Nominal voltage
Compact battery development
Small Lithium Polymer Batteries
Compact rechargeable LiPo pouch batteries customized for small electronics, wearables, trackers, tags, Bluetooth devices and space-constrained IoT hardware.
Typical capacity
20mAh to 5,000mAh
Format
Thin aluminum-laminate pouch
Product details & applications
See how the solution is configured and applied.
PCB layout, polarity, wire gauge, cable length, exit direction and connector are defined around the device interface.
Battery size, load behavior, charging method and enclosure allowances are evaluated together during prototype development.
Product overview
Engineered around the application.
Compact rechargeable LiPo pouch batteries customized for small electronics, wearables, trackers, tags, Bluetooth devices and space-constrained IoT hardware.
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 configurable ranges
Useful starting points for an RFQ.
These are selection ranges rather than fixed stock SKUs. Dimensions, capacity, load and interfaces must be evaluated together.
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
Electrical, mechanical and interface options.
01
Capacity
02
Length
03
Width
04
Thickness
05
Discharge rate
06
Charge profile
07
Protection PCB
08
NTC thermistor
09
Wire gauge
10
Wire length
11
Wire exit direction
12
Connector
13
Label
14
Packaging
Cells & construction materials
Selected for electrical, thermal and mechanical requirements.
Cell chemistry is only one part of the pack. Interconnects, insulation, spacing, 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. |
Typical specifications
Detailed engineering discussion range.
Values below describe common feasibility discussions—not a guaranteed stock model. Final limits are confirmed in the approved specification, prototypes and project validation.
Electrical characteristics
| Battery type | Rechargeable lithium-ion polymer pouch cell or protected pouch battery assembly |
|---|---|
| Nominal cell voltage | Typically 3.7V for conventional high-energy LiPo chemistry; the approved cell datasheet controls the final value |
| Pack voltage options | 3.7V / 1S is the main compact format; 7.4V / 2S, 11.1V / 3S and other series-parallel assemblies are evaluated as custom packs |
| Maximum charge voltage | Commonly 4.20V per series cell for conventional LiPo; high-voltage chemistry uses a different approved limit |
| Recommended charging method | Constant-current / constant-voltage charging with current, voltage termination and safety timing matched to the approved cell |
| Typical capacity discussion range | Approximately 20mAh to 5,000mAh for compact projects; achievable capacity depends on usable cell volume, load and construction |
| Nominal energy | Calculated from nominal voltage × rated capacity; final Wh value is stated on the approved specification and label |
| Standard charge current | Often discussed around 0.2C to 0.5C for standard-energy cells; the approved cell may specify a different rate |
| Maximum charge current | Cell-specific and confirmed after thermal, life and charging-system review; it must not be inferred from capacity alone |
| Continuous discharge current | Selected from the device steady-state load, connector rating, conductor size, protection circuit and thermal conditions |
| Pulse discharge current | Reviewed against pulse duration, duty cycle, voltage sag, cell impedance, PCB limits and recovery time |
| Discharge cut-off | Defined by the approved cell and device power architecture; a commonly discussed cell-level range is about 2.75V to 3.0V |
| Internal impedance | Cell-size, state-of-charge, temperature and measurement-method dependent; a project value is confirmed from the selected cell |
| Cycle-life target | Commonly evaluated after several hundred cycles to an agreed retained-capacity criterion; charge rate, depth of discharge, load and temperature materially affect life |
Mechanical and interface characteristics
| Cell construction | Soft aluminum-laminate pouch with sealed edges, positive and negative tabs, electrolyte system and internal separator |
|---|---|
| Typical thickness direction | Approximately 2mm to 10mm and above, subject to capacity, footprint, electrode design and manufacturing feasibility |
| Custom dimensions | Length, width and thickness are selected within cell-design, sealing-edge, tab-position, tolerance and minimum-order constraints |
| Dimensional tolerance | Defined for each approved drawing; the product enclosure must also allow for normal production variation and life-related expansion |
| Tab and lead exit | Same-side or project-specific tab orientation, lead direction and bend routing subject to cell construction and assembly access |
| Lead wire | Custom conductor gauge, insulation type, color, length and strip or termination detail, sized for load and assembly requirements |
| Connector | JST-, Molex- or Hirose-style connectors and other customer-specified interfaces, with polarity and pinout documented before production |
| Protection PCB / PCM | Optional compact circuit for overcharge, over-discharge, over-current and short-circuit protection; thresholds and current rating are project-specific |
| Temperature sensing | Optional NTC thermistor or other approved sensor, with resistance curve, lead arrangement and placement matched to the host device |
| Packaging and retention | Protective tape, label, foam, holder, heat-shrink or lightweight enclosure options selected to avoid sharp edges and damaging compression |
| Label content | Neutral or OEM label with approved model, ratings, polarity, traceability and required warnings; certification marks only when supported by valid evidence |
Environment, validation and supply
| Typical charge temperature discussion | Often around 0°C to 45°C for conventional cells; final limits follow the approved cell and charger specification |
|---|---|
| Typical discharge temperature discussion | Often around -20°C to 60°C; available capacity, voltage and pulse performance change with temperature |
| Storage conditions | Temperature, state of charge, duration and periodic inspection requirements are defined for the selected cell and shipping plan |
| Mechanical integration | The enclosure should prevent puncture, crushing, sharp-edge contact and excessive clamping while providing cable bend radius and expansion allowance |
| Incoming and production checks | Appearance, dimensions, polarity, open-circuit voltage, impedance or conductance method, protection function and traceability checks are defined in the control plan |
| Prototype validation | Fit, runtime, voltage sag, charging, surface temperature, protection behavior and representative device duty cycles are evaluated against the agreed plan |
| Transport planning | UN 38.3 test evidence and air/sea shipping documentation are reviewed for the exact cell or battery configuration before shipment |
| Compliance planning | IEC 62133, UL, CE, RoHS, REACH and market-specific requirements are evaluated for the final configuration; no certification is claimed by default |
| Development support | Feasibility review, dimensional drawing, connector definition, prototypes, validation, pilot build, change control and OEM production |
| Commercial configuration | Sample quantity, MOQ, production lead time, packaging and warranty are quoted only after the cell, assembly and validation scope are confirmed |
Applications
Typical product uses.
Wearable electronics
Configuration is evaluated against the device load, available space, operating environment and production requirements.
Smart tags
Configuration is evaluated against the device load, available space, operating environment and production requirements.
GPS trackers
Configuration is evaluated against the device load, available space, operating environment and production requirements.
Bluetooth products
Configuration is evaluated against the device load, available space, operating environment and production requirements.
IoT devices
Configuration is evaluated against the device load, available space, operating environment and production requirements.
Medical & wellness devices
Configuration is evaluated against the device load, available space, operating environment and production requirements.
Portable instruments
Configuration is evaluated against the device load, available space, operating environment and production requirements.
Smart sensors
Configuration is evaluated against the device load, available space, operating environment and production requirements.
Engineering support
From requirements to production.
- 01Requirement Review
- 02Electrical Evaluation
- 03Solution Design
- 04Prototype Development
- 05Testing & Validation
- 06Pilot Production
- 07Mass Production
FAQ
Planning your custom project.
Can a LiPo battery be made to an exact size?
Dimensions can be customized within electrochemical and manufacturing constraints. Share the maximum battery envelope, including tolerance and swelling allowance, together with the required capacity.
What details are most important?
Voltage, capacity or runtime, continuous and pulse load, maximum dimensions, charging method, connector, wire length, environment and estimated quantity are the best starting points.
How do dimensions affect capacity?
Capacity is mainly constrained by usable electrode volume. Making the cell thinner, narrower or shorter generally reduces available capacity, while tabs, sealing edges, protection and cable routing also consume space.
Can you add wires, connectors and protection?
Yes. Wire gauge, length, exit direction, connector, polarity, protection PCB and NTC thermistor can be integrated around the device interface.
Will the pouch battery swell?
Pouch cells require mechanical allowance for normal dimensional variation and life-related expansion. The enclosure should not clamp the cell or expose it to sharp edges.
Are certifications automatically included?
No. Test reports and certification scope depend on the exact cell, protection design, target market and shipping method and must be confirmed for the final configuration.
Faster engineering review
Send the details that define your application.
- Device and use environment
- Voltage, load and runtime
- Maximum dimensions
- Charging method
- Connector or interface
- Prototype and annual quantity
Start a project
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