From charge-discharge dynamics to multi-industry use cases, explore how our lithium battery packs deliver consistent performance, rigorous safety, and quality that meets the highest global standards.
Factors like cell chemistry, ambient temperature, C-rate (charge/discharge rate), and BMS control all impact performance. Overcharging or deep discharging will shorten battery lifespan.
Standard lithium batteries usually charge at 0.5C–1C and discharge at 1C–3C. High-performance cells can handle 5C or more, depending on design and cooling.
eBikes, energy storage systems, UPS, power tools, telecom base stations, medical devices, drones, and smart agriculture are all major applications.
Yes. For example, CE for Europe, UL for the US, UN38.3 for transport, and IEC62133 for reliability. MSDS and RoHS may also be required.
Standard tests include capacity, cycle life, BMS protection, insulation resistance, internal resistance, short-circuit test, and high-temp durability.
Yes. Reputable suppliers support inspections by SGS, TUV, Intertek, or your chosen agent. In-house reports are also commonly provided.
Low temperatures reduce ionic mobility, causing voltage drop and lower discharge capacity. Special low-temp cells or thermal solutions are used in such cases.
Certifications are valid for several years unless the battery design changes. Routine testing is recommended for each new batch or annual supply cycle.
Lithium batteries are known for their high energy density, efficiency, and relatively stable voltage discharge curve. However, how they charge and discharge varies significantly depending on current, temperature, cell type, and usage environment.
Unlike lead-acid batteries that use constant current, lithium batteries adopt a two-stage charging pattern: CC (Constant Current) followed by CV (Constant Voltage).
During the CC stage, the charger delivers a constant current until the cell voltage reaches its upper limit—typically 4.2V for Li-ion or 3.65V for LiFePO₄. Once this voltage is reached, the charger switches to CV mode, maintaining the voltage while the current gradually decreases to a cutoff point (usually 0.05C).
This process helps ensure maximum capacity without overcharging, which could lead to lithium plating or thermal runaway.
The discharge profile of lithium batteries is relatively flat compared to other chemistries, providing a stable voltage output throughout most of the cycle. Here’s what to expect:
High Energy Output: Voltage remains stable until around 80–90% of capacity is used.
Rapid Drop Near End of Cycle: Voltage falls steeply near the cutoff (e.g., 3.0V for Li-ion, 2.5V for LiFePO₄).
Rate Dependency: At higher discharge rates, both capacity and voltage drop faster due to internal resistance and thermal effects.
C-rate is a standardized way to express charge/discharge current relative to battery capacity:
| Symbol | Meaning | Example (for 10Ah cell) |
|---|---|---|
| 1C | Full capacity in 1 hour | 10A charge/discharge |
| 0.5C | Half capacity in 2 hours | 5A |
| 2C | Double capacity in 30 minutes | 20A |
Higher C-rates lead to:
Increased heat generation
Faster voltage drop
Shorter cycle life
LiFePO₄ cells usually support 2C to 3C discharge, while standard Li-ion ranges from 1C to 2C.
Lithium battery performance is highly sensitive to temperature. Charging below 0°C may cause lithium plating, while discharging above 60°C accelerates electrolyte breakdown.
| Temperature Range | Charging | Discharging | Notes |
|---|---|---|---|
| -20°C to 0°C | Not recommended | Limited capacity (~60%) | Risk of plating |
| 0°C to 10°C | Slow only | Reduced performance | Use 0.1C max |
| 10°C to 45°C | Optimal | Optimal | Ideal range |
| >45°C | Risk of swelling | Thermal stress | Need cooling |
A classic characteristic of lithium batteries is their voltage plateau during discharge, followed by a sudden drop. Here’s a simplified diagram you can use in visual format:
| Chemistry | Nominal Voltage | Charge Voltage | Cut-off Voltage | Max Discharge Rate |
|---|---|---|---|---|
| Li-ion (NCM) | 3.7V | 4.2V | 3.0V | 2C |
| LiFePO₄ | 3.2V | 3.65V | 2.5V | 3C |
| LTO | 2.3V | 2.8V | 1.5V | 10C |
Lithium battery charging and discharging behavior defines its safety, performance, and lifespan. Proper control of voltage, current, temperature, and C-rate is essential—especially when designing custom packs for mobility, energy storage, or high-drain applications.
From urban mobility to remote backup power, lithium batteries have revolutionized how industries store and use energy. Their lightweight structure, high energy density, and recharge efficiency make them indispensable across sectors.
This guide explores real-world industry applications, helping you match your product development or sourcing decisions with the right lithium battery solution.
The rise of eBikes and light electric vehicles has redefined urban commuting. Lithium battery packs provide the ideal balance of lightweight design, power density, and cycle longevity. eMobility applications demand high discharge performance (usually 1C–2C), intelligent BMS for cell balancing and safety, and robust housings for vibration resistance. Battery capacity typically ranges between 10Ah and 30Ah, with voltages like 36V, 48V, or 52V, depending on motor configuration and terrain adaptability. Waterproofing and fast charging options further enhance user satisfaction in urban and off-road environments.
Energy storage systems—both for residential and commercial use—rely heavily on lithium battery packs for stable, long-term energy retention. These systems are typically paired with solar or wind energy inputs, requiring batteries that support frequent charge/discharge cycles, low standby losses, and wide operating temperature ranges. The most common configuration is 48V or 51.2V using LiFePO₄ chemistry, with capacities ranging from 50Ah to over 200Ah per module. Features like battery modularity, stackability, and intelligent BMS (with RS485/ CAN communication) allow precise energy management, safety control, and scalability from homes to grid-scale installations.
UPS (Uninterruptible Power Supply) systems safeguard critical infrastructure—such as data centers, hospitals, and telecom facilities—by ensuring power continuity during outages. Lithium battery packs for UPS applications must deliver instant response (within milliseconds), stable voltage, and high reliability. Compared with lead-acid, lithium solutions offer smaller footprint, longer service life (3000+ cycles), and better heat tolerance. Typical voltages are 24V, 48V, or 96V, with capacity from 10Ah to 150Ah depending on backup duration requirements. For enterprise-grade setups, hot-swappable modules and smart BMS with real-time diagnostics are essential.
Cordless power tools rely on compact, high-drain lithium battery packs to deliver strong torque and long-lasting performance. These batteries must support high peak currents (up to 20A+), fast charging, and be rugged enough to withstand drops, dust, and vibration. Most tools use 18V or 21.6V packs based on 18650 or 21700 cylindrical cells, with BMS optimized for heat and overload protection. For industrial users, swappable battery packs reduce downtime, while fuel gauge LEDs and reinforced casings improve operator experience. The market prioritizes energy density, weight balance, and safety above all.
Wearable health devices demand lightweight, compact lithium batteries that provide consistent low-current output and extended runtime. Common use cases include heart monitors, insulin pumps, and portable ECGs. These batteries are typically pouch cell–based, rated 3.7V with capacities between 500mAh–3000mAh, and must meet strict safety and biocompatibility certifications (e.g. IEC 62133, UN38.3). Key requirements include low self-discharge, stable voltage, and soft-pack form factors that suit ergonomic designs. Integration with smart devices and Bluetooth modules also necessitates BMS with precise voltage regulation.
Mobile systems such as patient monitoring carts, portable ultrasound machines, and ventilators require high-capacity lithium batteries that deliver stable power across long shifts. These systems favor 24V or 36V packs built with Li-ion or LiFePO₄ cells, capacities ranging from 10Ah to 40Ah. Medical-grade BMS is essential to ensure fault detection, thermal control, and redundancy. Hospitals also prioritize silent operation, battery hot-swap ability, and certifications for medical electrical safety (IEC 60601). Long cycle life and clean integration into enclosure cabinets are top design priorities.
Modern agriculture is transforming with the rise of electric drones and smart farming equipment. Agricultural drones require lightweight yet high-capacity lithium battery packs capable of high discharge (5C–10C) to support lift, hover, and spray functions. Most use 6S–12S packs (22.2V to 44.4V) with capacities from 10Ah to 30Ah, often based on 21700 or pouch cells. Fast charging and modular replacement allow field workers to minimize downtime during operations. For ground-based autonomous machines, LiFePO₄ batteries offer long cycle life, weather tolerance, and GPS + sensor integration for precision farming.
Telecom base stations—especially in off-grid or remote regions—depend on lithium battery packs to maintain uninterrupted signal transmission during blackouts or grid instability. These battery systems must handle deep discharge, extreme temperatures, and long standby periods. LiFePO₄ batteries (48V, 51.2V, or 96V) are commonly used, with capacities ranging from 50Ah to 200Ah per rack. Systems typically integrate solar power and require intelligent BMS with RS485/CAN interfaces for remote monitoring. High energy density, fire safety, and long service life (4000+ cycles) make lithium the top choice over lead-acid alternatives.
In the lithium battery industry, quality control (QC) isn’t just a process—it’s a buyer’s safeguard. Poor battery quality can lead to overheating, swelling, shortened lifespan, or even serious safety hazards. For B2B buyers—especially those in Europe, North America, and industrial sectors—QC is tied to brand reputation, compliance, and customer trust.
At Junda, we treat every battery pack as a mission-critical component. That’s why we implement a multi-stage QC system—from cell inspection to final pre-shipment tests—ensuring that every battery delivered meets international safety, performance, and traceability standards.
Key benefits of strict QC include:
Reduced risk of product recall or failure in the field
Improved consistency across batches and production lines
Increased trust from partners, resellers, and certification bodies
Compliance with regulatory standards like UN38.3, IEC 62133, and ISO 9001
Before assembly begins, all raw materials are thoroughly checked for defects and consistency.
| Item | Test Content | Equipment |
|---|---|---|
| Battery Cells | Appearance, nominal capacity, voltage consistency | Multimeter, AC Impedance Tester (TH2512) |
| BMS PCB | Protection functions: overcharge, overdischarge, short circuit | Custom Function Test Bench |
| Connectors & Wires | Conductivity, coating quality, dimensional tolerance | Caliper, Resistance Tester |
At each step of assembly, we verify the integrity of the process to avoid cumulative defects.
| Procedure | Test Content | Equipment |
|---|---|---|
| Spot/Laser Welding | Weld strength, voltage drop | Laser Weld Monitor, CCD Imaging System |
| Cell Grouping | Voltage and current balance between cells/modules | Precision Multimeter, Programmable Load (ITECH IT8511) |
Every finished battery pack goes through a comprehensive validation process.
| Procedure | Test Content | Equipment |
|---|---|---|
| Spot/Laser Welding | Weld strength, voltage drop | Laser Weld Monitor, CCD Imaging System |
| Cell Grouping | Voltage and current balance between cells/modules | Precision Multimeter, Programmable Load (ITECH IT8511) |
Essential tests and equipment used to ensure lithium battery pack safety, stability, and compliance.
Lithium battery packs must undergo a series of standardized inspections to meet safety and performance requirements. These tests help detect issues early—before shipment—ensuring stable voltage output, safe BMS behavior, reliable welding joints, and certified safety under abnormal conditions. Here’s a breakdown of the most common test items and corresponding devices.
| Test Item | Purpose | Typical Parameters | Common Equipment | Equipment Model |
|---|---|---|---|---|
| Open Circuit Voltage (OCV) | Checks cell consistency and charge state | 3.0V–4.2V (Li-ion) | Digital Voltmeter / Cell Sorting Machine | HP-770D, BST-880 |
| Internal Resistance (IR) | Identifies aging or faulty cells | <20mΩ typical (depends on cell size) | IR Tester / ESR Meter | Yokogawa BT4560, TES-3092 |
| Capacity Test | Measures actual cell capacity | Measured in mAh or Ah | Charge-Discharge Tester | NEWARE BTS-4000, Arbin LBT |
| Charge/Discharge Cycle | Validates cycle life and stability | 300–2000 cycles | Programmable Cycler | LAND CT-4008, Chroma 17010 |
| BMS Function Test | Checks protection (OV, UV, OC, OT) | Cut-off at 4.25V / 2.5V / 50A / 65°C | BMS Tester / Software Debugger | JBD App, ChuangXinHi Debugger |
| Short Circuit Test | Evaluates reaction under high current | Short via 5mΩ shunt resistor | Short-Circuit Tester Box | Custom-built / UL1642 setup |
| Drop & Vibration | Simulates transport shock | 0.5–1m drop / 10–55Hz sweep | Drop Tester / Vibration Table | Haida HD-A520, Kingpo KM-8201 |
| Insulation Resistance | Checks insulation between terminals | >10MΩ @ 500V DC | Insulation Tester / Megohmmeter | HIOKI IR4057, Kikusui TOS9200 |
| High-Temp Aging | Evaluates stability over time | 45–60°C for 8–48h | Aging Oven / Temp Chamber | Shinewell SH-80, ESPEC SH-241 |
Lithium battery performance is defined not only by its charging and discharging behavior but also by how it’s tested, applied, and controlled. Fast charging, deep discharging, and high load demands all impact battery health. These batteries are now widely used across industries—from eBikes and energy storage systems to UPS, power tools, and medical devices. To ensure safe, stable operation, manufacturers rely on rigorous testing processes that evaluate capacity, thermal stability, cycle life, and real-world stress. Reliable suppliers must provide comprehensive test reports, support third-party inspections, and meet global standards like UN38.3, CE, and UL to reassure B2B buyers.
Need a custom lithium battery pack? Just send us your specs—we’ll help you choose the right voltage, case, and configuration for your application.
At JUNDA, we make customization easy. Follow these 3 simple steps to start today:
Send your battery requirements — voltage, capacity, casing type, or upload drawings/photos.
We’ll evaluate your specs and recommend the best configuration. A detailed quote will be sent within 24 hours.
After approval and deposit, we start production. Shipping and tracking will be arranged for fast, secure delivery.
