Lithium Ion/Polymer Battery Assembly Design and Trends · 2012-05-31 · Lithium Ion/Polymer...

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Lithium Ion/Polymer Battery Assembly Battery Assembly Design and Trends P t d b Bi M Presented by Brion Munsey Western Regional Sales Manager 1

Transcript of Lithium Ion/Polymer Battery Assembly Design and Trends · 2012-05-31 · Lithium Ion/Polymer...

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

Checklist:

ISO Certified?

Quality Department?

Engineering Staff?

Test Equipment?Test Equipment?

Hazmat Shipper?

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