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CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

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Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#31
Cells are subject to aggressive binning – akin to the early days of MOS process. And specs and process capability adhesion in the industry are not as "serious" as they are in the modern, U.S.-led semiconductor industry.

Source: I work on 100% Si anode batteries constructed in part with a litho-derived laser process at Enovix.

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#33
post #30

> Efest, Vapcell, Trustfire, Treasurecase, Benkia, SOOCOOL, Maxiaeon Sounds like a bunch of amazon merchants. Imagine buying lithium ion batteries from a vendor with "trust" and "fire" in their name at the same time.

Vapcell is very popular in the flashlight community for providing unusual sizes like 16340, 18350, 18500, 26800, etc.

They re-wrap other manufacturer's cells (but don't disclose who). I dislike this practice because, along with not knowing who makes the cell, you lose the original mfg batch codes, etc.

Sometimes they will simply rewrap something like a Samsung 50S. Those will be fine. But others ... who knows.

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#34
post #32

I went down their rabbit hole, and a conventional tech CT is 10 hours??

My understanding is that material composition can make a CT scan take a really long time. It makes sense to me that scanning a battery would be pretty slow, given what they're made out of.

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#35
post #15

Earlier quoted context omitted.

Won't help much. Way too much cheap lithium ion crap with incapsulated batteries is flooding the markets

It does help. It raise the opportunity to discuss it, which is helpful because not everyone is aware that this is a problem, and like many other lease clauses it is there to assign blame in case an exceptionally bad event comes to pass.

like many other lease clauses it is there to assign blame in case an exceptionally bad event comes to pass

That sounds like a job for the insurance company. You do have insurance, right? Did they have any input on this clause?

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#36
Seems like a good time to highlight this video from Grin Technologies and their experience with ebikes over the years.

https://www.youtube.com/watch?v=j92Gt4VviSQ

Summary Statement: He summarizes the results of the "sabotaging" attempts by saying, "we just couldn't for the life of ourselves get a nonprotected modern lithium battery to do anything" [02:40:27], in terms of causing a fire. (referring to 18650s)

There are certainly problems out there with cells but it was a surprising statement from someone with a ton of real-world experience. Also they are a very conscientious company so they don't deal with dodgy stuff if they can avoid it.

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#37
post #27

Your best predictor of cell failure is brand + where you sourced it. Good brand cells sourced through a reliable channel are pretty much impossible to get a failure out of without gross abuse of the cells. But far more dangerous than single cell failure is pack failure and there the quality of the welding and the balance wires is probably a much bigger factor than bad quality cells. You can easily create a nice looki…

> So buy packs made with quality cells and ensure that whoever makes the pack has proper welding gear and QA in place to avoid surprises. Never ever use cells without a BMS unless they are in a 1S configuration. How do you put that advice into action? When I'm in an electronics store, they don't typically let you look at the welds inside each battery bank. (And if they did, I have no idea what I'd be looking out for.…

Good point. It requires disassembly, and if you're not comfortable with that it is a lot harder to get a good idea on this. But there are plenty of videos and photos online of various disassembled packs from high volume manufacturers.

Quality cells are a relatively small group of brands so that should be easy enough to check for, and you'll know looking at just one side of a cell group whether or not it was put together half decently or whether it is messy.

Stuff to look for: loose balance wires, bad welds (welds that don't penetrate so they're loose), pointy edges of connecting strips that touch the plastic insulation of the cells, insufficient spacing between the cells, insufficient insulation near the welds.

For one-off purchases this won't help, but if you are a reseller or larger purchaser then it definitely is a good idea to tear down a pack and inspect.

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#38
post #2

To save everyone the hassle of filling out the "get the report" form: https://7802750.fs1.hubspotusercontent-na1.net/hubfs/7802750...

FWIW I found the report's summary (a few days ago when this was also discussed) essential for clarifying for me what the linked "article" was talking about regarding "anode overhang" and "edge alignment".

To summarize it myself, the battery is cylindrically wrapped sheets of anode/cathode material, and you want the top edge to have a straight line consistently having the anode layers (|) sticking out beyond the cathode layers ()

edit: Welp, the unicode I illustrated with got stripped out; so trying again with pipes

    anode
     cathode
      a a
       c c
    | | |
    ||||||
The pics with red and blue dots didn't immediately make this obvious to me, but made sense once I understood the "overhang" meaning.

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#39
post #34
post #32

I went down their rabbit hole, and a conventional tech CT is 10 hours??

My understanding is that material composition can make a CT scan take a really long time. It makes sense to me that scanning a battery would be pretty slow, given what they're made out of.

I just assumed it would be impractical due to physical changes of the object from multi-hour exposure to X-ray energy.

Re: CT scans of 1k lithium-ion batteries show quality risks in inexpensive cells

#40
post #38
post #2

To save everyone the hassle of filling out the "get the report" form: https://7802750.fs1.hubspotusercontent-na1.net/hubfs/7802750...

FWIW I found the report's summary (a few days ago when this was also discussed) essential for clarifying for me what the linked "article" was talking about regarding "anode overhang" and "edge alignment". To summarize it myself, the battery is cylindrically wrapped sheets of anode/cathode material, and you want the top edge to have a straight line consistently having the anode layers (|) sticking out beyond the catho…

So the big danger here is an internal short being far more likely?
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