High Temperature Battery Packs

−40°C to 85°C | UN38.3 Certified | All-in-one Solution

High Temperature Battery Packs for −40°C to 85°C Applications — UN38.3 Certified

With nearly 400 successful projects, CMB’s custom high-temperature lithium-ion battery packs deliver reliable operation from −40°C to 85°C for automotive systems, outdoor IoT devices, industrial sensors, smart agriculture equipment, biomedical instruments, drones, and humanoid robots operating in demanding environments.

The best battery for high temperature applications isn’t just a cell with a high rating — it’s a complete custom battery packs sloution engineered around your second requirement.
A high temperature resistant battery pack addresses not just heat, but what heat combines with: sealed enclosures, certification requirements, maintenance cycles, and safety zones. At CMB, we adhere to ISO9001:2015 standards and conduct rigorous in-house validation: temperature cycling, humidity, mechanical shock, and vibration tests. This ensures that what works in theory also survives In practical use.

Why Standard Batteries Fail When Your Environment Reaches 60°C

Capacity drops fast — and silently

Standard Li-ion cells rated at 60°C lose 30–40% of usable capacity when operating continuously above that threshold. Your device appears to be working — until the battery dies hours earlier than expected.

Thermal runaway risk multiplies above rated temperature

Above their rated temperature ceiling, standard cells accelerate electrolyte decomposition. In sealed enclosures, heat cannot dissipate — internal temperature can exceed ambient by 15–25°C. A device sitting in a summer outdoor cabinet at 40°C may expose its battery to 60°C or more.

Failing certification kills the deal

Shipping lithium battery packs to the EU or US requires UN38.3 compliance, a mandatory safety standard for air and sea transport. Many consumer-grade cells or non-engineered battery packs struggle to pass the required safety validations — including thermal shock, vibration, and extreme temperature cycling tests from -40°C to +85°C.

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High Temperature Battery Pack Solutions Built for Your Industry

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Procurement-Ready High Temperature Battery Packs

For buyers who need high temperature batteries with UN38.3 documentation, stable discharge performance, and clear engineering specifications before supplier approval.

Battery Packs for Scan Tools, GPS & Backup Systems

For automotive tools, truck GPS, industrial IoT, and backup equipment exposed to -40°C to +85°C operating conditions.

Wide-Temperature Battery Packs for Outdoor Devices

For IoT gateways, access control, outdoor sensors, and field devices that need reliable lithium-ion battery performance in high-temperature environments.

Long-Cycle High Temperature LiFePO4 Batteries

For outdoor IoT systems that need longer cycle life, strong thermal stability, and a safer chemistry option for elevated-temperature operation.

Waterproof High Temperature Battery Packs

For sealed enclosures, outdoor monitoring, and high-humidity environments where both waterproofing and heat-resistant pack construction matter.

Drop-In High Temperature Battery Replacements

For teams replacing NiMH AA cells or compact 14500 packs with higher-temperature lithium-ion batteries without redesigning the full device.

TECHNICAL SPECIFICATIONS

What Makes a High Temperature
Lithium Ion Battery Pack Perform at 85°C

Current high temperature battery technology requires four things working together: cell chemistry, BMS thermal strategy, pack construction, and enclosure thermal interface design. A high temperature resistant battery pack isn’t defined by its cell rating alone — it’s defined by how those four components are engineered to perform as a system. Here’s how CMB controls each one.

CORE PARAMETERS

Operating temperature -40°C to 85°C continuous

Cell format 18650 / 21700/26650/14500 cylindrical Li-ion

Capacity range 2,000 mAh – 100 Ah

Cycle life at 85°C 500+ cycles → 80% capacity

Self-discharge <3% / month at 25°C ref.

Protection class IP54 std · IP67 optional

PROGRAMME DETAILS

Certification UN38.3 (on file)

Compliance support CE / UL/KC/IEC 62133/CB pathway

Customisation Form factor · Connector · BMS

Engineering sample 3–5 weeks lead time

Production run 6–8 weeks lead time

MOQ200 units (proto from 10)

The High Temperature Battery Technology That Makes 85°C Reliable: BMS Configuration

At 85°C, a standard BMS triggers over-temperature shutdown before your application even reaches operating conditions. That’s not only a cell problem — it’s also a configuration problem.

A high temperature Li-ion battery pack works reliably at 85°C only when two conditions are met simultaneously:

      • 1.The cells are designed for high-temperature chemistry — high-temperature electrolyte, ceramic-coated separator, and heat-resistant tabs. CMB’s heat-resistant battery, for example, maintains a 1C discharge rate even at 85°C, enabled by this chemistry.

    Discharge rate capabilities

        • 2. The BMS is properly tuned for that environment — and at CMB, our engineering team has already designed hundreds of custom high temperature solutions for harsh outdoor environments.

    Without #1, the BMS cannot fix chemistry failure. Without #2, even the best cell will shut down prematurely.

    For the BMS specifically, four configuration levers are critical at 85°C:

    CUTOFF THRESHOLD

    Adjustable — typically set 88–90°C

    CHARGE LIMITING

    Current tapering begins at 75°C

    TEMPERATURE SENSING

    Multi-point NTC sensors within pack

    THERMAL BALANCING

    TIM selection + cell arrangement

    One often-overlooked requirement:
    the BMS hardware itself must be built with high-temperature-grade components, such as 105°C/125°C rated capacitors, thick copper PCB design, and avoiding electrolytic capacitors where possible. Otherwise, the BMS may age faster than the cells it is designed to protect.

    “An off-the-shelf ‘li-ion battery for high temperature use’ is not the same as a high temperature battery pack solution — and the difference lives largely in BMS engineering, but only when paired with the right cell chemistry, proven experience, and manufacturing discipline.”

The High Temp Battery Cycle Life Test Procedure (25℃ 0.5C Charge, 85℃ 1C Discharge)

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  • Initial Charging & Stabilization

    Step 1: Charge at 25℃

    Temp:25℃ ± 2℃ ; Mode: CC/CV ;
    Current:0.5C (1625mA); Voltage:4.2V; Cut-off:0.05C (162.5mA)

  • Evaluation of Test Results

    Rest

    Time:180 (min)

  • High Temperature Exposure

    Step 2 : Discharge at 85℃

    Temp:85℃ ± 2℃; Mode: CC
    Current:1C (3250mA); Cut-off Voltage:2.5V

  • Evaluation of Test Results

    Rest

    Time:300 (min)

  • Repeat the Test Process

    1 Cycle Done

    Cycle life termination?(Capacity ≤ 80% initial)
    Yes–Test End; No–Back to Step 1

Cycle Life(25℃ 0.5C charge,85℃ 1C discharge)
High Temperature Rechargeable Lithium Battery Pack FAQ

What size are your high temperature batteries?

We have the capability to design custom high temperature batteries in a range of shapes, sizes, and capacities to suit the specific needs of you and your equipment.

What's the best battery for high temperature applications up to 85°C?

For continuous 85°C operation, the best battery for high temperature use is a cylindrical Li-ion cell — 18650 or 21700 format — with high-temperature electrolyte formulation. These outperform LFP (lithium iron phosphate) and polymer pouch cells in sustained heat environments. But cell chemistry is only half the answer. BMS configuration and thermal management determine whether performance holds after 500 cycles. A correctly engineered high temperature lithium battery pack retains 80% capacity after 500+ cycles at 85°C.

What certifications are required to ship battery packs to Germany, France, or the US?

UN38.3 is mandatory for all international Li-ion shipments — a legal requirement under IATA (air freight) and IMDG (sea freight) regulations. EU market access additionally requires alignment with EU Battery Regulation 2023/1542 and CE marking where required by product category. US applications typically need UL listing or UN38.3 compliance, depending on application type. CMB maintains UN38.3 documentation for all standard configurations, available to qualified buyers on request.

What if my operating temperature is higher than 85°C?

If your operating temperature is higher than 85°C, our Chief Technology Officer will evaluate your specific needs and design a custom battery pack to meet your equipment’s operating requirements.

How does sustained heat affect lithium-ion battery lifespan?

Temperature is the single largest driver of lithium battery high temperature degradation — more than charge cycles alone.

At 25°C (standard): 500–800 cycles to 80% capacity retention
At 60°C continuous: roughly 200–300 cycles
At 85°C, without high-temp design: as few as 50–100 cycles

CMB’s lithium ion battery high temperature packs sustain 500+ cycles at 85°C — matching standard-temperature performance at a 60°C higher operating point — through combined cell selection, electrolyte formulation, and BMS thermal limiting. A li-ion battery at high temperature doesn’t have to degrade fast. It has to be engineered not to.

How long is your production/delivery lead time for your high temperature battery packs?

For battery samples, if we have the desired battery or a compatible battery in stock, the delivery time is generally 4-7 days. If we don’t have the desired battery in stock, we require 2-3 weeks for production. Mass production generally takes 30 days (without stock). If there are enough batteries in stock, it will take about 1-2 weeks to fulfill an order.

Why do outdoor IoT batteries fail even when ambient temperature seems safe?

This is the most underestimated failure mode in outdoor IoT deployments. A sealed enclosure in direct sunlight at 38°C ambient reaches 55–70°C internally within 30–60 minutes — because electronics generate heat with nowhere to go. A battery rated at 60°C is already at its ceiling before factoring in humidity, which independently accelerates electrolyte degradation.

The rule engineers miss: always specify battery operating temperature for the enclosure’s internal temperature — not the ambient air outside it. That gap is typically 15–25°C under real field conditions. A device “safe” at 38°C ambient may be running its battery at 63°C or more.

Can I build a high-temperature pack by pairing a high-temp cell with a standard BMS?

Technically possible — but a standard BMS rated −20°C to 60°C will trigger over-temperature shutdown before your application reaches operating conditions at 70–85°C. The cell isn’t the failure point. The BMS is.

A true 85°C pack needs three BMS requirements met simultaneously:
1. Adjusted cutoff thresholds (standard 60°C ceiling → configured 88–90°C)
2. Current tapering at elevated temperatures to protect cell longevity
3. Multi-point NTC temperature sensing across the pack

Without all three, even the best high temperature Li-ion battery will either shut down prematurely or degrade rapidly. This is why a cell swap alone won’t solve a high-temperature application problem.

Tailored Customization

Our design team can create custom battery designs for just about any device or machine.

Timely Delivery

Our efficient production and distribution process gets your product delivered in a timely manner.

Quality Guarantee

We stand by our products and guarantee you’ll be happy with your purchase.