Lithium Battery Cell Models and the Industry Shifts vs

By Anton Beck, Battery Product Manager
Epec Engineered Technologies

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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 .

Battery Cell Basics

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.

Battery Cell Basics

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.

vs. Cell Comparison

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.

Industry Expectations

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.

Higher Capabilities

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.

Summary

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.

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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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The rise of lithium-ion batteries has transformed industries from consumer electronics to electric vehicles (EVs). Among the many battery formats available, the  battery has gained significant attention due to its superior performance metrics and versatility. But what makes the battery so special? Let’s dive into the details to understand its performance and why it’s increasingly becoming the go-to choice for various applications.

What is a Battery?

The term "" refers to the dimensions of the battery: 21mm in diameter and 70mm in length. These cells were initially popularized by Tesla, which transitioned from the format to the in its Model 3 vehicles. The larger size of the offers increased energy capacity, improved thermal management, and better overall efficiency compared to its predecessor.

Key Performance of Battery

1. Energy Density

One of the standout features of the battery cell is its high energy density. A single battery can deliver approximately 30-50% more energy than an cell due to its larger size and optimized design. This translates to longer runtimes for devices and increased range for EVs.

2. Capacity

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Typical capacities for battery cells range between mAh and mAh, depending on the specific chemistry and manufacturer. This makes them ideal for applications requiring extended battery life without frequent recharging.

3. Thermal Performance

The larger size of the allows for better heat dissipation, reducing the risk of overheating during high-drain usage. This is particularly beneficial in applications like power tools and EVs, where batteries are subjected to continuous heavy loads.

4. Cycle Life

A well-designed battery can achieve a cycle life of 500 to cycles or more, depending on its chemistry. This longevity ensures cost-effectiveness over time, especially in commercial and industrial settings.

5. Discharge Rates

With discharge rates often exceeding 10A (and up to 35A for high-performance variants), cells are suitable for demanding applications such as drones, high-performance flashlights, and vaping devices.

6. Applications

The versatility of batteries makes them a popular choice across multiple sectors:

·  Electric Vehicles (EVs): The automotive industry leverages the high capacity and thermal efficiency of cells to enhance vehicle range and performance.

· Consumer Electronics: Devices like laptops and power banks benefit from their compact size and energy capacity.

· Power Tools: Their ability to handle high-drain scenarios makes them a reliable option for cordless drills and saws.

· Energy Storage Systems: Home and grid energy storage solutions increasingly incorporate batteries due to their durability and efficiency.

Advantages of Battery Compared to Other Formats Lithium Battery

Compared to the battery and other smaller lithium-ion formats, the offers:

· Higher Energy Output: Ideal for power-hungry applications.

· Reduced Battery Count: Fewer cells are required to achieve the same energy capacity, simplifying battery pack design and reducing potential points of failure.

· Improved Cost-Efficiency: With higher energy per cell, manufacturers can lower costs for production and assembly.

Battery Challenges and Limitations

While the battery boasts impressive advantages, it’s not without challenges:

· Weight: The increased size and capacity result in heavier cells, which might be a limitation for applications prioritizing lightweight designs.

·Initial Cost: High-performance cells can be more expensive upfront compared to smaller formats.

· Compatibility: Older devices designed for cells may not accommodate the larger without modifications.

Battery Future Outlook

As technology continues to advance, the performance of batteries is expected to improve further. Innovations in cell chemistry, such as silicon anodes and solid-state designs, promise even higher capacities and better safety profiles. With the growing demand for efficient and reliable energy storage, the format is poised to remain a dominant force in the battery industry.

Conclusion

The battery represents a significant step forward in lithium-ion technology. Its superior energy density, capacity, and thermal performance make it a standout choice for a wide range of applications. While challenges exist, the benefits often outweigh the drawbacks, solidifying the as a leading option in today’s battery market. Whether you’re powering an electric vehicle or a high-performance tool, the battery is a reliable and efficient choice for the future.

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