Battery Heating Elements/Battery Heating Solutions


At CHR Inc. heating batteries is one of our core applications.  Batteries do need to stay within an acceptable operating range to deliver the needed power.

These batteries are often used in critical applications such as defense, medical, telecommunication, aerospace, and more.

Both Lead-acid and lithium batteries have needs for heat in cold weather environments.

Lead-acid batteries which are used in cars, trucks and motorcycles when left in the open or in unheated garages require a strong charge to be able start the engines in harsh conditions. Although commonly done, it can be harmful or potentially risky to use or charge batteries if their temperature drops below 32°F (0°C).  Depending on the design we have seen some manufacturers suggest warming above freezing, to 41°F (5°C) to minimize wear. To maximize the operating efficiency of lead-acid batteries in cold temperatures, the batteries should be warmed to an optimal temperature of 68°F (20°C) to 77°F (25°C). Most batteries can be used at temperatures up to 122°F (50°C).

Lithium batteries have a higher charge density (giving them longer life) compared to other batteries, so their popularity has grown. This type of battery is utilized in electric vehicles where high performance is required to optimize the distance required between charges. Battery manufacturers typically utilize lithium batteries in their equipment where extended battery life is a must. However, ambient temperatures impact both charging and discharging of batteries.

Unfortunately, lithium batteries do not perform well in extremely cold weather temperatures. In environments below 14°F (-10°C) the batteries must be heated, and some manufacturers recommend heating when exposure temperatures drop to freezing, 32°F (0°C) as batteries should not be charged below this temperature. Low working temperatures will greatly reduce the discharging current and the overall energy available. The batteries quickly lose their capacity below 60°F (17°C).

Battery Heating Elements - Kapton Etched Foil
Battery Heating Solutions - Silicone Heaters
Battery Heating Solutions - Sensors under Silicone Patch


Custom Heaters and Research Inc. (CHR Inc.) offers Battery Heating Elements that can meet the requirements to keep batteries warm for the applications described as well and many others!

CHR Inc. has provided heaters for batteries for many unique applications:

  •   Aircraft batteries while the plane sits in cold areas
  •   Batteries of airport runway lights which serve as back-up should there be a power outage
  •   Batteries on Cell Phone Towers which serve as back-up
  •   Batteries on US Military equipment in the field (CHR Inc, is ITAR Registered)  

Rugged, powerful and efficient Custom Heaters and Research Inc. can create the proper solution to your battery heating needs.  When deciding upon a supplier, consider certified manufacturers with certifications such as being ITAR regulated, UL and CSA recognized, and ISO certified. 

“Custom” is our First Name!  We begin with a clean slate to create the design a Battery Heating Element to suit your application:

Inquire for a custom solution
Battery Heating Elements - Pre-formed for each Battery Cell

Kapton/Polyimide or Silicone Rubber Heaters can be created as needed:  

  •   Sized as required
  •   Holes or cut-outs are common
  •   Any supply voltage is possible
  •   Wattage/power to suit the application
  •   Silicone Rubber Heaters can have a foam insulation to improve efficiency
  •   PSA Adhesive backing
  •   Magnetic backing 
  •   Integrated thermostats or any type of sensor you require
    • Thermistors
    • Thermocouples
    • RTDs
    • PTCs or NTCs

These Battery Heating Elements can be paired with an existing Temperature Control System, have integrated thermostats or CHR Inc. can provide a Temperature Controller to meet your needs.

Kapton/Polyimide Heaters

CHR, Inc. manufactures Kapton (Polyimide) heaters for many different applications such as; process control, battery warming, telecommunications, laboratory equipment and anti-condensation.

When used for Battery Heating the polyimide heaters can suit any application requiring surface heating from -269°( to 200°C (-452F – 392F).  This is often why they are selected for Aerospace applications.

Their suitability for arduous conditions has been proven in applications from polar expeditions to space exploration. Using expertly and individually designed etched foil tracks, our Kapton heaters can be manufactured to a range of specifications, shapes and sizes to suit the customers’ requirements.

  • Minimal Thermal Mass
  • High Power Densities
  • Fast and Efficient Thermal Transfer
  • Low Outgassing
  • Precise Even Heating
  • Low Profile
  • IP64 Protection
  • Wide Temperature Range -269°( to 200°c (-452F to 392F)
  • Superb Electrical Insulating Properties
  • Extremely Flexible

Silicone Rubber Heaters

Our line of silicone heating mats is well suited to Battery Heating Applications. These silicone rubber heaters can use Etched Foil or Wire Wound heating elements which are laminated between sheets of silicone.

CHR has provided silicone heaters for a wide variety of battery applications including telecommunications, satellite communication antennae and here at CHR, we can assist you to find the proper solution to your heating needs. We’ve made heating solutions from the Arctic Circle to space exploration!

Our All-Weather PSA self-adhesive option is a simple and easy way to adhere our silicone heaters with superb bonding results; even to many low energy materials.  Available in both Acrylic and Silicone PSAs we can handle some of the most extreme environments!

We even offer Magnetic Backed heaters!

Dimensions: Width 940mm maximum x Length 3000mm maximum
Nominal Thickness: 0.7mm-3.0mm (Most Silicone Heaters are 1.5mm thick)
Construction: Two ply woven glass textile reinforced silicone rubber Temperature: -60°C to +200°C maximum continuous 230°C

Physical Silicone Rubber Properties

Weather & Aging Resistance: Very Good
Ozone Resistance: Very good
Gas Permeability: Adequate
Steam Resistance: Good — up to 130°C or 2.5 bar
Fungus & Bacteria Resistance: Very Good
Combustibility: Various Flame retarding materials available
Good Resistance to: Acetone, Alcohol, Formic Acid, Brake Fluid, Chlorodiphenyl, Acetic Acid, Greases, Polar Solvents, Hydrochloric Acid 10%, Sulphuric Acid 10%, Waxes, Plasticisers
Thermal Conductivity: Watt/Meter/K 0.22
Specific Heat: Joule/Kg/K 1623

Heaters are formed to go around the individual battery cells

Heaters are formed to go around the individual battery cells.