HOW IT'S MADE


BOLTED TOGETHER FOR SUPERIOR STRENGTH

Chargex Lithium Iron Phosphate Batteries are manufactured contrastingly superior from the competition with our bolted 32700 Stainless Steel Cylindrical LiFePO4 Battery Cells. Each cell is bolted through a rigid lengthway circuit board that strengthens the battery pack and provides superior current conductivity compared to tab welded cells. Chargex lithium battery packs are then bolted together with solid copper bus plates that maximizes current conductivity and strength to the battery pack.

CHARGEX® Lithium Iron Phosphate Battery

BUILT TOUGH, SAFE AND DEPENDABLE

The Chargex Battery Management Systems sets itself apart with top tier mosfets and electrical components for maximum efficiency, performance and reliability. Our BMS modules typically have higher charge and discharge current capability than competitor lithium batteries with the same capacity, this allows you to use our batteries for both deep cycle and starting applications. 

Each BMS has standard features including short circuit protection, reverse polarity protection, low voltage and over voltage protection. Chargex BMS modules vary across battery models, typically we do not add temperature features that can prevent you from using the battery in low temperatures, while this may reduce the life cycle of the battery, it allows you to keep running your Marine, RV and electronics regardless of the temperature.

Chargex Lengthway Circuit Boards

LENGTHWAY CIRCUIT BOARDS 

Chargex lithium battery cells are are bolted together through Lengthway Circuit Boards that connect to the BMS to balance individual cells. Lengthway circuit boards will shut down an individual cell in the unlikely event of failure, preventing short circuit and allowing the rest of the battery to continue functioning normally.

Other manufacturers typically tab weld cells together, if a single cell fails it can short circuit and will cause the whole pack to fail prematurely.

CHARGEX® Lithium Iron Phosphate Battery

The 32700 3.2V 5AH LiFePO4 Lithium Iron Phosphate Battery Cell

Chargex batteries are manufactured with 32700 - 3.2V Lithium Iron Phosphate (LiFePO4) Explosion Proof Stainless Steel Cells. Every cell is bolted together for a firm connection and more electrical conductivity compared to the tab welded method.

Each cell has a unique built-in thermal fuse that in the unlikely event a cell is overheating, internally disconnects shutting down the cell and preventing it from overheating. In addition, a high pressure safety vent and flame retardant electrolyte make this one of the world's safest batteries.

  • EXPLOSION PROOF
  • HIGH QUALITY STAINLESS STEEL
  • THERMAL FUSE
  • FLAME RETARDANT ELECTROLYTE 
  • HIGH PRESSURE SAFETY VENT


Chargex Lengthway Circuit Boards


THERMAL FUSE
 

Internal Cell Safety Fuse

Our cells have a built-in thermal safety fuse between the anode and cathode that will break in the unlikely event the cell overheats.

SAFETY VENT  
 

High Pressure Safety Vent

A high pressure safety vent will flip open to release energy and prevent explosion if exposed to extreme heat.

ELECTROLYTE
 

Flame Retardant Electrolyte 

Our cells are manufactured with a flame retardant additive in the electrolyte making them safe.

EXPLOSION PROOF 

Explosion Proof Stainless Steel

Every Lithium Battery cell is manufactured in an explosion proof stainless steel cylindrical case.

Download Our Cell Safety and Specifications Sheet

Chargex 32700 3.2V 5AH Stainless Steel Cells are bolted together for rigid strength, download our cell safety sheet to learn more about our battery pack structure, design and cell safety features. 

Chargex How It's Made
Download Cell Safety Sheet



CHARGEX® 32700 3.2V 5AH Stainless Steel LiFePO4 Cell


Cell Matching Process

1. Consistency of Self Discharge

2. Consistency of Voltage

3. Consistency of Inner Impedance

4. Consistency of Capacity

5. Consistency of Cycle Life

6. Consistency of Platform

7. Consistency of Constant Current Rate

8. Consistency of Cell Power Control

9. Consistency of Parallel Module Control

10. Consistency of Finished Battery Module

Essential Cell Safety Features & Design

The main issue with all lithium batteries is how to prevent a cell from over heating and rupturing if over charged. CHARGEX® Lithium Ion Batteries have several layers of safety redundancy systems at the cell level. The most notable safety feature in our latest cell design is the internal thermal fuse between the anode and cathode that will shut down the cell before the temperature rises, preventing pressure build up and activating the 1.5Mpa safety vent. In the unlikely event that the thermal fuse fails and pressure was released through the safety vent, the electrolyte has a flame retardant additive making the battery safe.

 These conditions would likely only occur if a charger or controller failed, spiking current into the battery. The BPS is designed to protect the cells from this anomaly by opening at 15.8V and would have to fail in the closed state allowing excess current into the cells. The CHARGEX® Group 31 - 12V 100AH lithium battery is built with 80 - cylindrical 3.2V 5AH (32650) cells combined with 4 sets of 20 cells in parallel and then combined in series. All 80 cells are matched by measuring 10 consistencies during several charge / discharge cycles at the end of production.





Download our Cell Safety Features 
Data Sheet Below to Learn More:


Download Now

Chargex Battery Cell Safety Features Data Sheet


Cylindrical Cells

Cylindrical cells are the most commonly used cell type today. The cylindrical design allows for better automation processes and techniques that increase consistency and lower cost.

Prismatic Cells

Prismatic cells have gained popularity because of their large capacity and prismatic shape that make it easy to connect 4 cells together and create a 12V battery pack. 



Cylindrical Advantages

Compared to prismatic cells, cylindrical cells can be produced much faster so more KWh per cell can be produced every day equaling lower $ per KWh. The electrodes in a cylindrical cell are wound tightly and encased in a metal casing. This minimizes electrode material from breaking up from the mechanical vibrations, thermal cycling from charging and discharging, and mechanical expansion of the current conductors inside from thermal cycling. Many cells are combined in series and in parallel to increase voltage and capacity of the battery pack. If one cell goes bad, the impact on the entire pack is low. CHARGEX® cells bolt through lengthway circuit boards that will prevent a bad cell from shorting out the rest of the pack, allowing it to continue functioning with slightly reduced capacity. With prismatic cells if one cell goes bad it can compromise the whole battery pack. Cylindrical cells will also radiate heat and control temperature better than prismatic cells.





Prismatic Disadvantages

Compared to prismatic cells, cylindrical cells can be produced much faster so more KWh per cell can be produced every day equaling lower $ per KWh. The electrodes in a cylindrical cell are wound tightly and encased in a metal casing, This minimizes electrode material from breaking up from the mechanical vibrations, thermal cycling from charging and discharging and mechanical expansion of the current conductors inside from thermal cycling. Many cells are combined in series and in parallel to increase voltage and capacity of the battery pack, if one cell goes bad, the impact on the entire pack is low. CHARGEX® cells bolt through lengthway circuit boards that will prevent a bad cell from shorting out the rest of the pack, allowing it to continue functioning with slightly reduced capacity. With prismatic cells if one cell goes bad it can compromise the whole battery pack. Cylindrical cells will also radiate heat and control temperature better than prismatic cells. Prismatic cells are made up of many positive and negative electrodes sandwiched together leaving more possibility for short circuit and inconsistency. The higher capacity makes it difficult for the BMS to protect each cell from over charging and dissipating heat. The larger cell size minimizes the possibility for automation leading to a lower degree of consistency. The internal electrodes can easily expand and contract causing deformation which can lead to a internal short circuit and are more prone to swelling similar to lead batteries.





CHARGEX® EnergyWave
Grade A Battery Protection System


Many of our Lithium Iron Phosphate Batteries are built with a fully automatic, built-in Battery Protection System. For OEM and prototype solutions, CHARGEX® is able to fully customize the BMS with the best parameters for your applications. 





Contact Us for more information by sending your message below or give us a call at 1-855-CHARGEX (1-855-242-7439)

first name *
last name *
phone
comments *