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BMS Design for 3C Discharge, Thermal Safety, and CAN/SMBus Communication Integration

battery thermal management

When it comes to high-performance lithium battery packs, especially those powering compact EVs, robots, and portable industrial equipment, safety and control are everything. At the heart of it all lies the Battery Management System (BMS).

A smart BMS not only protects the battery—it unlocks high discharge capabilities, ensures stable thermal performance, and allows seamless communication with host systems. In this article, we explore how advanced BMS design enables 3C continuous discharge, effective heat management, and dual communication support using CAN Bus and SMBus protocols—and how Himax has implemented these technologies in real-world custom battery solutions.

battery thermal management

Why Advanced BMS Design Matters

Every lithium battery pack requires a BMS to manage charging, discharging, voltage balancing, and safety cut-offs. But in high-rate applications—such as e-bikes, delivery robots, or mobile power stations—the BMS becomes a critical performance enabler.

An ordinary BMS might limit your device’s power output or trigger premature shutdowns under high load. A well-engineered BMS, however, empowers your product with:

  • Reliable 3C discharge rates(e.g., 30–45A continuous at 48V)
  • Integrated thermal protectionfor extended safety
  • Smart communicationwith host systems via CAN or SMBus
  • Real-time diagnostics and error reporting

 

1. Enabling 3C Discharge Through Intelligent BMS Architecture

(keyword: 3c discharge, bms protection, high-rate battery pack)

A 3C discharge means the battery can safely output current equal to three times its capacity per hour. For example, a 10Ah pack with 3C capability can sustain a 30A discharge—ideal for motors, pumps, and actuators.

At Himax, we achieve this using:

  • High-precision current sensors (shunt-based)
  • Ultra-low resistance MOSFET switching arrays
  • Custom-configured voltage and current thresholds
  • Dynamic control logic to prevent overcurrent and short circuits

 

Case Example: Our 48V 44Ah battery pack delivers a steady 45A discharge (just above 1C) but is tested and certified for short bursts of up to 120A peak without triggering thermal cut-off.

This level of output is ideal for:

  • Electric scooters and delivery bikes
  • Mobile robots and logistics platforms
  • High-power field tools and emergency equipment

 

2. Thermal Management: Staying Cool Under High Load

(keyword: battery thermal management, pcm cooling, heat control)

Discharging at high current naturally generates heat. Without thermal management, this heat can degrade the battery, damage components, or even cause failure.

At Himax, we design battery packs with:

  • PCM (Phase Change Material)inserts that absorb and release heat passively
  • Finned aluminum heat sinksto maximize air-cooled dissipation
  • Optional forced-air or active liquid cooling systemsfor large industrial units
  • Real-time thermal cutoffif any cell exceeds safe limits

smbus battery communication

Our compact 22.2V 28Ah pack for robotics, for example, uses a hybrid structure: PCM blocks embedded around the cells + passive air vents for lightweight, silent cooling.

With this approach, we maintain safe operation even at discharge currents above 3C in closed, compact housings.

3. CAN Bus vs. SMBus: Smart Communication with Host Systems

(keyword: bms can bus, smbus battery communication, smart battery protocol)

Communication between the battery and the rest of your system is just as important as raw performance. Himax BMS supports both CAN Bus and SMBus, depending on your application:

Protocol Best For Features
CAN Bus EVs, robotics, industrial equipment High-speed (1 Mbps), robust, multi-node
SMBus Portable devices, smart tools Lightweight, I²C-based, real-time alerts

Our dual-protocol BMS allows:

  • Real-time SOC/SOH reporting(State of Charge / Health)
  • Temperature and voltage broadcastto controllers
  • Fault flagging and event history logging
  • Firmware upgrades over the bus

 

If you’re developing a smart EV or a connected tool, this enables full system integration and battery analytics.

4. Himax’s OEM Approach to Integrated BMS Solutions

(keyword: custom battery bms, oem battery manufacturer)

Unlike off-the-shelf solutions, Himax provides end-to-end design for battery packs with tailored BMS configurations. Here’s what makes our offering unique:

✅ Custom BMS firmware – Set your thresholds, alerts, and logic
✅ Flexible communication setup – CAN, SMBus, UART, RS485 all available
✅ Heat optimization by design – Enclosure, cell layout, airflow modeling
✅ Compliance ready – UN38.3, IEC62619, CE, RoHS, UL standards
✅ Data logging + remote diagnostics – Optional flash memory support

From 22.2V 28Ah compact packs to 48V 60Ah industrial systems, we’ve helped dozens of OEMs worldwide build smarter, safer power systems.

5. Applications That Require Intelligent BMS Design

(keyword: high-discharge battery applications)

The demand for smarter, high-performance BMS is growing across:

  • E-mobility: electric scooters, city bikes, cargo trikes
  • Robotics: autonomous floor cleaners, patrol robots, warehouse AGVs
  • Field Tools: power drills, cable splicers, rescue gear
  • Medical & Military: mobile ventilators, communications gear
  • IoT & Energy: hybrid solar kits, portable UPS systems

3c discharge battery bms

In all of these, 3C discharge, precise heat control, and secure communication are not optional—they’re mission-critical.

FAQ – Battery Management System for High-Reliability Packs

Q1: What is 3C discharge in a battery pack?
A: It means the pack can safely deliver current 3x its capacity per hour—e.g., 30A for a 10Ah pack.

Q2: Why is thermal protection important in high-rate batteries?
A: It prevents cell degradation, swelling, and fire risk—especially under constant high current.

Q3: What’s the benefit of using CAN or SMBus in a BMS?
A: These allow real-time battery monitoring, system coordination, and safer shutdown in case of faults.

Q4: Can Himax combine both CAN and SMBus in one pack?
A: Yes. We offer dual-protocol BMS for complex systems needing multi-layer control.

Q5: How customizable is Himax’s BMS solution?
A: Fully. We customize thresholds, connectors, cell configurations, firmware, and even casing.

Build Safer, Smarter Battery Packs with Himax

Whether you’re developing a high-powered electric vehicle or a precision robotic platform, battery safety and intelligence are non-negotiable. Himax’s custom BMS solutions bring together the best of protection, performance, and integration—designed to fit your product, not the other way around.

Contact us now to explore a custom battery pack with 3C discharge capability, PCM thermal control, and seamless CAN/SMBus communication. Let’s engineer your power advantage—together.

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Why 48V and 22.2V Battery Packs Are Ideal for Compact Devices

48v battery pack

Today’s small-scale mobility and equipment manufacturers face two major challenges: space and power. You need a battery that fits your form factor without compromising energy or safety.

That’s where our 22.2V lithium battery packs shine—they’re compact, lightweight, and capable of high-performance output. Meanwhile, our 48V li-ion battery packs deliver more sustained power, making them ideal for longer-range electric scooters, bikes, and mobile platforms.

These voltage levels hit the sweet spot:

  • 22.2V: Best for lightweight robotics, drones, medical monitors, portable instruments
  • 48V: Ideal for e-bikes, warehouse trolleys, industrial equipment, and delivery carts

48v battery pack

Himax’s Custom 48V Battery Pack – A Real-World E-Mobility Solution

(keyword: 48v battery pack for electric bikes)

One of our best-selling solutions is the 48V 44Ah lithium-ion battery pack, engineered for electric bicycles and other compact EVs. Using high-performance 18650 cells, this pack delivers:

  • 44Ah capacity with a 45A continuous discharge rate
  • Full BMS protection (overcharge, overdischarge, short circuit)
  • Thermal management for safe high-load operation
  • Total weight of just 11.5 kg—light enough for two-wheelers
  • Flexible connector design and fast-swap terminals available

 

It’s a plug-and-play upgrade for businesses in the e-mobility sector looking for reliability and long range. With hundreds of units already deployed, we’ve seen it power scooters, delivery bikes, and even foldable golf carts.

Compact 22.2V Battery Pack – Power for Robotics and Field Devices

(keyword: 22.2v battery pack for robotics)

Need a battery for something smaller? Our 48V and 22.2V Battery Packs is custom-built for robotics, security units, and field service tools.

This solution offers:

  • 621.6Wh of energy in a compact footprint
  • Lightweight design with extended runtime
  • 3C discharge rate, perfect for motion and motor control
  • OEM port, enclosure, and labeling customization
  • 100% aging test before shipping

22.2v 10ah lithium battery pack

If you’re designing or maintaining professional field equipment that requires power, portability, and safety, this pack is an excellent match.

 

What Makes Himax’s Custom Battery Packs Different?

(keyword: custom 48v and 22.2v battery packs)

We don’t just make batteries—we engineer power solutions tailored to your product. Here’s how we stand out:

✅ Low MOQ, High Flexibility – Start with just 50–100 pcs.
✅ End-to-End Design Support – We help you choose cell types, casing, wiring, connectors.
✅ Certifications Ready – All packs are tested for UN38.3, CE, and RoHS compliance.
✅ Free Prototyping – Evaluate real performance before committing.
✅ Fast Delivery – 2–3 week turnaround for most configurations.

Whether you’re building your first smart scooter or scaling up a fleet of industrial robots, our OEM battery pack service is built for speed, safety, and scale.

Where 48V and 22.2V Battery Packs Excel

(keyword: lightweight battery pack applications)

Here are some of the most common (and exciting) use cases for our battery packs:

Use Case Recommended Pack Why It Works
Electric Scooters / Bikes 48V 44Ah High power, long range, compact build
Service / Patrol Robots 22.2V 28Ah Lightweight, stable discharge, easy swap
Portable Medical Devices 22.2V 10–20Ah custom Silent, safe, and high runtime
Warehouse Logistics Carts 48V 30–60Ah custom Reliable for all-day industrial use
Field Monitoring Equipment 22.2V 18Ah custom Portable, fast-charge capable

How to Get Started with Himax

(keyword: custom oem battery pack manufacturer)

Getting your custom battery pack has never been easier:

  1. Send us your voltage, current, and dimension requirements
  2. We propose the cell config, BMS, and connector options
  3. Approve the sample or request adjustments
  4. Place your bulk order—we handle the rest

22.2v 28ah lithium battery pack

You’ll get updates during every step of production, and we can ship globally, with local support in Europe, the U.S., and Australia.

FAQ – Everything You Want to Know of 48V and 22.2V Battery Packs

1.Can I use a 48V and 22.2V battery packs for my electric cargo trike?

Absolutely. Our 48V battery pack is ideal for low-speed EVs like trikes and delivery carts.

2.Can Himax customize shape or thickness for fitting tight spaces?

Yes. We offer custom enclosures, slim packs, and flexible wiring solutions.

3.What certifications are available?

We support UN38.3, CE, RoHS, IEC62133, and more depending on your market.

4. Are there any sample programs for 48V and 22.2V Battery Packs?

Yes—qualified OEM clients can receive free functional samples for testing.

5.How fast can you deliver?

2–3 weeks for most OEM configurations. Rush orders also available.

Let’s Build the Battery That Powers Your Innovation

At Himax, we believe a great product starts with a reliable power source. Whether you need a compact 22.2V battery pack or a high-capacity 48V pack, our engineers are ready to help you design, prototype, and mass-produce it.

Contact us now for a free！

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What Is the Best Storage Temperature for LiFePO4 Batteries During Long-Term Storage?

Lithium Iron Phosphate (LiFePO4) batteries are well known for their exceptional cycle life, safety, and stability. That’s why they’re widely used in solar storage, RVs, telecom systems, and industrial backup applications. But when it comes to long-term storage—such as during off-seasons or extended downtime—many users overlook the importance of proper storage temperature, which can significantly impact battery health and capacity retention.

At HIMAX Electronics, we design and manufacture reliable LiFePO4 battery packs for demanding applications. In this article, we explain the best practices for storing LiFePO4 batteries long-term, with a focus on optimal temperature conditions to avoid capacity loss and damage.

Why Storage Temperature Matters

Even when not in use, lithium batteries undergo slow chemical reactions and self-discharge. Extreme temperatures—either too hot or too cold—can accelerate cell degradation, shorten lifespan, and reduce available capacity once reactivated.

 

Proper storage conditions are essential to:

  • Prevent permanent loss of capacity
  • Avoid swelling or internal damage
  • Maintain safety and performance when reinstalled

Optimal Storage Temperature for LiFePO4 Batteries

According to industry standards and HIMAX Electronics testing data, the best storage temperature range for LiFePO4 batteries is :

Recommended Long-Term Storage Temperature:

10°C to 25°C (50°F to 77°F)

This range minimizes the rate of chemical aging and maintains the integrity of cell materials over months or even years.

Acceptable Short-Term Storage Range:

🔹 -10°C to 35°C (14°F to 95°F)
This range is safe for temporary storage (under 3 months), but long-term exposure should be avoided.

best_deep_cycle_batteries_for_rvs

Additional Storage Best Practices from HIMAX Electronics

1. Store at Partial State of Charge

For long-term storage (3 months or more), we recommend charging the battery to 40–60% before storage—not 100%.

This helps prevent over-voltage stress and leaves enough buffer for self-discharge.

2. Avoid Moisture and Humidity

Store batteries in a dry, ventilated space to prevent oxidation and internal corrosion. HIMAX batteries come with protective casings, but environmental moisture still poses a risk over time.

3. Check Every 3–6 Months

For extended storage periods, we advise checking voltage and state of charge at least twice a year. Recharge if the voltage drops below 3.2V per cell, or ~12.8V for a 4S pack.

4. No Metal Contact or Stack Pressure

Make sure terminals are insulated, and no heavy objects are stacked on the pack. Physical stress during storage can deform the casing or internal structure.

HIMAX Electronics Quality Commitment

At HIMAX Electronics, we build LiFePO4 battery packs using A-grade cells and advanced Battery Management Systems (BMS) to protect against overcharge, overdischarge, and thermal abuse. For our customers storing batteries in off-grid or backup scenarios, we also provide:

  • Custom storage enclosures with thermal insulation
  • Smart BMS with low-power sleep mode
  • Documentation for safe transportation and storage

Summary: Best Storage Practices for LiFePO4 Batteries

Parameter Recommended Value
Storage Temperature 10°C to 25°C (ideal), -10°C to 35°C (short-term)
State of Charge (SOC) 40% to 60% before storage
Humidity < 65% RH, dry and ventilated area
Storage Interval Check Every 3–6 months

rv_battery_comparison

Final Thoughts

Improper storage can shorten the lifespan of even the best battery. By following temperature and maintenance guidelines, you can ensure that your LiFePO4 batteries from HIMAX Electronics remain ready for service—whether next month or next year.

Need expert advice or custom LiFePO4 solutions? Contact HIMAX Electronics today and get support from our experienced battery engineers.

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How Advanced 3.7V & 7.4V Li-ion Batteries Enhance Smart Attendance Terminals

7.4V-4400mah-lithium-ion-battery

In the era of digital transformation, smart attendance terminals have become essential for modern workplaces, schools, and institutions. These devices require reliable, long-lasting power solutions to ensure seamless operation. HiMASSi 3.7V and 7.4V li-ion batteries (2000mAh–5000mAh), developed by Shenzhen Himax Electronics Co., Ltd., provide an efficient and durable power source for these systems. This article explores how these advanced batteries improve performance, efficiency, and sustainability in smart attendance solutions.

1. The Growing Demand for Smart Attendance Systems

Smart attendance terminals utilize biometric recognition (fingerprint, facial, or RFID technology) to track attendance accurately. Unlike traditional systems, they reduce human error and enhance security. However, these devices require stable and long-lasting power to function continuously.

Challenges: Frequent charging, battery degradation, and inconsistent power supply can disrupt operations.

Solution: High-capacity 3.7V and 7.4V Li-ion batteries ensure extended usage without frequent recharging.

 

2. Why HiMASSi 3.7V & 7.4V Li-ion Batteries Are Ideal for Smart Attendance Terminals

2.1 High Energy Density for Extended Usage

2000mAh–5000mAh capacity supports prolonged operation, reducing downtime.

Ideal for standalone terminals used in remote or high-traffic areas.

2.2 Stable Voltage Output (3.7V / 7.4V)

Ensures consistent performance for biometric scanners and data processing.

Prevents system crashes due to voltage fluctuations.

2.3 Long Cycle Life & Durability

500+ charge cycles with minimal capacity loss.

Built-in overcharge & over-discharge protection for enhanced safety.

2.4 Compact & Lightweight Design

Fits seamlessly into slim and portable attendance devices.

Enables flexible installation in various environments.

3. Applications in Modern Attendance Solutions

HiMASSi batteries power a variety of smart attendance systems, including:

Biometric Time Clocks (Facial/Fingerprint Recognition)

RFID Card-Based Attendance Systems

Mobile Attendance Devices (Used in fieldwork or construction sites)

AI-Powered Attendance Kiosks

These applications benefit from low self-discharge rates and fast recharge capabilities, ensuring 24/7 reliability.

4. Sustainability & Cost Efficiency

Rechargeable Li-ion technology reduces waste compared to disposable batteries.

Lower total cost of ownership due to long lifespan and minimal maintenance.

Compliance with RoHS & CE standards, ensuring eco-friendly production.

 

5. Future Trends: Smart Batteries for Smarter Attendance Systems

As IoT and cloud-based attendance tracking evolve, power demands will increase. Future advancements may include:

Smart battery management systems (BMS) for real-time monitoring.

Solar-compatible Li-ion batteries for off-grid solutions.

Higher-capacity models (6000mAh+) for AI-driven terminals.

2400mah-3.7v-battery

Conclusion

The HiMASSi 3.7V and 7.4V Li-ion batteries (2000mAh–5000mAh) from Shenzhen Himax Electronics Co., Ltd. provide a reliable, high-performance power solution for smart attendance terminals. With long-lasting energy, stable output, and robust safety features, these batteries ensure seamless operation in modern workforce management systems.

 

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How HiMASSi 18650 3.7V 2000-3500mAh Lithium-Ion Batteries Enhance Smart Lock Performance

3.7V-18650-battery-cell

In the era of smart homes, intelligent door locks have become a cornerstone of security and convenience. A critical component ensuring their reliability is the power source—specifically, high-performance lithium-ion batteries. HiMASSi 18650 3.7V 2000-3500mAh lithium-ion batteries, produced by Shenzhen Himax Electronics Co., Ltd., provide a stable and long-lasting power supply for smart locks. This article explores why these batteries are an optimal choice and addresses common challenges in smart lock applications.

Why Choose HiMASSi 18650 3.7V 2000-3500mAh for Smart Locks?

1. High Energy Density for Extended Usage

Smart locks require consistent power to maintain wireless connectivity, biometric recognition, and remote access features. The HiMASSi 18650 battery offers 2000-3500mAh capacity, ensuring months of uninterrupted operation. Its 3.7V voltage matches the power demands of most smart lock systems, reducing energy waste.

2. Enhanced Safety Features

Unlike low-quality alternatives, HiMASSi batteries incorporate:

Overcharge & Over-discharge Protection – Prevents damage from voltage fluctuations.

Thermal Stability – Minimizes risks of overheating, crucial for always-on devices.

Short-Circuit Prevention – Ensures safe operation even in faulty wiring scenarios.

3. Long Cycle Life & Cost Efficiency

With 500+ charge cycles, these batteries outlast standard alkaline cells, reducing replacement frequency. This makes them a cost-effective solution for both residential and commercial smart lock installations.

ICR 18650 Lithium-Ion Battery Pack 3.7V 2400mAh

Common Challenges & Solutions for 18650 Batteries in Smart Locks

While 18650 lithium-ion batteries are reliable, certain issues may arise in smart lock applications:

1. Problem: Voltage Drop in Low Temperatures

Issue: Lithium-ion batteries may experience reduced efficiency in cold environments (<0°C), leading to temporary power loss.

Solution: HiMASSi batteries use low-temperature-resistant electrolytes, maintaining stable discharge rates even in harsh climates.

2. Problem: Battery Drain Due to Frequent Connectivity

Issue: Smart locks with Wi-Fi/Bluetooth drain power faster when constantly syncing with apps.

Solution: Opt for higher-capacity 3500mAh variants or integrate energy-saving modes in lock firmware.

3. Problem: Swelling After Long-Term Use

Issue: Poor-quality Li-ion cells may swell due to internal degradation.

Solution: HiMASSi batteries employ premium electrode materials to delay aging. Regular maintenance (e.g., annual replacements) further mitigates risks.

4. Problem: Incompatibility with Some Smart Lock Models

Issue: Certain locks require specific battery dimensions or connectors.

Solution: Verify the 18650 size (18mm diameter, 65mm length) and voltage (3.7V) compatibility before installation.

26650 9.6V 3Ah battery

Conclusion: A Reliable Power Partner for Smart Security

The HiMASSi 18650 3.7V 2000-3500mAh lithium-ion battery stands out as a durable, safe, and high-capacity choice for smart locks. By addressing common pain points like temperature sensitivity and energy drain, Shenzhen Himax Electronics Co., Ltd. ensures seamless performance for modern security systems.

 

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Why Lithium Batteries Are the Ideal Power Source for Solar-Powered Surveillance Systems

backup-power-battery

As security becomes a greater concern in both urban and rural environments, solar-powered surveillance systems are emerging as a practical solution for remote monitoring. These systems are widely used in farms, parking lots, construction sites, and other off-grid areas where power access is limited. A critical component of every solar-powered surveillance system is its energy storage—and that’s where lithium batteries come in.

At Himax Electronics Co., Ltd., we specialize in the development and supply of custom lithium battery packs for solar monitoring systems. Our clients across North America, Europe, and Australia rely on us for dependable battery solutions that ensure stable performance in various outdoor conditions. But why are lithium batteries such a perfect fit for these systems? This article explores the key reasons and technical advantages in simple, clear terms.

1. Reliable Power Storage for Day and Night Operation

One of the main challenges of solar-powered equipment is energy fluctuation. While the sun can generate power during the day, the surveillance system still needs to operate at night or during cloudy weather. This is where a dependable battery becomes essential.

Lithium batteries, especially LiFePO4 (Lithium Iron Phosphate) types, are known for their high energy density and stable voltage output. They can store enough power during the day to keep the camera and communication systems running all night. Compared to lead-acid or NiMH batteries, lithium batteries can deliver consistent voltage over longer periods, ensuring uninterrupted surveillance.

At Himax, our most popular battery configurations for solar monitoring systems include:

3.7V 10Ah Li-ion battery packs

12V 20Ah or 50Ah LiFePO4 battery packs

25.2V 15Ah Li-ion battery packs (21700 cells)

Each pack is custom-made based on your equipment’s voltage, size, and current requirements.

2. Longer Lifespan in Harsh Outdoor Environments

Solar-powered surveillance systems are typically placed outdoors in extreme conditions—ranging from freezing winters to hot summers. This requires a battery that can withstand wide temperature ranges while maintaining performance and safety.

LiFePO4 batteries are especially suitable due to their strong thermal stability and long cycle life. Most Himax LiFePO4 packs operate between -20°C and +60°C, making them reliable even in deserts, mountains, or coastal regions. They also have a life cycle of 2000+ cycles, much longer than traditional lead-acid batteries that degrade after 300–500 cycles.

This long lifespan reduces maintenance needs, saving cost and effort for system owners—especially important in remote installations.

3. Lightweight and Space-Saving Design

When installing surveillance systems on poles or walls, battery weight and size matter. Heavy batteries require stronger mounting and increase installation complexity.

Lithium batteries are much lighter and more compact than lead-acid batteries with the same capacity. This allows the entire solar monitoring system to be smaller, neater, and easier to install.

For example, a 12V 20Ah LiFePO4 battery from Himax weighs around 2.5kg, while a similar-capacity lead-acid battery could weigh over 6kg. This compact design enables manufacturers to offer sleek, integrated camera units with solar panels and batteries all in one.

4. Fast Charging and High Efficiency

Solar-powered systems rely on efficient charging during limited daylight hours. The battery must be able to absorb solar energy quickly and efficiently before sunset.

Lithium batteries have a higher charging efficiency (over 95%) than lead-acid (around 70–80%), which means more solar power is stored in less time. They also support higher charge and discharge rates, making them well-suited for systems with varying power loads such as PTZ (Pan-Tilt-Zoom) cameras, motion sensors, and wireless transmitters.

Himax lithium battery packs come with smart BMS (Battery Management System) that optimizes charging performance while protecting the battery from over-voltage, over-current, and temperature issues.

5. Environmentally Friendly and Safe

More companies and governments are focusing on eco-friendly solutions. Lithium batteries are cleaner and safer than other battery types.

LiFePO4 batteries contain no toxic heavy metals and are easier to recycle. They are also chemically stable, with low risk of explosion or leakage, making them ideal for unattended installations in public or wildlife areas.

6. Smart Customization for Unique Projects

Each surveillance system is different. Some require high-current output, others need compact designs. This is where working with a custom battery manufacturer like Himax adds real value.

We work closely with our clients to design custom battery packs that fit their system’s housing, match voltage and current needs, and include the correct connectors (such as DC5521, XT60, or Molex).

We also support features like:

USB-C charging

Waterproof casing

LED power indicators

Built-in heating for cold climates

This customization allows our customers to launch products faster, reduce design errors, and improve end-user satisfaction.

Conclusion: Himax Powers Smarter, Safer Surveillance

As demand for off-grid security solutions increases, solar-powered surveillance systems are becoming a critical part of infrastructure, agriculture, logistics, and public safety. These systems depend on high-performance batteries to ensure reliability—day and night, summer or winter.

Lithium batteries offer the perfect balance of power, safety, longevity, and efficiency, making them the best energy storage solution for solar surveillance devices. Whether you’re installing a single unit or deploying hundreds across a city or rural area, choosing the right battery is key to system success.

At Himax Electronics Co., Ltd., we help manufacturers and solution providers power their solar security systems with dependable lithium battery packs. With over 13 years of experience in Li-ion and NiMH battery customization, advanced production capabilities, and global export expertise, we’re ready to support your next project.

If you’re looking for a long-term battery partner for solar surveillance systems, contact Himax today. Let’s build smarter security together.

 

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Why Lithium Batteries Are the Best Choice for Heated Lunch Boxes

electric-lunch-box-battery

In today’s fast-paced world, convenience and mobility are no longer luxuries—they are expectations. One device that has grown increasingly popular in recent years is the heated lunch box, allowing users to enjoy warm meals anytime and anywhere. From office workers and students to delivery drivers and field engineers, the demand for portable, reliable food-heating solutions continues to rise. Among the various power options available, lithium batteries have emerged as the top choice for this application. At Himax Electronics Co., Ltd., we specialize in providing reliable lithium battery packs tailored to heated lunch box manufacturers worldwide. But why are lithium batteries such a smart fit for this niche product? Let’s explore the reasons in detail.

7.4V lithium 18650 battery

1. Compact Size and Lightweight Advantage

One of the key selling points of a heated lunch box is its portability. Users expect the device to be easy to carry, especially when used in commuting or outdoor environments. This is where lithium batteries shine.

Lithium-ion and lithium-polymer (LiPo) batteries offer superior energy density compared to traditional battery types like nickel-metal hydride (NiMH) or sealed lead-acid (SLA) batteries. This means more power can be stored in a smaller and lighter package, directly benefiting the design of lunch boxes. Manufacturers can reduce the size and weight of the unit without sacrificing performance.

At Himax, we’ve developed custom lithium battery packs such as 3.7V 5000mAh or 7.4V 4000mAh configurations that are slim and compact enough to fit into small compartments, all while powering a heating element for up to an hour or more.

2. Higher Efficiency and Stable Output

A heated lunch box needs to deliver consistent heating performance, typically using a low-voltage heating plate or ceramic heating element. To do this effectively, the battery must deliver a stable output over the entire discharge cycle.

Lithium batteries are known for their flat discharge curve, which means they can maintain a consistent voltage output until the charge is nearly depleted. This contrasts with NiMH batteries, whose voltage drops more rapidly during use. This consistent power delivery is essential to keep food heated evenly, avoiding cold spots or underperformance.

Moreover, lithium batteries are highly efficient, reducing energy loss during discharge. For users, this translates into faster heating times and longer operating durations, even in compact designs.

3. Fast Charging Capabilities

Nobody wants to wait hours for their lunch box battery to recharge. One of the greatest benefits of lithium battery technology is its fast charging capability.

Lithium batteries typically support 1C charging rates, and with smart Battery Management Systems (BMS), can be safely recharged in 1 to 2 hours depending on capacity. Some advanced models even support USB-C charging, allowing users to top up the battery using power banks, car chargers, or wall adapters.

At Himax, we offer custom charging solutions, integrating protection circuits and smart charging modules that ensure both safety and speed, giving users peace of mind.

4. Longer Lifespan for Daily Use

Heated lunch boxes are often used daily, so battery durability becomes a major consideration. Fortunately, lithium batteries are built for longevity.

Whereas NiMH or SLA batteries may last for a few hundred cycles, LiFePO4 and Li-ion batteries can exceed 800–1000 charge/discharge cycles with proper care. This means the battery will continue to perform well even after a year or two of daily use.

Longer battery life also contributes to lower maintenance costs and a better user experience over time, reducing the need for frequent replacements.

Himax’s lithium battery packs are rigorously tested to meet international safety and durability standards (such as UN38.3, MSDS, CE, and RoHS), ensuring that manufacturers can confidently deliver a product that lasts.

5. Enhanced Safety Features

Safety is critical, especially when combining electricity with food and heat. Lithium battery packs designed for lunch boxes must be robust against overcharging, overheating, and short-circuit risks.

Modern lithium batteries come with built-in Battery Management Systems (BMS), which offer multiple levels of protection:

Overcharge/over-discharge protection

Short circuit protection

Temperature control

Balance charging (in multi-cell configurations)

At Himax, we customize our lithium battery packs with advanced BMS modules tailored to the application, ensuring safe performance in a wide range of environments—including offices, schools, and outdoors.

6. Eco-Friendly and Compliant with Regulations

Consumers are becoming more environmentally conscious, and product regulations are getting stricter worldwide. Compared to older battery chemistries, lithium batteries are more eco-friendly, especially LiFePO4, which contains no toxic heavy metals.

They are easier to recycle, and thanks to their longer lifespan, generate less electronic waste over time. Most importantly, lithium batteries meet the requirements of RoHS, REACH, and UN38.3 transport regulations—essential for global export.

Himax helps manufacturers meet these requirements by providing complete certification documentation, simplifying the compliance process.

lithium 7.4V 8ah

Conclusion: Himax Powers a Smarter Lunch Experience

Heated lunch boxes are not just a gadget—they represent a shift toward healthier, more convenient lifestyles. And powering them efficiently and safely is at the core of delivering user satisfaction.

Lithium batteries offer a perfect blend of power, size, reliability, and safety, making them the ideal energy source for this application. Whether it’s rapid heating, compact form factors, or long battery life, lithium technology checks all the boxes.

At Himax Electronics Co., Ltd., we bring over 13 years of experience in customizing Lithium and NiMH battery packs for global B2B clients. Our batteries power not only lunch boxes but also Bluetooth devices, medical tools, and portable lighting systems.

If you’re a manufacturer of heated lunch boxes looking for a reliable battery partner, contact Himax today—we’re ready to help you bring innovation and power into the hands of your customers.

 

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Can a Lithium Ion Battery Cell Be Reused After an Internal Short Circuit If It Passes Retesting?

high energy density lithium ion battery pack

During lithium ion battery manufacturing, internal short circuits in cells are a critical and potentially hazardous issue. In some cases, a shorted cell may later appear “normal” during retesting—for example, the voltage may recover, and no abnormal heat is detected. This leads many engineers to ask: Can a li-ion battery cell that once experienced an internal short circuit be reused if it passes retesting?

 

This article provides a detailed technical analysis and gives a clear conclusion:
Reusing such cells is strongly discouraged. Even if retesting results appear normal, the cell must be scrapped.

li-ion 18650 battery

1. Hidden and Recurrent Risks of Internal Short Circuits

Internal short circuits are typically caused by:

  • Metallic contaminants such as copper or aluminum particles;
  • Burrs on electrode edges piercing the separator;
  • Minor damage or thermal shrinkage of the separator.

These types of defects can be difficult to detect and may recur unpredictably. For example:

  • Metal particlesmay initially cause a short and then melt due to localized heat, seemingly “resolving” the problem. However, they can remain in the cell and trigger a short again later.
  • Copper debrismay lead to a cycle of melting and re-connection, resulting in intermittent short circuits.
  • Burr-induced shortsmay not be detected under low current testing but can reappear during high-rate charge/discharge cycles.

 

2. Irreversible Material Damage From Short Circuits

Even if the cell voltage returns to normal, the internal structure may already be compromised:

  • High temperatures at the short circuit site may melt the separator, enlarging pores or causing internal leakage;
  • Decomposition of active materials or conductive additivesmay occur;
  • These conditions accelerate side reactions, reducing capacity and increasing risk of failure.

Studies show that even after retesting, such cells may have near-normal capacity but significantly reduced coulombic efficiency (e.g., 99.3% vs. 99.9% in normal cells), indicating that side reactions are still active. This leads to faster degradation and higher thermal risk over time.

3. Limitations of Standard Li-ion Battery Cell Testing Methods

Common testing methods used in lithium battery production have clear limitations when detecting micro short circuits:

  • Hi-Pot (high-voltage insulation) testsare not sensitive enough to detect tiny conductive particles;
  • OCV (Open Circuit Voltage) monitoringand self-discharge (K value) tests cannot identify very low leakage currents;
  • Temperature rise monitoringmay fail to detect localized heating or increased internal resistance during short test durations.

Therefore, even if a cell passes all routine tests, its safety cannot be guaranteed.

4. Recommendations and Preventive Measures

1. All Cells With Any Short Circuit History Must Be Scrapped

Regardless of retest results, any cell that has experienced an internal short circuit must be classified as a non-conforming product and scrapped immediately. Continuing to use such cells may result in sudden failures in the field or act as a “weak link” in a battery pack, triggering systemic risks.

2. Process Optimization to Prevent Internal Short Circuits

 

  • Strengthen material cleanliness control to prevent contamination;
  • Optimize slitting, winding, or stacking processes to minimize burrs;
  • Use high-strength, thermally stable separator materials;
  • Introduce advanced detection technologies, such as X-ray inspection or micro-current leakage detection.

5. Conclusion: Prioritize Safety, Eliminate Risk at the Source

Lithium batteries are high-energy devices. Any potential defect poses a serious safety hazard. Even if a cell appears normal after an internal short circuit, the underlying risk remains. Eliminating such cells from the production line is the only responsible action.

True product safety and reliability come not from relying on retests, but from improving production processes and early-stage quality control.

For more information on lithium battery quality standards or internal short circuit prevention strategies, feel free to contact our team for support.

 

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How to Make a Safer Battery-Powered Surgical Robotics?

robotics_power_solutions

Lithium Battery Packs for Prosthetics and Exoskeletons

As the global medical device industry embraces the future of intelligent healthcare, battery-powered surgical robotics, including advanced prosthetics and wearable exoskeletons, are becoming more common in both rehabilitation and assistive mobility. At the heart of these robotic systems lies a vital component—the battery pack—which must be compact, lightweight, and most importantly, safe and reliable.

At HIMAX ELECTRONICS, we are a lithium battery manufacturer with over 12 years of experience, specializing in lithium-ion (Li-ion) battery packs, LiFePO4 battery packs, and LIPO battery solutions. In this blog, we explore the battery types used in mainstream prosthetic limbs and exoskeleton robots, the advantages of our promoted models, and trends shaping the future of medical robotics.

Powering Prosthetic Limbs: Lithium-Ion Battery Pack Applications

Modern myoelectric prosthetics from leading brands like Ottobock, Össur, and Open Bionics rely heavily on lithium-ion battery packs due to their compact size and high energy density. These artificial limbs require smooth, controlled motion powered by actuators and sensors—making a stable power source essential.

Our Recommended Battery Models for Prosthetics:

  • 6V 3000mAh lithium-ion battery pack
  • 2V 5000mAh lithium-ion battery pack
  • 8V 5000mAh lithium-ion battery pack

Key Advantages:

  • Lightweight and compact– ideal for upper or lower limb prostheses
  • High energy density– longer usage time between charges
  • Custom BMS integration– ensures protection against overcharge, over-discharge, and short circuit
  • Fast charging– reduces downtime for active users

These battery packs are commonly used in robotic hands, elbow joints, and knee motors, ensuring responsive and adaptive performance.

Powering Exoskeleton Robots: The Role of LiFePO4 Battery Packs

Exoskeletons—developed by companies like ReWalk Robotics, Ekso Bionics, and SuitX—are wearable robotic systems designed to restore mobility or assist in heavy lifting and rehabilitation. These systems require higher voltage and longer cycle life, making LiFePO4 (Lithium Iron Phosphate) battery packs the preferred choice.

Our Recommended Battery Models for Exoskeletons:

  • 6V 10Ah LiFePO4 battery pack
  • 2V 20Ah LiFePO4 battery pack

Key Advantages:

  • Exceptional thermal stability– minimizes fire risk during long-duration usage
  • 2,000+ cycle life– supports long-term rehabilitation or industrial usage
  • Low heat generation– safer for wearable devices close to the human body
  • Smart BMS compatibility– real-time monitoring and Bluetooth/serial diagnostics

These battery packs are suitable for lower-body or full-body exoskeletons, where high peak power and safe operation are critical.

Market Trends and Future Outlook

With the growing demand for wearable robotics in both medical and industrial applications, the trend is moving toward lighter, smarter, and safer battery solutions:

  • Miniaturization and modular battery designfor better device ergonomics
  • Integration with AI and IoT– batteries that communicate real-time status to healthcare professionals
  • Wireless and inductive chargingfor seamless user experience
  • Greener materials– shift toward eco-friendly battery chemistries like LiFePO4

Battery packs that combine safety, intelligence, and energy efficiency will dominate the future of prosthetic and exoskeleton technologies.

Why Choose HIMAX Battery Packs for Surgical Robotics?

At HIMAX ELECTRONICS, our medical-grade lithium battery packs are:

  • Manufactured in-house with automated production lines
  • Designed with BMS safety protocols
  • Available with custom shapes, casings, and connectors
  • Compliant with global certifications like 3, CE, RoHS, IEC62133

We offer OEM/ODM services for robotic startups, device manufacturers, and medical research teams looking for stable and reliable power solutions.

robotics-battery

Conclusion: Enabling Safer, Smarter Surgical Robotics Starts With the Battery

As prosthetics and exoskeletons continue to evolve, selecting the right lithium battery pack—whether it’s a 21.6V, 22.2V, 28.8V lithium-ion battery or a 25.6V, 51.2V LiFePO4 battery pack—will determine not only the performance but the safety and user experience of the device.

Let HIMAX ELECTRONICS be your trusted battery partner in building the future of surgical and assistive robotics.

✅ Need a customized battery pack for your prosthetic or exoskeleton project?
Get in touch with us for datasheets, samples, or a one-on-one engineering consultation.

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What to Pay Attention to When Using Li-ion 18650 Battery Packs in Security Systems

high-quality-18650-battery-holder-materials

Security systems—whether for homes, businesses, or industrial facilities—rely heavily on uninterrupted power to keep surveillance and alarm equipment operational. Li-ion 18650 battery packs have become the preferred power source due to their high energy density, long cycle life, and compact form factor. However, like all advanced technologies, they require proper handling and integration to perform safely and effectively.

At HIMAX Electronics, we specialize in designing and assembling high-performance Li-ion battery packs tailored for critical applications like security systems. In this article, we’ll outline the key points you need to pay attention to when using 18650 lithium-ion battery packs in your security solutions.

1. Battery Pack Design and Configuration

Each security system has different power demands based on camera quantity, data transmission, and backup requirements. Choosing the right series-parallel configuration of 18650 cells is essential:

  • Voltage Requirements:Most systems run on 12V or 24V, which means using a 3S or 7S configuration respectively.
  • Capacity and Runtime:Evaluate the amp-hour rating needed to keep your system running during outages. HIMAX Electronics offers custom 18650 packs up to 20Ah or more for extended runtime.

Tip: Always balance power requirements with physical space availability in enclosures.

2. Incorporation of a Smart Battery Management System (BMS)

A high-quality BMS is non-negotiable for safety and performance. HIMAX Electronics integrates intelligent BMS modules into every 18650 pack we produce to:

  • Prevent overcharging, overdischarging, and short circuits
  • Enable cell balancing to maximize lifespan
  • Support communication protocols (UART, CAN, SMBus) for remote monitoring

 

Important: Never use a pack without a properly rated BMS—doing so can risk fire or permanent system damage.

3. Thermal Management and Placement

Security systems often operate in confined, weatherproof enclosures or attics where heat buildup is an issue. 18650 batteries are sensitive to high temperatures.

  • Ideal Operating Temperature:0°C to 45°C (charge), -20°C to 60°C (discharge)
  • Avoid placing packs near heat-generating electronics or under direct sunlight
  • Consider passive or active cooling methods for high-load systems

HIMAX Electronics also offers temperature-sensor integrated BMS for enhanced safety shutdowns.

4. Regular Maintenance and Monitoring

Even the best 18650 packs degrade over time. Set up routine inspection and software-based battery health monitoring to detect:

  • Voltage imbalance between cells
  • Capacity fade
  • Abnormal charging/discharging rates

Some HIMAX smart packs include app or PC software interfaces to allow real-time diagnostics.

5. Storage and Backup Power Readiness

Security systems must be ready 24/7—even after weeks or months of low activity. Ensure:

  1. Packs are stored at 40–60% state of charge if unused for long periods
  2. Recharge every 3–6 months to avoid deep discharge
  3. Always test the system’s backup runtime quarterly

HIMAX Electronics uses low self-discharge cells and industrial-grade assembly to maintain long-term stability in standby mode.

6. Certifications and Compliance

Security systems often fall under building safety regulations. Use certified batteries to ensure regulatory compliance:

  • 3 for transportation
  • IEC62133 for safety
  • CE/RoHS for environmental compliance

HIMAX Electronics ensures every battery pack complies with international standards, helping integrators and installers pass inspections with confidence.

sodium battery 18650

Conclusion

Using Li-ion 18650 battery packs in security systems offers outstanding benefits—but only when properly designed, integrated, and maintained. At HIMAX Electronics, we understand the critical importance of reliability in life-safety systems. That’s why we engineer our battery packs with precision, safety, and long-term performance in mind.

For custom battery solutions tailored to your security system’s requirements, contact HIMAX Electronics today. Our engineers are ready to help you power your peace of mind.