At Holo Battery, we’ve been crafting gói pin tùy chỉnh for over 18 years. We understand that developing a new power solution raises important questions about performance and safety. That’s why we’ve created this FAQ to address common queries from engineers and project managers, assisting you in your custom battery pack journey.
Core Design and Component Selection
Question: How do you know what type of cell to select for your project?
Cell selection is the foundation of your battery pack’s performance. The choice depends on a careful balance of your application’s primary requirements:
- Energy Density (Wh/kg) vs. Power Density (W/kg): Does your device need long runtimes (e. g., UAVs, medical devices) or high bursts of power (e. g., power tools, robotics)? Lithium Nickel Manganese Cobalt (NMC) cells provide higher mật độ năng lượng, while Lithium Iron Phosphate (LiFePO4) excels in vòng đời.
- Cycle Life: How many charge/discharge cycles are required? LiFePO4 provides the longest cycle life, ideal for solar storage and industrial use.
- Operating Environment: Will the battery encounter extreme temperatures? Some chemistries, like sodium-ion batteries, are better for cold conditions.
- Safety Profile: Consider safety risks; LiFePO4 is known for its thermal stability.
Determine the capacity and voltage your device needs, including current draw. Different cells have varying capacities and discharge rates, so consider cell form factors to meet dimensional constraints. Holo Battery engineers analyze these factors to recommend Grade A cells from reputable suppliers that align with your project’s cost and performance goals.
Question: How do you determine what type of material will be required for an enclosure?
When selecting the right enclosure material, we consider factors like the required IP rating, weight capacity, heat management, and compliance with regulations (such as UL94 flammability).
If you need a lightweight, affordable option with good impact resistance and custom shapes, plastics like ABS and PC are excellent choices.
However, for high strength, effective EMI shielding, and heat management in demanding environments like industrial or military settings, metals like aluminum and steel are ideal.
We’re here to help you choose the best material to ensure your cells are safe, manage heat effectively, and integrate seamlessly with your product’s design.
Question: How do you plan for controlling thermals in the battery enclosure?
Effective Quản lý nhiệt is non-negotiable for safety and longevity. Poor heat management results in worse performance, faster wear and tear, and potential safety issues. Here’s how we’re addressing it:
- Passive Cooling: We use thermally conductive materials like aluminum cases and thermal interface pads that naturally dissipate heat, ideal for moderate power demands.
- Active Cooling: For high-power situations, such as EV powertrains or advanced energy storage, we employ fans or liquid cooling to manage excess heat.
- BMS Integration: Our custom Battery Management Systems monitor cell temperatures in real-time. If overheating occurs, they can reduce charge/discharge rates or shut down systems to ensure safety.
The Role of the Battery Management System (BMS)
Question: Do all battery packs need a BMS to control the charge and discharging?
Not all battery packs need a BMS, but lithium-ion packs do. A BMS is essential for:
- Safety: It protects against overcharge, over-discharge, over-current, and short circuits.
- Hiệu suất & Longevity: It balances cells to ensure even wear and maximize cycle life.
- Monitoring: It provides data on the State of Charge (SoC), State of Health (SoH), and other parameters through protocols like CANBus or Bluetooth.
Question: How do you determine when the battery should be charged if it’s not being used or has been in long-term storage?
Lithium-ion batteries have a low self-discharge rate, but a specific protocol is needed for long-term storage.
We recommends storing batteries at 30-50% SoC in a cool, dry place. For inventory or seasonal use, the smart BMS enters a low-power “sleep” mode but periodically checks voltage. If the voltage drops below a safe threshold, it alerts the user for maintenance charging.
Question: Can resettable fuses be used in packs?
Resettable fuses, or PPTCs, aren’t good for the main protection in high-performance battery packs. They have higher resistance and can trip due to temperature changes, not just over-current.
Therefore, we prefer using dedicated solid-state switches in the BMS, along with regular fuses for those rare major failures. This approach allows us to build a solid, multi-layered safety setup.
Certification, Shielding, and Cost
Question: Is EMI/RFI shielding needed for battery packs?
For basic packs with just cells and basic protection, you usually don’t need to worry about EMI/RFI shielding.
However, for smart packs with features like BMS, communication systems, DC-DC converters, or high switching currents, shielding might be necessary.
It really depends on regulations and the sensitivity of the device you’re working with.
Question: Can Holo Battery help to certify battery packs for customers?
Absolutely. As an ISO-certified manufacturer, we have extensive experience helping clients navigate the certification process. We can manage and secure all the major international certifications for your battery pack, including but not limited to:
- UL 2054 / UL 2580 (North America)
- IEC 62133 (International)
- CE (Europe)
- UN38.3 (Transportation)
By using pre-certified cells and các thành phần, we ensure your product reaches the market quickly and compliantly!
Question: What are the development costs, including certifications for the battery?
Costs can vary significantly based on the project’s complexity, the amount of work required, and necessary certifications. The main factors affecting costs include:
- Custom Engineering: The complexity of the BMS, mechanical design, and thermal management.
- Prototyping: The number of prototype units needed for testing.
- Certification: The specific standards and regions you’re targeting.
- Tooling: Costs for custom molds or fixtures for large-scale production.
At Holo Battery, we believe in transparency. Our quick quote promise provides a straightforward initial estimate. We collaborate with you to make the design as cost-effective as possible, without compromising safety or performance, ensuring you get the best value.
Have more questions? No worries! The team at Holo Battery is here to help. Contact us today, and let’s chat about your custom battery pack needs.
