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Panel 3 - High Energy Lithium Ion Batteries - North America Consumer Product Safety Summit

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Hazards associated with high energy density batteries are common to all three jurisdictions. How can risk to consumers be reduced and what steps have already been taken by stakeholders in North America? Points of focus: 1. Industry's product safety processes pre- and post-market. 2. Understanding and eliminating failure modes. Challenges and how can stakeholders and regulators work together to improve safety?
Presenters: Charlie Monahan, Director, Regulatory Compliance, Panasonic; Don Mays, Chief Safety and Quality Officer, Samsung; Rick Brenner, President, Product Safety Advisors, LLC.

Published in: Government & Nonprofit

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Panel 3 - High Energy Lithium Ion Batteries - North America Consumer Product Safety Summit

  1. 1. Panel 3 - High Energy Lithium Ion Batteries Charles P. Monahan Director Regulatory Compliance Panasonic Part 1: Battery Design and Manufacture
  2. 2. Part 2: Case study on Samsung Galaxy Note 7 Panel 3 - High Energy Lithium Ion Batteries Don Mays Chief Safety and Quality Officer Samsung
  3. 3. Panel 3 - High Energy Lithium Ion Batteries Rick Brenner President Product Safety Advisors Part 3: An Importer’s Perspective
  4. 4. Charles P. Monahan Panel 3 - High Energy Lithium Ion Batteries Part 1: Battery Design and Manufacture
  5. 5. How lithium ion batteries work Separator Positive Electrode Negative Electrode Part 1 - Battery Design and Manufacture
  6. 6. Cylindrical Cell Design Part 1 - Battery Design and Manufacture
  7. 7. Thermal Runaway Part 1 - Battery Design and Manufacture 1. Heating starts 2. Protective layer breaks down 3. Electrolyte breaks down into flammable gases 4. Separator melts, possibly causing a short circuit 5. Cathode breaks down, generating oxygen Anode (Carbon) Protective Layer Electrolyte (lithium salt in organic solvent) Separator Cathode (Lithium metal oxide)
  8. 8. Systems Approach to Safety Part 1 - Battery Design and Manufacture Environment • Communication • Software Interface • Power Conditioning and Protection Communication to the End User End UserCell Battery Pack Host Device Power Supply Accessories • Communication • Electronic and Mechanical Protection for Charge-Discharge, Short Circuit, and Temperature Extremes • Mechanical Characteristics • AC/DC Conversion • Power Conditioning and Protection • Notifications • Warnings • Actions Required End User Behaviour and Actions Cell End User Charge Control Source: IEEE 1725 
  9. 9. Panel 3 - High Energy Lithium Ion Batteries Part 2: Case study on Samsung Galaxy Note 7 Don Mays
  10. 10. Panel 3 - High Energy Lithium Ion Batteries  The Samsung Galaxy Note 7 Recall  Samsung’s 8 Point Battery Safety Check Test  Incident Data - Facts vs. Fiction  Authenticity Overview
  11. 11.  Introduced in August , recalled in September 2016  1 M in NA, 2.5 M globally  Over-communication to customers  97% recovery rate globally  Root cause analysis  Enhanced safety & quality process The Galaxy Note 7 Recall Part 2 - Case study: Samsung Galaxy Note 7
  12. 12.  - Part 2 - Case study: Samsung Galaxy Note 7 8-point Battery Safety Check Test ACCELERATED USAGE TEST
  13. 13. 8-point Battery Safety Check Test Part 2 - Case study: Samsung Galaxy Note 7
  14. 14. 8-point Battery Safety Check Test Part 2 - Case study: Samsung Galaxy Note 7
  15. 15. 8-point Battery Safety Check Test Part 2 - Case study: Samsung Galaxy Note 7
  16. 16. 8-point Battery Safety Check Test Part 2 - Case study: Samsung Galaxy Note 7
  17. 17. 8-point Battery Safety Check Test Part 2 - Case study: Samsung Galaxy Note 7
  18. 18. 8-point Battery Safety Check Test Part 2 - Case study: Samsung Galaxy Note 7
  19. 19. Part 2 - Case study: Samsung Galaxy Note 7 Multi-layer Safety Measures
  20. 20.  Use of Advanced Analytics to sense emerging issues  Internal, structured data  External, unstructured data  Smoke words lexicon  Identifying fraudulent claims Incident Data - Facts vs. Fiction Part 2 - Case study: Samsung Galaxy Note 7
  21. 21.  Testing fraud  Unauthorized repair service  The counterfeiting market  Trade dress infringements  Knock-offs  Back-room manufacturing  Fake/invalid safety certifications  Anti-counterfeiting strategies  Supply chain security and traceability  Overt and covert product identification  Web scraping and risk sensing  Government partnerships Authenticity – Challenges to Safety Part 2 - Case study: Samsung Galaxy Note 7
  22. 22. Part 2 - Case study: Samsung Galaxy Note 7 Don Mays Don.Mays@SEA.Samsung.com +1 (201) 957-2790
  23. 23. Panel 3 - High Energy Lithium Ion Batteries Part 3: An Importer’s Perspective Rick Brenner
  24. 24. Bringing Safe Lithium Ion Products to Market 4th North America Consumer Product Safety Summit May 4, 2018, CPSC Headquarters, Bethesda, MD Challenges for Suppliers, Distributors, Retailers and Importers
  25. 25. All views expressed and comments made in this presentation are my own and do not necessarily represent the views of any for profit or non-profit organization I have worked for or have the privilege to serve in a leadership position for. Disclaimer
  26. 26. Discussion Objectives • Challenges faced by suppliers, distributors, retailers and importers of lithium-ion powered products. • Contributing factors that make it difficult. • Suggestions of steps that could help make lithium-ion quality management easier and safer.
  27. 27. • Why did this occur? • What steps should we take in sourcing lithium-ion powered products to prevent this?
  28. 28. Power Bank Components • Lithium Ion Cell (18650 or Prismatic Shape) • Battery Management System (BMS) + Circuitry • Enclosure or Housing • Electrical Wire • Insulating materials.
  29. 29. Important Considerations • Cell Selection • Circuit Board Design (BMS + Voltage Regulator 5V USB to 3.7 V Lithium Cell) • Levels of Protection (if one circuit component fails in the life of the product, does the product protect itself) • Component Selection & Construction Requirements per robust safety standard(s) • 3rd party evaluation of circuit board design • 3rd party certification of battery/power bank
  30. 30. Is UN 38.3 Enough? • Should a transportation standard drive lithium-ion safety testing strategy? • UN 38.3 is about transporting a battery product, not using it. • Normal operation and foreseeable misuse tests from standards such as UL 2054 (Portable batteries), UL 2056 (power banks), UL 8139 (e-Cigs), etc. look well beyond the transportation of batteries, to the BMS, component quality and construction.
  31. 31. Is Generic Equivalent?
  32. 32. Are Claims of UL Compliance Misleading?
  33. 33. Licensing Surprise! Major Consumer Brand Name is the Same, Testing is not.
  34. 34. Request for Quotation MLB Team for Distribution at Stadium MLB Team Name Promotions Manager Name Job Title Address City State Zip Phone Fax Email PRODUCT DATA All dates, products, and quantities are subject to change Product: Portable Power Bank Description: 2000mAh – 5600mAh portable power bank (estimated) Event Date(s): Friday, May 1 Delivery Date: Friday, April 17 Pricing/Quantities: $3.00/ Bid 25,750 and 30,000 Dimensions: 3.75” x .75” x .75” (estimated) Materials: Hard Plastic or metal Material, easy to use, no on-off button Color: Color with Team Logo Printing on Product: Sponsor Logo TBD / Printed Box With Instructions inside. Packaging: Full Color Box Shipping: All cartons must be clearly marked and secured on pallets prior to actual delivery and each pallet must not exceed 7 feet in height. Shipments that are not palletized will be charged back for labor costs. Additional instruction may apply. All counts: units/carton, total cartons and total pallets along with any other pertinent shipping information should be provided as soon as available. – MUST PROVIDE SAMPLE UPON REQUEST Bid Information: Bid unit price must include and all fees and charges associated with production, handling and delivery to _________, and must also include expected art and production deadlines. Comments: Artwork will be provided on a confidential basis. Pre- production samples are requested. Quantity: 25-30K Target Price to Team: $3.00Cost to Distributor: $2.10 Cost to Importer: $1.50
  35. 35. Ideas to Improve Safety of Lithium Ion Powered Products CPSC current strategy is great first step. (“Status Report on High Energy Density Batteries Project” 2/12/18) • Improving Standards • Outreach to educate manufacturers, retailers and importers • Collaborate with external partners to broaden reach of information campaign • Improved screening of imported products CPSC endorse a stricter holistic standard for all lithium-ion powered products, including the battery management system, and mandate compliance as it did with personal e-mobility devices (hoverboards). Use Section 15(j) rule to declare that li-ion products without a certified BMS are a “substantial product hazard.” Greater clarity to manufacturers, retailers and importers of exactly what is required and expected, recognizing that a significant percentage of companies sourcing lithium-ion products – importers, distributors, retailers - have no electrical engineers on staff and no professional expertise in the chemistry, design or battery
  36. 36. Thanks and acknowledgments I am indebted to the generous technical assistance and professional guidance regarding lithium-ion safety provided for many years by Cindy Millsaps of Energy Assurance LLC and by Ibrahim Jilani of UL. Follow-up Questions: rick.brenner@productsafetyadvisors.com Thank you!
  37. 37. Questions? Panel 3 - High Energy Lithium Ion Batteries

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