4.1 General

Each battery shall be used within the frame of intended use. This is defined as "the use of a product, process or service under conditions or for purposes in accordance with specifications and instructions provided by the supplier - including information for publicity purposes".

In Sonnenschein Lithium Batteries, safety requirements are considered at the design state, as well as throughout the production, transport, intended use, foreseeable misuse and disposal. The design of Sonnenschein Lithium Batteries has inherent safety features, due to:

a) good heat dissipation

b) relatively small surface area of the electrodes

c) limited short-circuit current and thus limited temperature rise in the event of a short-circuit.

Due to these optimizations of the design, the batteries do not need a vent, which is a distinct difference to most of the other commercial lithium batteries.

4.2 Intended use tests

Following is a description of intended use and reasonably foreseeable misuse tests that are applicable to Sonnenschein Lithium Batteries. The test conditions are based on procedures which are published in the International Standard IEC 60086-4, second edition. IEC is the International Electrotechnical Commission in Geneva.

Discharge test
This test simulates the actual use of batteries. The limiting resistance value shall be specified for each battery type.

The undischarged battery is discharged, under limiting resistor R1 for a test duration td

td = Cn × R1 / Un

where

The test shall be carried out at 20 °C ± 2 °C until the battery is fully discharged and, in a separate test, at 60 °C ± 2 °C until the battery is fully discharged.
Test batteries pass the test if there is no leakage, no venting, no explosion and no fire.

Vibration test
This test simulates vibration during transportation.

The test batteries shall be subjected to simple harmonic motion with an amplitude of 0.8 mm (1.6 mm total maximum excursion). The frequency shall be varied at a rate of 1 Hz/min between 10 Hz and 55 Hz, and return in no less than 90 min and no more than 100 min. The test battery shall be tested in three mutually perpendicular directions. If a test battery has only two axes of symmetry, it shall be tested in two directions perpendicular to each axis.

The test shall be conducted with undischarged batteries and with fully discharged batteries.

Test batteries pass the test if there is no weight loss, no distortion, no leakage, no venting, no explosion and no fire.

Mechanical shock test
This test simulates crash conditions or rough handling during transportation.

The test batteries shall be secured to the testing machine by means of a rigid mount which will support all mounting surfaces of each test battery. Each test battery shall be subjected to a total of three shocks of equal magnitude. The shocks shall be applied in each of three mutually perpendicular axes. Each shock shall be applied in a direction normal to a face of the test battery. For each shock, the test battery shall be accelerated in such a manner that during the first three milliseconds the minimum average acceleration is 75 gn. The peak acceleration shall be between 125 gn and 175 gn.

The test shall be conducted with undischarged batteries and with fully discharged batteries.

The test shall be conducted using the batteries previously subjected to the vibration test.

Test batteries pass the test if there is no weight loss, no distortion, no leakage, no venting, no explosion and no fire.

Altitude test
This test simulates air transportation under low pressure conditions.

Test batteries shall be stored at a pressure of 11.6 kPa or less for at least 6 h and at a temperature of 20 °C ± 2 °C.

Test batteries pass the test if there is no leakage, no venting, no explosion and no fire.

Thermal shock test
This test assesses battery seal integrity under conditions of rapid temperature changes.

Test batteries shall be stored for 48 h at a temperature of 75 °C ± 2 °C, followed by storage for 6 h at a temperature of -20 °C ± 2 °C, followed by storage for at least 24 h at ambient temperature. The maximum time for transfer to each temperature shall be 5 min.

The test shall be conducted using the batteries previously subjected to the altitude simulation test.

Test batteries pass the test if there is no leakage, no venting, no explosion and no fire.

4.3 Reasonably foreseeable misuse tests

In order to evaluate the safety limits of lithium batteries even under extreme abuse conditions, he tests listed bellow are provided.

Warning
These tests call for he use of procedures which may result in injury if adequate precautions are not taken. It has been assumed in the drafting of these tests that their execution is undertaken by appropriately qualified and experienced technicians using adequate protection. The description of abuse tests in his brochure is for demonstration purposes only. During handling and application lithium batteries, abusive conditions must be avoided.

The range of intended use for Sonnenschein Lithium Batteries is specified in he data sheets (see also chapters 2 and 7 of his brochure). Any application or test requiring performance beyond the limits given in the data sheets must be approved by Sonnenschein Lithium.

Please refer to chapter 5 for abuse tests performed within the frame of the Underwriters Laboratories standard for safety as well as relevant military standards.

External short circuit test
This misuse may occur during handling of batteries.

The test batteries shall be stabilised at 55 °C ± 2 °C and then subjected to a short-circuit condition with a total external resistance of less than 0.1Ω at 55 °C ± 2 °C. This short-circuit condition is continued for at least 1 h after the battery case temperature has returned to 55 °C ± 2 °C.

The test shall be conducted using the batteries previously subjected to the vibration test and shock test, and, separately, using the batteries previously subjected to the altitude test and the thermal shock test.

Test batteries pass the test if there is no explosion and no fire.

Charge test 1
This test simulates the condition when one battery in a set is reversed.

A test battery is connected in series with three undischarged additional batteries of the same type in such away that the terminals of the test battery are connected in reverse.

A resistive load R2 is connected in series to the above assembly of batteries where R2 is selected such that the average current draw is the same as the maximum discharge current specified in the Sonnenschein Lithium Product Data Catalogue.
The circuit shall be closed, charging the test battery. The test shall be continued until the total voltage reaches 10 % of the original open circuit voltage or for 24 h, whichever is longer.

The test shall be carried out at 20 °C ± 2 °C.

Test batteries pass the test if there is no explosion and no fire.

Charge test 2
This test simulates the condition when a battery is fitted within a device and is exposed to a reverse voltage from an external power supply, for example memory backup equipment with a defective diode.

Each test battery shall be subjected to a charging current of three times the maximum reverse (charging) current IR max specified in the Sonnenschein Lithium Product Data Catalogue by connecting it in opposition to a DC power supply. Unless the power supply allows for setting the current, the specified charging current shall be obtained by connecting a resistor of the appropriate size and rating in series with the battery.

The test duration shall be calculated using the formula:

td = 2.5 × Cn / (3 × IR max)

where

The test shall be carried out at 20 °C ± 2 °C.

Test batteries pass the test if there is no explosion and no fire.

Overdischarge test
This test simulates the condition when one discharged battery is connected in series with other undischarged batteries.

Each test battery shall be predischarged to 50 % depth of discharge. It shall then be connected in series with three undischarged additional batteries of the same type.

A resistive load R3 is connected in series to the above assembly of batteries where R3 is selected such that the average current draw is the same as the maximum discharge current specified in the Sonnenschein Lithium Product Data Catalogue.

The test shall be carried out until the total voltage reaches 10 % of the original open circuit voltage or for 24 h, whichever is longer.

The test shall be carried out at 20 °C ± 2 °C.

The test shall be repeated with fully predischarged test batteries.

Test batteries pass the test if there is no explosion and no fire.

Free fall test
This test simulates the situation when a battery is accidentally dropped.

Undischarged test batteries shall be dropped from a height of 1 m onto a concrete surface. Each test battery shall be dropped 6 times, a prismatic battery once on each of its 6 faces, a round battery twice in each of its three axes. The test batteries shall be stored for one hour afterwards.

The test shall be repeated with 25 % predischarged test batteries.

Test batteries pass the test if there is no explosion and no fire.

Crush test
This test simulates the condition when a battery is exposed to forces encountered during household waste disposal, e.g. trash compaction.
A test battery shall be crushed between two flat surfaces. The force shall be applied by a vise or by a hydraulic ram with a 32 mm diameter piston. The crushing shall be continued until a pressure reading of 17 MPa is reached on the hydraulic ram, applied force approximately 13 kN. Once the maximum pressure has been obtained the pressure shall be released.

A cylindrical battery shall be crushed with its longitudinal axis parallel to the flat surfaces of the crushing apparatus. A prismatic battery shall be crushed by applying the force in the direction of one of the two axes perpendicular to its longitudinal axis, and, separately, by applying the force in the direction of the other one of these two axes. A button/coin battery shall be crushed by applying the force on its flat surfaces.

Each test battery shall only be crushed once.

Test batteries pass the test if there is no explosion and no fire.

Thermal abuse test
This test simulates the condition when a battery is exposed to an extremely high temperature.

A test battery shall be placed in an oven and the temperature raised at a rate of 5 °C/min to a temperature of 130 °C ± 2 °C at which the battery shall remain for 10 min.

Test batteries pass the test if there is no explosion and no fire.

4.4 Information for safety

This paragraph contains general safety information and is based on IEC publication 60086-4 which refers to lithium batteries of any kind, including those for consumer use.

Charge protection
When incorporating a primary lithium battery into a memory back-up circuit, a blocking diode and current limiting resistor or other protective devices shall be used to prevent the main power source from charging the battery (see Figure 7-1).

Parallel connection
Parallel connection should be avoided when designing battery compartments. However, parallel connection may be used in the assembly of battery packs as described in paragraph 7.3.

Safety precautions during handling
When used correctly, lithium batteries provide a safe and dependable source of power. However, if they are misused or abused, the following possible results may occur:

• leakage or
• venting or in extreme cases
• explosion and/or
• fire.

Do no insert batteries in reverse. Observe the + and - markings on battery and equipment.

When batteries are inserted in reverse they may be short-circuited or charged with the possible results mentioned above.

Do no short-circuit batteries

When the positive (+) and negative (-) terminals of a battery are connected directly with each other, the battery becomes short-circuited with the possible results mentioned above. One of the best ways to avoid short-circuiting is to store unused batteries in their original packaging.

Do no charge batteries

Attempting to charge a primary battery may cause internal gas and/or heat generation with the possible results mentioned above.

Do not force discharge batteries
When batteries are force discharged by means of an external power source, the voltage of the battery will be forced below its design capability with the possible results mentioned above.

Do not mix batteries
When replacing batteries, replace all of them at the same time with new batteries of the same brand and type. Otherwise some batteries may be charged due to a difference of cell voltage or overdischarged due to a difference of capacity with the possible results mentioned above.

Do not leave discharged batteries in equipment
Although Sonnenschein Lithium Batteries are most highly leak resistant, a battery that has been exhausted may be more prone to leak than one that is unused.

Do not overheat batteries
When a battery is overheated, electrolyte may be released and separators may deteriorate with the possible results mentioned above.

Do not weld or solder directly to batteries
The heat from welding or soldering directly to a battery may cause the lithium to melt with the possible results mentioned above.

Do not open batteries
When a battery cell is opened the components may cause personal injury or fire.

Do not deform batteries
Lithium batteries should not be crushed, punctured, or otherwise mutilated because this may lead to the possible results mentioned above.

Do not dispose of batteries in fire
When batteries are disposed of in fire the possible results mentioned above may occur. Do not incinerate batteries except for approved disposal in a controlled incinerator.

Do not expose contents to water
When the container of a lithium battery is damaged, lithium metal may be exposed. This may lead to the formation of hydrogen gas with the possible results mentioned above.

Keep batteries out of the reach of children
Especially keep swallowable batteries out of the reach of children. In case of ingestion of a cell or battery, seek medical assistance promptly.