With the continuous expansion of the application scenarios of lithium batteries, the demand for their use in extreme environments such as high temperature, extreme cold and high humidity is increasing day by day. However, extreme environments can have a significant impact on the performance and stability of software-protected board lithium batteries, posing numerous challenges. A thorough understanding of these challenges and the formulation of effective response plans are crucial for ensuring the reliable operation of lithium batteries in extreme environments.
I. Challenges and Solutions in High-temperature Environments
(1) Challenges Faced
In high-temperature environments, the chemical reaction rate inside lithium batteries accelerates, and the self-discharge phenomenon of the batteries intensifies, leading to a rapid decline in battery capacity. At the same time, high temperatures will cause the electrolyte inside the battery to volatilize and decompose, reducing the conductivity of the electrolyte and affecting the battery's charging and discharging performance. For software protection boards, high temperatures can cause the performance of electronic components to decline, such as slowing down the operation speed of control ics and increasing the on-resistance of MOSFETs, which in turn leads to delays or misoperations of the protection function of the protection board. In addition, high temperatures may also cause abnormal operation of the software program of the protection board, interfere with the data monitoring and communication functions, and affect the normal management of lithium batteries.
(II) Response Plan
Optimize heat dissipation design: Equip lithium batteries and protection boards with efficient heat dissipation devices, such as heat sinks, fans or liquid cooling systems. Heat sinks can increase the heat dissipation area and dissipate heat into the air through heat conduction. Fans accelerate air flow and improve heat dissipation efficiency. The liquid cooling heat dissipation system can remove a large amount of heat more quickly and effectively, keeping the battery and protection board operating within an appropriate temperature range.
Use high-temperature resistant materials: In the manufacturing process of lithium batteries and protection boards, high-temperature resistant materials are selected, such as high-temperature resistant electrolytes, electrode materials and circuit board materials. High-temperature resistant electrolyte has better stability at high temperatures and can reduce volatilization and decomposition. The high-temperature resistant circuit board material can withstand higher temperatures, ensuring the stable circuit performance of the protection board.
Software algorithm optimization: Optimize the software algorithm of the protection board to enable it to dynamically adjust the protection threshold and control strategy according to the characteristics of the battery in high-temperature environments. For example, appropriately lower the overcharge protection voltage threshold to prevent safety accidents caused by overcharging of the battery at high temperatures; Increase the frequency of real-time monitoring of battery temperature. When the temperature exceeds the set threshold, take measures such as derating charging or suspending charging in a timely manner.



Ii. Challenges and Response Plans in High-Altitude and Cold Environments
(1) Challenges Faced
In extremely cold environments, the electrochemical performance of lithium batteries declines significantly. The viscosity of the electrolyte in the battery increases, and the ion conduction speed slows down, resulting in an increase in the internal resistance during charging and discharging of the battery, a decrease in charging and discharging efficiency, and a significant capacity attenuation. Low temperatures may also cause a sudden drop in voltage in lithium batteries, affecting the normal operation of the equipment. For software protection boards, low temperatures can cause changes in the parameters of electronic components, such as the capacitance value of capacitors and the resistance value of resistors, leading to a decline in the detection accuracy of the protection board. Situations such as accidental triggering of over-discharge protection occur frequently. In addition, low temperatures may also cause the running speed of the software program on the protection board to slow down and the data processing capacity to weaken.
(II) Response Plan
Heating and insulation measures: Design heating and insulation devices for lithium batteries and protection boards, such as heating films and insulation cotton, etc. The heating film can automatically generate heat when the battery temperature is low, raising the battery temperature. The insulation cotton plays a good role in heat insulation and preservation, reducing heat loss and maintaining the working temperature of the battery and the protection board. Meanwhile, the battery temperature can be monitored in real time through a temperature sensor, and the start and stop of the heating device can be automatically controlled according to the temperature changes to achieve precise temperature control.
Low-temperature performance optimization: Develop lithium battery materials and electrolyte formulations suitable for low-temperature environments to enhance the electrochemical performance of batteries at low temperatures. For example, electrode materials with good low-temperature performance are adopted to reduce the internal resistance of the battery; Electrolyte with low-temperature additives added improves ion conduction performance. For the software protection board, electronic components with stable low-temperature performance are selected, and the circuit is optimized to reduce the impact of low temperature on component parameters and improve detection accuracy and control accuracy.
Software function enhancement: Add low-temperature protection and wake-up functions to the software of the protection board. When the battery temperature is detected to be too low, it automatically enters the low-temperature protection mode, limiting the charging and discharging current of the battery to prevent damage to the battery due to excessive discharge or abnormal charging. After the temperature rises, the battery and the protection board can be restored to their normal working state through the software wake-up function.
Iii. Challenges and Solutions in High Humidity Environments
(1) Challenges Faced
In a high-humidity environment, moisture can easily penetrate the interior of lithium batteries, undergo chemical reactions with the electrolyte, generate gases and impurities, increase the internal pressure of the battery, decline its performance, and even cause safety issues such as battery bulging and short circuits. For software protection boards, a humid environment can cause the circuit board to get damp, and the pins of electronic components to oxidize and corrode, leading to faults such as short circuits and open circuits in the lines, which affects the normal operation of the protection board. In addition, high humidity may also cause errors in the data storage and transmission of the protection board software program, affecting the management and control of lithium batteries.
(II) Response Plan
Sealed protection design: The lithium battery and protection board are sealed, and a waterproof sealed casing is adopted to ensure that moisture cannot penetrate. Waterproof rubber strips, sealing rings and other sealing materials are used at the joints, interfaces and other parts of the shell to improve the sealing performance. At the same time, the circuit board of the protection board should undergo three-proof treatment (moisture-proof, salt spray-proof, and mold-proof), such as applying three-proof paint, to enhance the moisture-proof and anti-corrosion capabilities of the circuit board.
Humidity monitoring and control: Install humidity sensors in lithium battery systems to monitor the environmental humidity in real time. When the humidity exceeds the set threshold, dehumidification devices such as desiccants and dehumidification fans are activated to reduce the environmental humidity. Meanwhile, the software of the protection board can adjust the battery management strategy according to the humidity conditions. For instance, in a high-humidity environment, it can enhance the short-circuit protection monitoring of the battery to improve safety performance.
Moisture-proof data processing: Optimize the data storage and transmission module of the protection board software, and add moisture-proof verification and error correction functions. Encrypt and verify the data before it is stored to ensure the integrity of the data. During the data transmission process, redundant transmission and error-correction coding technologies are adopted to reduce data errors caused by humidity and ensure the stable operation of the lithium battery management system.