4P401004S | Lithium-ion Polymer Rechargeable Battery Pack

Regulus was contracted to provide the full range of works, including: 

  • design-to-production analysis

  • production methods selection

  • alternative technologies testing

  • moulds and tools development

  • pre-production prototyping 

  • trial small production, including mechical components and electronics PCBA. 

  • mass quantity manufacturing, including mechanical components, PCBA and other accessories

Project Details

■ Application : Lithium-ion Polymer Rechargeable Battery Pack 3.7V / 7700mAh

■ Materials Applied 

1. Housing : Aluminum alloy ADC-12

2. Metal parts : 

    a) Brass, C2680

    b) Spring steel, SK7

    c) Cold-rolled steel sheet

    d) Cold-rolled brass strips

    e) Stainless steel, SUS301 3/4H with Heat-treatment 

3. Plastic parts : 

    a) ABS, 2020-31

    b) ABS, PA757 

4. Silicone & Rubber parts : Silicone, Self-adhesive tape Stip-n-Stick 2mm

5. PCB : Laminate, FR4 High Tg

6. Cell : Lithium-ion polymer, LT077S 1S2P, 3.7V / 7700mAh

■ Method of Production  

1. Die casting & Secondary Machining 

    1) Die casting

    2) CNC

    3) Vibrating Finishing

    4) Trimming

    5) Drilling

    6) Tapping

2. Plastic injection molding

3. Stamping

4. Silicone rubber injection molding

5. CNC Machining 

6. PCBA parts purchasing

7. PCBA assembly

■ Plating & Coating :  Cu 3um + Nickel 6um + Matte tin 9um ; Matt Sn 6um ; Zinc 3um ; White zinc

■ Surface Painting & Coating :  Soft-touch painting

■ Surface Final Finishing :  Laser engraving 

■ Pre-delivery Processes  

1. Paint adhesion testing

2. Product final assembly

3. Salt spray testing for final product

4. Thermal shock testing for final product

5. Vibration testing for final product

6. Low/high temperature testing for final product

7. Waterproof testing for final product

8. 1.2M drop test

9. UN38.3 safety test 

10. OQC control

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