A fast-growing Chinese EV manufacturer was preparing its new vehicle platform for colder-climate markets. During winter testing, the engineering team identified a critical performance gap:
The lithium battery system showed poor output, unstable discharge performance, and significantly reduced efficiency in cold weather.
To solve this, they needed a high-efficiency, fast-response, and safe preheating solution for the battery pack—without adding complex control systems or risking overheating.
Very slow activation when ambient temperature dropped below 0°C
Sharp efficiency drop, reducing driving range
Unstable discharge current, affecting safety and acceleration
Ineffective existing heating solution, which could not distribute heat evenly
Temperature imbalance between battery cells/modules
With plans to expand sales to northern China and overseas cold regions, improving cold-weather performance became urgent.
The customer searched for PTC-based heating solutions, known for self-regulating temperature and high safety. They found Tiancheng because of:
32 years manufacturing PTC heating technology
Proven experience in EV battery heating and thermal management
Strong R&D in aluminum-shell PTC heaters
Ability to customize voltage, power, temperature, and structure
Reliable mass-production quality for automotive applications
The engineering team wanted a heater that could:
Heat up quickly
Deliver stable temperature
Avoid overheating
Adapt to the battery’s thermal management system
Improve efficiency without high energy waste
Tiancheng supplied a custom aluminum-encapsulated PTC heater, designed specifically for EV battery pack preheating and cell-temperature equalization.
Self-regulating temperature (±5–10°C stability)
Fast heating response to raise battery temperature rapidly
Aluminum housing for high thermal conductivity
Even heat distribution, preventing cell-to-cell temperature imbalance
No overheating risk, even in zero-airflow or insulated environments
High insulation & safety level suitable for EV battery packs
Compact size, easy to integrate into the existing thermal module
The heater connects directly to the vehicle’s battery-management system (BMS) and operates automatically during cold starts.
The EV manufacturer achieved significant improvements:
Battery efficiency improved by 20–30% in cold conditions
Faster activation, reducing cold-start waiting time
More stable discharge performance, improving acceleration
Longer driving range in winter
No hot spots, thanks to uniform heating across modules
Zero overheating risk
Smoother thermal balance reduces battery stress
Improved long-term reliability of the battery pack
Better winter driving experience
Higher confidence in vehicle performance
Improved competitiveness in northern markets
30+ years deep expertise in PTC materials
Aluminum PTC heaters with excellent consistency and aging performance
Ability to tailor power, voltage, shape, and T-max
Automotive-grade testing (vibration, humidity, insulation durability)
Proven supply capability for EV and battery manufacturers
Fast engineering support during vehicle development
This project demonstrates how Tiancheng’s aluminum PTC heater significantly enhances EV battery performance in cold climates.
By integrating a self-regulating, high-efficiency PTC heating module, the customer successfully:
Improved winter efficiency
Stabilized battery performance
Balanced module temperatures
Enhanced safety
Increased EV competitiveness in cold-weather markets
Tiancheng continues to support EV manufacturers with reliable, customizable PTC heating solutions for modern battery thermal management.
