Guide to the 551525 LiPo Battery: Mechanical, Electrical, and Integration Specifications
The 551525 lithium polymer battery is a miniature rechargeable pouch cell specifying nominal dimensions of 5.5 mm (T) × 15.0 mm (W) × 25.0 mm (L), delivering a rated capacity of 140 mAh to 150 mAh at 3.7V (0.518 Wh to 0.555 Wh). Engineered specifically for space-constrained wearable electronics, smart audio cases, BLE tracking tags, and compact medical sensors, the 551525 integrates an ultra-low-quiescent-current protection circuit module (PCM ≤ 3 μA), maintains an initial AC internal resistance ≤ 120 mΩ, and guarantees ≥ 80% capacity retention over 500 charge-discharge cycles. Fully certified to UN 38.3, IEC 62133-2, and UL 1642, it represents an optimal volumetric density solution for micro-scale hardware architectures.
1. Mechanical Dimensions and Packaging Form Factor
In ultra-compact electronic devices, millimetric accuracy dictates product viability. The industry-standard 551525 designation follows the standard electrochemical pouch naming convention: a nominal maximum thickness of 5.5 mm, a width of 15.0 mm, and an overall cell length of 25.0 mm (excluding the top seal tab margin). General Electronics Battery (GEB) manufactures the cell with precision deep-drawn aluminum-laminated pouch film (typically 88 μm to 113 μm thickness) to ensure robust environmental hermeticity while minimizing dead volume.
Mechanical design engineers integrating the GEB 551525 3.7V 140mAh LiPo Cell must accommodate cyclic expansion. Over a standard 500-cycle operational lifespan, lithium intercalation and gas generation cause the pouch thickness to expand by approximately 8% to 10% (reaching up to 5.95 mm at end-of-life). Structural chassis cavities should incorporate a minimum 0.5 mm vertical clearance and compliant foam damping to prevent excessive mechanical compression against rigid enclosures.
2. Electrical and Electrochemical Performance Matrix
The 551525 utilizes high-purity cobalt-doped lithium cobalt oxide (LCO) or high-nickel NMC cathode formulations matched with fine-particle synthetic graphite anodes to maximize gravimetric energy density in sub-gram payloads. Below are the verified technical parameters for industrial qualification:
| Parameter | Specification Value | Engineering Test Condition |
|---|---|---|
| Nominal Voltage | 3.7 V | Reference 0.2C discharge plateau |
| Rated Capacity | 140 mAh (min. 135 mAh) | 0.2C discharge to 3.0V cutoff at 25°C ± 2°C |
| Charge Cutoff Voltage | 4.20 V ± 0.03 V | Constant Current / Constant Voltage (CC/CV) |
| Standard Charge Current | 28 mA (0.2C) to 70 mA (0.5C) | Taper current cutoff at 0.02C (2.8 mA) |
| Max Continuous Discharge Current | 140 mA (1.0C) | Continuous load, surface temp < 50°C |
| Max Peak / Pulse Discharge | 280 mA (2.0C for ≤ 2 seconds) | BLE / cellular RF transmit bursts |
| Internal Resistance (AC IR) | ≤ 120 mΩ | Measured at 1 kHz AC after full charge |
| Cycle Life | ≥ 500 cycles | 0.5C charge / 0.5C discharge, ≥ 80% initial capacity |
| Operating Temperature Window | Charge: 0°C to +45°C | Discharge: -20°C to +60°C | Storage: -10°C to +35°C at 50% SoC |
| Average Cell Weight | Approx. 3.2 g ± 0.2 g | Bare cell excluding lead wires / connector |
3. Integrated Protection Circuit Module (PCM) and Low-Quiescent Management
Given the modest total energy reserve (140 mAh), parasitic power draw from battery management circuitry can severely degrade shelf life. A generic battery protection IC drawing 10 μA would deplete a stored battery in less than 18 months. GEB outfits the 551525 with specialized micro-power PCMs utilizing low-RDS(on) dual MOSFETs (e.g., Seiko S-8261 or equivalent) maintaining standby quiescent current under 3.0 μA.
| Protection Parameter | Threshold Limit | Recovery Condition |
|---|---|---|
| Overcharge Detection Voltage | 4.28 V ± 0.025 V | Voltage release ≤ 4.08 V ± 0.05 V |
| Overdischarge Cutoff Voltage | 3.00 V ± 0.05 V | Connection to external charger (≥ 3.0V release) |
| Overcurrent Discharge Trip | 0.5 A to 1.2 A (customizable) | Automatic release upon load disconnection |
| Short Circuit Delay Time | ≤ 50 μs | Cutoff active until short circuit load is removed |
| Current Consumption (Operating) | ≤ 3.0 μA (typical 1.8 μA) | V_cell = 3.8 V, continuous measurement |
4. OEM Integration, Tab Soldering, and Lead Harness Standards
Ultrasonic spot welding of pure nickel tabs requires precise energy calibration to avoid micro-punctures in the underlying aluminum pouch sealing band. For OEM hardware builds, GEB provides the 551525 with either bare nickel tabs, insulated silicone lead wires (AWG 28 or AWG 30), or micro connectors such as JST ACH, Molex PicoBlade (1.25mm pitch), or Hirose DF13.
During manual assembly or reflow operations, soldering iron contact to battery lead terminals must never exceed 3 seconds at 350°C, and mechanical strain relief tape must isolate tab joints from bending fatigue. For broader insights on safe handling, refer to our comprehensive guide on LiPo battery safety and handling best practices.
Frequently Asked Questions (FAQ)
What do the numbers in the 551525 model designation signify?
The code follows standard lithium polymer nomenclature: 55 denotes a thickness of 5.5 mm, 15 denotes a width of 15.0 mm, and 25 denotes a length of 25.0 mm. Slight variations exist based on whether external insulation wrapping and PCM boards are included.
Can the 551525 support continuous high-rate discharge above 2C?
Standard energy-density 551525 cells are optimized for 0.2C to 1C continuous loads. While they easily withstand short RF transmission bursts up to 2C (280 mA), prolonged discharge above 1C will induce internal thermal buildup, accelerate impedance growth, and degrade cycle life. High-rate custom formulations are available upon engineering request.
What certifications are required to ship products containing the 551525 internationally?
Every commercial battery shipment requires a valid UN 38.3 test report (covering thermal cycling, altitude simulation, vibration, and impact) along with a compliant Material Safety Data Sheet (MSDS). For consumer and medical devices sold in North America and Europe, UL 1642 / UL 2054 and IEC 62133-2 test certificates are mandatory.
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