Epec's Blog | Electronics Manufacturing Solutions

When deciding on the types of power to supply equipment requiring high performance, rechargeable batteries are often chosen for several reasons. With rechargeable batteries, users can obtain longer device performance and consistent power. In addition, rechargeable batteries are ideal for devices that are lightweight, such as mobile applications. These devices may have a battery pack that can be taken from off the device, such as the ones on power tools, and placed into a charger that connects to a wall outlet.

Many applications do not run as standalone systems. Instead, there will be multiple subsystems involved that can perform a variety of functions for the work output or to monitor internal systems to ensure optimal and safe performance. These systems need additional logic support to keep systems running or to improve system performance. However, there will be times when the application itself does not have these logic functions originally installed. So, another system must be added into the application to provide these functions.

Customers who have products or applications using lithium-based batteries understand the risks involved in keeping the battery packs safe during manufacturing processes, when transporting them to specified locations and when they are in use.

Supplying custom battery packs to companies in aerospace, medical, military, oceanography, and other industries requires the skills and technical expertise provided by quality manufacturers such as Epec. Yet, the design and build of the battery pack is often only part of the customer's order.

With electronics becoming more portable and lightweight, they require batteries that offer long hours of battery life before recharging. Lithium batteries are becoming common place in electronics such as smartphones, laptops, and tablets as they can last for up to 2 years to 5 years. However, failures can cause lithium battery packs to malfunction. The type of problem will be based on the construction of the battery pack, how it is charged, how it is used and handled, and environmental factors.

Portable devices are everywhere. When thinking about the top portable devices that we use daily, smartphones, tablets, and laptops will dominate the list. Yet, there are numerous applications that rely on portable devices. Manufacturers of medical devices, military devices and even kid's toys rely on holder and mounting designs to secure batteries in portable devices. How the batteries are secured plays an important factor. These applications can experience a range of extremes such as shocks, vibrations, drops, and temperature fluctuations.

When power applications and equipment with custom battery packs, it's ideal to place batteries in storage when not in use for extended periods of time. This practice will prevent batteries from becoming overcharged in equipment and degrading.

Battery pack manufacturing relies on the proper selection of battery chemistries, materials, electronic components, and enclosure designs to meet application power, safety, recharge, and storage requirements. Understanding how these standard materials and components interact can help improve performance, shorten lead times, control costs, and support regulatory compliance.

At the conclusion of our webinar, Do You Really Need Lithium or Will Nickel Metal Hydride Suffice, 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.

Switching battery pack suppliers on an existing design introduces risks related to compatibility, component sourcing, and certification. Even when targeting a drop-in replacement, differences in materials, BMS design, and supply chain capabilities can impact performance and manufacturability. Careful validation, supplier evaluation, and recertification planning are essential to ensure continuity.