicles: Consistent performance during winter use
✔ Industrial trucks and logistics technology: safe operation in cold storage facilities
✔ Industrial and special applications: e.g. space travel, deep sea or military systems
Conclusion
Resistance heating mats are the right choice if Predictability, constant heat output and economical series production are crucial. Embro offers you tailor-made heating systems, which can be integrated precisely into your OEM product design.
Benefit from our experience in series production!
PTC heating mats: A complementary option for variable requirements
In addition to the classic wire systems, we can also offer, upon request, PTC heating mats . PTC stands for Positive Temperature Coefficient and describes materials whose electrical resistance increases with rising temperature. The result:
✔ Self-regulating heating output
✔ No risk of overheating
✔ High efficiency at changing ambient temperatures
Typical use cases: Electromobility in regions with highly fluctuating climates, cold storage logistics, or high-performance batteries with variable loads.
Embro focuses on the development and manufacturing of classic resistance heating mats. Additional products are also available upon request. PTC heating mats It will be integrated if the application requires it.
Thermal management for electromobility and industry
In the Electromobility is effective thermal management for Range, charging times and safety of crucial importance. Heating mats assist in preheating the battery in winter, thus ensuring the vehicle's full performance.
Are you developing applications in the fields of electromobility or industry? Then get in touch now and discuss your requirements!
The use of the technology also extends to industrial applications. Battery temperature control a central theme:
✔ Logistics vehicles They must operate reliably in cold storage facilities, even at -20 °C.
✔ Aerospace technology requires heating systems that can withstand extreme temperature fluctuations.
✔ Special machines and industrial trucks benefit from consistent performance during continuous operation.
What advantages do heating mats offer for battery performance?
A battery operated in sub-zero temperatures can lose up to 40% of its capacity. The Charging cycles are lengthening, and the Lifespan is shortenedEmbro heating mats ensure that batteries are always operated within their optimal range. This guarantees consistent charging and discharging performance, increased safety, and a longer service life.
Your benefits
✔ Stable battery performance even in cold weather
✔ Reliable operation under continuous load
✔ less wear and tear
Optimize the performance of your batteries with individual battery heating mats from Embro.
Integration into battery packs and OEM designs
For developers, the question of integration is a key issue: How can a heating mat be integrated into tight spaces and complex battery packs?
Embro focuses on textiles Embroidery technology, which allows for geometric freedom and flexible layouts:
✔ Heating mats are precisely tailored to the cell shape
✔ Fastening solutions such as self-adhesive films simplify installation
✔ Sensor integration enables continuous temperature monitoring
✔ Space-saving design reduces weight and height
Your advantage: A heating solution that integrates seamlessly into your OEM product design.
Develop your individual battery heating mat for your industrial application with us.
Reliability and durability under extreme conditions
Batteries are used in many industries heavy loads exposed, for example Vibration, humidity and large temperature fluctuations. Our heating mats are designed to function reliably for years:
✔ Robust materials such as stainless steel or carbon threads
✔ Consistent heating performance even after thousands of cycles
✔ Resistant to cold, heat and mechanical stress
Your advantage: durable heating systems, which reliably protect your batteries even during continuous operation.
Standards and safety
Especially in the automotive sector, strict standards apply. battery systemsEmbro supports you with heating mats designed for OEMs that meet all requirements:
✔ documented processes and material records
✔ Certified safety at all stages of production
✔ Optional antibacterial and biocompatible materials for special applications
Your advantage: Tested and documented components that integrate seamlessly into your certification processes.
Cost and scalability
Many developments work in the lab, but fail in real-world applications. Series productionEmbros textile heating technology is scalable:
✔ Rapid prototype development for functional testing
✔ Economical series production directly in Germany
✔ Reproducible quality in small and large production runs
Your advantage: predictable costs, short development times and a stable supply chain.
Do you want to be accompanied from the idea to the series?
Conclusion
Efficient thermal management is crucial for electromobility, logistics and industrial applications. Embro offers textile heating mats that reliably regulate the temperature of lithium-ion batteries, extending their lifespan and providing greater safety.
You will receive from Embro Proven resistance heating mats that can be flexibly adapted to any geometry and are suitable for economical mass production. PTC systems can also be integrated if required.
Choose Embro as your OEM partner for customized battery heaters!
Custom-made battery heaters and sensors – cost-effectively produced in Germany
embro is Production Heating elements and heating mats, Sensor mats and more for the B2B marketWe develop for you individual heating elements and produce cost-effective in Germany – for innovative industrial applications in Small and large production runs between 500 and 100.000 units. Learn more about our heaters.
Direct line to the experts
+49 (0)3745 75985-0Questions and answers about battery heaters and temperature control
How are heating mats attached to battery packs?
Embro textile heating mats can be integrated in various ways. The most common are self-adhesive films to be used, as this is a fast assembly enable. Alternatively, Velcro solutions or Tailor-made fastening systems available that can be precisely adapted to the geometry of the battery pack.
Are textile heating mats more durable than foil solutions?
Yes, because textile heating mats are flexible due to their construction. more resistant to mechanical stresses such as vibration or bending. While traditional foil solutions often reach their limits with complex geometries, textile heating mats can be optimally adapted. They offer consistent heating performance for many years.
What temperatures can be achieved with battery heaters?
The heating output is always individually tailored to the specific battery pack and application. Typical operating ranges are between -40 °C and +80 °C. Textile heating mats are therefore suitable for winter operation of electric vehicles as well as for specialized applications in industry, aerospace, or deep sea.
How long do textile battery heaters last?
Their lifespan depends on the operating environment and the load. Thanks to robust materials such as stainless steel or carbon fibers, textile heating mats achieve high cycle stability and remain reliable even in continuous operation.
Are the heating systems suitable for OEM approvals?
Yes, because Embro manufactures with documented processes and tested materials. This makes it easy to integrate the heating mats into the approval processes of the automotive and industrial sectors.
Which is better for lithium-ion batteries: resistance heating mats or PTC heating mats?
Resistance heating mats are the Proven solution for constant operating conditions. you are robust, durable and economical in series production. PTC heating mats can be used as a supplement when self-regulating heating output is required. Embro primarily develops resistance heating mats, but also considers PTC systems upon request.
