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Semi-Solid Soft Pack Battery Cell – EV, ESS and Drone Applications
While all-solid-state batteries promise ultimate performance, they are not yet commercially viable for most applications. Our semi-solid soft pack battery cell bridges the gap—offering significant safety and energy improvements over conventional lithium-ion while being manufacturable at scale today. It is the pragmatic choice for OEMs seeking next-generation performance without waiting for solid-state maturity.
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Product Overview: Why Semi-Solid Soft Pack Battery Cell Technology?
While all-solid-state batteries promise ultimate performance, they are not yet commercially viable for most applications. Our semi-solid soft pack battery cell bridges the gap—offering significant safety and energy improvements over conventional lithium-ion while being manufacturable at scale today. The semi-solid electrolyte replaces the flammable liquid electrolyte with a gel-like, non-flammable semi-solid matrix, dramatically reducing the risk of thermal runaway while maintaining high ionic conductivity. This is the pragmatic choice for OEMs seeking next-generation performance without waiting for solid-state maturity.
Technical Specifications
| Parameter | Value |
|---|---|
| Model Numbers | 7759156NSH3 / 9575175N8H3 / 10575175NSH3 |
| Capacity | 16Ah / 22Ah / 29.5Ah |
| Nominal Voltage | 3.7V |
| Energy Density (Gravimetric) | ≥ 350 Wh/kg |
| Energy Density (Volumetric) | Up to 710 Wh/L |
| Cycle Life | ≥ 1000 cycles (80% capacity retention) |
| Weight (Cell) | 160g / 258g / (custom) |
Dimensions (Max)≤7.9×≤60×≤158 mm / ≤9.7×≤76×≤177 mmOperating Temperature-20°C to 60°C (discharge)Safety CertificationsPasses nail penetration, overcharge, crush, short circuit tests – no fire, no explosion
Key Featuresof semi-solid soft pack cell
⚡ High Energy Density
Achieving up to 350Wh/kg or more – 30%+ higher than conventional lithium-ion batteries[reference:3]. Extended driving range for EVs, longer backup for ESS, and 30% increased flight times for drones[reference:4].
🛡️ Enhanced Safety
The semi-solid electrolyte is non-flammable and leak-proof, dramatically reducing thermal runaway risk. Passes nail penetration tests – no fire, no smoke, no thermal propagation[reference:5].
🔄 Long Cycle Life
Stable electrode-electrolyte interfaces enable 1000+ deep cycles with minimal capacity fade, reducing total cost of ownership for fleet operations.
📐 Flexible Form Factor
Soft pack (pouch) design allows for lightweight, customizable shapes that maximize space utilization in battery packs – ideal for space-constrained applications.
Comparison: Semi-Solid vs. Solid State vs. Conventional Li-Ion
| Parameter | Semi-Solid (PPCELL) | Conventional Li-Ion | All-Solid-State |
|---|---|---|---|
| Energy Density | 350+ Wh/kg | 200-260 Wh/kg | 400+ Wh/kg (target) |
| Safety | Non-flammable, leak-proof | Flammable electrolyte, thermal runaway risk | Inherently safe |
| Manufacturability | Available today – scales on existing lines | Mature, high volume | Not yet commercially viable |
| Cycle Life | ≥1000 cycles | 500-800 cycles | Targeting 2000+ cycles |
| Operating Temperature | -20°C to 60°C | 0°C to 45°C | Wide range (target) |
Application Areas by Industry
🔋 Electric Vehicles (EVs)
The demand for EV semi-solid battery cell technology is surging as automakers seek safer, higher-energy alternatives to traditional lithium-ion. Our cells enable extended range (more miles per charge), support fast charging without compromising safety, and deliver reliable performance in extreme temperatures, critical for EV operation. Major battery manufacturers plan to achieve 400 Wh/kg semi-solid pouch cells in mass production by 2026, with future targets exceeding 500 Wh/kg[reference:6].
🏭 Energy Storage Systems (ESS)
For stationary storage, reliability and longevity are paramount. Our ESS semi-solid lithium cell offers ideal solutions for grid-scale storage (peak shaving, renewable integration, backup power), deep cycle capability for daily charge/discharge, and non-flammable chemistry that eliminates fire risks associated with large-scale battery installations. Wanxiang A123’s semi-solid-state cell has demonstrated unprecedented intrinsic safety during rigorous testing[reference:7].
🚁 Unmanned Aerial Vehicles (UAVs) / Drones
Drones require lightweight, high-power cells. Our drone semi-solid pouch cell delivers high discharge rates for aggressive flight maneuvers and heavy payloads, lightweight construction (pouch format reduces weight), and consistent voltage output even at low state of charge. Industrial drones equipped with 350Wh/kg semi-solid batteries can achieve over 120 minutes of flight time, breaking the limitations of conventional battery technology[reference:8].
Semi-Solid vs. Solid State: Strategic Positioning
While all-solid-state batteries (ASSBs) are proposed as the ultimate solution for safety and energy density, their progress toward large-scale commercialization remains slow[reference:9]. In contrast, semi-solid technology is commercially viable today and can be manufactured on existing lithium-ion production lines with minimal modifications. This makes semi-solid the pragmatic choice for OEMs seeking next-generation performance without waiting for solid-state maturity.
Safety Features & BMS Integration
Our semi-solid cells incorporate multiple layers of safety protection. The semi-solid electrolyte is inherently non-flammable and will not leak even if the pouch is punctured. During rigorous nail penetration tests—where ten steel needles punctured the cell simultaneously—the battery exhibited no fire, no smoke, and no thermal propagation[reference:10].
Advanced BMS integration supports over-voltage, under-voltage, over-current, short-circuit, and temperature protection. The system communicates via RS485 or CAN bus protocols and provides real-time SOC (state of charge) and SOH (state of health) monitoring with <5% error, ensuring full traceability and data upload to MES systems.
FAQ – Frequently Asked Questions
Q1: What is the difference between semi-solid and all-solid-state batteries?
A: Semi-solid batteries use a gel-like electrolyte (a mixture of liquid and solid components) and can be manufactured on existing production lines. All-solid-state batteries use a completely solid electrolyte but are not yet commercially viable for most applications. Semi-solid offers a practical balance of safety, energy density, and manufacturability available today.
Q2: Can semi-solid batteries be used with existing BMS platforms?
A: Yes. Our semi-solid cells operate within standard voltage ranges (3.7V nominal) and are compatible with most existing BMS platforms. We recommend BMS configurations that include over-voltage, under-voltage, and temperature protection for optimal performance.
Q3: What is the typical lead time for custom cell orders?
A: Standard cells are available for immediate sampling. Custom cell development typically requires 8-12 weeks for engineering samples, with mass production lead times depending on order volume (typically 4-6 weeks after sample approval).
Q4: How does temperature affect semi-solid battery performance?
A: Our semi-solid cells maintain stable performance from -20°C to 60°C during discharge. Compared to conventional lithium-ion batteries, semi-solid technology demonstrates superior low-temperature performance and reduced capacity fade in high-temperature environments, making them suitable for diverse climate conditions.
Q5: What safety certifications do PPCELL semi-solid cells hold?
A: Our semi-solid cells have passed GB 31241 and enterprise-standard safety tests including external short circuit, overcharge, crush, temperature cycling (-40°C ↔ 85°C), and needle penetration—all with no fire or explosion. Cells also meet UN38.3 transport safety requirements.
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Our engineering team can provide detailed datasheets, sample cells for testing, and custom cell development services tailored to your specific voltage, capacity, and form factor requirements.