April 21, 2022

Ultrathin Rechargeable Lithium Polymer Batteries from PowerStream

battery discharge test equipment for tiny batteries

Battery capacity tester for small and tiny cells

ultra thin lithium primary (non-rechargeable) cells

For non-rechargeable lithium ultrathin cells click here

Cells as thin as 500 microns, and bendable!

Batteries, Chargers, and Power Supplies, Custom and off-the-shelf.

Battery discharge and capacity tester for small and tiny cells

PowerStream has been working with a team of engineers in China to develop the thinnest possible lithium polymer batteries. We can now offer design engineers batteries of 2.0 mm to 0.5 mm thick. These cells should be useful for smart cards, RFID tags and other applications that require energy storage in a very thin battery.

Lithium ion cells are used in a wide variety of portable equipment and instruments. Lithium polymer cells have a better form factor than cylindrical cells for a variety of applications, such as cell phones, PDAs, cameras. These cells are high-quality Chinese cells, made in an ISO certified environment. PowerStream has qualified this factory as being one of the premier factories for lithium polymer cells. Not exactly paper thin, but as thin as we know how!

Though these cells have small capacities they are about the same as coin and button cells and have a wide range of applications. There are microcontrollers that draw less than 1 microamp, such as the TI MSP430 in standby mode, so a 50 mAH battery could run these for 2 years between charges.

Flat batteries can be used for military, sensors, tags, and cards. At about 2 mAH per square cm these, and with power levels at 10 mA per square cm.

Since these are not thin-film batteries they are available now, have a flexible substrate, and can generate much higher powers if need be. They use a solid-electrolyte technology that minimizes or eliminates any free liquid. They do not have to be kept flat. The 0.5 mm cells can be flexed or bent into a cylinder, into a hat band, belt, etc.

Features:
1. High operating voltage(3.6V)
2. Energy density is high,
3. No memory effect
4. Self-discharge is less than 3% per month
5. Charge/discharge cycle characteristics are excellent
6. Safety characteristics are excellent
7. Processing temperatures for these cells is 100°C for less than 60 seconds, 120°C for less than 20 seconds and 140°C for less than 5 seconds.
8. End-of-discharge voltage cut off 2.8 volts.
9. Temperature range of charging is 0-45°C, discharging is -20 to +60°C

Ultrathin Lithium Polymer Cells

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Note at this time we have a few standard products (see the table with the "add to cart" buttons below. Most customers at this time are using cells made to their specifications and will require a tooling charge and minimum order of 2000 pieces. Below are listed typical parameters for such cells.

Engineering quantities the following cells are available off-the-shelf		Quantity 1-19	20-99	100-999	1000-4999	5000+
PGEB021212 10mAH	2x12x12mm	$15.00 each	$10.00	$7.64	$3.95	$2.88
GM201021 24mAH TUV UL1642 cert.	2x10x21mm	$13.00	$13.00	$4.30	$3.56
GM201021-PCB 24 mAH with protection circuit board TUV UL1642 cert.	3x10x21mm	$15.00	$15.00	$6.30	$4.06
PGEB0042255 25 mAH	0.4 x 22 x 55 mm	$15.00	$13.00	$6.30	$4.06
PGEB021235 40 mAH	2x12x35mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
PGEB021235-PCB 40mAH with protection circuit board	2x12x35mm	$12.00 each	$8.20	$5.25	$4.20	$3.68
PGEB0052081 20-40 mAH	0.5x20x81mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
PGEB0054018 10 mAH	0.5x40x18mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
GM201515 20mAH	2x15x15mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
PGEB014018 25 mAH	1x40x18mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
GM103333 35mAH	1x33x33mm	$8.00 each
GM103333-PCB 35mAH (the PCB is 2.5mm thick)	1x33x38mm	$10.00 each	$8.20	$4.95	$3.80	$3.38
GM201030 43mAH	2x10x30mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
GM201030-PCB 43mAH	2x10x30mm	$12.00 each	$8.20	$4.95	$3.80	$3.38
GM0086535 50mAH 500mA 10C discharge rate	0.8x65x35mm	$10.00 each	$8.20	$4.95	$3.80	$3.38
GM014241 52mAH	1x42x41mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
GM171538 53mAH	1.7x15x38mm	$10.00	$6.20	$3.95	$3.80
GM171538-PCB 53 mAH	1.7x15x38mm	$12.00	$8.20	$4.95	$3.30
GM271921 65mAH	2.7x19x21mm	$7.50	$5.75
GM271921-PCB 65mAH	2.7x19x21mm	$9.50	$7.75
GM153030	1.5x30x30mm	$7.50
GM171452 90mAH	1.7x14x52mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
GM171452-PCB 90mAH	1.7x14x52mm	$12.00 each	$8.20	$4.95	$3.80	$3.38
GM161652 90mAH	1.6x16x52mm	$10.00 each	$6.20	$3.95	$3.30	$2.28
GM251341 95mAH	2.5x13x41mm	$10.00 each	$6.20	$3.95	$3.30	$2.28
GM251341-PCB 95mAH	2.5x13x41mm	$12.00 each	$8.20	$4.95	$3.80	$3.38
PGEB0084545 100mAH	0.8x45x45 mm	$15 each	$13.00	$6.30	$4.06	$2.88
GM251534 100mAH (AKA GM261534)	2.514x34mm	$10.00 each	$6.20	$3.59	$3.30	$2.88
GM251534-PCB 100mAH with protection circuit board (AKA GM261534-PCB)	2.5x13x34mm	$12.00 each	$8.20	$4.95	$3.80	$3.38
PGEB0104348 130mAH	1x43x48mm	$10.00 each	$6.20	$3.95	$3.30	$2.88
PGEB016144 200 mAH PGEB014461	1x61x44mm	$10.00	$6.20	$3.95	$3.30	$2.88
PGEB0054338 45 mAH	0.5x43x38mm	$10.00 Out of stock	$6.20	$3.95	$3.30	$2.88
PGEB0083559 65 mAH	0.8x35x59mm	$10.00	$6.20	$3.95	$3.30	$2.88
PGEB1225180 300mAH	1.2x25x180mm	No longer available
PGEB01180270	1x180x270mm	No longer available

Examples of batteries that we have made	Thickness	Nominal Voltage (V)	Theoretical Capacity (mAh)	Dimensions T x W x H mm	Weight (grams)
PGEB201212	2 mm	3.7V	10mAH	2x12x12.5 mm	0.45 g
PGEB021235	2 mm	3.7 V	40 mAH	2 x 12 x 35 mm
PGEB0052081	0.5-0.55 mm	3.7 V	40 mAH	0.6 x 81 x 20 mm	1.7 g
PGEB0054018	0.8 mm	3.7 V	10 mAH	0.8 x 40 x 18 mm
PGEB014018	1.0-1.1	3.7V	25 mAH	1.0 x 40 x 18 mm
GM201030	2 mm	3.7V	43 mAH	2 x 10 x 30 mm
GM014241	1 mm	3.7V	52 mAH	1 x 42 x 41 mm
GM171452	1.7mm	3.7V	90 mAH	1.7 x 14 x 52mm
GM251534	2.5mm	3.7V	100mAH	2.5 x 15 x 34 mm
PGEB0104348	1mm	3.7V	130mAH	1 x 43 x 48	3.5 g
PGEB016144	0.85-1 mm	3.7 V	200 mAH	1.0 x 44 x 61 mm
PGEB0054338	0.6 mm	3.7 V	35-45 mAH	0.6 x 43 x 38 mm
PGEB0083559	0.8 mm	3.7 V	65 mAH	0.8 x 35 x 59 mm
PGEB01180270	1.0 mm	3.7V	2.8AH	1.0±0.2 x 118 x 270 mm	85 g

Discharge curves for ultra-thin batteries

These are great cells. They are designed for low current discharge, but the above curve shows what they do at high current discharge rates, up to 10C.
Note the following features:

At 100 mA (about 2C) you still get 90% of the rated capacity, terminating at 3 volts
At 200 mA (about 4C) you get 86% of the rated capacity terminating at 2.8 volts
The voltage stays high even at these extreme currents
Even at half an amp (10C) there is enough energy for over 3300 pulses, 100 mSec each.

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