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“Rare earth thick film heater: redefining the ‘warm technology’ of new energy vehicles”

Under the industry pain point of the cliff-like decline in the range of new energy vehicles in winter, the thermal management system is ushering in a technological revolution. Traditional PTC heaters are gradually being eliminated due to defects such as low efficiency and high energy consumption, while rare earth thick film heaters have become the core solution of the new generation of thermal management technology with their high thermal efficiency, fast response, and long life. By integrating multiple technological breakthroughs and market demand, this technology is reshaping the thermal management pattern of new energy vehicles.

Technical breakthrough of rare earth thick film heaters
Energy efficiency leap: electric energy conversion rate exceeds 95%
Rare earth thick film heaters use micron-level resistance layer printing technology, and the electric energy-heat energy conversion rate exceeds 95%, which is greatly optimized compared with traditional PTC solutions (generally less than 90%), significantly reducing the consumption of battery power for winter heating.
Extremely compact: volume reduced by 80%
The thickness is only 0.3-1.5mm, and the volume is reduced by 80% compared with traditional PTC heating modules, which is suitable for the compact design requirements of battery packs and motor compartments. The dimensions of the Zhengheng Power solution are only 250*200*55mm (34mm shorter than similar competing products), and the weight is as light as 1.9kg. The installation interface is fully compatible with mainstream models.
Based on rare earth materials and flow channel structure optimization, the operating temperature range covers extreme low temperature to high temperature environment, effectively solving the problem of battery low temperature performance attenuation.

Differentiation advantage
Cabin heating: response speed increased by 60%
The liquid cycle adaptive heating system is adopted. By optimizing the heat exchange path, the heating response time is shortened to 40% of the traditional PTC solution, the energy consumption is reduced by 20%, and the passenger compartment can output warm air within 3-5 seconds.
Motor waste heat recovery: intelligent heat supplement
When the motor stops or in a low temperature environment, the thick film water heating unit integrated in the drive system can quickly fill the heat gap of the heat pump, ensuring that the temperature in the car is stable at 22℃±1.5℃ in an environment of -20℃, and the cruising range is increased by more than 15%.
Reliability upgrade: life of 20,000 hours, accuracy of ±1.5℃
Compared with the metal electric heating tube solution, the service life of the rare earth thick film heater is extended to 20,000 hours, the temperature uniformity error is controlled within ±1.5℃, and the coolant contact area is increased by 40% through the flow channel topology optimization design, which completely solves the problem of thermal efficiency attenuation caused by bubble attachment.

Zhengheng Power’s rare earth thick film heater has passed rigorous DV experimental verification, including 23 tests such as vibration resistance, salt spray corrosion, high and low temperature cycles, and its key performance is fully leading:
Thermal efficiency >95% (@10L/min, 60℃), supports 250~500V wide voltage input;
Protection level IP6K9K/IP67, adaptable to complex vehicle environments;
Intelligent control: supports LIN/CAN communication, and can accurately adjust power, water temperature and duty cycle.
According to industry forecasts, the domestic new energy vehicle heater market size will exceed 25 billion yuan in 2025. With its comprehensive advantages of high efficiency, high reliability and low-cost operation and maintenance, Zhengheng Power has promoted the upgrade of thermal management systems from “functional satisfaction” to “performance leap”, integrating green energy power, passion and innovation, and exploring unlimited possibilities for thermal management systems.