In this article, we'll analyse the lithium cell formats available on the market and understand which are best for industrial applications. One of the fundamental elements of lithium batteries is undoubtedly the cells they are made up of.
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The 3 most common lithium cell formats in production today are:
Cylindrical cells for lithium batteries are very similar to the batteries in our remote controls at home. The most common format is the cell (18mm diameter, 650mm height), with other formats such as the cell or custom solutions chosen by the cell manufacturer.
The advantages of using cylindrical lithium ion cells are the durable case and the option to change chemistry while keeping the containment mechanism the same.
The negative aspects of cylindrical lithium ion cells include the low capacity of individual cells, reaching a maximum of 3Ah, and the fact that the cells are assembled in series and parallel using welding. This type of construction does not allow the replacement of individual cells, but requires the replacement of the entire module using more invasive and costly procedures.
If your equipment has a battery problem, the entire module needs to be replaced, resulting in costly downtime.In addition, the low capacity of the individual elements and the resulting 'parallel' nature of many elements often result in a decrease in safety of the entire lithium battery pack.
Most lithium ion battery assemblers put a number of cells in parallel to achieve the desired capacity: for example, to achieve a 200Ah capacity using 2.5Ah cells, 80 cells must be arranged in parallel, will all these cells connected in parallel.If, due to an internal problem, one of these short-circuits, it will not only absorb its own energy but must also dissipate all the energy of the 80 cylindrical cells in parallel.
This could result in very high heat in the module, with disastrous effects such as fire. To avoid this, major manufacturers such as Tesla use highly sophisticated production processes which enable the cells to be connected in parallel using a type of fuse. If a cell shorts, the 'fuse' blows and the safety of the battery pack is not compromised.
Unfortunately, none of the lithium ion battery manufacturers in the industrial market has this type of technology. As a result of these negative aspects, we avoid this type of cell in Flash Battery batteries.
In lithium pouch cells, called this because of their package/envelope shape, the dimensions change significantly according to the construction choices of the manufacturer.
The positive aspects of this lithium technology are the high energy density that can be obtained and the low-cost casing. Pouch cells on the market vary from a few hundred mAh up to 20Ah, but few manufacturers exceed this threshold.
The most negative aspect is certainly the fragility of the casing, which doesn't take much to break; even a fingernail can damage it irreparably.
When using this type of cell, the cell packaging system is very important. This must prevent any kind of stress on the individual cells: vibrations, squashing and warping. The cell packaging system for the creation of modules is very important, and therefore it is complicated, if not impossible, to develop custom modules.
The cells always have medium-low capacity.
To create industrial battery packs, it would take dozens of cells in parallel, thus lowering the safety of the battery pack. Again in this case, the individual cells are welded to connect them in series or parallel, and it is therefore impossible to replace a cell, and necessary to replace the whole module.
Prismatic lithium cells have a solid case, usually in plastic or metallic (aluminium) material, and have screw or welded terminals.
The case of prismatic cells is very durable, lending themselves very well to the production of custom battery packs, avoiding complicated studies and expensive tests on mechanical stress.
High capacity of the individual elements: with one cell it is possible to reach up to 300Ah, which is an important quality for the creation of batteries with large capacities, such as in the industrial market, avoiding cells in parallel, which significantly increases the safety of the whole pack.
Another significant aspect is the screw poles. This simplifies assembly and makes the replacement of an element easier, even on-site.
The disadvantage of prismatic lithium cells is the slightly inferior high energy density due to the type of containment case.
Summarising the information above on lithium cells, we could say that:
Flash Battery has chosen prismatic cells for its batteries precisely because of their characteristics. They enable us to achieve high-quality performance in both industrial machinery and electric vehicle applications. Find out more about our lithium technology
Editorial'Grepow
Issue Date'-01-31
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Lithium-ion batteries have become the energy storage solution of choice for a myriad of applications, ranging from portable electronics to electric vehicles and renewable energy systems. Within the realm of lithium-ion technology, there are various cell designs, each with its unique characteristics and applications. In this article, we delve into the world of prismatic, pouch, and cylindrical lithium-ion battery cells, comparing their structures, advantages, and use cases.
What is a Prismatic Cell in a Lithium Battery?
A prismatic cell is a type of lipo battery cell that is characterized by its rectangular or square shape. Unlike cylindrical cells, which are tubular, lithium prismatic cells have a flat and often stackable design. The electrode materials are typically arranged in layers, and the cell is enclosed in a sturdy metal casing. These cells are often used in applications where space efficiency is crucial, as their flat shape allows for better packaging in certain devices. It's important to note that lithium ion prismatic cells are just one of several form factors available for lithium-ion batteries. Each form factor has its own advantages and disadvantages, and the choice of cell type depends on the specific requirements of the application.
Advantages of Prismatic Cells
'Space Efficiency: Prismatic cells are known for their space-efficient design, making them ideal for applications with limited space constraints.
'Stackability: The flat shape of lithium prismatic cells allows for easy stacking, enabling the creation of battery packs with higher energy density.
'Enhanced Thermal Performance: The flat design aids in heat dissipation, contributing to improved thermal performance.
What is a Pouch Lithium-ion Battery Cell?
A pouch lithium-ion battery cell, also known as a flexible or flat-cell battery, is a type of lithium-ion battery that features a flexible, flat, and pouch-like design. Unlike traditional cylindrical or prismatic cells, pouch cells are generally made by laminating flat electrodes and separators, then sealing them in a flexible, heat-sealed pouch or bag made of a flexible material, often aluminum or other polymers.
Advantages of Pouch Cells
'Flexibility and Adaptability: Pouch cell battery can be molded into various shapes, making them highly adaptable to irregular spaces and unconventional designs.
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'Weight Reduction: The absence of a rigid casing reduces the overall weight of the cell, making lithium ion pouch cells a preferred choice for applications where weight is a critical factor.
'Cost-Effectiveness: The manufacturing process for lithium ion pouch cells is often simpler and less resource-intensive, contributing to cost savings.
What is a Cylindrical Lithium-ion Battery?
A cylindrical lithium-ion battery is a type of rechargeable battery that has a cylindrical shape. These batteries consist of a cylindrical metal casing that houses the internal components, including the positive and negative electrodes, separator, and electrolyte. The most common type of cylindrical lithium-ion battery is the cell, named for its dimensions: 18 millimeters in diameter and 65 millimeters in length. While the cell is the most well-known, there are other cylindrical cell form factors, such as and cells, each with different dimensions and specifications.
Advantages of Cylindrical Cells
'Proven Reliability: Cylindrical lithium ion battery cells have been in use for a long time and have a proven track record of reliability and safety.
'Ease of Manufacturing: The cylindrical design lends itself to mass production, leading to economies of scale and lower manufacturing costs.
'Widespread Applications: Cylindrical lithium ion battery cells are commonly found in a wide range of applications, including consumer electronics, power tools, and electric vehicles.
Prismatic vs Pouch vs Cylindrical Lithium-ion Battery Cell
Prismatic, pouch, and cylindrical lithium-ion battery cells are three common form factors used in various applications. Each type has its own set of advantages and disadvantages, and the choice of form factor depends on the specific requirements of the application. Here's a brief comparison:
'Space Efficiency
Prismatic cells are known for space efficiency due to their flat design.
Pouch cells offer adaptability to various shapes and sizes.
Cylindrical cells are compact and easy to stack, making them efficient for specific applications.
'Flexibility
Prismatic cells are less flexible due to their rigid shape.
Pouch cells are highly flexible and can adapt to unconventional spaces.
Cylindrical cells are moderately flexible but less adaptable to irregular shapes.
'Weight
Prismatic cells have a moderate weight, depending on the materials used.
Pouch cells are lightweight due to their flexible packaging.
Cylindrical cells have a moderate weight, influenced by the metal casing.
'Cost
Prismatic cells may have higher manufacturing costs due to their specialized design.
Pouch cells are often cost-effective, thanks to a simpler manufacturing process.
Cylindrical cells benefit from economies of scale and widespread use, contributing to cost-effectiveness.
Conclusion
In the ever-evolving landscape of lithium-ion battery technology, the choice between prismatic, pouch, and cylindrical cells depends on the specific requirements of the application. Each design offers unique advantages, and manufacturers carefully consider factors such as space constraints, flexibility, weight, and cost to determine the most suitable cell type for a given purpose. As technology advances, innovations in lithium-ion cell design continue to drive progress in energy storage solutions across diverse industries. As a global leader in lithium battery cell manufacturing, Grepow offers professional customization solutions for lithium-ion battery packs and Battery Management Systems (BMS), catering to your specific application requirements. If you have any questions or needs, please feel free to contact us at .
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