Lithium Battery Facts - A Primer

alylea

New member
So here's the thing with Lithium based batteries.

Lithium cells come in a number of chemistries but all are made by a handful of companies due to the expense and danger of production. Sony & Toshiba are two that have suffered major fires destroying their faclities. Everyone buys from the handful of vendors and assembles the packs themselves. Generally manufactureres grade the cells once they are produced so you may get "b" or "c" cells in your pack. There is no way to know and a lower grade cell may = a reduced run time even if it rated the same as the oem.

All charging control is done by the micro processor in the pack. You won't hurt your device by using a non-oem pack so long as it is the proper voltage. It may not last in terms of runtime or overall life but you won't hurt the device.

The charging processor is programed to shut off the charge voltage once the cells reach a certain finish voltage. Charging shut-off is a function of comparison. The circuit charges the battery for a set time, shuts off the charge and looks at the pack voltage. If the measured voltage is below the pre-programmed setpoint, the charger turns back on. It repeats this process until the pack voltage hits or is above the setpoint voltage at which time it terminates the charge cycle. Most circuits also have a"maximum" number of times the battery can be charged. Once that number is reached the charge circuit will no longer charge the battery regardless of its condition - good, bad, or indifferent. The charger circuit also monitors things like pack temperature and shuts down if the pack starts to overheat or if the input voltage is excessive or revered polarity. Sometimes the manufacturer will even put in code to communicate with the device and tell it if it is OEM, if not the device won't turn on. This can be circumvented by code in the non-oem pack (ala non Motorola packs in the '90s) or by doing things to the firmware of the device ala the GH13 hack

The quality of the housing and of the contacts may be lower but there is no real way of knowing. Most of the non-OEM product out of Asia is decent, they can't afford to make junk and stay in business.

The big safety issue is in over-charging but that would as a rule happen the first time although any in-pack circuit oem or non-oem can fail and cause overheating or ignition of the pack.

:violent5: Lithium cells can create a major fire hazzard which is why airlines want them as carryons and not checked in a bag that could catch fire in the hold and possible bring a plane down. Many a UPS/FED Ex truck has burned due to a Lithium based battery fire. All it takes is an internal short in the cell itself and the cell can go exothermic creating self ignition of that cell and the rest of the cells in the pack. I've seen it in the lab and it's pretty scary. The cell can actually look like a disposable lighter with a flame under pressure coming out of it. Talk about ruining you day... NEVER puncture a pack/cell or put it in a fire. Shorting out a cell can also create major problems if the short circuit/over heat protection in the cell itself fails. It can get ugly pretty quickly.

If you want to buy an aftermarket pack and save a few bucks but have some recourse if something happens, buy a pack from someone like Best Buy or Radio Shack. They are the same China packs as the no-names but at least they are US based retailers you can go after if you have a problem.

You may ask how I know these things; the answer is that I worked for AC Delco, Anton Bauer and a company known as DPP who OEM'd 10's of thousands of NiCD, NiMH & LiIon packs for Duracell, BJ's Wholesale, Sears & Walmart over a 9 year period.

BTW; I have used non-oem's since the '90's and have never had an issue beyond sometimes slightly poorer performance.

Lyle
 
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While you've touched on a number of points, there are a few more that need mentioning, mainly giving a little more info. Side note: I design consumer electronics and work with battery(pretty much all Li-ION) and charger design daily.

There are MANY different lithium chemistries for lithium chemical batteries. Some are dangerous, some are not, even within the different groups. None are very dangerous unless mishandled or misused somehow. Mostly when discharged too heavily(shorting or very heavy current demand).

The standard lithium battery (http://en.wikipedia.org/wiki/Lithium_battery) has dozens of chemistries itself, some are dangerous, some are not. Most of the problems of Li don't apply to these since they are not rechargeable. The remaining problems are from shorting and/or opening them. Elemental LI is somewhat explosive with water and air.

The lithium Ion battery (http://en.wikipedia.org/wiki/Lithium_ion_battery) is more dangerous overall but is still not something to worry about. The cells contain an organic liquid/paste with lithium compounds suspended in it. The cells need to work within a range of voltages and currents or they will precipitate metallic Li out of the chemical suspensions and ultimately burst. When the Li hits the atmosphere it will ignite and burn. Most packs have built-in battery management "watchdog" circuits that cut off the input/output from the pack in case of over/under voltage, over/under current and/or over/under temperature. Most devices have special charging circuits that interact/communicate with the watchdog in the battery pack in order to maintain proper charge/discharge rates. The problem with non-oem packs is that some *might* be designed incorrectly or use poor quality parts that might fail. I've rejected battery packs from vendors due to shortcuts that they've used in their designs. It's important to also know that Li-ion batteries need to maintain a minimum charge or they *could* burst and catch fire. Any battery that is not charged for an extended period should be recycled and replaced.

The lithium Polymer pack is a newer design (http://en.wikipedia.org/wiki/Lithium_ion_polymer_battery) where the polymer suspension is a solid. There is much less chance of metallic Li from precipitating out of the suspension and burning (although they still can). They don't use metal cases and are much lighter and cheaper to make. Overall they offer a bit more safety but can still be somewhat dangerous when abused.
 
While you've touched on a number of points, there are a few more that need mentioning, mainly giving a little more info. Side note: I design consumer electronics and work with battery(pretty much all Li-ION) and charger design daily.

There are MANY different lithium chemistries for lithium chemical batteries. Some are dangerous, some are not, even within the different groups. None are very dangerous unless mishandled or misused somehow. Mostly when discharged too heavily(shorting or very heavy current demand).

The standard lithium battery (http://en.wikipedia.org/wiki/Lithium_battery) has dozens of chemistries itself, some are dangerous, some are not. Most of the problems of Li don't apply to these since they are not rechargeable. The remaining problems are from shorting and/or opening them. Elemental LI is somewhat explosive with water and air.

The lithium Ion battery (http://en.wikipedia.org/wiki/Lithium_ion_battery) is more dangerous overall but is still not something to worry about. The cells contain an organic liquid/paste with lithium compounds suspended in it. The cells need to work within a range of voltages and currents or they will precipitate metallic Li out of the chemical suspensions and ultimately burst. When the Li hits the atmosphere it will ignite and burn. Most packs have built-in battery management "watchdog" circuits that cut off the input/output from the pack in case of over/under voltage, over/under current and/or over/under temperature. Most devices have special charging circuits that interact/communicate with the watchdog in the battery pack in order to maintain proper charge/discharge rates. The problem with non-oem packs is that some *might* be designed incorrectly or use poor quality parts that might fail. I've rejected battery packs from vendors due to shortcuts that they've used in their designs. It's important to also know that Li-ion batteries need to maintain a minimum charge or they *could* burst and catch fire. Any battery that is not charged for an extended period should be recycled and replaced.

The lithium Polymer pack is a newer design (http://en.wikipedia.org/wiki/Lithium_ion_polymer_battery) where the polymer suspension is a solid. There is much less chance of metallic Li from precipitating out of the suspension and burning (although they still can). They don't use metal cases and are much lighter and cheaper to make. Overall they offer a bit more safety but can still be somewhat dangerous when abused.

Very good points. I chose to skip Chemistry for the sake of simplicity. Why don't you PM me, I'm curious who you are and work for since you mentioned rejecting product from vendors. I actually came out of the CE side of things before moving towards broadcast.
Lyle
 
Wow! I never knew how dangerous these LI battery packs were and I travel by air quite extensively with some of my camera batteries checked in.

This thread is definitely worthy of being a sticky.
 
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