Lithium-ion battery construction: Firefighters should know the ...

Lithium ion (Li-ion) batteries are becoming extremely popular. They can be found in many consumer electronics, e-mobility devices and electric vehicles.

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Most firefighters are aware that Li-ion batteries can be hazardous; however, many do not realize that Li-ion is a fairly generic term. There are multiple types of Li-ion chemistries as well as different types of cell constructions. Basic understanding of battery cell chemistry and construction will help firefighters when failures result in fires.

Battery cells and modules

A battery cell is the smallest part inside a battery pack. Inside of the battery cell are layers of film that provide the chemistry needed to supply an electrical charge. The materials inside the cell use different chemicals and are typically only 3-4 volts.

Battery cells are typically packaged into three different types of containers:

1. Cylindrical cells have the layers of film rolled up and positioned inside a hard (typically steel) outer shell. They are very similar to the size and appearance of a AA battery and can be bigger than a D battery. One of the most common sizes is currently an battery (18mm diameter x 65mm long). Tesla has started using the battery (46mm diameter x 65mm long).

2. Prismatic cells are square/rectangular containers that have a hard outer shell. The layers of film inside the shell are stacked and roughly the same size as the box that they are inside of. They are typically very durable and heavier than other types of cells.

3. Pouch (polymer) cells are very similar to prismatic cells, but the layers of film are packaged inside of a soft or flexible outer shell. These types of cells will slightly expand as the battery cell is charged and slightly contract when the battery cell discharges. These cells are prone to swelling if they fail.

A battery module is a case that contains multiple battery cells linked together to provide a higher voltage. The number of battery cells and voltage depend purely on the size of the device the module is powering. Smaller products (e.g., cell phones) might only contain a single battery cell. A larger product could contain a battery module.

The number of modules in a device depends on the size of device they are powering. For example, an e-bike may only have one or two modules, while some electric vehicles could have 10 or more.

Battery cell chemistry

There is a misconception that Li-ion batteries contain pure lithium metal. While there are lithium metal batteries on the market, they are typically not rechargeable. Lithium metal is highly reactive, which is why they are not used for rechargeable products. Further, this is one of the many reasons that a Class D fire extinguisher will not stop a thermal runaway.

Rechargeable batteries use different types of Li-ion battery chemistries with some of the more popular chemistries listed below.

Battery cell failures modes

A battery cell can fail due to mechanical damage, an electrical short, thermal damage from abnormal operation (i.e., improper charging) or thermal damage from an external source. If the cells heat up for any reason, they can catastrophically fail at a relatively low temperature. The temperature threshold is different for every type of Li-ion battery chemistry.

Signs a battery cell is about to fail include off-gassing, hissing, popping and/or heat buildup. When the cell fails, it gives off a tremendous amount of heat (1,200 degrees F) in tenths of a second. The failure is an exothermic chemical reaction that does not require oxygen from the atmosphere. This is because most chemistries contain oxygen within the chemical makeup.

For firefighters

Having the basic knowledge of battery construction is very similar to studying building construction. It will help significantly when analyzing hazards and deciding the best tactics to move forward with at an incident.

The size and number of cells in a battery will give a rough indication of the voltage inside that battery. An e-scooter, for instance, has a voltage of 24-48 while an electric vehicle is at 300-800. Finding a damaged battery can be hazardous, but a small e-mobility device is far less hazardous when compared to a fully electric vehicle.

If the battery is on fire, your strategy will be based on the size of the battery. A thermal runaway in a smaller battery will finish fairly quick, while a large electric vehicle battery can burn for a much longer time. As firefighters, we must always continue to train and learn as new technology and products become available to the public.

The future of batteries

Battery technology is advancing at a fast pace. The chemistries used today will likely be different in 5 to 10 years. Ideally these advancements will lead to safer battery cells that are less sensitive to heat and won’t fail catastrophically when mechanically damaged. One thing to remember, even when such advancements are made, firefighters will still face fires related to legacy consumer electronics, e-mobility devices and electric vehicles that pose the risks we are dealing with today.

Battery news and resources

Are you considering using cylindrical lithium-ion batteries for your next project? If so, it’s important to understand the different sizes available and how they can be used to meet your specific requirements. In this comprehensive guide, we will walk you through everything you need to know about cylindrical lithium-ion battery sizes.

From the popular to the smaller and larger , we’ll explore the most common sizes used in various applications . Whether you’re an engineer, designer, or hobbyist, this guide will equip you with the knowledge to make informed decisions when it comes to selecting the right battery size for your needs.

Not only will we discuss the physical size and capacity of each size battery, but we’ll also delve into their benefits, limitations, and compatibility with different devices. By the end of this guide, you will have a clear understanding of which size cylindrical lithium-ion battery is best for your specific application.

Cylindrical lithium-ion batteries come in a variety of sizes, and its number usually indicates its physical size. The first two digits are the diameter of the battery in millimeters, the last two digits are generally the height in millimeters, and the fifth digit indicates the cylindrical shape. For example, the cylindrical battery has a diameter of 18 mm and a height of 65 mm, with 0 indicating cylindrical shape. This complies with the IEC standard for cylindrical primary cells. Manufacturers can also use non-IEC names for their products.

1.

The battery is a lithium-ion battery with a diameter of 10mm and a height of 44mm. It usually has a small capacity of only a few hundred mAh. This type of battery is ideal for devices that require a compact power source and is mainly used in small electronic products such as micro flashlights, mini stereos, speakers, etc.

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2.

The battery is a lithium-ion battery with a diameter of 14mm and a height of 50mm, similar in size to an AA battery. The nominal capacity is usually below mAh. It is widely used in various consumer electronic products, such as LED flashlights, wireless speakers, wireless keyboards, electric toys, digital cameras, etc.

3.

The battery is a lithium-ion battery with a diameter of 16mm and a height of 50mm. Capacity is usually slightly higher than .Commonly used in flashlights, headlights, laser lights, lighting fixtures, etc.

4.

The battery is perhaps the most popular cylindrical lithium-ion battery size. It has a diameter of 18 mm and a length of 65 mm. The nominal capacity is usually between ~mAh. It offers a balance between capacity and size. is widely used and is the first choice for many electronic devices. It is commonly used in applications such as laptops, flashlights, power tools, e-scooters and e-bikes.

5.

The is a lithium-ion battery with a diameter of 21 mm and a height of 70 mm. The nominal capacity of the battery is generally between and mAh. Widely used in solar street lights, LED lights, balance vehicles, electric bicycles, electric vehicles, etc.

is larger and has higher capacity than , and its volume and energy density are higher than battery. Therefore, some products will use instead of batteries in their power supply design.

6.

If you need a larger cylindrical lithium-ion battery, the size may be the right choice. With a diameter of 26mm and a length of 65mm, it offers a higher capacity than the battery. This size is commonly used in high-power devices such as electric vehicles, solar energy storage systems, and power banks. It can also be used for larger high-power LED flashlights and some electronic cigarettes. The battery’s larger size allows for more energy storage, making it suitable for applications that require extended runtimes.

1. Diameter: The diameter of a cylindrical lithium-ion battery determines its physical size and compatibility with devices and battery holders. Common diameters include 18mm, 14mm, and 26mm for , , and cell sizes respectively.

2.Length: The length of a cylindrical lithium-ion battery also affects its physical size and compatibility. Longer batteries generally have higher capacities but may not be suitable for all devices. For example, the and cells are 65 mm long, while the cell is 50 mm long.

3.Capacity: Battery capacity is a measure of the amount of energy a battery can store. Usually measured in milliamp hours (mAh) or ampere hours (Ah). The capacity of cylindrical lithium-ion batteries varies depending on their size, with larger batteries generally having higher capacities. For example, batteries range in capacity from mAh to mAh, while batteries typically have a capacity around 800mAh.

4.Voltage: Voltage is another important parameter to consider when choosing a cylindrical lithium-ion battery. Most have a nominal voltage of 3.7 volts, but their voltage will vary depending on the charge level.

5.Discharge current: The discharge current is the maximum current that a battery can deliver continuously. It is usually measured in amperes (A) or milliamperes (mA). High-power applications require batteries with higher discharge currents, while low-power devices can work with lower discharge currents.

1.Application requirements: First understand the specific requirements of the application. Consider factors such as power consumption, voltage requirements, and physical space constraints. High-power applications such as electric vehicles may require larger batteries, while low-power devices can use smaller batteries.

2.Size and weight: Consider the physical size and weight limitations of the device. Smaller batteries (such as the ) may be suitable for compact devices, while larger batteries (such as the ) may be more appropriate for devices with ample space.

3.Energy Density: Energy density refers to the amount of energy stored in a battery per unit volume or weight. If you need a battery with a high energy density, you may opt for a larger size like the or . However, keep in mind that higher energy density often comes at a higher cost.

4.Cost: Consider your budget when selecting a cylindrical lithium-ion battery size. Larger batteries with higher capacities tend to be more expensive. Evaluate the cost-benefit ratio and choose a size that offers the best balance between price and performance.

5.Availability and Compatibility: Ensure that the battery size you choose is readily available and compatible with your device or application. Some battery sizes, such as the , have a wide range of options from various manufacturers, making them easily accessible.

With these factors in mind, you can narrow down your choices to a cylindrical lithium-ion battery that suits your specific needs.

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