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Development of a Li-Ion Battery for Drones
8mm Thin Battery for High-Performance Applications

HighEnergyDensityLithiumIonPowerManagementUltraThinBattery

Background and Customer Requirements

AMICELL was approached with a unique challenge: to design a Li-Ion battery with a maximum thickness of just 8mm. The battery was intended to be integrated along the wing of a drone, requiring it to provide high power output, feature a rigid casing, and include connectors (Power & Balance) positioned at the centerline of the wing.

Key Challenges

  • Minimal Casing Thickness: The casing had to be designed with a minimal thickness of 8mm, maximizing internal volume while maintaining structural integrity.
  • Maximum Capacity: Achieving the highest possible capacity within the limited available space.
  • High-Power Wiring: A solution was needed to manage high-power wiring from one side of the wing to the other within a constrained space.

Development Process

Casing Design
  • Due to the strict thickness requirement, traditional insulation materials couldn’t be used. Instead, a non-conductive material was selected for the casing.
  • After extensive prototyping and testing, fiberglass with a thickness of 0.25mm was chosen, reinforced with beams running through the center for added strength.
  Maximizing Capacity
  • Custom Li-Ion polymer (pouch) cells were designed with specific dimensions and thicknesses to optimize the available space and achieve the highest capacity possible.
  Wiring Solution
  • Copper strips were integrated alongside the reinforcement beams inside the casing to effectively handle the wiring within the narrow space.
  • All electrical connections were routed to a custom-designed PCB located at the battery’s centerline, ensuring efficient power distribution and balance.

Additional Request

In addition to the size and power requirements, the battery had to operate in extreme temperatures as low as -30°C for use in search and rescue missions in harsh environments.

Final solution

The outcome was a highly efficient, ultra-thin Li-Ion polymer battery pack, meeting all of the customer’s requirements. The battery featured:
  • A robust fiberglass casing.
  • An optimized cell configuration for maximum capacity.
  • An innovative wiring solution to manage high power within the confined wing structure.

Conclusion

AMICELL successfully delivered a custom-designed battery solution that not only met but exceeded expectations. This case study demonstrates AMICELL’s expertise in developing advanced battery solutions tailored to the most demanding applications.

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