Electric vehicle battery coolant heater assembly with electrical connection through gasket

A method of assembling an electric vehicle battery coolant heater assembly, the method comprising:

• providing a coolant manifold including liquid coolant pathways and at least one heat transfer surface for transferring heat to liquid coolant flowable within the coolant manifold, at least one electric heater element thermally contactable to the at least one heat transfer surface, and a cover for sealably enclosing the at least one heater element between the at least one heat transfer surface and the cover via a gasket between the cover and the at least one heat transfer surface, the at least one electric heater element electrically connectable to at least one electrical connector extending through and formed integrally with the gasket;
• placing the at least one electric heater element upon the at least one heat transfer surface so that the at least one electric heater element is thermally contacted to the at least one heat transfer surface and heat transferable from the at least one heater element is transferable to the liquid coolant flowable within the coolant manifold;
• placing the gasket with the at least one integral electrical connector on the coolant manifold so as to circumscribe the at least one heater element and the at least one heat transfer surface there below;
• connecting electrical conductors extending from the at least one electrical connector extending through and formed integrally with the gasket with corresponding mating electrical connections of the at least one heater element;
• and
• placing the cover upon the gasket and sealably enclosing the at least one heater element between the at least one heat transfer surface and the cover.