I dropped by the retail store of a PC recycling shop yesterday and picked up some used packs for $1 each. Pickings were pretty slim and mostly DELL from the late 2000s. I am pretty turned off Dell after the shitty quality and poor yield of a bunch of 6-cell packs I took apart a few weeks ago, but I’d made the trip, so I decided to pick up 5 packs and get a broader view of Dell’s battery pack engineering.
The first of two Dell Type TC030, 11.1v, 85 Wh packs I tore into was labeled as having Korean cells. Once I got the pack open, I saw they were teal LGDB118650 cells, which are rated at 2,600 mAh capacity. They were arranged as 3s3p.
The voltage of the pack, measured with a multimeter was 8.25v. The individual banks, starting from the positive end of the pack were 3.78v, 0.8v and 3.70v. When I pulled the first bank of cells apart, I found that the welds were strong and intact, but I saw the problems I saw with the earlier 6-cell packs: The cell voltages within a bank weren’t uniform. Two were ~3.78v, but one was 0.12v.
Concerned that I might have been breaking an internal weld when tearing the nickle strips free at the negative end, I took more care with the next two banks, disconnecting the positive terminals and measuring voltages before tearing the strips at the negative end. Even so, each bank contained cells with major variations in voltage, something that shouldn’t be happening.
Out of 9 cells in the pack, only 4 had voltages above 2v. I’ve run them through a charge/discharge cycle @500mA on my Opus and they all have about 1,500mAh capacity, or just 57% the original rated capacity. Update: it looks like these cells are supposed to be charged to 4.35v. I can’t find any comparisons of how much capacity is sacrificed by charging to 4.2 for these specific cells, but it looks like other LG cells give up 10-15%, which would put these at 1,660-1,750mAh, or 2/3rds of the original capacity.
According to PackProbe, the pack has seen 186 cycles, and was manufactured in the summer of 2007. This seems to me to be above average wear-and-tear, perhaps not surprising given that all the banks had at least one bad cell and are 7 years old. The datasheet for these cells indicates that they should retain 75% of original capacity after 300 cycles.
I have started tearing apart a superficially identical pack that is marked as made in Japan. It’s actually quite different.