Premier Batteries - 20 years on

Premier Batteries commenced business in 1986 in a small factory unit at Chipping Norton. Initially the business focus was the assembly of mainly Nicad battery packs for the hobby market. Today Premier Batteries has grown, changed direction, moved to larger premises and evolved to be the largest local manufacturer of two-way radio batteries in Australia. They continue to invest in their business and to commission new tooling and ultra-sonic welding horns to expand the range of batteries available.

Certainly technology has changed with the development of new chemistry batteries from the major manufacturers, batteries are now lighter in weight and provide higher capacities and offer longer running time. A flood of new manufacturing particularly in China increased competition for all types of chemistries. Although this resulted in reduced pricing, in the initial development this resulted in some quality and reliability problems.

The demand for batteries is expected to grow steadily as the new generation of energy-hungry electronic devices (digital cameras, camera phones and portable computer devices) continue to drive the market. Manufacturers hoping for the 'miracle' battery technology that would power a laptop for days are limited as the technology is still some way into the future. In the last 20 years electronics have surged ahead and developed at an incredible rate with the miniaturisation of electronic components. Batteries appear to have been left behind when you consider the first Lead Acid battery was invented nearly 150 years ago.

Some of the developments of the past 150 years and current technologies are documented below:

Primary batteries

Alkaline - invented in 1914

Although this technology was first invented in 1914 it was not until mid 1960's they became commercially available.

Don't expect to see much change in Alkaline batteries in the future for although we see advertisements with toys powered with Alkaline batteries lasting forever, the average user of Alkaline batteries would hardly be aware of changes in real terms.

Perhaps the only development has been with the Oxyride battery.

This marketed as being suitable for consumer digital camera use offering high power that lasts longer, particularly suited to high drain applications. Manufactured with a combination of newly developed materials for the cathode.

This is marketed as lasting up to twice as long as the standard Alkaline in high drain applications. No advantage in low drain applications.

Lithium

The first non-rechargeable Lithium cells were available in mid 1970's. Although they will last 50% longer than Alkaline cells, they are more expensive. The same feature that makes them attractive for use, high electrochemical potential, can also cause serious difficulties in the manufacturing processes. Lithium is an unstable metal with a low melting temperature during the manufacturing process and is very flammable.

Safety parameters necessary for safe handling of the metal combined with transport restrictions (not suitable for passenger aircraft transportation) add to the manufacturing cost of the goods.

Rechargeable batteries

Sealed lead acid - invented 1859

Lead Acid is at a very mature stage of cycle life and most developments are focused around improvements in quality and reliability. The demand for Lead Acid Batteries is governed by vehicle production and low cost. The move to a 42V system in the next generation of vehicles is likely to be the mainstay in this market segment for years come.

Nickel Cadmium - invented 1899

It was not until 1947 this technology became available in a sealed form.

Nickel Cadmium is also at a mature stage it its cycle life but is still the preferred chemistry for Power Tools and the Two Way radio market, mostly because of high durability and reliable service. Some countries have environmental bans in place to discontinue the importation of Nickel Cadmium cells into their country due to disposal and environmental concerns. Nickel Metal Hydride and Lithium Ion batteries will fill the void.

Nickel Metal Hydride - invented 1976

Although invented in 1976 it was not until the 1980's that stable alloys were developed for use in Nickel Metal Hydride batteries. Commercially cells were not available prior to 1990. At the time this new technology offered lots of promise with up to 50% increase in capacity over Nickel Cadmium cells. Nickel Cadmium still holds a major share of power tools, two-way radio batteries and consumer hobby batteries due to high durability and reliable service under extreme conditions.

However, with the banning of importation of Nickel Cadmium cells in some countries a number of major manufacturers are discontinuing production of these Nicad cells in favour of more environmentally friendly products, Nickel Metal Hydride and Lithium Ion.

Lithium Ion - invented 1991

Lithium Ion with high density and high voltage has become the predominant battery for handheld electronic equipment although it offers only a 30% increase in running time over Nickel Metal Hydride and is more expensive. Li-Ion cells are significantly lighter and with an open circuit voltage of 3.7V per cell (instead of 1.2V for NiMh) one cell only can be used in many applications. Li-Ion cells have a low self discharge and can be stored in equipment for 2-3 months and used again without recharging.

Some negatives for every positive!

• Li-Ion batteries require electronic protection against overcharge and over discharge.
• Electronics are required in every battery pack, you are not likely to see individual cells at your local electronic store in the near future.
• This electronic circuitry means Lithium-Ion packs are often expensive.
• Increased production and world wide demand is influencing pricing and pricing now is reducing by 5-10% per annum.

In the year 2000 Japan produced nearly 100% of the total market, with the introduction of Korea and China into the market the Japanese share of the market in 2004 was reduced to 60%.

Lithium Ion ages from the date of manufacture losing up to 10% of rated capacity every year regardless of use, this does not alter if it is used or unused during the life of the battery.

Lithium-Ion batteries are significantly safer than those made with the pure Lithium Metal. This is due to the fact Lithium Ion is kept in the Ionic state and it is the ions that move between the positive and negative electrodes. Cells are available in both cylindrical and prismatic form. The prismatic cell is more expensive to make and has lower energy density per cell than the cylindrical form. However the prismatic cell has a much higher packing density. The prismatic form makes it ideal for cellular phones.

Lithium-Ion Polymer

The Lithium Ion Polymer cell is similar to the Lithium-Ion cell but uses a gel electrolyte and stacked plate cell architecture. The use of a gel electrolyte allows for the development of very thin batteries (less than 4mm) and the best use of space.

There are some disadvantages in slimline packaging:

• It is a more expensive construction
• The outer casing which is very thin is prone to allow swelling during the charge-discharge process
• Load current capability is reduced
• Cycle life is currently less than Lithium-Ion

The 'miracle' battery is along way off but tomorrow promises to produce even more powerful devices that consume less power, so perhaps we will have our laptops running for days.