Maxell Develops ER-Size Compatible All-Solid-State Battery Power Module to Reduce Maintenance and Environmental Impact
Maxell, Ltd. (TOKYO: 6810) has announced the development of a new all-solid-state battery power module designed to be fully compatible in size and output voltage with conventional lithium thionyl chloride batteries, commonly known as ER batteries. This innovation represents a significant step forward in backup power solutions for industrial and infrastructure applications, particularly in sectors where reliability, longevity, and reduced maintenance are critical requirements.
ER batteries have long been a standard power source in a wide range of applications, including industrial equipment backup systems, smart utility meters, and distributed IoT sensors. Their popularity stems from their stable voltage characteristics, long shelf life, and ability to operate reliably over extended periods. However, ER batteries are primary, non-rechargeable cells. Once depleted, they must be replaced, which creates recurring maintenance demands, increases operational costs, and generates a growing volume of waste batteries that must be collected, transported, and disposed of responsibly.
Against this backdrop, Maxell’s newly developed all-solid-state battery power module directly addresses the limitations associated with conventional ER batteries. By offering a rechargeable alternative that fits seamlessly into existing systems, the company aims to reduce both the economic and environmental burdens associated with periodic battery replacement.
A key feature of the new module is its mechanical and electrical compatibility with existing ER battery designs. The module is housed in a casing that matches the standard ER battery form factor, with a diameter of 17.9 millimeters and a height of 50 millimeters. This design choice allows users to adopt the module without redesigning equipment or modifying battery compartments, enabling straightforward replacement in legacy systems that currently rely on ER batteries.
Electrically, the module is engineered to deliver the same nominal output voltage of 3.6 volts as an ER battery. This voltage-matching capability is achieved through a dedicated internal circuit, ensuring stable power delivery to connected devices. As a result, equipment designers and operators can integrate the new module with minimal changes to existing power management architectures.
Inside the module, Maxell has incorporated eight mass-produced all-solid-state battery cells, designated as the “PSB401010H.” These individual cells are combined to deliver a total capacity of approximately 35 milliampere-hours (mAh). While this capacity may appear modest compared to some conventional batteries, it is optimized for backup power and low-energy applications where long-term reliability and rechargeability are more important than high energy density alone.
An integrated charging circuit further enhances the module’s functionality. Designed to operate with a 5-volt charging input, the circuit allows the all-solid-state batteries to be recharged repeatedly during the equipment’s operating life. This rechargeable capability dramatically reduces the frequency with which backup power sources need to be replaced, particularly in applications where power interruptions are infrequent but reliability during those events is essential.
From an operational perspective, the benefits of this approach are significant. In industrial environments, battery replacement can be time-consuming and labor-intensive, often requiring skilled technicians to access equipment installed in hard-to-reach or hazardous locations. By reducing the need for regular battery changes, Maxell’s power module helps decrease maintenance workloads, lower operating costs, and minimize equipment downtime. Increased operating hours and reduced service interruptions directly translate into higher productivity and improved asset utilization.
The environmental implications are equally important. The widespread use of non-rechargeable batteries in industrial and IoT applications contributes to a steady stream of battery waste. Even when recycling programs are in place, the collection and processing of used batteries involve energy consumption and logistical challenges. By enabling long-term reuse through rechargeability, the all-solid-state battery module helps reduce the total number of batteries entering the waste stream, supporting broader efforts to minimize environmental impact and promote sustainable resource use.
At the core of this innovation is Maxell’s continued investment in all-solid-state battery technology. Unlike conventional lithium-ion batteries that use liquid electrolytes, all-solid-state batteries employ solid electrolytes, offering inherent advantages in safety, durability, and thermal stability. These characteristics make them particularly well-suited for demanding industrial applications where exposure to heat, vibration, or harsh operating conditions can compromise traditional battery chemistries.
Maxell has identified four key performance pillars guiding its all-solid-state battery development strategy: high reliability, high heat resistance, high output, and large capacity. By focusing on these attributes, the company aims to expand the range of applications in which all-solid-state batteries can be deployed, including areas where existing battery technologies face technical or safety limitations.
High reliability is especially critical for backup power systems, which may remain idle for long periods but must perform flawlessly when called upon. The solid-state design reduces risks associated with electrolyte leakage, swelling, or degradation over time. High heat resistance further extends applicability to environments where elevated temperatures would accelerate aging or failure in conventional batteries. High output characteristics ensure that sufficient power can be delivered during peak demand events, while ongoing efforts to increase capacity aim to support longer backup durations and broader use cases.
Looking ahead, Maxell is also developing advanced modules that combine all-solid-state batteries with complementary technologies such as wireless power transfer and energy harvesting. These integrated solutions are designed to capture energy from ambient sources—such as light, vibration, or radio waves—and store it efficiently for later use. When paired with rechargeable all-solid-state batteries, such systems could enable near-maintenance-free operation for sensors and devices deployed in remote or inaccessible locations.
Through these initiatives, Maxell positions its all-solid-state battery technologies not only as incremental improvements over existing solutions, but as foundational components of next-generation energy systems. By reducing maintenance requirements, enhancing safety and reliability, and lowering environmental impact, the company’s ER-size compatible power module contributes to addressing broader social and industrial challenges.
As industries worldwide continue to expand the use of smart infrastructure, automation, and IoT technologies, demand for dependable, sustainable power sources will only grow. Maxell’s latest development reflects a strategic response to these trends, offering a practical pathway for upgrading existing systems while laying the groundwork for more resilient and sustainable energy solutions in the future.
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