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A tour of Apple's iPhone 6 battery helps nail down the one variable that determines manufacturing cost. Li-polymer batteries are ubiquitous. They are everywhere: cellphones, tablets, laptops and hybrid or electric cars. We rarely think about them except when the discussion turns to the rather short battery life seen in some consumer electronics. Smartwatches, like some laptops, come to mind where battery life is measured at less than a day. This has me thinking about batteries, and are there commonalities between the batteries seen in smartwatches, cellphones and tablets. And this has our curiosity piqued at TechInsights as to whether a single variable can be used to predict their manufacturing cost (bill of materials or BoM)? Simple proxies would include the battery mass or its charge capacity as both are easily measured. Figure 1 shows a typical lithium-polymer pouch-type battery taken from a smartphone, in this case the Apple iPhone 6 Plus. The copper anode and aluminum cathode current collector tabs are seen extending out of the right end of the battery package. A flex ribbon containing control electronics has been removed from this battery but is shown on another iPhone 6 Plus battery in Figure 2 (on next page). We note the use of two Ricoh battery protection IC`s and a Texas Instruments Li-ion fuel gauge. Figure 1: Apple iPhone 6 Plus Li-polymer Battery. (Source: TechInsights) Figure 2: iPhone 6 battery electronics. (Source: Deep Dive Teardown of the Apple iPhone 6 Plus A1524, TechInsights) Our first question: is this battery special? And to answer this we examine the energy density (Wh/g) for a number of batteries used in smartphones, cellphones and tablets that have passed through TechInsights labs over the last year or so. The graph shown in Figure 3 includes smartwatch batteries that tend to be less than 25 g in weight, cellphones of various kinds, and tablets weighing in at more than 70 g. The slope of the straight line through the data is about 220 Wh/kg and it is a pretty good fit to most of the data points. The small scatter in the data points about the fitted line indicates that these batteries are using the same or at least fairly similar cell technologies. A significantly improved battery should lie well above the trend line, and a poor battery technology would be below the trend line. A few batteries are measurably below the trend line, though this underperformance might be due to excess packaging that would increase the weight of the battery without adding capacity. Figure 3: Li-Polymer battery capacity. (Source: TechInsights) The iPhone 6 Plus battery, weighing in at 43 g, is not standing out from the trend line and does not seem to be special. But being Apple it is nonetheless interesting. Our next item of interest is the BoM cost for the battery and to do this we need to know more about the battery`s structure. Our teardown begins with Figure 4 where we peel away the outer foil casing to expose a polymer film that envelopes the battery cells. This polymer film has been peeled away to expose the outer aluminum cathode collector layer shown in Figure 5. Figure 4: Cutting away outer casing.(Source: Deep Dive Teardown of the Apple iPhone 6 Plus A1524, TechInsights) Figure 5: Outer aluminum cathode collector layer. (Source: Deep Dive Teardown of the Apple iPhone 6 Plus A1524, TechInsights) Figure 6 is a cross section taken through the iPhone 6 Plus battery showing its layered structure. The battery contains eleven cathode (positive battery terminal) and 10 aluminum anode (negative battery terminal) current collector layers that are connected in parallel. The anode and cathode collector electrodes are coated with their electrode respective active layers and then stacked one on top of the other. Separator layers are inserted between the anode and cathodes to prevent short circuits but at the same time allows for the transfer of lithium ions between the anode and cathodes. Figure 6: iPhone 6 Plus battery in cross section. (Source: Detailed Structural Analysis of the Apple iPhone 6 Plus Li-ion Polymer Battery, TechInsights) Figure 7 shows the edge of the battery where the cathode current collector layers are brought and welded together to form the battery`s anode battery terminal. The anode current collectors are brought out of the package in a similar fashion. Figure 7: Cathode battery terminal. (Source: TechInsights) From TechInsights` Detailed Structural Analysis report, we know that the iPhone 6 Plus battery uses lithium cobalt oxide (LiCoO2) for the cathode and graphite for the anode as shown in Figure 8. Figure 8: SEM cross section iPhone 6 battery. (Source: Detailed Structural Analysis of the Apple iPhone 6 Plus Li-ion Polymer Battery, TechInsights) LiCoO2 (LCO) is a mature battery technology commonly used for mobile battery applications such as cell phones, tablets and laptops, and this likely explains why all of the batteries shown in Figure 3 fall on the same energy density curve. Table 1 lists as few other cathode materials. The last three are used in electric vehicles such as the Chevy Volt and Nissan Leaf. TechInsights has previously analysed the Chevy Volt battery fabricated by LG Chemical where we observed a mixture of lithium manganese oxide (LMO) and lithium nickel manganese oxide (NMC) being used for the cathode. Cathode Material Application Lithium cobalt oxide (LiCoO2) cell phones, tablets, laptops, cameras Lithium nickel manganese cobalt oxide (LiMnCoO2) Chevy Volt Lithium iron phosphate (LiFePO4) Electric vehicle Lithium nickel cobalt aluminum oxide (LiNiCoAlO2) Tesla Table 1: Common lithium ion battery compositions and applications The graphite anode and CoO2 cathode have lattice structures in which lithium ions are reversibly inserted (intercalation) into the interstitial spaces between the atomic layers. Figure 9 is a high resolution TEM image of the cathode`s CoO2 layer, while the graphite layered structure is shown in Figure 10. Figure 9: CoO2 cathode layers. (Source: Detailed Structural Analysis of the Apple iPhone 6 Plus Li-ion Polymer Battery, TechInsights) Figure 10: Graphite anode layers. (Source: TechInsights) Finding manufacturing cost models (BoM) for mobile Li-ion batteries has proved to be a bit of a challenge. Several papers have been published on the manufacturing costs for electric vehicle (EV) or hybrid electric vehicle (HEV) Li-ion batteries: Argonne National Laboratories (2000 and 2012), Rempel et al. (TIAX presentation 2013), and Wood et al. (J. Power Sciences 2015) to name a few. But we found little in the way of the manufacturing costs for the smaller batteries used in cellphones and laptops. The TIAX presentation provides a $0.47/Wh for PHEV type batteries, and Wood et al. derive a baseline model calculation of $ 0.50/Wh for the complete battery. This last report was published in 2015 and represents the most recent calculation that we found. Our Teardown business routinely disassembles electronic devices such as watches, smartphones, tables and laptops and derives their BoM using a sum of the parts methodology. These Teardown reports often include the BoM for the complete battery including its electronics, labor and margin. We are interested in the battery maker`s cost so we have subtracted the margin from the Teardown.com BoM`s and have plotted this in Figure 11 for many of the devices used in Figure 3. Figure 11: Battery Mmaker`s BoM vs. cell capacity. (Source: TechInsights) The data (red diamonds) shows a BoM trend line of about $0.37/Wh with a fair amount of scatter. The scatter is not too surprising as the batteries often contain different sets of electronics appended to them. The $ 0.37/Wh BoM is less than the $0.50/Wh of Wood and this is perhaps no surprise as cell phones and car batteries use different technologies even if they both use lithium ions as the energy storage medium. The cell phone battery is also a mature technology that would support a lower build cost. We have also plotted the retail prices for Li-ion batteries that we found on Amazon. We have been a bit selective with these, picking the lowest priced batteries that we found. Our thought here is that the lowest priced batteries are priced with the least margin for the battery maker, the wholesaler and retailer. The retail price is about twice that of estimate our BoM for the battery, and this seems quite reasonable. Figure 11: Battery Mmaker`s BoM vs. cell capacity. (Source: TechInsights) I have a predilection for plotting graphs of everything in sight and it gives me a small thrill to find straight lines. It is a physics thing, straight lines fitted to data. So returning to my question: Is there a simple proxy for the BoM? We think so, as the results shown in Figure 11 suggest that battery capacity (Wh) or even its weight do a pretty good job of it. And this makes sense; the battery cost comprises materials and labor, and we might suggest that both scale with the battery size. - Kevin Gibb is the product line manager for Process at TechInsights. As PLM, Dr. Gibb is responsible for the technology coverage, manufacturing processes, and pricing strategies for TechInsights` semiconductor process open market reports covering state-of-the-art semiconductor devices. Dr. Gibb has a broad knowledge of CMOS, bipolar, III-V, and MEMS technologies gained over nearly 25 years of working in semiconductor consulting firms, manufacturing, and government research laboratories. He has written process analysis reports on hundreds of devices over the past decade and half, spanning: CMOS, memory, MEMS and CMOS image sensors. Last Edited by Marketing1 at 6/12/2015 10:40 AM

For some, it may be a cheap alternative to learn how to replace an iPhone 5 battery. If you are considering this option, you must first understand how to remove a battery from the iPhone 5: Power off your device. Remove the two pentalobe screws near the Lightning connector. Press a suction cup to the screen just above the home button. (Use tape first to cover and seal the screen in the case that it is cracked.) Press down gently on the edges of the phone and lift up with the suction cup. The front and back panels will separate slightly. Insert plastic opening device between the panels and gently pry around the edges, detaching the clips on the right and left sides that hold the case together. Lift the front panel up about 90 degrees from the rear panel with the tops still close together (as there will still be ribbon cables attached at the top). Locate the silver front panel assembly cable bracket to the top right-hand side of the battery. Unscrew the three screws attaching it to the logic board (and pay attention to where each individual screw goes). Lift and remove the front panel assembly cable bracket. Locate the three cables hidden beneath, and disconnect these with the plastic opening tool. Completely separate the front and rear panels of the phone. Locate metal battery connector bracket to the lower right side of the battery. (It looks like a skinny backward [J.") Remove the two lower screws on the metal battery connector bracket. Use the plastic opening tool to gently pry the battery connector bracket up from the socket on the logic board. Take care not to pry up the socket, or you could damage the connector. Pull slowly and smoothly on the clear plastic pull tab until your battery detaches and comes free. If it does not come free, you can use the plastic opening tool. But be warned that doing so in the wrong place may permanently damage the logic board. Replace battery and all parts in reverse. Power on your device and voila! (Think carefully before you decide on this course of action. Opening up your device will nullify warranties that may still exist on your device. In addition, internal repairs are always best handled by experts like those at CPR so that no further damage comes to your device.) Age, use, settings, and defects are all aspects to take into consideration when assessing if you might need any phone battery replacement. You may choose to live with a battery at a lower capacity, talk with an Apple store Genius, or even try to figure out how to replace an iPhone 5 battery yourself with our DIY guide. If you need help making this decision, CPR is here to help! With stores across the country and in Canada, you can walk in and get a free consultation to discover if your iPhone 5 battery is at high capacity or if it needs repair. They will also provide you with an estimate that you can compare with Apple`s iPhone 5 battery replacement service and cost. Forget the hassle of doing the repair yourself and potentially further damaging your device. With CPR, you will get personal service and have your phone back in your hands and running smoothly again within a day or two.

If your iPhone doesn't hold a charge like it used to, these tips should help you get a boost from your battery. by Rick Broida February 17, 2017 3:42 PM PST

You'll get more life out of your iPhone and maybe a performance boost to boot. Find out the costs, pros and cons of hiring a pro or doing it yourself. by Rick Broida December 21, 2017 4:29 PM PST Your iPhone 6 is probably losing juice pretty quick, and a battery case like this isn't always convenient.So you have an aging iPhone that's perfectly fine except for one thing: the battery. These days you're lucky to make it to midafternoon before the power gives out. It's a common dilemma. Or perhaps you've noticed another issue? Does your iPhone seem slower than it was before? Turns out there's a reason for that: Apple recently admitted that iOS may impede performance if it detects an older battery. The slowdown is designed to allow older iPhones (iPhone 7, 6S, 6 and SE) to perform tasks without instantaneously shutting down. Unfortunately, all lithium ion phone batteries lose capacity over time. You'll probably first start to notice it after a year, then really notice it after 18 months. Once it gets intolerable, you have only a few options: Buy a new phone Start using a battery case Replace the battery Buying a new phone seems ridiculous, especially given the price. And the last few iPhone models have afforded little more than small boosts in speed and camera quality -- hardly compelling reasons to upgrade, in my opinion. (And maybe you don't want to give up your headphone jack.) A battery case can help, but it'll add bulk and weight to your phone while forcing you to switch from Lightning cables to Micro-USB. Both are hassles. It's also unlikely that a battery case will prevent Apple from slowing down your phone. That leaves replacing the battery. It's not the easiest solution, but it's the best one, because a new battery will effectively buy your iPhone another couple years of useful service. It will also solve the aforementioned slowdown issue, because iOS will treat the new battery like, well, a new battery. The only question is whether to do the job yourself or seek out a pro. (TL;DR? Go pro.) But first: Check the warranty Because replacing the battery involves cracking open the iPhone, it's only logical to ask: Won't this void my warranty? If the phone is more than a year old, the warranty has already expired -- unless you purchased an extended AppleCare+ plan, in which case you may be entitled to a free battery replacement from Apple. But assuming you're post-coverage, it doesn't matter if you go DIY or third-party. However, if you hire a service or shop to replace the battery, you may receive a warranty on that repair -- something you won't get if you do the work yourself. Go pro Hire iCracked and a tech will come to you. Rick Broida/CNET Straight to the math: It'll likely cost you anywhere from $50-$80 to hire a shop or service to replace your iPhone battery. That can be a hard pill to swallow knowing that DIY kits cost as little as $10, but I'll make the case it's money well spent. For starters, these folks are experienced with this kind of repair. They know what they're doing. You're also likely to get the benefit of some kind of warranty. Side-benefit: They're probably using reliable batteries so there's less chance you'll actually need that warranty. The best option is Apple Apple offers a battery replacement service that costs $79 for any iPhone model -- a competitive price, and arguably your best option given that no company is better at servicing iPhones. However, there's one catch: You'll have to be without your phone for at least a few days. Apple estimates three to five business days if you ship it and "up to five business days" if you bring it to an Apple Authorized Service Provider. (If you've tried either of these options, hit the comments and let us know how long it actually took.) Other third-party services Few users are likely to want to wait that long, which leaves either a local phone repair shop or a service like iCracked, which I evaluated a couple years back and is not an Apple Authorized Service Provider. Although I used it for screen repair, the company offers battery replacement as well. The big benefit: iCracked dispatches a tech to pretty much any location you like -- home, office, the local Starbucks, wherever. And the repair will probably take no more than an hour. Similarly, if there's a phone-repair shop near you, it probably offers same-day battery replacement. Pricing tends to vary depending on the age and model of your phone. Based on the quotes I received, you should expect to pay around $50-$70 for anything in the iPhone 6 ($255.00 at Amazon.com) family. If the price is anywhere close to Apple's $79 repair fee, we highly recommend that you try going to Apple first. That may seem high for something as small and inexpensive as a battery, but it's still considerably less than buying a new phone. The DIY option A kit like this one will cost you anywhere from $10-$30. How hard can it be to replace an iPhone battery? Remove some screws, open up the case, take out the old battery, plug in the new one and you're done, right? Right. Except those screws are tiny. The case is hard to get open. Inside, you have to remove a bunch more screws and some fragile ribbon cables just to get to the battery. Which is glued in place. Then you have to do it all in reverse. If you've never ventured inside an iPhone before, this can be some nerve-wracking surgery. It helps to have video-tutorial guidance (see below), but trust me when I say it's easy to make a mistake. And if you flub along the way, you'll brick your phone. The DIY option, however, is definitely the cheapest. Replacement battery kits are available from Amazon, eBay and countless other sources, most of them priced anywhere from $10-$30. Personally, I recommend spending a few dollars more to buy from a reputable (and customer-reviewed) vendor on Amazon.