Pouch, Cylindrical or Prismatic: Which Battery Format Will ...

When we talk about battery formats, we refer to three main forms: cylindrical, prismatic, and pouch cells. Cylindrical cells, with their shape and construction, are one of the first mass-produced battery types and continue to be used in high volumes for certain applications. Prismatic cells, known for their large capacity and efficient use of space, have gained popularity, while pouch cells are recognized for their lightweight structure due to their flexible foil container.

You can find more information on our website, so please take a look.

While each type of battery cell is suited to different situations, the cylindrical cell has proven convenient and adaptable despite its limitations. However, the use of pouch cells is growing due to their flexibility and optimization, and they are set to dominate the automotive market.

In 2020, total usage in the passenger vehicle market was approximately 147 GWh for around $17B. The market share was split roughly as follows: prismatic ~40%, pouch ~35%, cylindrical ~15%, based on the top manufacturers LG, CATL, Panasonic, Samsung, BYD, and SKI. The remaining 10% from tier 2 players is likely divided among the three formats.

The Cylindrical Cell

According to a recent report, the global cylindrical lithium-ion battery market was valued at USD 7975.1 million in 2019.

With its high mechanical stability and design, the cylindrical cell is mostly produced using optimized automation processes and techniques, increasing consistency and lowering the cost per unit. Many manufacturers provide this type of battery cell, ensuring product uniformity. This makes it easier for businesses to switch suppliers if necessary, as they can find another producing the same product in terms of performance and dimensions.

However, due to its shape, the cylindrical cell cannot fully utilize available space in the battery pack, leading to lower packing density. This is why cylindrical cells have reached their limit in terms of performance and optimization, raising questions about their potential for next-generation batteries.

Photo credit: Crystal Kwok, Unsplash

An additional limitation is that a larger cell count is needed: even with a 4680 cell with ~25 Ah capacity, as Tesla presented last year, the cell count is four times that of a 100 Ah flat cell for the same pack capacity. This increases the overhead for BMS, TMS, etc.

The Prismatic Cell

Used mainly in consumer electronics and EVs, the prismatic cell’s packing advantages lie in its layered approach to materials. Their shape resembles a box of chewing gum or a small chocolate bar, and though they exist in different sizes, there is no universal format; each manufacturer designs its own.

The Pouch Cell

The soft aluminum coating allows for a more lightweight battery and, depending on the use, an adaptable size for available space. This flexibility translates to between 90%-95% packaging efficiency and increased energy density. Moving to more convenient designs, pouch cells have the potential to match next-generation performance needs for EVs and consumer electronics.

For example, in Tesla’s first EV, they used many cylindrical cells at the same time to get a lot of energy at a low cost. Tesla bought cheap 18650 cylindrical batteries from Panasonic and used a high-quality energy management system to manage them.

Related links:
The Difference Between Cylindrical, Prismatic And Pouch Cell ...

Link to sinopoly

An outstanding limitation of the pouch cell format lies in the lack of standardization, impacting production costs and selling prices. As the development of pouch cells continues, availability will increase, adoption will grow, and it will become more widely used. Standardization will improve production efficiency, lower costs, increase volumes, and optimize performance.

Additionally, the pouch cell still requires optimization as it has lower mechanical resistance and can suffer from potential expansion due to aging caused by gas development.

While the cylindrical cell has reached its limit in increasing energy density, it won't disappear from the market. Instead, the pouch cell will likely gain a more significant stake in the battery market, especially with further development and investment, leading to mass production.

Pouch cells are expected to be used the most because solid-state batteries, considered the holy grail of EV batteries, can only work in the pouch cell format. As solid-state batteries are commercialized between 2025-2030, the industry will embrace them, leading to more batteries adapted to the pouch format.

Looking forward, as the pouch cell is optimized and moves to higher volume production, flat formats (pouch and prismatic) will be the most used, especially in automotive and energy storage applications.

Photo credit: Matt Henry, Unsplash

Battery Formats and New 3D Architecture Technologies

Addionics’ unique technology is compatible with all formats, improves mechanical stability by embedding layers, and has additional benefits for pouch cells. Therefore, it makes sense to focus more on the pouch cell as it benefits the most from Addionics and is one of the dominant formats for next-generation batteries. This combined with the natural properties of pouch cells ensures one of the most adaptable and powerful batteries on the market.

Additionally, Addionics’ technology is currently embedded in pouch cell batteries with three different chemistries: LFP (lithium iron phosphate), silicon, and solid-state, and is also compatible with other formats.

Find out more about our technology and how it can elevate battery performance to the next level, or contact us for collaboration opportunities.

The differences between lithium cylindrical and prismatic cells

We all know lithium batteries come in three packaging formats: lithium cylindrical, pouch, and prismatic cells. Cylindrical and prismatic cells are usually made of steel and aluminum cases, while pouch cells use Al-plastic films. Today, we discuss the differences between lithium cylindrical and prismatic battery cells.

Energy Density

Energy density refers to the capacity of a battery per unit weight. The energy density of mainstream 18650 lithium cylindrical cells in China is around 215Wh/kg, while 50Ah lithium prismatic cells reach 205Wh/kg. However, prismatic cells will have a significant advantage in the future due to smaller gaps between each when packed into a battery pack.

Charging/Discharging Rate

The charging/discharging rate is the ratio of charging and discharging current to nominal capacity. A higher charging rate means faster charging speed. Cylindrical cells usually have a charging rate of 1C, while prismatic cells have a charging rate of 1.5-2C.

Cycle Life

The best lithium prismatic cells maintain more than 80% of their capacity after 2000 cycles, whereas cylindrical cells have around 70%. This demonstrates that prismatic cells have a longer cycle life than cylindrical cells.

The company is the world’s best cylindrical vs prismatic cells supplier. We are your one-stop shop for all needs. Our highly-specialized staff will help you find the product you need.