Complete comparison of prismatic and pouch cells

Nowadays, the use of rechargeable batteries is becoming increasingly common in our daily lives due to technological advancements. Among the various types of rechargeable batteries, prismatic and pouch cells are particularly popular.

In this article, we offer a complete comparison between prismatic cells and pouch cells to help you understand their properties.

Part 1. What are prismatic LiFePO4 batteries?

Prismatic cells are a type of lithium-ion battery characterized by their rectangular or square shape. They typically consist of metal casings and are commonly used in laptops, tablets, and power banks. Prismatic lithium-ion batteries use an aluminum alloy or stainless steel for their rigid casing. The battery's internal structure can be either wound or laminated, which offers better protection for the battery cell compared to the flexible packaging of pouch cells.

Power Queen 12.8V 100Ah Prismatic Cell – HOBOTECH Tear Down Review

Characteristics of Prismatic Cells

Prismatic cells are characterized by several distinctive features:

• Shape and size:

  Prismatic cells have a rigid rectangular shape, resembling a brick or a flat box. They are available in various sizes and dimensions, from small to large.

• Energy density:

  Prismatic cells offer a higher energy density compared to other lithium-ion battery types. This means they can store more energy in the same space, making them suitable for high-energy applications.

• High voltage:

  Prismatic cells generally have a higher output voltage, which can be advantageous in certain applications. This can lead to better performance and efficiency in devices that require higher voltage levels.

• Durability and safety:

  Prismatic cells are typically supplied with a metal casing, which offers better protection against external stresses and damage. This can increase safety and durability, especially in applications where the battery may be exposed to harsh conditions.

• Thermal management:

  Due to their metal casing, prismatic cells have better thermal management capabilities. The casing allows for more effective heat dissipation, thus reducing the risk of overheating and potential battery damage.

Part 2. What are pouch cells?

Pouch LiFePO4 (lithium iron phosphate) batteries are a type of lithium-ion battery that uses LiFePO4 as the cathode material. The soft aluminum coating makes the battery lighter and allows for adaptable sizes and available space depending on the application. This makes it easy to adapt flexible units to the available space of a specific product. In terms of space optimization, this translates to a packaging efficiency of 90–95% and higher energy density.

By introducing a more convenient design, softpack batteries have the potential to compete with next-generation high-performance batteries, thereby accelerating the electrification needs of electric vehicles and consumer electronics products.

Power Queen 12.8 V 100 Ah MINI pouch cell – Roll2 Videos

Advantages of pouch cells

• Security:LiFePO4 chemistry is inherently safer than other lithium-ion chemicals, such as lithium cobalt oxide (LiCoO2). It has higher thermal stability and is less prone to thermal runaway, making it less likely to catch fire or explode.
• Long lifespan:LiFePO4 pouch cells typically have a longer lifespan compared to other lithium-ion batteries. They can withstand hundreds or even thousands of charge-discharge cycles without significant capacity loss and are therefore suitable for applications requiring long-term reliability.
• High power density:LiFePO4 pouch cells have a high power density, enabling them to deliver high currents when needed. This makes them suitable for applications requiring high power output, such as electric vehicles or power tools.
• Wide temperature range:LiFePO4 pouch cells can operate in a wide temperature range from -20 °C to 60 °C (-4 °F to 140 °F) without any loss of performance. This makes them suitable for use in extreme temperatures and harsh environments.
• Environmental friendliness:LiFePO4 chemistry contains no harmful heavy metals such as cadmium or lead, making it more environmentally friendly and easier to recycle.
• Lightweight and compact: The pouch cell design allows for a flexible and lightweight form factor, making it ideal for applications with limited space where size and weight are critical factors.

Power Queen 12V 100Ah Mini LiFePO4 battery Due to its compact size and low weight, this battery is in high demand on the market, weighing only 8.96 kg. Being only 3/5 the size of other batteries with the same capacity, it stands out from the competition. The use of pouch cell technology plays a key role in enabling such a small and lightweight design.

Safety concerns regarding LiFePO4 pouch cells

A common problem with pouch cells, including LiFePO4 pouch cells, is the potential for swelling. Swelling can be caused by a variety of factors, such as improper charging or discharging, overcharging, or exposure to extreme temperatures.

However, it is important to note that LiFePO4 pouch cells are generally considered safer than other lithium-ion chemistries such as lithium cobalt oxide (LiCoO2) or lithium nickel manganese cobalt oxide (NMC). This is primarily due to the inherent stability of LiFePO4 chemistry, which is less susceptible to thermal runaway.

LiFePO4 Pouch cells exhibit higher thermal stability and lower energy density compared to other lithium-ion chemistry. This means that the risk of overheating and thermal runaway is lower, making them a safer option for certain applications.

Furthermore, LiFePO4 pouch cells typically have a number of safety features, such as a pressure relief valve and thermal protection measures. These safety mechanisms help to reduce the risk of swelling, overcharging, or thermal runaway.

Furthermore, the flexible design of the pouch cells allows for more effective heat dissipation, preventing excessive temperature build-up and reducing the risk of swelling.Pouch cells also have a lower internal resistance compared to prismatic cells, which helps to minimize heat generation during charging and discharging.

It is worth noting that ensuring proper charging and discharging practices, as well as adherence to the recommended temperature range, is crucial for maintaining the safety and longevity of any lithium-ion battery, including LiFePO4 pouch cells.

In summary, while swelling can be a potential problem for pouch cells, LiFePO4 pouch cells are generally considered safer than other lithium-ion chemistry due to their inherent stability and built-in safety features. Adhering to proper care and maintenance guidelines can minimize the risk of swelling and other safety issues, making LiFePO4 pouch cells a reliable and safe choice for various applications.

To ensure compliance with legal standards such as UL, CE, and RoHS, it is important to verify that LiFePO4 pouch cells have the necessary safety certifications. These certifications demonstrate that the batteries meet stringent safety and environmental requirements and have undergone thorough testing and quality control procedures.

The batteries of Power Queen They offer the highest level of safety, as confirmed by UL test reports.

Difference between prismatic and pouch cells

form

Prismatic cells have a rigid rectangular shape, while pouch cells have a flexible, flat design. Prismatic cells are typically larger and bulkier, while pouch cells offer greater design flexibility and can be manufactured in various shapes and sizes.

Packaging materials

Prismatic cells generally have a metal casing, which offers better durability and thermal management. Pouch cells, on the other hand, use a flexible pouch made of laminated materials such as aluminum and polymer, making them lightweight and allowing for more efficient use of space.

Size

Prismatic cells tend to be larger and thicker due to their rigid rectangular shape. Pouch cells are generally thinner and more compact, making them suitable for devices with limited space.

Weight

Prismatic cells are typically heavier due to their rigid metal casing. Pouch cells, on the other hand, are lighter because they are lightweight and use flexible packaging.

Cell voltage &erage

Both prismatic and pouch cells can have different voltages and capacities depending on their specific chemistry and design. They generally offer similar voltage ranges, but the capacity can vary depending on the design and size.

durability

Prismatic cells, with their metal casing, offer better durability and resistance to external stresses compared to pouch cells. Pouch cells, due to their flexibility, are more susceptible to damage and may require additional safety measures.

Cost

Prismatic cells are generally more expensive to manufacture due to their special metal casing design. Pouch cells are often less expensive to manufacture due to their simpler construction and flexible packaging.

Performance

Prismatic cells have a higher energy density and are suitable for high-energy applications where durability and thermal management are crucial, such as electric vehicles. Pouch cells, due to their lightweight and flexible design, offer a higher power density and are therefore suitable for devices requiring rapid power surges, such as smartphones and tablets.

Application of prism cells vs. pouch cells

Lithium-ion batteries have revolutionized the way we power our electronic devices, from smartphones to electric vehicles. Among the various types of lithium-ion batteries available, prismatic cells and pouch cells are frequently used due to their unique properties.

Prismatic cells: Powerhouses for robust applications

Prismatic cells, with their rectangular or square shape, are known for their durability and robustness. They are frequently used in applications requiring high performance and structural stability. Some notable applications include:

• Electric vehicles (EVs): Prismatic cells serve as the backbone of EV battery packs due to their ability to handle high currents and provide sufficient energy density. The rigid metal casing offers excellent protection against physical damage, ensuring safety and long-term reliability.
• Power tools: Power-hungry tools like cordless drills and saws require batteries capable of delivering high performance. Prismatic cells excel in these scenarios, providing the necessary power and endurance for extended operation.
• Energy Storage Systems (ESS): Prismatic cells are used in large energy storage projects where reliability and longevity are crucial. Their robust design, combined with their high capacity, makes them suitable for grid-level applications and contributes to stabilizing renewable energy sources.

Pouch cells: Lightweight and versatile

Pouch cells, on the other hand, offer a lighter and more flexible design, making them ideal for portable electronic devices and space-constrained applications. Let's delve into some outstanding areas where pouch cells excel:

• Consumer electronics: Smartphones, tablets, and wearable devices greatly benefit from the thin and compact form factor of pouch cells. These cells can be individually tailored to the specific dimensions of the electronics, thereby maximizing space utilization while providing sufficient power capacity.
• Medical devices: Pouch cells are used in various medical devices, such as pacemakers and insulin pumps. Due to their small size and light weight, they are ideally suited for implantable and wearable medical technologies.
• Aerospace and drones: The aerospace industry relies on lightweight components to optimize fuel efficiency. Due to their low weight and adaptable form factor, pouch cells are increasingly used in aircraft and drones to power onboard systems and ensure longer flight times.

Advantages of prism and pouch cells

While each cell type has its specific applications, both prismatic and pouch cells offer certain advantages:

• Prismatic cells offer greater durability and better protection due to their rigid metal casing.
• Pouch cells are lighter and more flexible, allowing for greater design freedom and higher energy density in a compact space.
• Both cell types deliver reliable performance at similar cell voltage and capacity.
• Prismatic cells excel in high-performance applications, while pouch cells shine in portable and space-constrained devices.

A to Prismatic vs. Pouch Cells

1. Why compress LiFePO4 cells?

The compression of LiFePO4 cells improves contact between components, increases energy density, enhances safety, and extends lifespan, making them more efficient and reliable energy storage solutions. It offers advantages such as improved performance, compactness, and the reduction of risks like internal short circuits and gas leakage.

2. How do you charge prism or pouch LiFePO4 batteries?

You can charge LiFePO4 batteries using generators, solar panels, and LiFePO4 battery chargers. Read on, How to charge LiFePO4 batteries, to learn more.

Conclusion

In summary, both prismatic and pouch cells are safe to use, and each type has its own advantages. Choosing reliable brands like Power Queen, which have passed safety certifications such as UL testing, is definitely important when deciding which batteries to use.