507090-3S Lithium Polymer Battery Pack

Lithium Polymer Battery Pack 3S Structure Overview

Engineers design the 507090 lithium polymer battery pack (3S configuration) using a modular pouch-cell assembly process. First, they arrange three LiPo cells in a series connection layout to form a stable voltage structure. Then, technicians align each pouch cell with controlled spacing to reduce mechanical stress during operation. Meanwhile, insulation sheets are inserted between cells to prevent internal abrasion and electrical interference. After alignment, the pack proceeds into welding, integration, and enclosure preparation stages. The overall structure is formed through a controlled stacking and fixing process.

Cell Material System and Electrochemical Design

Manufacturers construct each pouch cell using lithium metal oxide cathodes coated on aluminum foil, while graphite-based anodes are applied on copper foil. In addition, a microporous polymer separator is placed between electrodes to allow lithium-ion transport while preventing direct contact. Furthermore, the electrolyte consists of lithium salts dissolved in organic carbonate solvents, and moisture is tightly controlled during filling. Meanwhile, the aluminum-plastic laminated film acts as the outer shell, replacing rigid casing with a flexible sealing structure.

Pack Assembly and Electrical Integration

Technicians begin by matching cell capacity, internal resistance, and voltage consistency before assembly. Next, they connect the cells in a 3S series configuration using nickel tabs through controlled spot welding. After that, a protection circuit module (PCM/BMS) is integrated to manage overcharge, over-discharge, and short-circuit conditions. Meanwhile, wiring harnesses are routed with insulation sleeves to maintain electrical safety and reduce resistance loss. In addition, continuity testing is performed to confirm stable current pathways across the entire pack.

Formation Testing and Compliance Standards

Engineers perform initial charge-discharge cycling to activate electrochemical balance across all cells. Afterwards, aging tests are conducted to evaluate voltage stability and internal resistance drift. Finally, insulation testing, weld inspection, and electrical performance verification are completed. Throughout manufacturing, the lithium polymer battery pack follows IEC 62133 and UN38.3 standards, ensuring structural reliability, electrical safety, and transportation compliance.

Product Features

• Medical-grade safety standards: Utilizing a polymer soft-pack structure with no metal casing, it will only bulge rather than explode even in abnormal situations, providing the highest level of safety for medical devices.
• Stable and consistent power output: Built-in intelligent protection circuitry monitors the charging and discharging process in real time, ensuring stable and unfluctuating voltage output, guaranteeing accurate and reliable diagnostic and treatment data.
• Flexible adaptation and space flexibility: The soft-pack design can be customized in various shapes and sizes, easily embedding into various compact medical devices, providing greater freedom in product design.
• Leading energy density: Compared to traditional liquid batteries, it has higher capacity and lighter weight for the same volume, effectively extending device life while reducing carrying burden.
• Rigorous testing and comprehensive certifications: Certified by multiple international authoritative certifications including KC, CB, UN38.3, TUV, CQC, MSDS, CE, and IEC62133, its quality withstands the test of the global market.
• Long-lasting cycle life and stable reliability: With a cycle life of over 500 cycles and no memory effect, it significantly reduces replacement frequency and lowers the total cost of ownership over its entire lifespan.
• Pre-charged at the factory, ready to use right out of the box: Factory voltage is 12.0V, eliminating the need for pre-charge and allowing for more efficient equipment deployment.

Application Scenarios

• Medical equipment (patient monitors, diagnostic instruments, rehabilitation therapy equipment)
• Portable medical terminals
• Handheld testing instruments
• Mobile devices with stringent safety and stability requirements