Lithium-Ion Battery Standards

Lithium-Ion Battery Standards is an essential guide for understanding Lithium-ion batteries and the standards that govern them. This comprehensive resource covers everything from the basics of Lithium-ion battery systems to the intricacies of safety, design, and regulatory requirements. The book explains the differences between Lithium-ion batteries and other battery systems, highlighting the critical importance of system integration and design. It offers insights into battery system architectures, terminology, and the safety features that can be specified for Lithium-ion cells. Cover Half Title Lithium-Ion Battery Standards Copyright Contents Preface 1. Lithium-Ion Battery Introduction 1.1 Introduction 1.2 Terminology in Battery Systems 1.3 Lithium-Ion Battery System 1.3.1 Form Factor and Battery Cell Identification 1.3.2 Output Voltage 1.3.3 Implementation 1.4 Lithium-Ion Battery Cell Construction 1.4.1 Battery Cell Packaging Materials 1.4.2 Battery Cell Form Factors 1.4.2.1 Cylindrical Battery Pack Cells 1.4.2.2 Pouch and Prismatic Battery Pack Cells 1.4.2.3 Button or Coin Lithium-Ion Battery Pack Cells 1.4.3 The Components Used in a Lithium-Ion Battery Pack Cell Electrode Assembly 1.4.3.1 Positive Electrode 1.4.3.2 Negative Electrode 1.4.3.3 Separator 1.4.3.4 Electrolyte 1.4.4 The Electrode Assembly 1.4.5 Graphite-Based System Operation 1.5 Lithium-Ion Battery Cell Performance Characteristics by Definition References 2. Battery Systems Architectures 2.1 The Battery Pack System 2.1.1 The Lithium-Ion Cell 2.1.1.1 The Lithium-Ion Battery Pack 2.1.2 The Charger 2.1.3 The Discharger 2.1.4 The Power Source 2.2 Lithium-Ion Battery System Subsystems 2.2.1 Battery System Power Sources 2.2.1.1 AC Power Converters 2.2.1.2 DC Power Converters 2.2.1.3 AC and DC Power Converter 2.2.2 Battery Pack Charger Architectures 2.2.2.1 The Battery Pack Charger Integrated into the Power Converter 2.2.2.2 Battery Pack Charger Integrated into the Product 2.2.2.3 Battery Pack Charger Integrated into the Battery Pack Enclosure 2.2.3 Battery Pack Battery Management Unit Circuit Architectures 2.2.3.1 Single-Cell Battery Pack BMU 2.2.3.2 Multiseries Cell Battery Pack BMU 2.2.4 Battery Pack Architectures 2.2.4.1 Series Cell Battery Pack Architectures 2.2.4.2 Series Cell Battery Pack Architecture 2.2.4.3 Battery Module Architecture 2.2.5 The Battery Pack Cell 2.2.5.1 Battery Pack System Architectures 2.2.6 The Exchangeable Battery Pack Architecture 2.2.7 User-Replaceable Battery Pack and Internal Device Battery Pack Charger 2.2.8 Nonuser-Replaceable Battery Pack and Internal Device Battery Pack Charger 2.2.9 Portable Power Source 2.2.10 The Modular Battery 2.2.11 Nonmodular Universal Serial Bus Storage System Architecture 2.2.12 Modular and Nonmodular Electrical Storage System Architecture 2.3 The Battery Pack Cell Datasheet and the Battery Pack Cell Specification References 3. Lithium-Ion Battery Safety Considerations 3.1 Introduction 3.2 Product or System Reliability Versus Safety 3.3 Lithium-Ion Battery Cell Failure Causes and Modes 3.3.1 Thermal Runaway 3.3.2 Internal Short Circuit 3.3.3 Lithium Plating 3.3.4 Cell Failure Mechanisms 3.3.4.1 Cell Design 3.3.4.2 Manufacturing 3.3.4.3 Mechanical Stress 3.3.4.4 Electrical Over Stress 3.3.4.4.1 Charge Voltage Over Stress 3.3.4.4.2 Charge Current Over Stress 3.3.4.5 Thermal Stress 3.3.4.6 Charge Algorithm 3.3.4.7 Discharge Algorithm 3.3.5 Battery Pack Failure Modes 3.3.5.1 Organic Carbonization Resistive Fault 3.3.5.2 Protection Devices 3.3.6 Electrical and Electronic Component Failures 3.3.6.1 Surface Mount Chip (MLC) Ceramic Capacitors 3.3.6.2 Metal Oxide Varistors 3.3.6.3 Electrolytic Capacitors 3.3.6.4 Electromechanical Relays 3.3.6.5 Field Effect Transistors 3.3.6.6 Solid State Relays 3.3.7 High-Voltage Isolation 3.3.8 Environment and Environmental Conditions to Consider 3.3.9 Environmental Compatibility 3.3.10 Critical and Unique Requirement Considerations 3.3.11 Recyclability 3.3.12 Storage References 4. The Law and Battery Product Safety 4.1 Introduction 4.2 The Evolution of Product Safety 4.2.1 Product Safety and Product Battery System Regulations 4.2.2 Product and Product Battery System Safety Control Management 4.2.3 Product and Product Battery System Safety Certifications 4.3 The Law and Product and Product Battery System Safety Compliance 4.3.1 Product and Product Battery System Liability 4.3.2 Historical Background 4.3.3 Types of Battery Product and Product Battery System Defects 4.4 Product and Product Battery System Compliance 4.4.1 Why is Product and Product Battery System Compliance Necessary? 4.4.1.1 Engineering and New Product and Product Battery System Management 4.4.1.2 Legal 4.4.1.3 Sales and Marketing 4.4.1.4 Customer Support 4.4.1.5 Quality 4.4.1.6 Operations and Logistics 4.4.1.7 Distribution 4.4.2 Risks of Nonconformance of the Product and Product Battery System References 5. Regulatory Requirements and Safety Standards 5.1 Introduction 5.2 International and Foreign Regulatory Organizations 5.3 International Battery Standards 5.4 Regulatory Organizations in the United States 5.5 Battery Standards Organizations Located in the United States 5.5.1 Lithium-Ion Battery Standards in the United States 5.5.2 Description of Selected Standards Used in the United States 5.5.2.1 UN/DOT 38.3 Transportation and Testing of Lithium-Ion Batteries and Cells 5.5.2.2 International Electrotechnical Commission 5.5.2.2.1 IEC 62281 5.5.2.2.2 IEC 62619 5.5.2.2.3 IEC 62660 5.5.2.2.4 IEC 61960 5.5.2.2.5 IEC 62133-2:2017 5.5.2.2.6 IEC 61959:2004 5.5.2.3 International Organization for Standards 5.5.2.3.1 ISO 12405 5.5.2.4 Underwriters Laboratory Standards 5.5.2.4.1 UL 1642 5.5.2.4.2 UL 2054 5.5.2.4.3 UL 62133-2 5.5.2.4.4 UL1973 5.5.2.4.5 UL 2271 5.5.2.4.6 UL 2272 5.5.2.4.7 UL 2580 5.5.2.4.8 UL 1974, 1st Edition 5.5.2.4.9 UL 1998 5.5.2.4.10 UL 9540A, 4th Edition 5.5.2.5 Society for Automotive Engineers 5.5.2.5.1 SAE J1772 5.5.2.5.2 SAE J2464 5.5.2.6 Institute for Electrical and Electronic Engineers 5.5.2.6.1 IEEE 1625 – 2008 5.5.2.6.2 IEEE 1725–2021 5.5.2.6.3 IEEE P2686 Recommended Practice for Battery Management Systems in Energy Storage Applications 5.5.3 Procedural Test Standards 5.5.3.1 ISO 26262 5.5.3.2 SAE J3220_202301 5.5.3.3 SAE J3235_202303 5.5.3.4 LV 123 5.5.3.5 FreedomCAR 5.5.3.6 USABC 5.5.4 Codes and Authority Having Jurisdictions References 6. Portable Consumer Product Battery System Standards 6.1 Introduction 6.2 Power Source 6.2.1 AC Power Converters 6.2.2 Variations 6.2.3 Relevant Standards 6.2.4 Safety Compliance 6.2.4.1 AC Mains Power Source 6.2.4.2 DC-DC Converters 6.3 Charger 6.4 Relevant Standards 6.5 Safety Compliance 6.6 The Battery Pack 6.7 Single-Series Cell Battery Pack Architecture 6.8 Series Cell and Series-Parallel Cell Lithium-Ion Battery Pack Architectures 6.9 Relevant Standards 6.10 Battery Cell 6.11 Relevant Standards 6.12 The Product Lithium-Ion Battery System 6.13 Lithium-Ion Battery System Architectures 6.13.1 Relevant Standards 6.13.2 Other Relevant Standards 7. Medical Product Battery System Standards 7.1 Introduction 7.1.1 Relevant Standards 7.2 Power Source 7.2.1 AC Power Converters 7.2.2 Relevant Standards 7.2.2.1 AC Mains Connection 7.3 Battery System Battery Charger Architectures 7.3.1 Relevant Standards 7.4 The Battery Pack 7.4.1 Typical Battery Architectures 7.4.1.1 Series Cell Battery Architecture 7.4.1.2 Series Cell Battery Architecture 7.4.2 Relevant Standards 7.5 Battery Cell 7.5.1 Relevant Standards 7.6 The Integrated Battery System 7.6.1 Relevant Standards 7.6.2 Implementation of the Standards 7.7 Other Relevant Standards 7.7.1.1 ANSI C18 Series 7.7.1.2 UL 1642 Lithium Batteries 7.7.1.3 UL 2054 Household and Commercial Batteries 7.7.1.4 United Nations Manual of Tests and Criteria, Section 38.3 8. E-Mobility Battery System Standards 8.1 Introduction 8.2 Battery System Power Sources 8.2.1 Relevant Standards 8.2.1.1 Implementation of the Standards 8.3 The Battery Charger Architectures 8.3.1 Relevant Standards 8.3.2 Implementation of the Standards 8.4 The Battery Pack 8.4.1 The Battery Module 8.4.2 Relevant Standards 8.5 The Battery Cell 8.6 The Battery System 8.6.1 Relevant Standards 8.7 Summary of E-Mobility Standards and Product Categories 8.7.1.1 ANSI C18 Series 8.7.1.2 UL 1642 Lithium Batteries 8.7.1.3 UL 2054 Household and Commercial Batteries 8.7.1.4 United Nations Manual of Tests and Criteria, Section 38.3 9. Automotive Battery System Standards 9.1 Introduction 9.2 Chargers 9.2.1 Level 1 Charging 9.2.2 Level 2 Charging 9.2.3 Level 3 Charging 9.2.4 Relevant Standards 9.3 The Vehicle Battery 9.3.1 Relevant Standards 9.4 Battery Cell Standards 9.4.1 Relevant Standards 9.5 Other Relevant Standards 9.5.1 ANSI C18 Series 9.5.2 UL 1642 Lithium Batteries 9.5.3 UN/DOT 38.3 Transportation Testing 9.5.4 UL 2054 Household and Commercial Batteries 9.6 Additional Product Categories 9.6.1 E-Motorcycles 9.6.2 E-Bike (Recreational Use) 9.6.3 Heavy-Duty Electric Vehicles 9.6.4 Electric Forklifts 9.6.5 Electric Autonomous Cleaners 9.6.6 Electric Mining Vehicles 9.6.7 Electric All-Terrain Vehicles and Utility Terrain Vehicles 10. Toy Battery System Standards 10.1 Introduction 10.2 Battery System Power Sources 10.2.1 Power Converters 10.2.2 Relevant Standards 10.3 Battery System Charger 10.3.1 Relevant Standards 10.4 The Battery Pack 10.4.1 Single-Series Cell Battery Architecture 10.4.2 Multiseries Cell Battery Architecture 10.4.3 Relevant Standards 10.4.4 Battery Standards 10.5 Battery Cell Standards 10.6 The Battery-Powered Product 10.6.1 Relevant Standards 10.6.1.1 ANSI C18 Series 10.6.1.2 UL 1642 Lithium Batteries 10.6.1.3 UL 2054 Household and Commercial Batteries 10.6.1.4 United Nations Manual of Tests and Criteria, Section 38.3 11. Cellular Device Battery System Standards 11.1 Introduction 11.2 Battery System Power Sources 11.2.1 Relevant Standards 11.3 Battery System Battery Charger Architectures 11.3.1 Relevant Standards 11.3.2 The Battery Pack 11.3.3 Battery Architectures 11.3.3.1 Single Series Cell Battery Architecture 11.3.3.2 Multiseries Cell Battery Architecture 11.3.4 Relevant Standards 11.4 Battery Cell Standards 11.5 The Integrated Battery System 11.5.1 Relevant Standards 11.5.1.1 ANSI C18 Series 11.5.1.2 UL 1642 Lithium Batteries 11.5.1.3 UL 2054 Household and Commercial Batteries 11.5.1.4 United Nations Manual of Tests and Criteria, Section 38.3 11.5.2 Relevant Product Categories and Safety Standards 11.5.2.1 Tablets 11.5.2.2 Remote Monitoring Devices 12. Clothing Battery System Standards 12.1 Introduction 12.2 Battery System Power Sources 12.2.1 AC Power Converters 12.2.2 Relevant Standards 12.3 Battery System Battery Charger Architectures 12.3.1 Relevant Standards 12.4 The Battery Pack 12.4.1 Battery Pack Architectures 12.4.1.1 Single-Series Cell Battery Pack Architecture 12.4.1.2 Multiseries Cell Battery Pack Architecture 12.4.2 Relevant Standards 12.5 The Battery Cell 12.5.1 Relevant Standards 12.6 The Product-Integrated Battery System 12.6.1 Relevant Standards 12.6.1.1 Bracelets (Fitness Trackers) 12.6.1.2 Glasses (Video Capture and Monitor) 12.6.1.3 Rings (Heart Monitor) 12.6.1.4 Smart Watch (May Include Mobile Phone Features) 12.6.1.5 Gloves 12.6.1.6 Jackets 12.6.1.7 Socks 12.6.1.8 Footwear 12.6.2 Other Relevant Standards 12.6.2.1 ANSI C18 Series 12.6.2.2 UL 1642 Lithium Batteries 12.6.2.3 UL 2054 Household and Commercial Batteries 12.6.2.4 United Nations Manual of Tests and Criteria, Section 38.3 13. Electrical Storage Battery Standards 13.1 Introduction 13.2 Portable Power Pack 13.2.1 The Battery Pack System Power Source 13.2.2 The Battery Pack Charger Architectures 13.2.3 The Lithium-Ion Battery Pack 13.2.3.1 Single-Series Cell Battery Pack Architecture 13.2.3.2 Multiseries Cell Battery Pack Architecture 13.2.4 The Battery Pack Cell 13.2.5 The Portable Power Pack System Architecture 13.3 6V/12V Lithium-ion Batteries 13.3.1 The Battery System Power Source 13.3.2 The Battery Pack Charger Architectures 13.3.3 The Battery Pack 13.3.4 The Battery Cell 13.3.5 The Battery System Architecture 13.3.6 Relevant Standard 13.4 Home Electrical Storage Systems (Home Backup Power) 13.4.1 The Battery System Power Source 13.4.2 The Battery Pack Charger Architectures 13.4.3 The Lithium-Ion Battery 13.4.4 The Battery Cell 13.4.5 The Battery System Architecture 13.4.6 Nonmodular Battery System Architectures 13.4.7 Relevant Standard 13.5 Uninterrupted Power Supply Systems 13.5.1 Relevant Standard 13.6 Grid Battery Electric Storage Systems 13.6.1 The Battery System Power Source 13.6.2 The Battery Pack Charger Architectures 13.6.3 The Battery Pack Architectures 13.6.4 The Battery Cell 13.6.5 The Battery System Architecture 13.6.6 Relevant Standards Reference 14. Aviation Battery System Standards 14.1 Introduction 14.2 Battery System Power Sources 14.2.1 Relevant Standards 14.3 Battery System Charger Architectures 14.4 The Battery Pack 14.4.1 Relevant Standards 14.5 The Battery Cell 14.6 The Integrated Battery System 14.7 Product Category Specific Relevant Standards 14.7.1 Unmanned Commercial Drones 14.7.2 Passenger Winged Aircraft 14.7.3 Rideshare Taxis 15. Lithium-Ion Battery Shipping in the United States 15.1 Introduction 15.2 Local Shipping in the United States and International Shipping 15.3 Shipping Testing Requirements 15.4 Lithium-Ion Battery Shipping Descriptions and Testing Requirements 15.5 Shipping Prototype Batteries 15.6 Damaged Batteries 15.7 Does Battery Size Matter? 15.8 PHMSA Document Shipping Guidelines 15.9 International Shipping 15.10 Private Shippers in the United States 15.11 Noncompliance References Appendix: The Cell Datasheet Glossary of Terminology Used in Battery Systems About the Authors Index Artech House Power Engineering Library Series