Informal working group: Large Lithium batteries testing
RECHARGE & SAFT
Brussels, March 16, 2015
1
Content:
1.
2.
3.
4.
UN 38-3 Definitions purpose.
Existing definitions review
What needs to be defined
New products definition
2
1- Definitions purpose
“UN Manual 38.3.2.3 : For the purposes of classification, the following
definitions apply: ….”
-for UN 38.3: identify clear categories of products allowing un-ambiguous
testing categories: example: small cell is defined with weight limit 500g.
- For UN model regulation: product categories to identify the transport
conditions: example: small cell size for SP188 is defined as lower then 20
Wh.
Definition purpose should be clearly identified to correctly define:
• the granularity of the categories:
• The boundaries definitions and coherence according the used
characteristics
Existing definitions:
- battery size: Wh, Kg, dimensions ( for example in T6 are defined batteries
less than 20 mm in diameter).
- Battery complexity
- Battery chemistry (based on UN numbers)
Definitions purpose: battery size
-
Existing definitions: battery size: Wh, Kg, dimensions ( for example in T6 are define
batteries less than 20 mm in diameter).
increasig size
UN Model/ size identification
buttons cells
small /large cell ( <1g Li or 20 Wh)
Testing UN 38.3/ size identification
small cell (<500g)
large cell (> 500g)
small /large battery of small cells ( <2
g Li or 100 Wh)
Small/large battery of large cells (<2g
Li or 100 Wh)
small battery of small cells (<12kg)
small battery of large cells (<12 kg)
large battery of small cells
large battery of large cells
assembled battery of small batteries
assembled batteries of large batteries
assembled battery of small batteries (
>500g Li or 6200 Wh)
assembled battery of large batteries (
>500g Li or 6200 Wh)
Definitions purpose: complexity and protection
-
Existing definitions: Battery
complexity and protection
UN definition
component cell
increasing complexity
cell
No overcharge protection
bare single cell
bare multiple cell in one casing
overcharge protection
single cell with electronics
multiple cell in one casing +
electronics
single cell
battery
single cell with electronics +
overcharge protection
multiple cell in one casing +
electronics+ overcharge protection
battery
multiple cells connected with
electronics
multiple cells connected with
electronics + overcharge
protection
assembled
battery
multiple batteries connected with
electronics
multiple batteries connected with
electronics + overcharge
protection
Content:
1.
2.
3.
4.
UN 38-3 Definitions purpose.
Existing definitions review
What needs to be defined
New products definition
6
Purpose 1: Electrochemical system identification
- Existing definitions at general description level ( but not in UN 38.3, as
already identified in the [38.3.1 purpose] )
[European Battery Directive 2006/66/EC]
Battery or Accumulator: means any source of
electrical energy generated by direct conversion
of chemical energy and consisting of one or
more primary battery cells (non-rechargeable) or
consisting of one or more secondary battery
cells (rechargeable).
Battery Pack means any set of batteries that
are connected together and/or encapsulated
within an outer casing so as to form a complete
unit that the end-user is not intended to split up
or open.
Identification of
electrochemical
system
[IEV ref 151-12-11 ]
... bank
battery of ...
set of devices of the same type so
connected as to act together
Note – Example of use of this concept are:
capacitor bank, filter bank, battery of cells.
[IEV ref 811-20-01 ]
(electrochemical) cell
battery
an electrochemical system capable of
storing in chemical from the electric energy
received and which can give it back by
reconversion
Purpose 2: Cell ( not battery)
-
Existing definitions
Design
description
[UN 38.3 definitions]
Cell means a single encased electrochemical
unit (one positive and one negative electrode)
which exhibits a voltage differential across its
two terminals. Under the Model Regulations and
this Manual, to the extent the encased
electrochemical unit meets the definition of "cell"
herein, it is a "cell", not a "battery", regardless of
whether the unit is termed a "battery" or a
"single cell battery" outside of the Model
Regulations and this Manual.
Component cell means a cell contained in a
battery.
Overlaps risks
Single cell battery means a single
electrochemical unit fitted with devices
necessary for use, for example, case, terminals,
marking and protective devices
[IEV ref 482-01-01]
cell
basic functional unit, consisting of an
assembly of electrodes, electrolyte,
container, terminals and usually
separators, that is a source of electric
energy obtained by direct conversion of
chemical energy
Note – See primary cell and secondary
cell.
[IEV ref 114-03-01]
Is in purpose 1
electrochemical cell
composite system in which the supplied
electric energy mainly produces chemical
reactions or, conversely, in which the
energy released by chemical reactions is
mainly delivered by the system as electric
energy
Note 1 to entry: This entry was numbered
111-15-10 in IEC 60050-111:1996. It has
been modified.
Purpose 3: battery (not cell)
-
Existing definitions
[UN 38.3 definitions]
Battery means two or more cells which are
electrically connected together and fitted with
devices necessary for use, for example, case,
terminals, marking and protective devices. A
single cell battery is considered a cell and shall
be tested according to the testing requirements
for "cells" for the purposes of the Model
Regulations and this Manual (see also the
definition for "cell").
NOTE: Units that are commonly
referred to as "battery packs", "modules" or
"battery assemblies“ having the primary function
of providing a source of power to another piece
of equipment are for the purposes of the Model
Regulations and this Manual treated as
batteries.
[IEV ref 482-01-04]
Battery
one or more cells fitted with devices
necessary for use, for example case,
terminals, marking and protective devices
Cells assembly
description
Purpose 4: battery size = button cells
-
Existing definitions: button cells are supposed to describe small cells, but no information
about size.
UN 38.3 Definitions:
Button cell or battery means a round
small cell or battery when the overall
height is less than the diameter.
IEV ref 482-02-40
button cell
coin cell
cell with a cylindrical shape in which the
overall height is less than the diameter e.g. in
the shape of a button or a coin
Note – In practice, the term coin is used
exclusively for non-aqueous lithium cells.
Purpose 4: small and large cells /batteries
-
Existing definitions:
in UN Model, the limit in size is expressed in Li content or
in Wh, not in weight.
UN 38.3 Definitions:
Small battery means a lithium metal battery or
lithium ion battery with a gross mass of not more
than 12 kg.
Small cell means a cell with a gross mass of not
more than 500 g.
Purpose 5: battery chemistry identification
-
Existing definitions: IEC Li cells include Lithium metal and Lithium sulfur chemistries, but
no definition UN 38.3?
No « Lithium metal »
battery definition in
UN 38.3 or IEC
[UN 38.3 definitions]
Lithium ion cell or battery means a
rechargeable electrochemical cell or battery in
which the positive and negative electrodes are
both intercalation compounds (intercalated
lithium exists in an ionic or quasi-atomic form
with the lattice of the electrode material)
constructed with no metallic lithium in either
electrode. A lithium polymer cell or battery that
uses lithium ion chemistries, as described
herein, is regulated as a lithium ion cell or
battery.
[IEV ref 482-01-06 ]
lithium cell
cell containing a non-aqueous electrolyte
and a negative electrode of lithium or
containing lithium
Note – Depending on the design features
chosen, a lithium cell may be primary or
secondary
IEV ref 482-05-07
lithium ion battery (NOT CELL?)
secondary battery with an organic solvent
electrolyte and positive and negative
electrodes which utilize an intercalation
compound in which lithium is stored
Note – A lithium ion battery does not
contain lithium metal.
Purpose 5: UN Numbers for batteries chemistry
Identified needs: Battery chemistry => UN numbers corresponding name and description
-
-
UN 3090, UN 3091
class 9
UN 3480, UN 3481
Class 9
UN 2794
class 8
UN 2795
class 8
UN 2800
class 8
UN 3028
class 8
UN 3292
Class 4.3
UN 3496
Class 9
UN3499
Class 9
UN3508
Class 9
Lithium metal batteries, and Lithium metal in/packed with equipment
Li ion batteries (and Li ion polymer), and Li-ion in/packed with equipment
Batteries, Wet, filled with acid, electric storage
Batteries, Wet, filled with alkali, electric storage
Batteries, Wet, non spillable
Batteries, dry containing KOH solid
Batteries or cells containing sodium
Batteries Ni Metal hydride
Capacitors
Asymmetric capacitors
- Li-S? Li-metal polymer?
Is it a need to have a
definition for new
chemistries?
Definitions purpose: capacitors
-
Existing definitions: only in IEC, no definition of assymetric capacitor ?
[IEV ref 114-03-03]
electrochemical capacitor
supercapacitor
device that stores electrical energy using a double layer in
an electrochemical cell
Note 1 to entry: The electrochemical capacitor is not to be
confused with electrolytic capacitors (114-03-04).
[IEV ref 114-03-04]
electrolytic capacitor
capacitor consisting of a metallic plate as first conductor, a very thin oxide film
formed on the metal as the dielectric and an electrolyte as second conductor
Note 1 to entry: Electrolytic capacitors typically have large capacitance
because the dielectric is very thin.
Note 2 to entry: The electrolytic capacitor is not to be confused with
electrochemical capacitors
(114-03-03).
Note 3 to entry: Definition 436-03-05 in IEC 60050-436:1990 doesn’t mention
electrolyte.
Content:
1.
2.
3.
4.
UN 38-3 Definitions purpose.
Existing definitions review
What needs to be defined
New products definition
15
Definitions coordination for size and complexity
-
UN Testing 38.3 and UN transport Model Regulation can be made coherent
UN size
identification
small
battery
of small
cells ( <2
g Li or
small
cell ( <1g
buttons Li or 20
cells
Wh)
small
battery
of large
cells
(<2g Li
small
cell
large cell
(<500g) (> 500g)
small
battery
of small
cells
(<12kg)
small
battery of
large cells
(<12 kg)
large
battery
of small
cells
large
battery
of large
cells
assemble
d battery
of small
batteries
assemble
d
batteries
of large
batteries
assembled
battery of
small
batteries (
>500g Li or
6200 Wh)
assembled
battery of
large
batteries (
>500g Li or
6200 Wh)
UN transport
Testing UN 38.3 size
identification
UN definition
No overcharge
protection
overcharge
protection
component cell
bare single cell
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
bare multiple cell in
one casing
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
single cell with
electronics
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
multiple cell in one
casing + electronics
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
multiple cell in one
casing + electronics+
overcharge
protection
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
SP188
SP188
SP188 or SP188 or
SP 230 SP 230
SP230
SP230
N.A.
N.A.
N.A.
N.A.
cell
single cell with
electronics +
overcharge
protection
single cell battery
battery
multiple cells
connected with
electronics
N.A.
N.A.
Definitions coordination for size and comlexity
-
small
battery
of small
cells ( <2
g Li or
small
cell ( <1g
buttons Li or 20
cells
Wh)
UN size
Testing 38.3 and transport can be made
coherent
identification
small
battery
of large
cells
(<2g Li
small
cell
large cell
(<500g) (> 500g)
small
battery
of small
cells
(<12kg)
small
battery of
large cells
(<12 kg)
large
battery
of small
cells
large
battery
of large
cells
assemble
d battery
of small
batteries
assemble
d
batteries
of large
batteries
assembled
battery of
small
batteries (
>500g Li or
6200 Wh)
assembled
battery of
large
batteries (
>500g Li or
6200 Wh)
UN transport
Testing UN 38.3 size
identification
UN definition
No overcharge
protection
overcharge
protection
component cell
bare single cell
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
bare multiple cell in
one casing
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
single cell with
electronics
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
multiple cell in one
casing + electronics
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
multiple cell in one
casing + electronics+
overcharge
protection
SP188
SP188
SP188 or
SP 230 SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
SP188
SP188
SP188 or SP188 or
SP 230 SP 230
SP230
SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
SP188
SP188
SP188 or SP188 or
SP 230 SP 230
SP230
SP230
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
SP230
SP230
N.A.
Authorisati
Authorisati on
on required required
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
SP230
SP230
SP230
cell
single cell with
electronics +
overcharge
protection
single cell battery
battery
multiple cells
connected with
electronics
multiple cells
connected with
electronics +
overcharge
protection
assembled
battery
multiple batteries
connected with
electronics
multiple batteries
connected with
electronics +
overcharge
protection
SP230
Definitions coordination for size and comlexity
-
small
battery of
small cells (
<2 g Li or
100 Wh)
Testing 38.3 and transport cansmall
becellmade
coherent
(
UN size
identification
UN testing
UN
definition
No overcharge
protection
single cell with
electronics +
overcharge
protection
multiple cells
connected with
electronics
multiple batteries
assembled connected with
battery
electronics
multiple batteries
connected with
electronics +
overcharge
protection
large cell (>
500g)
T6 and T8
or T1-T6
and T8
T6 and T8
or T1-T6
and T8
T6 and T8
or T1-T6
and T8
?
T1-T6 and
T8 (small)
?
T1-T6 and
T8 (small)
?
T1-T6 and
T8 (small)
?
?
T1-T6 and
T8 (small)
N.A.
multiple cells
connected with
electronics +
overcharge
protection
small cell
(<500g)
T6 and T8
or T1-T6
and T8
multiple cell in one
casing + electronics+
overcharge
protection
?
battery
<1g Li or 20
Wh)
Testing UN 38.3 size
identification
overcharge
protection(for
rechargeable)
component
cell
bare single cell
bare multiple cell in
one casing
single cell with
cell
electronics
multiple cell in one
casing + electronics
single cell
battery
buttons
cells
small
battery of
small cells
(<12kg)
large
small battery battery
of large cells of small
(<12 kg)
cells
large
battery
of large
cells
assemble
d battery
of small
batteries
assemble
d
batteries
of large
batteries
assembled
battery of
small batteries
( >500g Li or
6200 Wh)
assembled
battery of
large batteries
( >500g Li or
6200 Wh)
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
?
T1-T6 and
T8 (large)
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
?
?
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
T1-T6 and
T8 (small)
T1-T6 and
T8 (small)
T1-T6 and
T8 (large)
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
?
?
?
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
T1-T5
(small)
T1-T5
(small)
T1-T5
(small)
T1-T5
T1-T5 (small) (large)
T1-T5
(large)
N.A.
N.A.
N.A.
N.A.
T1-T5
T1-T5
T1-T5
(small) and (small) and T1-T5 (small) (large)
T7
T7
and T7
and T7
T1-T5
(large)
and T7
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
T3-T5
(small or
large)
T3-T5
(large)
Authorization
Authorization
N.A.
T3-T5
(small or T3-T5
large) and (large)
T7
and T7
Protection
system
Protection
system
N.A.
N.A.
N.A.
N.A.
T1-T5
(small) and
T7
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
small
battery of
large cells
(<2g Li or
100 Wh)
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
UN38-3 applicable tests table
Table describing the existing testing requirements:
reference
1-Cells
tests
38.3.2.1
componant cell scope
38.3.2.1
Cell
scope
38.3.2.3
Single cell battery definition
conditions
without overcharge protection ( for
with overcharge protection
rechargeable batteries)
(for rechargeable batteries)
non transported
separately
transported separately
T6 and T8
T1-T6 and T8
N.A
N.A.
T1-T6 and T8
N.A
N.A.
T1-T6 and T8
N.A
2 -Batteries Rechargeable
38.3.2.1
tests
Single cell battery scope
N.A
N.A
T7
38.3.2.1
scope
N.A
T1-T5
T1-T5 and T7 (for
rechargeable batteries)
T3-T5 or protection
system
T3-T5 and T7 (for
rechargeable batteries) or
protection system
battery
Assembled
battery
38.3.3 (f)
N.A
In addition, tests conditions are different for small and large cells or
batteries
UN 38-3 definitions simplification proposal
Table describing the existing testing requirements:
reference
conditions
without overcharge protection ( for
with overcharge protection
rechargeable batteries)
(for rechargeable batteries)
non transported
separately
transported separately
1-Cells
tests
componant cell
38.3.2.1 scope
Cell
38.3.2.1 scope
38.3.2.3
Single cell battery definition
2 -Batteries Rechargeable
tests
Single cell battery 38.3.2.1 scope
T6 and T8
T1-T6 and T8
N.A
component cell
N.A.
T1-T6 and T8
N.A
single cell battery
N.A.
T1-T6 and T8
N.A
N.A
N.A
battery
38.3.2.1 scope
N.A
T1-T5
Assembled
battery
38.3.3 (f)
N.A
T3-T5 or protection
system
T7
single cell battery with overcharge protection
T1-T5 and T7 (for
rechargeable batteries)
multicell battery
T3-T5 and T7 (for
rechargeable batteries) or
protection system
assembled multicell battery
1- A component cell transported separately from battery is tested exactly as a cell, so there is no need
to create a specific case. On the contrary, it is a specific case when the component cells are
transported only in a battery. It should be clarified in the definition that a component cell cannot be
proposed for transport separately from a battery.
2- A single cell battery is different from a cell only if it is equipped with an overcharge protection: in
this case it shall be tested with T7. In other cases, the tests applicable are the same than for a cell.
This should be reflected in the definition.
UN 38-3 simplified table
Table describing the existing testing requirements, with
modified definitions:
component cell
single cell battery
multicell battery
assembled battery
asembled battery over 6200 Wh or 500g Li
without overcharge
protetion
T6 and T8
T1-T6 and T8
T1-T5
T3-T5
protection system
with overcharge
protection (for
rechargeable
batteries)
N.A.
T1-T8
T1-T5 and T7
T3-T5 and T7
protection system
 Objective: a single simplified table, no overlap, no alternative
options for cells or batteries, each test linked to a definition.
 The table has to be duplicated for small and large single
cell/multicell batteries.
 Question : is a multicell battery in a single casing acceptable
for transport without T6 and T8 test? Decision to be included
in the definition.
Content:
1.
2.
3.
4.
UN 38-3 Definitions purpose.
Existing definitions review
What needs to be defined
New products definition
22
New products: Lithium metal polymer characteristics
Lithium metal polymer:
anode: Lithium metal
cathode: LiFePO4 (high temperature stable oxide)
electrolyte: solid polymer (no liquid flammable electrolyte)
Functionning internal temperature: 80°C => thermal insulation of the
battery is required.
Transport conditions: room temperature = limited current in case of
short circuit. Completely inert when <0°C (used for the transport of
damaged and defective batteries): no current in case of short circuit or
any damage.
Safety: Main risk due to the presence of Li metal in case of fire.

should it be classified as Li metal batteries 3090 ?
Similarities to UN 3292 Batteries containing sodium, Class 4.3?

is it a need to adapt the tests in 38.3 ( only today applicable to
Li-ion and Li metal)?
23
New products testing: Li metal polymer
Issue: the product is functioning at higher temperature than the one
specified in the 38.3
Proposal: amendments to specify temperatures when needed.
• altitude simulation: specify temperature at 20°C?
• Thermal test 38.3.4.2 : OK
• Vibration 38.3.4.3 and shock 38.3.4.4 and Impact 38.3.4.6: specify a
temperature?
• External short 38.3.4.5: maintain 57°C?
• Overcharge 38.3.4.7: applicable only at functionning temperature (not
specified)?
• Forced discharge 38.3.4.8: maintain ambiant temperature or transport
temperature?
24
New products: Lithium Sulfur characteristics
Lithium Sulfur:
anode: Lithium metal
cathode: A sulfur-based cathode which includes carbon and a
polymer binder
electrolyte: non-flammable electrolyte
Functionning internal temperature: room temparture.
Transport conditions: room temperature (SOC to be confirmed)
Safety: not sensitive to mechanical abuse. Main risk linked to the
presence of Lithium in case of fire

should it be classified as Li metal batteries 3090 ?
Definition is today not covering Li sulfur.

is it a need to adapt the tests in 38.3 ( only today applicable to
Li-ion and Li metal)?
25
New products: Hybrid supercapacitors
Hybrid supercapacitor :
anode: lithiated graphite
cathode: carbon
electrolyte: same type of electrolyte as Li-ion
Functionning internal temperature: room temparture.
Transport conditions: room temperature, fully discharged ( no energy
content)
Safety: Main risk linked to the presence of Lithiated carbon and
electrolyte in case of fire

classified as UN3508, with SP 372 ( not refereing to UN 38.3)

is it a need to create a definition for UN Model?
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