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Heated Clothing Battery Application

In extremely cold weather, whether it’s skiers, outdoor workers, mountain enthusiasts, or sanitation workers braving snow and wind to keep the city running, heated clothing has gradually become a “high-tech essential” for staying warm. And the core component that powers these garments to maintain consistent heat output is the battery system behind them. Without a high-performance battery, even the most advanced heating wires and temperature control systems cannot provide stable warmth.
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Heated Clothing Battery Guide | How to Choose the for Heated Apparel?

The battery in a heated garment does more than just supply power—it must also meet demanding technical requirements for safety, portability, and low-temperature endurance. It needs to deliver strong, consistent output to keep the user warm, without adding extra burden or discomfort during wear.
Today’s consumers place high expectations on heated clothing batteries in terms of battery life, safety performance, and weight control. Behind these expectations lies a real challenge: the comprehensive performance of the battery itself. Unfortunately, many heated garments on the market are still equipped with low-cost, outdated battery modules that offer short runtimes, slow heating, and significant power loss in cold environments—greatly compromising the wearing experience.
So, what qualifies as a “reliable” heated clothing battery? And how should one go about choosing the right battery supplier for heated apparel? In this guide, IRAY Energy will walk you through everything from basic concepts, performance requirements, and type comparisons to safety considerations and supplier recommendations—to help you gain a comprehensive understanding of heated clothing batteries.

1、What Is a Heated Clothing Battery?
A heated clothing battery is a portable power module specifically designed for heated garments and other wearable heating devices. Its primary function is to provide a continuous and stable DC power supply to the heating elements embedded within the clothing—typically made of carbon fiber or metal heating wires—allowing the garment to increase temperature, maintain warmth, and perform intelligent temperature regulation based on the user’s needs. Most mainstream heated clothing batteries today use rechargeable lithium-ion cells. Some are designed as detachable modules (worn on the waist or in a pocket), while others are integrated seamlessly into the garment structure, such as in ski jackets or smart heated liners.
2、What Are the Basic Requirements for Heated Clothing Batteries?
A qualified heated clothing battery must meet several core requirements in real-world applications:
1) Strong Battery Life
One of the primary concerns for users is “how long will it stay warm.” In typical outdoor scenarios—such as all-day skiing or extended duty shifts—the battery is expected to provide at least 6 to 10 hours of stable heat output. Therefore, battery capacity (commonly ranging from 5000mAh to 20000mAh) must be appropriately matched with the power level and the size of the heating area.
2) Excellent Low-Temperature Discharge Performance
Heated clothing is generally used in cold environments, where standard batteries struggle to discharge effectively. This demands that the battery used in heated garments must operate reliably at –20°C or even lower temperatures without performance degradation.
3) Lightweight and Slim Design
For optimal wearing comfort, the battery must be kept within a reasonable weight limit—typically under 300g. Its form factor should also be compact enough to be easily concealed or worn around the waist or back, without interfering with movement or daily activity.
4) High Safety Standards
The battery must comply with safety certifications such as IEC62133 and include multiple layers of protection, including thermal cut-off, short-circuit protection, and overheat prevention. These features are essential to avoid malfunctions that could lead to garment damage or even bodily injury.
5) Smart and Versatile Interfaces
Many heated garments today are equipped with USB-A, USB-C, DC ports, or dedicated aviation connectors, often integrated with temperature control systems. As such, the battery must support standard output specifications (e.g., 5V 2A, 9V 2A, 12V 1.5A) and be compatible with the garment’s heating controller for intelligent operation.
3、Common Types of Heated Clothing Batteries and Their Comparison
Currently, the batteries used in heated clothing can be categorized into several main types. Each type differs significantly in terms of capacity, safety, temperature adaptability, and other performance aspects.
Type Advantages Disadvantages Common Applications
Lithium-ion Battery (18650)
High energy density, supports high-rate discharge, long lifespan
Slightly higher cost, fixed dimensions, not ideal for ultra-thin designs
Outdoor heated clothing, smart heated vests
Lithium Polymer Battery
Customizable shapes, lightweight, ultra-thin design
Relatively higher cost
Smart heated liners, women’s heated wear, slim-fit styles
Nickel-Metal Hydride Battery
Low cost, high safety
Low energy density, short battery life
Some low-end heated accessories, heated insoles
Disposable Lithium Battery
Ready-to-use, suitable for short-term emergencies
Non-rechargeable, not environmentally friendly
Military emergency heated apparel, disaster relief gear
4、Why Are Lithium-ion Batteries Chosen as the Power Source for Heated Clothing?

Thanks to their excellent overall performance, lithium-ion batteries have become the mainstream power source in the heated clothing industry. Compared with traditional disposable batteries and nickel-metal hydride (NiMH) batteries, lithium-ion batteries offer several key advantages:

1) High Energy Density, Compact Size, and Lightweight
Lithium-ion batteries can deliver more energy within a limited space. For example, a 10,000mAh lithium battery can weigh under 250g, whereas a NiMH battery with the same capacity often exceeds 500g. This makes lithium-ion batteries far more suitable for built-in and portable applications.
2) Superior Low-Temperature Discharge Performance
With optimized cell chemistry and manufacturing processes, lithium-ion batteries can maintain stable discharge performance even at –20°C. The voltage remains relatively stable under cold conditions. In contrast, traditional batteries like NiMH or alkaline types experience rapid voltage drops or even fail to start, severely impacting the heating function of the garment.
3) Rechargeable and Eco-Friendly
Lithium-ion batteries typically support 500–1000 charge-discharge cycles. When paired with intelligent charging systems, their effective service life can reach 2–3 years. This not only reduces long-term usage costs but also significantly cuts down on environmental pollution caused by disposable batteries—aligning well with modern sustainability goals.
4) Supports Intelligent Control and Adjustable Output Voltage
Heated garments usually feature multiple heat settings, which require precise and stable power output. Lithium-ion batteries can be configured in series and parallel combinations, and paired with a dedicated Battery Management System (BMS) to achieve accurate voltage outputs (e.g., 5V, 7.4V, 12V), working in coordination with thermal control chips.
5) Strong Customization and Integration Capabilities
For OEM or ODM manufacturers, lithium-ion batteries—especially soft pack polymer types—can be flexibly customized in size, thickness, and packaging. This allows them to conform to different styles and sections of heated garments, enabling truly seamless and unobtrusive power integration.
5、How to Choose the Right Battery Supplier for Heated Clothing?

For heated clothing brands, ODM/OEM manufacturers, or procurement teams, selecting a reliable battery supplier is critical to ensuring product performance, user experience, and long-term brand reputation. The following are key criteria for identifying a high-quality heated clothing battery manufacturer from multiple dimensions:

1) Technical R&D Capability
A qualified battery supplier must possess end-to-end technical capabilities—from cell selection and battery pack design to BMS (Battery Management System) development and low-temperature adaptation. They should be able to offer professional customization based on different heating zones, voltage requirements, and usage environments (e.g., extreme cold, outdoor sports, etc.).
2) Verified Product Stability
Batteries used in heated clothing must not only meet performance requirements but also withstand harsh conditions such as extreme temperature fluctuations, long-term wear and tear, and repeated bending. Therefore, product consistency and reliability are crucial.
3) Flexible Customization Capabilities
Heated garments come in a wide variety of styles and structures, with varying requirements for battery shape, capacity, connector type, and voltage specification. A capable battery supplier should offer flexible customization, adjusting battery dimensions and packaging processes to match the garment design.
4) Support for Prototyping and Mass Production

The development cycle for heated apparel often involves multiple rounds of prototyping and refinement before moving to mass production. An ideal supplier should provide low-volume sampling services and have the capability to respond quickly and deliver stably at scale.

5) Extensive Industry Experience

Not all battery manufacturers are suitable for heated clothing applications. It is advisable to prioritize suppliers with proven experience in wearable battery projects. Review their past collaboration cases, product test reports, and industry references to assess their expertise and reliability.

6、What Are the Key Precautions for Using Heated Clothing Batteries?

As the “energy source” of the entire heating system, the battery in heated clothing not only determines how long heat can be supplied, but also directly impacts user safety and comfort. Therefore, users must strictly follow certain usage guidelines to ensure consistent heating performance while avoiding safety risks and premature battery degradation. Based on extensive project experience and industry feedback, here are the critical precautions for using heated clothing batteries:

1) Do Not Charge the Battery Directly in Low Temperatures

In environments of –10°C to –20°C, the activity of lithium ions inside the battery drops significantly, the electrolyte becomes more viscous, and internal resistance increases. Forcing the battery to charge under such conditions may lead to lithium plating, internal short circuits, swelling, or even thermal runaway.
Recommended Practice: After use, place the heated garment in a room-temperature environment and allow the battery to naturally warm up to above 5°C before charging. If the outside temperature remains extremely low, it is advisable to use a charger with built-in temperature control or pre-heating features.

2) Avoid Using the Heated Clothing While Charging

While some batteries are designed to support simultaneous charging and discharging, in real-world scenarios this practice can lead to localized overheating—especially in winter when thick clothing impairs heat dissipation. This can accelerate battery aging and even pose serious safety hazards.
Recommended Practice: Always disconnect the charger before turning on the heating function. If extended use is needed, consider rotating between multiple battery packs.

3) Do Not Use Non-Original or Incompatible Chargers

Heated clothing batteries are typically equipped with dedicated chargers whose parameters (voltage, current, charging protocol) are carefully matched to the battery protection board. Using third-party USB chargers, fast-charging adapters, or incompatible power supplies may result in excessive current, unstable voltage, battery swelling, aging, or even damage to the BMS circuit.
Recommendation: Always use the original or manufacturer-approved charger to ensure charging safety and long-term battery performance.

4) Use Appropriate Heat Settings and Duration Based on Conditions

Most heated garments offer multiple heating levels (e.g., 40°C, 50°C, 60°C). As the heat level increases, so does the battery’s discharge current. Continuous high-power output may lead to excessive heat buildup, shortened battery life, or the activation of overcurrent protection features.
Recommended Practice: Adjust the heating level according to the ambient temperature and personal comfort needs. For extreme cold environments requiring prolonged heating, select a high-capacity battery pack with multiple cells in parallel to reduce the load on individual cells.

7、Which Manufacturers Specialize in the R&D and Production of Heated Clothing Batteries?
Choosing a professional and experienced manufacturer of heated clothing batteries is essential to ensuring the performance, safety, and user experience of the product. IRAY Energy is a national high-tech enterprise dedicated to the R&D and manufacturing of high-performance lithium-ion batteries, with deep technical expertise in the field of wearable power solutions. The company operates a 10,000㎡ modern production facility with a team of over 300 employees, more than 10% of whom are R&D engineers. Its heated clothing battery products offer the following advantages:

  • Specialized Low-Temperature Battery System: Utilizes high-rate, high and low-temperature lithium-ion soft pack cells that maintain stable discharge even at –20°C.

  • Multiple Standard and Custom Modules: Supports a variety of voltage outputs including 5V, 7.4V, and 12V, compatible with USB-A, DC, and TYPE-C interfaces.

  • One-on-One Technical Support: Engineers assist clients with structural design, battery selection, and BMS matching.

  • Comprehensive Certification System: Products can be supplied with international certifications such as UN38.3, MSDS, IEC62133, RoHS, and REACH.

  • Fast Response and Flexible Delivery: Supports both small-batch prototyping and large-volume orders.

FAQs About Heated Clothing Battery

Can the battery of a heated garment be replaced?
Most heated clothing batteries are designed to be removable and can be replaced by the user. However, some models have built-in batteries that require professional technical support or assistance from the manufacturer’s after-sales service. When replacing the battery, always use a module with the same voltage, current, and connector specifications as the original.
This depends on the battery’s capacity and the heating power level. A 5000mAh battery can typically support low-level heating for 3–4 hours, a 10,000mAh battery lasts about 6–8 hours, and a high-capacity 20,000mAh battery can provide heat for a full day outdoors. Actual runtime may vary depending on ambient temperature, heat settings, and usage conditions.
Although some batteries support simultaneous charging and discharging, it is strongly discouraged during actual wear. Because heated clothing is worn close to the body, using it while charging can cause localized overheating, posing potential safety risks.
Lithium-ion batteries typically support 500–1000 full charge and discharge cycles and can last 2–3 years under normal use. If you notice significant decline in battery life, swelling, or unusual heat, the battery should be replaced immediately.
Some low-power heated garments support standard USB power banks (5V 2A), but most medium- to high-power garments require 7.4V or 12V power, which typical power banks cannot provide. It is recommended to use the original manufacturer-supplied battery.
Charging time varies depending on capacity. Typically, it takes 2–6 hours to fully charge. With fast-charging protocols like PD or QC, a 10,000mAh battery can be fully charged in about 3–4 hours.
Properly designed and certified heated clothing is safe for the human body under normal usage. These garments use carbon fiber or metal wires to generate heat, regulated by temperature control systems to stay within a safe range (typically 35°C–60°C). However, using low-quality products or malfunctioning systems may cause localized burns, electromagnetic interference, or short circuits. To ensure safety, always choose certified products with multiple protection mechanisms and avoid prolonged direct skin contact at high temperature settings—especially for individuals with sensitive skin.

📌 Tip:
For professional Heated Clothing Battery customization or replacement solutions, feel free to contact the IrayEnergy engineering team. We’re here to provide efficient, reliable, and high-performance power solutions!

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