In the competitive consumer electronics market, “Power” and “Portability” are often at odds. Recently, a leading European tech brand approached Reachinno with a challenging request: they needed a 65W high-output laptop power bank that was slim enough to fit into a suit pocket, without sacrificing safety or thermal performance.
Here is how we turned their ambitious concept into a market-ready product in just 90 days.
1. The Challenge: High Power in a Tight Space
The client’s requirements were specific and demanding:
- Thickness: Must not exceed 18mm.
- Output: Genuine PD 65W to support MacBook Pro and high-end Windows laptops.
- Safety: Must remain cool to the touch even during peak power delivery.
- Timeline: Ready for mass production within 3 months for the Q4 holiday season.
The hurdle? High-wattage charging generates significant heat. In a slim enclosure, traditional cooling methods fail, leading to thermal throttling or potential safety risks.
2. The Reachinno Solution: Innovation in Engineering
To achieve the “Impossible Trinity” of slimness, power, and safety, our R&D team implemented three core innovations:
A. Custom High-Density PCB Design
We utilized a 10-layer HDI (High-Density Interconnect) PCB to minimize the internal footprint. By optimizing the component layout, we reduced the circuit board size by 25% compared to standard 65W power banks.
B. Advanced Thermal Management (Graphene Cooling)
Standard heat sinks were too bulky. Instead, we applied graphene thermal pads on both sides of the PCBA and battery cells. This allowed heat to be distributed evenly across the aluminum alloy casing, preventing “hot spots” and maintaining a safe surface temperature.
C. Intelligent Firmware Optimization
Our software engineers developed a custom Smart Power Distribution algorithm. It monitors the real-time temperature of the Li-polymer cells and adjusts the charging curve dynamically, ensuring the highest efficiency with minimal heat buildup.
3. The Result: From Prototype to Mass Production
Within 45 days, we delivered the first functional prototype. After rigorous reliability testing— 1.2m drop tests, thermal shock, and aging tests—the final design was approved.
- Development Cycle: 90 Days (Concept to Mass Production).
- Performance: Sustained 65W output with a surface temperature under 45°C.
- Market Impact: The product became the client’s best-seller within the first month of launch, receiving a 4.8-star rating for its “premium feel and incredible thinness.”
4. Why Partner with Reachinno for your ODM Project?
This project is a testament to Reachinno’s core values: Innovation and Customer Satisfaction. We don’t just manufacture batteries; we solve engineering puzzles that help your brand lead the market.
Looking to develop your next high-performance power product? Contact our Engineering Team Today to discuss your custom solution.
