May. 06, 2024
The power tool world is learning about the benefits of lithium-ion pouch cell technology. The Flex Stacked Lithium battery leverages that technology and elevates it to new heights.
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Pouch cells offer more than just an alternative form factor compared to round cells. Connection tabs enable greater energy flow, resulting in higher power output and faster charging without producing dangerous levels of heat.
How significant is the difference?
According to Flex's data, it's substantial. Just look at this chart from the Flex Faceoff Round 2 video.
First, keep in mind Flex uses a 24V max system based on rows of 6 cells instead of 5, so there's already an inherent advantage. Even so, two things stand out from this data. First, Flex's compact 3.5Ah battery produces the same power as DeWalt and Milwaukee's 8.0Ah packs.
At the top of the chart, DeWalt and Milwaukee top out at 1800 watts—the maximum power from a 15-amp, 120-volt circuit. Flex leaps all the way up to 2520 watts, giving the 10.0Ah pack potential beyond any 15-amp corded tool. In fact, it's more than a 20-amp, 120-volt power source can provide.
See how Flex Stacked Lithium batteries compare to their standard ones in terms of power:
Additionally, these packs can charge up to twice as fast and last up to three times longer than round cell packs, all while remaining 100% compatible with all Flex 24V tools.
With the 550-watt dual fan-cooled Flex Super Charger, here's what you can expect for full charge times:
While the cell itself opens significant opportunities, there's more to the story. You can't just install some pouches in a battery housing, attach it to the tool, and hope for the best.
Flex's impressive heat management system, known as ThermaTech Plus, allows the cells to dissipate heat more effectively than other brands. The design also offers some cushioning that reduces the risk of failure if you drop the pack to the ground.
Add in the electronic monitoring of each cell with advanced communication to the tool, and you have a battery that's safe to use in demanding applications, providing far greater productivity than standard round cell packs.
Look for individual and multi-packs, starter kits, and combo kit packages with Stacked Lithium batteries to be released throughout this year. Here's what we expect the individual prices to be:
The additional power potential from smaller batteries is truly exciting. When you add in faster charging and a much longer service life, the transition to Flex Stacked Lithium batteries makes a lot of sense, opening the door to unprecedented levels of power tool performance.
Editorial: Mike
Issue Date: 2019-09-30
Views: 10923
The battery cell using stacking technology has the advantages of small internal resistance, long life, high space utilization, and high energy density. In terms of battery performance, compared to the winding technology, the lamination stacking technology can increase the energy density of the battery by 5%, increase the cycle life by 10%, and reduce the cost by 5% under the same conditions.
The lamination & stacking process is a lithium polymer battery manufacturing process in which a positive electrode and a negative electrode are cut into small pieces, and a separator is laminated to form a small cell. Multiple small cells are then stacked in parallel to form a large cell.
However, there are different ways to stacking process. Let’s watch a video from Scienceviz:
[embed]https://youtu.be/8WEGVxliKJ8[/embed]As the video shows, there are four stacking processes, and Grepow uses the Z-Folding with single electrodes method, which is less complicated and increases the pass rate of the battery.
As mentioned before, the lamination stacking technology can increase energy density, cycle life, and reduce costs. Now, I will compare the advantages and disadvantages of the stacking and winding process from different aspects.
1. The internal resistance of the battery is different
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Related links:The cell produced by the stacking process has lower internal resistance compared to the winding process. This difference in internal resistance leads to less heat generation during the charge and discharge cycles, resulting in slower battery capacity attenuation.
2. Different battery life
As the charge and discharge cycles continue, heat generation inside the battery affects its temperature. For the laminated battery, the internal temperature distribution is more uniform compared to the winding battery. This uniform temperature distribution helps prevent rapid capacity decay, extending the battery’s life.
The temperature distribution of stacking and winding cells (Image from the Internet. All rights reserved)
3. The stress inside the cell is different
The mechanical characteristics differ between the two manufacturing methods. Laminated cells distribute stress evenly, reducing the risk of mechanical failure. In contrast, winding cells concentrate stress at the edges, increasing the likelihood of issues such as short circuits and lithium deposition.
4. Battery rate performance is different
The stacking process allows for better discharge of high currents in a short time, improving the rate performance of the battery. Conversely, the single tab in winding cells slightly lowers their rate performance.
5. Different battery capacity density
The laminated battery has a higher capacity density because its internal space is more efficiently used. In contrast, the winding battery has circular ends and the final two coil layers take up more space, resulting in lower capacity density.
The safety of the battery varies based on internal resistance, stress, and temperature distribution. Winding batteries with higher internal resistance and inconsistent temperature distribution are less safe.
Film Production Complexity
The winding process is simpler and more suited to automated manufacturing. In contrast, the stacking process is more complex and less consistent, impacting battery performance.
Battery Manufacturing Complexity
The winding process is easier to operate and suitable for both semi-automatic and fully automatic production. The stacking process, however, is labor-intensive and challenging to automate.
Quality control is also easier with winding cells, while the complex steps of the stacking process make consistency more difficult to achieve.
Film Cutting: Winding cells are easier to cut and have a higher pass rate, requiring only one slit for each electrode. Stacked cells are more cumbersome to cut and have a lower pass rate due to the intricate slicing process.
Grepow has high-speed stacking technology equipment capable of mass-producing stacking square batteries with an efficiency of about 1.0 seconds per chip.
Keep an eye on Grepow's official blog for industry-related articles and updates.
Grepow: https://www.grepow.com/
Grepow Blog: https://www.grepow.com/blog.html
Grepow Launches Rapid Battery Sampling Service
Advantages of Pouch Cell Battery: Trend and Opportunities
The Importance of the Separator in Battery Cells
For more stackable lithium ion battery information, please contact us. We will provide professional answers.
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