May. 06, 2024
The power tool world is learning about the benefits of lithium-ion pouch cell technology. The Flex Stacked Lithium battery takes advantage of that tech and sends it to a whole new level.
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Pouch cells open up the possibility for more than just a different form factor compared to round cells. Connection tabs open up far greater energy flow, resulting in higher power output and faster charging without producing dangerous levels of heat.
How much of a difference does it make?
According to Flex’s data, it’s massive. Just look at this chart from the Flex Faceoff Round 2 video.
First of all, keep in mind Flex uses a 24V max system based on rows of 6 cells instead of 5, so there’s already an advantage built-in. Even so, two things stand out from this data. First, Flex’s compact 3.5Ah battery is producing 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—exactly the maximum power you get from a 15-amp, 120-volt circuit. Flex jumps 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.
Check out 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 up significant doors, there’s more to the story. You can’t just slap some pouches in a battery housing, install it on the tool, and hope for the best.
Flex has impressive heat management from what they call ThermaTech Plus. It 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 electronic monitoring of each cell with advanced communication to the tool and you have a battery that’s safe to use in demanding applications with 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 roll out over this year. Here’s what we expect the individual prices to run:
The additional power potential coming from smaller batteries is really exciting. When you add in faster charging and a much longer service life, the transition to Flex Stacked Lithium batteries is one that makes a lot of sense and opens the door to all-new levels of power tool performance.
Editorial：Mike
Issue Date：2019-09-30
Views：10923
The battery cell used stacking technology has the advantages of small internal resistance, long life, high space utilization, and high energy density after group. In terms of battery performance, compared with 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, a negative electrode is cut into small pieces and a separator is laminated to form a small cell, and a single cell is 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 increased the pass rate of the battery.
As I mentioned before, the lamination stacking technology can increase the energy density, cycle life, and reduce the cost. Then 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 a lower internal resistance and a higher winding internal resistance. Because the winding cell is usually a single pole, the laminated cell can be seen as a multi-pole type, which greatly reduces its internal resistance. The difference in internal resistance causes the difference in heat generation between the finished battery during the charge and discharge cycle and the decay of the battery capacity. It is obvious that the battery capacity of the stacked battery is attenuated more slowly.
2. Different battery life
As the charge and discharge cycle continues, heat is generated inside the battery, which in turn affects the temperature of the battery. For the laminated battery, the internal temperature distribution is relatively uniform, and the winding battery has a single-direction heat transfer mode between the pole piece and the diaphragm, which causes the temperature gradient distribution phenomenon to be serious, and the internal high temperature and external appearance occur the low-temperature phenomenon. The uneven temperature distribution leads to the inactivation of the live material at the high-temperature position during the charging and discharging process, and the function of deintercalation lithium ions cannot be performed, thereby affecting the rapid decay of other locations and affecting the performance of the battery.
The temperature distribution of stacking and winding cell (The picture from Internet. All rights reserved)
3. The stress inside the cell is different
Two ways of making the battery have different mechanical characteristics. The laminated area of the laminated core electrode diaphragm has the same force area, no specific point of stress concentration, and the battery does not have sharp damage in a certain part during use. At the edge of the winding cell, stress is concentrated. According to the previous experience of battery disassembly analysis, the pole piece bend is more prone to micro-short circuit, electric breakdown and lithium deposition. The stress concentration point is the primary location for battery deactivation, which also results in reduced cycle life of the winding battery.
4. Battery rate performance is different
The stacking process is equivalent to the parallel connection of multi-pole pieces, which makes it easier to discharge large currents in a short time, which is beneficial to the rate performance of the battery. The winding process is just the opposite, with a single tab causing a slightly lower rate performance.
5. Different battery capacity density
The laminated battery has a higher capacity density because its internal space is more fully utilized. In contrast, the winding battery has a circular shape on both sides of the battery and the last two layers of the coil occupy a certain thickness, so the capacity density is low.
The safety is also different, from the aspects of internal resistance, stress, temperature distribution, etc., the winding battery with high internal resistance and inconsistence temperature are less safe.
1. The film production complexity is different
The winding process is simpler and has been operated, making it easy for automated manufacturing. Most companies currently on the market use a form of winding. The stacking process is very cumbersome and the pass rate of the pole piece is very low. For a winding core, only two knives at the beginning and the end are required, and each piece of the laminated piece requires four knives. The quality of the pole piece (section, burr, etc.) is difficult to maintain a high degree of consistency, which affects the ultimate performance of the battery.
2. The complexity of battery manufacturing is different
Winding cells are easy to operate and can be completed quickly, either semi-automatic or fully automatic. The stacking process is highly complex, manual operation is time-consuming and laborious, and automation is difficult to industrialize due to equipment problems. In addition, in the quality control of the battery core, the winding type is easier to control, and the stacking type is difficult to achieve good consistency due to the cumbersome process steps. In short, it is necessary to select a suitable process according to its own conditions and battery requirements. After the process change, the pole piece cutting and the subsequent welding and assembly need to be greatly changed.
Film Cutting: The coiled lithium battery is convenient for cutting and has a high pass rate. Each cell only needs to perform one slitting of the positive and negative electrodes, which is difficult and has a low probability of producing defective products. The laminated lithium battery is cumbersome and has a low pass rate. Each battery has dozens of small pieces, each of which has four cut faces, and the slicing process is easy to produce bad punching, so the probability of producing a pole piece and burr is greatly increased for a single battery.
Grepow has the 0.6-second high-speed stacking technology production equipment, which can realize mass production of stacking square batteries, and the stacking efficiency of single-chip is about 1.0 seconds/chip.
Keep an eye on Grepow's official blog, and we'll regularly update industry-related articles to keep you up-to-date on the battery industry.
Grepow: https://www.grepow.com/
Grepow Blog: https://www.grepow.com/blog.html
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