Lithium Polymer Battery - Technology

Technology

Cells sold today as polymer batteries are pouch cells. Unlike lithium-ion cylindrical cells, which have a rigid metal case, pouch cells have a flexible, foil-type (polymer laminate) case. In cylindrical cells, the rigid case presses the electrodes and the separator onto each other; whereas in polymer cells this external pressure is not required (nor often used) because the electrode sheets and the separator sheets are laminated onto each other. Since individual pouch cells have no strong metal casing, by themselves they are over 20% lighter than equivalent cylindrical cells.

The voltage of a Li-poly cell varies from about 2.7 V (discharged) to about 4.23 V (fully charged), and Li-poly cells have to be protected from overcharge by limiting the applied voltage to no more than 4.235 V per cell used in a series combination.

Early in its development, lithium polymer technology had problems with internal resistance. Other challenges include longer charge times and slower maximum discharge rates compared to more mature technologies. In December 2007 Toshiba announced a new design offering a much faster rate of charge (about 5 minutes to reach 90%). These cells were released onto the market in March 2008 and are expected to have a dramatic effect on the power tool and electric vehicle industries, and a major effect on consumer electronics. Recent design improvements have increased maximum discharge currents from 2 times to 65 or even 90 times the cell capacity charge per hour.

In recent years, manufacturers have been declaring upwards of 500 charge-discharge cycles before the capacity drops to 80% (see Sanyo). Another variant of Li-poly cells, the "thin film rechargeable lithium battery", has been shown to provide more than 10,000 cycles.