Design Considerations for Lithium Batteries Used in Portable Devices
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The document discusses key considerations for designing lithium-ion batteries for portable devices. It emphasizes that specifications are important to outline physical, environmental, and performance requirements upfront to guide development. Physical constraints, operating ranges, safety systems, and smart battery capabilities that provide information to devices affect costs. A good specification treats the battery design like a blueprint and ensures all necessary factors are addressed to reduce risks.
Design Considerations for Lithium Batteries Used in Portable Devices
- 1. Manufacturing That Eliminates Risk & Improves Reliability Design Considerations for Lithium Batteries Used in Portable Devices 09.26.2019
- 2. Manufacturing That Eliminates Risk & Improves Reliability 2 Agenda What goes into a specification that can be easily turned into a product. Understanding how the physical and environmental requirements affect the design. Cover the major cost drivers of a final battery to power a device. Safety Systems used to protect the battery pack during operation and charging. Smart Batteries – what are they and what does this really mean?
- 3. Manufacturing That Eliminates Risk & Improves Reliability 3 Creating a Specification
- 4. Manufacturing That Eliminates Risk & Improves Reliability 4 Importance of a Specification A specification is necessary. It would be like building a house without building plans. – Project failure and cost overruns happen without it Upfront requirements and performance specs are outlined early at the start of each project. – It is an investment with great return.
- 5. Manufacturing That Eliminates Risk & Improves Reliability 5 Importance of a Specification A specification provides a full understanding of the requirements upfront before development begins. – Provides clear and concise direction – Opens dialog with the customer on options available – Reduces wasted time and cost in changes – No surprises at the end of the project. Helps with product integration, interface, and handshaking requirements. – It goes beyond just the battery. – Seamless integration
- 6. Manufacturing That Eliminates Risk & Improves Reliability 6 Importance of a Specification Physical and electrical interface and environmental aspects must be defined. – Needed for proper cell selection – Additional electronics defined, if required. – Electrical and physical protection.
- 7. Manufacturing That Eliminates Risk & Improves Reliability 7 Physical and Environmental Requirements
- 8. Manufacturing That Eliminates Risk & Improves Reliability 8 Physical and Environmental There are many factors of how the physical and environmental requirements affect the design. – How big or small is the battery? – Is it required to deliver power or energy or both? – Is it even possible to design a battery solution to meet the requirements?
- 9. Manufacturing That Eliminates Risk & Improves Reliability 9 Physical and Environmental What are the high and low operating ranges? – Do these exceed today’s battery technologies? – What can be done if they do?
- 10. Manufacturing That Eliminates Risk & Improves Reliability 10 Cost Drivers
- 11. Manufacturing That Eliminates Risk & Improves Reliability 11 Cost Drivers Basic cells that go into a battery are normally inexpensive, so what makes some batteries more expensive than others?
- 12. Manufacturing That Eliminates Risk & Improves Reliability 12 Cost Drivers Chemistry and number of cells. – What protections are required? – Quality of the cells: • Tier 1 cells • Tier 2 cells – The power and energy rating of the cells.
- 13. Manufacturing That Eliminates Risk & Improves Reliability 13 Cost Drivers Physical geometry of the cells and how they sit within the battery. – Plastic enclosure or heat shrink? – What are the drop requirements? – Does the design need IP67 rating?
- 14. Manufacturing That Eliminates Risk & Improves Reliability 14 Cost Drivers Does the battery have electronics enclosed within? – Fuel gauging – Integrated charger within the battery – Customer electronics in the battery – High-power / high-current connector needed – Built-in inrush protection – Built-in fan
- 15. Manufacturing That Eliminates Risk & Improves Reliability 15 Safety and Protection
- 16. Manufacturing That Eliminates Risk & Improves Reliability 16 Safety and Protection All chemistries require protection to some degree. All chemistries can overheat when shorted, – Overcurrent protection is required. All chemistries can overheat when overcharged. – Over temperature and/or overvoltage protection is needed.
- 17. Manufacturing That Eliminates Risk & Improves Reliability 17 Safety and Protection Li-Ion based chemistries require more protection than others. – Protection from overheating • Heat prevention • Heat dissipation – Protection from reduced cycle life • Undervoltage protection – Protection charging and discharging outside of allowable parameters • Voltage / Current / Temperature – Secondary protection • Medical and IT
- 18. Manufacturing That Eliminates Risk & Improves Reliability 18 Smart Batteries
- 19. Manufacturing That Eliminates Risk & Improves Reliability 19 Smart Batteries A Smart Battery Pack is a battery capable of providing information about its operating parameters to the outside world. – These parameters can include: • Charge level • Battery voltage • Cell voltage • Charge and discharge currents • Battery temperature • State of health • Remaining run time • Remaining charge time • And many more
- 20. Manufacturing That Eliminates Risk & Improves Reliability 20 Smart Batteries The most common method of conveying the information to the host system is through: – I2C – SMBus – Single wire communication
- 21. Manufacturing That Eliminates Risk & Improves Reliability 21 Smart Batteries A smart battery can also be a battery with additional circuitry added that it controls: – Built-in charger with various topologies – Customer electronics – Built-in fan – Integrated Heater
- 22. Manufacturing That Eliminates Risk & Improves Reliability 22 Summary
- 23. Manufacturing That Eliminates Risk & Improves Reliability 23 Summary Treat your specification like a blueprint. Know your physical and environmental requirements. Understand what the major cost drivers are. Know what safety systems need to be in place. What operating parameters need to be provided to the outside world. Additional built-in electronics increase cost.
- 24. Manufacturing That Eliminates Risk & Improves Reliability 24 Our Products Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards RF Products User Interfaces Flexible Heaters EC Fans & Motors
- 25. Manufacturing That Eliminates Risk & Improves Reliability 25 Q&A Questions? – Enter any questions you may have in the control panel – If we don’t have time to get to it, we will reply via email
- 26. Manufacturing That Eliminates Risk & Improves Reliability 26 Thank You Check out our website at www.epectec.com. For more information email sales@epectec.com. Stay Connected with Epec Engineered Technologies Follow us on our social media sites for continuous technical updates and information: