from chemistry to pack
Separator Failure Modes and Internal Short Circuit This is a worked example accompanying Failure Mode and Effects Analysis (FMEA) in Battery Design. It walks through a single DFMEA line at cell level in full, from failure mode to recommended action, using the separator as the subject. The separator is a good first example because it … Read more
Virtual temperature sensors (also referred to as “soft sensors” or “sensorless estimators”) are software-based algorithms that estimate the temperature of battery cells without relying on a direct, physical hardware sensor at the measurement location [2]. Instead of measuring heat directly, these virtual sensors act as real-time state reconstruction algorithms running within the Battery Management System … Read more
Anode overhang is intentional as cathode overhang can result in: The issue is that extra anode material increases cost, weight and volume of the cell. Hence it is important to design the cell with the right amount of anode overhang taking into account the manufacturing process variability and quality control inspection capability. Here we look … Read more
Author Dr. Simon Madgwick of Nuvvon Inc. Nuvvon Solid State Passes Nail Test with Graphite-NMC811 and Lithium-NMC9 Nuvvon has been building solid state cells for years and has long since exposed the things SSB players don’t tell you. There are some 60 so called Solid-State offerings out there but none with a completely dry cell that operates … Read more
AION Engineering INC Safety is at the core of every lithium-ion cell design. To ensure reliable operation in demanding applications, the cell assembly and structure integrate multiple layers of protection. These features collectively reduce the risk of failure, overheating, or explosion. PTC (Positive Temperature Coefficient Device) The PTC acts as a resettable fuse: Applications: CID … Read more
AION Engineering INC All cells discussed here are 18650 NMC cells. Balancing Energy Density and Safety Using silicon-based additives in the anode requires a delicate trade-off in cell design. While silicon increases the energy density, it also brings significant challenges for cell safety. Why More Space is Needed Silicon expands and contracts during charge-discharge cycling, … Read more
The Current Interrupt Device (CID) in a cell is designed to electrically disconnect a cell if the internal pressure increases beyond a design point. If the gas pressure increases further the burst disc breaks and the gas is vented. However, is the CID operation safe under High Voltages (HV)? As the CID opens the circuit … Read more
Author: Woody Wu at power9tech.cn Alumina and Boehmite are examples of ceramic coating materials used on separators. These can be applied on one side or both sides of the separator. Ceramic-Coated Separators Ceramic-coated separators consist of a base film (PP/PE) with a surface layer of heat-resistant inorganic ceramic particles (e.g., Al₂O₃, SiO₂, Mg(OH)₂), bonded tightly … Read more
Author: Glimpse Battery defects are a major scourge on the industry. In fact, battery defects have been deemed responsible for major billion-dollar electric vehicle recalls.1 Furthermore, dozens of battery safety incidents have been attributed to poor-quality and/or counterfeit batteries, which often have poor performance, reliability, and safety.2–6 In short, battery defects directly threaten both the … Read more