Learn about the difference of energy and power requirements in a battery.

The early Li-ion battery was considered fragile and unsuitable for high loads. This has changed, and today lithium-based systems stand shoulder to shoulder with the robust nickel and lead chemistries. Two basic types of Li-ion have emerged: The Energy Cell and the Power Cell.

The performance of these two battery types is characterized by energy storage, also known as capacity, and current delivery, also known as loading or power. Energy and power characteristics are defined by particle size on the electrodes. Larger particles increase the surface area for maximum capacity and fine material decreases it for high power.

Decreasing particle size lowers the presence of electrolyte that fills the voids. The volume of electrolyte within the cell determines battery capacity. Decreasing the particle size reduces the voids between the particles, thereby lowering the electrolyte content. Too little electrolyte reduces ionic mobility and affects performance. Think of a drying felt pen that needs recuperating to keep marking papers.

Energy Cell

The Li-ion Energy Cell is made for maximum capacity to provide long runtimes. The Panasonic NCR18650B Energy Cell (Figure 1) has high capacity but is less enduring when discharged at 2C. At the discharge cutoff of 3.0V/cell, the 2C discharge produces only about 2.3Ah rather than the specified 3.2Ah. This cell is ideal for portable computing and similar light duties.

Figure 1: Discharge characteristics of NCR18650B Energy Cell by Panasonic.
The 3,200mAh Energy Cell is discharged at 0.2C, 0.5C, 1C and 2C. The circle at the 3.0V/cell line marks the end-of-discharge point at 2C.

Cold temperature losses:
25°C (77°F) = 100%
0°C (32°F) = ~83%
–10°C (14°F) = ~66%
–20°C (4°F) = ~53%
^{Source: Panasonic}

Power Cell

The Panasonic UR18650RX Power Cell (Figure 2) has a moderate capacity but excellent load capabilities. A 10A (5C) discharge has minimal capacity loss at the 3.0V cutoff voltage. This cell works well for applications requiring heavy load current, such as power tools.

Figure 2: Discharge characteristics of UR18650RX Power Cell by Panasonic.
The 1950mAh Power Cell is discharged at 0.2C, 0.5C, 1C and 2C and 10A. All reach the 3.0V/cell cut-off line at about 2000mAh. The Power Cell has moderate capacity but delivers high current.

Cold temperature losses:
25°C (77°F) = 100%
0°C (32°F) = ~92%
–10°C (14°F) = ~85%
–20°C (4°F) = ~80%

^{Source: Panasonic}

The Power Cell permits a continuous discharge of 10C. This means that an 18650 cell rated at 2,000mAh can provide a continuous load of 20A (30A with Li-phosphate). The superior performance is achieved in part by lowering the internal resistance and by optimizing the surface area of active cell materials. Low resistance enables high current flow with minimal temperature rise. Running at the maximum permissible discharge current, the Li-ion Power Cell heats to about 50ºC (122ºF); the temperature is limited to 60ºC (140ºF).

To meet the loading requirements, the pack designer can either use a Power Cell to meet the discharge C-rate requirement or go for the Energy Cell and oversize the pack. The Energy Cell holds about 50 percent more capacity than the Power Cell, but the loading must be reduced. This can be done by oversizing the pack, a method the Tesla EVs use. The battery achieves exceptional runtime but it gets expensive and heavy.

Discharge Signature

One of the unique qualities of nickel- and lithium-based batteries is the ability to deliver continuous high power until the battery is exhausted; a fast electrochemical recovery makes it possible. Lead acid is slower and this can be compared to a drying felt pen that works for short markings on paper and then needs rest to replenish the ink. While the recovery is relatively fast on discharge, and this can be seen when cranking the engine, the slow chemical reaction becomes obvious when charging. This only gets worse with age.

A battery may discharge at a steady load of, say, 0.2C as in a flashlight, but many applications demand momentary loads at double and triple the battery’s C-rating. GSM (Global System for Mobile Communications) for a mobile phone is such an example (Figure 3). GSM loads the battery with up to 2A at a pulse rate of 577 micro-seconds (μs). This places a large demand on a small battery; however, with a high frequency, the battery begins to behave more like a large capacitor and the battery characteristics change.

Figure 3: GSM discharge pulses of a cellular phone.
The 577 microsecond pulses drawn from the battery adjust to field strength and can reach 2 amperes.

^{Courtesy of Cadex}

In terms of longevity, a battery prefers moderate current at a constant discharge rather than a pulsed or momentary high load. Figure 4 demonstrates the decreasing capacity of a NiMH battery at different load conditions from a gentle 0.2C DC discharge, an analog discharge to a pulsed discharge. Most batteries follow a similar pattern in terms of load conditions, including Li-ion.

Figure 4: Cycle life of NiMH under different load conditions.
NiMH performs best with DC and analog loads; digital loads lower the cycle life. Li-ion behaves similarly.

^{Source: Zhang (1998)}

Figure 5 examines the number of full cycles a Li-ion Energy Cell can endure when discharged at different C-rates. At a 2C discharge, the battery exhibits far higher stress than at 1C, limiting the cycle count to about 450 before the capacity drops to half the level.

Figure 5: Cycle life of Li-ion Energy Cell at varying discharge levels.
The wear and tear of all batteries increases with higher loads. Power Cells are more robust than Energy Cells.

^{Source: Choi et al (2002)}

Simple Guidelines for Discharging Batteries

• Heat increases battery performance but shortens life by a factor of two for every 10°C increase above 25–30°C (18°F above 77–86°F). Always keep the battery cool.
• Prevent over-discharging. Cell reversal can cause an electrical short.
• On high load and repetitive full discharges, reduce stress by using a larger battery.
• A moderate DC discharge is better for a battery than pulse and heavy momentary loads.
• A battery exhibits capacitor-like characteristics when discharging at high frequency. This allows higher peak currents than is possible with a DC load.
• Nickel- and lithium-based batteries have a fast chemical reaction; lead acid is sluggish and requires a few seconds to recover between heavy loads.
• All batteries suffer stress when stretched to maximum permissible tolerances.

 

Learn how to extend battery life by moderating ambient temperatures.

Batteries operate over a wide temperature range, but this does not give permission to also charge them at these conditions. The charging process is more delicate than discharging and special care must be taken. Extreme cold and high heat reduce charge acceptance, so the battery must be brought to a moderate temperature before charging.

Older battery technologies, such as lead acid and NiCd, have higher charging tolerances than newer systems. This allows them to charge below freezing but at a reduced charge C-rate. When it comes to cold-charging NiCd is hardier than NiMH.

Table 1 summarizes the permissible charge and discharge temperatures of common rechargeable batteries. The table excludes specialty batteries that are designed to charge outside these parameters.

Battery type	Charge temperature	Discharge temperature	Charge advisory
Lead acid	–20°C to 50°C (–4°F to 122°F)	–20°C to 50°C (–4°F to 122°F)	Charge at 0.3C or lessbelow freezing. Lower V-threshold by 3mV/°C when hot.
NiCd, NiMH	0°C to 45°C (32°F to 113°F)	–20°C to 65°C (–4°F to 149°F)	Charge at 0.1C between –18°C and 0°C. Charge at 0.3C between 0°C and 5°C. Charge acceptance at 45°C is 70%. Charge acceptance at 60°C is 45%.
Li-ion	0°C to 45°C (32°F to 113°F)	–20°C to 60°C (–4°F to 140°F)	No charge permitted below freezing. Good charge/discharge performance at higher temperature but shorter life.

Table 1: Permissible temperature limits for various batteries. Batteries can be discharged over a large temperature range, but the charge temperature is limited. For best results, charge between 10°C and 30°C (50°F and 86°F). Lower the charge current when cold.

Low-temperature Charge

Fast charging of most batteries is limited to 5°C to 45°C (41°F to 113°F); for best results consider narrowing the temperature bandwidth to between 10°C and 30°C (50°F and 86°F) as the ability to recombine oxygen and hydrogen diminishes when charging nickel-based batteries below 5°C (41°F). If charged too quickly, pressure builds up in the cell that can lead to venting. Reduce the charge current of all nickel-based batteries to 0.1C when charging below freezing.

Nickel-based chargers with NDV full-charge detection offer some protection when fast charging at low temperatures; the poor charge acceptance when cold mimics a fully charged battery. This is in part caused by a high pressure buildup due to the reduced ability to recombine gases at low temperature. Pressure rise and a voltage drop at full charge appear synonymous.

To enable fast charging at all temperatures, some industrial batteries add a thermal blanket that heats the battery to an acceptable temperature; other chargers adjust the charge rate to prevailing temperatures. Consumer chargers do not have these provisions and the end user is advised to only charge at room temperature.

Lead acid is reasonably forgiving when it comes to temperature extremes, as the starter batteries in our cars reveal. Part of this tolerance is credited to their sluggish behavior. The recommended charge rate at low temperature is 0.3C, which is almost identical to normal conditions. At a comfortable temperature of 20°C (68°F), gassing starts at charge voltage of 2.415V/cell. When going to –20°C (0°F), the gassing threshold rises to 2.97V/cell.

A lead acid battery charges at a constant current to a set voltage that is typically 2.40V/cell at ambient temperature. This voltage is governed by temperature and is set higher when cold and lower when warm. Figure 2 illustrates the recommended settings for most lead acid batteries. In parallel, the figure also shows the recommended float charge voltage to which the charger reverts when the battery is fully charged. When charging lead acid at fluctuating temperatures, the charger should feature voltage adjustment to minimize stress on the battery. (See also BU-403: Charging Lead Acid.)

 

Figure 2: Cell voltages on charge and float at various temperatures.
Charging at cold and hot temperatures requires adjustment of voltage limit.

Freezing a lead acid battery leads to permanent damage. Always keep the batteries fully charged because in the discharged state the electrolyte becomes more water-like and freezes earlier than when fully charged. According to BCI, a specific gravity of 1.15 has a freezing temperature of –15°C (5°F). This compares to –55°C (–67°F) for a specific gravity of 1.265 with a fully charged starter battery. Flooded lead acid batteries tend to crack the case and cause leakage if frozen; sealed lead acid packs lose potency and only deliver a few cycles before they fade and need replacement.

Li ion can be fast charged from 5°C to 45°C (41 to 113°F). Below 5°C, the charge current should be reduced, and no charging is permitted at freezing temperatures because of the reduced diffusion rates on the anode. During charge, the internal cell resistance causes a slight temperature rise that compensates for some of the cold. The internal resistance of all batteries rises when cold, prolonging charge times noticeably.

Many battery users are unaware that consumer-grade lithium-ion batteries cannot be charged below 0°C (32°F). Although the pack appears to be charging normally, plating of metallic lithium can occur on the anode during a sub-freezing charge. This is permanent and cannot be removed with cycling. Batteries with lithium plating are more vulnerable to failure if exposed to vibration or other stressful conditions. Advanced chargers (Cadex) prevent charging Li-ion below freezing.

Advancements are being made to charge Li-ion below freezing temperatures. Charging is indeed possible with most lithium-ion cells but only at very low currents. According to research papers, the allowable charge rate at –30°C (–22°F) is 0.02C. At this low current, the charge time would stretch to over 50 hours, a time that is deemed impractical. There are, however, specialty Li-ions that can charge down to –10°C (14°F) at a reduced rate.

High-temperature Charge

Heat is the worst enemy of batteries, including lead acid. Adding temperature compensation on a lead acid charger to adjust for temperature variations is said to prolong battery life by up to 15 percent. The recommended compensation is a 3mV drop per cell for every degree Celsius rise in temperature. If the float voltage is set to 2.30V/cell at 25°C (77°F), the voltage should read 2.27V/cell at 35°C (95°F). Going colder, the voltage should be 2.33V/cell at 15°C (59°F). These 10°C adjustments represent 30mV change.

Table 3 indicates the optimal peak voltage at various temperatures when charging lead acid batteries. The table also includes the recommended float voltage while in standby mode.

BATTERY STATUS	-40°C (-40°F)	-20°C (-4°F)	0°C (32°F)	25°C (77°F)	40°C (104°F)
Voltage limit on recharge	2.85V/cell	2.70V/cell	2.55V/cell	2.45V/cell	2.35V/cell
Float voltage at full charge	2.55V/cell or lower	2.45V/cell or lower	2.35V/cell or lower	2.30V/cell or lower	2.25V/cell or lower

Table 3: Recommended voltage limits when charging and maintaining stationary lead acid batteries on float charge. Voltage compensation prolongs battery life when operating at temperature extremes.

Charging nickel-based batteries at high temperatures lowers oxygen generation, which reduces charge acceptance. Heat fools the charger into thinking that the battery is fully charged when it’s not.

Charging nickel-based batteries when warm lowers oxygen generation that reduces charge acceptance. Heat fools the charger into thinking that the battery is fully charged when it’s not. Figure 4 shows a strong decrease in charge efficiency from the “100 percent efficiency line” when dwelling above 30°C (86°F). At 45°C (113°F), the battery can only accept 70 percent of its full capacity; at 60°C (140°F) the charge acceptance is reduced to 45 percent. NDV for full-charge detection becomes unreliable at higher temperatures, and temperature sensing is essential for backup.

Figure 4: NiCd charge acceptance as a function of temperature. High temperature reduces charge acceptance and departs from the dotted “100% efficiency line.” At 55°C, commercial NiMH has a charge efficiency of 35–40%; newer industrial NiMH attains 75–80%.

Lithium-ion performs well at elevated temperatures but prolonged exposure to heat reduces longevity. Charging and discharging at elevated temperatures is subject to gas generation that might cause a cylindrical cell to vent and a pouch cell to swell. Many chargers prohibit charging above 50°C (122°F).

Some lithium-based packs are momentarily heated to high temperatures. This applies to batteries in surgical tools that are sterilized at 137°C (280°F) for up to 20 minutes as part of autoclaving. Oil and gas drilling as part of fracking also exposes the battery to high temperatures.

Capacity loss at elevated temperature is in direct relationship with state-of-charge (SoC). Figure 5 illustrates the effect of Li-cobalt (LiCoO2) that is first cycled at room temperature (RT) and then heated to 130°C (266°F) for 90 minutes and cycled at 20, 50 and 100 percent SoC. There is no noticeable capacity loss at room temperature. At 130°C with a 20 percent SoC, a slight capacity loss is visible over 10 cycles. This loss is higher with a 50 percent SoC and shows a devastating effect when cycled at full charge.

Figure 5: Capacity loss at room temperature (RT) and 130°C for 90 minutes
Sterilization of batteries for surgical power tools should be done at low SoC.

Test: LiCoO2/Graphite cells were exposed to 130°C for 90 min.at different SoC between each cycle.

Discover familiar battery formats, some of which going back to the late 1800s.

Early batteries of the 1700s and 1800s developed in Europe were mostly encased in glass jars. As batteries grew in size, jars shifted to sealed wooden containers and composite materials. In the 1890s, battery manufacturing spread from Europe to the United States and in 1896 the National Carbon Company successfully produced a standard cell for widespread consumer use. It was the zinc-carbon Columbia Dry Cell Battery producing 1.5 volts and measuring 6 inches in length.

With the move to portability, sealed cylindrical cells emerged that led to standards sizes. The International Electrochemical Commission (IEC), a non-governmental standards organization founded in 1906, developed standards for most rechargeable batteries. In around 1917, the National Institute of Standards and Technology formalized the alphabet nomenclature that is still used today. Table 1 summarizes these historic and current battery sizes.

Size	Dimensions	History
F cell	33 x 91 mm	Introduced in 1896 for lanterns; later used for radios; only available in nickel-cadmium today.
E cell	N/A	Introduced ca. 1905 to power box lanterns and hobby applications. Discontinued ca. 1980.
D cell	34.2 x 61.5mm	Introduced in 1898 for flashlights and radios; still current.
C cell	25.5 x 50mm	Introduced ca. 1900 to attain smaller form factor.
Sub-C	22.2 x 42.9mm 16.1mL	Cordless tool battery. Other sizes are ½, 4/5 and 5/4 sub-C lengths. Mostly NiCd.
B cell	20.1 x 56.8mm	Introduced in 1900 for portable lighting, including bicycle lights in Europe; discontinued in in North America in 2001.
A cell	17 x 50mm	Available in NiCd, NiMH and primary lithium; also in 2/3 and 4/5 sizes. Popular in older laptops and hobby applications.
AA cell	14.5 x 50mm	Introduced in 1907 as penlight battery for pocket lights and spy tool in WWI; added to ANSI standard in 1947.
AAA cell	10.5 x 44.5mm	Developed in 1954 to reduce size for Kodak and Polaroid cameras. Added to ANSI standard in 1959.
AAAA cell	8.3 x 42.5mm	Offshoot of 9V, since 1990s; used for laser pointers, LED penlights, computer styli, headphone amplifiers.
4.5V battery	67 x 62 x 22mm	Three cells form a flat pack; short terminal strip is positive, long strip is negative; common in Europe, Russia.
9V battery	48.5 x 26.5 x 17.5mm	Introduced in 1956 for transistor radios; contains six prismatic or AAAA cells. Added to ANSI standard in 1959.
18650	18 x 65mm 16.5mL	Developed in the mid-1990s for lithium-ion; commonly used in laptops, e-bikes, including Tesla EV cars.
26650	26 x 65mm 34.5mL	Larger Li-ion. Some measure 26x70mm sold as 26700. Common chemistry is LiFeO4 for UPS, hobby, automotive.
14500	14x 50mm	Li-ion, similar size to AA. (Observe voltage incompatibility: NiCd/NiMH = 1.2V, alkaline = 1.5V, Li-ion = 3.6V)
21700*	21 x 70mm	New (2016), used for the Tesla Model 3 and other applications, made by Panasonic, Samsung, Molicel, etc.
32650	32 x 65mm	Primarily in LiFePO4 (Lithium Iron Phosphate)

Table 1: Common old and new battery norms.
^{* The 21700 cell is also known as 2170. IEC norm calls for the second zero at the end to denote cylindrical format.}

Standardization included primary cells, mostly in zinc-carbon; alkaline emerged only in the early 1960s. With the growing popularity of the sealed nickel-cadmium in the 1950s and 1960s, new sizes appeared, many of which were derived from the “A” and “C” sizes. Beginning in the 1990s, makers of Li-ion departed from conventional sizes and invented their own standards.

A successful standard is the 18650 cylindrical cell. Developed in the early 1990s for lithium-ion, these cells are used in laptops, electric bicycles and even electric vehicles (Tesla). The first two digits of 18650 designate the diameter in millimeters; the next three digits are the length in tenths of millimeters. The 18650 cell is 18mm in diameter and 65.0mm in length.

Other sizes are identified with a similar numbering scheme. For example, a prismatic cell carries the number 564656P. It is 5.6mm thick, 46mm wide and 56mm long. P stands for prismatic. Because of the large variety of chemistries and their diversity within, battery cells do not show the chemistry.

Few popular new standards have immerged since the 18650 appeared in ca. 1991. Several battery manufacturers started experimenting using slightly larger diameters with sizes of 20x70mm, 21x70mm and 22x70mm. Panasonic and Tesla decided on the 21×70, so has Samsung, and other manufacturers followed. The “2170” is only slightly larger than the 18650 it but has 35% more energy (by volume). This new cell is used in the Tesla Model 3 while Samsung is looking at new applications in laptops, power tools, e-bikes and more. It is said that the best diameters in terms of manufacturability is between 18mm and 26mm and the 2170 sits in between. (The 2170 is also known as the 21700.) The 26650 introduced earlier never became a best-seller.

The 32650 is primarily available in LiFePO₄ (Lithium Iron Phosphate) with a nominal voltage of 3.2V/cell and a typical capacity of 5,000mAh. The dimensions are 32x65mm; true sizes may be slightly larger to allow for insulation and labels.

On the prismatic and pouch cell front, new cells are being developed for the electric vehicle (EV) and energy storage systems (ESS). Some of these formats may one day also become readily available similar to the 18650, made in high energy and high power versions, sourced by several manufacturers and sold at a competitive prices. Prismatic and pouch cells currently carry a higher price tag per Wh than the 18650.

The EV and ESS markets advance with two distinct philosophies: The use of a large number of small cells produced by an automated process as low cost, as done by Tesla, versus larger cells in the prismatic and pouch formats at a higher price per Wh for now, as done by other EV manufacturers. We have not seen clear winners of either format; time will tell.

Looking at the batteries in mobile phones and laptops, one sees a departure from established standards. This is due in part to the manufacturers’ inability to agree on a standard, meaning that most consumer devices come with custom-made cells or battery packs. Compact design and market demand are swaying manufacturers to go their own way. High volume with planned obsolescence allows the production of unique sizes in consumer products.

In the early days, a battery was perceived “big” by nature, and this is reflected in the sizing convention. While the “F” nomenclature may have been seen as mid-sized in the late 1800s, our forefathers did not anticipate that a battery resembling a credit card could power computers, phones and cameras. Running out of letters towards the smaller sizes led to the awkward numbering of AA, AAA and AAAA.

Since the introduction of the 9V battery in 1956, no new formats have emerged. Meanwhile portable devices lowered the operating voltages to between 3V and 5V. Switching six cells (6S) in series to attain 9V is expensive to manufacture, and a 3.6V alternative would serve better. This imaginary new pack would have a coding system to prevent charging primaries and select the correct charge algorithm for secondary chemistries.

Starter batteries for vehicles also follow battery norms that are based on the North American BCI, the European DIN and the Japanese JIS standards. These batteries are similar in footprint to allow swapping. Deep-cycle and stationary batteries follow no standardized norms and the replacement packs must be sourced from the original maker. The attempt to standardize electric vehicle batteries may not work and might follow the failed attempt to standardize laptop batteries in the 1990s.

Future Cell Formats

Standardization for Li-ion cell formats is diverse, especially for the electric vehicle. Research teams, including Fraunhofer,* examine and evaluate various formats and the most promising cell types until 2025 will be the pouch and the 21700 cylindrical formats. Looking further, experts predict the large-size prismatic Li-ion cell to domineer in the EV battery market. Meanwhile, Samsung and others bet on the prismatic cell, LG gravitates towards the pouch format and Panasonic is most comfortable with the 18650 and 21700 cylindrical cells.

Large battery systems for ESS, UPS, marine vessels and traction use mostly large format pouch cells stacked with light pressure to prolong longevity and prevent delamination. Thermal management is often done by plates drawing the heat between layers to the outside and liquid cooling.

Safety Concerns with Rechargeable Cells

Off-the-shelf cells have primarily been non-rechargeable and for public use. Typical applications are spares for flashlights, portable entertainment devices and remote controls. Accidental shorting with keys or coins in a jean pocket only causes an alkaline cell to heat up and not catch fire. The voltage collapses on an electrical short because of high internal resistance; removing the short stops the reaction. (See BU-304c: Battery Safety in Public.)

Rechargeable cells are normally encapsulated in a for-purpose pack. The exception is the 18650 available as a spare cell for vaping. Looking like a large AA cell, these Li-ion cells can inflict acute injury, even death, if mishandled. If shorted, an unprotected Li-ion cell will vent with flame. Once the jet-like explosion is in progress, removing the short no longer stops the reaction and the cell burns out. Li-ion’s ability to deliver high power is a characteristic that must be respected. (See also BU-304c: Battery Safety in Public.)

The 18650 cell can be made safe with built-in safety circuits described in BU-304b: Making Lithium-ion Safe. With protection, excessive current shuts the cell down, either momentarily by a heat element or permanently by an electric fuse. But the fused 18650 has the disadvantage of shutting down when high current is needed on purpose, such as vaping. Spare cells for vaping are normally unprotected.

Another cause of fire is low quality no-brand cells. Li-ion batteries are safe if made by a reputable manufacturer. Many aftermarket cells do not have the same rigorous safety checks as brand name products have. (See BU-810: What Everyone Should Know About Aftermarket Batteries.) Cells can also be damaged by stress related to heat, shock, vibration and incorrect charging or loading.

Learn how to extend battery life by moderating ambient temperatures.

Batteries operate over a wide temperature range, but this does not give permission to also charge them at these conditions. The charging process is more delicate than discharging and special care must be taken. Extreme cold and high heat reduce charge acceptance, so the battery must be brought to a moderate temperature before charging.

Older battery technologies, such as lead acid and NiCd, have higher charging tolerances than newer systems. This allows them to charge below freezing but at a reduced charge C-rate. When it comes to cold-charging NiCd is hardier than NiMH.

Table 1 summarizes the permissible charge and discharge temperatures of common rechargeable batteries. The table excludes specialty batteries that are designed to charge outside these parameters.

Battery type	Charge temperature	Discharge temperature	Charge advisory
Lead acid	–20°C to 50°C (–4°F to 122°F)	–20°C to 50°C (–4°F to 122°F)	Charge at 0.3C or lessbelow freezing. Lower V-threshold by 3mV/°C when hot.
NiCd, NiMH	0°C to 45°C (32°F to 113°F)	–20°C to 65°C (–4°F to 149°F)	Charge at 0.1C between –18°C and 0°C. Charge at 0.3C between 0°C and 5°C. Charge acceptance at 45°C is 70%. Charge acceptance at 60°C is 45%.
Li-ion	0°C to 45°C (32°F to 113°F)	–20°C to 60°C (–4°F to 140°F)	No charge permitted below freezing. Good charge/discharge performance at higher temperature but shorter life.

Table 1: Permissible temperature limits for various batteries. Batteries can be discharged over a large temperature range, but the charge temperature is limited. For best results, charge between 10°C and 30°C (50°F and 86°F). Lower the charge current when cold.

Low-temperature Charge

Fast charging of most batteries is limited to 5°C to 45°C (41°F to 113°F); for best results consider narrowing the temperature bandwidth to between 10°C and 30°C (50°F and 86°F) as the ability to recombine oxygen and hydrogen diminishes when charging nickel-based batteries below 5°C (41°F). If charged too quickly, pressure builds up in the cell that can lead to venting. Reduce the charge current of all nickel-based batteries to 0.1C when charging below freezing.

Nickel-based chargers with NDV full-charge detection offer some protection when fast charging at low temperatures; the poor charge acceptance when cold mimics a fully charged battery. This is in part caused by a high pressure buildup due to the reduced ability to recombine gases at low temperature. Pressure rise and a voltage drop at full charge appear synonymous.

To enable fast charging at all temperatures, some industrial batteries add a thermal blanket that heats the battery to an acceptable temperature; other chargers adjust the charge rate to prevailing temperatures. Consumer chargers do not have these provisions and the end user is advised to only charge at room temperature.

Lead acid is reasonably forgiving when it comes to temperature extremes, as the starter batteries in our cars reveal. Part of this tolerance is credited to their sluggish behavior. The recommended charge rate at low temperature is 0.3C, which is almost identical to normal conditions. At a comfortable temperature of 20°C (68°F), gassing starts at charge voltage of 2.415V/cell. When going to –20°C (0°F), the gassing threshold rises to 2.97V/cell.

A lead acid battery charges at a constant current to a set voltage that is typically 2.40V/cell at ambient temperature. This voltage is governed by temperature and is set higher when cold and lower when warm. Figure 2 illustrates the recommended settings for most lead acid batteries. In parallel, the figure also shows the recommended float charge voltage to which the charger reverts when the battery is fully charged. When charging lead acid at fluctuating temperatures, the charger should feature voltage adjustment to minimize stress on the battery. (See also BU-403: Charging Lead Acid.)

Figure 2: Cell voltages on charge and float at various temperatures.
Charging at cold and hot temperatures requires adjustment of voltage limit.
^{Source: Betta Batteries}

Freezing a lead acid battery leads to permanent damage. Always keep the batteries fully charged because in the discharged state the electrolyte becomes more water-like and freezes earlier than when fully charged. According to BCI, a specific gravity of 1.15 has a freezing temperature of –15°C (5°F). This compares to –55°C (–67°F) for a specific gravity of 1.265 with a fully charged starter battery. Flooded lead acid batteries tend to crack the case and cause leakage if frozen; sealed lead acid packs lose potency and only deliver a few cycles before they fade and need replacement.

Li ion can be fast charged from 5°C to 45°C (41 to 113°F). Below 5°C, the charge current should be reduced, and no charging is permitted at freezing temperatures because of the reduced diffusion rates on the anode. During charge, the internal cell resistance causes a slight temperature rise that compensates for some of the cold. The internal resistance of all batteries rises when cold, prolonging charge times noticeably.

Many battery users are unaware that consumer-grade lithium-ion batteries cannot be charged below 0°C (32°F). Although the pack appears to be charging normally, plating of metallic lithium can occur on the anode during a sub-freezing charge. This is permanent and cannot be removed with cycling. Batteries with lithium plating are more vulnerable to failure if exposed to vibration or other stressful conditions. Advanced chargers (Cadex) prevent charging Li-ion below freezing.

Advancements are being made to charge Li-ion below freezing temperatures. Charging is indeed possible with most lithium-ion cells but only at very low currents. According to research papers, the allowable charge rate at –30°C (–22°F) is 0.02C. At this low current, the charge time would stretch to over 50 hours, a time that is deemed impractical. There are, however, specialty Li-ions that can charge down to –10°C (14°F) at a reduced rate.

High-temperature Charge

Heat is the worst enemy of batteries, including lead acid. Adding temperature compensation on a lead acid charger to adjust for temperature variations is said to prolong battery life by up to 15 percent. The recommended compensation is a 3mV drop per cell for every degree Celsius rise in temperature. If the float voltage is set to 2.30V/cell at 25°C (77°F), the voltage should read 2.27V/cell at 35°C (95°F). Going colder, the voltage should be 2.33V/cell at 15°C (59°F). These 10°C adjustments represent 30mV change.

Table 3 indicates the optimal peak voltage at various temperatures when charging lead acid batteries. The table also includes the recommended float voltage while in standby mode.

BATTERY STATUS	-40°C (-40°F)	-20°C (-4°F)	0°C (32°F)	25°C (77°F)	40°C (104°F)
Voltage limit on recharge	2.85V/cell	2.70V/cell	2.55V/cell	2.45V/cell	2.35V/cell
Float voltage at full charge	2.55V/cell or lower	2.45V/cell or lower	2.35V/cell or lower	2.30V/cell or lower	2.25V/cell or lower

Table 3: Recommended voltage limits when charging and maintaining stationary lead acid batteries on float charge. Voltage compensation prolongs battery life when operating at temperature extremes.

Charging nickel-based batteries at high temperatures lowers oxygen generation, which reduces charge acceptance. Heat fools the charger into thinking that the battery is fully charged when it’s not.

Charging nickel-based batteries when warm lowers oxygen generation that reduces charge acceptance. Heat fools the charger into thinking that the battery is fully charged when it’s not. Figure 4 shows a strong decrease in charge efficiency from the “100 percent efficiency line” when dwelling above 30°C (86°F). At 45°C (113°F), the battery can only accept 70 percent of its full capacity; at 60°C (140°F) the charge acceptance is reduced to 45 percent. NDV for full-charge detection becomes unreliable at higher temperatures, and temperature sensing is essential for backup.

Figure 4: NiCd charge acceptance as a function of temperature. High temperature reduces charge acceptance and departs from the dotted “100% efficiency line.” At 55°C, commercial NiMH has a charge efficiency of 35–40%; newer industrial NiMH attains 75–80%.
^{Courtesy of Cadex}

Lithium-ion performs well at elevated temperatures but prolonged exposure to heat reduces longevity. Charging and discharging at elevated temperatures is subject to gas generation that might cause a cylindrical cell to vent and a pouch cell to swell. Many chargers prohibit charging above 50°C (122°F).

Some lithium-based packs are momentarily heated to high temperatures. This applies to batteries in surgical tools that are sterilized at 137°C (280°F) for up to 20 minutes as part of autoclaving. Oil and gas drilling as part of fracking also exposes the battery to high temperatures.

Capacity loss at elevated temperature is in direct relationship with state-of-charge (SoC). Figure 5 illustrates the effect of Li-cobalt (LiCoO2) that is first cycled at room temperature (RT) and then heated to 130°C (266°F) for 90 minutes and cycled at 20, 50 and 100 percent SoC. There is no noticeable capacity loss at room temperature. At 130°C with a 20 percent SoC, a slight capacity loss is visible over 10 cycles. This loss is higher with a 50 percent SoC and shows a devastating effect when cycled at full charge.

Figure 5: Capacity loss at room temperature (RT) and 130°C for 90 minutes
Sterilization of batteries for surgical power tools should be done at low SoC.

Test: LiCoO2/Graphite cells were exposed to 130°C for 90 min.at different SoC between each cycle.
^{Source: Greatbatch Medical}

Caution:

In case of rupture, leaking electrolyte or any other cause of exposure to the electrolyte, flush with water immediately. If eye exposure occurs, flush with water for 15 minutes and consult a physician immediately.