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

Panel 3 - High Energy Lithium Ion Batteries
Charles P. Monahan
Director
Regulatory Compliance
Panasonic
Part 1: Battery Design and Manufacture

Part 2: Case study on Samsung Galaxy Note 7
Don Mays
Chief Safety and Quality
Officer
Samsung

Rick Brenner
President
Product Safety Advisors
Part 3: An Importer’s Perspective

Charles P. Monahan
Part 1:
Battery Design and
Manufacture

How lithium ion batteries work
Separator
Positive
Electrode
Negative
Electrode
Part 1 - Battery Design and Manufacture

Cylindrical Cell Design

Thermal Runaway
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)

Systems Approach to Safety
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

Part 2:
Case study on Samsung
Galaxy Note 7
Don Mays

 The Samsung Galaxy Note 7 Recall
 Samsung’s 8 Point Battery Safety Check Test
 Incident Data - Facts vs. Fiction
 Authenticity
Overview

 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

 -
8-point Battery Safety Check Test
ACCELERATED
USAGE TEST

8-point Battery Safety Check Test

Multi-layer Safety Measures

 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

 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

Don Mays
Don.Mays@SEA.Samsung.com
+1 (201) 957-2790

Part 3:
An Importer’s Perspective
Rick Brenner

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

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

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.

• Why did this occur?
• What steps should we take in sourcing lithium-ion
powered products to prevent this?

Power Bank Components
• Lithium Ion Cell
(18650 or Prismatic Shape)
• Battery Management System
(BMS) + Circuitry
• Enclosure or Housing
• Electrical Wire
• Insulating materials.

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

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.

Are Claims of UL Compliance Misleading?

Licensing Surprise!
Major Consumer Brand Name is the Same, Testing is not.

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

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

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!

Questions?

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

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