{"id":1496,"date":"2023-07-15T16:08:50","date_gmt":"2023-07-15T16:08:50","guid":{"rendered":"https:\/\/holobattery.com\/?p=1496"},"modified":"2026-09-22T20:24:32","modified_gmt":"2026-09-22T20:24:32","slug":"custom-battery-pack-voltage","status":"publish","type":"post","link":"https:\/\/holobattery.com\/custom-battery-pack-voltage\/","title":{"rendered":"Custom Battery Pack Voltage: Comprehensive Guide for Determining Voltage Requirements"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\"><strong>Key Takeaway:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Voltage is pivotal in custom battery pack design, impacting power output and device compatibility. Understand nominal, charged, and discharged voltages, and consider battery chemistry, application requirements, and shipping regulations.<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Designing a <a href=\"https:\/\/holobattery.com\/product\/\" data-type=\"URL\" data-id=\"https:\/\/holobattery.com\/product\/\">custom battery pack<\/a> is like putting together a complex puzzle. You need to think about power specifications, current, capacity, size requirements, cell configuration, and the number of cells. But there&#8217;s one crucial piece that&#8217;s often overlooked: voltage. So let&#8217;s dive into the electrifying world of battery voltage and understand its importance.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">What is Voltage and Why Does It Matter?<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Voltage is like the water pressure in your garden hose. It pushes the electricity through your devices. The higher the voltage, the more power your devices can use.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-full\"><img fetchpriority=\"high\" decoding=\"async\" width=\"800\" height=\"400\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/water-analogy-voltage-and-current.png\" alt=\"water analogy voltage and current\" class=\"wp-image-4391\" srcset=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/water-analogy-voltage-and-current.png 800w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/water-analogy-voltage-and-current-300x150.png 300w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/water-analogy-voltage-and-current-768x384.png 768w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/water-analogy-voltage-and-current-600x300.png 600w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Low-Voltage vs High-Voltage Products<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Devices have different power needs. A low-voltage product doesn&#8217;t need much power to run, so the battery pack only needs to push out a small amount of current. In reverse, high-powered products need a lot of power to run, so they need a battery pack that can push out a lot of current.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Deciphering Battery Voltage<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">To understand a battery pack&#8217;s voltage, we need to look at three things:<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">1. The nominal voltage<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">2. The voltage when fully charged<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">3. The voltage when fully discharged<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Let&#8217;s decode these terms.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Nominal Voltage<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">This is the voltage output a cell gives out when charged. It&#8217;s like the average speed of a car on a long journey.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Fully Charged Voltage<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">This is the highest voltage that a battery can reach when fully charged. It&#8217;s like the top speed your car can reach on a straight road.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Fully Discharged Voltage<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">This is the lowest voltage level a battery can reach before it&#8217;s considered &#8220;empty&#8221;. It&#8217;s like the slowest speed your car can go before it stops moving.&nbsp;<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-full\"><img decoding=\"async\" width=\"800\" height=\"400\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/battery-pack-voltage.png\" alt=\"battery pack voltage\" class=\"wp-image-4394\" srcset=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/battery-pack-voltage.png 800w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/battery-pack-voltage-300x150.png 300w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/battery-pack-voltage-768x384.png 768w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/battery-pack-voltage-600x300.png 600w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Voltage by Battery Chemistry<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Just as different cars have different speeds, different batteries have different voltages. Here are the nominal voltages for some common battery chemistries:<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">1. NiCad: 1.2 volts<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">2. NiMH: 1.4 volts<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">3. Lithium-ion: 3.6 volts<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">4. Lead-acid: 2 volts<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Remember, these are just the &#8220;average speeds&#8221; &#8211; the actual output may vary.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">NiMH batteries have a nominal voltage of 1.2V, but they can provide up to 1.4V when fully charged. NiCad and NiMH batteries both have a fully charged voltage of 1.4V. Lead-acid batteries have a fully charged voltage of 2.1V, while lithium-ion batteries have a fully charged voltage of 4.2V.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">NiCad and NiMH batteries can fully discharge to 1.0V, while lead-acid batteries discharge to 1.75V. Lithium-ion batteries should not be fully discharged, as this can damage them. A safety cut-off feature ensures that lithium-ion batteries never go below 2.5V to 3.0V.\u00a0<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-full\"><img decoding=\"async\" width=\"800\" height=\"400\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lifepo4-cell-voltage-chart.png\" alt=\"lifepo4 cell voltage chart\" class=\"wp-image-4396\" srcset=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lifepo4-cell-voltage-chart.png 800w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lifepo4-cell-voltage-chart-300x150.png 300w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lifepo4-cell-voltage-chart-768x384.png 768w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lifepo4-cell-voltage-chart-600x300.png 600w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Determining Voltage for an Application<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Determining voltage for an application is like balancing a seesaw. The resistance of the application is like the weight on one end of the seesaw, and the current is like the weight on the other end. The equation is simple:<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Voltage (V) = Current (I) x Resistance (R)<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Utilizing a current meter and a modifiable power source can aid in determining the present draw for the system. This arrangement can be used to ascertain both the maximum and minimum voltage required for your system. It&#8217;s crucial to record the current readings. Your goal should be to find a value that falls between these two measurements, which will represent the point of minimum power usage.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Comprehending the voltage spectrum in this way is crucial for products and applications that might depend on fluctuating power supplies. Conversely, some products and applications will exhibit a steady power consumption.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Voltage Ranges<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Every product has a specific voltage range it can handle before it starts to malfunction. It&#8217;s like a car&#8217;s acceptable speed range. If you go too slow, the engine might stall. If you go too fast, it might overheat.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Cell Capacity and Voltage<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Another important factor is cell capacity. This determines how long your product can run before recharging the battery. Take it as the size of your car&#8217;s gas tank. A larger cell capacity means that your product can run for a longer period of time on a single charge. A smaller cell capacity means that you&#8217;ll need to recharge your product more often.<\/p>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe title=\"Lithium Ion Battery Pack Architecture\" width=\"800\" height=\"450\" src=\"https:\/\/www.youtube.com\/embed\/q46Ev9KVNLI?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Shipping Limitations Based on Voltage<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Shipping high-voltage devices, especially those with lithium-based batteries, requires special care due to their potential instability. It&#8217;s like transporting volatile chemicals &#8211; you need to follow strict safety regulations like <a href=\"https:\/\/holobattery.com\/the-transport-of-lithium-batteries-according-to-un-38-3\/\" data-type=\"URL\" data-id=\"https:\/\/holobattery.com\/the-transport-of-lithium-batteries-according-to-un-38-3\/\">UN 38.3<\/a>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">As per the guidelines set by the <a href=\"https:\/\/www.iata.org\/contentassets\/05e6d8742b0047259bf3a700bc9d42b9\/lithium-battery-guidance-document.pdf\">IATA<\/a>, lithium-based batteries can be transported either independently or within equipment. If transported independently, their state of charge (SoC) must not exceed 30%.&nbsp;<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Furthermore, the quantity of cells or batteries that can be transported simultaneously is determined by the amount of lithium metal contained within the battery, and whether they are being transported within a device, independently, or along with the equipment. Some packages might necessitate specific markings to signify the presence of a lithium battery inside the container.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"400\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lithium-ion-batteries-shipping-rule.png\" alt=\"lithium ion batteries shipping rule\" class=\"wp-image-4399\" srcset=\"https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lithium-ion-batteries-shipping-rule.png 800w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lithium-ion-batteries-shipping-rule-300x150.png 300w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lithium-ion-batteries-shipping-rule-768x384.png 768w, https:\/\/holobattery.com\/wp-content\/uploads\/2023\/07\/lithium-ion-batteries-shipping-rule-600x300.png 600w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Battery Pack Voltage for Product Designs<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">To customize a battery pack for your product, you&#8217;ll need to consider a variety of factors, including voltage, chemistry, cell arrangement, and battery size. The goal is to create a battery that provides the right amount of power while also fitting within the product&#8217;s design constraints.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For example, a 10-pack of NiMH battery cells can provide 14 volts of power while keeping costs low. However, as more cells are added, the pack will become bulkier and heavier. A more lightweight solution might be to use lithium-based batteries with fewer cells. By the way, these batteries must undergo additional transportation certification processes and restrictions, which can increase costs.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Conclusion<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Partnering with a <a href=\"https:\/\/holobattery.com\/custom-battery-pack-manufacturers-in-china\" data-type=\"URL\" data-id=\"https:\/\/holobattery.com\/\">qualified custom battery pack manufacturer<\/a> early in the design process can be a huge help when figuring out the required voltage. At Holo Battery, we can help you determine the design of the battery pack enclosure to ensure there&#8217;s enough room for the pack. With these designs, you can test the functionality of your product and make any necessary modifications.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Related Articles:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><a href=\"https:\/\/holobattery.com\/cost-control-for-customized-battery-packs\">Cost Control for Customized Battery Packs<\/a><\/li>\n\n\n\n<li><a href=\"https:\/\/holobattery.com\/custom-battery-pack-testing\">Custom Battery Pack Testing: Ensuring Quality and Performance<\/a><\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Key Takeaway: Designing a custom battery pack is like putting together a complex puzzle. You need to think about power specifications, current, capacity, size requirements, cell configuration, and the number of cells. But there&#8217;s one crucial piece that&#8217;s often overlooked: voltage. So let&#8217;s dive into the electrifying world of battery voltage and understand its importance. [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":1499,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Custom Battery Pack Voltage: How to Determine Your Requirements","_seopress_titles_desc":"Voltage: the unsung hero in custom battery pack assembly. It's the driving force behind your devices' power. Let's explore its critical role in battery design.","_seopress_robots_index":"","_seopress_robots_follow":"","_seopress_robots_imageindex":"","_seopress_robots_snippet":"","_seopress_robots_primary_cat":"none","_seopress_robots_breadcrumbs":"","_seopress_robots_freeze_modified_date":"","_seopress_robots_custom_modified_date":"","_seopress_robots_canonical":"","_seopress_social_fb_title":"","_seopress_social_fb_desc":"","_seopress_social_fb_img":"","_seopress_social_fb_img_attachment_id":0,"_seopress_social_fb_img_width":0,"_seopress_social_fb_img_height":0,"_seopress_social_twitter_title":"","_seopress_social_twitter_desc":"","_seopress_social_twitter_img":"","_seopress_social_twitter_img_attachment_id":0,"_seopress_social_twitter_img_width":0,"_seopress_social_twitter_img_height":0,"_seopress_redirections_value":"","_seopress_redirections_enabled":"","_seopress_redirections_enabled_regex":"","_seopress_redirections_logged_status":"both","_seopress_redirections_param":"","_seopress_redirections_type":301,"_seopress_analysis_target_kw":"","footnotes":"","_members_access_role":[],"_members_access_error":""},"categories":[109],"tags":[],"class_list":["post-1496","post","type-post","status-publish","format-standard","has-post-thumbnail","category-tips-and-how-to-articles"],"_links":{"self":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/posts\/1496","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/comments?post=1496"}],"version-history":[{"count":16,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/posts\/1496\/revisions"}],"predecessor-version":[{"id":4401,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/posts\/1496\/revisions\/4401"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/media\/1499"}],"wp:attachment":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/media?parent=1496"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/categories?post=1496"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/tags?post=1496"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}