Insights

When developing a battery-powered product, performance specifications like voltage, capacity, runtime, and size are only part of the equation. Depending on the application and where the product will be sold, a battery pack may also need to meet specific safety, transportation, and industry standards.

For OEMs, understanding these requirements early in the development process can help prevent costly redesigns, testing delays, and unexpected obstacles on the path to market.

At Cell-Con, we work with customers to consider certification and compliance requirements throughout the battery development process, from initial cell and component selection through prototype testing and production.

Why Battery Certifications Matter

Battery packs store a significant amount of energy in a relatively small space. Certifications and industry standards are designed to evaluate how cells, battery packs, and their protection systems respond to electrical, mechanical, and environmental conditions.

Depending on the standard, testing may evaluate conditions such as:

• Overcharge and over-discharge
• External short circuits
• Abnormal charging
• Temperature exposure
• Vibration and mechanical shock
• Impact or other mechanical stresses
• Transportation conditions

The standards that apply to a project depend on factors including battery chemistry, application, geographic market, transportation method, and requirements of the end product.

That makes certification planning an important engineering consideration, not simply something to address after the battery pack has been designed.

Understanding UL Standards

UL standards are commonly encountered when developing battery-powered products for the North American market.

One example is UL 2054, which addresses household and commercial batteries used as power sources in products. Other UL standards may apply depending on the battery chemistry, pack configuration, application, or end product.

It is also important to distinguish between the certification of an individual cell and the evaluation of a completed battery pack. Using cells that have already been evaluated to an applicable safety standard can be an important part of the design strategy, but it does not necessarily mean that a newly designed battery pack automatically meets all requirements applicable to the finished assembly.

For engineers, identifying the appropriate standard early can influence cell selection, protection circuitry, mechanical construction, wiring, materials, and other design decisions.

IEC 62133 and International Battery Safety

For portable rechargeable batteries, IEC 62133 is another important standard engineers may encounter.

The IEC 62133 family addresses safety requirements for portable sealed secondary cells and batteries containing non-acid electrolytes. Different portions of the standard address nickel and lithium systems.

IEC requirements can be particularly important for products intended for international markets or applications where the end-product standard references IEC battery safety requirements.

As with UL requirements, engineers should determine whether IEC 62133 or another application-specific standard applies before the design is finalized.

UN 38.3: Certification for Transportation

One of the most commonly misunderstood battery requirements is UN 38.3.

Unlike product safety standards, UN 38.3 focuses specifically on the transportation of lithium cells and batteries. Lithium battery designs must successfully complete a defined series of tests before they can be transported under applicable shipping regulations.

These tests address conditions batteries may encounter during transportation, including altitude simulation, thermal cycling, vibration, shock, external short circuit, impact or crush, overcharge, and forced discharge, as applicable.

A battery pack that has successfully completed UN 38.3 testing is not automatically certified to UL or IEC product safety standards. Likewise, meeting a product safety standard does not eliminate applicable transportation requirements.

For OEMs shipping lithium-powered products, both areas may need to be addressed.

What About Medical and Other Specialized Applications?

Battery certification becomes even more application-specific when the pack is incorporated into regulated or specialized equipment.

Medical devices, industrial systems, mobility products, communications equipment, and other applications may be subject to additional standards governing the complete product.

The battery and charger can therefore affect a much larger compliance strategy. For example, component selection, protection circuitry, charging behavior, temperature monitoring, and electrical isolation may all influence the evaluation of the finished device.

This is why Cell-Con encourages customers to discuss certification requirements early in the development process rather than waiting until a battery design is ready for production.

Certification Should Begin at the Design Stage

One of the biggest mistakes an OEM can make is treating certification as the final step of battery development.

Requirements identified late in a project can result in changes to:

• Cell selection
• Battery management and protection circuitry
• Connectors and wiring
• Enclosure materials
• Mechanical construction
• Charging systems
• Labeling and documentation

Even seemingly minor changes to a battery design after testing may need to be reviewed to determine whether additional evaluation is necessary.

By defining target markets, end-product requirements, and anticipated certifications at the beginning of the project, engineers can design with those requirements in mind.

Testing the Complete Battery Solution

Certification is only one part of developing a reliable battery pack. Functional testing during production is also important for confirming that manufactured packs continue to meet the intended design requirements.

Cell-Con uses automated battery pack testing equipment to evaluate key electrical and functional parameters. Depending on the battery design, testing can include open-circuit voltage, overvoltage and overcurrent protection, temperature sensing, impedance, charging functionality, and communication functions within smart battery packs.

This combination of thoughtful design, third-party certification support, and production testing helps create a more complete approach to battery pack quality and reliability.

How Cell-Con Supports Battery Certification

Navigating battery standards can be complex, particularly when a product will be sold in multiple markets or used in a highly regulated industry.

Cell-Con works with established third-party testing laboratories and supports customers throughout the testing and approval process. Our engineering team can produce the samples required for testing and help incorporate certification requirements into the battery pack design from the beginning.

The goal is not simply to design a battery that meets electrical specifications. It is to develop a battery solution that supports the performance, safety, compliance, and market requirements of the complete product.

Whether you are developing a new battery-powered device or updating an existing design, involving your battery partner early can help make the certification process more predictable and reduce the risk of costly changes later in development.

Contact Cell-Con to discuss your battery pack requirements, target certifications, and application needs with our engineering team.