Longer Runtime, Same Size: An 85mm LED Module Battery Upgrade

The requirement: longer battery life in the same installation space.

An existing customer wanted a rechargeable LED module to operate for more hours in a new product line. The size needed to remain compatible with the modules already purchased. The challenge was to improve the battery arrangement without creating a module that the finished product could not accommodate.

The customer also hoped to use a suitable solution across the existing and new product lines, rather than manage two different module stocks. Fit and cost therefore mattered alongside operating time.

This was a later development stage in a continuing relationship. The earlier 500-set RGB module order without a remote concerned control functions and supplied accessories. The battery proposals here should not be read as the specification of that first order.

Why the first larger-battery proposal did not fit.

Vcan initially described an approximately 1200mAh polymer battery in the existing 85mm base. An alternative placed an approximately 2200mAh battery at the centre of the PCB, with a taller cover to make room.

That proposal increased the stated height from approximately 5cm to 9cm. The customer checked the available space and reported that one product would not accept the 9cm design, then asked whether a 7.5cm version could be developed.

These heights describe the historical project discussion. For a new integration, check a dimensioned drawing and an actual sample: the module name alone does not specify the installation opening, flange diameter or usable internal clearance.

A 2000mAh soft-pack battery inside the original housing.

The revised proposal used a 2000mAh soft-pack battery. Vcan clarified that the external shape and dimensions would remain the same as the previously purchased product. Later correspondence specifically discussed the H5cm version with the 2000mAh soft-pack battery.

This distinction resolved an important misunderstanding: the revised proposal was not a confirmed 7.5cm-high product. It offered a different battery arrangement within the original housing instead of requiring the taller cover.

For a manufacturer with limited space, the useful comparison is the complete module configuration. Agree the battery, enclosure, electronics and charging arrangement together. This case is an OEM development example, rather than instructions for an owner to substitute a loose battery.

For a broader fit review, see the small rechargeable LED module size guide.

The result: runtime exceeded the customer's requirement.

Vcan's sales team confirms that the upgraded module delivered more operating time than this customer required in actual use. The customer continued placing repeat orders over the years. The project progressed beyond a proposed battery layout to a solution used in the customer's products.

The correspondence described an operating-time requirement of more than eight hours and later reported a Vcan test lasting more than ten hours for the revised arrangement. A later application enquiry also specified a six-to-eight-hour target.

This customer outcome is confirmed, while the available emails do not record the exact brightness, RGB colour or full conditions of the historical ten-hour test. For a new application, agree the light setting and required duration rather than treating that figure as a guarantee at every setting.

For a similar project, define the useful light setting first and test the approved sample in the finished housing. Record the selected colour or cycle mode, brightness setting and operating duration. A change from 1200mAh to 2000mAh alone is not a measured runtime comparison.

Our LED module runtime, brightness and battery guide covers that broader planning question. This case focuses on the separate problem of accommodating a battery upgrade without a taller housing.

Samples, remote compatibility and a later confirmed order.

Two upgraded samples were arranged and shipped for evaluation. The buyer subsequently asked about remote control, and Vcan confirmed that the discussed stock remote would work with those samples. Supplying a remote remained a separate accessory choice.

In later correspondence, the customer revisited the compact soft-pack option for another product, requested product information and battery shipping documents, and then confirmed an order and reported payment. Vcan's sales team confirms that the relationship has continued with repeat orders over the years.

The confirmed runtime outcome and continuing orders show that the revised solution met this customer's application needs. Exact cumulative quantities and order frequency are not stated here.

For a new order, confirm the exact configuration, accessory list, required shipping documents and production lead time. Historical quotations and availability do not establish current terms.