Hotwatt Blog

How Heaters are Powering the Future of EV Charging and Battery Thermal Management

Written by Backer Hotwatt | Jun 7, 2024 6:51:03 PM

Advanced Heating Technologies Support Faster Charging, Stable Performance, and Reliable Control Across Next-generation EV and Energy-storage Systems

The United States is undergoing a significant transformation in its energy and transportation sectors, driven by the push towards sustainability and the reduction of carbon emissions. Central to this transformation is the role of lithium, a key component in electric vehicle (EV) batteries and charging infrastructure. As the demand for EVs and renewable energy sources grows, so does the need for a robust infrastructure to support these technologies, including efficient EV charging networks.

The Lithium Landscape

Lithium-ion batteries are at the heart of the renewable energy industry. They are essential for storing energy generated from renewable sources, such as solar and wind, and for powering electric vehicles. Lithium batteries are light weight and can hold high voltage, making them an efficient, dense form of energy storage.

Global demand for lithium is growing rapidly. In the U.S. alone, the demand for lithium is expected to increase five-fold over the next several years, to around $55 billion annually by 2030.[i] And advancements in battery technology are enhancing energy density, reducing costs, and extending the lifespan of lithium-ion batteries.

EV Charging Infrastructure

The expansion of the EV market requires a robust and widespread charging infrastructure. Among the challenges of achieving the widespread adoption of EVs is the lack of charging stations. Public and private sector efforts are underway to address this deficit. The number of publicly accessible EV charging ports has more than doubled since January 2021, with more than 206,000 ports reported as of early 2025.[ii]

Auto makers and energy companies are working to build an efficient charging network and companies such as Tesla, ChargePoint, and Electrify America are developing extensive networks of fast-charging stations. As supply catches up with demand, the need for lithium batteries, including newer technologies such as high-capacity lithium-ion batteries and portable lithium batteries, creates exceptional market opportunities.

Expanding U.S. Lithium Resources Fuel a Growing EV Market

Up until the 1970s, the U.S. was a major producer of lithium, but as foreign production surged, domestic production waned. Today the top three lithium producers are Australia, Chile, and China. The U.S. has some of the largest lithium deposits, but less than 1% of the world’s lithium is mined here.[iii]

Ensuring a steady supply of lithium is crucial. Geopolitical factors and market fluctuations affect the availability and price of lithium. Sourcing lithium within the U.S. would significantly impact the ability of manufacturers to ramp up production of EV batteries and infrastructure.

he most significant lithium deposits are located in Nevada, California, and North Carolina. Thacker Pass project in Nevada—estimated to contain 179 million tons of lithium ore—has the potential to become one of the largest lithium mines in the world. Other areas include Clayton Valley, Nevada, known for its rich lithium brine resources, and Salton Sea, California, a potential source of lithium from geothermal brines.

In Newry, Maine a very large deposit of spodumene (crystals that contain the lithium) was discovered that has the potential to supply $1.5 billion worth of lithium.[iv] Environmental concerns and the potential impact on the local community are being examined as the state decides whether to allow extraction of the lithium crystals.

The use of lithium as an energy source helps to transition the U.S. away from fossil fuels and towards cleaner energy sources. While the growth of lithium mining in the U.S. presents significant opportunities—job creation, infrastructure development, and manufacturing growth—it also comes with challenges. Mining for lithium can have detrimental effects on local ecosystems and water resources.

Sustainable mining practices and advances in battery technology will help to mitigate environmental impacts and improve efficiency. Ultimately, the transition to electric vehicles and renewable energy sources will reduce the use of fossil and greenhouse gas emissions. The ability to source lithium domestically will help to ensure a continuous supply of lithium, reduce dependency on other countries, and fuel a growing EV market.

Unlocking Safer, Faster, and More Sustainable EV Charging and Thermal Management

Lithium cells perform best within a narrow thermal window and charge fastest when they’re warm enough to accept high current. Whether warming battery packs before fast charging or stabilizing the thermal environment inside charging hardware, heaters have become a critical enabler of both performance and safety.

When designing EV-charging infrastructure or battery-pack thermal systems, Backer Hotwatt partners with product manufacturers, engineers, and R&D teams early in the design process to ensure:

  • Flexibility, Peformance & Customization: From flexible foil/glasrope to rigid tubular or cartridge heaters, our heating solutions can be tailored to specific battery architectures, thermal-management strategies (liquid vs. solid vs. surface heating), and charging infrastructure designs.
  • Reliability & Robustness: Hotwatt heaters are designed to withstand harsh industrial and environmental conditions, such as shock, vibration, corrosion resistance, and high temperature, that EV charging hardware, coolant systems, and battery packs are often required to operate within.
  • Efficient Thermal Control: For battery systems, controlling temperature is critical for performance, charging speed, and longevity. Foil heaters (for gentle, uniform warming) and tubular or cartridge heaters (for rapid or intensive heating) offer complementary options depending on whether the goal is slow preconditioning, coolant warming, or quick heat-up before charging.

Backer Hotwatt offers a broad portfolio of heating solutions for EV charging infrastructure and battery thermal management. These include:

Cartridge & Immersion Heaters

  • Cartridge Heaters (including high-watt-density variants) deliver localized, high-intensity heat to small or restricted spaces, useful for heating small battery modules or internal components to bring them up to optimal temperature quickly.
  • Immersion Heaters (cartridge-style designed for fluids or gases) support heating of coolant loops, oils, or thermal fluids. These heaters work well for liquid-based battery thermal management systems, such as maintaining coolant temperature during charging or conditioning in cold climates.

Foil & Glasrope Heaters (Flexible Surface/Area Heating)

  • Foil Heaters are thin, flexible, self-contained assemblies that can be embedded in battery pack enclosures or thermal-management housings to provide gentle, uniform pre-heating or temperature maintenance. They are ideal in cold ambient conditions where lithium batteries need to be brought into optimal operating temperature before charging or use.

Strip, Finned-Strip & Tubular Heaters (Robust Heating Elements)

  • Strip & Finned-Strip Heaters provide clean, dependable heat with sheath temperatures up to 1200 °F and watt densities up to 40 W/in², suitable for heavy-duty or industrial-scale heating applications.
  • Tubular & Finned Tubular Heaters are built for shock, vibration, corrosion, and temperature extremes often present in challenging EV infrastructure environments (including charging station enclosures, thermal-management housings, and coolant tank heaters).
  • Heaters can be engineered for pre-conditioning of battery packs, coolant tank heating, or maintaining thermal stability in battery-storage or charging-station hardware with appropriate sheath materials (such as stainless steel or Incoloy) and configuration.  

Band, Ceramic, and Other Specialized Heaters

  • Band Heaters are typically used for cylindrical housings, drums, and tanks. In an EV-charging or stationary storage context, they can be used to heat coolant drums, battery-pack housings, or fluid reservoirs that require uniform heat over a curved surface.
  • Ceramic Heaters with high-temperature resistance (up to ~1300 °F) offer another robust option for applications requiring tight thermal control, potentially for battery-pack pre-heating under extreme cold or specialized thermal-management enclosures.

Custom EV Battery Heating Solutions for Diverse Applications

Backer Hotwatt heaters can be adapted or customized to accommodate a wide range of applications. Our team is ready to tackle any EV charging infrastructure or battery thermal management application requirement; no heating challenge is too specialized, too small, or too complex. A few scenarios include:

  • Battery pre-conditioning before charging: Flexible foil heaters can be embedded inside battery-pack enclosure to gently bring cells to optimal temperature before DC fast-charging.
  • Coolant-loop heating for liquid-cooled battery packs: Immersion or tubular heaters can be used to maintain coolant temperature during cold weather or idle periods.
  • Stationary energy storage / battery-storage units: Strip or band heaters can be used to maintain module temperature in outdoor or unheated enclosures.
  • EV charging station hardware conditioning: Robust tubular or finned heaters can protect electronics, connectors, or coolant tanks from cold, condensation, or temperature swings.

Innovating Together: How Backer Hotwatt Powers High-Performance EV Battery Solutions

The U.S. is well-positioned to become a leader in the EV industry, with significant natural resources and a growing commitment to sustainable energy. Backer Hotwatt partners with industrial users and OEMs to design dynamic heating solutions for the rapidly advancing green energy market.

In addition to custom heaters for lithium batteries, we are well versed in hydrogen fuel cell technology—including the development of heaters for heavy duty, fuel cell powered vehicles that operate in extreme cold weather environments.

We can help you solve difficult engineering and performance challenges, custom designing and building the best heater for your EV battery and other green energy applications. Contact an engineer today to set up an exploration consultation. We look forward to helping you soon.

 

[i] https://www.reuters.com/markets/commodities/global-demand-lithium-batteries-leap-five-fold-by-2030-li-bridge-2023-02-15/

 

[ii] https://highways.dot.gov/newsroom/investing-america-biden-harris-administration-announces-635-million-awards-ev-charging#:~:text=As%20of%20today%2C%20there%20are,paying%20jobs%20in%20communities%20nationwide.

 

[iii] https://investingnews.com/daily/resource-investing/battery-metals-investing/lithium-investing/top-lithium-producers/

 

[iv] https://time.com/6294818/lithium-mining-us-maine/