eNewsletter

March 2010

Compared to NiMH (nickel-metal hydride) batteries, Li-ion batteries have a better energy-to-weight ratio, offer more efficient storage capacity over multiple charge-discharge cycles and suffer less charge leakage when not in use. And unlike NiMH batteries traditionally used in high-voltage applications, battery stacks using Li-ion technology can comprise a large number of individual cells totaling hundreds of volts. Each cell must be properly monitored and balanced to ensure user safety, improve battery performance and extend battery life. ADI’s new Li-ion battery monitoring and protection system performs these functions while also allowing power system designers to replace costly discrete components, decrease power consumption and reduce system space.

The Li-ion battery monitoring and protection system includes a safety monitor, the AD8280. The new safety monitor provides the designer with the final piece needed to develop the complete front-end of a battery monitoring and protection system. The AD8280 is an integrated solution that monitors six cell voltages and two temperature inputs. It is powered completely from the battery stack providing either a shared or a separate alarm for any of three conditions: over-voltage, over-temperature or under-voltage.

Planar Power Resistors Provide External Thermal Dissipation for Battery Packs in Hybrid Electric Vehicles
Giving alternative-energy automotive design engineers a rugged resistive device capable of dissipating significant amounts of heat generated during the battery charging cycle, TT electronics IRC has developed a series of planar power resistors for hybrid electric vehicles.  Designated the WDBR series, the planar thick-film resistors carry surge power ratings up to 7 kW and feature a steel substrate that provides direct transfer of thermal energy to an external heat sink.

"In alternative energy vehicles with battery packs, charging of the individual battery cells within the module has to be balanced, since the overall cell bank can only be effectively charged to the level of the highest capacity cell and discharged to the lowest and most limiting capacity cell," said Wilson Hayworth, application engineer for TT electronics IRC. "The WDBR series resistors are used to bypass higher state of charged cells so that the other cells can continue charging, resulting in the battery bank's ability to hold a higher overall charge."

The WDBR series resistors can also be used in bleeder circuits to safely absorb excess energy that results when alternative energy systems such as fuel cells or onboard generators are switched off. "In both of these applications, the resistor's ability to transfer heat directly to a heat sink outside of the controls module is a tremendous advantage for the designer," Hayworth continued. The resistor's planar geometry also provides smaller size, less weight and lower cost than conventional resistor technology.

The WDBR series planar power resistors are rated for 0.5, 1.0, 2, 3, 5 and 7 kW (maximum pulse power rating). Standard resistance values include 12, 22, 47, 100 and 150 ohms, with tolerances to ±10 percent (custom resistance values and tolerances are also available).  Minimum dielectric withstanding voltage is specified at 2,500 VDC.  Inductance values range from less than 3 µH to less than 6 µH.

The thick film resistive element is printed on an insulated stainless steel substrate, with a high temperature overglaze for protection.  The closely matched thermal expansion coefficient between the steel substrate and the dielectric film enable the WDBR series resistors to withstand severe temperature cycling (up to 400°C). Dimensions for the resistor range from 1.94 inches by 1.41 inches to 4 inches by 6 inches, with substrate thickness of either 0.035 or 0.059 inches.

2,500 Watt, Rectifier/Battery Charger for 120 V Batteries in Heavy-Duty Industrial Environments
Absopulse has introduced the BCH 2K5-120-EQ rugged, industrial quality battery charger, which uses field-proven high-frequency conversion technology to deliver up to 2,500 W continuous output power. This charger accepts an input voltage range of 190 V to 264 VAC, and in float-mode it provides 135 VDC/16 A for charging a 120 V (60 cell) battery.

This design has a manually initiated equalize cycle. Activated by a push-button “EQ/ON”, the equalize function elevates the output voltage to 141 VDC for the battery. The equalize time is controlled by a built in timer, adjustable in the one to nine hour range. This mode can be manually de-activated at any time.

The BCH 2K5-120-EQ is rated for heavy-duty applications with -40⁰C to 70⁰C temperature rating for full specification. Cooling is by convection via louvers on the cabinet. The absence of fans, low component count and the use of components with established reliability result in a high MTBF. The robust chassis was designed for a wall-mounted application.

This charger is constructed with internal modules, connected in parallel, which also provide inherent redundancy;  the failure of one module would only cause a minor loss in total output power. The charger output is equipped with a built-in crossbar diode and output breaker as a safety feature against accidental reverse battery connection. Other protection includes input inrush current limiting, over-voltage protection, short circuit protection and a self-resetting thermostat for thermal protection. An optional Charger Fail Alarm (Form C) indicates loss of AC input power.

Primary lithium battery markets all over the world have witnessed growth, with escalating defense budgets and spending on sophisticated, technologically advanced equipment creating a huge market for them. Manufacturers have been developing novel chemistries for an increasing number of new and specific applications. Further, increasing industrial automation and automation of the manufacturing sector are bolstering the need for primary lithium batteries. The spurt in demand for these batteries over the last several years has been in response to the advancements and breakthroughs occurring in portable and miniaturized electronic and medical products. The batteries for such applications need to be lightweight, compact and have wide operating temperatures. Several lithium chemistries can already meet these requirements due to their high energy density storage and efficient performance in rugged atmospheres.

Military applications are likely to remain the primary driver for primary lithium batteries due to their advantages of simple logistics, long shelf life as well as rugged and robust construction. Moreover, the batteries can be used as soon as they are fitted in the equipment. These benefits give primary lithium batteries a distinct edge over lithium-ion (rechargeable type) in military applications. The key features of a battery for military applications include high power rate, light weight (more power per unit volume), ready usability, says the analyst of this research. Lithium batteries have superior energy density (three times that of conventional alkaline), long life cycle compared with other primary chemistries, and an average replacement rate of more years, making them well suited to remote and robust applications.

However, even though primary lithium batteries have many desirable features, some inherent features dampen the demand for these batteries. Some of the primary lithium batteries are still not considered safe for wide temperature ranges and disposal, as they could explode at high temperatures. Similarly, anode passivation, which is the formation of a salty layer when the anode and cathode touch each other, also reduces the performance and efficiency of the batteries. The threat from other primary chemistries and secondary lithium-ion batteries could also hinder the growth of primary lithium batteries for certain applications. However, the market could grow for the next four to five years before the threat from alternative chemistries starts manifesting. The medical, industrial, automotive and military applications markets are developing and are expected to buoy the primary lithium batteries market for the next five to seven years.

To stand out in this intensely competitive market, manufacturers must offer robust manufacturing process control and quality. Once they achieve this, they can expect steady growth, as each chemistry is preferred for a particular application. In a market with fierce competition, high expectations and quality consciousness, there is always a pressing need to revise both short-term as well as long-term strategies to maintain consistent cash flow, notes the analyst. Participants must actively adopt cost-saving and restructuring strategies such as alliances, mergers, acquisitions and partnerships. Though growth within the numerous market segments varies with multiple factors, success will depend on continuous market and product evaluations.

Micro Power Awarded New Patent for Battery Charger Technology
Micro Power Electronics, Inc. has been awarded a US patent covering a battery charger configuration to reduce thermal conduction.

The newly issued patent describes a method for separating a housing containing circuit charging components from a housing containing battery charging contacts and a rechargeable battery pack for the purpose of minimizing heat transfer from the components of the battery charging circuit to the rechargeable battery pack.  This patent ensures that battery does not receive excessive heat while charging, which extends battery pack life and minimizes the risk of battery overheating during charging.

”This innovative and novel use of a passive system architecture is not only very cost effective for our clients, but is a reliable and safe method of minimizing the heat transferred to the battery while charging,” said Ron Pitchel, vice president of Engineering and Continuous Improvement for Micro Power.  “This system performs nearly as well as the conventional approach of embedding a fan within the charger enclosure for thermal management.”

Electrochem Lithium Batteries Power Iditarod Tracking for Third Year
Electrochem is once again powering satellite tracking technology for the racing teams in the famous Iditarod Trail Sled Dog Race. Chosen for its performance in extreme environmental conditions, Electrochem’s High Rate Lithium batteries will ensure reliable power to the Satellite Race Telemetry (SRT) unit through low temperatures, severe weather conditions and pounding shock and vibration.

Every team participating in the race will be outfitted with the SRT unit, developed by IonEarth LLC, providing organizers,  volunteers, media and fans with mapping of location, speed,  temperature, heading and more. The SRT unit transmits  through Iridium’s constellation of 66 Low-Earth-Orbit satellites  to a central server every 15 minutes, and a live map is refreshed  to show the position of the race teams.

“With Electrochem’s battery solution, we can depend on the device’s performance in the harsh Alaskan conditions through the full duration of the race,” said Jerry Miller of IonEarth LLC. “The batteries are lightweight yet extremely energy dense, which means we get a lot of power without adding significant size or weight to the musher’s sled.”

The race course from Anchorage to Nome covers 1,150 miles in 10 to 17 days and as such is tagged the “Last Great Race on Earth.”

Celgard Announces Expansion of Lithium-Ion Battery Capacity in Korea
Celgard, LLC, a wholly-owned subsidiary of Polypore International, Inc., and a global supplier of microporous separators used in lithium-ion batteries, has announced plans to expand production capacity at its existing lithium-ion separator manufacturing facility in Ochang, South Korea.

Celgard plans to invest approximately $30 million in the expansion project, which is expected to begin the second half of this year. The expansion will significantly increase Celgard's lithium-ion battery separator production capacity in Korea and is a result of the company's accelerated success in the region. The additional capacity is expected to come online in 2011, and will serve customer growth in consumer electronics applications.

In January 2010, Celgard also announced plans to expand capacity at its Charlotte, North Carolina, US facility as well as construct a new manufacturing facility in Concord, North Carolina, to support increasing demand in the electric drive vehicle market.

Celgard is a global supplier of specialty microporous membranes.These separators play a critical role in the performance and life of lithium-ion battery cells by providing a barrier between the positive and negative electrodes, preventing short circuits while controlling the exchange of lithium ions from one side of the battery to the other.

KEMET and United States Department of Energy Sign Contract for $15.1 Million Government Grant
KEMET Corp., a manufacturer of tantalum, multilayer ceramic, solid aluminum, plastic film, paper and aluminum electrolytic capacitors, has signed a $31.7 million contract with the US Department of Energy's (DOE) National Energy Technology Laboratory. This contract is based on the $15.1 million grant awarded on August 5, 2009 as part of the American Recovery and Reinvestment Act Electric Drive Vehicle Battery and Component Manufacturing Initiative plus a $16.6 million matching investment by KEMET.

KEMET has been working with the DOE on the details of the contract since that original announcement. The contract will enable the company to produce film and aluminum electrolytic capacitors within the US to support alternative energy products and emerging green technologies such as hybrid electric drive vehicles.

"We are aiming to have two production lines operational by the last quarter of the current calendar year with an additional two lines coming on board by the end of 2011 and another two by the end of 2012," said Dr. Johnny Boan, KEMET's senor director of Business Development, and the project lead in securing this grant.

The conference program evolves every year to feature more than 35 presentations on the latest advancements in the industry and we are we are pleased to announce the preliminary sessions for 2010.

Changing Global Regulatory Requirements for Battery Powered Consumer Electronics
H. Scott Griggs, General Manager Consumer Goods & Retail • TÜV SÜD America, Inc.

The Cost of Safety, Designing for Safety and the Changing Lithium Ion Battery Pack Regulatory Requirements
Dr. Like Xie, Vice President of Technology • Palladium Energy
Dr. Kerry Lanza, Strategic Marketing Manager • Palladium Energy

Battery Performance and Plug-In Hybrid Electric Vehicles and Other Electric Vehicle Adoption
Greg Ayres, Managing Consultant • Navigant Consulting, Inc.

Using Lithium Polymer Batteries in Commercial Devices
Dr. Robin Sarah Tichy, Technical Marketing Manager • Micro Power Electronics, Inc.

Overcoming Battery Pack Design Issues
Stephen Christo, Director of Product Management • Boston-Power

Design Advantages and Comparisons of Large Format Li-Ion Batteries
John Battaglini, Vice President of Business Development • International Battery, Inc. 

High Efficiency and High Safety LiFePO4 Battery Charger System for Industrial and Medical Applications
Jinrong Qian, Battery Charging Management - Advanced Portable • Texas Instruments, Inc.
Jing Ye • Texas Instruments, Inc.

A Simple Topology for Solar-Charged Battery Systems
Keith Curtis, Technical Staff Engineer • Microchip Technology Inc.

Commercial Applications of Lithium Titanate Batteries for Mass Transit
Terry Copeland, Ph.D., President and CEO • Altairnano

Deciphering Cell Variations in Battery Manufacturing
Matthieu Dubarry, Hawaii Natural Energy Institute
Bor Yann Liaw, Hawaii Natural Energy Institute

Nanotechnology Manufacturing Techniques for More Efficient Lithium Ion Batteries
John Hill, Application Process Advisor • NETZSCH Fine Particle Technology
Steve Miranda, Director of Sales • NETZSCH-CONDUX

New Advances in Lithium Ion Battery Monitoring
Joern Tinnemeyer, Vice President - Research and Development • Cadex Electronics, Inc.

Ready for the Grid: How Battery Storage will Support Renewable Energy and the Smart Grid
Haresh Kamath, Strategic Program Manager for Technology Innovation • Electric Power Research Institute

Making the Transition to Lithium Ion and Qualifying the Right Li-Ion Cell Technology for Your Large Format Battery Application
Chris Turner, Director of Battery Technology • Nexergy

Upscaling New Battery Technologies to Lab to Fab
Thomas Kolbusch, Vice President, Coatema Coating Machinery GmbH

Datacenter Trends Creates Sweetspot for Entry of New Materials
William Muscato, Product Manager for Power Infrastructure Products • Dell, Inc.

Click Here to Read the Complete Session Descriptions

Click Here to Register for Battery Power 2010

April
27-28 - 3rd China & Global Lithium Battery Industry Summit 2010, Beijing, China

May
17-19 - BATTCON International Stationary Battery Conference, Hollywood, Fla.

17-21 - 10th International Advanced Automotive Battery Conference, Orlando, Fla.

IWCE is the pre-eminent integrated communications systems event for the working world. Having the ability to receive the right information has never been more important. If you are responsible for the dependability, reliability and interoperability of your organization’s communication system, then IWCE is your must attend event.  IWCE provides the applications and systems you need in order to communicate anytime, anywhere. Make connections with 360+ leading edge exhibitors and collaborate in an educational environment that delivers meaningful information that allows you to do a better job. 

From Land Mobile Radio…to Wireless Mobility…Voice…Video…Data…and everything in-between…Communications Technology is Changing…and so is IWCE.

International CTIA WIRELESS
March 23-25
Las Vegas, Nev.

The International CTIA WIRELESS® show represents a $1 trillion global marketplace that brings together every component of the wireless and broadband ecosystem. For 25 years, International CTIA WIRELESS® has been THE premier marketplace for all things wireless and 2010 is guaranteed to be another crucial and groundbreaking event for the industry. Join us in Las Vegas, March 23-25. Early bird pricing ends February 16 -- register now at www.ctiawireless.com!

ENTELEC 2010
April 13-15
Houston, Texas

The ENTELEC 2010 Conference & Expo provides an incredible opportunity to take advantage of cutting edge technical education and training, hands on exhibits and product demonstrations, and industry networking.  Take advantage of the energy industry’s most comprehensive technical conference with seminars, round tables and discussions that focus on real-world challenges, applications and provide take-away solutions.  The education program has been “re-engineered” to include open discussions and more interaction with peers and vendors that will provide attendees with more information, options and eventually, more solutions.  The 2010 conference will also include several seminars focused on professional and career advancement. Check out our Schedule of Events at www.entelec.org

Battcon 2010 International Stationary Battery Conference
May 17–19
Hollywood, Fla.

The Battcon Stationary Battery Conference is a three day, noncommercial, technical event for storage battery users from the power, telecom, UPS and other industries.

This well-established event brings over 500 end-users, engineers, battery and battery test equipment manufacturers, installers, and standards and safety experts together to discuss storage battery innovations and solutions for existing systems.

Presentations by users and manufacturers address everyday battery applications, technical advances, and industry concerns. The dialogue between the audience and the presenters make Battcon a truly interactive experience. A two evening trade show featuring storage power related vendors is also part of the conference.

For more information contact Jennifer Stryker, Albér, 3103 N. Andrews Ave. Ext., Pompano Beach, FL 33064. (954) 623-6660 or visit www.battcon.com.

Sensors Expo & Conference
June 7-9
Rosemont, Ill.

For 24 Years, Sensors Expo & Conference Has Been the Leading Industry Event Focusing Exclusively on Sensors & Sensor-Integrated Systems! The in-depth conference program features the world's leading authorities, in a carefully designed program, including topics such as: Energy Harvesting, Wireless Networking, Low-Power Sensing, Bio-Sensing, MEMS & MCUs, Monitoring Tools & Applications, Novel Approaches to Measurement, Power/Smart Grid Monitoring & Control, and more!  PLUS – save months of time researching, by examining solutions to your toughest sensing challenges from best-in-class vendors on the Expo floor!  Whether you're looking to find the latest sensing solutions, evaluate emerging standards, find and compare suppliers, or solve new design challenges, you can't afford to miss Sensors Expo & Conference! 

Visit www.sensorsexpo.com for details!

NSTI Nanotech 2010
June 21-25
Anaheim, Calif.

NSTI Nanotech 2010 is the largest international annual nanotechnology & small tech community conference worldwide, and attracts the most targeted, influential and qualified attendees. The conference no longer exclusively focuses only on scientists and researchers, although sharing research and developments remains a cornerstone of the conference. Nanotech now reaches out to investors, venture capitalists and business executives interested in how nanotechnology can drive business in the 21st century. Any company with a product or service associated with these technologies and solutions is encouraged to exhibit. NSTI Nanotech 2010 is expected to sell out. Don't miss the most important event of the year by reserving your space today.  Please contact Denise Lee, 203-245-4201 or email at dlee@nsti.org.

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