Technology

Our patent-pending lithium-ion battery technology platform is based on a design that emphasizes a whole system approach capable of powering end applications that include electric vehicles, next-generation utility energy storage and portable consumer electronics. Our breakthrough technology, with over 150 patents pending in the United States and internationally, is based on a combination of unique chemistry formulations, plus mechanical engineering and electrical designs at the cell and system level that enable us to deliver on the promise.

Our cells are based on a flat, oval-shaped prismatic design with external dimensions equivalent to two conventional 18650 lithium-ion cells. The cell design supports high energy density, dependable cycle-life, a broad operating temperature range, fast charge and multiple independent safety features. We have introduced two cell products from our technology platform: Swing? cells for transportation and stationary energy storage applications and Sonata? cells for notebook and portable power applications, as well as a family of battery blocks, modules and systems for large format applications.

Our batteries are in mass production today, in our advanced lithium-ion battery manufacturing facilities in Asia, with the capacity to scale to millions of cells per month.

Boston-Power Long Cycle Life Battery Technology

A key advantage of our lithium-ion battery technology platform is uncompromised, extended calendar and cycle life. The ability for our batteries to undergo a large number of charge/discharge cycles before "fading" or losing capacity allows us to deliver systems that last longer than conventional lithium-ion solutions.

For transportation and utility applications, our high energy cells, blocks, modules and battery systems contribute to extended driving range and field reliability, respectively. Specifically, our cells can undergo over 2000 charge/discharge cycles at 90% depth of discharge (DOD), delivering greater than 10 years reliable calendar life. Traditionally, the long cycle life of lithium-ion cells has only been available when reducing the voltage range or significantly lowering the energy density, but with the combination of long cycle and calendar life, high energy density and sufficient power, Boston-Power's battery technology platform delivers a significant runtime advantage over current technology solutions, particularly in the emerging long-range Battery Electric Vehicle (BEV) and Plug-in Hybrid Electric Vehicle (PHEV) markets, as well as new-generation utility energy storage applications.

Over 10 Years of Reliable Performance

For portable power applications like notebook PCs, our battery cells retain 80% or more of their capacity after over 1000 charges, offering consistently high performance over 3 years or more (depending on use) - the entire lifetime of a typical notebook computer. Conventional lithium-ion solutions begin to fade noticeably after only 100 charges and have to be replaced after about a year. As a testament to our long life, notebook PC manufacturers, such as HP and ASUS, can offer industry-leading three year warranties on notebook batteries based on Boston-Power's technology platform.

The Myth About Battery Capacity

Boston-Power Wide Operating Temperature Range

Our patented chemistry supports a broad operating temperature range, greatly increasing the potential applications where our batteries can be used. Specifically, by achieving high performance at both high and low temperature extremes, our battery systems support better all-weather performance for electric vehicles (EVs), utility energy storage devices, and a variety of military and industrial device applications where low temperature performance is critical.

Additionally, battery heating and cooling requirements are greatly simplified, reducing the cost and complexity of the battery system design. 

Our cells support one of industry's widest operating temperature ranges with minimal performance impact, specifically a discharge temperature range from -40°C to 70°C, and a charge temperature range from -20°C to 60°C.

Boston-Power Fast Charge Battery Technology

Whether used for electric vehicle applications or portable power applications, our lithium-ion battery technology platform is designed from the ground up with mobility in mind.

For portable power applications, the ability of our batteries to rapidly recharge allows us to offer industry-leading fast charge capability. Specifically, our cells can be recharged to 80% capacity in 30 minutes, (or 40% in 12 minutes), by accepting higher charge rates of up to 2C -- over 50% faster than conventional lithium-ion cells. Combining fast charge with long cycle life for portable power applications like notebook PCs provides significant user mobility, convenience and value.

For automotive applications, our Swing? battery systems are compatible with Level 2 chargers today, and Level 3 chargers when available. With a Level 2 charger, the estimated time to charge a fully depleted battery is five hours for a 35kWh pack. Fast charging our Swing battery systems does not degrade the cycle or calendar life performance.

Boston-Power Safe Battery Technology

At Boston-Power, we gave safety equal weight at the design table when we created our lithium-ion battery technology platform. Our cell design incorporates multiple independent safety features that activate at precise trigger points, resulting in possibly the safest battery system on the market today. For large format applications, safety is further architected into blocks, modules and systems. Additionally, we have implemented stringent controls in our manufacturing processes through Six Sigma methods to augment the safe design of the batteries, including full traceability to the individual cell level. Through a combination of inherently safe chemistry and novel safety devices integrated in the cell design for over-charge and short-circuit protection, our technology platform provides superior cell and pack-level safety when compared to alternative solutions on the market today. Each cell incorporates multiple, independent safety devices located in different areas of the cell. The design of each safety component is optimized independent of the other components, and the distributed location eliminates unwanted interactions between them.

One of the safety devices is the integrated Current Interrupt Device (CID), which electrically disconnects the cell if internal pressures get too high. The CID is located inside the aluminum can, away from the vents for greater reliability. A cell may also contain a discrete Positive Temperature Coefficient (PTC), (*Sonata only), to protect against shorts if the cell is mishandled during pack assembly. There are also two vents on the side of the can for redundancy, lessening the chance of cascading failures in a multi-cell pack. In addition, because the cell can is constructed from aluminum, supporting a low pressure design allows safety components to activate earlier, minimizing the chance that the cell will enter thermal runaway. The activation pressure and tolerances of each of the components are designed to prevent inadvertent activation.

View our certifications.

Boston-Power Green Battery Technology

At Boston-Power, we are committed to developing products designed with the environment in mind. In fact our battery cells bear the most stringent international accreditations for environmental sustainability, namely the Nordic Ecolabel and also the Chinese Ecolabel.

Since 2007, our Swing? and Sonata? cells have remained the only rechargeable lithium-ion batteries to receive these accreditations.

These recognitions signify adherence to stringent guidelines regarding hazardous materials, long product life and corporate social responsibility through sustainable manufacturing processes, audited each year.

Boston-Power High Energy Density Battery Technology

Boston-Power’s batteries deliver a significant competitive advantage in the growing electric transportation and utility energy storage markets, offering the highest energy density available today, without sacrificing long cycle life. High energy density directly equates to more runtime (or miles traveled) between charges, as well as reduced battery weight and size, and therefore cost. Specifically, our cells offer 490Wh/L total volumetric energy density and 207Wh/kg total gravimetric energy density, significantly outperforming today’s lithium-ion pouch (soft-packaged) solutions with 50% more energy density in Wh/L, and 20-30% more in Wh/kg. (This also represents twice the gravimetric energy density available with lithium-iron phosphate solutions). In addition, our cells have a wide depth of discharge (DOD), enabling more usable energy compared to other lithium-ion solutions. Our greater usable energy results from a combination of a deep discharge cycle life (2000 cycles at 90% DOD), and a higher total energy density, which when combined, deliver over 45% more usable energy density by weight, and 50% more by volume, compared to other battery systems. More usable energy means better efficiency and less waste, translating into lower overall cost per usable kWh.