PI Heating Films for New Energy Applications | Battery & EV Heater Solutions
PI Heating Films for New Energy Applications: Batteries, EVs & Energy Storage
As electric vehicles (EVs), lithium batteries, and energy storage systems continue to expand globally, temperature control has become a critical factor in safety, efficiency, and lifespan. Among various heating solutions, PI heating films (polyimide heaters) are increasingly adopted as a reliable and lightweight thermal management technology for new energy applications.
PI heating films are widely used for battery preheating, low-temperature protection, and thermal stabilization in EVs and energy storage systems.
1. Why Temperature Control Matters in New Energy Systems
Lithium-ion batteries are extremely sensitive to temperature. At low temperatures, battery performance drops sharply, while extreme temperatures can cause degradation or safety risks.
- Reduced charging efficiency below 0°C
- Increased internal resistance at low temperatures
- Risk of lithium plating and shortened battery life
- Thermal imbalance between battery cells
This is why active heating solutions are essential in EVs and energy storage systems operating in cold climates.
2. What Is a PI Heating Film?
A PI heating film is a flexible electric heater made from polyimide insulation layers with etched metal heating circuits (typically copper or alloy foils). It converts electrical energy into heat with high efficiency and uniformity.
Key Characteristics
- Ultra-thin structure (0.15–0.3 mm)
- Fast thermal response
- Excellent electrical insulation
- Wide operating temperature range (−40°C to 200°C+)
- Customizable shapes, voltages, and power densities
3. Applications of PI Heating Films in New Energy
3.1 EV Battery Preheating
In electric vehicles, PI heating films are installed directly on battery modules or battery packs. They ensure batteries reach optimal operating temperature before charging or driving.
- Cold start battery heating
- Improved charging efficiency in winter
- Extended battery lifespan
[Image: PI heating film installed on EV battery module]
3.2 Energy Storage Systems (ESS)
Large-scale energy storage systems often operate outdoors and are exposed to extreme weather conditions. PI heaters help maintain stable internal temperatures.
- Containerized battery storage heating
- Prevent electrolyte freezing
- Improve system reliability and safety
[Image: PI heaters applied in energy storage battery cabinets]
3.3 Battery Modules & Cells
Flexible PI heaters can be customized to fit cylindrical, prismatic, or pouch cells, providing uniform heating without increasing system weight.
4. Advantages of PI Heating Films Compared to Other Heaters
| Feature | PI Heating Film | Traditional Heating Solutions |
|---|---|---|
| Thickness | Ultra-thin & flexible | Bulky, rigid |
| Heating Speed | Very fast | Slow response |
| Temperature Uniformity | Excellent | Uneven hotspots |
| Customization | High | Limited |
| Reliability | High | Medium |
5. Design Considerations for Battery Heating
- Operating voltage (12V / 24V / 48V / 110V / 220V)
- Power density (W/cm²)
- Adhesive selection for battery surfaces
- Integration with BMS and temperature sensors
- Safety and insulation requirements
Well-designed PI heating films can be seamlessly integrated into battery systems without affecting mechanical structure or energy efficiency.
6. About Our PI Heating Film Manufacturing Capability
As an experienced PI heating film manufacturer, we provide custom-designed heating solutions for new energy applications, including EV batteries and energy storage systems.
- Custom voltage, size, and power design
- Integrated SMT thermistors and connectors
- ISO 9001 quality management system
- Compliance with IPC and international standards
- Stable supply for global OEM customers
Looking for a Reliable PI Heating Film Supplier?
If you are developing EV batteries, energy storage systems, or new energy equipment, our engineering team can support you from design to mass production.
Contact us today to discuss your PI heating film requirements.
7. Frequently Asked Questions (FAQ)
Q1: Can PI heating films operate in very cold environments?
Yes. PI heaters are designed to work reliably at temperatures as low as −40°C or lower.
Q2: Are PI heaters safe for lithium batteries?
Yes. With proper insulation and temperature control, PI heaters are widely used in battery thermal management systems.
Q3: Can the heater be customized for different battery shapes?
Absolutely. PI heating films can be customized for cylindrical, pouch, and prismatic battery designs. © 2025 Polyimide Heating Technology Insights · New Energy Thermal Management