Extend the life of Lithium-Ion batteries

Why lithium batteries age

Lithium-ion batteries operate through the movement of ions between the positive and negative electrodes. In theory, this process could continue indefinitely, but in practice factors such as charge cycles, high temperatures, and natural aging gradually reduce battery capacity over time.

Every time a battery is charged and discharged, it undergoes a cycle. Over time, these cycles contribute to capacity loss. Deep discharges (100% DoD — Depth of Discharge) can significantly reduce battery lifespan.

Avoiding full discharges and charging more frequently at partial discharge levels, for example around 20% DoD, is therefore an important strategy for extending battery life. A Cadex laboratory study showed that Li-ion batteries subjected only to partial discharge cycles lasted significantly longer than batteries that were fully discharged during each cycle.

- High temperatures

Exposure to high temperatures accelerates the chemical reactions inside the battery, leading to faster degradation. For example, a battery continuously stored at 40 °C may lose up to 35% of its capacity after one year, while the same battery stored at 25 °C may lose only around 20%.

This highlights the importance of temperature management in extending the lifespan of lithium-ion batteries. For business applications, storing batteries in cool environments and minimizing operation in high-temperature conditions is essential.

- High charging voltages

Continuously charging a battery to its maximum voltage can also shorten its lifespan. Most Li-ion batteries are charged to 4.2 V per cell to achieve maximum capacity, but lower charging voltages have been shown to extend battery life.

Reducing the charging voltage to, for example, 4.0 V per cell can significantly increase lifespan, although this comes at the expense of total capacity. This principle is already applied in industries such as aerospace and electric vehicles, where longevity is often more important than achieving maximum capacity.

- Natural aging over time

Regardless of usage, lithium-ion batteries gradually lose performance over time due to internal chemical processes. This natural aging process can be slowed by storing batteries under optimal conditions, such as in a cool, dry environment and at a partial charge level of approximately 40–60%.

Methods to extend life

Fortunately, there are several strategies business users can apply to extend the lifespan of lithium-ion batteries:

First, it is important to use proper charging and discharging practices. Avoid deep discharges and charge batteries more frequently at partial discharge levels. This reduces stress on the cells and helps extend operational life.

In addition, temperature management is essential. Batteries should be stored in cool, dry environments and protected from excessive heat. For applications operating in high-temperature environments, cooling systems can help regulate temperature and protect battery performance.

Elfa also offers advanced technologies and products that help optimize and extend the lifespan of lithium-ion batteries. These include advanced Battery Management Systems (BMS) and specially designed chargers that regulate charging voltage and reduce voltage-related stress.

Such systems can automatically optimize charging and discharging levels while continuously monitoring battery temperature to ensure safe operating conditions.

Best practices for business users

Different industries have specific requirements when it comes to maximizing battery lifespan.

- Medical devices

In the medical sector, batteries must perform reliably over long periods. High-cycle batteries combined with regular maintenance and calibration are essential. Since medical devices are often used continuously, carefully managing charging cycles and avoiding deep discharge is especially important.

- Industrial applications

Industrial applications require robust and reliable batteries capable of operating under demanding conditions. Battery management systems can optimize charging and discharging cycles while regulating temperature. This helps extend battery lifespan and improve overall equipment reliability.

- Transport sector

In sectors such as electric mobility and rail transport, proper thermal insulation and efficient charging systems are crucial. Effective temperature management helps minimize the impact of environmental conditions on battery performance, extending lifespan and improving operational reliability.

Conclusion

By understanding the factors that contribute to lithium-ion battery aging and implementing the right technologies and operating practices, business users can significantly extend battery lifespan.

Elfa Elementenfabriek offers a range of solutions to support this process, helping companies maximize the return on their battery technology investments. By following the recommendations outlined above, organizations can not only reduce operational costs, but also contribute to a more sustainable future.

What can Elfa do for your company?

Elfa offers high-quality batteries and lighting solutions tailored to professional and industrial applications. With more than 100 years of experience, we provide both standard products and customized solutions designed for optimal reliability and performance.

Our specialists are ready to advise and support you in selecting the right technologies for efficient and sustainable operation.

Contact us today and discover how Elfa can strengthen your business operations.