How Dragonfly Energy is Manufacturing the Safest Batteries on the Market|Lithium Battery Standards & Certifications

Dragonfly Energy R&D lab

Innovation and evolving technology have characterized modern society. As new technologies come to the market every day, there is often very little transparency about safety and mitigating inherent risks. In order to provide more information to consumers, standards and certifications have been created to signal that a technology is safe and reliable. At Dragonfly Energy, we value the safety and well-being of our consumers above all else. We’re committed to rigorous third-party testing to ensure we are producing the safest and most durable lithium-ion batteries on the market.  

An Unwavering Commitment to the Highest Quality Standards 

In a market saturated with lithium batteries, what makes one stand out above the rest? While the quality of components, overall craftsmanship, and level of expertise are all key factors, safety and durability tend to rest high in the minds of consumers. More than anything, consumers want to ensure that the batteries they’re placing near the people and things they love most will operate in a safe and efficient manner. With headlines full of stories of batteries of all shapes, sizes, and chemistries malfunctioning, consumers are searching for information that points them to the safest batteries. 

As the manufacturer of Battle Born Batteries, Dragonfly Energy is the leader in lithium batteries for RV, marine, and off-grid markets. Each component used in our products is strictly vetted to conform to the highest quality standards. Additionally, we can prove the safety of our batteries through third-party listings granted by passing stringent certifications. This confirms that our batteries are some of the safest and most durable on the market.  

In a recent article, Benzinga noted that “[b]attery brands that fail to conduct rigorous testing and certification processes risk releasing unsafe and potentially dangerous products onto the market.” While many companies are willing to take that risk to lower the cost of their batteries, Dragonfly Energy remains unwavering in our commitment to safety and durability. Through these rigorous testing procedures, we’re able to confidently offer consumers top-of-the-line, safe, and reliable batteries.  

Why is Proper Testing Important? 

Lithium-ion batteries are being used in everything from personal electronics to e-bikes, electric vehicles, and even home energy storage systems. As demand increases, many product offerings are coming to market with very little transparency about their production and testing processes. In a perfectly stable environment, many batteries would be able to perform flawlessly. Since lithium batteries are an integral part of our everyday lives, it is likely they will be facing less-than-ideal conditions. Ensuring the batteries can withstand these conditions is paramount to consumer safety and peace of mind.  

“Without proper testing, electric vehicle and other battery brands may fail to take into account real-world scenarios and user environments, which could impact the functionality and safety of their products.” As the market is flooded with new lithium battery brands, oftentimes, products tend to be untested, unregulated, and come with safety risks. It’s now more important than ever for OEMs and end consumers to have peace of mind in their choice for power—whether their lithium battery system is on board their marine vessel, inside their RV, or inside their home.  

Once fully assembled and completed, our batteries are exposed to aggressive, above-standard testing. These tests subject our batteries to extreme environments and conditions to prove their durability and performance. By withstanding such harsh conditions, the safety and reliability of our batteries shines through. We have an unwavering commitment to providing our consumers with a battery that’s been held to the highest standards. Dedicated to quality and precision, we help ensure safety and peace of mind for our customers. 

Conforming to the Most Stringent Standards and Certifications 

When commenting on the reasoning behind their standards, the UL institute mentions that “[t]he world thrives on innovation, but with every new product or service come new dangers or risks associated with the technology.” To help minimize risks and provide consumers with easily accessible information about the products they purchase, standards and listings have been created. These listings act as a signal to consumers of the inherent safety and effectiveness of new technologies.  

UL standards are used as a benchmark to allow consumers to feel confident about the products they purchase. These are applied to a variety of “environmentally sustainable products, renewable energies, food and water products, recycling systems and other innovative technologies.” Additionally, the United Nations established UN 38.3 certifications to specifically ensure the safety of lithium batteries, and the Canada Electrical Code created CSA C22.2 standards for electrical equipment safety.   

Each of our batteries has been strictly tested and held to the stringent testing of the above certifications. Accordingly, they have been listed to the various standards they conform to, including:  

Our flagship 12V 100Ah and GC2 12V 100Ah batteries have been listed to  

  • ETL Listed by Intertek Lab  
  • Conforms to UL STD 2054  
  • Conforms to UL STD 62133-2  
  • Certified to CSA STD C22.2# 62133-2  
  • Conforms to UN38.3 
  • IP65 Rated 

The GC3 12V 270Ah and 8D 12V 270Ah batteries have been listed to   

  • By Lab: LabTest Certification Inc.  
  • Conforms to UL STD 62133-2  
  • Certified to CSA STD C22.2# 62133-2:20  
  • Conforms to UN38.3  
  • IP65 Rated 

Our Group 24 12V 50Ah and Group 24 12V 75Ah batteries have been listed to   

  • ETL Listed by Intertek Lab  
  • Conforms to UL STD 62133-2  
  • Certified to CSA STD C22.2# 62133-2  

Rigorous Third-Party Testing   

In order to receive these listings and certifications, each of our batteries were sent to third-party labs for rigorous testing. Each listing includes a variety of tests that put the batteries in the most extreme conditions possible. To pass each test, there are a variety of requirements each battery must meet. Then, to receive the listing, the batteries must pass a variety of tests. These tests simulate the following conditions to get a comprehensive picture of the overall safety and durability of each battery.   

Electrical Testing  

One of the most critical aspects of battery evaluation is electrical testing. Both UN 38.3 and UL 62133 standards implement multiple tests that put extensive electrical abuse on the batteries. Each test is implemented to determine a battery’s response to a variety of conditions. By simulating overcharging, over-discharging, short-circuiting, and extreme temperature fluctuations, the batteries must possess electrical fortitude to withstand such conditions.  

Through the subjection of the batteries to controlled abuses, manufacturers can review performance, assess potential hazards, and include further safety measures to prevent an accident or malfunction. This ensures that our batteries can withstand a multitude of extreme electrical conditions, giving our consumers peace of mind.   

Impact Shock Testing  

As a part of the UN 38.3 listing, batteries must withstand stringent impact shock testing. During this test, the battery is expected to endure 150 G-force. For perspective, 1 G-force is equivalent to Earth’s gravity. Most fighter pilots will blackout anywhere between 4 and 6 G-force. Approaching 100 G-force are some of the worst, high-speed racing crashes, making 150 G-force conditions some of the most extreme that can be simulated. Additionally, the 150 G-force conditions are applied three times to each of the six sides of our batteries.  

Subjecting our batteries to such intense shock conditions ensures that our batteries can endure extensive impact, drop, and jolt conditions without compromising functionality or integrity. Following the full testing procedure, the battery will only pass if it doesn’t display any signs of leaking, venting, disassembly, rupture, fire, or open circuit voltage of no less than 90% of its voltage prior to the test. Passing this test signifies the robustness of the cells and battery against cumulated shocks.  

Drop Testing  

Another key component of the UL 2054 and UL 62133-2 standards is the ability to withstand free fall. During drop testing, each battery is dropped from a height of 1 Meter (3.28 Feet). This drop test occurs three times. Each time, the battery is placed in a random orientation onto a flat concrete or metal floor. Then, the battery is observed for the next 6 hours, and if there is no sign of fire or explosion, it passes the test, proving the integrity of the battery’s structure and enclosure.  

The 1973 version of this listing required batteries to withstand a drop of only a few inches. While many industries still require compliance with the 1973 listing, Dragonfly Energy has opted to endure the more rigorous testing to receive the UL 62133-2 listing. Putting our batteries through more stringent testing than some industries require allows us to have the utmost confidence in the safety of our products.   

Battery Management System (BMS) Testing  

The Battery Management System (BMS) operates as the internal control for each battery. This is an essential component, as the BMS tells the battery to shut down when it enters unsafe operating conditions. In turn, this ensures the batteries cannot get to a point that would start a fire or cause an explosion. A proper functioning BMS is imperative to the overall safety of our batteries. Within UN 38.3, UL 2054, and UL 62133-2 listings, multiple tests are completed that simulate extreme conditions to assess the effectiveness of the BMS.  

Within UN 38.3 and UL 62133 – 2, an External Short Circuit Test subjects the battery to one short circuit condition over the course of at least one hour. For the battery to pass this test, its external temperature must not exceed 170° C, and it must have no signs of disassembly, rupture, or fire during or up to 6 hours after the test. These two listings also require an Overcharge test. During this test, the battery is given twice the manufacturer’s recommended maximum continuous charging current. If the battery can withstand an overcharge current and remain functional, it passes the test.  

In addition to testing for short-circuiting, the UL 2054 listing extensively tests varying charging conditions to ensure proper BMS functioning. An Abnormal Charge test subjects the battery to a constant charging current of three times what is recommended by the manufacturer. Then, an Abusive Overcharge test subjects the battery to a constant charging current of ten times what is recommended. Finally, a Forced Discharge test connects the battery in series with fully charged batteries of the same kind. Passing each of these tests signifies the battery’s BMS can operate correctly, even in the most rigorous conditions.  

Altitude Testing  

While an important way to measure the safety of a battery is to subject it to extreme operating conditions, testing extreme transportation conditions is equally important. Before a battery even reaches a consumer, it often encounters rough conditions during transport. To account for this, the UN 38.8 listing includes a test with an Altitude Simulation. This test subjects the battery to a pressure of 11.6kPa for at least 6 hours to simulate low-pressure conditions.  

This test is used to assess the battery’s performance in low-pressure conditions that occur during high altitude. To pass this test, the battery must not show any signs of leaking, venting, disassembly, rupture, fire, or open circuit voltage of no less than 90% of its voltage prior to the test. By passing this stringent test, the battery can meet Department of Transportation regulations. Compliance is essential for the safe transport of batteries to reduce the risk of incidents during storage or transit.  

IP65 Ratings 

To rate the quality of enclosures around electronic and other devices, “Ingress Protection” (IP) ratings were created. These standards are used to signal the effectiveness of sealing on electronic devices to protect against foreign objects and moisture. IP ratings are based on a two-digit scale. The first digit represents intrusion protection, rated on a scale from 0-6 based on the ability to resist foreign bodies. This is followed by a second digit that represents moisture protection, rated on a scale from 0-9. 

Our 100Ah 12V, GC2, GC3, and 8D Battle Born Batteries have received a rating of IP65. The 6 rating shows that the enclosure on our batteries is “totally dust tight” and fully protected against other particulates. Then, the five represents water resistance, tested by protection against low-pressure water jets of 6.3mm directed from any angle. 

Dragonfly Energy Leads the Way to a Greener Future  

Achieving the listings of UN 38.3, UL 2054, UL 62133-2, and IP65 certifications is no small feat. Creating a battery that can withstand the stringent guidelines of rigorous testing conditions requires using the highest quality components and maintaining close attention to detail. At Dragonfly Energy, we are willing to go as far as needed to ensure the safety and peace of mind of our consumers. We pride ourselves in manufacturing a product that we can stand behind.  

In a market flooded with lithium-ion batteries, Dragonfly Energy remains the leader in RV, marine, and off-grid markets. Through compliance with the strictest standards, beyond what many industries require, our customers can rest assured that the people and things they care about won’t be put in harm’s way. Looking to the future, we plan to continue exceeding industry standards. Dragonfly Energy will continue to provide the safest and highest-performing battery products on the market, offering a variety of sustainable power solutions paving the way to a greener future.  

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