Lithium and Copper
to the Extreme

The history of the battery begins in the late 18th century with the pioneering work of Italian scientist Alessandro Volta. In 1800, Volta invented the first true battery, known as the “voltaic pile,” which consisted of alternating discs of zinc and copper separated by cardboard soaked in saltwater. This device produced a steady electric current, marking a significant breakthrough in electrical science. Volta’s invention built upon earlier experiments by Luigi Galvani, who discovered that frog legs twitched when exposed to electricity, hinting at the connection between chemical reactions and electrical energy. The voltaic pile laid the foundation for future developments in battery technology, enabling scientists and inventors to explore electricity in practical applications.

Throughout the 19th century, battery technology evolved with notable advancements. In 1836, British chemist John Frederic Daniell developed the Daniell cell, which improved upon the voltaic pile by using a copper sulfate and zinc sulfate solution to generate a more stable current. This design reduced corrosion and made batteries more reliable for early telegraph systems and other emerging technologies. Later, in 1866, French engineer Georges Leclanché introduced the Leclanché cell, a wet cell battery using a zinc anode and a manganese dioxide cathode in an ammonium chloride solution. This became the precursor to the modern zinc-carbon battery and was widely used due to its simplicity and affordability. These early batteries, while innovative, were limited by their bulkiness, short lifespan, and inability to be recharged.

The 20th century brought rechargeable batteries, revolutionizing energy storage. In 1899, Swedish engineer Waldemar Jungner invented the nickel-cadmium (NiCd) battery, the first rechargeable battery, using nickel oxide and cadmium electrodes. Around the same time, Thomas Edison developed the nickel-iron (NiFe) battery, which offered durability and a long lifespan, though it was less efficient. The real game-changer came in 1949 with the invention of the alkaline battery by Canadian engineer Lewis Urry, which used a zinc and manganese dioxide chemistry in an alkaline electrolyte. Alkaline batteries were more powerful and longer-lasting than their predecessors, becoming a staple in household electronics. Meanwhile, lead-acid batteries, invented by Gaston Planté in 1859, continued to dominate automotive applications due to their rechargeability and robustness.

The late 20th and early 21st centuries saw the rise of lithium batteries, particularly for high-end electronics. In the 1970s, researchers like M. Stanley Whittingham began exploring lithium as a lightweight, high-energy material for batteries, leading to the development of lithium-ion (Li-ion) technology. John B. Goodenough, Akira Yoshino, and others refined this concept in the 1980s and 1990s, creating a rechargeable battery with a lithium cobalt oxide cathode and a carbon anode, which Sony commercialized in 1991. Lithium-ion batteries offered higher energy density, longer life cycles, and no memory effect, making them ideal for smartphones, laptops, and electric vehicles. Recent advances have focused on improving safety and capacity, with innovations like solid-state lithium batteries and lithium-sulfur designs promising even greater performance for cutting-edge devices, driving the electronics industry into a new era of portability and power.

Today, BikeLink uses the latest technology-driven battery designs for outstanding durability, faster charge times, and constant power output. The BikeLink Helmet Unit pushes technology to its limit by balancing the extreme brightness and adjustability of Cree LEDs, long run-times (est. 4-5 hrs of standard use) on a single charge, and provide multiple charging options, all this while deploying a sophisticated Battery Management System (BMS) onboard the custom (PCB).

Printed Circuit Board (PCB) creation for high-end electronics is a sophisticated process that demands meticulous attention to detail, advanced technology, and a deep understanding of electrical engineering principles. High-end electronics—such as those found in aerospace systems, medical devices, or cutting-edge consumer gadgets, like  BikeLink Products, rely on PCBs to serve as the backbone of their functionality, connecting intricate networks of components with precision and reliability. The design and manufacturing of these PCBs go far beyond simple layouts, incorporating multiple layers of conductive traces, advanced materials, and stringent quality controls to meet the performance demands of modern technology.

Power management is a critical aspect of PCB design in high-end electronics. These devices often operate under tight power constraints, requiring efficient distribution and regulation of electricity to ensure optimal performance without overheating or energy waste. Designers must carefully plan the placement of power planes, ground planes, and decoupling capacitors to minimize noise, stabilize voltage, and prevent power-related failures. For example, in a high-performance processor or a sensitive imaging system, even minor fluctuations in power delivery can lead to data corruption or system crashes. Advanced PCB layouts integrate power management circuits directly into the board, using techniques like impedance matching and thermal vias to dissipate heat and maintain stability under heavy loads.

Precision manufacturing is equally vital in this domain. High-end PCBs often feature extremely fine trace widths, tight tolerances, and microvias that connect multiple layers in a compact space. These elements require state-of-the-art fabrication techniques, such as laser drilling and automated optical inspection, to ensure flawless execution. A single defect—like a misaligned via or an incomplete solder joint—can compromise the entire system, leading to costly failures in applications where reliability is non-negotiable, such as satellite communications or life-saving medical equipment. Materials also play a key role; high-frequency circuits might demand low-loss substrates like PTFE or ceramic-filled laminates to maintain signal integrity, further elevating the need for exacting production standards.

The complexity of tracing multiple layers to connect each component is another defining challenge. High-end PCBs can have 10, 20, or even more layers, each hosting a web of copper traces that link processors, sensors, memory chips, and other critical elements. These layers must be meticulously aligned and interconnected through vias, with signal paths optimized to reduce interference, crosstalk, and latency. For instance, in a 5G-enabled device, high-speed signals require careful routing to avoid degradation over distance, while differential pairs must be matched in length to ensure timing accuracy. Designers use advanced software to simulate electromagnetic behavior and validate the layout before production begins, but the physical execution still hinges on cutting-edge equipment and skilled expertise. Together, power management, precision manufacturing, and multilayer tracing on all BikeLink powered products, enable these high-end PCBs to meet the extraordinary demands of sophisticated electronics needed for an ultra-modern product.