Epec's Blog | Electronics Manufacturing Solutions

Charging batteries, whether they are small batteries in laptops to large ones in electric vehicles, requires the right rate of charge based on the battery chemistry. While technology has provided more ways for people to charge their electronics, especially portable devices, customers are looking at ways to speed up the process so they can use their items faster.

Designing medical devices is no simple task. The stakes are higher for these devices compared to most other industries. Because of that, medical device engineers need to think carefully about which design elements should be prioritized.

Battery power constantly runs applications on a daily basis to perform a wide variety of functions. Yet, there will be certain instances where battery packs will be stored for short-term and long-term periods. This situation may occur due to infrequent use of the equipment or when storing extra battery packs.

More people are taking into consideration the types of vehicles they use for work, school, and to get around town. Electric vehicles (EVs) are becoming a trend for both individuals as well as commercial operations. Aside from the tax benefits and reduced need for fossil fuels, battery technologies have matured enabling the EVs of today to offer comparable performance to the traditional internal combustion engine.

When machines operate, they generate internal heat that may compromise working components. The same situation holds true for battery cells. Cells undergo a chemical process that provides power to devices.

Developing a custom battery pack requires balancing electrical, mechanical, and chemical considerations while ensuring the final design performs reliably in its intended application. Beyond selecting a cell chemistry, engineers must understand how the battery pack will behave under different operating and environmental conditions, including its shelf life, charge and discharge characteristics, thermal behavior, and potential safety risks.

Consumers use battery packs for devices used in diverse environments. While the ideal device would experience cool temperatures without drastic temperature changes and be free from corrosion, chemicals, water, shocks, and vibrations, this setup is not always the case. Some devices used in chemical manufacturing processes may experience chemical exposure. Other devices used outdoors may have to deal with harsh temperatures and an abundance of moisture.

The appeal of lithium-based batteries for products has grown immensely. They provide high amounts of power while being light enough for portable devices. However, the battery chemistry is considered unstable, as it requires a battery management system to monitor the pack's temperatures, State of Health (SoH), State of Charge (SoC), and other factors. If the battery should experience a short or thermal runaway, it could cause the pack to catch fire or explode.

At the conclusion of our webinar, Dealing With Component Shortages That Impact Battery Packs Designs, we had several questions submitted to our presenter, Randy Ibrahim, Battery Development Consultant at Epec. We have compiled these questions into a readable format on our blog.

Designing a custom battery pack for your application requires figuring out the power specifications. Yet there are several other considerations that dictate the type of battery chemistry to use. In addition to the current, capacity (amp-hours), size requirements, cell configuration, and the number of cells for the battery pack within the application, the voltage must also be determined.