Compact battery development

Small Lithium Polymer Batteries

We customize small rechargeable LiPo pouch batteries for wearables, trackers, smart tags, Bluetooth products and other electronics with limited internal space.

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Nominal voltage: 3.7V single-cell
Typical capacity: 20mAh to 5,000mAh
Format: Thin aluminum-laminate pouch

Product details & applications

Small Lithium Polymer Batteries: Details and Application Examples

Connection detailsProtection, wire and connector options

PCB layout, polarity, wire gauge, cable length, exit direction and connector are defined around the device interface.

Application engineeringDesigned into compact electronic products

Battery size, load behavior, charging method and enclosure allowances are evaluated together during prototype development.

Product overview

Small Lithium Polymer Batteries for OEM Product Development

Small lithium polymer batteries are useful when a compact device needs a thin or custom-shaped power source. We balance capacity, thickness, discharge demand, protection, wire position and connector choice within the available enclosure.

Small lithium polymer batteries integrated into wearable, tracker and smart sensor prototypes — Battery size, load behavior, charging method and enclosure allowances are evaluated together during prototype development.

Key Features

Thin and compact pouch construction
Dimensions selected around the device enclosure
Energy and discharge behavior matched to the load
Optional protection PCB and NTC thermistor
Custom wire gauge, length, direction and connector
Tabs, leads and exit position coordinated with assembly
Prototype samples for runtime and fit validation
OEM labeling, packaging and volume production support

Common customization ranges

Common Small Lithium Polymer Batteries Design Choices

These ranges help start the discussion; they are not fixed stock models. We review dimensions, capacity, load and interfaces together before confirming a design.

Voltage architecture: 3.7V / 1S7.4V / 2S assembly11.1V / 3S assemblyCustom pack architecture
Capacity discussion range: 20–100mAh101–500mAh501–1,500mAh1,501–5,000mAhOther by feasibility
Interface options: Bare tabsFlying leadsJST-styleMolex-styleProject-specified connector

Customization Capabilities

Customization Options for Small Lithium Polymer Batteries

Voltage, capacity, dimensions, protection and interfaces affect one another. We review them as one system, then confirm the final design through drawings, specifications and samples.

Capacity

Defined against the device load, runtime target and operating limits.

Length

Mechanical details reviewed against available space, assembly method and product handling.

Width

Mechanical details reviewed against available space, assembly method and product handling.

Thickness

Mechanical details reviewed against available space, assembly method and product handling.

Discharge Rate

Defined against the device load, runtime target and operating limits.

Charge Profile

Defined against the device load, runtime target and operating limits.

Protection PCB

Protection, sensing and control functions coordinated with the approved system architecture.

NTC Thermistor

Protection, sensing and control functions coordinated with the approved system architecture.

Wire Gauge

Interface type, position and electrical rating matched to the host product.

Wire Length

Interface type, position and electrical rating matched to the host product.

Wire Exit Direction

Interface type, position and electrical rating matched to the host product.

Connector

Interface type, position and electrical rating matched to the host product.

Label

Material, finish and presentation options confirmed for the product and supply program.

Packaging

Material, finish and presentation options confirmed for the product and supply program.

Cells & Construction Materials

Small Lithium Polymer Batteries Cells and Construction

Cell chemistry is only one part of the solution. Interconnects, insulation, sensing and enclosure materials must work together as an approved assembly.

Cell construction	Rechargeable lithium-ion polymer pouch cell with aluminum-laminate film enclosure.
Cathode system	Common high-energy Li-ion cathode systems are selected according to size, performance, life and supply requirements.
Electrodes and tabs	Copper and aluminum current collectors with welded nickel or aluminum tab transitions, depending on the approved cell.
Insulation	Kapton, fish paper, foam, PET barriers and edge protection applied according to the pack and device design.
Outer protection	Cell label, protective tape, heat-shrink or a lightweight holder / enclosure where required.
Interface materials	UL-style lead wire and project-specified connector materials subject to the approved bill of materials.

Technical Specifications

Technical Specifications: Small Lithium Polymer Batteries

These values provide a clear starting point for product selection and engineering review. Final electrical, mechanical, environmental and compliance values are confirmed for the approved design.

Product type: Rechargeable lithium polymer pouch battery
Nominal voltage / voltage range: Typically 3.7V per cell
Capacity / energy / power: Approximately 20mAh to 5,000mAh for compact projects
Dimensions: Custom to the approved cell platform, capacity target, protection, tolerances and available enclosure space.
Construction / format: Selected for the electrical, mechanical, handling and environmental requirements.
Electrical output: Defined from continuous load, peak demand, voltage window and interface losses.
Protection / control: Protection, sensing and charging controls are matched to the approved system architecture.
Cable & connector: Custom wire gauge, length, exit direction, connector, polarity and pinout where applicable.
Operating environment: Application-specific temperature, exposure, vibration and handling limits are confirmed for the approved design.
Customization: Capacity, Length, Width, Thickness, Discharge rate, Charge profile, Protection PCB, NTC thermistor, Wire gauge, Wire length, plus additional project-specific options
Production & compliance: Prototype, validation, labeling, packaging and target-market compliance scope are confirmed for the exact configuration.

Need another value? Send the device voltage, load profile, runtime target, maximum dimensions, charging method and operating environment for an engineering review.

Applications