PTC versus Thin Film-Based Heaters in BTMS

As can be seen in the schematic, one of the key components of the BTMS is the heater, which will heat the coolant and, therefore, in turn, the battery when the battery temperature drops below the minimum threshold. For the high voltages common to commercial EVs, there are two key heater technologies: Positive Temperature Coefficient (PTC) Heaters and Thin Film-Based Heaters.

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PTCs are characterized by a heating element that&#;s electrical resistance increases significantly with temperature. This rise in resistance reduces the current drawn and thus reduces the power output of the heater. Consequently, this decrease in power dissipation effectively limits the heater&#;s temperature.

In contrast, Thin Film-Based heating technology, utilized in Modine&#;s BTMS heaters, comprises a complex layer system of heating elements securely and directly bonded to a heat-exchanging structure that is in contact with the coolant. This design enables nearly loss-free and rapid conversion of electrical power into heat.

Advantages of Thin Film-Based Heaters in the BTMS of Commercial EVs over PTC Heaters are:

• Fast and Precise Heating Adjustment: The intrinsic characteristics of the heating layer of the Thin Film-Based Heater, along with Pulse Width Modulation (PWM) control, allow for rapid and precise adjustment of the heat output of the heater, providing more stable operation than possible with PTC heaters and faster heating of the battery pack.
• Higher Efficacy: Thin Film-Based Heaters maintain a constant power output regardless of coolant temperature across a very wide coolant temperature range. Conversely, with PTC technology, power output decreases as soon as the coolant temperature increases. This limits their effectiveness in heating the battery. Additionally, Thin Film-Based Heaters provide the same power output across a wide voltage range, whereas with PTC heaters, any reduction in voltage reduces power output.
• Increased Battery Life: Thin Film-Based Heaters heat up faster than PTC whilst not generating an inrush current when turned on. The lack of any spikes from the inrush current contributes to increased battery lifespan and reduces damage to other electrical components, too.
• Higher Efficiency: As Thin Film-Based Heaters can be controlled seamlessly in small steps (for example, 50W), the energy wastage of the system is reduced.
• Environmental Benefits: Thin Film-Based Heaters are free from rare earth metals and lead, making them more environmentally friendly and supporting robust supply chains.

In summary, Thin Film-Based Heaters offer advantages in terms of fast responsiveness, high levels of control, high efficiency, improved reliability, and environmental considerations when compared to PTC heaters. These characteristics make them an appealing choice, especially for a Commercial EV BTMS.

Modine&#;s BTMS heaters have operating voltages between 400VDC and 850VDC, delivering up to 10kW of power. In addition, they are IP67 rated, providing assurance around durability in harsh environments. Lastly, they conform to ISO and ISO.

As part of the overall BTMS, therefore, the heater plays a critical role. It assures battery life and battery performance during cold weather, demanding a responsive, efficient solution. The Thin Film-Based Heaters that Modine uses are ideal for this, especially when integrated with the other high-performance components in the Modine BTMS. Additionally, the integrated master controller of the BTMS, which includes Modine&#;s proprietary firmware, ensures that the heater and all other BTMS components work optimally as a system and deliver peak performance to the application. The Modine application engineering team can support determining suitability and product selection based on their varied and extensive experience across a range of commercial EVs.

The market for electric vehicles in the U.S. is rising, with record sales reported in the second quarter of . This has resulted in a need for more efficient vehicle components, such as the ones used in modern heating and cooling systems. That is why KUS now offers components for energy-efficient vehicles, including our positive temperature coefficient (PTC) heating units. Here&#;s what you need to know about PTC heaters and their role in thermal management systems.

What Is a PTC Heater?

PTC heaters operate on the principle that the electrical resistance of the heater increases as the heater&#;s temperature increases. The result is a self-regulating heating system. Unlike traditional heating elements that might require external thermostats or regulators, PTC heaters automatically adjust their heat output based on ambient temperature, this increases performance and reduces risks of potential thermal events.

One of the standout benefits of using PTC heaters over traditional heating elements is their efficiency. These systems can generate more heat while using less energy. By conserving energy, these heaters offer tangible benefits for electric vehicles, such as increased cruising ranges.

Comparing PTC Coolant Heaters and PTC Air Heaters

While PTC heaters have gained popularity in the automotive industry, it&#;s important to understand that different types are designed for specific applications. Two of the most commonly used types are PTC coolant heaters and PTC air heaters.

PTC Coolant Heaters

PTC Coolant Heaters

PTC coolant heaters are designed to heat a vehicle&#;s coolant. It primarily serves as a channel with a heating element to help maintain the vehicle&#;s battery at an optimal temperature. For this reason, they serve as an essential component for electric applications, especially during colder months. Maintaining the correct temperature for the battery ensures longevity and maximizes the vehicle&#;s performance.

PTC Air Heaters

PTC Air Heaters

As the name suggests, PTC air heaters focus on heating air directly. They are often used with a vehicle&#;s HVAC system to ensure the interior remains comfortable for passengers. In many modern vehicles, PTC air heaters have replaced the traditional heater core used in older models. PTC air heaters provide immediate warmth since they don&#;t rely on a secondary medium like coolant. This direct method can offer more rapid temperature changes in the cabin, enhancing passenger comfort, and help to decrease additional leak path potentials.

The Role of PTC Heaters in Alternative Energy Vehicles

KUS heaters feature impressive designs that help them serve in various applications. Our heaters stand out for several reasons, including:

• In-vehicle air conditioning. Air conditioning systems are necessary in modern vehicles, and PTC heaters ensure that the in-vehicle A/C systems are up to the mark.
• Battery thermal management. Batteries, especially those in electric vehicles, need to operate within a specific temperature range to ensure longevity and efficiency. PTC heaters help maintain this optimal temperature, especially during colder months.
• Hydrogen fuel cell cold starts. Starting a new energy vehicle in cold conditions can be challenging, especially if it&#;s a fuel-cell vehicle. PTC heaters assist in these cold starts, ensuring the vehicle operates smoothly regardless of the external temperature.

PTC Heater Benefits and FAQs

KUS PTC heaters offer several advantages over traditional heating elements. However, many are unfamiliar with these benefits. Here are some of the most common questions we receive about our PTC heater products.

What is the benefit of the PTC heating element?

The main benefits are energy efficiency, precise temperature control, and compact size. PTC heaters self-regulate their heat output based on conditions, maximizing efficiency.

How efficient is a PTC heater?

PTC heaters are very efficient. They generate more heat using less energy compared to traditional heating elements, thanks to their automated, self-regulating design.

What is the maximum temperature for a PTC heater?

PTC heaters can typically heat up to around 572°F (300°C) efficiently. The maximum temperature depends on the specific heater&#;s design and specifications.

Are PTC heaters cheaper to run?

Yes, PTC heaters are generally cheaper to operate. Their energy efficient design means they use less electricity to produce heat. This saves on energy costs compared to less efficient heating methods.

What size are KUS PTC heaters?

With the push toward more compact vehicles, every inch of space counts. KUS PTC heaters feature compact designs without compromising efficiency. At the same time, we offer multiple PTC heater products that meet the needs of a wide variety of applications.

PTC Heater Models and Specifications

From Electric Automotive vehicles to Material Handling and Industrial/Commercial platforms, KUS PTC heaters can be used in a wide range of applications. Review our popular PTC heater models in the chart below.

KUS PTC Water (Coolant) Heater Models

Model Rated Voltage Rated Power Rated Condition Dimension (L*W*H) Customized Pressure Drop

NPH10A

80V

3kW

Flow rate: 10L/min

Coolant temp: 32°F/0&#;

182*136*112

10kPa

NPL20

350V

5kW

Flow rate: 10L/min

Coolant temp: 140°F/60&#;

182*136*110

5.5kPA

NPH30A

600V

7kW

Flow rate: 10L/min

Coolant temp: 32°F/0&#;

221*136*110

20kPa

NPH30C

600V

7kW

Flow rate: 25L/min

Coolant temp: 32°F/0&#;

321*170*128

14.7kPa

NPH40

600V

10kW

Flow rate: 10L/min

Coolant temp: 32°F/0&#;

255*299*104

3kPa

NPH50

600V

15kW

Flow rate: 25L/min

For more information, please visit Electric Vehicle Ptc Heaters.

Coolant temp: 32°F/0&#;

255*229*104

8.6kPa

NPK40

800V

10kW

Flow rate: 12L/min

Coolant temp: 140°F/60&#;

255*247*104

3kPA

NWL40

350V

4kW

Flow rate: 12L/min

Coolant temp: 68°F/20&#;

153*191*88

3kPa

NWH80

800V

8kW

Flow rate: 12L/min

Coolant temp: 68°F/20&#;

200*237*88

5kPa

 

KUS PTC Air Heater Models

Model Rated Voltage Rated Power Rated Condition Dimension (L*W*H mm) Weight

Air Heater (Integrated Type)

800V

10kW

Inlet air temp: 77°F/25&#;

Air speed: 7m/s

370*260*108

6.5kg

Air Heater (Split Type)

600V

5kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

250*280*32

3.0kg

Air Heater (Integrated Type)

600V

5kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

317*180*108

3.7kg

Air Heater (Split Type)

350V

5kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

250*280*32

2.8kg

Air Heater (Integrated Type)

48V

4kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

227*167*98

3.1kg

Air Heater (Integrated Type)

350V

3kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

305*180*108

3.1kg

Heat Pump Air Conditioning Auxiliary Heater

12V

1kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

27*93*30

0.7kg

For more information, visit our PTC heaters product page.

Explore More New Energy Products From KUS

PTC heaters will play an increasingly important role in vehicles moving forward. With their efficiency, safety features, and adaptability, they are set to redefine vehicle heating systems.

At KUS, we&#;re ready to meet the changing demands of the automotive industry. With our range of PTC heaters and other new energy products built and tested in-house, we&#;re your trusted partner for a large selection of marine, vehicle, and industrial applications. Contact us today to speak with an expert on our team to learn more about how our products can meet your project needs.

Contact us to discuss your requirements of Ptc Heater for Warmer. Our experienced sales team can help you identify the options that best suit your needs.