In today’s industries, from robotics and medical devices to solar energy storage and electric mobility, lithium battery packs play a crucial role in ensuring reliable and efficient power. Designing an optimal battery pack requires careful consideration of safety, performance, longevity, and compliance with industry standards.
As a leading battery manufacturer, Himax specializes in providing custom lithium battery solutions tailored to industrial needs. This guide outlines key design principles and application-specific recommendations to help B2B buyers create the most efficient and durable lithium battery packs.
1. Implementing Robust Protection Mechanisms
A well-designed battery pack must include a comprehensive protection system to ensure safety and longevity.
1.1 Battery Management System (BMS)
The BMS serves as the first line of defense in protecting lithium battery packs from common issues like overcharging, deep discharge, overcurrent, and short circuits.
- Overcharge protection: The BMS cuts off charging when the cell voltage exceeds 4.2V to prevent overheating.
- Over-discharge protection: To avoid battery damage, the BMS disconnects loads when voltage drops below 2.5V per cell.
- Short circuit prevention: Integrated MOSFETs act as circuit breakers to instantly disconnect in case of a short circuit.
- Temperature monitoring: Using NTC thermistors, the BMS tracks cell temperature, ensuring it stays within -20°C to 60°C.
1.2 Secondary Protection Mechanisms
Apart from the BMS, additional safety components ensure enhanced protection:
- PTC Resettable Fuses: Automatically reset after overcurrent conditions.
- CID (Current Interrupt Device): Disconnects in case of extreme overpressure or overheating.
- Thermal Cutoff Switches: Stop operation at 80°C to prevent fire hazards.
Industry Example:
For medical ventilator battery packs, safety is non-negotiable. Himax integrates dual-layer protection using a high-precision BMS + fuse system, ensuring reliable power delivery in critical applications.
2. Battery Pack Enclosure Design
2.1 Structural Integrity
A well-designed battery enclosure protects cells from mechanical shocks, vibrations, and moisture, extending the battery’s lifespan.
- Cylindrical cell packs (18650, 21700, 32700): Enclosures with rigid ABS or aluminum cases provide impact resistance.
- Pouch cell (LiPo) packs: Flexible casings with foam padding reduce pressure points and expansion risks.
2.2 Thermal & Environmental Protection
- Vibration-resistant materials: Ideal for industrial robotics and EVs.
- IP67-rated waterproof enclosures: Essential for outdoor applications like solar energy storage.
- Ventilation design: Prevents thermal buildup in high-discharge applications.
Industry Example:
For solar energy storage, Himax designs 48V 200Ah LiFePO4 battery packs with fire-resistant aluminum enclosures, ensuring 10+ years of reliable performance in extreme temperatures.
3. Custom Lithium Battery Design Solutions for Key Applications
3.1 Industrial Robotics
Key Requirements:
- High discharge rates for motors and actuators.
- Long cycle life to support continuous operation.
- Fast charging capability.
Himax Solution:
- Battery: 24V 30Ah LiFePO4 battery (6S5P configuration with 32700 cells).
- Design Features:
- Continuous 60A discharge (peak 100A).
- IP67-rated waterproof housing.
- CANBus-enabled BMS for real-time diagnostics.
- 5,000+ cycles lifespan, ensuring durability in 24/7 factory automation.
3.2 Medical Equipment (Portable Ventilators & Diagnostic Devices)
Key Requirements:
- Stable voltage output with low self-discharge.
- Lightweight and compact for portability.
- Compliance with medical safety standards (IEC62133, ISO13485).
Himax Solution:
- Battery: 14.8V 6.4Ah Li-ion pack (4S2P with Samsung 18650-35E cells).
- Design Features:
- Redundant safety protection (BMS + fuse).
- Lightweight, high energy density.
- Medical-grade enclosure, allowing for sterilization.
- Real-time power monitoring system for hospital use.
3.3 Solar Energy Storage Systems
Key Requirements:
- High-capacity storage with a long cycle life.
- Scalability for increased energy demand.
- Reliable performance in outdoor environments.
Himax Solution:
- Battery: 48V 200Ah LiFePO4 battery (16S configuration).
- Design Features:
- 5,000+ cycles lifespan (10+ years).
- Active cell balancing for uniform energy distribution.
- Remote BMS monitoring via Wi-Fi/Bluetooth.
- Expandable modular design, allowing parallel connections for higher capacity.
3.4 Electric Bikes & Scooters
Key Requirements:
- High energy density for long-range performance.
- Fast charging capability (2C+ rate).
- Compact and lightweight design.
Himax Solution:
- Battery: 36V 10Ah Li-ion pack (10S4P with 21700 cells).
- Design Features:
- High power output (continuous 20A discharge).
- Thermal management system to prevent overheating.
- Integrated regenerative braking support.
- Water-resistant casing for outdoor use.
4. Battery Replacement & Maintenance
Recommended Replacement Cycles:
| Application | Expected Battery Life |
| Industrial Robotics | 3–5 years |
| Medical Equipment | 2–3 years |
| Solar Energy Storage | 7–10 years |
| E-bikes & Scooters | 3–5 years |
Best Practices for Longevity:
- Avoid deep discharge below 20% capacity.
- Store batteries at 40-60% charge in cool (15-25°C) environments.
- Perform regular BMS diagnostics to check for anomalies.
5. Compliance & Certifications
Industry Standards & Compliance
Himax ensures all battery packs meet global safety and performance standards:
- Medical: IEC62133, UL2054, ISO13485.
- Automotive: ISO26262, UN38.3, SAE J2929.
- Energy Storage: IEC62619, UL9540.
Certification & Testing Support
We provide full support for regulatory compliance, including custom certification services for unique industry applications.
Designing an efficient, safe, and durable lithium battery pack requires expert-level customization based on application-specific needs. At Himax, we specialize in tailored battery solutions, offering cutting-edge protection features, high-performance configurations, and compliance-ready designs.
Need a custom lithium battery solution? Contact Himax Battery for expert guidance and a tailor-made design for your business.
