This entire section is devoted to batteries, and the promises, mistruths, false advertising, from the manufacturers. From the days of the first cameras that needed them and the flash and strobe units who really need them batteries are a necessary evil…  And there are enough evil-sellers out there. We go back to the beginning, the first true portable light source now updated.

The most economical flash unit of all time was the Redneck Mark II Light Spear which required no batteries…  
It was not for use in gas-filled mines… a few tried…and m
ade good use of the phrase “ It was a killer unit”…  the first edition used Black Powder and then road flares which equally blew everything to piece in mines with gas.

Electric batteries have come a long way since some unknown Parthian first stuck some iron and copper cylinders into a jar of acidic grape juice. The things that power our cameras today, 2,000 years later, work on the same basic principle, though they sure don't look like a clay jar. 

But there is some evidence to suggest that they may possibly have been the first known people to harness the power of electricity too. Central to this theory was the discovery of a ‘battery’ in 1938 by a German archaeologist called Wilhelm Konig.  The battery consists of a little pot, dated 250BC, containing a roll of thin copper surrounding a central iron rod. 

Wilhelm Koenig surmised that with a liquid such as grape juice or vinegar in the pot an electrical current would be created by the potential difference between the iron and copper.  Don’t worry you will not be pouring grape juice into your Nikon or Canon.  Pour the grape juice over Vodka in a glass full of ice and a lemon slice. And screw the experiment, just drink it

The clay has been replaced by plastic, the grape juice has been replaced by an electrolyte gel, and the iron and copper are now lithium, cobalt, or carbon.   A proven point that grapes are good for more than getting drunk, the birth of fermenting preceded batteries.

Pioneer work with the lithium battery began in 1912 under G.N. Lewis but it was not until the early 1970s when the first non-rechargeable lithium batteries were sold.  Previous attempts blew up and killed a few people, and even took out half a dozen airliners.

This section is my devotion to public service for educational purposes and it explains about batteries, their uses in our disposable society, safe transportation and is designed to make you aware of their dangers and pitfalls.

Being in the battery business, I will integrate some personal experiences with the correct information to add “some color” to what is usually very boring technical writing about a subject no one seems to be enamored with.  Enjoy.

Being a pilot has a lot to do with batteries.  I have written several papers on the subject including my synopsis of the MH 370 mystery missing Boeing 777 and my suspicions, that Lithium had a lot to do with it.

My Battery Packs 
Our Black Box and Tuxedo batteries are Sealed Lead Acid and rated or tested at the 20 AMP draw.  Some new models are Lithium.

Two could start a car and they weigh less than 2.5 pounds.  And the quality of the boxes is industry high rated.  The internal boards and workings, of most battery operated products, the batteries themselves, even the plastic cases are made all over the world. 

China having the largest share in particular but were poor, make that very poor quality.  Mine come from Denmark.  How long we do not know

SLA batteries are strong and most weather and temperature conditions don’t bother them, no problems with lack of usage,  thats why we developed the charger we use.  We eliminated Sulfating. The major applications for lead acid batteries are automotive, related marine, and deep-cycle.   .

Our real SLA battery pack is a compartmented unit like the battery in your car.  Two volts per cell, three cells equals 6.4 volts internal. Most strobe units are six volts so we are not overclocking your strobe and doing it harm.  

Every day about 125 million cars start on SLA Batteries. It’s a proven chemistry.  And you would really be p*ssed if your car battery lasted a year and cost you over $100.00 to be exchanged.  It’s done everyday in the photo industry.  Thats before Hybrid cars, with NiMH, can cost you 3000-4000 dollars with an out of warrantee failure.  

No chance of burning, or leaking as there is nothing flammable in the SLA construction. Sealed Lead Acid batteries are legal for shipment through the USPS and other postal services  and the airlines have no restrictions, thats one reason why we use them.  

Equipment containing non-spilling wet cell batteries (gel cell or absorbent glass mat) can be carried as cargo (Shippers must meet all applicable security requirements). The equipment with the battery installed must be protected from short circuit and securely packaged. The package must be marked “Non-spillable”.

SLA Batteries generally are tamperproof.  Packs should not be tampered with.  It is vitally important to understand there are potential chemical, electrical, and fire risks with the more powerful accelerated packs.  Again our Black Box and Tuxedo batteries can be changed rapidly, charge rapidly and last longer with Higher Capacity - They can  cover the whole wedding or event, have extended capacity and duration. Our packs can last the day.

One of the main advantages of our SLA system is that they do not require additional AA cells in the flash to operate which adds to corrosion and overheating.  Your strobe stays cooler and can operate for longer periods of time without harm to the flash.

AGING  —  All batteries age, it is a fact of life so it is no surprise that lithium-ion batteries also age, most manufacturers remain silent about this issue.  Shelf lives of one to two years means they better get sold.  

LITHIUM is STILL UNSTABLE  —  Lithium battery technology got a bad rap in 1991 when one of the old-style solid-metal batteries caught fire. Took out the SONY plant.  The entire plant.  Four fires and explosions, later, the Lithium computer batteries took out the laptops and still are dangerous today.  

NOTE:  And the smart Japanese decided to outsource their production to China.  We called it giving the Chinese their due. Then Boeing wished they had better Lithium science and in the car business Tesla leads the science.  And put a car into space.  

Somewhat sketchy, the real reason just might be COBALT.   Lithium batteries require cobalt about as hard to find as gold.  Cobalt is mined in only one area of  Africa,  That might explain CHINA is so invested in infrastructure in the AFRICAN CONTINENT is investing a lot of money, deep water ports.  Fifty companies, all Chinese, operate in AFRICA buying Cobalt.  Basically mined by young slave labor using kids digging in trenches and tunnels by hand for about nine dollars a week.  Tesla leading the science and soon might have a Cobalt Free Lithium Matrix.

NO MEMORY - OLD NEWS    The phrase belongs to older nickel-cadmium (NiCad or Ni-Cd) batteries. This is why manufacturers recommend that you go ahead and plug in your charger when the device gives you its low battery alert or when you are done with a shoot.  Memory problems do not pertain to Lithium nor NiMH. You can charge them any time.

CHARGE TIMES  —  Battery makers say the first 2 hours of charging takes your battery to 80% of its full capacity. During the next 2 hours, the batteries will trickle-charge slowly to top off.  IF YOU ARE USING A SMART CHARGER.  But since there’s no memory effect, you don’t have to devote 4 hours to topping off the battery with the appropriate charger for the device.  The caveat is the speed of the charger which is not mentioned, nor the maximum MAH capacity of the battery.

AIRLINE TRAVEL WITH LITHIUM BATTERIES  LIKE CANON BP-511  —  If original packaging (those little plastic coffins) are not available for these spare batteries when traveling, effectively insulate the battery terminals by using good electrical tape over the contacts, not the cheap gummy fabric type that leaves residue.  Or 3M paint tape, the blue stuff.  No residue is the key.

FOR IDIOTS WHO DON’T BELIEVE ME  —  If Lithium contacts internally, you will experience a life changing experience, called a boomer or fire.  Being in the battery business dealing on a daily basis exclusively with photographic packs, cell phone, walkie talkies (police and fire department rebuilds)  UPS, motorcycle and car batteries, we have respect for Lithium.  

Customers will get mad at their cellphone batteries and slam them down on our counter.   Unfortunately,  one customers hand stopped the fire when it lit off.    Looked like he put a cigarette, well a cigar out in his hand.  He is a marked man, now identified as being presidential material  in the “Order of the Schmucks

NICKEL METAL HYDRIDE (Ni-MH)  AAA-AA-C-D  —  Is environmentally friendly and with a higher capacity than NI-Cad.  A simple replacement for NI-Cad,  it was praised it as a more powerful battery option BUT,  it produces more internal resistance and its associated heat generation is higher. 

It is this heat production that’s causes some photographic flash units to overheat.  This damages the battery, and the result is the NI-MH gives you less re-charges, and a shorter life cycle.   But it is cheap and a very good profit maker. Those three dollar AA ones cost 12 cents to make... avery profitable battery, about a two year life.

LITHIUM AND LI-ION BATTERIES - RECHARGEABLE  —  Li-Ion and NiMH camera batteries can be recharged within their designated battery chargers. Heavy users such as professionals and avid enthusiasts will benefit from the economic cost-per-use value of rechargeable battery packs. However, rechargeable camera batteries will perform considerably less in comparison to its brethren primary batteries. And find they have a few quirks.
As it explains above they have a tendency to lite off, usually when you don
’t expect it.  the rest of this article is all about those incidences.

1991 - When Sony introduced the first lithium-ion battery, they knew of the potential safety risks. A recall of the previously released rechargeable metallic lithium battery was a bleak reminder when the entire plant went up.  Not just a section, the entire plant blew up.

1912 - 1970 - Pioneering work for the lithium battery began in 1912, but is was not until early 1970 when the first non-rechargeable lithium batteries came to the market.  Attempts to develop rechargeable lithium batteries followed in the eighties. These early models were based on metallic lithium and offered very high energy density. 

1991 - However, inherent instabilities of lithium metal, especially during charging, put a damper on the development. The cell had the potential of a thermal run-away. The temperature would quickly rise to the melting point of the metallic lithium and cause a violent reaction. A large quantity of rechargeable lithium batteries had to be recalled in 1991 after the pack in a cellular phone released hot gases and inflicted burns to a man’s face.   A billion (with a B) dollars worth of laptop batteries also caused a few problems.

Because of the inherent instability of lithium metal, research shifted to a non-metallic lithium battery using lithium ions. Although slightly lower in energy density, the lithium-ion system is safer, providing certain precautions are met when charging and discharging. Today, lithium-ion is one of the most successful and somewhat safer battery chemistries available. 

•  Lithium-ion cells w/cobalt cathodes can hold twice the energy of a nickel-based battery and four-times that of a SLA. 
•  Lithium-ion is a low maintenance system, an advantage in some cases.  
•  There is no memory and the battery does not require scheduled cycling to prolong its life.
•  Nor does lithium-ion have the sulfating problem of Sealed Lead Acid that occurs if the battery is stored without charge
•  Lithium-ion has a low self-discharge and is environmentally friendly. Disposal causes minimal harm.
•  They do have a two year shelf life.


  • The higher energy density comes at a price. Manufacturing methods become more critical the denser the cells 
  • With a separator thickness of only 20-25µm, any small intrusion of metallic dust particles can be devastating
  • Appropriate measures will be needed to achieve the mandated safety standard set forth by UL 1642.
  • Whereas a nail penetration test could be tolerated on the older 18650 cell with a capacity of 1.35Ah, today’s high-density    2.4Ah Lithium cell would become a bomb when performing the same test. 
  •  Lithium-ion batteries are nearing their theoretical energy density limit and battery manufacturers are beginning to focus on improving manufacturing methods and increasing safety. 
  • With the high usage of lithium-ion in cell phones, digital cameras and laptops, there are bound to be issues. A one-in-20,000 failure rate triggered a recall of almost six million lithium-ion packs used in laptops manufactured by Dell and Apple.  Replacing the battery is cheaper than replacing the entire laptop when it goes south.  ( Boom, Dead, On Fire, Explodes, and/or  burns your house down)
  • Safety issues are enticing battery manufacturers to change the manufacturing process. According to Sony, contamination of Cu, Al, Fe and Ni particles during the manufacturing process may cause an internal short circuit.  A mild short will only cause an elevated self-discharge.   Little heat is generated because the discharging energy is very low. 
  • If, however, enough microscopic metal particles converge on one spot, a major electrical short can develop and a sizable current will flow between the positive and negative plates. This causes the temperature to rise, leading to a thermal runaway, also referred to as Venting with Flame.
  • Lithium-ion cells with cobalt cathodes (same as the recalled laptop batteries) should never rise above 130°C (265°F). At 150°C (302°F) the cell becomes thermally unstable, a condition that can lead to a thermal runaway in which flaming gases are vented.
  • During a thermal runaway, the high heat of the failing cell can propagate to the next cell, causing it to become thermally unstable as well. In some cases, a chain reaction occurs in which each cell disintegrates at its own timetable. A pack can get destroyed within a few short seconds or linger on for several hours as each cell is consumed one-by-one. To increase safety, packs are fitted with dividers to protect the failing cell from spreading to neighboring cells. 

•  There are two basic types of lithium-ion chemistries: cobalt and manganese (spinel). To achieve maximum runtime, cell phones, digital cameras and laptops use cobalt-based lithium-ion.  Manganese is the newer of the two chemistries and offers superior thermal stability. It can sustain temperatures of up to 250°C (482°F) before becoming unstable. In addition, manganese has a very low internal resistance and can deliver high current on demand. Increasingly, these batteries are used for power tools and medical devices. Hybrid and electric vehicles will be next.

•  The drawback of spinel is lower energy density. Typically, a cell made of a pure manganese cathode provides only about half the capacity of cobalt. Cell phone and laptop users would not be happy if their batteries quit halfway through the expected runtime. To find a workable compromise between high energy density, operational safety and good current delivery, manufacturers of lithium-ion batteries can mix the metals. Typical cathode materials are cobalt, nickel, manganese and iron phosphate. 

•  The battery manufacturers achieve this high reliability by adding three layers of protection and they are:
   1-Limiting the amount of active material to achieve a workable equilibrium of energy density and safety
   2-Inclusion of various safety mechanisms within the cell
   3-The addition of an electronic protection circuit in the battery pack.

•  We need to keep in mind that these safety precautions are only effective if the mode of operation comes from the outside, such as with an electrical short or a faulty charger. Under normal circumstances, a lithium-ion battery will simply power down when a short circuit occurs.    If, however, a defect is inherent to the electrochemical cell, such as in contamination caused by microscopic metal particles, this anomaly will go undetected. Nor can the safety circuit stop the disintegration once the cell is in thermal runaway mode. Nothing can stop it once triggered.