Prismatic Battery Cells: Making the Switch From Cylindrical

• Introduction to Battery Cell Technologies: Prismatic vs Cylindrical
• The Essence of Prismatic Battery Cells: Understanding Their Structure and Function
• Size and Shape Benefits: How Prismatic Cells Maximize Space Efficiency
• Enhanced Safety Features of Prismatic Battery Cells
• Thermal Management Advantages in Prismatic Cell Design
• Prismatic Cells’ Impact on Electric Vehicle Battery Packs
• The Economic Implications: Cost-Benefit Analysis of Prismatic vs Cylindrical Cells
• Longevity and Lifecycle: Assessing the Durability of Prismatic Cells
• Compatibility and Integration: Adapting to the Prismatic Cell Standard
• Environmental Considerations: The Sustainable Choice in Battery Technology
• The Future of Batteries: Why Prismatic is Paving the Way
  • Efficiency in Packaging and Integration
  • Thermal Management and Safety
  • Cost-Effectiveness and Production Scalability
  • Adaptability and Durability
• Conclusion: Embracing the Transition to Prismatic Battery Cells

Introduction to Battery Cell Technologies: Prismatic vs Cylindrical

In the realm of portable energy, two primary forms of lithium-ion battery cells widely used across various industries are prismatic and cylindrical. Each type exhibits unique characteristics and advantages that make it suitable for specific applications.

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Prismatic battery cells are encased in flat, aluminum, or steel rectangular housings offering efficient stacking with no wasted space, hence optimizing battery pack density. The architecture of prismatic battery cells allows for larger individual cells, which can result in reduced manufacturing complexities with fewer cells needed for a given battery pack capacity.

On the other hand, cylindrical cells are housed in a circular steel or aluminum casing resembling traditional AA batteries. This configuration provides inherent rigidity and excellent mechanical stability. The cylindrical design is also typically more cost-effective to manufacture due to established production processes.

The construction differences between prismatic and cylindrical cells impact several factors critical to battery performance, including:

• Thermal Management: Prismatic battery cells usually have better heat dissipation due to their larger surface area, which helps in maintaining battery longevity and safety.
• Energy Density: Cylindrical cells often have a higher energy density, meaning they can store more energy for their size, which is beneficial for applications where space constraints are a priority.
• Assembly Complexity: The assembly of prismatic cells into battery packs is generally more straightforward, resulting in potentially lower labor costs and assembly time.

Understanding these characteristics is crucial for industries that rely heavily on battery cell technologies, such as automotive, consumer electronics, and renewable energy storage solutions. As technology advances, the debate between prismatic and cylindrical designs continues, with each having its proponents based on the specific needs of the application.

The Essence of Prismatic Battery Cells: Understanding Their Structure and Function

Prismatic battery cells are a type of rechargeable battery that have become increasingly popular in various applications, notably in the automotive industry for electric vehicles (EVs). What sets prismatic cells apart is their distinctive design and construction compared to their cylindrical and pouch cell counterparts.

• Structure: The structure of a prismatic cell typically features a hard outer shell made from aluminum or steel, which provides robustness and helps retain the shape of the cell. Inside, the battery’s electrodes and separators are stacked or folded in layers. This configuration allows for efficient use of space and contributes to the high energy density that prismatic cells are known for.
• Space Optimization: In a prismatic cell, the space within the casing is optimally utilized, as the rectangular shape fits neatly into battery packs without wasting the void spaces that occur between cylindrical cells. This characteristic makes prismatic battery cells a preferred choice for applications where space is a constraint and where the battery pack design calls for modularity and ease of cooling.
• Energy Storage: A prismatic cell’s energy storage capabilities stem from the chemical reactions within its electrodes—typically lithium-based compounds. During discharge, lithium ions move from the anode to the cathode through the electrolyte, releasing energy in the process. When charging, the ions are pushed back to the anode, storing energy for later use.
• Thermal Management: The prismatic cell’s design assists in more effective thermal management. The flat surfaces provide a better area for heat dissipation and are compatible with cooling systems that help in maintaining optimal operating temperatures, ensuring longevity and safety.
• Voltage and Capacity: Prismatic cells can be designed to meet specific voltage and capacity requirements by altering the size of the electrodes and the number of layers within the cell. This flexibility allows manufacturers to create batteries tailor-made for the energy and power demands of particular applications.

Their function and structural advantages position prismatic battery cells as a savvy choice for engineers and manufacturers aiming for compact, energy-dense, and reliable energy storage solutions.

Size and Shape Benefits: How Prismatic Battery Cells Maximize Space Efficiency

Prismatic battery cells are paving the way for advancements in energy storage by offering unique benefits in terms of size and shape, which make them especially suitable for electric vehicles (EVs) and portable electronic devices.

Firstly, prismatic cells provide a significant advantage in their compact form factor. With a rectangular shape, these cells can be stacked closely together, reducing wasted space that is inherent to cylindrical cells, which have vacant spaces between them when packed. This tight stacking translates to higher energy density within a given volume, making the most of the available space in battery packs.

Secondly, the flat surfaces of prismatic battery cells are inherently easier to cool. Efficient thermal management is critical for maintaining battery performance and longevity, and the prismatic design facilitates the attachment of cooling plates or incorporation into cooling systems. This is particularly beneficial in automotive applications where temperature regulation is a fundamental concern.

Moreover, the rigidity of prismatic cells lends itself to the structural integrity of the battery pack. When assembled, these cells can contribute to the overall strength of the housing, potentially reducing the need for additional structural support. This can further reduce the weight and cost of the battery system.

Finally, prismatic battery cells are amenable to flexible design parameters. Manufacturers can modify the width and length of these cells to fit specific applications, thereby maximizing space utilization in custom-designed battery packs. This versatility is an important consideration for product designers looking to integrate batteries into devices with complex or irregular shapes.

In short, prismatic battery cells are the keystones of efficient space utilization in modern battery technology, offering optimized packing, better thermal management, structural benefits, and design flexibility.

Enhanced Safety Features of Prismatic Battery Cells

Prismatic battery cells have risen in prominence for their various safety advantages over traditional cylindrical cells. These enhanced safety features make them a preferable choice in applications where safety is a primary concern.

• Stable Structure: Prismatic cells have a hard outer shell that maintains its shape and integrity even under pressure, reducing the likelihood of physical deformation that could lead to internal short circuits or battery failure.
• Built-in Safety Valves: These cells often incorporate safety valves that activate to relieve internal pressure if it rises to dangerous levels, which significantly diminishes the risk of explosion or combustion.
• Thermal Management: The design of prismatic battery cells allows for better thermal management. Their flat surfaces enable more effective heat dissipation and integration with cooling systems, which helps to prevent thermal runaway—a chain reaction that can result in a fire or explosion in lithium-ion batteries.
• Space Efficiency: As these cells are designed to fit snugly together with minimal wasted space, there is less risk of battery movement that could potentially cause internal damage or short-circuiting.
• Robust Connections: The electrode connections in prismatic cells are more reliable. These robust connections reduce the risk of a failed connection leading to overheating and potential cell failure.

Engineers of prismatic battery cells have also focused on chemical stability within the battery. By utilizing stable cathode materials and electrolyte formulations, the prismatic battery’s inherent risk of a chemical reaction that could lead to a safety hazard is minimized.

With these reinforced safety features, prismatic battery cells offer a compelling option for manufacturers and consumers alike, prioritizing safety without compromising on performance.

Thermal Management Advantages in Prismatic Cell Design

In examining the benefits of prismatic battery cells, thermal management stands out as a significant advantage over cylindrical counterparts. Prismatic battery cells, with their flat surfaces, allow for more efficient cooling strategies. Unlike cylindrical cells, which can present challenges to uniform heat dissipation due to their rounded shape, prismatic cells facilitate better thermal contact with cooling systems. This design feature enhances the capability to remove heat efficiently from the battery pack.

Conventional cooling systems, such as liquid cooling plates, can directly interface with the large flat sides of prismatic cells. The extensive contact area afforded by the prismatic design ensures that thermal transfer is more uniform across the cell’s surface, leading to a more consistent temperature distribution within the battery pack.

The benefits of efficient thermal management include:

• Extended battery life: By maintaining optimal operating temperatures, prismatic battery cells are less likely to suffer from thermal degradation, which can compromise battery longevity.
• Improved safety: Effective heat dissipation mitigates the risk of thermal runaway – a dangerous scenario where excessive heat could lead to battery failure or even fire.
• Increased performance: Batteries that operate within their ideal thermal range can deliver better performance, including higher power output and faster charging times.
• Scalability: The uniform thermal properties of prismatic cells make it easier to design battery packs for larger applications, such as electric vehicles, where managing the heat of hundreds of cells is crucial.

Overall, the prismatic cell design simplifies the integration of thermal management systems within battery packs, providing an essential advantage for applications that demand high reliability and safety.

Prismatic Battery Cells’ Impact on Electric Vehicle Battery Packs

The integration of prismatic cells into electric vehicle (EV) battery packs heralds several notable impacts on their design, performance, and longevity. Prismatic cells offer a compact, efficient energy storage solution, enabling manufacturers to optimize space within the battery pack casing.

• Space Optimization: Prismatic battery cells, with their flat, rectangular shape, can be packed closely together, reducing wasted space between cells. This allows for a more compact battery pack design, which is critical in the space-constrained environment of an electric vehicle.
• Improved Energy Density: Due to their larger size and reduced need for supportive casing material compared to cylindrical cells, prismatic cells can boast a higher energy density. This results in EVs that can travel further on a single charge while keeping the battery pack’s size to a minimum.
• Thermal Management: The design of prismatic cells facilitates better thermal management. The flat surfaces offer enhanced heat dissipation, allowing for more straightforward integration of cooling systems. This can lead to a more stable thermal environment, which is essential for maintaining the cell’s integrity and longevity.
• Structural Rigidity: The prismatic cell’s structure contributes to the overall rigidity of the battery pack. This rigidity can provide additional protection to the cells during an impact or collision, potentially improving the safety of electric vehicles.
• Manufacturing Advantages: From a manufacturing perspective, prismatic cells can be easier to assemble into packs and automate, leading to increased production efficiency and potentially lower costs.
• Scalability: The modular nature of prismatic cells makes them well-suited for scaling. Packs can be easily customized for various vehicle models, enabling manufacturers to use the same cell design across different vehicle platforms.

The transition to prismatic battery cells in EV battery packs is a move towards more reliable, efficient, and safe energy storage solutions, reflecting advancements in battery technology that are critical for the future of electric mobility.

The Economic Implications: Cost-Benefit Analysis of Prismatic vs Cylindrical Cells

When considering the switch from cylindrical to prismatic battery cells, it is essential to conduct a thorough cost-benefit analysis to understand the economic implications of such a transition. This analysis hinges on several key factors, including manufacturing costs, energy density, durability, and integration expenses.

• Manufacturing Costs: Prismatic battery cells typically require higher initial capital investment for production due to the complexity of their design and construction. However, economies of scale and maturing production technologies are gradually reducing these costs. Cylindrical cells benefit from a well-established production process, resulting in potentially lower per-unit costs.
• Energy Density: Prismatic cells often provide higher energy density compared to cylindrical counterparts, which leads to better space utilization and can reduce the overall cost of battery packs for applications where space is at a premium, like in electric vehicles.
• Durability and Maintenance: The design of prismatic cells contributes to their longevity and lower maintenance requirements over time. Less degradation can translate into lower lifecycle costs, which should be factored into any comprehensive economic analysis.
• Integration Expenses: Prismatic cells, due to their shape and construction, can be easier to integrate into a battery pack. This reduces labor and manufacturing costs associated with the assembly of battery systems, which can be a significant consideration for large-scale production.
• Supply Chain Considerations: Raw material availability and supply chain logistics differ for both types of cells. Fluctuations in material costs may affect the overall economics favorably or unfavorably, depending on the cell type.

In conclusion, the decision to switch to prismatic cells requires an in-depth understanding of not only the acquisition costs but also the impacts on performance and lifetime costs. As technology advances and production methods become more efficient, the scale may tip in favor of prismatic battery cells, potentially offering a more economically viable solution in the long term.

Longevity and Lifecycle: Assessing the Durability of Prismatic Battery Cells

When evaluating battery technology for long-term applications, prismatic cells stand out due to their robust longevity and predictable lifecycle. The durability of these cells is influenced by several factors that highlight their suitability for various uses.

Firstly, the architecture of prismatic cells promotes efficient temperature management. The flat sides allow for better contact with cooling systems, which reduces the risk of overheating during operation and charging. Efficient heat dissipation directly correlates with longer battery life.

Secondly, the materials used in prismatic battery cells are typically high-quality, ensuring solid performance over numerous charge cycles. With the ability to withstand high levels of stress without significant degradation, these cells maintain their capacity over time better than some alternatives.

Moreover, the design of prismatic battery cells minimizes the mechanical stress associated with swelling and contraction during charge cycles. This aspect is particularly beneficial:

• The rigid casing protects the internal components from external pressures and potential damage.
• It ensures a consistent form factor, a crucial feature for space-constrained applications.

In terms of lifecycle, studies show that prismatic battery cells can sustain several thousand charge cycles while retaining a considerable percentage of their original capacity. This trait is a testament to their longevity, rendering them a cost-effective option over their lifespan.

However, it’s crucial to recognize that no battery is immune to wear and tear. Factors such as depth of discharge, operating temperature, and the rate of charge will invariably impact the durability of a prismatic battery cell. Nonetheless, within controlled parameters, the prismatic cell design inherently offers a commendable balance between lifespan and performance, supporting its growing preference in various industries.

Compatibility and Integration: Adapting to the Prismatic Cell Standard

As prismatic battery cells gain popularity, the standardization around their design is becoming increasingly significant. For industries considering a shift from cylindrical to prismatic cells, understanding the nuances of compatibility and integration is vital. Prismatic cells can potentially offer a more straightforward integration process due to their structured, rectangular shape, which can be easily stacked and incorporated into a wide range of applications.

• Modular Design: Prismatic battery cells’ design facilitates modular usage, allowing for more efficient space utilization within battery packs. They can be arranged in compact, flat layers, which is highly conducive to consistent energy density in larger battery systems.
• Thermal Management: The flat surfaces of prismatic cells simplify the implementation of cooling systems, which are essential for maintaining battery efficiency and longevity. The ease of integrating thermal management solutions can reassure manufacturers about the consistent performance of their products.
• Robust Housing: The hard casing of prismatic cells provides innate protection against mechanical stress, which can reduce the need for additional protective components within the battery module. This robust housing also simplifies the cell’s integration into electric vehicles or stationary energy storage systems, offering greater resilience to environmental factors.
• Electrical Connections: Establishing electrical connections within a prismatic cell array is generally streamlined compared to cylindrical batteries. The design often includes built-in terminals that can be easily linked with neighboring cells, facilitating faster assembly and maintenance processes.

The transition to prismatic battery cells does require thoughtful consideration of existing design and manufacturing processes. Companies need to evaluate their production capabilities and potentially invest in new equipment or retraining personnel. However, following the prismatic cell standard can significantly enhance compatibility and integration, ensuring a sustainable transition to more efficient and reliable battery technology.

Environmental Considerations: The Sustainable Choice in Battery Technology

In the realm of battery technology, environmental sustainability is a paramount consideration. Prismatic battery cells are paving the way for a more sustainable future with their unique advantages over traditional cylindrical designs. The materials used in prismatic cells can be more easily recycled due to their standardized shapes and sizes, which helps reduce environmental waste.

• Resource Efficiency: Prismatic battery cells make more efficient use of internal space within a battery pack. This design leads to fewer materials being required for casing and connections compared to cylindrical cells, resulting in a reduced ecological footprint.
• Thermal Management: The flat surfaces of prismatic cells provide more effective cooling capabilities. Better thermal management reduces the risk of overheating, thereby extending the life of the battery and minimizing waste disposal of batteries that can have harmful environmental impacts.
• Production Processes: The manufacturing process for prismatic cells is typically more streamlined than that of cylindrical batteries. It involves less waste production and can often be more energy-efficient, reducing the overall carbon footprint of the production phase.
• Transportation and Installations: Due to their shape and size, prismatic batteries can be packed and transported more efficiently, resulting in lower emissions associated with their distribution. Moreover, their design allows for more compact and lightweight end products, such as electric vehicles, which further enhances energy efficiency and reduces emissions.

By choosing prismatic battery cells, manufacturers and consumers alike are investing in a technology that supports an environmentally conscious approach. Embracing batteries that facilitate recycling, enhance life span, and minimize production and operational impacts plays a crucial role in the journey towards sustainability in energy storage solutions.

The Future of Batteries: Why Prismatic is Paving the Way

The trajectory of battery development points toward a landscape dominated by prismatic battery cells, for several compelling reasons. Prismatic battery cells are increasingly favored in the electric vehicle (EV) market, as well as in portable electronics and energy storage systems, due to their scalability, energy density, and ease of manufacturing.

Efficiency in Packaging and Integration

Prismatic cells are heralding a new era of efficient battery packaging. Their rectangular shape allows for a more optimal use of space within battery packs, leading to compact designs and leaving minimal wasted volume. This geometric advantage is critical for EVs, where every cubic centimeter of space is valuable. Additionally, prismatic battery cells can be stacked or layered, providing designers with versatile options for integrating larger battery systems.

Thermal Management and Safety

The enhanced thermal management properties of prismatic cells contribute to their future dominance. Their design facilitates better heat dissipation, reducing the risk of overheating and thermal runaway—a serious concern in densely packed battery modules. With intrinsic safety being a priority for consumers and manufacturers alike, prismatic cells’ ability to maintain a stable temperature plays a significant role in their adoption.

Cost-Effectiveness and Production Scalability

Cost considerations are vital in battery technology. Prismatic battery cells offer economies of scale that are not as readily achievable with cylindrical alternatives. Their manufacturing process is amenable to automation, leading to a decrease in production costs as demand and production volumes increase. Stakeholders across the battery supply chain recognize the potential cost benefits, driving investments and research into prismatic technology.

Adaptability and Durability

Advancements in material science complement the structural benefits of prismatic cells. They are typically encased in hard shells that offer added protection against physical stress, contributing to their longevity and reliability. As research in electrode and electrolyte materials progresses, prismatic battery cells have shown that they can adapt to these innovations, enhancing their performance and energy density.

The alignment of prismatic cells with industry priorities—space optimization, safety, cost reduction, and performance—positions them as a cornerstone of future battery development. Their design and manufacturing advantages are set to make them the preferred choice for a range of applications, thereby advancing the modern battery era.

Conclusion: Embracing the Transition to Prismatic Battery Cells

As industries and technologies continue to evolve, the transition to prismatic battery cells represents a forward-thinking approach to meeting the growing demand for energy storage solutions that are efficient, reliable, and environmentally sustainable. Prismatic battery cells, with their flat, rectangular shape, offer superior space utilization and enable more straightforward cooling systems, which contribute to better safety profiles. The simplified packaging and higher energy density make them increasingly favorable for use in electric vehicles (EVs), consumer electronics, and renewable energy storage systems.

Ready to power up your energy solutions with cutting-edge technology? Dive into the world of solar battery innovation with Solar Battery Manufacturer! Discover how our prismatic battery cells are revolutionizing the renewable energy landscape, offering enhanced safety, efficiency, and sustainability. Whether you’re a homeowner looking to harness the power of solar energy or a business seeking reliable backup power solutions, we’ve got you covered.

In conclusion, embracing prismatic battery cells is a necessary step for industries looking to stay competitive in a market that increasingly values energy efficiency, safety, and sustainability. The shift to prismatic technology is not just about keeping pace with current trends but paving the way for the future of energy storage.

Frey New Energy – 3 reasons that Prismatic LFP lifepo4 lithium battery cell is the winning cell for battery packs of modern underground mine equipment.

Mining vehicle manufacturers are developing new, game-changing BEVS (Battery powered Electric Vehicles) powered by lithium-ion batteries as an alternative to diesel power. Given the high energy density of Li-ion batteries, they’re currently the most common and convenient battery for new BEV applications.

The quiet, low heat, and zero-emission of Li-ion battery quickly improves underground work environments and eliminates health hazards to workers. Not to mention they’re responsive, have fewer moving parts, and require less maintenance.

The Lithium-ion battery industry has expanded rapidly in the last 10 years. Because of this, we also see many accidents of lithium-ion battery explosions and issues associated with fighting big battery fires. According to OSHA/CPSC, 25,000 overheating or fire incidents involving more than 400 types of lithium battery-powered consumer products occurred over a five-year period.

As the concern of safety becomes more obvious, some lithium-ion battery cells are claimed to be explosion-proof and fire resistant. It can be confusing and misleading if we don’t understand the different chemistries and types of lithium batteries.

This article will uncover the myth of their differences and provide a deep analysis from the aspects of safety, lifespan, and commercial maturity, so you will understand why we think Prismatic LFP LifePO4 Lithium battery is the winning chemistry for modern underground mine equipment.

What is a Lithium Ion Battery?

In a Li-ion battery, lithium ions travel back and forth between the anode and cathode during charge and discharge (negative electrode being anode, positive electrode being cathode). The ions move in an electrolyte and across a separator that sits between the two electrodes (Figure 1).

The sequence involves reduction/oxidation (redox) reactions specific to the particular chemistry of the cathode, and the chemical energy of these reactions is harnessed to store and discharge electrical energy from the positive and negative terminals of the battery.

Anode materials include:

Graphite (the most common type)

Hard Carbon

LTO (Lithium Titanate Oxide)

Cathode materials include:

Are you interested in learning more about LiFePO4 Rechargeable Prismatic Battery? Contact us today to secure an expert consultation!

Additional reading:
10 Things to Consider When Buying 18650 Battery Manufacture

LCO-Lithium Cobalt Oxide

NMC-Lithium Nickel Manganese Cobalt Oxide

LFP- Lithium Iron Phosphate

The choice of the cathode material will affect greatly the end battery properties such as safety, energy, life cycle, and cost.

The electrolytes include:

Liquid organic solvents

Gels

Polymers

Ionic liquids

Below, we made a comparison between the most common cathode materials that could be used in mine BEVs.

LCO-Lithium Cobalt Oxide

NMC-Lithium Nickel Manganese Cobalt Oxide

LFP- Lithium Iron Phosphate （LiFePO4）

LTO- Lithium Titanate LTO is anode, which can be combined with any cathode.

From the prospects of safety, life span, and cost, LFP battery is not doubt the winner among them all. It does have relatively low energy density. However, in the industrial application, the weight and space are not equally as demanding as, say, a passenger car. In reality, low energy density can turn to an advantage, it will require less counter weight in applications where counterweight is required.

Safety

Safety is always the #1 priority in the mine industry. One accident happens, it can cost businesses millions of dollars. The primary hazard from Li-ion batteries is a catastrophic event called thermal runaway in which the battery quickly and sometimes violently releases its stored electrochemical energy.

We’ve seen several severe incidents of car and airplane explosions due to li-ion battery thermal runaways. This is why the mining industry must use the battery that has the highest thermal stability and tested explosion proof; both the battery pack and the cell itself.

The key advantage of LFP as a cathode material lies in its chemical stability and the ability to withstand relatively high temperatures. The molecular structure absorbs and releases lithium ions without a large change in volume, and it’s resistant to the growth of defects from daily charge and discharge cycles.

The P-O bond in the lithium iron phosphate crystal is stable and difficult to decompose. Even at high temperature or overcharge, it will not collapse and heat up like lithium cobalt oxide nor form strong oxidizing substances.

In China, for lithium-ion battery to be able used in mine equipment in coal mining, it has to be approved by Mining Products Safety Approval and Certification Center (MA Center) in Beijing, a stress test of the li-ion battery cell and modules needs to be done. There are 23 test items for lithium-ion batteries.

Some of the extreme stress tests that can be related to real life battery abuse includes: nail penetration, baking with flame, external short circuit and over-charge.

During the some of the toughest tests, the LFP cell was smoking, no fire or burning occurred. In the baking with flame and external short circuit tests, LFP cell remains explosion-proof and fire-free.

In the overcharge stress test, high charging voltage that was several times higher than the rated discharge voltage was used, and it was found that there was still no explosion on the LFP battery. The safety of overcharge is extremely important, as it is one of the most common thermal runaways.

LFP batteries can be used safely in ambient temperatures up to 55°C (131°F). Even if it catches fire, it shoulders like coal, and needs oxygen to burn. On the other hand, the popular NCM battery burns violently like gunpowder, and requires no oxygen to be set aflame.

There are also differences in putting out the fire when your battery is burning. For LFP, normally water or foam can kill the fire. However. for NCM, it can get very complicated.

Frey New Energy shared some details of the nail penetration test they conducted to a 3.2V100Ah Cell. After the battery was fully charged, a steel nail was directly penetrating the center of the cell. With a speed of 40mm/S, the nail remained inside the cell. There was no fire or explosion.

Battery Life

Mine trucks and equipment are durable, built to last. They consume high power compared to passenger EVs. They need an equally durable and reliable power pack to match the nature of the equipment. That’s why it is wise to choose a battery pack that lasts long term and require few replacements in a very long period of time.

Current expectations on the lifetime for a battery in heavy‐duty vehicles is 6 years. However, for future generation batteries, the expectation is that they would last the lifetime of the vehicle. A defining factor in determining battery life is the particular cell chemistry used in the battery pack.

According the table, LTO has the best life span. However, due to its high cost and low energy density, it has not been widely used and hasn’t reach commercial maturity in mine industry. The cycle life of Lifepo4 is over 3,000 with 80% depth of discharge, while NCM only reaches 800. When the LFP battery is used with 50% depth of discharge, the cycle life can reach 4,000 times, and when 20% depth of discharge, it can reach even 6,000 times.

In the mine industry, the cycle life can be up to 3,000 times. If the machines run 365 days a year, then it has a life span of 8.2 years. Most lithium-ion manufacturers give warranty on material handling, a very standard warranty of 5 years or 10,000 hours uptime. some are giving energy Amp hour of 2,000 x nominal capacity, for example, if a

battery is rated 200ah, then it gives warranty of 200× =400KWH total power output for the entire life span. That means 2,000 times with of the battery capacity is 100% used. This is 4 times longer than a traditional lead-acid battery. LFP chemistry is winner again in the life span.

Production Efficiency

The electric passenger cars take 67% of global EV li-ion battery market, with a small fraction of 16% for commercial vehicles. The mine equipment takes a small part among the 16%. Small quantity, customized mine equipment is built in small batches, unlike passenger EVs. Massive production of one battery model to fit thousands of vehicles? That doesn’t work for mine equipment.

Lithium batteries for mine equipment needs to be custom built. In the battery pack building process, it’s critical to choose the most ideal cell for the best efficiency, and we’ve concluded that the LFP chemistry is most ideal. There are many different shapes of LFP battery cells; the most common prismatic and cylindrical. It’s important to choose the right shape to make the lithium battery pack. Below is a comparison of advantages of drawbacks.

The prismatic battery has a large capacity from 3.2V50Ah to 3.2V200Ah. The cylindrical cell has a small capacity from 3.2V1.5Ah to 3.2V6Ah. Among the most common type of cylindrical cells is the . The term comes from the IEC naming scheme for round cells based on their physical dimensions. The first two digits are its diameter in millimeters, while the last 3 digits are for its height in 1/10th millimeters.

But the question remains: why it is important to use large capacity cells?

Better consistency

We can explain this better with the “barrel theory”. Just like the capacity of a barrel is determined by the shortest wooden bars, the performance of the whole battery pack is determined not by the best performing cell, but by the worst. In the lithium battery pack assembling process, it is always an important step to choose the most consistent level cells.

The consistency of the battery pack is also related to the number of cells. The more cells, the worse the consistency and the worse the performance of the battery pack will be.

Easy Assemble

For example, to make an 80V500Ah lithium battery pack, using a lithium iron phosphate LFP 3.2V100Ah prismatic battery cell will only require 125 battery cells. Use 25 of 3.2V100Ah to make 80V100Ah, and then serial connect 5 of the 80V100Ah to make 80V500Ah. If you use LFP cylindrical battery -6Ah batteries, you’re looking at 2,075 battery cells.

If you want to maintenance the battery pack by checking each battery cell’s performance or repair the pack by replacing bad cells, it would impossible for identifying the bad cylinder cells. It would be easy on the prismatic cells. Some battery suppliers even designed a battery kit system that you can check the voltage of each cell easily without taking apart the whole pack.

Making a battery with large prismatic cells has simplified assembling technology and convenient processing.

Large lithium battery packs can be assembled together through bus bar or laser welding process. This process is simple and convenient. However, if a cylindrical battery cell is used, the method is spot-welding, complicated, and much more difficult manufacturing. Recently, there have been cylindrical batteries using aluminum wire welding technology, which is costly with mediocre results.

The one advantage of cylindrical cell is that when the battery pack is assembled, the gap between two cells is large, and the heat dissipation is improved. A cylindrical battery coupled with the cell bracket has a stable structure, large cell gap, and better heat dissipation. However, this can also be the case when using prismatic cells. The cell bracket be designed with a gap between each cell too.

Further Thought

Prismatic LFP cells are widely used in energy storage, nowadays more and more EV makers. Companies like Tesla have started adapting their LFP cells, due to the excellent safety features, lack of toxic metal chemicals and low raw material cost.

However, we have to keep in mind that the power consumption is very different between passenger EV and industrial EV. Passenger EVs pursuit long distances with small power consumption in short periods of time.

Heavy-duty mine machines pursuit very high-power consumption in short periods of time. Should mining BEVs use the same standard on the battery as it is for passenger EVs and energy storage? Or it should be reviewed with the actual application of itself?

Production engineer of Zhenghai Hu, VP of Engineer at Frey New Energy.

Industrial heavy-duty machines need high c-rate and reinforced internal cell construction that brings more challenges on manufacturers who are used to making the lithium battery cells for the passenger EV industry.

“To achieve this heavy-duty feature matching tough mine vehicles, the production procedure needs to have a complete reset, and the material sourcing of electrodes, separators, even the terminal posts will need to have a completely new standard. For example, the aluminum film and copper film used for the separators all need to be thicker.”

Overall, there are thousands of lithium battery manufactures in China, and the global EV marketing’s booming lead is Tesla. However, this global mine industry is the one that demands a far safer and cleaner energy; more so than any other industries.

Luckily, there are some manufacturers that know the special requirements of the mining industry. There is a clear path and solution of the mining industry’s lithium battery needs; it’s up to you to take it.

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