Key Considerations When Choosing Custom Battery Solutions

When it comes to finding a custom battery for your unique application, there are several crucial factors that deserve careful consideration. Selecting the right battery chemistry, capacity, size, and safety features can significantly impact your device's performance, safety, and lifespan. In this blog post, we will explore the key factors to keep in mind when searching for a custom battery solution.

Battery Chemistry

Choosing the appropriate battery chemistry is fundamental. Each chemistry has its own advantages and characteristics, such as energy density, discharge rates, and cycle life. Understanding and matching your application's requirements with suitable battery chemistry is essential for optimal performance.

Primary batteries, also known as non-rechargeable batteries, offer advantages such as long shelf life, high energy density, and immediate use without the need for charging. However, they have limited capacity, generate waste when depleted, and can be more expensive in the long run compared to rechargeable batteries.

Secondary batteries, also known as rechargeable batteries, offer advantages such as reusable nature, cost-effectiveness in the long term, and reduced environmental impact due to their recharging capability. However, they may have a lower energy density, limited lifespan with each recharge cycle, and require periodic recharging, which can be inconvenient in certain situations.

Capacity and Voltage

Consider the required capacity and voltage of the battery based on your application's power demands. Factors such as device requirements, runtime, and power consumption should be taken into account. A battery with insufficient capacity or voltage can lead to performance issues or inadequate runtime. Packs can either be assembled in series or parallel to achieve the desired capacity and voltage.

A battery pack assembled in series may be required to achieve a higher total voltage output, suitable for powering devices that operate at elevated voltage levels. On the other hand, a parallel battery configuration may be necessary to increase the overall capacity, providing longer runtime or higher current output for devices that demand more power. Packs can be assembled in both series and parallel to achieve both higher capacity and higher voltage.

Figure 1: Diagram of packs built in series and parallel

Size and Form Factor

Ensure that the custom battery's physical dimensions and form factor align with the available space in your device or equipment. Custom batteries can be tailored to meet specific size requirements, enabling seamless integration into your product.

If you are facing space constraints while designing your custom battery pack, we recommend contacting one of our specialists who can assist you in exploring available options and discussing potential solutions.

Operating Environment

Evaluate the operating conditions and environmental factors in which the battery will be used. Consider temperature range, humidity, vibration, and any other specific challenges that may impact battery performance and lifespan.

Temperature holds significant importance in battery selection. Extreme temperatures, whether hot or cold, can have adverse effects on a battery's capacity and power output. Higher temperatures raise internal resistance, accelerating self-discharge and diminishing energy storage. Conversely, cold temperatures hinder the battery's power delivery capabilities. Furthermore, temperature plays a crucial role in battery safety, especially for chemistries like lithium-ion, which are sensitive to temperature extremes. Elevated temperatures can trigger thermal runaway, potentially causing overheating, venting, or even explosions.

Choosing a battery that can withstand the intended operating environment is crucial for longevity, reliability and safety.

Cycle Life and Lifespan

Assess the expected cycle life and overall lifespan of the battery. Cycle life refers to the number of charge-discharge cycles a battery can endure, while lifespan refers to the battery's expected usable life before degradation.

Choosing a battery with a longer cycle life is vital for applications that need frequent or prolonged use to maintain performance over time. Similarly, selecting a battery with an extended lifespan reduces replacements and repairs, minimising downtime and costs. Such batteries with extended cycle life and lifespan offer cost savings in the long run by reducing the overall lifecycle expenses.

It is worth noting that the cycle life of batteries is affected by the depth of discharge (DoD), representing the amount of capacity utilized during each charge-discharge cycle. Batteries discharged to shallower depths, like 20% DoD, generally exhibit longer cycle lives than those discharged more deeply, such as 80% DoD. When choosing a battery, it is important to evaluate how your specific application may impact this factor and select an appropriate cell accordingly.

Figure 2: Cycle life of a typical Lithium cell

Customisation and Compatibility

Confirm that the custom battery can be tailored to your specific requirements, including electrical connections, connectors, and mounting options. Ensure compatibility with your device or equipment, as a well-integrated battery solution enhances overall functionality and performance.

Feel free to reach out to us if you need any custom modifications or non-standard adjustments, as our team members are available to discuss and explore the available options with you.

Supplier Expertise and Support

Choose a reputable and experienced battery supplier who can provide guidance, technical support, and customisation services. Look for a supplier with a proven track record, relevant certifications, and the ability to meet your production demands. Their expertise and support can be invaluable throughout the process.

Our ISO 9001:2015 accreditation demonstrates our dedication to quality, supplier expertise, consistency, and customer satisfaction. It serves as proof that we are a dependable and trustworthy supplier, well-suited for clients in search of expert support and superior battery solutions.

Cost and Budget

When evaluating the cost of a custom battery solution, it is important to consider factors such as development, production, and maintenance costs. Balancing desired performance and features with the budget is crucial. However, compromising on quality to save costs may lead to subpar results and safety risks.

While primary batteries may have a lower initial cost, secondary batteries offer long-term cost savings due to their reusability and extended lifespan. They can be recharged multiple times, reducing the need for frequent pack replacements and resulting in lower lifetime costs. Component quality, transportation costs, and additional expenses for express orders must also be considered when establishing a budget for batteries, as they impact the overall cost.

By carefully considering the factors mentioned above, you can confidently select the most suitable custom battery solution for your specific application. Taking into account battery chemistry, capacity, size, safety features, environmental factors, cycle life, customisation options, supplier expertise, cost, and regulatory compliance will help you make an informed decision. Ultimately, choosing the right custom battery will ensure optimal performance, safety, and longevity for your device or equipment.