Post on 10-Mar-2020
Lithium Ion/Polymer Battery AssemblyBattery AssemblyDesign and Trends
P t d b B i MPresented by Brion MunseyWestern Regional Sales Manager
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Cell Types
Safety CircuitsSafety Circuits
Charging
Storage
Shipping/RoHsShipping/RoHs
Qualifying Assemblers
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Cell Types:Cobalt basedManganese (Spinel)Manganese (Spinel)Nickel-Cobalt ManganeseNickel-Cobalt Aluminum PolymerPolymerLithium Iron Phosphate
New Developments:Capacity ImprovementsLower CostsHi Drain Cells
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Safer Cells
Lithium Ion Advantages g
High energy density - potential for yet higher capacities.
Does not need prolonged priming when new. One regular charge is all that's needed.
Relatively low self-discharge - self-discharge is less than Relatively low self discharge self discharge is less than half that of nickel-based batteries.
Low Maintenance - no periodic discharge is needed; there is no memory. there is no memory.
Specialty cells can provide very high current to applications such as power tools.
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Lithium Ion Limitations
Requires protection circuit to maintain voltage and current within safe limits.within safe limits.
Can be subject to aging, even if not in use - storage in a cool place at 40% charge reduces the aging effect.
Transportation restrictions - shipment of larger quantities may be subject to regulatory control.
Expensive to manufacture – due to added safety and regulatory requirementsregulatory requirements.
Not fully mature - metals and chemicals are changing on a continuing basis.
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Lithium Cobalt Oxide LiCoO22
Voltage: 3.7/cell
Pro:
High Capacity
CCon:
Moderate Drain Rate Capability Moderate SafetyModerate Life Spanp
Applications:
Cell Phones, Laptops, Cameras
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Lithium Manganese Oxide LiMn2O4Lithium Manganese Oxide LiMn2O4
Voltage: 3.7/cell
PPro:
SafeHigh PowerLong Life
Con:
Lower Capacity
Applications:
Power Tools, EV, Medical, Hobby
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Lithium Iron Phosphate LiFePO4p 4
Voltage: 3.2/cell
Pro:Pro:
SafeHigh PowerLong LifeLarge Format Available
Con:
Lower Capacity p y
Applications:
Power Tools, EV, Medical, Hobby, Back Up Power
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Back Up Power
Lithium Nickel Manganese Cobalt Oxide
LiNiMnCoO2
Voltage: 3.7/cell
Pro:Pro:
SafeHigh PowerLong Life
Con:
Lower Capacity
Applications:
Power Tools, EV, Medical, Hobby
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Lithium Nickel Cobalt Aluminum Oxide
LiNiCoAlO2
Voltage: 3.7/cell
Pro:
High Capacity High PowergLong Life Span
Con:
Higher CostNot as Safe as LiMn O & LiFePONot as Safe as LiMn2O4 & LiFePO4
Applications:
Portable and EV
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Smart Grid
Lithium Titanate Li4Ti5O124 5 12
Pro:
High Power Fast Charge (10C)Good Low Temp PerformanceLong Cycle Life (6000)
Con:Con:
Lower Cell Voltage (2.4)
Applications:
XEV, Grid, Medical, Military, UPS
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Lithium-Ion Polymery
Voltage: 3.7/cell
PPro:
Flexible PackagingThinLow CostLightweight
Con:Less DurableCan SwellCan Swell
Applications:
Mobile, Medical, Military, EV
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Typical Energy Densities of Rechargeable Battery ChemistriesBattery Chemistries
Lithium-cobalt has the highest specific energyManganese and phosphate are superior
in terms of power and thermal stability and cycle life
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in terms of power and thermal stability and cycle life.
Series:Up to four cells/groups in series (14.4V to14.8V) standard. More than four cells custom requiring cell balancing.
Issues with 5S to 10S Cell StringsCell balancing requiredg qExtra components and custom design increase cost and development time.
FIFO (stock rotation) of cells Important practiceCells lose capacity permanently if stored too long
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Safety Circuit Features
Overcharge ProtectionLimit the charge voltage
Over-discharge Protection Designed to cut off the current path if the battery is discharged below the manufacturer's recommended voltage
Over-current ProtectionDischarge is stopped when output terminals are shortedResettable on PCBA and one time device as backup
Temperature Sensing Via ThermistorDisconnects the charge if the cell temperature approaches 90°C (194°F)
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(194°F)
Charging
Always use a CC/CV charger designed specifically for use with
g g
y / g g p yyour particular Li-ion or Li-Poly battery
Lower charge voltage can increase cycle life at the expense of capacity
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Storageg
Batteries should be stored at room temperature at about 30% to 50% of capacity. Batteries should be charged about once a year to prevent over discharge if not being used y p g g
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Performance
Th lif t f b tt i d d h il h th The life expectancy of batteries depends heavily on how the batteries are used Different cells models are designed for specific benefits such as high capacity, high power, or long cycle life
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Shippingpp g
All lithi i / l b tt i t b t t d d hi i d ith All lithium-ion/polymer batteries must be tested and ship in accordance with the rules outlined in U.S. Hazardous Materials Regulations 49 CFR sub section 173.185 for lithium batteries and cells and/or meet the requirements for shipping according to the IATA Dangerous Good Regulations when applicable regardless of lithium content or Watt/Hour rating.
Testing and Transportation Requirements
All lithium and lithium ion/polymer cells and batteries
ga d ss o u o o a / ou a g
/p ymust pass the following UN Tests prior to being transported:
Test 1: Altitude Simulation Test 2: Extreme temperature changesTest 3: Vibration Test 4: Shock Test 5: External Short Circuit
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Test 6: Impact Test 7: Overcharge Test 8: Forced Discharge
Shippingpp g
Packaging, marking, and shipping documentation requirements for shipments of lithium and lithium ion cells and batteries and batteries
Boxes must be marked appropriately
Shipments must be accompanied by proper documentation
Boxes must be able to pass drop test (must be certified)
Boxes may not exceed 30 kg gross mass
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R HRoHs
House of Batteries is fully committed to meeting the i f h E U i (R HS) Di i requirements of the European Union (RoHS) Directive.
The RoHS directive specifically excludes cells & batteries batteries.
Legislation mandates specific recovery (recycling) programs for batteries and battery assemblies Any programs for batteries and battery assemblies. Any potentially harmful waste stream (WEEE) is avoided.
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Inexpensive poorly designed and cheaply built Inexpensive, poorly designed, and cheaply built batteries are a source of trouble.
Product and corporate reputation is compromised when Product and corporate reputation is compromised when problems occur in the field
Public safety is threatened when poorly designed and built batteries malfunction to the point of presenting a hazard
Product returns increase and extra demand is placed on customer servicecustomer service
Many major manufacturers including Sony, Apple, Nikon, and Disney have had recalls on lithium rechargeable batteries due to quality issues
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to quality issues
Pack Design Best Practices
Qualified Cells: Avoid use of inexpensive, substandard cellsIs assembler certified by manufacturer?
Safety Circuit: Avoid use of substandard components on circuit (counterfeit) Back up with passives Do not use circuit as primary source of discharge termination
Packaging:Plastic enclosure best. Careful layout in soft packs can be safeSoft packs should not be user
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preplaceable