Full comparison of prismatic and pouch cells
, From Sally Zhuang, 11 min reading time
Nowadays, with technological advances, the use of rechargeable batteries is becoming increasingly common in our daily lives. Among the various types of rechargeable batteries, prismatic and pouch cells are very popular.
In this article, we provide 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 internal structure of the battery can be either wound or laminated, which provides 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 characteristic features:
- Shape and size:
Prismatic cells have a rigid rectangular shape, resembling a brick or a flat box. They are available in a variety of sizes and dimensions, from small to large.
- Energy density:
Prismatic cells offer higher energy density than 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 result in better performance and efficiency in devices requiring higher voltage levels.
- Durability and safety:
Prismatic cells typically come with a metal casing, which provides better protection against external stress 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 damage to the battery.
Part 2. What are pouch cells?
Pouched 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 customizable size and available space depending on the intended use. This allows flexible units to be easily adapted 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, soft pack batteries have the potential to compete with next-generation high-performance batteries, 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 chemistries, such as lithium cobalt oxide (LiCoO2). It has greater thermal stability and is less susceptible to thermal runaway, making it less likely to catch fire or explode.
- Long service life:LiFePO4 pouch cells typically have a longer lifespan than other lithium-ion batteries. They can withstand hundreds or even thousands of charge-discharge cycles without significant capacity loss, making them suitable for applications requiring long-term reliability.
- High power density:LiFePO4 pouch cells have a high power density, allowing 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 over a wide temperature range of -20°C to 60°C (-4°F to 140°F) without any degradation in performance. This makes them suitable for use in extreme temperatures and harsh environments.
- Environmental friendliness:The LiFePO4 chemistry does not contain harmful heavy metals such as cadmium or lead, making it more environmentally friendly and easier to recycle.
- Light and compact: The pouch cell design enables a flexible and lightweight form factor, making it ideal for space-constrained applications where size and weight are critical factors.
Power Queen 12V 100Ah Mini LiFePO4 battery It is highly sought after in the market due to its compact size and lightweight design, weighing only 8.96 kg. Being only three-fifths 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 of this battery.
Safety concerns regarding LiFePO4 pouch cells
A common problem with pouch cells, including LiFePO4 pouch cells, is the possibility of swelling. Swelling can be caused by a variety of factors, such as improper charging or discharging, overcharging, or exposure to extreme temperatures.
However, it's 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 chemistries. This means there is less risk of overheating and thermal runaway, making them a safer option for certain applications.
In addition, LiFePO4 pouch cells typically incorporate a number of safety features, such as a pressure relief valve and thermal protection measures. These safety mechanisms help reduce the risk of swelling, overcharging, or thermal runaway.
In addition, the flexible design of the pouch cells allows for more effective heat dissipation, preventing excessive temperature buildup and reducing the risk of swelling.Pouch cells also have lower internal resistance than prismatic cells, which helps minimize heat generation during charging and discharging.
It is worth noting that ensuring proper charging and discharging practices and adhering to the recommended temperature range are critical to 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 chemistries due to their inherent stability and built-in safety features. Following 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 regulatory standards such as UL, CE, and RoHS, it is important to ensure that LiFePO4 pouch cells have the necessary safety certifications. These certifications demonstrate that the batteries meet strict safety and environmental requirements and have undergone rigorous testing and quality control procedures.
The batteries from Power Queen have 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 a variety of shapes and sizes.
Packaging materials
Prismatic cells generally have a metal casing, which provides 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 are lighter because they are lightweight and use flexible packaging.
Cell voltage & capacity
Both prismatic and pouch cells can have different voltages and capacities depending on the specific chemistry and design. They typically offer similar voltage ranges, but capacity can vary depending on the design and size.
durability
Prismatic cells, with their metal casing, offer greater durability and resistance to external stress compared to pouch cells. Pouch cells are more susceptible to damage due to their flexibility 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 more cost-effective 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 critical, such as electric vehicles. Pouch cells offer higher power density due to their lightweight and flexible design, making them suitable for devices that require rapid bursts of power, 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 commonly 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 widely 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 provides excellent protection against physical damage, ensuring safety and long-term reliability.
- Power tools: Power-hungry tools like cordless drills and saws require batteries that can deliver high performance. Prismatic cells excel in these scenarios, providing the power and endurance needed for extended operation.
- Energy storage systems (ESS): Prismatic cells are used in large-scale energy storage projects where reliability and longevity are critical. Their robust design combined with high capacity makes them suitable for grid-level applications and contribute to the stabilization of 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 applications with limited space. Let's dive into some outstanding areas where pouch cells shine:
- Consumer electronics: Smartphones, tablets, and wearable devices greatly benefit from the thin and compact form factor of pouch cells. These cells can be customized to the specific dimensions of the electronics, maximizing space utilization while providing sufficient power capacity.
- Medical devices: Pouch cells are used in various medical devices, such as pacemakers and insulin pumps. Their small size and light weight make them ideal 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 being 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 longer durability and better protection due to their rigid metal casing.
- Pouch cells are lighter and more flexible, allowing greater design freedom and higher energy density in a compact space.
- Both cell types deliver reliable performance with similar cell voltage and capacity.
- Prismatic cells excel in high-performance applications, while pouch cells excel in portable and space-constrained devices.
A to Prismatic vs. Pouch Cells
1. Why compress LiFePO4 cells?
Compression of LiFePO4 cells improves contact between components, increases energy density, enhances safety, and extends service life, making them more efficient and reliable energy storage solutions. It offers advantages such as improved performance, compactness, and mitigates risks such as 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 batteriesto learn more.
Conclusion
In summary, both prismatic and pouch cells are safe to use. Each type has its own advantages. Choosing reliable brands like Power Queen that have passed safety certifications like UL testing is definitely important when deciding which batteries to use.
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