Lumafield has printed the outcomes of its examine on the standard and security of lithium-ion batteries. The industrial x-ray CT expertise specialist’s examine evaluates over 1,000 18650 lithium-ion battery cells from ten manufacturers. Its outcomes revealed a big high quality hole between brand-name batteries and low-cost cells accessible by on-line marketplaces. Nearly 8% of low-cost or counterfeit batteries had been discovered to doubtlessly have a harmful defect generally known as adverse anode overhang. Moreover, key indicators of high quality in low-end batteries had been discovered to be seven occasions worse in comparison with name-brand choices.
Lithium-ion batteries present dense, transportable, rechargeable energy, and the 18650-form issue is ubiquitous. These cells can energy all the pieces from vapes and digital toothbrushes to medical units and choose electrical automobiles. Nevertheless, high quality ranges fluctuate considerably between brand-name unique gear producer (OEM) cells, re-wrap cells which have had their plastic wrapper eliminated and changed (usually with inflated specs), and low-cost or counterfeit cells.
Battery defects like adverse anode overhang and alignment misregistration can improve the chance of failure, impede the efficiency of the units they energy, or trigger catastrophic fires. In 2024, the Shopper Product Security Fee (CPSC) issued 26 remembers and 9 product security warnings associated to fireside and burn hazards posed by battery overheating.
Overview of the report’s findings
To analyse the standard of 18650 cells, the corporate utilised its Extremely-Quick CT scanning on over 100 cells from every of ten totally different manufacturers. The pattern included cells from high-quality OEMs to counterfeits. The important thing findings from the evaluation had been:
- Of the 1,054 battery cells scanned, 33 had adverse anode overhang.
- All 33 of the faulty cells got here from low-cost or counterfeit manufacturers, that means one in 13 low-cost/counterfeit batteries may have this defect.
- One low-cost model purchased on Temu had a 15% charge of adverse anode overhang defects.
- Low-cost/counterfeit batteries are seven occasions worse than their OEM counterparts in different high quality measures.
- Low-cost/counterfeit 18650 cells had 50% worse edge alignment in comparison with OEM cells, which might result in efficiency degradation and inner brief circuits.
- Not one of the brand-name OEM cells from Murata, Samsung, and Panasonic suffered from adverse anode overhang.
- The dangers in particular person cells are compounded by the truth that many merchandise embrace a number of 18650 cells, from 5 in a typical cordless drill to 39 in an e-bike battery pack that was scanned for the examine.
“Non-OEM batteries are a minefield,” mentioned Eduardo Torrealba, Co-Founder and CEO of Lumafield. “We’re seeing harmful defects at a scale that ought to alarm each manufacturing chief. Should you’re not policing your provide chain, you’re playing along with your model and your clients’ security. With commerce limitations shifting weekly, threat compounds. Fast industrial CT isn’t elective; it’s one of the best ways to implement security and cease dangerous components earlier than they attain individuals.”
Industrial X-ray CT can be utilized to confirm product high quality; nonetheless, till not too long ago, it has been a sluggish and costly instrument accessible solely to the biggest producers. Lumafield has endeavoured to make industrial X-ray CT accessible and quick, with automated options that may scan greater than 12 components per minute and immediately flag defects.
“Many people have grow to be desensitised to warnings concerning the risks of lithium-ion batteries, however our analysis underscores why customers should be vigilant,” added Alex Hao, Creator of the Lumafield Battery High quality Report. “It may be inconvenient to correctly use, retailer, and get rid of batteries, however there’s no room for complacency. Moreover, customers needs to be conscious of the place they purchase their batteries. If a deal seems to be too good to be true, it in all probability is.”
Learn the Lumafield Battery High quality Report in full right here.
