Ultra-Thin 85046 (085046) Li-Polymer Battery: 0.8mm Profile for Smart Cards & Wearables
The GEB 85046 (standard industry code: 085046) is a specialized ultra-thin lithium-ion polymer pouch cell with an absolute thickness profile of just 0.80 mm (±0.05 mm), a width of 50.0 mm, and a length of 46.0 mm. Delivering a nominal 3.7V and 80 mAh of capacity (0.296 Wh) at a weight under 1.8 grams, the 085046 cell is purpose-engineered for ISO-compliant dynamic display smart cards, one-time-password (OTP) security tokens, disposable medical sensor patches, and skin-conforming wearable bio-monitors.
1. The 0.8mm Packaging Breakthrough: Micro-Cavity Thermoforming
Manufacturing a lithium-ion polymer cell thinner than 1.0mm represents one of the pinnacle challenges in electrochemical process engineering. Standard pouch cells rely on deep-draw cold-forming of 113 μm or 153 μm aluminum-laminated barrier films. At sub-millimeter thicknesses, conventional deep drawing causes micro-fracturing along the foil corner edges, compromising hermetic seal integrity.
The GEB 085046 cell overcomes this through precision micro-cavity shallow thermoforming combined with ultra-thin double-sided cathode (LiCoO2) and graphite anode foil coatings. A 12 μm ceramic-reinforced microporous separator is interleaved between planar electrode sheets, followed by micro-dosed gel polymer electrolyte vacuum injection and ultra-narrow thermal impulse edge sealing.
2. Technical Datasheet: GEB 085046 (85046) Ultra-Thin Cell
Complete mechanical dimensions and electrical performance thresholds for hardware integration:
| Specification Parameter | Engineering Value | Measurement Conditions / Test Method |
|---|---|---|
| Industry Model Code | GEB-085046 (85046) | 0.8mm (Thickness) × 50mm (Width) × 46mm (Length) |
| Nominal Voltage | 3.70 V | Mean voltage during 0.2C discharge to 3.0V |
| Rated Capacity | 80 mAh (±5%) | Standard charge 0.2C (16mA) / discharge 0.2C @ 25°C |
| Maximum Thickness | 0.85 mm Max (Fresh cell: ≤ 0.80 mm) | Optical micrometer under 100g load plate |
| AC Internal Resistance | ≤ 120 mΩ | Measured at 1 kHz AC four-terminal Kelvin clip |
| Continuous Discharge Current | 1.0C (80 mA) | Continuous operating ceiling without thermal rise >10°C |
| Peak Pulse Current (100ms) | 2.0C (160 mA) | RF transmission burst (NFC / Bluetooth LE beacon) |
| Cell Weight | Approx. 1.75 g | Gravimetric energy density ~ 169 Wh/kg |
3. Profile Comparison: Ultra-Thin 0.8mm vs. Standard Miniature Pouch Cells
Choosing between ultra-thin form factors and standard small cells depends on mechanical casing depth constraints:
| Design Characteristic | 0.8mm Ultra-Thin (085046) | 3.0mm Standard Pouch (302025) | Engineering Trade-Off |
|---|---|---|---|
| Lamination & Flexibility | Tolerates moderate curved lamination (R ≥ 40mm) | Planar rigid mounting only (Bending damages electrodes) | 085046 conforms inside wristbands and laminated card stock. |
| Volumetric Efficiency | Higher foil-to-active-mass ratio (~160 Wh/L) | Optimal active mass ratio (~260 Wh/L) | Thicker cells achieve higher volumetric energy density. |
| PCM Integration Method | Micro-FPC with bare-die wire bonding (≤0.6mm PCB) | Standard FR4 rigid PCB strip with SMT components | Ultra-thin cells require specialized low-profile PCM boards. |
Related Technical Guides & Solutions: Lithium Polymer Battery Selection Guide | OEM/ODM Custom Battery Design & Prototyping | GEB 085046 Ultra-Thin Product Datasheet
Ultra-Thin Li-Polymer Battery Manufacturing – GEB
General Electronics Battery (GEB) is an established industrial pioneer in sub-1mm ultra-thin lithium polymer battery fabrication. We partner with global card manufacturers, medical wearable innovators, and smart patch developers to deliver customized dimensional cells certified for high-reliability applications.
- Hot Lamination Ready: Engineered to withstand temporary ISO card hot-lamination cycles up to 130°C for 30 seconds under hydraulic pressure.
- Flexible Lead Termination: Laser-welded nickel tabs, gold-plated contacts, or customized flexible printed circuits (FPC).
- Complete Safety Certifications: Compliant with UN 38.3, IEC 62133-2, CE, and RoHS directives.
Frequently Asked Questions: 085046 Ultra-Thin Batteries
Can the 085046 ultra-thin battery survive standard smart card hot-lamination?
Standard lithium polymer batteries will gas and rupture if exposed to prolonged lamination temperatures. GEB manufactures a specialized “High-Temp Card Grade” version of the 085046 cell featuring high-boiling-point electrolyte solvents and ceramic separators capable of enduring card lamination cycles (up to 125°C–135°C for 25–35 seconds under 1.5 MPa pressure) without swelling.
What is the minimum bending radius of the 085046 pouch cell?
While the 085046 cell is pliable, it is classified as a “semi-flexible” pouch cell. It can be pre-curved during device integration down to a static radius of R ≥ 40 mm. Dynamic, continuous flexing (like a hinge) must be avoided to prevent fatigue cracking of the internal current collector foils.
What charging ICs are best suited for an 80mAh ultra-thin battery?
Linear charge ICs with programmable low charge currents (e.g., Texas Instruments BQ25100 or Analog Devices LTC4065) are recommended. The charging current should be programmed to 0.5C (40mA) or 0.2C (16mA) with a termination current set to 2mA (C/40) to guarantee safety and preserve battery longevity.
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