Custom Battery Packs

Battery packs are a vital component of contemporary technology. Whether your product needs a standard battery or one designed for your specific application, we’re here to help.

Cylindrical cells like 18650 are a popular choice for custom battery pack because they don’t require high MOQ and can be easily sourced. They also provide a good balance between price and performance.

Customization

A battery pack is a group of batteries connected to deliver a specific voltage and capacity. Its design is determined by the device it will power. These devices may include medical equipment such as heart monitors, surgical tools, and ventilators. In addition, batteries are used in many consumer electronics products.

The most common types of battery packs are nickel cadmium (NiCd) and nickel metal hydride (NiMH). Each type of pack has its advantages and disadvantages, so it is important to know what the differences are before choosing a solution. A knowledgeable engineer can help you choose the right battery for your application.

Custom battery packs can be made to fit the intricacies of a product, allowing it to perform at its best. These packs can be sealed to discourage tampering or battery swapping, and they can also contain specialized features. For example, if your device will be subjected to extreme temperatures, engineers can add heat management capabilities.

To connect the pack to your device, vinyl clad electrical wire is typically used. The wires are colored red for positive and black for negative. custom battery pack It is important to use high-quality wires that are UL-certified. You should also ensure that the connectors are rated for your application. It is also important to check whether your battery is UL-listed before using it.

Design

A custom battery pack is designed to meet the voltage, capacity, and form factor required for a specific device. Battery designers will use their knowledge of cell chemistry, protective circuitry and other components to create a prototype that will power the device while offering the maximum performance possible.

The design process also considers the battery’s working environment. This will influence the choice of enclosure material and other features that are included in the pack to protect it from extreme temperatures, vibrations and other environmental challenges.

For example, a vented battery is typically used when it will be exposed to long-term thermal effects. These effects can cause batteries to swell, and a venting system will ensure that the pack does not damage or short.

Once the pack is designed, it must undergo rigorous quality and testing. This includes capacity testing, charge and discharge testing and more. These tests will verify that the battery is delivering the expected level of performance, and any issues are corrected at this stage. Once the test results are approved, the pack will be assembled and packaged for shipment. Robust packaging materials are used and all safety protocols and transportation regulations for lithium batteries are followed. This ensures that the pack arrives in good condition, ready to be used. In most cases, the package will include instructions for safe handling and proper charging practices.

Assembly

A custom battery pack is assembled with a variety of different components, including cells, protective cases, and connectors. Depending on the power requirements of your application, you may need a different battery configuration, voltage, and capacity. A custom design also allows you to add a BMS (Battery Management System) that monitors cell status and ensures that the battery is properly charged, discharged, and cooled. BMSs are especially useful for lithium batteries, as they prevent overcharging and under-charging, maximizing battery life.

Once your custom battery packs are assembled, they must be tested to comply with safety regulations. In particular, lithium batteries must be certified to meet UN38.3 standards for air transport, which helps minimize the risk of fires or other hazards during shipping. In order to achieve compliance, manufacturers must carefully consider certification costs and timelines when planning their battery packs.

A reputable custom battery pack manufacturer can help you navigate the complex logistics of air transport. In addition to providing streamlined production processes, they can offer expert knowledge on battery technology and the latest safety standards. The right manufacturer can also provide optimized fit, increased energy output, and other advantages for your product.

Testing

Once a custom battery pack has been designed and Auto starter battery built, engineers conduct rigorous testing and evaluation of the finished product. These tests include altitude simulation, thermal abuse, mechanical vibration and high-voltage protection to ensure the battery pack can perform as expected in varying environmental conditions.

Additionally, the BMS design is tested to ensure that it properly communicates with each of the cells in the pack. Tests may also examine the batteries’ temperature range, state of charge (SoC), and energy. This is sometimes called “pack level testing” or “end-of-line testing.”

Battery pack certification regulations are constantly changing as new technology and safety standards evolve. Manufacturers can mitigate risks by staying up-to-date on regulatory developments and regularly reviewing publications from industry organizations and certification bodies.

For lithium battery packs, manufacturers must comply with UN38.3 requirements for safe transportation. This requirement minimizes the risk of accidents or hazards during transportation and helps to prevent the loss or theft of the battery pack.

Once the battery pack has passed all necessary testing, it can be certified for use. This process involves submitting the battery pack for a UN report and providing additional documentation like a bill of materials and the battery cell labeling. Once the battery pack has been certified, manufacturers can affix the CE marking to the unit. This marks the unit as compliant with EU regulations and contributes to the safety of the product in global logistics operations.