Emerging Power: Robust, Reliable, and Innovative Battery Packs for Defense Applications

Thomas Corbett, President, Emerging PowerThomas Corbett, President
It’s a sunny afternoon at the Dugway proving ground in Utah. A small group of military personnel with ballistics equipment have set up their tent, watching diligently as a specialist walks into the clearing with a small backpack. He takes out a small tube and plants it firmly on the ground. Then, tilting it forward at an angle, he braces the base of the tube with his foot and shouts, “Fire!”

A small missile-shaped object shoots up from the tube and snaps open a pair of wings like a switchblade, rising high, before correcting its course and locating its target—a small white van. The drone then shoots straight through the windshield, destroying the van with little to no damage to the surroundings. The smart weapon, aptly dubbed ‘The Switchblade,’ is a state-of-the-art, high-precision munition that blurs the line between a drone and a missile (avinc.com). Unlike the $150,000 hellfire missile, the Switchblade is a highly sophisticated piece of weapon tech that requires state-of-the-art circuitry and a zero-failure power source at its heart. The drone battery pack was designed by AeroVironment and Emerging Power thru concurrent engineering to meet the drone’s power needs, incorporating the precise energy density requirements specified by the manufacturer.

In another instance, Emerging Power worked with THALES (Thalesdsi.com) to develop a Lithium Ion battery pack and charger. The battery pack for the radio was designed by Thales and thru concurrent engineering with Emerging Power the design was finalized and then manufactured by Emerging Power to meet THALES’ most demanding specifications—submersible in 2 meters of water for 30 minutes, rigorously field-tested, and compliant with Emerging Power’s high zero-defect standards. In fact, Emerging Power has the skills and expertise to design battery packs for any type of device a manufacturer chooses to engineer. The company is proud to have had numerous Fortune 500 companies that they have serviced and built for in the last 10 years.

If it can be built safely, Emerging Power can build it.

Our team consists of engineers and battery technology experts, with hundreds of years of combined experience in developing custom battery solutions


Experience to Power Mission-Critical Applications

Emerging Power is an expert in engineering high-end battery packs for several such mission-critical devices. The solutions are battery and cell agnostic. The company picks the best cells for the job, based on safety and availability (due to the EV market). Especially when it comes to the military, engineering robust solutions require superior capabilities and pre-established agreements between the manufacturer and the United States Military. To that end, Emerging Power is one of the few International Traffic in Arms Regulations (ITAR) registered battery pack manufacturers in the U.S. The company sources its components—the circuit board, the plastics, etc.—only from ITAR approved suppliers/countries.

This accreditation extends to Emerging Power’s full suite of battery solutions that they design, manufacture, and sell. The company’s team consists of engineers and battery technology experts, with hundreds of years of combined experience in developing custom Lithium-Ion, Li-Polymer, Lithium Iron Phosphate (LFP), Lithium Primary, Nickel Metal Hydride, Alkaline, Lead Acid, and Lithium-Thionyl Chloride battery solutions that meet the requirements of a wide variety of markets. Emerging Power is also Energizer’s primary OEM partner, helping them create lithium/alkaline battery packs for Energizer’s customers. These include using the L91, AA Primary Lithium Cell which has a 20 year shelf life. This cell and these battery packs are used in harsh outdoor climates for meters and GPS devices which demand extreme hot and cold temperature performance. (Electronics Manufacturers) can then solder these packs onto their device’s boards or put in battery packs.
Power-Packed Science in Every Battery

The experts at Emerging Power carefully vet and execute each step of the development process to ensure that every one of their battery packs delivers 100 percent operational efficiency. For example, the PCM that goes into the pack monitors the cells for safety, power and temperature. It shuts down the battery in the event of a catastrophe or potential overheating. It is a smart board that works like a notebook computer, with a fuel gauge telling the user when the battery is low.

The manufacturing process behind the battery packs follows a precise and regulated methodology. Emerging Powerfirst conducts a preliminary review of the battery and device specification and the client’s wish list of their wants in terms form, fit, size, function, and capacity—everything they need to power a device they intend to build. The company will then go back and forth with the client to examine all available cells in the market that meet their specs. Emerging Power has partnered with several brand name cell manufacturers in the market, including Panasonic, Samsung, Moli, Energizer, ROV and AriCell, enabling the company to develop custom, best-fit battery solutions. Once the specifications are defined, Emerging Power will generate a 3D plastic battery model and submit it for client review. The company will then conduct an accelerated testing routine to examine battery performance and render a performance evaluation across extreme temperature and pressure ranges. Once the final version is confirmed and agreed to by all, Emerging Power will proceed to build prototype samples. These will help the client to check the duty cycle, battery life and a portion of these samples will go toward testing, UL, UN/DOT and any other agency approvals that the customer deems necessary.

Emerging Power is AS9001 certified—a tougher standard to meet than the ISO standard. Certifications like this allow the company to maintain a rejection/failure rate of less than 1/100th of a percent, which is exceptional in the industry. Moreover, with a warehouse and office in Hong Kong and Taiwan, and a competent team stationed in Asia, Emerging Power will audit any and all suppliers before purchasing from them.

EP has also partnered with a battery pack assembler in Mexico, to avoid the numerous Chinese tariffs and long shipping time, and brings battery pack operations closer to home.

Dynamic Innovations to Meet Ever-Evolving Market and Manufacturing Needs

Emerging Power always strives to push the envelope in battery tech innovation. After all, their clients are always looking for batteries that can store more power and have a longer life. Complex applications, such as drones and UAV/Drones, need battery packs that meet the highest safety and quality standards. Emerging Power’s engineering team delivers its expertise to support even the most demanding electrical and mechanical design requirements. “Emerging Power only uses high-quality cells from top suppliers offering both standard and high discharge rates and a wide range of temperature limits to meet the most demanding performance requirements,” states Thomas Corbett, President of Emerging Power. The company is audited and approved by cell manufacturers such as Panasonic, Samsung and MoliCell, to build batteries and is currently working with a dozen new customers.
  • We produce high-quality cells from top suppliers offering both standard and high discharge rates and a wide range of temperature limits to meet the most demanding performance requirements


Having carved a unique niche in battery tech manufacturing business, Emerging power is looking to expand in the outdoor electric metering space. Today, companies require meter readers to physically walk up to each electric meter to take the readings manually. Emerging Power has developed battery pack solutions that will allow the readers to remotely capture and record the meter reading. While working on innovative solutions like this, the company will continue to create battery tech solutions to power radio, UAV, and drone markets for the military, US law enforcement and security agencies. As a select breed of homegrown battery manufacturers for the defense sector, Emerging Power aims to establish itself as a company that consistently upholds the high standards of American quality in battery tech for the years to come, with a critical focus on meeting client needs.
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Company
Emerging Power

Headquarters
Hackensack, NJ

Management
Thomas Corbett, President

Description
Emerging Power is one of the few International Traffic in Arms Regulations (ITAR) registered battery pack manufacturers in the US

Emerging Power

"Our team consists of engineers and battery technology experts, with hundreds of years of combined experience in developing custom battery solutions"

- Thomas Corbett, President