For manufacturers of portable devices, it is difficult to select the right battery pack for the handheld device. Because the choice of battery will have a great impact on the function, model and cost of the device. Designers face many options, from simple lead-acid battery packs to complex lithium-ion batteries that integrate electronic safety, surveillance and charge control circuits.
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NiMH battery
This battery has twice the capacity of the same volume of NiCd battery, is lighter, more environmentally friendly, and does not require electronic safety equipment. NiMH batteries are replacing lead-acid batteries as transitional products for lithium-ion and lead-acid batteries in many applications, while NiCd batteries are focused on high-speed applications.
In general, these batteries must be recharged at least once a year when not in use. Moreover, NiMH batteries are also subject to the memory effect caused by voltage drop.
Lithium Ion Battery
Compared with NiMH batteries, lithium-ion batteries can provide 1.5 to 2 times the capacity of electric energy, without memory effect, and the self-discharge rate is only 1/3 of that of nickel-based batteries. However, lithium-ion batteries require protection circuitry to limit voltage and current.
Until recently, lithium-ion batteries were not suitable for power tools and other devices that required high discharge rates. However, several battery manufacturers have begun to manufacture lithium ion batteries with high discharge rates. Using nanotechnology, A123 Systems of the United States has developed a lithium-ion battery with 5 times current gain, 10 times life, and 90% battery capacity in 5 minutes. This battery is a very stable electrochemical system that can withstand overcharging or overdischarging without thermal collapse and can be used as a safe and durable alternative to traditional lithium chemistry batteries.
lithium polymer battery
Lithium polymer batteries have higher energy density than lithium ion batteries of the same weight. Lithium polymer batteries provide designers with a high safety factor under overpressure and high temperature conditions at any board area.
The boiling point of lithium-ion battery electrolytes is usually very low, causing the metal casing to expand at high temperatures. In comparison, the electrolyte of a lithium polymer battery is a gel or a solid with a high boiling point, which is less prone to expansion at high temperatures.
Lithium-ion batteries have less tolerance for improper use than other chemical batteries. In addition, lithium-ion batteries must meet certain regulations. For example, if the battery contains more than 8g of lithium, it must be transported as a Class 9 hazardous material.
NiCd battery
NiCd batteries are cheaper than NiMH batteries and are a cost-effective option for portable applications. Another attraction is the long life cycle and high discharge rate.
There are several disadvantages in the chemistry of NiCd batteries, the most important being the toxicity of Cd and the relatively low energy density. In addition, if the NiCd battery is repeatedly charged and discharged, its voltage and capacity will change significantly.
Closed lead acid battery (SLA)
Sealed lead acid batteries are easy to maintain, have a low self-discharge rate, and are less expensive than rechargeable chemical batteries. The main disadvantage is that the energy density is low and it becomes very cumbersome.
Pure lead-tin SLAs are ideal for outdoor applications such as scooters, wheelchairs, and other applications where a wide temperature range is required, while lead-calcium batteries are typically used in standby power systems or other low-cost power supplies.
Main battery
Cheap and disposable properties make alkaline batteries widely available. It has a moderate leakage rate and a five-year or longer shell life. On the other hand, its energy density is much smaller than that of lithium batteries, and the electrolyte will freeze at around -20 °C.
Lithium sulfide batteries are high-end alternatives to traditional alkaline batteries and are ideally suited for smoothing large pulse currents. The life of the enclosure is up to 15 years and can operate over the -40 to +60 °C temperature range. Lithium manganese dioxide batteries have high energy density, reliability and long shell life. Relative to lithium sulphur dioxide batteries, it is characterized by low volatilization and low cost, providing a good balance between performance and safety. Lithium sulphur dioxide batteries have high rates and good performance at low temperatures. These features make it a versatile choice for military equipment such as portable radios, night vision equipment and emergency positioning buoys.
Lithium thionyl chloride batteries have the highest energy density in lithium-ion batteries and can be used for 15 to 20 years, making them suitable for applications with low continuous current and the need to moderate pulse currents.
Figure shows the energy density of several main and rechargeable batteries
safety
A poor quality battery can't be safed by simply adding a protective circuit. It can easily cause a thermal collapse. It can explode if it falls on the floor or is exposed to high temperatures. On the other hand, high energy density batteries can be in an unsafe condition if there is no suitable device to prevent overdischarge or charging, large inrush currents or short circuits in time.
When the protection circuit becomes less reliable for a number of reasons, the battery pack will require a backup safety system, or at least one specialized thermal protection circuit or device. Thus, if the temperature rises to a dangerous level, the thermal fuse or electronic control unit will shut down the battery.
The most ideal battery pack should have a battery with similar capacity and state of charge, and can balance the power between the batteries through electronic components to achieve balance.
Manufacturing a battery pack requires a lot of design and manufacturing experience, as well as an in-depth understanding of the components of the battery pack. Some OEMs have the ability to produce themselves, while others give it to a specialized company to produce. In any case, everyone's goal is the same, that is, the production of the smallest, lightest, most cost-effective battery pack to meet the power transfer needs of handheld devices safely and efficiently.
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