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Prismatic vs Pouch LiFePO4 Cells: Differences and Benefits

David Lee
David Lee
—
17/03/2023

Choosing the right LFP battery for your RVs, boats, or solar homes can be challenging without knowing the differences in battery construction, performance, and durability. Therefore, it's essential to understand the significance of battery cell packing type when selecting a Lithium Iron Phosphate (LiFePO4) battery. The cell packing type plays a vital role in the battery's overall performance and longevity, making it a crucial factor to consider.

In this blog, we'll explore why understanding battery cell is critical when choosing the right battery for your specific application, and take an in-depth look at pouch and prismatic LiFePO4 batteries.

Part 1: What are Prismatic Cells

Prismatic LiFePO4 batteries are named for their rectangular, prism-like shape. They typically have a hard plastic casing that protects the battery cells and can be stacked together to create larger battery packs. Prismatic LiFePO4 batteries are commonly used in electric vehicles, solar power systems, and other applications that require high-performance and long life. Most of LiTime LiFePO4 batteries are made of prismatic cells.

litime 12v 100ah prismatic cell

Benefits of Prismatic Cells

  • Space Efficiency: Prismatic cells have a rectangular or square shape, which allows for efficient use of space in battery packs, making them ideal for certain applications with specific space constraints.
  • Stackability: They can be stacked more easily than cylindrical cells, simplifying the construction of larger battery packs.
  • Ease of Assembly: Prismatic cells can be easier to assemble into battery modules or packs due to their uniform shape.

Part 2: What are Pouch LiFePO4 Cells

These cells are thin and flexible, making them ideal for use in portable devices. They offer higher energy density than other types of LiFePO4 cells but are still highly reliable and long-lasting.

litime mini pouch cell

Benefits of Pouch Cells

  • Flexibility: Pouch cells are lightweight and flexible, making them suitable for applications where space and weight are critical factors.
  • Customization: They can be manufactured in various sizes and shapes, allowing for greater design flexibility.
  • Cost-Effectiveness: Pouch cells are often cost-effective to produce and can offer a good balance between performance and cost.

2.1 Pouch Cell Swelling? Satety Concerns of Pouch Cells

Pouch cell swelling, also known as "pouch ballooning," is a phenomenon commonly observed in lithium-ion pouch cells. It occurs due to several factors related to the cell's construction and operation:

  • Gas Formation: During the normal operation of a lithium-ion cell, especially during charging, a small amount of gas can be generated as a byproduct of the electrochemical processes occurring within the cell. This gas primarily consists of oxygen and hydrogen, which can lead to the buildup of internal pressure.
  • Electrolyte Decomposition: Over repeated charge-discharge cycles, the electrolyte within the cell can undergo decomposition. This decomposition can produce gases, such as carbon dioxide, which contribute to the internal pressure buildup.
  • Formation of Solid-Electrolyte Interphase (SEI) Layer: The formation and growth of the SEI layer on the electrodes during cycling can also contribute to the generation of gases within the cell, leading to increased internal pressure.
  • Volume Changes in Electrodes: During charging and discharging, the electrodes within the pouch cell undergo volume changes as lithium ions are inserted and extracted. These volume changes can lead to mechanical stress on the pouch packaging, potentially causing it to swell.
  • Heat Generation: Heat generated during charging and discharging can also contribute to the expansion of the cell components, including the electrodes and the electrolyte, leading to swelling.

The combination of these factors can lead to the expansion of the pouch cell, causing it to swell. Pouch cell swelling can affect the performance and safety of the cell, potentially leading to mechanical stress on the internal components, degradation of the electrode materials, and compromise of the cell's structural integrity.

Although LiFepo4 Pouch Cells are considered safer than other lithium-ion battery technologies, it remains crucial to handle them with care. Choosing a reputable supplier is a key factor to guarantee the cells' quality and reliability. Additionally, following proper handling and storage protocols, minimizing the risk of physical damage or puncture, and conducting regular monitoring for any signs of malfunction are essential practices. Lastly, it's important for customers to plan for the safe disposal or recycling of batteries and prevent exposure to extreme temperatures or moisture.

Ensuring that LiFePO4 Pouch Cells adhere to regulatory standards such as UL, CE, and RoHS is vital. These safety certifications confirm that the batteries meet stringent safety and environmental criteria and have undergone thorough testing and quality control procedures.

All of LiTime LiFePO4 lithium batteries have passed the test of UL, CE, and RoHS.

LiTime 12V 100Ah Mini is made of pouch cells, here's the battery cell drill test. 

Part 3: Prismatic VS Pouch Cells: Key Differences

Basic Differences

Shape

Prismatic cells are rigid and rectangular. Pouch cells are flexible and flat. Prismatic cells are bulkier, while pouch cells offer more design flexibility, adapting to various shapes and sizes.

Packaging

Prismatic cells use a metal casing for durability and thermal control. Pouch cells are wrapped in a flexible pouch, typically made from laminated materials like aluminum and polymer. This makes pouch cells lighter and more space-efficient.

Size

Prismatic cells are larger and thicker due to their rigid design. Pouch cells are thinner and more compact, perfect for devices with limited space.

Weight

Prismatic cells are heavier, thanks to their metal casing. Pouch cells are lighter, benefiting from their flexible packaging.

Cell Voltage & Capacity

Both types can offer varying voltages and capacities based on chemistry and design. While their voltage ranges are similar, their capacity depends on size and construction.

Durability

Prismatic cells are more durable and resistant to external stress due to their metal casing. Pouch cells are more vulnerable to damage, requiring extra safety measures.

Cost

Prismatic cells are pricier to produce because of their complex metal casing. Pouch cells, with their simpler construction, are generally cheaper.

Performance

Prismatic cells provide higher energy density, making them ideal for high-energy applications like electric vehicles. Pouch cells offer higher power density, suited for devices that need quick bursts of power, such as smartphones and tablets.

Applications of Prismatic VS Pouch Cells

1. Prismatic Cells: Built for Tough Tasks

Prismatic cells are robust and durable, designed for high-performance applications that need reliability. Here’s where they excel:

  • Electric Vehicles (EVs): Prismatic cells are the backbone of EV battery packs. Their metal casing protects against damage, ensuring safety and long-term performance.
  • Power Tools: For tools that demand high power, like drills and saws, prismatic cells provide the endurance and output needed for extended use.
  • Energy Storage Systems (ESS): In large-scale energy storage projects, prismatic cells’ strength and capacity make them ideal for stabilizing renewable energy grids.

2. Pouch Cells: Light and Flexible

Pouch cells are lightweight and customizable, perfect for portable devices and space-constrained applications. Key uses include:

  • Consumer Electronics: Smartphones, tablets, and wearables benefit from the thin, compact form of pouch cells. They fit snugly into small spaces while providing sufficient power.
  • Medical Devices: Pouch cells are used in pacemakers and insulin pumps, where their small size and light weight are essential for implantable technologies.
  • Aerospace & Drones: In the aerospace industry, where weight is critical, pouch cells help power drones and aircraft systems, optimizing fuel efficiency and extending flight time.
Feature Prismatic Cells Pouch Cells
Shape Rigid, rectangular or square Flexible, flat
Packaging Metal casing for durability and thermal control Flexible pouch made of laminated materials
Size Larger and thicker Thinner and more compact
Weight Heavier due to metal casing Lighter, benefiting from flexible packaging
Cell Voltage & Capacity Similar voltage range; capacity varies with design Similar voltage range; capacity varies with design
Durability More durable, resistant to external stress More vulnerable, requires extra safety measures
Cost Higher production cost due to metal casing Lower production cost due to simpler design
Performance Higher energy density, ideal for high-energy tasks Higher power density, suitable for quick power bursts
Applications EVs, power tools, energy storage systems (ESS) Consumer electronics, medical devices, aerospace & drones

Part 4: Frequently Asked Questions

1. What is a Pouch LiFePO4 battery, and how does it work?

A Pouch LiFePO4 battery cell is typically made up of a thin Aluminum plastic pouch that contains the battery components, including the electrodes, electrolyte, and separator. The pouch is then sealed to prevent leakage and protect the cell from moisture and damage. The battery works by transferring lithium ions between the cathode and the anode during charging and discharging.

2. What are the advantages of using a Pouch LiFePO4 battery?
The advantages of using a Pouch LiFePO4 battery include long cycle life, fast charging, high energy density, low self-discharge rate, and improved safety features.

3. Why are prismatic cells better than other types of cells?

Prismatic cells were developed to enhance manufacturing efficiency, as they are larger while still being more compact than cylindrical cells.

4. 

5. Can I overcharge or over-discharge a LiFePO4 battery?
No. Over charge or over discharge the battery will damage the lifespan of using. Therefore, many LiFePO4 battery manufactures like LiTime have  installed battery management system to prevent the batteries from overcharging or over-discharging, ensuring the battery's safety and longevity.

Visit LiTime user-stories and youtube reviews for more information about LiTime batteries.

6. Can I use a Pouch LiFePO4 battery in place of a lead-acid battery?
Yes, Pouch LiFePO4 batteries can be used as a direct replacement for lead-acid batteries in many applications, including electric vehicles, off-grid solar systems, and marine applications.

7. How fast can a LiFePO4 battery charge?
A LiFePO4 battery can be charged at a faster rate than a traditional lead-acid battery, and in some cases, can be charged up to 80% in less than an hour. We suggest you using LiFePO4 battery charger in order to keep the battery in good conditions.

8. How do I store a LiFePO4 battery properly?
It is recommended to store LiFePO4 batteries in a cool and dry place, away from direct sunlight and heat sources. It is also recommended to keep them charged to about 50% of their capacity during storage. 

Conclusion

In summary, when selecting a LiFePO4 battery for specific applications such as RVs, boats, or solar homes, it is crucial to understand the significance of battery cell packing type. Pouch and prismatic LiFePO4 batteries are two different types of cells with their advantages and disadvantages.

Pouch batteries offer higher energy density, flexibility, improved thermal management, and reduced risk of internal short circuits and swelling. They are ideal for portable electronics, solar-powered lighting, electric vehicles, marine applications, off-grid systems, RVs, and camping applications.

On the other hand, prismatic batteries are typically used in larger applications such as electric vehicles, solar power storage systems, and backup power supplies for buildings. The choice between the two depends on the specific needs of the application.

David Lee
David Lee
David Lee is a renewable energy consultant with global experience in off-grid systems and battery applications, especially in golf carts. A graduate of the University of Sydney, he shares insights on sustainability through his writing.

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