Product Engineering ProcessesBattery Primer
A short battery primer
Handbook of batteries, Linden and Reddy
Short Primer on BatteriesTypes
Primary (dry cell): non rechargeablelow power applicationsinfrequent use
Secondary: rechargeablehigh discharge ratesfrequent use
Short Primer on BatteriesSelection considerations
Physical characteristics: size, shape weightVoltage: nominal, maximum, minimum, discharge profileLoad current: rate, constant power, constant resistance, pulsedDuty cycle: continuous, intermittent, cyclicCharge/discharge cycle: cycling (float), deep cycle, efficiency of chargingTemperature range: maximum, minimum and nominalService life: required operation timeSafety: failure rates, leakage, off-gassing, toxicity, disposalEnvironment: vibration, acceleration, orientationMaintenance: regular upkeep, replacementCost: initial, life-cycle cost
Short Primer on BatteriesCell voltage
Cell voltage
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Alkaline (p) Lead-acid (s) Nickel-Cadmium (s) Nickel-metal
hydride (s)
Lithium-ion (s)
Battery type
Vo
ltag
e (
V)
Short Primer on BatteriesSpecific energy
Specific energy
0
20
40
60
80
100
120
140
160
Alkaline (p) Lead-acid (s) Nickel-Cadmium (s) Nickel-metal
hydride (s)
Lithium-ion (s)
Battery type
Sp
ecif
ic e
nerg
y (
Wh
/kg
)
Short Primer on BatteriesEnergy density
Energy density
0
50
100
150
200
250
300
350
400
450
Alkaline (p) Lead-acid (s) Nickel-Cadmium (s) Nickel-metal
hydride (s)
Lithium-ion (s)
Battery type
En
erg
y d
en
sit
y (
Wh
/l)
Short Primer on BatteriesSelf discharge
Shelf life
0
10
20
30
40
50
60
Alkaline (p) Lead-acid (s) Nickel-Cadmium (s) Nickel-metal hydride
(s)
Lithium-ion (s)
Battery type
Sh
elf
lif
e (
mo
nth
s@
20
Celc
ius)
Short Primer on BatteriesEstimated cycle life
Typical cycle life
0
200
400
600
800
1000
1200
Alkaline (p) Lead-acid (s) Nickel-Cadmium (s) Nickel-metal
hydride (s)
Lithium-ion (s)
Battery type
Typ
ical
cycle
lif
e (
dis
ch
arg
e/
ch
arg
e c
ycle
s)
Short Primer on BatteriesTemperature range
Operating temperature
-60
-40
-20
0
20
40
60
80
Alkaline (p) Lead-acid (s) Nickel-Cadmium (s) Nickel-metal
hydride (s)
Lithium-ion (s)
Battery type
Tem
peratu
re (
Celc
ius)
Short Primer on BatteriesRelative cost
Cost
0
5
10
15
20
25
30
35
40
45
50
Alkaline (p) Lead-acid (s) Nickel-Cadmium (s) Nickel-metal hydride
(s)
Lithium-ion (s)
Battery type
Rela
tive c
ost/
Wh
Short Primer on BatteriesPower and discharge rate
1000
100
10
1
0.20.1 1 10 100 1000
Hours to discharge
Wat
ts/lit
re
Alkaline (p)
Nickel-Cadmium (s)
Nickel-metal hydride (s)Lithium ion (s)
Short Primer on BatteriesSecondary battery comparison
advantages disadvantages Cycle life Life (years)
Lead-acid SLI (starting, lighting, ignition) low cost, high availability, high current, low temperature, good float service, maintenance free
low cycle life, shallow discharge cycles, low energy density, poor charge retention, hydrogen evolution
200-700 4
Lead-acid traction lowest cost of deep cycle systems
low energy density, less rugged, hydrogen evolution
1500 6
Lead-acid stationary designed specifically for float charging cycles
hydrogen evolution 25
Lead-acid portable maintenance free, long flat service life, low and high temperature, operates in any position
Cannot be stored discharged, lower cycle life, difficult for small batteries
250 8
Nickel-Cadmium (sealed) rugged, excellent storage, high current, low temperature, operates in any position
high cost, memory effect, poor for float service
500 5
Nickel-metal hydride rugged, high energy density, high current, operates in any position, good cycle life
high cost (between Nickel-Cadmium and Lithium ion)
600 5
Lithium ion rugged, high energy density, high specific energy, operates in any position, good cycle life, low self discharge
lower current, very high cost
1000+
Short Primer on BatteriesSecondary battery charging
charge method current rate C(A) charging energy efficiency
Lead-acid constant current, constant voltage 0.1 75%
Nickel-Cadmium (sealed) constant current 0.3 60%
Nickel-metal hydride constant current, constant voltage 0.1 60%
Lithium ion constant current, constant voltage 0.2 95%