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I. Introduction
The Lithium-ion battery is a rechargeable battery that has become increasingly popular in the past few years due to its high energy density, long cycle life, and low self-discharge rate. The name derives from the battery&#;s specific measurements,18 means a diameter of 18mm, 65 means a height of 65mm, and 0 means the battery shape is cylindrical.
In this section, we will discuss the working principle, development history, advantages, and applications of the Lithium battery.
1. Working Principle
The Lithium-ion battery is a type of rechargeable battery that uses lithium ions to store energy. The battery is made up of three main components: the anode, the cathode, and the electrolyte. When the battery is charged, lithium ions move from the cathode to the anode through the electrolyte. During discharge, the ions move back from the anode to the cathode, producing electrical energy.
2. Development History
The Lithium-ion battery was first introduced in the s by Sony Corporation. It was initially used in small electronic devices such as laptops, camcorders, and digital cameras.At the time, thehad a relatively low energy density, limited capacity, and a high cost, which restricted its use to high-end products. However, as the technology improved, the battery became more affordable and widely available. In the early s, the battery's capacity and energy density increased significantly, making it suitable for use in electric vehicles, power tools, and other high-performance applications. This led to an explosion in demand for the battery, with sales doubling every year.Today, the battery is used in a wide range of applications, from electric bikes and power tools to flashlights, portable electronic devices, and even some medical equipment. The battery's popularity continues to grow due to its high energy density, long cycle life, and low self-discharge rate, which make it an ideal choice for many applications.
3. Advantages & Applications
One of the main advantages of the Lithium-ion battery is its high energy density, which means it can store a lot of energy in a small space. This makes it ideal for use in devices where space is limited, such as laptops, smartphones, and other portable electronics.
Another advantage of the Lithium-ion battery is its long cycle life. Unlike other types of rechargeable batteries, such as nickel-cadmium and nickel-metal hydride, the Lithium-ion battery can be recharged hundreds of times without losing its capacity. The Lithium-ion battery is also known for its low self-discharge rate, which means it can hold its charge for a long time, making it ideal for use in emergency backup power supplies.
One of the major drivers of the battery's continued development has been the growth of the electric vehicle industry. Electric vehicles require high-capacity, high-performance batteries that can deliver reliable and consistent power over long periods of time. The battery's high energy density and long cycle life make it a perfect fit for electric vehicles, helping to drive innovation and improve performance in the sector.
II. Basic Lithium Battery Terminologies
In this section, we&#;ll discuss the basics of lithium battery terminology and explain the differences between capacity, discharge rate, charge rate, continuous discharge rating (CDR), cycle life, cut-off voltage, power circuit module (PCM), and battery management system (BMS).
1. Capacity
The capacity of a lithium-ion battery refers to the total amount of energy it can store. Capacity is typically measured in ampere-hours (Ah) or milliamp hours (mAh).
The battery ranges from -mAh. A higher capacity means that the battery can store more energy for a given battery size and weight than a lower-capacity model. Higher capacities also tend to be more expensive.
2. Discharge-Rate & Charge-Rate
The maximum rate at which a battery can safely discharge its stored energy is referred to as its discharge rate. This is usually measured in amps (A) or milliamps (mA).
The higher the discharge rate, the faster the battery will drain its stored energy when used in an application. Similarly, charge rate refers to the maximum rate at which a battery can be recharged without damaging battery cells or reducing its lifespan.
3. Continuous Discharge Rating (CDR)
The continuous discharge rating (CDR) measures the maximum amount of current that a lithium-ion cell can safely deliver over time without overheating or damaging itself. This rating is expressed in amps or milliamps per cell and will vary depending on the type of cell being used.
This rating should never be exceeded when using lithium batteries for an application, as doing so could cause them to become unstable and even explode due to overheating.
4. Cycle Life
The cycle life of a lithium-ion battery refers to how many times it can be fully charged and discharged before reaching the end of its lifespan.
Typically, these batteries have cycle lives ranging from 500 up to cycles, depending on their quality and usage conditions.
The number of cycles that a particular cell has left before it reaches the end of life is usually indicated by its internal protection circuit, which monitors remaining capacity levels over time - if this drops below 80%, then it&#;s likely time for a new cell.
5. Cut-Off Voltage
The cut-off voltage is a crucial parameter for the safe and efficient operation of the Lithium-ion battery. It refers to the voltage level at which the internal protection circuitry of the battery disconnects load current flow to prevent further draining of the cell's energy stores.
Discharging the cell below the cut-off voltage level can lead to irreversible damage, reducing the battery's overall lifespan and performance.
In addition to protecting the battery during use, the cut-off voltage also plays a crucial role in protecting the battery during storage periods between uses, especially in applications such as solar lighting systems, where the battery may remain unused for extended periods.
Discharging the battery below the cut-off voltage level during storage can lead to a complete loss of capacity or even permanent damage.
6. Power Circuit Module (PCM) and Battery Management System (BMS)
To ensure the safe and efficient operation of the Lithium-ion battery, the battery incorporates several safety features, including the power circuit module (PCM) and the battery management system (BMS).
The PCM is installed inside each individual cells and provides essential safety features such as overcharge and over-discharge protection circuitry, ensuring that the battery is not overcharged or discharged beyond its safe limits.
The PCM also includes balancing currents across all cells within any series-connected packs to prevent any single cell from becoming overly depleted while others remain charged up, leading to potentially dangerous destabilizing effects within large series-connected packs made up of multiple cells, such as those found in many large-scale solar lighting systems.
The BMS is a more comprehensive system that monitors the battery's overall health and performance, including parameters such as temperature, voltage, and current. The BMS also controls the charging and discharging of the battery, ensuring that it operates within its safe limits and prolongs its overall lifespan.
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III. The Different Comparisons of Lithium Batteries
With dozens of different variations on the market today, it can be difficult to discern which one is right for your project.
In this section, we&#;ll take a look at three important distinctions between various lithium batteries: flat top vs. button top, protected vs. unprotected, and PCB-built-in vs. bare cell battery.
1. Flat Top Vs. Button Top Battery
The primary difference between a flat top and a button top battery lies in their physical design; the latter has an extended protrusion at its positive end, while the former does not.
Depending on what device they are being used with, one might be more suitable than the other due to size constraints or compatibility requirements. The button top can also provide extra security when inserted into a device as it prevents slipping out easily when compared to the flat top design.
2. Protected Vs. Unprotected Battery
The main factor that sets protected and unprotected batteries apart are safety features. A protected battery will always come with an integrated safety circuit designed to protect against common issues such as overcharging and short-circuiting.
An unprotected cell lacks any integrated protection measures; while they may be cheaper upfront, they carry more risk and should only be used by experienced users who know how to safely store and use them.
3. PCB Built-in Vs. Bare Cell Battery
PCB built-in batteries have their own printed circuit boards (PCBs) within the casing that allow for better power distribution, monitoring of current draw, temperature regulation, and improved overall performance.
On the other hand, bare cells lack any form of additional electronics within their design; these types are generally best suited for basic applications where additional monitoring or control isn't necessary.
Conclusion
The Lithium-ion battery has revolutionized the world of portable electronics, electric vehicles, and renewable energy systems. Its high energy density, long cycle life, and low self-discharge rate have made it a popular choice for various applications. From laptops and smartphones to electric cars and bikes, the Lithium-ion battery has played a critical role in powering modern-day technology.With the rise in popularity of electric vehicles, the Lithium-ion battery is also becoming increasingly important in powering electric trike . Its compact size, high energy density, and long cycle life make it an ideal choice for powering the electric motors of these vehicles, providing a sustainable and efficient transportation option for the future.
By Anton Beck, Battery Product Manager
Epec Engineered Technologies
The lithium battery industry has undergone great strides to meet the ever-increasing power demands of electronics and equipment. These batteries are found in power tools, cars, medical devices, and a range of other machines. Many different sizes and shapes of lithium batteries were being produced during the past two decades as demand fluctuated.
Cylindrical cell models come in a number of sizes as their popularity has caused massive growth in production. Several cell models are available, however, the two that are competing head-to-head when it comes to size and capacity are the vs. models (Figure 1).
Figure 1: Example of lithium battery cell models vs .
The battery cell model became the most optimized lithium battery to be produced in , although it has been around since as Panasonic first debuted this cell. The battery was longer and wider than the standard AA batteries as the numbers designate the cell model&#;s size. For the , it was 18mm diameter and a length of 65mm. These batteries provide 2,300 mAh to 3,600 mAh capacities and about 3.6 volts to 3.7 volts.
The cells neared a peak reaching , yet then came into new demand with the rollout of electric cars such as the Tesla. The production of drones, medical devices, and mil-aero equipment also required these batteries. In , nearly 2.55 billion cells were produced. The batteries had a good reliability rate and were low in costs to produce per watt hour.
When looking at the current market, many electronics have gone through drastic design changes. Equipment that required greater levels of power was becoming slimmer and flatter, such as tablets and smartphones. While the demand waned in these market sectors, the fear of battery shortages for the electric vehicle, mil-aero, and medical industries caused manufacturers to create an oversupply of these types of cells. However, the increasing power demands of electronics will soon cause a need for cells with greater capacity. Due to this scenario, the cell models may meet this rising demand.
The cells became introduced in . They were made in a joint effort between Panasonic and Tesla. The battery cell has a dimension of 21mm diameter and 70mm in length. The cells are slightly larger than the and have a higher capacity. These cells have the same nominal capacity of the batteries they were designed to replace, as they still came as 3.6 volts to 3.7 volts. Yet, they have a greater capacity of 4,000 mAh to 5,000 mAh.
The batteries may come protected or unprotected. Protected cells have a battery management system (BMS) for protection and to prevent overheating. Unprotected cells do not have these safety protections. While being available as cylindrical, the batteries may also come as flat and may also have a button-top version. These battery cells were designed to replace the for electric vehicles.
When comparing cells to cells (Figure 2), the batteries have a 50% capacity. The cells also have a greater energy density and a discharge rate of 3.75c. Energy density increases are also lower for the as they may range from 2% to 6% depending on the manufacturer's internal construction for the cells.
The charge and discharge rates for both cells are basically similar. There may be higher polarization for the cells, while the cells have lower resistance and stronger heating. When the battery undergoes cycling, the capacity fades for cells and cells are the same.
Figure 2: Dimensional characteristics of the and cell models.
Electronics and car manufacturers have looked at the as a suitable replacement for previous lithium cell versions based on their ease of manufacturing as well as the higher capacity options. The design options for these cells are numerous, as they can come as button cells, prismatic cells, and pouch cells. For designs that have higher costs to the manufacturer, such as pouch cells, cost reductions can be obtained with both the cells as well as the cells. In addition, major cost reductions are expected for several years when manufacturing pouch cells as more economical production methods are introduced with the increase and changes in technology.
The benefits of having a battery cell with greater runtime and more capacity will allow the to be a suitable alternative to the . Yet manufacturers will still continue to roll out the cells for various applications that do not require the larger capacity to function and when space requirements force the cell design to be smaller in size than the .
When looking at the manufacturing industry for lithium cells, the need for lightweight batteries with flexible designs and high capacities will remain in demand for the foreseeable future. This increased capacity will force manufacturers to consider how to make changes to the cell models to convert them to without any redesign.
The flexible PCB areas in rigid-flex circuit boards offer a higher range of capabilities than traditional rigid circuit boards with wired interconnects. When the product design requires high-speed signals and controlled impedance (Figure 4), the flexible board can handle the transmission loads effortlessly. The flexible areas can also provide high levels of shielding for EMI and RF interference from either component within the product or from outside sources. Another benefit to rigid-flex circuits is that they work reliably even when being used for applications in harsh environments. The boards have good corrosion resistance, chemical resistance, and UV resistance. They can also handle higher temperatures up to 200°C while being able to dissipate generated heat.
Many top-tier cell manufacturers are shifting their focus from the historically predominant cell model to the cell model. As more manufacturers move in this direction, the cell designs and chemistries will vary between each company. Selecting the right cell will be dependent on the requirements of the application, the size of the required battery, and other specifications. One of the major design considerations that will become an important factor with battery manufacturing rests with the flat cells. If the same cell performance of a cylindrical cell can be met when forming it into a flat cell design, the market for these cells will rocket forward for decades to come.
In the near future, the demand for cells will continue onward for many mil-aero, medical, and automotive applications. As more cell designs saturate the market, this saturation may cause manufacturers to lower the amount of available batteries when switching over their production line capabilities. Speaking with a battery pack manufacturer like Epec, regarding the design of their cells allows a company to figure out which type of batteries to use currently and what changes may need to be made in the future if a battery cell becomes obsolete.
From design to production, our team of experienced engineers at Epec is here to help you design a custom battery pack that meets all safety standards and regulations involved with lithium chemistries.
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