Step by step guidance: how to customize Li-Polymer Battery

June 12 16:42 2024

Customized lithium polymer battery is used more and more widely in various electronic devices as its’ high energy density and flexible shape.

Sometimes, customizing process seems to be complex and costy, which make clients suffering from it.

So how to customize lipo battery effectively and correctly? Below is some experience.

Understand application of product at first

At first, clients should fully understand application of their product, for example:

1.Safety camera is used outdoor, facing lower than minus 20 centigrade low temperature and high humidity especially in north America, clients should consider water proof and how much energy they expect to get from the battery in low temperature.

2.Vehicle camera is used in car where the temperature is easy to reach over 60 centigrade in summer, how to ensure safety of battery is important.

3.Peak working current, frequency and duration time are important technical parameters to determine the rate of battery.

It may be difficult for clients to capture all data clearly especially at the beginning stage of project, but please try best to do.

Provide sufficient and correct information to battery supplier

Nowadays, there are many different lipo battery solutions, such as high temperature battery, low temperature battery, fast charging battery, high rate battery, high voltage battery, high density battery, ultra-thin battery…also, different cathode materiel result in different cycle life. 

A professional battery supplier with high responsibility always ask clients questions at first to try to understand accurate application of product and client’s cost pressure, then evaluate a best battery solution.

On the contrary, if a supplier only gives an existent battery part number and quote fast without knowing enough information may result in totally wrong battery solution, which is a potential disaster for product.

Considering above, please provide sufficient and correct information to battery supplier.

Ensure enough space for battery

Lipo battery’s thickness will expand after hundreds times’ cycles, there is an expansion rate; please pay attention to it and ensure enough space for battery when design product.

Sometimes, the space of battery compartment is limit but clients pursue higher battery capacity, this situation always happen on some small wearable and IOT devices.

A qualified battery supplier can seek a good balance and give the best suggestion, normally, they will calculate max dimension and max capacity of battery based on client’s 2D or 3D design file of battery compartment, also ensure the battery design is safe.

Pay attention to battery certificates

Different markets request different battery certificates, for example:

1. CB report (IEC62133-2:2017), there are 54 countries participate in the CB Scheme.

2. UL certificate for American market, but not mandatory.

3. BIS certificate for Indian market, mandatory.

4. KC certificate for Korean market, mandatory.

Some tips:

1. To obtain UL2054 certificate of the battery pack then battery supplier needs to add double-protection for when design PCM board.

2. Price of different test institutions may vary, for example, the cost of obtaining UL certificate is much more expensive than TUV’s, because UL certificate process is more comprehensive and involves more testing and monitoring. However, the additional cost can be offset by the increased market competitiveness and improved brand image that comes with UL certification.

Normally, each battery manufacturer has their common battery part numbers with some certificates such as UN38.3, MSDS, CB (IEC62133-2:2017), KC, BIS, UL1642, UL2054 already, if an existent battery model can perfectly match to product then can save test fee and time for clients, otherwise, need to do certificates for the customized battery model.

Choose original connectors or not? 

Normally, battery supplier will use local replaced brand of connectors because substitution of such as Molex and JST connectors is very mature technology in China.

Clients should tell frankly to battery manufacturer if request original connector for their high-end products.

Further, try to choose common connectors, otherwise, may face long-lead time or shortage problems for unconventional connectors, another bad situation is having re-do some critical certificates if changing connectors after project goes into mass production stage.

Reserve enough time for battery test

Several months is needed if doing cycle life test for battery; further, clients may revise mechanical design, battery supplier may improve battery solution after the first prototyping, so please reserve enough time to carefully test and choose the battery, never take it as a simple thing.

Choose a correct battery supplier

There are thousands of battery factories in China, mainly in Yangtze River Delta and pearl river delta, some are pack factories who don’t produce battery cells by themselves, some focus on low-end consumer markets, some with very good quality but high MOQ… Choose a correct supplier, it’s better they have rich experience in handing similar projects before, their MOQ is suitable, and their quality and after-sale service can be guaranteed.

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Motoma Power is is an original lithium battery manufacturer since 1994, from raw material to battery cell and battery pack, support worldwide clients to handle hundreds of lipo battery projects effectively and correctly in the past years.

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Company Name: Shenzhen Motoma Power Co.,Ltd.
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Country: China