Epec's Blog | Electronics Manufacturing Solutions

Technologies are becoming lightweight and smaller to allow for portability. From drones, laptops, and phones to power tools and medical devices, these applications require a high amount of power to function and a battery that guarantees long run times and safety.

When designing a product, the focus is often spent on the functionality of the device. For most instrument-measuring devices, most of the focus is spent on the sensors themselves and the data capture that will occur during their use. Often factors such as power delivery are left in theory until it’s time to finish the design of the product.

Battery packs are designed to have fixed capacities and voltages to power specific applications for a required length of time before recharging. To transfer this power to the device, connectors, and interfaces are required to form the connection between the battery cells and the devices, as well as with the chargers.

Devices are becoming smaller and lightweight. To power these applications, customers are seeking battery packs that are compact while providing efficient energy. Compact batteries are found in a variety of applications, from smartphones to medical devices. These batteries provide consistent power and a long lifespan.

Extensive research and development in the battery manufacturing industry has pushed out vast innovations in the custom battery pack segment. The need for these battery packs has grown exponentially due to higher-performance products, utility companies utilizing storage devices, and the expansion of electric and hybrid vehicle markets.

Customers clearly understand the power needs of their applications that require a custom battery pack. They may also have narrowed down their choices in battery chemistry, placement of cells in the pack, the form of the cell, and battery management system (BMS) functions. Another important feature to consider is the battery enclosure.

Technology has required the need for energy storage devices to become lightweight and small to accommodate a range of devices. These devices need storage devices that can store high amounts of energy that can provide for long periods of time.

Battery lifespan is influenced by more than cell chemistry. In a custom battery pack, the electronics, mechanical construction, cell configuration, charge rate, discharge rate, and operating environment can all affect how the pack performs over time.

Battery packs power a wide range of products, from portable electronics to industrial equipment, electric vehicles, and energy storage systems. Proper maintenance and storage practices play an important role in preserving battery performance, extending service life, and reducing safety risks.

Custom battery packs charge and discharge at different rates. During these processes, they can generate heat. While a small amount of heat is expected, elevated levels can lead to battery problems. Battery pack operation can also be influenced by environmental temperatures. In addition to being negatively impacted by high temperatures, low temperatures also cause lower battery performance.