Battery packaging materials are critical in the production of lithium-ion batteries. Indeed, significant cost savings can be realised when the chosen packaging material has an adequate combination of mechanical, permeation, and seal-strength properties.
With the widespread use of Lithium-ion batteries to power a variety of applications over the last decade, three primary packaging technologies have emerged as the most common in the Lithium-ion battery industry: cylindrical, prismatic, and pouch-based.
Cylindrical Cells Packaging
It is one of the most popular primary and secondary battery packaging styles. The benefits of using this cell format include ease of manufacturing and mechanical stability. This cell design is simpler to manufacture and, with a sealed can exterior, can withstand high internal pressures. The cylindrical cell package also includes a resealable vent to release pressure in the event of an overcharge. Wireless communications, biomedical instruments, power tools, and other applications that do not require an ultra-compact battery size are the main users of cylindrical cells packaging.
Prismatic Cells Packaging
The prismatic cell design allows for thinner cell geometries, and its rectangular packaging is easily customizable for each application. Prismatic cell packaging is used exclusively in lithium polymer batteries. Heavier gauge metals are preferred for prismatic casings because they reduce the risk of bulging due to internal pressure buildup.
Pouch Cells Packaging
Unlike other cell designs, which can only be packaged with hard metallic enclosures, lithium-ion pouch cells can be packaged with conductive multilayer foils. A pouch cell's electrical contacts are made up of foil tab conduits that are welded to the electrode and sealed to the pouch material. Pouch cells have the advantage of being lighter and less expensive than other cell geometries, as well as taking up the least amount of space. Due to their properties, pouch cells are the preferred choice for compact applications such as smartphones, tablets, and other portable consumer electronics that require ultra-thin enclosures.