Rechargeable Batteries Applications Handbook

Gates Energy Gates Energy Products

• Publisher: Newnes
• Year: 1998
• ISBN:
  9780080515939
• Topic: Technology & Engineering
• Subtopic: Power Resources
• Index: Technology & Engineering

Represents the first widely available compendium of the information needed by those design professionals responsible for using rechargeable batteries. This handbook introduces the most common forms of rechargeable batteries, including their history, the basic chemistry that governs their operation, and common design approaches. The introduction also exposes reader to common battery design terms and concepts.

Two sections of the handbook provide performance information on two principal types of rechargeable batteries commonly found in consumer and industrial products: sealed nickel-cadmium and sealed-lead cells. For each type of cell, this book covers discharge performance, charging and charger design, storage, life, applications information, testing, and safety.

• New paperback edition of a best-seller
• First widely-available book on rechargeable cells
• Operation, applications, and testing

Section 1

Introduction

As the world increasingly comes to rely on electrical and electronic systems for its daily functions, both vital and mundane, it also becomes increasingly dependent on batteries. As electrical and electronic systems become smaller and more efficient, batteries provide the key to portability. And, even with stationary systems, batteries are becoming increasingly important to provide memory backup or keep essential functions operational when the main power is not available.

Not only has the world become more dependent on batteries in general, it has also come to appreciate the economy and reliability of rechargeable batteries. Thanks to rechargeable batteries, travellers can now work at their laptop computer throughout a transcontinental airline flight and then recharge their batteries overnight using only a few cents worth of electricity. At home, rechargeable appliances kept on their chargers are always fully charged and ready for use. Rechargeable flashlights provide the security of knowing they will respond when needed — eliminating the mystery of when the last time the batteries were changed and guessing at how much they have been used since then.

Now, improvements in battery technology are opening many new uses for batteries. The rapid development of markets such as portable electronics and cordless appliances and power tools has relied heavily on today’s improved batteries. In a diversity of applications, creative use of batteries is translating directly into improved sales and increased profits. Only recently, cold feet were the bane of many skiers; now, ski boots heated by rechargeable battery packs are keeping skiers happy and boot manufacturers scrambling to meet demand. But, creative use of batteries is aided greatly by knowing how batteries operate. This Handbook introduces the two leading forms of rechargeable batteries: sealed nickel-cadmium and sealed-lead batteries. Its objective is to help users and potential users of these battery systems understand how to best apply them. From this knowledge will come not only better designs for battery-powered equipment, but also creative new uses for batteries.

The Rechargeable Battery Application Handbook provides design and application information which is directly relevant to the sealed nickel-cadmium and sealed-lead battery families. This Handbook is designed to offer practical explanations of battery behavior with the focus on results rather than theory. The information included herein has been collected over the last quarter century by scientists, engineers, and technicians at Gates Energy Products.

ORGANIZATION OF THE HANDBOOK

The Battery Application Handbook is designed for ready use by people at all levels of experience in batteries. For the newcomer, it offers an introduction to the basics of batteries, including their history, how they operate, and representative applications. The glossary at the back of the Handbook explains many terms relevant to batteries. For the experienced user, it provides in-depth discussions of charging, discharging, and other battery performance aspects important to designing a rechargeable battery into a particular application. The Appendices (Appendix-Sealed Nickel-Cadmium Cells and Appendix B - Sealed-Lead Cells and Batteries) contain a wealth of performance data and specifications for these battery types as produced by Gates Energy Products.

The one area that the Rechargeable Battery Application Handbook does not treat in great detail is choosing between sealed nickel-cadmium and sealed-lead batteries for a specific application or product design. Experience indicates that making this choice is either very easy or reasonably difficult. In the “easy” category are situations where only one type of battery is feasible. For example, only one chemistry is available at the needed size or the application is a retrofit designed to fit only one battery shape. If the choice is not self-evident for this sort of reason, then selection between the two forms of battery becomes more difficult. Both the sealed nickel-cadmium and sealed-lead batteries are excellent high-performance systems. They do, however, have a wealth of differences that have to be evaluated before choosing one over the other. Consultation with full-line battery manufacturers offering both technologies may prove useful in choosing the appropriate battery type for a specific application.

The remainder of the Handbook is organized as follows:

• Section 2 - Rechargeable Cells and Batteries

• Section 3 - Sealed Nickel-Cadmium Cells and Batteries

• Section 4 - Sealed-Lead Cells and Batteries

• Glossary

• Index

• Appendices

Section 2 is a general description of rechargeable batteries including a brief history of batteries, an introduction to some common battery terms, and discussion of the construction and theory of operation of nickel-cadmium and sealed-lead cells. It also provides a summary of the current status of development efforts for advanced rechargeable batteries that are beginning to enter the market.

Sections 3 and 4 cover application details for the sealed nickel-cadmium and sealed-lead battery systems respectively. The format within each section is identical. A brief introduction presents some of the features and benefits of the battery system. Then Sections 3.1 and 4.1 discuss discharge performance and how cell discharge performance may be affected by various use, design, and environmental factors. This is the information necessary to determine the basic suitability of the battery for the proposed application. After determining that the battery can meet the electrical load, it is time to develop the charging strategy best suited to the requirements of the application. Sections 3.2 and 4.2 cover various schemes for charging the batteries including discussions of charging efficiency, continuous and fast charging, and overcharging. Proper storage is covered next. Understanding how self-discharge may affect storage is important in designing a storage procedure that is compatible with the application. These concerns are covered in Sections 3.3 and 4.3. Sections 3.4 and 4.4 present methods of estimating battery life under various use patterns. Methods of prolonging life are also discussed here. Sections 3.5 and 4.5, the application sections, supplement the information presented in the earlier sections with application and design-related factors affecting battery operation. A brief discussion of battery use in specific applications is also included. The next sections (3.6 and 4.6) talk about quality control and test procedures: ways to ensure that the system design (battery and charger) is adequate to the duty and methods to ensure batteries are ready for use. The last sections (3.7 and 4.7) are devoted to safety and ensuring that batteries are used in a way that does not present a hazard.

Note that the information provided in the body of the Handbook (Sections 3 and 4) is fairly generic to the particular battery family being discussed. The curves shown in these sections are not usually dimensioned. Instead they are intended to provide general indications of cell and battery behavior in various situations. Detailed information on actual performance for specific cell types as manufactured by Gates Energy Products is provided in the appropriate Appendix. Appendix A provides performance data for sealed nickel-cadmium cells. Appendix B provides equivalent detail on the performance of sealed-lead cells and batteries.

NOTICE TO READER

It is the responsibility of each user to ensure that each battery application system is adequately designed, safe and compatible with all conditions encountered during use, and in conformance with existing standards and requirements. The circuits contained herein are illustrative only and each user must ensure that each circuit is safe and otherwise completely appropriate for the desired application.

This Handbook and its appendices contain information concerning products manufactured by Gates Energy Products. This information is generally descriptive only and is not intended to make or imply any representation or warranty with respect to any product. Cell and battery designs are subject to modification without notice. All product descriptions and warranties are solely as contained in formal offers to sell or quotations made by Gates Energy Products.

Section 2

Rechargeable Cells and Batteries

As electrical and electronic devices become increasingly essential parts of modern society, we are ever more dependent on our sources of electrical power. Batteries are one of the few practical methods of storing electrical energy. As such, they are vital components in electrical and electronic devices ranging from portable electrical shavers to satellites in space. Recent advances in battery technology, both in new battery types and in improvements to existing batteries, have fueled a surge in battery applications. As battery applications become more diverse and more critical to system operation, it is especially important that system designers and users understand the fundamentals of battery function.

This section provides a general introduction to rechargeable batteries before the Handbook splits into more specific discussion of the two major rechargeable battery types that are widely available today. It begins with a brief history of battery development and then talks about some general concepts important to batteries. The section then presents the chemistries and construction details of nickel-cadmium, nickel-hydrogen, and sealed-lead battery cells. It then briefly discusses some recent developments in rechargeable battery technology and usage.

2.1 Rechargeable Battery History

Batteries of one form or another have existed for nearly 200 years. From the beginning, researchers have been attempting to improve the energy density and make battery packaging more convenient for the user. This development work continues today because market opportunities expand immensely with each significant improvement in battery performance.

2.1.1 EARLY WO...

Table of contents

• Cover image
• Title page
• Table of Contents
• EDN Series for Design Engineers
• Copyright
• List of Figures
• List of Abbreviations
• Section 1: Introduction
• Section 2: Rechargeable Cells and Batteries
• Section 3: Sealed Nickel-Cadmium Cells and Batteries
• Section 4: Sealed Lead Cells and Batteries
• Appendix A: Sealed Nickel-Cadmium Cell and Battery Product Line Data
• Appendix B: Sealed-Lead Cell and Battery Product Line Data
• Glossary
• Index