BatteryEducation – Page 30 – Battery Education

Garmin Nuvi 260 Battery Replacement Instructions

Garmin Nuvi 260 Battery Installation Instructions

The following Garmin Nuvi 260 Battery Replacement Instruction guide can be used for the following models:

1. Garmin has hidden the first 2 screws underneath the Nuvi's label. Remove the lable to reveal the 2 screws.

2. Remove the two screws.

3. Using the pry tool sepearte the Garmin nuvi working your way around – this will release the power button cover – remove the button cover.

4. Remove the three screws securing the circuit board.

5. Carefully lift up the circuit board to reveal the battery's wire and connector.

6. Disconnect the original battery.

7. Use the pry tool to lift up the original battery. The original battery is held in place by an adhesive. After you remove the original battery you may need to add some more adhesive to hold your new battery in place. Double sided tap can do the trick.

8. Place the newGarmin Nuvi 260 battery from Batteryship.com into the battery compartment and connect the battery into the socket you removed the original from.

9. Replace the circuit board to its original position and screw back in.

10. Reposition the power button cover

11. Gently snap the device shut.

12. Screw the 2 screw back into the casing of the device.

13. Place the label back to its orginal postion to cover the 2 screws and charge the Nuvi for at least 4 hours.

PLEASE NOTE: Patience and care, along with moderate technical and hand tool ability, are required for the successful replacement of a battery. Excessive force may result in damage to your device. The instructions above come with no warranty or guarantee. By utilizing these instructions, you agree to hold Batteryship.com and BatteryEducation.com blameless and unaccountable for any and all damages, problems, or personal injuries that may or may not arise by your use of these instructions. Replacing your battery may void any warranty you have on your device. Please read all instructions BEFORE replacing the battery.

How To Replace a Tungsten E2 Battery

To install a Tungsten E2 battery follow these installation instructions.

1. Be sure you have a Tungsten E2 battery. If you do not you can order a Tungsten E2 Battery at:

http://www.batteryship.com/htmlos/htmlos.cgi/batteryship/catalog.html?item=TUNGSTENE2&model=Tungsten+E2

2. Remove the four screws in the back of the Tungsten E2 case and set them aside. The BatteryShip tool kit includes 2 Torx screwdrivers. The smaller T5 Torx screwdriver should be used to remove standard screws. If the screws seem larger than the T5 screwdriver, try the T6 Torx instead.

3. Open the back case very carefully and not completely, keeping in mind that the Tungsten E2 battery will probably stick to the back case while it is connected to the motherboard, so the case will not be able to open completely until the battery has been disconnected from the motherboard. You can use the larger metal flathead screwdriver in our tool kit or the green plastic pry tool to help pry open the case if needed.

4. When you have opened the Tungsten E2 case enough to access the connector, unplug the battery connector for the original battery from the motherboard.

5. Open the back of the Tungsten E2 case completely and remove the original battery (carefully prying it out if needed), making sure to notice how the battery was oriented. Be very careful not to puncture or damage the battery when you remove it.

6. Plug the new Tungsten E2 battery's connector into the motherboard.

7. Place the new Tungsten E2 battery (oriented correctly) into the battery compartment.

8. Replace the Tungsten E2 back cover and re-install the four screws.

9. Charge the new Tungsten E2 battery for at least 3-4 hours.

10. Dispose of the original battery correctly.

*****PLEASE NOTE: Patience and care, along with moderate technical and hand tool ability, are required for the successful replacement of a battery. Excessive force may result in damage to your device. The instructions above come with no warranty or guarantee. By utilizing these instructions, you agree to hold Batteryship.com and BatteryEducation.com blameless and unaccountable for any and all damages, problems, or personal injuries that may or may not arise by your use of these instructions. Replacing your battery may void any warranty you have on your device. Please read all instructions BEFORE replacing the battery.

How To Replace a Palm Zire 71 Battery

To install a Palm Zire 71 battery follow these installation instructions.

1. Be sure you have aPalm Zire 71 battery. If you do not you can order a Zire 71 Battery at: http://www.batteryship.com/htmlos/htmlos.cgi/batteryship/catalog.html?item=IA1W721H2&model=Zire+71

2. Patience and care, along with moderate technical and hand tool ability, are required for the successful replacement of a Palm Zire 71 battery.

3. Read all instructions and back up your data BEFORE beginning. Excessive force may result in damage to your Palm Zire 71. The instructions below come with no warranty or guarantee. By utilizing these instructions, you agree to hold BatteryShip.com and BatteryEducation blameless and unaccountable for any and all damages, problems, or personal injuries that may or may not arise by your use of these instructions. Replacing your Zire 71 battery may void any warranty on your device.

IMPORTANT: In some rare cases you may need a technician to assist in the Zire 71 battery replacement. If the blue tabs on the inside of the back case are attached to the motherboard, you may need a technician to remove the tabs. Also, if there is a blue casing covering the battery connector or battery wires and attached/soldered to the motherboard, you may need to consult a technician in order to remove the battery.

4. Make sure your Zire 71 is off and your hold switch is activated (if applicable) before beginning.

5. With the Zire 71 face down, pull the back cover toward the bottom of the Zire 71 to display the digital camera lens and 2 screws located at the top of the device.

6. Remove the two screws at the top of the Zire 71 using a Torx T5 screwdriver. The screws will be located near the two top corners of the device. Set the screws aside for reassembly.

7. Once the screws have been removed, GENTLY pry open the Palm case starting at the top using a plastic pry tool or any small flathead screwdriver (plastic preferred to avoid scratches). Pry all around the device until the back cover is attached only by a ribbon cable. Do not remove the back cover completely- set it aside without detaching the back cover from the ribbon cable.

8. Make sure that you are grounded before coming into contact with the Zire’s internal parts.

The Zire 71 battery will be in a silver battery case at the top of the PDA, and will be attached to the motherboard by two wires and a small white connector at the end of the two wires. Note the orientation of the original battery within the case and within the device. You can flip the case outward (toward the top of the device) for easier access to the battery.

9. Disconnect the old Zire 71 battery at the connector by CAREFULLY pulling upward on the connector with your thumb and forefinger or tweezers. Be very sure that you are pulling upward on only the part of the connector that comes out, NOT on the entire socket or on the wires themselves.

10. Remove the original Zire 71 battery from the battery case, using the pry tool to assist if needed. The battery may be attached to the case with glue or tape. Be very careful not to bend or break the battery as you remove it.

11. Making sure that your new Zire 71 battery is facing the right direction, place the new battery into the battery case and connect the new battery to the device by pressing the connector at the end of the battery wires into the socket. Note the shape of the socket and the shape of the connector, and connect them accordingly. Do not press too hard or try to force the pieces together. They will fit easily when correctly aligned. Place the new battery and case in the battery compartment.

12. Press the back cover of the PDA on over the new battery (making sure that all wires are out of the way). Screw the two top screws back in. FULLY CHARGE your new battery before use. Allow at least three hours.

PLEASE NOTE: The tools at www.batteryship.com fit the majority of Palm Zire 71’s, but some devices may have different screws installed for various reasons. If our tools do not fit your device, you may have the appropriate tool in a tool kit you already own. You can also check your local hardware or electronics store if you do not have the right tool at home.

Lithium Cell Manufacturing Part 5

We are coming to the end of our article series on the manufacturing of lithium battery cells. In the first few articles we introduced the battery cell and looked at it a macro level, the lithium metal and saw how it was formed, we looked at the cathode and its material composition, and now we are going to look at the battery’s electrolyte.

Every battery has an anode, a cathode, and an electrolyte solution. There are mnay variations of an electrolyte solution. One common solution is sulfuric acid. Another common solution that is in use today is a Lithium hexaflourophosphate (LiPF₆) in a mixture of organic solvents including: [Ethylene Carbonate (EC) + DiEthyl Carbonate (DMC) + DiEthyl Carbonate (DEC) + Ethyl Acetate (EA). This electrolyte solution like others is used to facilitate the transport of ions between the anode and the cathode. In fact that is the purpose of the electrolyte in a battery is to conduct or transport ions from the negative and positive terminals.

One other newly developed electrolyte solution is a high-purity lithium hexafluorophosphate (LiPF₆), a conductive salt that was developed by Honeywell International. In fact this electrolyte research and development was paid for through the American Recovery and Reinvestment Act of 2009. The U.S. Department of Energy awarded Honeywell a $27.3 million grant that is designed to accelerate the market introduction and penetration of advanced electric drive vehicles, reducing fuel consumption and vehicle emissions of greenhouse gases. This electrolyte is one of the primary components that is intended to be used in these upcoming electric cars.

Until next time, Dan Hagopian www.batteryship.com

Lithium Cell Manufacturing Part 4

We are currently in the middle of a series on the manufacturing of lithium battery cells. We have looked at the battery cell on a macro level and then at the lithium ingot. Now we are looking at the cathode.

In every battery there must be present a cathode. The cathode is an electrode (electrical conductor) by which electrical current flows out of a polarized electrical device. A cathode can be either positively charged or negatively charged depending on the device type and operating mode.

There are various material compositions that cathodes can be made of including the common metallic oxide cathode. Metal oxides are crystalline solids that contain a metal cation (an ion with more protons than electrons) and an oxide anion (an ion with more electrons than protons). But other cathode compositions do exist and all have their positive benefits and negative side effects.

Some other cathode material compositions include: LiCoO₂ , LiMn₂O₄ ,LiNiO₂ , Li₂FePO₄F. There are others but all variations include oxygen.

In the next article we will look at the battery's electrolyte.

Until next time, Dan Hagiopian www.batteryship.com

Lithium Cell Manufacturing Part 3

We are currently in the middle of a series on the manufacturing of lithium battery cells. In the first 2 articles we introduced the battery cell and looked at it a macro level. We looked at what processes are used to make a cell, how a battery is hermetically sealed, and the four main components of a cell (lithium, the metallic oxide cathode, the electrolyte, the metallic current collector. Now we want to look at the processes of battery cell manufacturing more closely by breaking down how the four main components of a cell come together.

Lithium Ingots

Battery cell manufacturing processes begins with a lithium ingot. A lithium ingot is often times a cylindrical roll of lithium that weighs about 11 pounds on average. Special order ingots of course can be requested thereby changing the average weight.

Lithium ingots come from technical grade lithium carbonate which is a byproduct of lithium and a solution of lithium hydroxide. The conversion of lithium in the lithium hydroxide solution results in lithium carbonate as a fine white powder. This powder is placed into a billet container prior to being processed through the extrusion. The extruded billet may be solid or hollow in form, commonly cylindrical, used as the final length of material charged into the extrusion press cylinder. It is usually a cast product, but may be a wrought product or sintered from powder compact. This billet of lithium carbonate is the ingot.

As mentioned above the extrusion press – used to shape lithium by forcing it to flow through a shaped opening. The extruded lithium emerges as an elongated piece with the same profile as the opening. The shape is typically a thin piece of metal that stretches over 650 feet. Once the ingot is made the ingot is transformed by the extrusion press and accompanied roller system into a thin sheet of metal that is only 1/100th of an inch thick and 650 feet in length. A laminator furthers the process by stretching the 655 foot lithium roll to about 1.25 miles of lithium used to make 210 lithium batteries. The battery cell is then tested to measure 3.6V. Volts – or V – are an electrical measure of energy potential. You can think of it as the pressure being exerted by all the electrons of a battery’s negative terminal as they try to move to the positive terminal.

A punch machine is then used to cut the thin metal into the physical cell size requirements and a purification machine remove dirt and other unwanted particles.

In the next part of the series we will look at the metallic oxide cathode.

Until next time, Dan Hagopian – www.batteryship.com
Copyright © BatteryEducation.com. All rights reserved.

Lithium Cell Manufacturing Part 2

In this current series on lithium cell manufacturing we are going to be looking at the processes that are used to construct a lithium battery cell. These processes are highly technical and require complete precision in order to make an individual battery cell function according to the specific power demands of the device that the cell will ultimately be used within.

On a macro level when we look at a battery we see completed unit (which we call a battery) however the battery is actually an assembled collection of material and hardware. The outside plastic cover is called the casing. The casing encloses and hermetically seals the battery cell and specialized hardware. Battery casing is manufactured in layers. The casing layers are developed from various raw materials and can include one or two, for example, of polyethylene terephthalate layers, a polymer layer, and a polypropylene layer. Another example may be a casing with layers of carbonized plastic.

Within the casing is the hardware and the battery cell. When we look inside a lithium based battery cell, for example, there are four main components and they include:

The lithium (which acts as an anode)
The metallic oxide cathode
The electrolyte
The metallic current collector

Lithium

As noted above lithium within the battery cell is used as the battery’s anode. The anode is the part of the cell that acts an electrical conductor (electrode) through which electrical current flows into a polarized device. As current flows into the lithium, a chemical process called intercalation occurs. Intercalation is the joining of a molecule (or molecule group) between two other molecules (or groups). When it comes to charging your battery you are in effect pushing ions in and out of solid lithium compounds. These compounds have minuscule spaces between the crystallized planes for small ions, such as lithium, to insert themselves from a force of current. In effect ionizing the lithium loads the crystal planes to the point where they are forced into a current flow. The current flow is then channeled back and forth from anode to cathode and thereby creating an electrical flow to power on your device.

To create an electrical flow from lithium you have to move the lithium. To move the lithium chemistry (lithium-ion, lithium polymer, lithium iron phosphate, etc) you have to have a minimum voltage applied to the lithium. Most battery cells are charged up to 4.2 volts with relative safe workings at about 3.8 volts. Anything less than 3.3 volts will not be enough to charge or move the chemistry. One thing to note here is that volts are an algorithmic measurement of current. So in a sense to create current through your battery you have to introduce current into your battery’s lithium.

The Metallic Oxide Cathode

The cathode is an electrode (electrical conductor) by which electrical current flows out of a polarized electrical device. The metallic oxide component of the cathode is the composition of the cathode. Metal oxides are crystalline solids that contain a metal cation (an ion with more protons than electrons)and an oxide anion (an ion with more electrons than protons).

The Electrolyte

In the battery cell the electrolyte solution is the conducting medium in which the flow of electric current passes through between the electrodes. Electrolytes can be wet, solid, gel, or dry. Dry polymer design offers simplifications with respect to fabrication, ruggedness, safety and thin-profile geometry. Dry polymers do not conduct electricity but allows for ion exchange. The real benefit is the fact that the dry polymer design is only one millimeter (0.039 inches) thick. The drawback is that the dry polymer design suffers from poor conductivity. Today lithium hexafluorophosphate and tetrafluoroborate are the preferred electrolyte salts for lithium batteries.

The Metallic Current Collector

A current collector is an inert structure of high electrical conductivity used to conduct/transmit current from or to an electrode during discharge or charge. There a variety of metal based current collector from zinc to liquid metal that can provide a good conductive path between the electrodes.

Closing

From the above we can see that a battery cell, being just one component of a battery is a highly complex system. As we move into the next portion of the series we will break down each of these 4 key components of a battery cell and see how they are actually made.

Lithium Cell Manufacturing Part 1

Smart Battery packs have very specialized hardware that make possible a battery to provide just the right power at just the right moment. This hardware includes the connector, the fuse, the charge and discharge FETs, the cell pack, the sense resistor (RSENSE), the primary and secondary protection ICs, the fuel-gauge IC, the thermistor, the pc board, and the EEPROM or firmware for the fuel-gauge IC. One of the most critical component in this list is the cell pack. The battery cell pack can be thought of as the holding area of the battery’s chemical. The battery cell pack is critical to the overall capability of the smart battery. Cell packs have to be designed and integrated based upon the vitals of the battery including chemistry type (Li-ion, Li-po, NICD, NIMH, etc.) cycle life, storage-capacity loss, shelf life, impedance, capacity at different rates of discharge and temperature, and mechanical and environmental requirements. It is critical to say the least. But how do you make a battery cell pack? What are the manufacturing processes necessary to make lithium based cell?

Lithium cell manufacturing was first developed in Japan using heavy machinery and automated equipment to perform certain steps while using robots to transfer partially assembled materials from one step to another. Chinese companies developed a manual approach to take advantage of inexpensive labor. This is not to say that it is 100% manual on the contrary it more correct to say that it is a semi-automatic production process of Li-ion cells using automated equipment in the most critical areas such as mixing of powder, coating and winding.

In this series we are going to look at the critical processes involved in the manufacture of lithium-ion cells. What critical components are required for a lithium battery and how each component is made.

How Much Demand for Lithium is There?

Lithium is used in a very wide variety of resources including lithium for use in primary and secondary batteries. This type of lithium is called battery grade metal. Battery grade lithium has been on the increase by about 25% year over year since 2000. With the push for lithium to be used in electric cars the obvious question would be is how much lithium is available worldwide?

In the most recent edition of “The Economics of Lithium” (Roskill Market Reports, 11th Edition, 2009), worldwide lithium reserves are as follows:

Current worldwide production is about 22,800 tonnes Lithium. (or 114,000 tonnes carbonate)*
Current worldwide demand is about 23,000 tonnes Lithium. (or 122,000 tonnes carbonate)*
Current estimates of worldwide Lithium reserves total about 30,000,000 tonnes Lithium (or 150,000,000 tonnes Lithium Carbonate)*

Interesting the world’s supply of lithium is concentrated by producers in very few countries. The largest concentration of lithium is in the America’s (Argentina and Chile). Australia also has a large producer, Talison Minerals, and in the U.S. Chemetall is the only U.S. domestic source of lithium raw material and the largest global producer of lithium and lithium compounds used in batteries, pharmaceuticals and many other industries.

According to the USGS (U.S. Geological Survey, Mineral Commodity Summaries, January 2010):

identified lithium resources the United States total 2.5 million tons
identified lithium resources for Bolivia total 9 million tons
identified lithium resources for Chile total in excess of 7.5 million tons
identified lithium resources for Argentina total in excess of 2.5 million tons
identified lithium resources for China total in excess of 2.5 million tons

Battery Grade Lithium

If you drove 211 miles north of Las Vegas off the I-95 you would come to a small town called Goldfield, Nevada. It is a very small town whose population counts at the 2000 census was only 440 people. What makes Goldfield very important to the US and the world is its close proximity to Silver Peak Nevada (home of 80 full time residents). Silver Peak is home to Chemetall Foote Corporation's local lithium mine, the area's largest employer and the only lithium producing mine in the United States.

Chemetalls’s net sales from mining operation are just over $1 Billion. Not too shabby! In August of 2009 Chemetall was awarded $28.4 million in the Federal Recovery and Reinvestment Act funds to expand and upgrade the production of lithium materials for advanced transportation batteries. The funds will be used by Chemetall in part to expand and upgrade the production of lithium carbonate at the company’s Silver Peak, Nevada, site. Again it should be noted that Chemetall is the only U.S. domestic source of lithium raw material and the largest global producer of lithium and lithium compounds used in batteries, pharmaceuticals and many other industries. Chemetall is a very important partner in the U.S., economy due to the fact that over the past 7 years about 2.4 Billion batteries are in use and are utilizing approximately 35 million pounds of battery grade lithium.

So what is standard battery grade lithium? Standard battery grade lithium is a lithium carbonate manufactured for solid ion conductors and monocrystals used in the electronics industry. Such carbonate is a source of a raw material for the production of cathode material used in lithium ion batteries (lithium cobalt oxide, lithium manganese oxide).

In terms of its chemical composition standard battery grade lithium, or Lithium bis-(oxalato)borate – LiBOB. LiBOB is a conductive agent for the use in high performance lithium (Li) batteries and lithium ion (Li-ion) batteries and lithium polymer (Li-po) batteries.

In terms of appearance it is a white and free flowing powder. It’s chemical formula is C₄BO₈Li. Its molecular weight is 193.79 g/mol. Its density is 0,8 – 1,2 g/ccm (at 20°C). Its thermal stability is decomposition > 290°C; hygroscopic; decomposes slowly on contact with water. Its solubility is 17 % in propylene carbonate (25°C) about 35 wt.-% in water; (hydrolysis) good solubility in carbonate mixtures, carboxylic esters, glymes, ketones, and lactones.

A chemical analysis reveals that C₄BO₈Li is 97.4% assay (a procedure for measuring the molecular structure of an organic sample); 0.03% water; 2.5% insolubles; 10 ppm of Cyanoacrylate; 10 ppm of Iron; 20 ppm of Sodium; 20 ppm of Chlorine.

So how important is C₄BO₈Li and is there enough available resource? Current available lithium reserves is estimated at 28,000,000 tonnes. Current worldwide demand is estimated at 23,000,000 tonnes. So there is enough no and for the foreseeable future as long as mines like the Silver Peak mine in Nevada continues to operate.