Any equipment used in the front line of surgical or medical applications must meet the stringent requirements and industry standards of this demanding sector.

Steatite has decades of experience in designing, prototyping and manufacturing batteries for use in healthcare settings, and our capabilities in this area are extensive.

What are the common requirements for medical batteries?

The paramount requirement in supplying battery packs for medical applications is reliability. Batteries must run continuously, often for lengthy procedures, without experiencing overheating or variation in discharge performance.

Battery packs must meet rigorous safety standards to prevent any risks of fire, explosions, or leakage of hazardous substances. A BMS (Battery Management System) should be incorporated to provide built-in protection mechanisms, such as protection against overcharge, over-discharge and short-circuiting.

Being able to easily monitor the battery’s state of charge is also essential. Some devices even require a certain threshold capacity before they are operable at all, to ensure that they don’t require changing or charging at a critical point of surgery.

Almost all batteries for use in the medical sector will need to comply with IEC 62133 or its regional equivalent. This is an international standard for the safety of rechargeable batteries, and is a cornerstone for obtaining approval for devices from the UK Medicines and Healthcare products Regulatory Agency (MHRA), US Food and Drug Administration (FDA) and other global regulatory bodies.

Our proven expertise

We have several customers in the medical sector who have specified a range of parameters for their power requirements, so we have various tried-and-tested battery designs for this industry.

Examples of existing Steatite battery systems

Patient monitoring systems

We currently supply a battery consisting of 2S3P 18650 cells for a ruggedised ambulatory patient monitoring system, capable of recording and transmitting patient data from first responders directly to A&E departments and receiving hospitals.

The cell selection enables the monitor to perform across the widest operational environments while maintaining and communicating critical patient data. The lithium-ion 7.4V 10.2Ah battery is built and tested to the highest tolerances using free issue plastics maintaining the IP66 rating for the device and its UN certification. It also includes a TI fuel gauge and state of charge LED indicators.

Hand-held surgical power

For another customer, our team has developed power packs for battery-operated tools for bone surgery to deliver consistent, reliable power within a highly-regulated medical environment. The range includes both Nickel-Metal Hydride (NiMh), Lithium Ion and Lithium Ferro Phosphate (LiFePO4) batteries. NiMh cells offer good power delivery, tolerate a wide operating temperature, and can be less complex than lithium alternatives. Where runtime and comfort are important, our Lithium based options improve overall energy density including battery capacity-to-weight ratio by around 25% and an increase in delivered power of up to 20%.

Battery-powered ventilators

Another medical customer approached us about providing batteries for its range of portable ventilators. The result was a new rechargeable battery solution that is the sole source of energy for the equipment, including one internal and one external battery, all thoroughly tested and compliant to medical standards.

Powered air-purifying respirators (PAPRs)

For these devices, we have designed batteries with bespoke mechanical enclosures fit for respiratory protection in harsh and critical environments, which may be helmet integrated or body worn. We’ve engineered solutions using both NiMH cells, which are recommended for hazardous areas, and Li-ion cells where space, weight, run time and whole life costs are important.

Portable microwave devices

Our battery design skills have also been put to good use for a compact and portable device in the fight against cancer. Our team was involved right from the beginning of a new project and helped guide the manufacturer through the cell selection process, battery design, prototype development, testing and final production. We also designed the electronics for the custom-built charging station.

One stipulation for this project was that the customer requested all our electronics to establish a handshaking protocol in order to operate, meaning that batteries couldn’t be replaced at a later date with alternative models which may not have been tested to the correct medical standards.

Mobile ultrasound

In the veterinary  sector, where adaptability to diverse weather conditions and limited space are the norm, handheld devices are essential tools.

Partnering with IMV, the leaders in veterinary imaging, we supply cutting-edge battery technology that powers their reliable handheld porcine ultrasound devices. This collaboration yields several thousand units annually, demonstrating both companies’ commitment to powering innovation. Together with IMV, we’ve engineered a robust and enclosed power solution, specially designed for monitoring lively piglets in challenging environments. This collaboration showcases our dedication to delivering advanced, reliable, and versatile solutions for the veterinary industry.

Medical carts and UPSs

Another customer in the medical sector has benefitted from our lead acid battery provision for medical carts. These provide an uninterruptible power supply (UPS) to provide automated backup power in the event of battery or mains failure. Therefore, it goes without saying that reliability is absolutely critical.

Why choose Steatite?

Our large portfolio of customers in the medical sector prove that we are trusted to deliver reliable and efficient battery solutions to this industry. Many of our designs are already certified to IEC 62133 or UL 62133 and these designs can be quickly customised by our expert team to fit the space, power and performance requirements of a huge range of medical devices and scenarios.

In addition to our proficiency in power, we have further capabilities across the business and can combine solutions beyond just batteries.

For example, we offer a wide selection of computers and panel PCs specifically for medical applications. Many of these are certified to EN60601 and incorporate IP rated enclosures to allow for thorough cleaning, plus the transmission of viruses and bacteria is prevented by anti-microbial housing.

Our imaging business unit, Active Silicon, is a leading provider of imaging products for surgical microscopy, ophthalmology, patient positioning systems and other medical devices. Embedded vision systems support computer vision assisted surgery, frame grabbers enhance image acquisition for digital slide scanners and autofocus-zoom cameras capture and transmit HD video for real-time viewing and training purposes.

If you’re involved with designing and manufacturing medical devices, contact our team to discuss your requirements and see what proven products we can offer or modify to meet your exact needs.

Transporting lithium metal and lithium ion batteries means adhering to international regulations. These cover stringent testing, package and storage requirements to ensure the safe containment and carriage of all lithium-ion cells and batteries.

Our battery team has thorough knowledge of the safest and fastest way to transport lithium cells and batteries over land, sea and air. We’ve compiled some FAQs to support you with your transportation queries, but get in touch directly for door-to-door expert assistance.

Why are there rules in place for storing and transporting lithium batteries?

Lithium batteries, under certain conditions, can disassemble rapidly, leading to the risk of fire which can be particularly difficult to extinguish. Should this happen in storage or transit, it poses a risk to life which transport companies must mitigate. Regulations are in place to minimize the chance of a fire breaking out.

Who makes the rules?

Transporting lithium batteries via air is regulated by the global trade association for airlines, the International Air Transport Association (IATA), and the UN specialised agency, the International Civil Aviation Organisation (ICAO) within their Technical Instructions for the Safe Transport of Dangerous Goods by Air document.

Sending lithium batteries via sea is overseen by the UN specialised agency, the International Maritime Organisation (IMO), according to their International Maritime Dangerous Goods Code (IMDG).

When transporting lithium batteries via road within Europe, carriers must adhere to the Agreement concerning the International Carriage of Dangerous Goods by Road (ADR), set by the United Nations Economic Commission for Europe (UNECE).

For rail transport, the Intergovernmental Organisation for International Carriage by Rail (OTIF) has its Regulations concerning the International Carriage of Dangerous Goods by Rail (RID).

It’s important to note that local or national regulations take priority over UN instructions and must be legally adhered to over and above the standards set by UN bodies.

Which UN Regulations need to be met?

UN 3090 comprises the United Nations regulations covering Lithium metal batteries (shipped by themselves).

UN 3091 comprises the United Nations regulations covering Lithium metal batteries contained in equipment or packed separately with a piece of equipment.

UN 3480 comprises the United Nations regulations covering Lithium-ion batteries (shipped by themselves).

UN 3481 comprises the United Nations regulations covering Lithium-ion batteries contained in equipment or packed separately with a piece of equipment.

Is there a difference in transporting lithium cells and lithium batteries?

To clarify, a lithium cell is a single unit consisting of a positive and negative electrode that exhibits a voltage differential across the two terminals. A battery is a collection of cells which are electronically connected. Both batteries and cells are subject to the same transportation regulations under the Dangerous Goods Act.

How should lithium batteries be packed for transport?

Cells and batteries must be packaged so that they can’t come into contact with conductive material which may result in a short circuit leading to disassembly. Devices should therefore be wrapped individually in rigid, strong non-conductive packaging unless the device itself provides comparable protection.

It’s also advisable to ensure that any switches on devices are covered or secured so the device can’t be accidentally switched on during travel.

What labelling and documentation is required?

Packaging containing lithium cells or batteries must display all of the relevant markings, see the example below. The border of the mark must have red diagonal hatchings with a minimum width of 5mm. The symbol (group of batteries, one damaged and emitting flame, above the UN number for lithium ion or lithium metal batteries or cells) must be black on white or a suitable contrasting background.

The mark must be in the form of a rectangle or a square with minimum dimensions of 100mm x 100mm. See reference to the relevant shipping method required for full details.

IATA does not require a material safety data sheet (MSDS or SDS), or the UN 38.3 test data report as part of the required documentation requirements when offering lithium batteries for transport.

What else do I need to know?

When shipping Section IB lithium cells and batteries, it’s important to know that Dangerous Goods Training will be required. This is because all elements of the Dangerous Goods Regulations apply to these cells and batteries (exceptions are listed in Section IB). “IB” must be added next to the packing instruction number “965”.

I’m confused, who can help me?

The transportation of lithium cells and batteries is complex, but at Steatite we have the expertise and necessary authorisation to transport lithium batteries both nationally and internationally. Our battery specialists are always on hand to guide you through your engineering and logistical requirements.

Contact the team for help.

Designing and manufacturing superior custom batteries

Steatite has extensive experience of manufacturing custom battery packs and we’ve just added extra capability to our remit.

Our engineers have been successfully spot welding and arc welding packs for a number of years. Spot welding is suitable for the vast majority of our cells, where parts are up to 3mm in thickness. The process does not require excessive heat and the energy delivered to the spot can be carefully controlled to produce reliable welds. Our semi-automated production lines are tailored specifically to create the optimum bond for specific cells and applications, and regularly adapted for changing requirements.

We’ve recently installed an Asterion wire bonder, manufactured by K&S and provided by Inseto to add wire bonding to our inhouse capabilities.

Compared to traditional methods of interconnecting, wire bonding enables manufacturers to offer custom battery packs with high discharge capabilities and reduced assembly time (in a shorter lead time) which meet even higher levels of reliability and safety. Wire bonding helps to prolong cell life and improve battery performance as a result of lower resistance.

Steatite specialises in creating custom batteries which often need to be built in a particular size and shape for unusual housings, and wire bonding allows us the flexibility to place cells in tailored positions and still maintain strong and dependable connections.

What is wire bonding?

Wire bonding is an interconnect technology used to bond integrated circuits, semiconductors and other electronic devices. The process is used by high quality battery manufacturers for the production of Lithium-ion battery pack assembly.

There are three different types of wire bonding: ball bonding, suitable for small wires only; wedge bonding, suitable for small and wide diameter wires; and compliant bonding.

In addition, different wire bonding techniques can be used:

• Thermocompression (wedge: ball) bonding is the original technique, dating back to 1957. This method requires high force and high temperature – around 300°C – but is
viewed as reliable and robust.

• Ultrasonic (wedge: wedge) bonding relies on pressure and vibrational energy and so is carried out at lower temperatures (around 25°C) and is the most common technique for
Aluminium wires.

• Thermosonic (ball: wedge) bonding is the most prevalent method of wire bonding and is conducted at temperatures between 100°C and 240° High pressures are not required
as the bond is formed through ultrasonic energy.

Gold was originally the material of choice for wire bonding technology but Aluminium has now become increasingly widespread due to its good electrical performance and lower cost. Copper wire is another option and is favoured by some manufacturers due to its inherent stability and similarly low cost.

Steatite’s wire bonder

The Asterion model is a rotary head ultrasonic wedge bonder featuring a graphical bond head setup, advanced bond process diagnostics, integrated pull test & loop control with an optional configurable bond head, segmented bonding, extensive logging capabilities, and advanced vision for component alignment.

This model was selected due to the larger bondable area: the 300 x 300mm working area and 0.1μ resolution is ideal for ultrasonic bonding of large wires and ribbons to batteries. The low operating temperature means that components are less likely to be damaged during the process, making the resultant battery packs robust and reliable. Creating new wires is simple and intuitive using the windows-based graphical user interface.

Pull testing capability was also particularly important in the selection process to ensure every pack which leaves our manufacturing site is as robust as possible. The process involves positioning a hook underneath the wire and pulling either until the bond breaks (destructive testing) or a pre-defined force is reached (non-destructive testing).

The location of the wire bond on the bond pad is, of course, extremely important for a secure bond, and we are confident that the Asterion bonder maintains excellent control of bond positioning.

Build, test and test some more

To ensure that Steatite battery packs are correctly and safely bonded, they are tested to comply with several standards, including MIL-STD-883. This military-grade standard stipulates the following mechanical tests for electronics:

• Internal visual.

• Destructive bond pull test.

• Non-destructive bond pull test.

• Ball bond shear test.

• Constant acceleration.

• Random vibration.

• Mechanical shock.

• Stabilisation bake.

• Moisture resistance.

Our engineers also have the capability to design and build bespoke test equipment to analyse, program and test many of the custom battery packs that we design and manufacture. For our more advanced batteries that are designed to operate in high temperature environments, we also have a large thermal test chamber.

Additionally, our battery test facility houses a large selection of power supplies and electronic loads to enable automated emulation of customer applications to aid with testing suitability and projected lifetime of battery packs, often before the final application design is completed.

Power failure is not an option in many of the critical applications we manufacture batteries for. With our best-in-class wire bonding facilities and stringent test capability, customers can be assured that our battery packs will deliver consistent power throughout the lifecycle of the pack.

Expert battery engineering

We will now be able to deliver wire bonded battery packs to customers covering a range of applications including medical, industrial, oceanographic, transport and energy.

We know that every cell that leaves our factory having been wire bonded is safe, reliable and robust. This is in addition, of course, to our traditionally bonded battery packs which have been tried and tested over decades.

See more of what we do and how we can support your standard or custom battery pack requirements: https://custompower.co.uk/

Since the Industrial Revolution, humans have relied more and more on innovations in the Energy sector to keep up with their insatiable demand for power. In this insight, we take a look at some of the developments around powering industry, and keeping maintenance costs and downtime low. 

From renewable wind power to alternative uses for fossil fuels, the technology driving the Energy sector is hugely diverse.

UAVs for wind turbine inspection

Inspection is an essential aspect of operations and maintenance (O&M) in many industrial settings, and inspection in the Energy sector presents some particularly unique challenges. Wind turbines can be up to 250m high with blades reaching over 100m in length¹ and, by their very nature, are often in remote and wind-swept locations.

Assessing each turbine within an on- or offshore wind farm using the traditional methods of ropes or elevated platforms is both dangerous and hugely time-consuming, and those factors together make it expensive. Cameras on the ground can be used for visual inspection, but errors can easily be missed. Remote controlled UAVs are transforming the inspection process as they are able to perform accurate inspections much more quickly and safely.  

The environmental conditions for these inspection drones present multiple challenges. Extremes of temperature, high levels of dust in arid regions and high salinity in offshore installations all mean that UAVs must be ruggedly built and rigorously tested before being deployed. Add to that the high winds and huge turbulence created by the massive blades, and it’s clear that drone operation and communication are likely to be tested to the limit. 

Batteries for UAVs must be reliable and lightweight and there’s a happy medium to find in terms of balancing this power to weight ratio. Longer flights are more cost-effective than multiple, shorter ones so it’s important to get the right power supply. Similarly, communication between the vehicle and the controller, or even between multiple drones, is paramount but a drone must remain aerodynamic and agile without being restrained by protruding antennas. Transmission must be able to navigate around obstacles and through turbulent air flows. Video and image capture needs to be high-resolution and easy to process. Technicians will find themselves with thousands of images and hours of video to monitor, and machine learning techniques and developments in AI are helping to accurately identify flaws, oil leaks and damage to the turbines faster and more reliably than the human eye.  

Of course, UAVS designed for inspection of wind turbines will also be suited to other Energy processes such as surveying dams providing hydroelectric power and examining vast areas of solar panels, where similar difficulties arise. 

Our battery experts have decades of experience in designing and building battery packs for challenging applications. Inspection drones have very specific requirements and our team will advise designers on the best size, shape and performance options, whether that’s using Lithium-ion based cells or alternative chemistries. Furthermore, Steatite manufactures and supplies custom Battery Management Systems (BMS) which optimise the lifetime and performance of any battery pack as well as keeping the pack safe. 

Steatite’s Communications business unit provides market-leading wireless RF Unmanned Communication solutions which are ideal for ground-to-air contact and control. Based on the functional MPU5 radio unit, the Embedded Module provides built-in HD video encoding, Ethernet, RS-232 over IP, range extension, and an extremely high throughput Mobile ad hoc network (MANET) to make sure operators have secure, consistent and practical communication with their UAV. 

For compact and powerful image capture and transmission, our imaging subsidiary, Active Silicon, has a range of autofocus-zoom cameras and versatile camera interface boards which makes imaging simple. Cameras and processor boards can output in several formats including HD-SDI, USB3, HDMI and Ethernet IP meaning image data can be processed by a wider range of software. 

Crawler robots for nuclear inspection

When nuclear power plants were first built, inspection had to be carried out by humans operating for short periods of time so as to not expose themselves to dangerous levels of radiation for too long. Thankfully, robotic solutions were quick to make an appearance, and even by the 1980s non-destructive examination (NDE) was automated in many plants.

The first systems were large, inflexible and required assembly onsite. Developments over the last decade or so have transformed inspection capabilities with the introduction of highly technical climbing and crawler robots. 

Requirements of crawler robots are mostly fourfold: the device must have the mechanics and power to move, roll or climb as required; the ability to capture images and video footage in a suitable format; tools to navigate around tanks, pipes and platforms; and the necessary software to make judgements on the flaws or leaks that it “sees”. Many robots are additionally fitted with gas detection instruments to identify invisible gas seepages. Another complication is that water and chemical storage tanks need to be inspected inside and out, so some robots are required to successfully operate underwater. Robots and ROVs must be exceptionally agile, being required to turn on a small axis to get in and out of tight spots, and rotate around the whole circumference of pipes, internally and externally. This will require compatibility with slip rings for robots operating with an umbilical cord. 

Through its imaging business unit, Steatite provides a range of cameras and interface boards which are capable of transmitting high-speed, high-resolution image and video data along very long cables even over slip rings. The use of High-Definition Visually Lossless CODEC (HD-VLC) technology means that our Harrier range of cameras and processor boards can transmit over twisted pair cables up to 150m and coax cables up to 700m, with fibre optic offering the option of many kilometres.  

The Steatite Power team are well used to customising battery packs for specific applications such as remote inspection, and can design and manufacture housing that can withstand high levels of dust, vibration and water ingress. Our embedded computing capabilities add intelligence and powerful processing to robotics and ROVs, often being based on an NVIDIA Jetson AI-ready solution. 

Position/Navigation/Time (PNT) components supplied by Steatite can be built into ROV and robot solutions to add precise location and navigational capability. Using both GNSS and an IMU (inertial measurement unit), the units benefit from low SWaP (Size, Weight and Power) ratio and are designed to military-grade shock, vibration and EMC standards.

Meeting battery requirements for oil and gas

While the drive for cleaner, renewable energy is surging, we can’t avoid the truth that fossil fuels are still currently essential in our energy grids. In 2019, it was estimated that gas provided 38,517 terawatt hours and oil 53,620 terawatt hours of our power – roughly doubled from the provision in 1980². 

Oil and gas can be broken into three branches – upstream (exploration and extraction), midstream (storage and transport) and downstream (refining and distribution).

Each of these branches has specific requirements when it comes to developing technical solutions and the good news is that these developments will inevitably also benefit other areas of industry and research. 

At the upstream phase, the downhole environment is particularly challenging for batteries, with extremes of temperature, shock and vibration way beyond that found in other harsh environments. Due to oil and gas field locations, temperatures at the surface can drop to -40°C while operating temperatures underground can easily reach 180°C. Luckily, Steatite has a range of battery packs for use in the oil and gas industry that are UN approved for transportation, and highly suited for use with industry standard tools and gauges.  

Similar to the robotic inspection devices mentioned above, requirement for pigging batteries are also complex. Supplying reliable and rugged battery packs for PIGS (pipe inspection gauges) allows critical data to be continuously and accurately collected to monitor the condition of pipelines in the midstream phase. 

Tools used in the upstream phase for refining and distributing oil and gas are subject to hazardous and potentially explosive conditions. Steatite supplies ATEX batteries for such environments, specifically designed to conform to European Union directive 94/9/EC. This means that battery-powered equipment for use in such conditions provides increased levels of protection to operators. Furthermore, our power experts will select the optimum chemistry and cell design for the varied complications presented by fuel distribution. 

The Energy sector is transforming rapidly as it adapts to pressures from depleting natural resources and demands for more sustainable output. Global leaders are under pressure to reduce their national reliance on fossil fuels to help meet stringent targets for greenhouse gas emissions and greatly reduce harmful pollutants. Pressure from environmental organisations will only increase in the coming years, and energy providers are quickly adapting existing skills and adopting new methods of producing cleaner energy. 

The technology supporting this industry therefore has to transform too, and Steatite products and expertise are enabling developments across the globe. One such area is that of energy storage, and we can advise on power packs with larger capacities and more gradual discharge to meet these requirements.

Read more about our capabilities in the Energy sector: https://www.steatite.co.uk/wp-content/uploads/Steatite_Capability_Datasheet_07_2020_Rev-5.pdf  

Footnotes: 

1. https://www.ge.com/renewableenergy/wind-energy/offshore-wind/haliade-x-offshore-turbine 

2. https://ourworldindata.org/fossil-fuels  

Lithium-ion (Li-ion) rechargeable (secondary) cells are often seen to be advantageous over Nickel Metal Hydride (NiMH), also a rechargeable cell type. Steatite works with both, but what do the different chemistries offer in reality? We’ve taken a look into the pros and cons of both in this insight, Nickel Metal Hydride vs Lithium-ion Cells.

Nickel Metal Hydride cells

NiMH cells have been developed from Nickel-cadmium (NiCd) cells, which provided rechargeable options for electrical devices for over 100 years (Waldemar Jungner introduced them in Europe in 1899 and Thomas Edison patented a version in the US in 1902). While this chemistry was robust and reliable, manufacturers in the 1990s started producing NiMH cells which had a lower environmental impact and up to 40% higher energy density. 

Modern NiMH cells offer lower production and development costs and a safe, stable chemistry. They are widely used in consumer goods, with most of the largest manufacturers offering AA and AAA sizes. In industry, NiMH cells are often used for lower power consumption applications, small scale backup power and where standard size single use cells are commonly used, in applications such as torches and remote control units.

Additionally industrial battery sizes are available to manufacture larger packs with more capacity include 18650, D, F and other sizes. A large number of hybrid powered vehicles use NiMH as the energy store, notably Toyota in their Prius model. 

Lithium-ion battery

This is currently the most requested rechargeable chemistry and has been available for almost thirty years. These cells offer the most energy dense solution of the currently available chemistries, measured both by mass (watts per kilogram) and volume (watts per cubic metre). 

Li-ion packs come in assorted shapes and sizes. Primarily there are three formats, cylindrical cells, prismatic cells and pouch cells. Pouch cells are typically used for applications that need the battery in a particular shape, or where the highest energy density (energy within a given volume) is sought. Examples include smart watches, tablet computers and some battery powered electric vehicles.

A drawback of pouch cells is they are prone to swelling, particularly as they age, which leads to rapid loss of capacity and, ultimately, failure. In larger applications they are frequently contained in strong structures to keep them compressed to avoid this swelling which helps in maintaining their life. Cylindrical cells are the most produced format securing the chemical and electrical components in a steel can.

These cells offer a similar energy density to pouch cells, and are also used in a diverse range of applications including laptops, power tools, robotics and electric vehicles. Prismatic cells are the least common type but are still widely used and are also formed in a metal case but of a broadly rectangular shape. They were most commonly found in mobile phones in the 90s when the battery was replaceable and are now often used in medical devices and other consumer/industrial applications.

Knowing what battery will work best depends on numerous factors and you’ll need to consider every aspect of the requirements in order to make an informed and accurate decision. There is no overall better or worse option – only the best option for your application. 

Steatite offers a range of battery packs which can be customised where required; you can see more by browsing this website. We’ve been providing reliable power to sectors across military, oceanographic, oil and gas, transport, industry and robotics for over 50 years and our service extends far beyond the sales process.

We provide battery support throughout the lifecycle of our products from initial design, through the custom build and testing process to distribution and transportation, and finally environmental disposal of depleted packs. 

Contact our team of battery specialists to see what the best option will be for your power needs.