battery Related Articles

An infographic has been published by Accutronics, offering guidelines for Original Equipment Manufacturers on what should be considered when specifying a rechargeable smart battery to power their next product. The infographic highlights the importance of considering batteries at the earliest possible stage in the development process. Accutronics believes the most common and most costly mistake a design engineer can make when choosing a power source is leaving specification until it's too late.With smart batteries becoming increasingly common in industries such as medical and military, the demands placed on them are also becoming increasingly challenging. The infographic highlights the key features a design engineer or purchasing team should look for in a smart battery, including fuel gauging which can provide accurate state of charge prediction regardless of temperature, load and age. An accurate fuel gauge provides confidence whilst an inaccurate gauge can result in ‘runtime anxiety’ with the user constantly in fear that their device will run out of power. If the device is being used in a medical or mission-critical military application then the premature depletion of battery power could have severe implications.Other essential features include protection circuitry which prevents the battery cells from being over-charged, over-discharged, or operated at extreme temperatures. Smart power management ensures the battery only receives charge when it is required - this enhances both the life and safety of the battery. The ability for the battery to operate under differing power modes also allows it to hibernate when it is stored, maximising the shelf-life of batteries which may be in the supply chain for prolonged periods.“As the complexity of battery powered applications increases, OEM buyers need to ask themselves how fit for purpose their current design methodology is," explained Michele Windsor, Global Marketing Manager for Accutronics and Ultralife. “By choosing a smart battery, OEMs can rest assured that their device will continue to deliver optimum performance in a variety of applications. Whether it's the reliability and security demanded in the medical industry, or the extreme temperatures and harsh conditions faced in military and defence use, smart batteries can step up to any environment.“Because smart batteries are used in many life-critical situations, we’re also concerned about the rise of counterfeiting in the battery industry. Counterfeit batteries may be built using inferior battery cells and often lack the critical protection electronics which are required to make them operate safely. Also, a lack of quality control during manufacture, or forged regulatory certification means that fake batteries could prove costly for many OEMs."The infographic also highlights the importance of selecting a battery with built in digital algorithmic security, which can be used by a host device or charger to ensure that that the installed battery is the genuine article.”Reference:BHSD-2032-COVERBI-UM-3-4BC2/3AC

It's a summer night in 2025, and suddenly a power cut strikes. Naturally, you expect your ceiling fan to keep spinning, but instead, it slows to a halt. When you check your power backup system, you find the inverter body is excessively hot to the touch. Worse yet, the battery itself feels dangerously warm. This overheating issue is a common challenge in modern households with increasing energy demands. However, there is no need to panic; with the right maintenance strategies, you can resolve this heating problem and extend your system's lifespan.Here are some professional solutions for the inverter battery overheating problem:1. Monitor the maximum load capacity:Overloading is a primary cause of battery overheating. If your power draw exceeds the inverter's rated capacity, internal resistance spikes, generating excess heat. Read your instruction manual to note the optimum load capacity. In 2025, many "Smart Inverters" feature LCD displays or mobile apps that show real-time load percentage—use these tools to ensure your connected devices never exceed the maximum limit.2. Inspect your connections for resistance:Faulty wiring is a silent fire hazard. Loose connections between the inverter, the mains, and the battery terminals create electrical resistance, which manifests as heat. You must check these connections frequently. Ensure nuts and bolts are tightened securely and that current is flowing without obstruction to prevent unnecessary thermal buildup.3. Optimize charging cycles (Avoid Deep Discharge):Older advice suggested fully discharging batteries, but for modern Lead-Acid and Tubular batteries, frequent deep discharging significantly shortens their lifespan and increases heat during recharge. Instead, aim for shallow cycles. Ensure your battery is fully recharged after use. If you anticipate a long period of inactivity, reliable charging habits prevent the hardening of electrolytes (sulfation), which is a leading cause of overheating.4. Eliminate corrosion on battery terminals:Carbon buildup and rust on battery terminals act as insulators, forcing the system to work harder and generate heat. regularly inspect your terminals for white or greenish deposits. Clean any corrosion using a solution of hot water and baking soda with an old toothbrush. Once clean and dry, apply a thin layer of petroleum jelly (Vaseline) to the terminals to seal them against future oxidation.5. Maintain electrolyte levels with distilled water:For Flooded Lead-Acid or Tubular batteries, electrolyte loss is natural over time. Low water levels expose the lead plates, causing rapid overheating and permanent damage. Check the water level indicators once a month. Top up *only* with distilled water to the specified mark. Note: Never use tap water, as impurities will damage the cells. If you use Sealed Maintenance Free (SMF) or Lithium batteries, this step does not apply.6. Ensure proper ventilation:Placement is critical. Batteries emit heat during charging and discharging. If they are stored in a closed cabinet or a room with poor airflow, that heat accumulates. The ideal operating temperature for most inverter batteries is around 25°C (77°F). Ensure there is at least 6 inches of clearance around the unit for air circulation to dissipate heat effectively.Leading manufacturers like Microtek have updated their technology for [Current Year] to include smart thermal management and high-efficiency designs. investing in these modern, sustainable power sources can provide a pocket-friendly solution that minimizes maintenance faults. 

Researchers have developed a prototype of a next-generation lithium-sulphur battery which takes its inspiration in part from the cells lining the human intestine. The batteries, if commercially developed, would have five times the energy density of the lithium-ion batteries used in smartphones and other electronics.The new design, by researchers from the University of Cambridge, overcomes one of the key technical problems hindering the commercial development of lithium-sulphur batteries, by preventing the degradation of the battery caused by the loss of material within it. The results are reported in the journal Advanced Functional Materials.Working with collaborators at the Beijing Institute of Technology, the Cambridge researchers based in Dr Vasant Kumar's team in the Department of Materials Science and Metallurgy developed and tested a lightweight nanostructured material which resembles villi, the finger-like protrusions which line the small intestine. In the human body, villi are used to absorb the products of digestion and increase the surface area over which this process can take place.In the new lithium-sulphur battery, a layer of material with a villi-like structure, made from tiny zinc oxide wires, is placed on the surface of one of the battery's electrodes. This can trap fragments of the active material when they break off, keeping them electrochemically accessible and allowing the material to be reused."It's a tiny thing, this layer, but it's important," said study co-author Dr Paul Coxon from Cambridge's Department of Materials Science and Metallurgy. "This gets us a long way through the bottleneck which is preventing the development of better batteries."A typical lithium-ion battery is made of three separate components: an anode (negative electrode), a cathode (positive electrode) and an electrolyte in the middle. The most common materials for the anode and cathode are graphite and lithium cobalt oxide respectively, which both have layered structures. Positively-charged lithium ions move back and forth from the cathode, through the electrolyte and into the anode.The crystal structure of the electrode materials determines how much energy can be squeezed into the battery. For example, due to the atomic structure of carbon, each carbon atom can take on six lithium ions, limiting the maximum capacity of the battery.Sulphur and lithium react differently, via a multi-electron transfer mechanism meaning that elemental sulphur can offer a much higher theoretical capacity, resulting in a lithium-sulphur battery with much higher energy density. However, when the battery discharges, the lithium and sulphur interact and the ring-like sulphur molecules transform into chain-like structures, known as a poly-sulphides. As the battery undergoes several charge-discharge cycles, bits of the poly-sulphide can go into the electrolyte, so that over time the battery gradually loses active material.The Cambridge researchers have created a functional layer which lies on top of the cathode and fixes the active material to a conductive framework so the active material can be reused. The layer is made up of tiny, one-dimensional zinc oxide nanowires grown on a scaffold. The concept was trialled using commercially-available nickel foam for support. After successful results, the foam was replaced by a lightweight carbon fibre mat to reduce the battery's overall weight."Changing from stiff nickel foam to flexible carbon fibre mat makes the layer mimic the way small intestine works even further," said study co-author Dr Yingjun Liu.This functional layer, like the intestinal villi it resembles, has a very high surface area. The material has a very strong chemical bond with the poly-sulphides, allowing the active material to be used for longer, greatly increasing the lifespan of the battery."This is the first time a chemically functional layer with a well-organised nano-architecture has been proposed to trap and reuse the dissolved active materials during battery charging and discharging," said the study's lead author Teng Zhao, a PhD student from the Department of Materials Science & Metallurgy. "By taking our inspiration from the natural world, we were able to come up with a solution that we hope will accelerate the development of next-generation batteries."For the time being, the device is a proof of principle, so commercially-available lithium-sulphur batteries are still some years away. Additionally, while the number of times the battery can be charged and discharged has been improved, it is still not able to go through as many charge cycles as a lithium-ion battery. However, since a lithium-sulphur battery does not need to be charged as often as a lithium-ion battery, it may be the case that the increase in energy density cancels out the lower total number of charge-discharge cycles."This is a way of getting around one of those awkward little problems that affects all of us," said Coxon. "We're all tied in to our electronic devices - ultimately, we're just trying to make those devices work better, hopefully making our lives a little bit nicer."Reference:KY605-ML-621S/ZTNKY605-MS412FE-FL26EKY605-MS518SE-FL35E

A molecule that transports oxygen in blood could be key to developing the next generation of batteries, and in a way that's environmentally friendly.Lithium-oxygen (Li-O2) batteries have emerged in recent years as a possible successor to lithium-ion batteries—the industry standard for consumer electronics—due to their potential for holding a charge for a very long time. Electronic devices would go for weeks without charging, for instance; electric cars could travel four to five times longer than the current standard.But before this could happen, researchers need to make the Li-O2 batteries efficient enough for commercial application and prevent the formation of lithium peroxide, a solid precipitate that covers the surface of the batteries' oxygen electrodes. One obstacle is finding a catalyst that efficiently facilitates a process known as oxygen evolution reaction, in which lithium oxide products decompose back into lithium ions and oxygen gas.The Yale lab of Andre Taylor, associate professor of chemical and environmental engineering, has identified a molecule known as heme that could function as a better catalyst. The researchers demonstrated that the heme molecule improved the Li-O2 cell function by lowering the amount of energy required to improve the battery's charge/discharge cycle times.The results appear Oct. 19 in Nature Communications. The lead author is Won-Hee Ryu, a former postdoctoral researcher in Taylor's lab, who is now an assistant professor of chemical and biological engineering at Sookmyung Women's University in South Korea.The heme is a molecule that makes up one of the two parts of a hemoglobin, which carries oxygen in the blood of animals. Used in an Li-O2 battery, Ryu explained, the molecule would dissolve into the battery's electrolytes and act as what's known as a redox mediator, which lowers the energy barrier required for the electrochemical reaction to take place."When you breathe in air, the heme molecule absorbs oxygen from the air to your lungs and when you exhale, it transports carbon dioxide back out," Taylor said. "So it has a good binding with oxygen, and we saw this as a way to enhance these promising lithium-air batteries."The researchers added that their discovery could help reduce the amount of animal waste disposal."We're using a biomolecule that traditionally is just wasted," said Taylor. "In the animal products industry, they have to figure out some way to dispose of the blood. Here, we can take the heme molecules from these waste products and use it for renewable energy storage."By using recyclable biowaste as a catalyst material, the technology is both effective and could be preferential in developing green energy applications.Reference:ML-621S/ZTNMS412FE-FL26EMS518SE-FL35E 

 Samsung's recall of 2.5 million Galaxy Note 7 phones after several dozen caught fire and exploded may stem from a subtle manufacturing error, but it highlights the challenge electronics makers face in packing ever more battery power into ever thinner phones, while rushing for faster release dates.Announcing the recall on Sept. 2, Samsung confirmed dozens of cases where Note 7 batteries caught fire or exploded, mostly while charging. It plans a software update that will cap battery recharging at 60 percent capacity to help minimize risks of overheating. But it is urging owners to keep the phones turned off until they can get them replaced, beginning Monday.U.S. safety regulators stepped in Thursday with an official recall, saying Samsung's voluntary efforts were inadequate. Though Samsung promised replacement devices, the U.S. Consumer Product Safety Commission said U.S. customers would be eligible for refunds if they choose. Replacements are expected in stores by next Wednesday.The Note 7 debuted to rave reviews in August thanks to its speed, new software features and—not least—the estimated nine hours it would run between charges. But all that power comes at a price: Users began reporting the phones were catching fire or exploding, in one case incinerating the SUV it had been left in.Aviation authorities in the U.S., Australia and Europe have urged passengers not to use or charge Note 7s while flying and not to put them in checked baggage. On Monday, Canada issued an official recall.Koh Dong-jin, Samsung's mobile president, said in announcing the recall on Sept. 2 that an investigation turned up a "tiny error" in the manufacturing process for the faulty batteries in the Note 7s that was very difficult to identify. The end of the pouch-shaped battery cell had some flaws that increased the chance of stress or overheating, he explained.That kind of manufacturing error is unimaginable for top-notch battery makers with adequate quality controls, said Park Chul Wan, a former director of the next generation battery research center at the state-owned Korea Electronics Technology Institute.Samsung and other experts should search for factors outside the battery cells that could have led to overheating, he said."If Koh's argument is right, that makes Samsung SDI a third-rate company," Park said. "But it does not appear to be a simple battery problem."Time also is a factor in marketing and making the phones.In 2015, Samsung moved up its unveiling of its new Galaxy Note model to August from September, seeking a leg up on Apple's September iPhone upgrades.Before the issue of battery explosions emerged, supplies were not keeping pace with demand for the Note 7.Samsung has not recalled Note 7s sold in China, but the company has refused to say which of its two battery suppliers made the faulty batteries or clarify whose batteries are used in which Note 7 smartphones. The company also refused comment on South Korean media reports that it has stopped using batteries from Samsung SDI, one of its two suppliers, in the Note 7.C.W. Chung, an analyst at Nomura Securities in Seoul, cited SDI officials in estimating that about 70 percent of the batteries for the Galaxy Note 7 smartphones came from SDI.The other 30 percent are thought to have been supplied by Amperex Technology Ltd., a Chinese-based manufacturer that reportedly also is a main supplier of batteries for the iPhone.Problems with lithium batteries have afflicted everything from laptops to Tesla cars to Boeing's 787 jetliner, though having so many lithium-ion battery fires in a short time is unheard of, Park said.The batteries are ubiquitous in consumer electronic devices, favored by manufacturers because they are lightweight and pack much more energy into a small space than other power cells.But storing so much energy in a tiny space, with combustible components separated by ultra-thin walls, makes them susceptible to overheating if exposed to high temperatures, damage or flaws in manufacturing. If the separators fail, a chemical reaction can quickly escalate out of control.That's what happened with the Note 7, Samsung's Koh explained."The flaw in the manufacturing process resulted in the negative electrodes and the positive electrodes coming together," he told reporters in Seoul.It is unclear how Samsung failed to discover the battery problem before launching the Note 7. It confirmed delays in shipments for extra quality tests weeks later, in late August, after photos of charred phones began popping up on social media.South Korean experts suggested Samsung may have been so ambitious with the Note 7's design that it compromised safety."There was no choice but to make the separator (between positive and negative anodes) thin because of the battery capacity," said Lee Sang-yong, a professor at Ulsan National Institute of Science and Technology who worked more than a decade at LG Chem, a leading lithium battery maker. Thicker separators can improve safety but will not necessarily prevent all overheating issues, he said.Doh Chil-Hoon, head of the state-run Korea Electrotechnology Research Institute's battery research division, said that based on the limited information provided by Samsung, he believes the push to increase battery power was part of the problem."Even with a small manufacturing mistake, if there had been enough elements to ensure safety, it would not explode," Doh said. "It is a roundabout way of admitting weak safety."The Note 7 phones have a powerful 3,500 milliampere hour battery, whereas the Galaxy S7 smartphone, which has a slightly smaller body than the Note 7, features a 3,000 mAh battery. So does the Note 5, launched in 2015.Apple does not provide information on the iPhone's battery capacity in milliampere hours. But two research firms that specialize in analyzing tech gadgets and their components said the battery in the iPhone 6S Plus is 2,750mAh. The size of the battery in the newly released iPhone 7 is not yet known.The 3,500 mAh battery in the Samsung Note 7 is "one of the highest, if not the highest, capacity battery we've seen in a phone," said Wayne Lam, an industry analyst at IHS Markit Technology.Lam said he thinks the Note 7 battery problem resulted from weak controls in manufacturing, not a poor or unsafe design.A spokeswoman at iFixit, which publishes repair guides for electronic gadgets, offered a similar view. "We don't think any internal design changes in the Note 7 are responsible for the exploding batteries—more likely just a manufacturing defect," IFixit's Kay-Kay Clapp said in an email.Apple has tweaked hardware and software it developed itself to make iPhones use power more efficiently, while Samsung has increased the capacity of the batteries in its phones.That can be done without increasing size by adjusting components or changing the production process, Lam said."You have two different trajectories, with Samsung packing in more energy density, versus Apple trying to trim it down by optimizing everything else," he said, adding that the two rivals are "constantly locked in this arms race of improving and one-upping."While Apple and Samsung are using built-in batteries for their premium phones, LG Electronics, Samsung's smaller South Korean rival, has opted for a replaceable, 3,200 mAh capacity battery for its new premium, jumbo screen smartphone, the V20.LG chose to make the phone thinner and allow customers to extend battery life by swapping out batteries."The security of the battery isn't directly related to whether the battery is replaceable or not," Cho Joon-ho, head of LG's mobile business, told reporters. "But we make efforts to secure safety with quality controlling tests beforehand."  

Stream video on your smartphone, or use its GPS for an hour or two, and you'll probably see the battery drain significantly. As data rates climb and smartphones adopt more power-hungry features, battery life has become a concern. Now a technology developed by MIT spinout Eta Devices could help a phone's battery last perhaps twice as long, and help to conserve energy in cell towers.The primary culprit in smartphone battery drain is an inefficient power amplifier, a component that is designed to push the radio signal out through the phones' antennas. Similar larger modules are found in wireless base stations, where they might use 10 or even 100 times the power.Prepared to send sizeable chunks of data at any given time, the amplifiers stay at maximum voltage, eating away power—more than any other smartphone component, and about 75 percent of electricity consumption in base stations—and wasting more than half of that power as heat. This means smartphone batteries lose longevity, and base stations waste energy and lose money.But Eta Devices has developed a chip (for smartphones) and a shoebox-size module (for base stations)—based on nearly a decade of MIT research—to essentially "switch gears" to adjust voltage supply to power amplifiers as needed, cutting the waste."You can look at our technology as a high-speed gearbox that, every few nanoseconds, modulates the amount of power that the power amplifier draws from the battery," explains Joel Dawson, Eta Devices' chief technology officer and a former associate professor of electrical engineering and computer science who co-invented the technology. "That turns out to be the key to keeping the efficiency very high."When trialed in a base station last year, Eta Devices' module became the first transmitter for 4G LTE networks to achieve an average efficiency greater than 70 percent, Dawson says. "The highest number we've heard before that was 45 percent—and that's probably being generous," he says.Backed by millions in funding, Eta Devices—co-founded by David Perreault, an MIT professor of electrical engineering, and former MIT Sloan fellow Mattias Astrom—has partnered with a large base-station manufacturer. The goal is to deploy the technology in live base stations by the end of 2015. The savings could be substantial, Dawson says, noting that a large carrier could save $100 million in annual electricity costs.Eta Devices has also entered conversations with major manufacturers of LTE-enabled smartphones to incorporate their chips by the end of next year. Dawson says this could potentially double current smartphone battery life.Besides battery life, Dawson adds, there are many ways the telecommunications industry can take advantage of improved efficiency. Eta Devices' approach could lead to smaller handset batteries, for example, and even smaller handsets, since there would be less dissipating heat. The technology could also drive down operating costs for base stations in the developing world, where these stations rely on expensive diesel fuel for power.And ultimately, it could impact the environment: If all midsized carrier networks were to replace current radio amplifiers with Eta Devices' technology, he says, the reduction in greenhouse gases would be equivalent to taking about 5 million cars off the road. "There are so many ways to leverage high efficiency if you have it," Dawson says.In August, the World Economic Forum named Eta Devices the 2015 Technology Pioneer, a designation awarded previously to Dropbox, Spotify, and Twitter, to name a few.In the mobile marketEta Devices' commercial success is, in part, a product of engineering ingenuity intersecting with business acumen at MIT.In 2008, Dawson and Perreault, who directs the Power Electronics Research Group, submitted an early concept of the Eta technology—then called asymmetrical multilevel outphasing (AMO)—to an Innovation Teams (i-Teams) class that brought together MIT students from across disciplines to develop commercial products.The AMO technology was a new transmitter architecture, where algorithms could choose from different voltages needed to transmit data in each power amplifier, and select the optimal choice for power conservation—and do so roughly 20 million times per second. This could be done on the transmitting and receiving end of data transfers.This caught the eye of Astrom, who had come to MIT after working in the mobile industry for 10 years, "looking for the next big thing." With help from Astrom, the professors started designing the technology for the mobile market—initially leaning toward base stations."At the time, I was suffering, as everyone else was, from my iPhone running out of battery at lunchtime," Astrom says. "The iPhone was only a year old, but you could see how much data traffic would explode."Fleshing out a business plan from an i-Teams draft, the two professors earned a Deshpande Center for Technological Innovation grant in 2009, allowing for the first demonstration of the hardware, showing a 77 percent gain in efficiency over standard systems. (A paper detailing the technology was presented at that year's IEEE Radio Frequency Integrated Circuits Symposium.)"That Deshpande Center grant was big in terms of the funding and connecting us with local venture capitalists, and really helping with being in that business mindset," Dawson says.Spinning out a company has been the best way to validate the technology—especially with novel power-electronics hardware, Dawson says. "People in our industry take ideas a lot more seriously when there's a company behind it," he says. "We had impressive performance at MIT, but now we have a team of professionals working on the technology full-time. The resulting performance numbers are jaw-dropping. Now people are going back and frantically studying the original MIT research papers."Luckily, Dawson says, several significant changes were made to those old research projects in order to develop today's ETAdvanced—so the secret ingredients of the technology are safe. "The joke I like to tell is: When I was a professor, I was going around the world trying to give the technology away," Dawson says, laughing. "If I had succeeded, then there'd be no business."Future-proofing technologyToday, Eta Devices' major advantage is that its technology is able to handle ever-increasing data bandwidths.A few major smartphone manufacturers are now using envelope tracking (ET), which adjusts voltage to power amplifiers on the fly. But by adjusting that voltage continuously, ET efficiency falls apart for 4G/LTE and 802.11ac (WiFi) wireless standards, even up to 20 MHz bandwidth. ETAdvanced, in contrast, already accommodates ultrahigh bandwidths used by newer communication standards, such as LTE Advanced (up to 80 megahertz), and the next-generation WiFi standard (up to 160 megahertz).Prepping for future communication standards is one thing that's helped the company thrive, Dawson says. "As a small company, you'll lose a fair fight with another technology—you have to have some overpowering advantage that they can't match you on," he says. "In introducing new hardware, you not only have to be better than the product of today, but also have to make compelling case for being future-proof."