Cylindrical Battery vs Prismatic Battery, What is the Difference?

Lithium batteries are typically composed of various cells, with the two main types being cylindrical cells and prismatic cells. In this article, we will explore the differences and similarities between cylindrical and prismatic batteries.

What Is Cylindrical Battery Cells?

Cylindrical lithium-ion battery is a lithium ion battery with cylindrical shape, so called cylindrical lithium-ion battery.

Cylindrical lithium-ion batteries are categorized based on their anode materials, including:

- Lithium Cobalt Oxide (LiCoO2)

- Lithium Manganese (LiMn2O4)

- Lithium Nickel Manganese Cobalt (LiNiMnCoO2 or NMC)

- Lithium Nickel Cobalt Aluminum (LiNiCoAlO2 or NCA)

- Lithium Iron Phosphate (LiFePO4)

- Lithium Titanate (Li4Ti5O12)

Common cylindrical lithium battery sizes include 14500, 14650, 18500, 18650, 21700, 26650, and 32650. These batteries are widely used in various applications, such as special equipment, medical devices, instrumentation, handheld tools, security systems, and communication devices.

How Are Cylindrical Cells Made?

Incoming material inspection

Preparation of positive and negative pole pieces

Mixing

Coating

Pressing

Baking pole pieces

Slitting

Tab forming

Winding

Vacuum baking

Put it in the battery case

Inject the electrolyte

Seal

Formation

Outer packaging

Inspection and storage

What Are the Most Common Cylindrical Cells?

The 18650, 21700, and 4680 battery cells used in Tesla vehicles are all cylindrical batteries. Cylindrical batteries are the most established and widely used packaging form, benefiting from mature technology and market development. Among these, the 18650 and 21700 cells are particularly prevalent due to their high production yield and cost-effective packaging.

What Are Prismatic Battery Cells?

Prismatic lithium-ion batteries are characterized by their rectangular or prismatic shape. These batteries are typically encased in aluminum alloy or stainless steel, offering improved protection compared to aluminum-plastic film (soft-pack) batteries. The use of winding or lamination processes enhances their safety and structural integrity compared to cylindrical batteries.

The development of lithium batteries with aluminum cases has advanced from steel cases. Aluminum cases are lighter and offer superior safety and performance benefits, making them the preferred choice in the lithium battery market. Ongoing advancements aim to enhance the hardness and lightweight properties of aluminum cases, further advancing the technology and offerings in lithium batteries.

How Are Prismatic Cells Made?

Nearly all the production process are same except the Back-end process. The typical difference is that the prismatic battery cells are uses the Lamination process, while the cylindrical battery uses the winding process.

What Is the Difference Between Cylindrical Cells and Prismatic Cells?

1. Energy Density: Prismatic cells typically offer higher energy density compared to cylindrical cells. This advantage arises from their simpler structure and production process. Unlike cylindrical batteries, which use high-strength stainless steel for their casing, prismatic batteries employ less complex and lighter materials. As a result, prismatic cells are increasingly being used in electric vehicles.

2. Thermal Characteristics and Cycle Life: Prismatic cells exhibit superior thermal management, requiring less cooling per unit of energy compared to cylindrical cells. They also provide excellent cycle life, even under varied and high loads, which can negatively impact other lithium cell types. Prismatic cells can have a cycle life up to four times longer than cylindrical cells, significantly reducing operational and ownership costs.

3. Development and Standardization: Cylindrical batteries have the longest development history and the most mature technology, with high standardization. Their design allows for more space between cells, which enhances heat dissipation. Many cylindrical cell models benefit from cost-effective air cooling technologies due to this efficient heat management.

How to Choose Battery Cells for My Application: Cylindrical Cells or Prismatic Cells?

If your application demands high power, long service life, and reliable performance, and if space optimization is less of a concern, cylindrical cells might be the best choice. On the other hand, if your application is constrained by limited space and you can accommodate a higher cost, prismatic cells may be more suitable.