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Solar Stik® Inc., is a leader in the portable renewable power industry. Our administrative offices and production facility are located in downtown Saint Augustine, Florida, where we manufacture renewable energy power systems, battery storage systems, power management devices, and high-efficiency appliances for a broad range of markets.

As a Solar Stik® team member, you are not an employee, but part of a family. We offer full-time employees health insurance, paid holidays, personal time off, and reimbursement for wellness/fitness classes. Monthly, we get together for a catered lunch or cookout to celebrate our achievements as individuals and as a company.

Our camaraderie is just as strong off the field as on the field! We surf together, attend concerts together, and participate in team-building events for worthy causes, such as the Walk MS for MS Research and the Wounded Warrior Project 8K Run.

Solar Stik is an Equal Opportunity Employer. Our recruiting and hiring practices are based on job-related criteria only. We do not discriminate on the basis of any federal, state, or locally protected class. Please note, as part of our selection requirements, we request authorization from applicants to perform drug screens and background checks.

If our mission rings true to you and you have the skills to meet one of the opportunities listed below or related areas, please send your resume and contact information to careers@solarstik.com for consideration.

Current Job Openings (Scroll down for more info)

Job Title: Electrical Engineer
Department: Engineering
Position: Full-Time

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

The Electrical Engineering role is a dynamic role offering boundless opportunities for innovation and design, working alongside our talented and diverse Engineering team. The selected candidate will be responsible for the analysis, conceptual design, development, testing, and integration of complex digital control hardware and software to new and existing Solar Stik products. Apply today!

Description of Duties

  • Research, design, development of electrical/electronic power and control solutions.
  • Produce technical documentation and test procedures required for all new designs utilizing technologies that will provide the best cost solutions.
  • Improve engineering processes and practices wherever possible.
  • Provide accurate and timely reports to management as required.
  • Prototype, validate, and test new designs as necessary.
  • Assist with the specification of new products based on the translation of customer needs, assembly, and engineering design principles.
  • Recommend, develop and implement tools and practices to improve Engineering Team productivity and capability.
  • Provide training and support to other departments whenever necessary.
  • Stay up to date with current technology as it applies to our products and markets.

 

Qualifications and Education Requirements

  • Bachelor’s Degree in Electrical Engineering or related field from an ABET accredited institution or equivalent experience.
  • 1+ years progressive experience in a manufacturing environment.

 

Required Skills and Qualifications

  • Proficient with the use of SolidWorks electrical CAD design software.
  • Proficient in writing and maintaining embedded software.
  • Proficient with Microsoft Office Programs.
  • Proficient using basic hand tools.
  • Experience building and testing prototypes.
  • Ability to interpret customer specifications into finished design.
  • Ability to develop and implement test plans.
  • Ability to analyze data and provide clear and concise reports with recommendations and supporting data.
  • Strong critical thinking, problem solving, and troubleshooting skills in a team environment.
  • Strong verbal and written communication skills.

 

Preferred Skills and Qualifications

  • Experience designing solar/hybrid power systems.
  • Experience designing electrical/electronic systems for rugged applications.
  • Experience with thermodynamics and cooling techniques.
  • Familiarity with UL, NFPA 70: NEC, IEC, ANSI, and military standards.
  • Familiarity with EMI/RFI and their mitigation.

 

Quick Apply: Electrical Engineer 
https://solarstik.isolvedhire.com/jobs/795445.html

Job Title: Quality Technician
Department: Quality
Reports To: Quality Manager

Mission Statement
Saving lives across the globe through innovative power solutions.

Job Description
The Quality Technician position is a cross-functional role that ensure products meet company Quality expectations and standards. This position is responsible for executing and analyzing QC inspections, tests, and results, and will work hand in hand with the Sales, Production, and Engineering Departments. The successful Quality Technician will possess exceptional critical-thinking skills, have superior attention to detail, and have a passion for root-cause problem-solving.

Roles and Responsibilities

  • Assist the Quality Manager in the creation and improvement of documented Quality Control Standard Operating Procedures (SOPs).
  • Responsible for testing individual units and maintaining related documentation.
  • Responsible for testing entire system and maintaining related documentation.
  • Load test all battery contained products, and document the results.
  • Maintain PM’s on generators.
  • Assist Engineering Department in understanding components and systems.
  • Responsible for the overall quality of work in each product, including inspections, managing documentation, etc.
  • Maintain IPC 620 Class 3 Standards.
  • Maintain all testing equipment and ensure all equipment being used is certified and calibrated.
  • Responsible for ensuring the quality standards set forth by the customer are being maintained.
  • Responsible for troubleshooting customer returned product and creating CRAs if required.
  • Responsible for having a first piece available during the entire production run for reference.
  • Responsible for communicating any errors found in work instructions, quality check lists, or other documentation to the Production and Quality Manager


Qualifications and Education Requirements

  • A.S. in Quality Assurance, Engineering Technology, or equivalent experience.
  • Experience troubleshooting AC and DC circuits.
  • Strong understanding of Electrical Theory.


Preferred Skills Preferred Skills

  • 3+ years in Quality related role.
  • Familiarity with ISO 9001 and Quality Management Systems.
  • Proficient written, verbal, and interpersonal communication skills.
  • Strong attention to detail.
  • Effective time-management skills.
  • Strong analytical skills and problem-solving capabilities.
  • Proficient written, verbal, and interpersonal communication skills.
  • Detail oriented, with a logical and data analysis driven approach to problem-solving/decision making.


Quick Apply: Quality Technician
https://solarstik.isolvedhire.com/jobs/861446.html

Job Title: Wiring Assembly Technician
Department: Production
Reports To: Production Manager

Mission Statement
Saving lives across the globe through innovative power solutions.

Description of Duties

  • Read and interpret schematic drawings, diagrams, specifications, work orders, or reports to determine materials requirements or assembly instructions.
  • Position, align, or adjust workpieces or electrical parts to facilitate wiring or assembly.
  • Inspect or test wiring installations, assemblies, or circuits for resistance factors or for operation and record results.
  • Assemble electrical or electronic systems or support structures and install components, units, subassemblies, wiring, or assembly casings, using rivets, bolts, soldering equipment.
  • Prepare wires for installation using pneumatic stripper and crimper.
  • Follow the work instructions as they pertain to the production processes and suggest improvements.
  • Adjust, repair, or replace electrical or electronic component parts to correct defects and to ensure conformance to specifications.
  • Confer with supervisors or engineers to plan or review work activities or to resolve production problems.
  • Drill or tap holes in specified equipment locations to mount control units or to provide openings for elements, wiring, or instruments.
  • Fabricate or form parts, coils, or structures according to specifications, using drills, calipers, cutters, or saws.
  • Explain procedures or techniques to other workers.
  • Verify the BOM on each First Piece.
  • Use the correct material called for by the BOM.
  • Use the correct and approved tooling called for by the work instructions.

Qualifications and Education Requirements

  • High School diploma or equivalent education (College degree or vocational training preferred)
  • Minimum 1-2 years relevant experience

Preferred Skills and Qualifications

  • Knowledge of electrical theory and circuitry.
  • Basic use of hand-tools and measuring equipment.
  • Proficient written, verbal, and interpersonal communication skills.
  • Strong attention to detail.
  • Effective time-management skills.
  • Strong analytical skills and problem-solving capabilities.
  • Detail oriented, with a logical and data analysis driven approach to problem solving/decision making.


Quick Apply: Wiring Assembly Technician
https://solarstik.isolvedhire.com/jobs/805478.html

Job Title: Cable Assembly Technician
Department: Production
Reports To: Production Manager

Mission Statement
Saving lives across the globe through innovative power solutions.

Description of Duties

  • Assemble cables using standard specified hand tools and equipment.
  • Read and interpret schematic drawings, diagrams, specifications, work orders, or reports to determine materials requirements or assembly instructions.
  • Inspect completed units to ensure that standards, specifications, tolerances, and customer order requirements are met.
  • Perform visual and dimensional inspection of in-process assemblies and finished products.
  • Consistently maintain acceptable levels of production according to established standards.
  • Confer with supervisors or engineers to plan or review work activities or to resolve production problems.
  • Explain procedures or techniques to other workers.

 

Qualifications and Education Requirements

  • High School diploma or equivalent
  • Ability to read and follow assembly instructions
  • Experience in production/assembly environments
  • Experience with hand tools and crimpers
  • Ability to lift 50 lbs
  • Excellent hand dexterity

 

Preferred Skills and Qualifications

  • Vocational or technical school training
  • Ability to interpret electrical schematics
  • Basic knowledge of electrical theory and circuitry
  • Basic use of hand-tools and measuring equipment
  • Proficient written, verbal, and interpersonal communication skills
  • Strong attention to detail


Quick Apply: Cable Assembly Technician
https://solarstik.isolvedhire.com/jobs/897115.html

Job Title: Inventory and Sales Support Specialist
Department: Production
Reports To: Production Manager

Mission Statement
Saving lives across the globe through innovative power solutions.

Job Description

The Inventory and Sales Support Specialist is responsible for the overall support of the Sales team, and effective liaison between the Purchasing and Accounting Departments. The successful Inventory and Sales Support Specialist is a detail-oriented team player with exceptional time management and communication skills.

 

Description of Duties

  • Generate customer quotes.
  • Review, process, and maintain knowledge of Purchase Orders and Internal Sales Orders.
  • Update past, current, and future customer orders and/or equipment status.
  • Provide support to sales channel partners with price lists, quotes, comparable items, etc.
  • Support Finance and BD in the maintenance of VPL, key customer files, and partner contracts.
  • Monitor and evaluate status of open Purchase Orders and oversee MISys Dashboard.
  • Process inventory invoices via MISys and communicate with Accounting on PO closures and overall invoice timing.
  • Reconcile invoices with receiving slips to ensure accuracy.
  • Verify inventory is received in and corresponding documentation (invoices, packing slips, etc.) are received and correct.
  • Manage inventory related records and documents on the server.
  • Support Financial Controller in entering non-inventory invoices in QBs, credit references, and following up on any memo, payment, or other issues on as needed basis.
  • Audit purchases and receivables on weekly basis (open Pos and current and valid) with Purchasing Specialist.
  • Distribute resale tax certificates to suppliers on as needed basis.
  • Update prices in MISys and verify quantities on as needed basis.

 

Required Qualifications and Education Requirements

  • High school graduate or equivalent
  • Excellent time management and communication skills
  • Proficiency with QuickBooks, Microsoft Office Suite, and MRP software (MISys)

 

Preferred Skills and Qualifications

  • Associate’s or Bachelor’s degree in Administration, Finance, or equivalent
  • Meticulous attention to detail
  • Excellent analytical and critical thinking skills

 

Quick Apply: Inventory and Sales Support Specialist
https://solarstik.isolvedhire.com/jobs/875648.html

Job Title: Shipping and Receiving Specialist
Department: Production
Reports To: Production Manager
Position: Full-Time

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

The Shipping and Receiving Specialist role is a dynamic position responsible for the coordination of all incoming and outgoing goods while complying with internal and external requirements. The successful Shipping and Receiving Specialist has a comprehensive, detailed approach to shipping and documentation and will have a thorough understanding of Hazmat and Export Compliance laws, regulations, and policies. This is an exciting and diverse role that encompasses a variety of responsibilities and offers opportunities for continuous learning. Apply today!

Description of Duties

  • Coordinate outgoing small parcel and freight shipments
  • Produce and prepare all shipping related documentation: Bills of Lading (BOLs), Shipping Labels, Packing Lists, Packing Slips, Hazardous Material Documents, Import/Export Documents, etc.
  • Estimate freight or postal rates and record shipment costs and weights
  • Keep accurate and updated records of goods shipped and track delivery progress of shipments
  • Ensure adherence with Export Compliance laws, regulations, and policies with emphasis on Export Administration Regulations (EAR) and Foreign Trade Regulations (FTR), including Electronic Export Information (EEI) submission requirements
  • Ensure adherence with all Hazmat shipping laws, regulations, and policies with an emphasis on Shipping Lithium Batteries
  • Provide appropriate HAZMAT documentation for Solar Stik personnel hauling HAZMAT materials in vehicles
  • Coordinate with Production Manager on ship dates
  • Store and maintain safety data sheets (SDS)
  • Accept and route received goods to appropriate storage areas or departments, using forklifts, hand trucks, or other equipment
  • Properly pack items for shipment and coordinate pallet packing
  • Coordinate and supervise activities of workers engaged in packing and shipping merchandise

Qualifications and Education Requirements

  • High School diploma or equivalent. College, vocational training, or professional certifications a plus
  • Minimum 3 years of domestic and international shipping experience
  • Thorough knowledge of Export Compliance laws and regulations (EAR, FTR, EEI)
  • Thorough knowledge of international and HazMat transport
  • Knowledge of incoterms
  • Excellent written and verbal communication skills
  • Excellent organizational and problem-solving skills
  • Ability to handle multiple tasks with awareness of deadlines
  • Proficiency in Microsoft Office Suite and Gmail

Preferred Skills and Qualifications

  • Experience with shipping Class 9 Lithium Batteries
  • Background in Defense Industry
  • Familiarity with Lean Six Sigma Principles
  • Capable of lifting 75 lbs.
  • Forklift Operator Certification a plus

Quick Apply: Shipping and Receiving Specialist
https://solarstik.isolvedhire.com/jobs/804709.html

Job Title: Buyer
Department: Production
Reports To: Production Manager
Position: Full-Time

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

The successful Buyer is a tech-savvy specialist responsible for facilitating communications with key suppliers and fostering positive relationships with vendors; they are detail-oriented, focused, and disciplined. You should be comfortable both working alone and as part of a small team. You may be occasionally asked to help with shipping, receiving, physical inventories, and entry-level assembly work. This is a fast paced, dynamic position with boundless opportunities for growth. Apply today!

Description of Duties

Purchasing and Receiving

  • Review and verify invoices, vendor packing lists, and bills of lading to ensure accuracy and compliance with company policies.
  • Manage relationships with suppliers.
  • Assist Manufacturing Manager in coordinating manufacturing activities by scheduling, projecting lead times, and providing reports of parts availability.
  • Record receipt of supplies and components, record serial and other identification numbers, and adjust stocking levels in MISys.
  • Document routine purchasing procedures.
  • Develop and maintain strong working relationships with suppliers
  • Negotiate with suppliers for best price and lead times
  • Manage parts requests and purchasing all for ISOs, SOs, and R&D projects
  • Communicate with suppliers to rectify any cost, quality, and delivery discrepancies
  • Create work orders for placards and materials made by CNC & Laser or 3D printed by R&D
  • Identify more cost-efficient acquisition strategies using MISys production workflow utilities.
  • Facilitate ensuring that the Station’s office and janitorial supplies stay well-stocked.

Qualifications and Education Requirements

  • High school diploma or equivalent education
  • 5 years related job experience preferred
  • Five years’ experience working with an automated industry-standard Material Requirements Planning (MRP) tool, such as MISys, NetSuite, Oracle, or SAP, to manage complex multi-layer inventories.
  • Excellent computer skills and proficiency in MS Office suite
  • High attention to detail and level of analytical skills
  • Excellent interpersonal and written and verbal communication skills
  • Excellent organizational and problem solving skills
  • Ability to handle multiple tasks with awareness of deadlines
  • Must be willing to work extended hours on limited occasions.
  • Extensive experience working in a small to medium sized manufacturing company.
  • Familiarity with Lean/Six Sigma methodologies.
  • Team player

Preferred Skills and Qualifications

  • Uses time efficiently and completes work in timely manner
  • Demonstrates attention to detail
  • Demonstrates accuracy and thoroughness
  • Observes safety and security procedures
  • Able to cross-train in different areas

Physical Demands

  • Occasionally required to:
    • Bend, lift, or climb
    • Lift light weights (less than 25 pounds)
    • Lift moderate weights (25-50 pounds)
    • Lift heavy weights (50 pounds or greater)
  • Finger dexterity required
  • Good hand-eye coordination required
  • Specific vision abilities required for this job include: close vision, distance vision, ability to adjust or focus

Work Environment

  • Protective clothing or equipment (including gloves, helmets, steel-toed boots, and protective eyewear) required in certain areas in the production facility
  • Noise level in the work environment typically minimal

Quick Apply: Buyer
https://solarstik.isolvedhire.com/jobs/809000.html

Job Title: Wiring Assembly Technician
Department: Production
Reports To: Production Manager
Position: Full-Time

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

The Wiring Technician plays a vital role in the Production process, and is responsible for the implementation and connection of wiring and electrical components in our products. The successful Wiring Technician will have a background in wiring, experience reading schematics, and knowledge of circuit theory. Apply today!

Description of Duties

  • Read and interpret schematic drawings, diagrams, specifications, work orders, or reports to determine materials requirements or assembly instructions.
  • Position, align, or adjust workpieces or electrical parts to facilitate wiring or assembly.
  • Inspect or test wiring installations, assemblies, or circuits for resistance factors or for operation and record results.
  • Assemble electrical or electronic systems or support structures and install components, units, subassemblies, wiring, or assembly casings, using rivets, bolts, soldering equipment.
  • Prepare wires for installation using pneumatic stripper and crimper.
  • Follow the work instructions as they pertain to the production processes and suggest improvements.
  • Adjust, repair, or replace electrical or electronic component parts to correct defects and to ensure conformance to specifications.
  • Confer with supervisors or engineers to plan or review work activities or to resolve production problems.
  • Drill or tap holes in specified equipment locations to mount control units or to provide openings for elements, wiring, or instruments.
  • Fabricate or form parts, coils, or structures according to specifications, using drills, calipers, cutters, or saws.
  • Explain procedures or techniques to other workers.
  • Verify the BOM on each First Piece.
  • Use the correct material called for by the BOM.
  • Use the correct and approved tooling called for by the work instructions.

Qualifications and Education Requirements

  • High School diploma or equivalent education (College degree or vocational training preferred)
  • Minimum 1-2 years relevant experience

Preferred Skills and Qualifications

  • Knowledge of electrical theory and circuitry.
  • Basic use of hand-tools and measuring equipment.
  • Proficient written, verbal, and interpersonal communication skills.
  • Strong attention to detail.
  • Effective time-management skills.
  • Strong analytical skills and problem-solving capabilities.
  • Detail oriented, with a logical and data analysis driven approach to problem- solving/decision making.

Quick Apply: Quality Technician Position
https://solarstik.isolvedhire.com/jobs/805478.html

Job Title: Administrative Assistant
Department: Administration
Position: Part-Time

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

The Administrative Assistant is responsible for supporting the Administrative Services Coordinator and Administration Senior Manager in facilitating day-to-day administrative duties at Solar Stik. The successful Administrative Assistant is a proactive problem-solver with exceptional communication skills and pays meticulous attention to detail. In the administrative landscape of the company, the Administrative Assistant is relied upon for their collaborative flexibility and ability to anticipate needs that may arise while also managing multiple responsibilities successfully.

Description of Duties

  • Assist in the creation, editing, and maintenance of Administrative SOPs and other company documentation
  • Greet visitors at the door and ensure proper processes are followed (check in, issue visitor badge, etc.).
  • Responsible for IT and miscellaneous company asset tracking including intake and tagging, employee assignment tracking, internal transfers, coordinating, and decommissions.
  • Assist Administrative Services Coordinator in booking all company related travel accommodations including filling out related Expense Reports and maintaining Travel Tracking documentation for potential audits.
  • Responsible for Conference Room set up when hosting guests.
  • Assists Administrative Services Coordinator in booking in planning and executing all team events including ordering, picking up, and setting up food and misc. supplies (All Hands, Christmas Party, WMS, etc.).
  • Assists Administrative Services Coordinator in preparing agendas for quarterly All Hands meetings.
  • Manages incoming correspondence, screening when necessary (mail, phone, etc.). Act as primary operator of phone portal actions (extension changes, call forwarding, voicemail set ups).
  • Assist with company safety program: ensures monthly inspections are conducted, makes recommendations on safety training programs and ensures PPE is stocked.
  • Supports Administrative Services Coordinator and Production Manager by ensuring compliance with OSHA and other various safety requirements.
  • Supports basic campus maintenance tasks (bathroom and kitchen cleaning schedule, garbage/recycling schedules, etc.)
  • Runs as needed miscellaneous errands and provides direct support to Administration Department and to the company as a whole.
  • Responds to and resolves administrative inquiries and questions.

Qualifications and Education Requirements

  • S. Diploma or equivalent experience, Associates Degree a plus.
  • 2+ years of Administrative experience a plus.
  • Exceptional written, verbal, and interpersonal communication skills.
  • Strong time-management skills and the ability to organize and coordinate multiple projects at once
  • Strong critical thinking, problem solving, and troubleshooting skills in a team environment.
  • Computer literacy and proficiency in Microsoft Office and other office productivity tools, with aptitude to learn new software and systems.

Preferred Skills and Qualifications

  • Ability to multitask and prioritize.
  • Basic understanding of fundamental IT functions.
  • Experience using asset tracking applications/software.
  • Events/team building exercise planning experience.

 

Quick Apply: Administrative Assistant
https://solarstik.isolvedhire.com/jobs/791431.html

Job Title: CNC & Laser Operator
Department: Production
Reports To: Production Manager
Position: Full-Time

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

The CNC & Laser Operator position is a pivotal, hands-on role that manages the execution of the company CNC and Laser operations. The successful CNC & Laser Operator will have experience with the operation of CNC Router tables (4-Axis and Lathe, CR-508 ATC), engraving lasers, and have the ability to troubleshoot and multitask multiple priorities. This is a fast paced, dynamic position with boundless opportunities for growth. Apply today!

Description of Duties

  • Build to internal purchase orders (IPOs) and complete required paperwork.
  • Maintain proper inventory levels on materials needed, keeping a minimum stock level.
  • Maintain machines and remove and replace broken or worn machine tools, using hand tools.
  • Measure dimensions of finished workpieces to ensure conformance to specifications, using precision measuring instruments, templates, and fixtures.
  • Mount, install, align, and secure tools, attachments, fixtures, and workpieces on machines, using hand tools and precision measuring instruments.
  • Set up and operate computer-controlled machines to perform one or more machine functions on metal or plastic workpieces.
  • Insert control instructions into machine control units to start operation.
  • Review program specifications or blueprints to determine and set machine operations and sequencing, finished workpiece dimensions, or numerical control sequences.
  • Remove and replace dull cutting tools.
  • Monitor machine operation and control panel displays and compare readings to specifications to detect malfunctions.
  • Enter commands or load control media, such as tapes, cards, or disks, into machine controllers to retrieve programmed instructions.
  • Modify cutting programs to account for problems encountered during operation and save modified programs.
  • Calculate machine speed and feed ratios and the size and position of cuts.
  • Adjust machine feed and speed, change cutting tools, or adjust machine controls when automatic programming is faulty or if machines malfunction.
  • Perform minor maintenance and cleaning of cutting equipment and work area in accordance with company standards and manufactures machine recommendations.
  • Implement changes to machine programs and enter new specifications, using computers.
  • Set up future jobs while machines are operating.

Qualifications and Education Requirements

  • CNC Machinist/Fabricator Certificate or Technical Degree
  • Proficient in Fusion 360
  • 3+ years progressive CNC Router Table experience
  • 3+ years progressive engraving laser operation experience
  • Experience working in CAD software
  • Must be able to lift 50+ lbs

Preferred Skills and Qualifications

  • Proficient written, verbal, and interpersonal communication skills.
  • Detail oriented, with a logical and data analysis driven approach to problem-solving/decision making.
  • Ability to prioritize and multitask in a fast-paced environment
 

Job Title: General Assembly Technician, Temporary & Permanent
Department: Production
Reports To:  Production Manager
Position: Temp/Permanent

Mission Statement

Saving lives across the globe through innovative power solutions.

Description of Duties

  • Places parts in specified relationship to each other
  • Bolts, clips, screws, or otherwise fastens parts together
  • Works at different work stations as production needs require
  • Works on line where tasks vary as different model of same article moves along line
  • Helps pack and receive goods
  • Clean parts, using cleaning solutions, air hoses, and cloths.
  • Complete, review, or maintain production time or component waste reports.
  • Confer with supervisors or engineers to plan or review work activities or to resolve production problems.
  • Distribute materials, supplies, or subassemblies to work areas.
  • Drill or tap holes in specified equipment locations to mount control units or to provide openings for elements, wiring, or instruments.
  • Explain assembly procedures or techniques to other workers.
  • Fabricate or form parts, coils, or structures according to specifications, using drills, calipers, cutters, or saws.

Qualifications and Education Requirements

  • High school diploma or equivalent education
  • 1-2 years related job experience preferred
  • Basic understanding of electrical theory preferred but not required
  • Use of basic hand tools
  • Team player

Preferred Skills and Qualifications

  • Uses time efficiently and completes work in timely manner
  • Demonstrates attention to detail
  • Demonstrates accuracy and thoroughness
  • Observes safety and security procedures
  • Able to cross-train in different areas
 
The above cited duties and responsibilities describe the general nature and level of work performed by people assigned to the job. They are not intended to be an exhaustive list of all the duties and responsibilities that an incumbent may be expected or asked to perform.
 
Quick Apply: General Assembly Technician
https://solarstik.isolvedhire.com/jobs/760030.html

Job Title: Electrical Engineering Intern
Department: Engineering/Technology
Position: Intern

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

Engineering internship students at Solar Stik, Inc. are considered to be an integral part of the Engineering staff and are provided with tasks that are both technically challenging and educationally stimulating. Under guidance of the senior engineering staff, the students will be assigned to teams associated with ongoing production and Research & Design programs.

Description of Duties

  • Assist Engineering team with creating schematic and wiring diagrams for new products.
  • Assist Engineering team with building prototypes, performing product tests, troubleshooting, and analyzing test results.
  • Assist Engineering team with the documentation of new and modified products.
  • Analyze existing product designs for areas where the electrical design may be improved.
  • Implement and document changes as required for ECO’s.
  • tasks as defined by the Engineering team and Director of Technology.

Qualifications and Education Requirements

  • Enrolled full-time and pursuing B.A.S. in Electrical Engineering with completion of Junior year from an accredited college/university.
  • Familiarity with SolidWorks Electrical software.
  • Familiarity with Microsoft Office software.

Preferred Skills and Qualifications

  • Be available to work full-time (40 hours per week) for the duration of the internship
  • Proficient written, verbal, and interpersonal communication skills.
  • Detail oriented, with ability to work autonomously.
  • Ability to follow written and verbal instruction.

The above cited duties and responsibilities describe the general nature and level of work performed by people assigned to the job. They are not intended to be an exhaustive list of all the duties and responsibilities that an incumbent may be expected or asked to perform.

 
Quick Apply: Electrical Engineering Intern
https://solarstik.isolvedhire.com/jobs/795841.html

Job Title: Mechanical Engineering Intern
Department: Engineering/Technology
Position: Intern

Mission Statement

Saving lives across the globe through innovative power solutions.

Job Description

Engineering internship students at Solar Stik, Inc. are considered to be an integral part of the Engineering staff and are provided with tasks that are both technically challenging and educationally stimulating. Under guidance of the senior engineering staff, the students will be assigned to teams associated with ongoing production and Research & Design programs.

Description of Duties

  • Assist Engineering team with creating mechanical drawings using SolidWorks Mechanical.
  • Assist Engineering team in the design, documentation and prototyping of future products.
  • Analyze new and existing designs using DFMA principles and produce reports making recommendations for improvement.
  • Implement and document changes as required for existing products.
  • Additional tasks as defined by the Engineering team and Director of Technology.

Qualifications and Education Requirements

  • Enrolled full-time and pursuing B.A.S. in Mechanical Engineering with completion of Junior year from an accredited college/university.
  • Familiarity with SolidWorks CAD software or equivalent.
  • Familiarity with Microsoft Office software.

Preferred Skills and Qualifications

  • Be available to work full-time (40 hours per week) for the duration of the internship
  • Proficient written, verbal, and interpersonal communication skills.
  • Detail oriented, with ability to work autonomously.
  • Ability to follow written and verbal instruction.
  • A teachable attitude coupled with the desire to learn quickly and explore designs and processes.

The above cited duties and responsibilities describe the general nature and level of work performed by people assigned to the job. They are not intended to be an exhaustive list of all the duties and responsibilities that an incumbent may be expected or asked to perform.

 
Quick Apply: Mechanical Engineering Intern
https://solarstik.isolvedhire.com/jobs/795843.html

There are currently no jobs available at this time.

Note: Solar Stik, Inc. is committed to ensuring equal employment opportunities to all qualified individuals without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, veteran or disability status.

Veteran Commitment

Solar Stik commits to hiring returning veterans.

The above cited duties and responsibilities describe the general nature and level of work performed by people assigned to the job.  They are not intended to be an exhaustive list of all the duties and responsibilities that an incumbent may be expected or asked to perform.

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  • 13 North Leonardi Street, St Augustine, FL 32084
  • +1 800.793.4364
  • © 2023 Solar Stik®, Inc. All rights reserved.
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Lead-acid Battery Testing

Battery Voltage
Battery voltage, or state of charge (SOC), of a lead-acid battery can be estimated by measuring the open (no load) battery terminal voltage using a digital voltmeter. Prior to measuring, the battery must have rested for 4 to 8 hours after charge or discharge and resided at a steady room temperature. With these conditions met, voltage measurements provide an amazingly accurate SOC for lead-acid batteries.

Specific Gravity
Specific gravity can be measured in wet-cell batteries with removable caps that provide access to the electrolyte. To measure specific gravity, you must use a tool called a temperature-compensating hydrometer, which can normally be purchased at an auto parts store or tool supply.

 

Load Testing
Load testing removes and measures the amps from a battery, similar to what happens when you start the engine of a car. Some battery companies label their battery with the amp load for testing. This number is usually about half of the CCA rating. A battery rated at 500 CCA would therefore be load-tested at 250 amps for 15 seconds.

A load test can only be performed if the battery is at or near a full charge. Some electronic load testers apply a 100-amp load for 10 seconds, and then display battery voltage. This number is then compared to a chart on the tester, which compares common load testing results to CCA ratings to determine battery condition.

LiFePO4

Solar Stik uses only lithium iron phosphate (LiFePO4) battery chemistry in its lithium-ion energy storage products because it has safety characteristics similar to lead-acid batteries. LiFePO4 uses a nonflammable electrolyte, so when it’s completely discharged it becomes inert, making it safe for users.

So why do we hear so much about dangerous lithium battery fires?

In some lithium-ion polymer batteries, improper charging and storing can cause the formation of crystalline “needles” that can puncture the internal separator, resulting in failure or fire. This is not the case with LiFePO4 batteries because the reactants that store the charge are not flammable. All other lithium battery chemistries are volatile, reactive, and flammable, and if they do overheat and catch fire, conventional halon fire extinguishers will not put out the fire.

Common LiFePO4 cell types include cylindrical and prismatic (LiFePO4 chemistry is not packaged in pouch cells, another lithium cell type). It is easy to see how these were named, as they are actual descriptions of their physical attributes; they look like what they sound like.

Cylindrical

LiFePO4 cylindrical cells are all made of the same basic components. Each cell, and the entire battery, is enclosed by a resilient plastic container. Inside the container there is a “rolled” foil, and between the foil there is a layer of permeable “separator” material. A safe, nonflammable electrolyte (unique to LiFePO4) is added to each cell and saturates the “foil” and “separator”. The battery terminals are typically threaded (rather than posts) so that heavier-duty connections can be made to the load.

LiFePO4 is slightly less powerful than other commercially available lithium chemistries, but for many applications, the safety of its chemistry makes it the best choice despite its lower energy density. A LiFePO4 battery can be installed safely in any orientation. Safety vent valves are usually not required because the battery management system (BMS) will not allow the battery to overheat and vent gasses.

History of Lithium-ion Batteries

Experimental lithium batteries were developed as early as 1912, but it took nearly 70 years before a commercial lithium battery was developed for a wide market. Today, lithium batteries are most associated with enhancing “portable” capabilities. For example, they are the standard battery technology for high performance in portable electronics ranging from cell phones to laptop computers. There is a diverse family of lithium chemistries available. At first glance, they might all seem to be the same, but there are exploitable, distinct differences between them. The unique nature of the various chemistries allows each type to fill special application niches.

Even with wide market adoption in the early 1990s, as societal demands for lightweight portable electronics was burgeoning, the high cost barrier and complexities in battery management circuits would prevent lithium batteries from being used widely in support of larger devices or in scaled energy-storage systems such as large vehicles or uninterruptible power supply (UPS) systems.

Today, lithium battery technology continues to evolve at a rapid pace. Manufacturers, driven by demands from new applications, are constantly pushing the envelope by making changes in the chemistry and structure in search of improved battery life and greater energy density.

Lead-acid Batteries

Lead-acid batteries are the most commonly used batteries and come in several different configurations. The oldest of the lead-acid battery types are flooded-cell (or wet-cell) batteries and can be either the sealed or the open variety. In both types, the electrolyte evaporates due to charging, age, or ambient heat.

In the mid 1970s, a “maintenance-free” valve-regulated lead-acid (VRLA) battery was developed.

  • Can be used in any orientation

  • Liquid electrolyte is gelled into moistened lead plate-separators

  • Gelled electrolyte allows the case to be sealed

  • Safety valves allow venting during charge, discharge, and atmospheric pressure changes


VRLA batteries can be absorbed glass mat (AGM) or gel cells. Solar Stik uses AGM batteries in its lead-acid products.

Flooded Lead-acid Battery Configurations

Sealed Flooded Cells

  • Frequently found as starter batteries in cars
  • Electrolyte cannot be replenished
  • Battery has to be replaced when enough of the electrolyte has evaporated

Open Flooded Cells

  • Usually have removable caps that allow you to replace any evaporated electrolyte
  • Battery life is extended due to replaceable electrolyte

VRLA batteries remain under constant pressure of 1–4 psi. This pressure helps the recombination process during charging when more than 99% of the hydrogen and oxygen generated are turned back into water.

Unlike the flooded lead-acid battery, VRLA batteries are designed with a low overvoltage potential, which prohibits the battery from reaching its gas-generating potential during charge. This safeguard prevents excess charging, which would cause gassing and electrolyte depletion.

History of Lead-acid Batteries

Lead-acid is the oldest rechargeable battery technology in existence. Invented by the French physicist Gaston Planté in 1859, lead-acid was the first rechargeable battery to be used in commercial applications. More than one hundred fifty years later, we still have no real cost-effective alternatives for cars, boats, RVs, wheelchairs, scooters, golf carts, and UPS systems.

The lead-acid battery is still the most widely used 12 V energy storage device. A lead-acid battery is an electrical storage device that uses a chemical reaction to store and release energy. It uses a combination of lead plates and an electrolyte to convert electrical energy into potential chemical energy and back again.

There are many newer battery technologies available in the marketplace. However, lead-acid technologies are better understood and are widely accepted as the standard by which all other batteries are measured. Newer technologies often have operational constraints, including maximum and minimum operating temperatures and special charging requirements that make them less versatile and useful for the average consumer in everyday applications.

Flexible Solar PV Panels

Flexible solar PV panels fuse form factor with capability and deliver maximum power generation with minimum weight. Flexible panels use amorphous silicon or copper indium gallium selenide (CIGS) thin-film technology, which can be used with many substrate options that allow flexible panels to be folded or rolled.

Solar Stik uses extremely rugged, paper-thin, flexible PV panels that can withstand harsh conditions.

Construction

As the name implies, thin-film solar PV cells lack the thickness of other PV technologies. Composed of a very thin layer of substance on a substrate, today’s thin-film cells are one percent as thick as the first manufactured silicon solar cells.

Portability

Foldable or rollable thin-film panels make storage and transport convenient. For low-power applications that require portability, thin-film solar PV panels are an excellent option.

Panel Types and Performances

Numerous thin-film solar PV technologies exist today. However, they are slightly less efficient than other types of PV cells, so more surface area is required to generate the same amount of power. Most thin-film panels are designed for single-device applications, like recharging a battery-operated device.

The two most common types of thin-film solar PV panels are amorphous silicon and copper indium gallium selenide (CIGS).

Amorphous Silicon Solar PV Panel

Amorphous silicon is the oldest thin-film technology and arguably the best. When laid on a substrate, amorphous silicon does not require a grid configuration to conduct electricity, allowing it to be used on large areas with ease. However, it does not conduct as well as crystalline silicon solar PV cells used in rigid panel technology because the connections between the silicon atoms are not as consistent. This inconsistency results in interrupted electron flow.

Numerous substrate materials can be used with amorphous silicon, making the technology highly adaptable. Polymer plastic is one option for substrate. Because polymer plastic is flexible and able to be folded or rolled, it excels in applications requiring ease of storage or transport.

Amorphous silicon solar PV panels perform better in low light intensities. This makes amorphous silicon a good choice for environments with interrupted sunlight or dusty conditions.

Rigid Solar PV Panels

Rigid solar PV panels are ideal for stationary applications that require maximum power and a small installation footprint. They are the first generation of solar PV panels, provide more power per square foot than other PV panel types, and are highly durable. Rigid panels do not degrade significantly over time, making them a good choice for long-term investment.

Solar Stik uses both multi- and monocrystalline, glass and non-glass—impact-resistant and shatterproof—rigid panels.

Rigid Solar PV Panels

Rigid solar PV panels are typically made of glass or non-glass panels and aluminum frames. Rigid panels are among the best performing panels, but their physical characteristics make them a poor choice for certain applications—especially when portable power is desired.

Portability

Travel and storage can be difficult because rigid panels often contain breakable glass and cannot be folded.

The Solar Stik system design overcomes many of the physical challenges associated with the rigid panels. This results in portable power systems that draw from the best available PV technology.

Panel Types and Performances

The two main types of rigid solar PV panels are monocrystalline and multi- or polycrystalline.

Monocrystalline Solar PV Panel

A rigid monocrystalline solar PV panel is distinctly recognizable by the arrangement of the individual solar PV cells (squares with no corners) that appears as a uniform, flat color.

Polycrystalline Solar PV Panel

The surface of a rigid multi- or polycrystalline solar PV panel has the appearance of a rectangular grid and more of a bluish speckled color.

Performance differences between rigid solar PV panels can be experienced in high operating temperatures and shaded conditions. Monocrystalline panels perform better in higher external temperatures and full sun. Multi- or polycrystalline panels suffer performance losses in higher heats but have slightly higher outputs compared to monocrystalline panels when the panel is partially shaded.

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Battery Management System (BMS)

The role of the battery management system (BMS) is simple: It controls the actual voltage of each cell, so that it doesn’t get too high or too low.

BMS means different things to different people. To most it is simply battery monitoring, keeping track of the key operational parameters—such as voltages, currents, and the battery internal and ambient temperature—during charging and discharging. The monitoring circuits normally provide inputs to protection devices which would generate alarms or disconnect the battery from the load or charger if any of the parameters stray out of limits.
There are three main objectives common to all BMS:
1Protect the cells or the battery from damage

2Prolong the life of the battery

3Maintain the battery in a state in which it can fulfill the functional requirements of the application

To achieve these objectives, the BMS may incorporate one or more of the following functions:

Cell Protection Protecting the battery from out of tolerance operating conditions is fundamental to all BMS applications. In practice the BMS must provide full cell protection to cover almost any eventuality. Operating a battery outside of its specified design limits will inevitably lead to failure of the battery. Apart from the inconvenience, the cost of replacing the battery can be prohibitive. This is particularly true for high voltage and high power automotive batteries which must operate in hostile environments and which at the same time are subject to abuse by the user.

Bricking a LiFePO4 Battery

As soon as the BMS senses that the cell voltage is too low to discharge, time is of the essence to place the batteries on charge. Failure to do this may cause a fatal error known as “bricking”. Once the batteries reach their internal disconnect voltage, the voltage can fall very rapidly in the internal cells, causing the battery to brick. This means that the battery cells are nonrecoverable, and the battery module must be replaced.

Specific Gravity

Specific gravity of the electrolyte can be defined as:

A measure of the density of the liquid electrolyte compared to the density of water at a specific temperature and pressure.

The chemical reaction takes place inside the pores of the active material on the battery’s lead plates. If the battery has just been charged, the electrolyte in the pores of these lead plates is very rich in sulfuric acid. As a result, the battery’s voltage will be high, perhaps as much as 13 to 14 volts. As the battery rests following a charge, its voltage slowly drops and then levels off as the electrolyte stabilizes its chemical state between the plates.

“Zero Gravity” by Scott Robinson is licensed under CC BY 2.0

A similar change in battery voltage occurs during discharge. During the battery discharge process, the electrolyte transfers its sulfur content to the lead plates. As the electrolyte loses sulfur, its specific gravity gets “lighter” or closer to that of water, indicating that the battery has been discharged. Because the specific gravity of the electrolyte is measurable, it can be used to determine the state of a battery’s charge and health. While a fully charged battery may read 12.68 volts, the voltage will drop and then stabilize at a somewhat lower value as a load is applied.

The change in voltage occurs even though the state of charge of the battery has not significantly changed. This is due to the local electrolyte in the pores of the plates becoming less rich in sulfur as the battery supplies current. As the battery discharges, electrolyte more like sulfuric acid enters the pores while electrolyte more like water exits the pores.

As discharge continues, the electrolyte in the pores eventually stabilizes at a specific gravity somewhat lower than the average value in the battery, producing the slightly lower battery voltage.

Capacity and CCA

The operational characteristics of the lead-acid battery can be explained best by the terms capacity and cold-cranking amps (CCA).

Capacity is the amount of energy a battery can store. It is usually given in amp hours (Ah), or the amount of current measured in amps that the battery can provide over a period of one hour before rendering the battery discharged.

The secret of any battery’s runtime lies in the battery’s plate capacity. During charging and discharging, the lead on the plates gets gradually eaten away and the sediment falls to the bottom. The service life of a lead-acid battery can be measured by the thickness of the positive plates. The thicker the plates, the longer the life will be and the more energy storage you can expect.

  • The plates of automotive starter batteries are about 0.040 in (1 mm) thick.
  • Forklift batteries may have plates that exceed 0.250 in (6 mm).
  • A typical golf cart battery has plates that are 0.07–0.11 in (1.8–2.8 mm) thick.

The weight of a battery is another good indicator of the lead content and the life expectancy. Generally speaking, the heavier the battery, the more lead it contains and the longer it will last.

Most industrial flooded deep-cycle batteries use lead-antimony plates. Antimony is a metal that stiffens the lead plate and helps prevent battery failure due to structural failure of a plate. This improves the plate’s life but increases gassing and water loss. Antimony is not necessary in AGM batteries due to the rigid construction of the overall battery.

1953 automotive lead-acid battery

High CCA
High-CCA
Low CCA
Low-CCA

Cold-cranking amps (CCA) is the amount of energy a battery can deliver in short bursts. It is the maximum amount of current (amps) that a battery can deliver at 0 °F for 30 seconds without dropping below 7.2 volts. A high CCA battery rating is good, especially in cold weather. Starter batteries are often rated in CCA and are designed to deliver a short-duration burst of power, such as that required to start a vehicle.

Age and environmental conditions can affect the capacity and the CCA. As a battery ages, capacity and CCA will not degrade at the same rate. CCA tends to stay high through most of the battery’s life, but it drops quickly towards the end. If you drive a car, you’ve probably experienced this when, near the end of the battery’s life, suddenly the battery won’t start the car in the morning.

High Capacity
High Capacity
Aged
Aged

Capacity decreases gradually. A new battery is designed to deliver 100% of its rated capacity. As the battery ages, the capacity steadily drops and it should be replaced when its ability to store power falls below 70% of its original rating.

The overall health of a battery is most directly related to its capacity, not its CCA. As noted before, the CCA remains within the optimal range for most of a battery’s life, so performance and health declines will be most notable in the loss of capacity.

The illustration shows two fully charged lead-acid batteries, one with a high capacity and one that has aged. The buildup of visible “rock content” (crystalline formation, also called sulfation or memory) due to aging robs the battery of usable capacity, although the battery may still provide good cranking power.

Appliance Efficiency

Appliance efficiency is also known as load efficiency. As appliances consume less power, power source requirements also change. When designing a portable power system, purchasing highly efficient components can provide many benefits.

Appliance loads can often be matched to the electrical characteristics of the circuit. This will increase the system’s overall efficiency by allowing direct connection to the circuit without the need for additional power management devices to aid in the function.

The fewer management components used in a system, the more efficiently it will operate. For example, components such as inverters, converters, or similar devices used in a circuit to “adapt” appliances for use in a particular electrical circuit themselves require power to operate, and thus the total power required to operate the appliance is increased.

For example, a 12-volt direct current (DC) electrical circuit powered by a 12 V battery can directly support a refrigerator that also operates at 12 VDC. This setup will transfer power through the circuit more efficiently than if the refrigerator requires 120 V alternating current (AC) power. In the latter example, an inverter would be required.

It is prudent to shop around when looking for appliances because power consumption varies among models even within a particular appliance class. Purchasing an energy-efficient device can be more expensive up front, but could mean future savings in energy costs as well as a flexibility of use that makes the device compatible with a variety of portable power sources. When purchasing an electrical appliance, remember to ask if a 12 VDC adapter is available for the product.

Inverter Waveforms

PSW Power Inverters

A pure sine (also referred to as a sinusoidal) wave can be produced by rotating machinery (a generator). This is the type of waveform provided by electric utility companies. This type of power is available anywhere an outlet is tied to the power grid, such as in homes or businesses.

A PSW inverter reproduces this waveform through the use of advanced internal circuitry.

Advantages of PSW Inverters

  • Is compatible with household AC power
  • Is the best type of waveform for all AC electrical appliances
  • Eliminates interference, noise, and overheating
  • Reduces audible and electrical noise in fans, fluorescent lights, electronics gear, and magnetic circuit breakers
  • Prevents crashes in computers, unreadable printouts from printers, and glitches and noise in monitoring equipment
  • Can be efficiently electronically protected from overload, over- and undervoltage, and overtemperature conditions.
  • Allows inductive loads like microwave ovens and variable-speed motors to operate properly, quietly, and without overheating
  • Enables appliances that use pure sine wave power to produce full output

Disadvantages of PSW Inverters

  • More expensive than modified sine wave power inverters
  • Physically larger than modified sine wave power inverters

MSW Power Inverters

A modified sine wave (also referred to as non-sinusoidal or step-wave) inverter is different from a pure sine wave power inverter because the modified waveform output is step-shaped.

AC appliances that are not specifically designed to work with this type of inverter waveform output may take more power to operate, thereby reducing the efficiency of the entire electrical system. For example, some appliance motors may produce more heat and burn out when they are operating.

Other appliances that use electronic controls will not be able to vary speed or temperature when using modified sine wave power. Some fluorescent lighting may not get as bright or may make buzzing noises. Appliances with digital clocks or electronic timers may not work properly with this type of inverter because the waves are rougher and cause extra noise to be created in the circuitry.

The following appliances may experience problems when operated from MSW inverters:

  • Electronic equipment
  • Audio systems
  • Wall-mounted light dimmers
  • Corded power tools with variable speed controls
  • Some battery chargers for cordless tools
  • Devices with speed or microprocessor controls
  • Medical equipment
  • Lamp dimmers

Advantages of MSW Inverters

  • Substantially less expensive than pure sine wave inverters
  • Readily available and commonly used in the marketplace for items other than medical equipment and sensitive electronics
  • Smaller in physical size for the same power output as its pure sine wave counterpart

Disadvantages of MSW Inverters

  • Lower quality construction
  • Not compatible with all AC appliances

Categories of Inverters

Low-wattage Inverters

Most vehicle starting batteries will support a low-wattage inverter for short time periods. Actual operating time will vary depending on the age and condition of the battery, the Ah capacity of the battery, and the AC appliance powered by the inverter. If you use a low-wattage inverter that is powered through a DC accessory socket, and the vehicle engine is turned off, you should periodically run the engine to recharge the battery.

Medium- and High-wattage Inverters

It is strongly recommended that only deep-cycle batteries be used for any inverter with a continuous output of 200 W or more. This will ensure that you have several hundred complete charge and discharge cycles. If you use a normal vehicle starting battery to support a medium- or high-wattage inverter, it will quickly fail after repeated charge/discharge cycles (since starting batteries are not designed to perform this type of work).

When the inverter operates power-hungry appliances with continuous loads for extended periods, it will drain the battery to the point where the battery has insufficient energy to support the inverter. In these cases, it’s a good idea to have additional deep-cycle batteries available to extend the appliance operating time.

Lead-acid Batteries

Lead-acid batteries are the most commonly used batteries and come in several different configurations. The oldest of the lead-acid battery types are flooded-cell (or wet-cell) batteries and can be either the sealed or the open variety. In both types, the electrolyte evaporates due to charging, age, or ambient heat.

In the mid 1970s, a “maintenance-free” valve-regulated lead-acid (VRLA) battery was developed.

  • Can be used in any orientation
  • Liquid electrolyte is gelled into moistened lead plate-separators
  • Gelled electrolyte allows the case to be sealed
  • Safety valves allow venting during charge, discharge, and atmospheric pressure changes


VRLA batteries can be absorbed glass mat (AGM) or gel cells. Solar Stik uses AGM batteries in its lead-acid products.

VRLA batteries remain under constant pressure of 1–4 psi. This pressure helps the recombination process during charging when more than 99% of the hydrogen and oxygen generated are turned back into water.

Unlike the flooded lead-acid battery, VRLA batteries are designed with a low overvoltage potential, which prohibits the battery from reaching its gas-generating potential during charge. This safeguard prevents excess charging, which would cause gassing and electrolyte depletion.

History of Lead-acid Batteries

Lead-acid is the oldest rechargeable battery technology in existence. Invented by the French physicist Gaston Planté in 1859, lead-acid was the first rechargeable battery to be used in commercial applications. More than one hundred fifty years later, we still have no real cost-effective alternatives for cars, boats, RVs, wheelchairs, scooters, golf carts, and UPS systems.

The lead-acid battery is still the most widely used 12 V energy storage device. A lead-acid battery is an electrical storage device that uses a chemical reaction to store and release energy. It uses a combination of lead plates and an electrolyte to convert electrical energy into potential chemical energy and back again.

There are many newer battery technologies available in the marketplace. However, lead-acid technologies are better understood and are widely accepted as the standard by which all other batteries are measured. Newer technologies often have operational constraints, including maximum and minimum operating temperatures and special charging requirements that make them less versatile and useful for the average consumer in everyday applications.

Heart of the System

Lead-acid Batteries

Lead-acid batteries are commonly made of five basic components:

  • A resilient plastic container
  • Positive and negative internal plates made of lead
  • Plate separators made of porous synthetic material
  • Electrolyte, or a diluted solution of sulfuric acid and water, known as battery acid
  • Battery terminals—the connection point between the battery and the load that requires the battery’s power

A battery cell is a container in which electrolyte and lead plates can interact. The electrolyte is usually a solution made up of 35% sulfuric acid and 65% water. The lead plates are treated with lead oxide and powdered sulfates to give them their positive and negative properties.

When the positive and negative lead plates are submerged in the battery’s electrolyte, a chemical reaction occurs. This reaction causes electrons to flow between the lead plates. The negative lead plate builds up an excess of electrons in a process called oxidation. This causes an electrical difference between the negative plate and positive plate.

The extra electrons on the negative lead plate want to displace the electrons on the positive plate in a process called reduction. However, the electrolyte solution of sulfuric acid and water ensures the electrons cannot travel directly to the positive plate. When the circuit is closed (with the help of a “conductive path”, or load, between the negative and positive plates), the electrons are able to travel to the positive plate. This, in turn, provides power to any appliance placed along the path.

This electrochemical process can be summarized as a reversible transfer of sulfate between the water and the lead plates during charging and discharging. As the battery is discharged, sulfate in the solution combines chemically with the lead plates of the battery to form lead sulfate. As the plates accumulate this sulfate, the electrolyte solution becomes more like water and less like sulfuric acid. The reverse occurs as the battery is charged. As charging current flows into the battery, the battery plates revert back to their original condition and the electrolyte reverts back to its original sulfuric acid content.

Lithium-ion Batteries

Lithium-ion batteries are made of the following basic components:

  • A cell in which the active materials can interact
  • A negative electrode typically made of carbon
  • A positive electrode of metal oxide
  • A separator material
  • An electrolyte of lithium salt in an organic solvent (web)

The exact chemistry is often patented and proprietary to each battery maker.

When a charge is applied to a lithium-ion battery, electrons flow between the internal components. The basis of this reaction is the lithium metal binding and unbinding with the other chemicals in the electrodes at the ionic level. As power is drawn out of the battery, the metal moves from one electrode to the other, and when the battery is charged, it moves back to the original state. The metallic lithium ions literally move through the separator material.