Power banks have become widely popular because of the use of battery-powered electronics like our smartphones. Some batteries just aren’t powerful enough to go all day without needing a recharge, so power banks are often a necessity! The real question is: How are these portable chargers even made?

We’ve got the power to show you exactly how the mighty power bank was made, along with some helpful tips and tricks to keep yours in perfect working order. This small mobile accessory packs a large punch!

How Does a Power Bank Work?

A power bank is a wireless battery that can receive and produce charge. For a power bank to work, it must be charged to store energy. First, an adapter cable provided with the power bank is used to charge it with a wall outlet. Once the indicator light on the power bank shows the accessory is charged, it can be used to charge electronic devices.

The energy stored inside of a power bank is then transferred through a charging cable from the USB port to the device.

How to Make a Power Bank

If you’ve ever wondered what’s inside your power bank, we have the answers. A power bank is made through 10 simple steps!

Here’s how a power bank is made:

  • Step 1: Terminals are attached to the lithium-ion battery.
  • Step 2: The circuit board is assembled.
  • Step 3: The batteries are soldered to the circuit board.
  • Step 4: Each power bank is tested to determine current and voltage.
  • Step 5: The batteries are encased in a protective housing.
  • Step 6: Electrical connections are tested again to ensure working order.
  • Step 7: A burn-in test is performed to check the battery capacity.
  • Step 8 (Optional): The brand name or a design is printed or engraved onto the protective housing.
  • Step 9: Finished power banks are given one last visual inspection before shipping.
  • Step 10: The power banks are ready to charge your electronic devices.
  1. Step 1
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    Attach the Battery

    The terminals are attached to the positive and negative ends of the lithium-ion battery using soldering.

  2. Step 2
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    Assemble the Circuit Board

    Next is the Printed Circuit Board Assembly (PCBA) where the electric components are soldered on to the circuit board. A circuit board is the brains of a power bank.

  3. Step 3
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    Solder the Batteries

    The batteries are soldered to the circuit board by the terminals. The newly conjoined circuit boards and batteries are then sent down a conveyor belt for the next step.

  4. Step 4
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    Test the Power Bank

    A DC Power Tester is used to determine the current and voltage of the power banks. The power bank is tested through the USB and USB min ports on the circuit board.

  5. Step 5
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    Add Protective Housing

    The battery and circuit board are encased in protective housing made of aluminum or ABS plastic.

  6. Step 6
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    Test Electrical Connections

    CT100 testers are used to check the electrical connections in the power bank. The chargers are checked to make sure they can receive and produce a charge.

  7. Step 7
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    Test Battery Capacity

    A burn-in test is performed to monitor the battery capacity of the newly produced power banks. Hundreds of power banks are charged at once for several hours.

  8. Step 8 (Optional)
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    Add Label and Design

    Labeling and design is added to the power banks using screen printing, pad printing, or laser engraving.

  9. Step 9
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    Final Visual Inspection

    The power banks are given one final visual inspection before they are packaged and shipped to the destination.

  10. Step 10
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    Ready to Charge Your Device

    Your new power bank is now ready to be used! Simply plug in your device and enjoy.

Check out how power banks are made in this video!

And there you have it! The simple process allows large quantities of power banks to be made at once for a lower cost. You now know how your power bank came to be one of your most important tech accessories.

What Is the Lifetime of a Power Bank?

The average working life of a power bank is between 200 to 1000 cycles. A cycle is one charge and one use to charge a device, either partially or fully. The average lithium-ion battery inside power banks will start to lose their capacity after so many charging cycles. Larger power banks require less charging cycles, so they will last longer than smaller power banks.

There is no guarantee to how long your power bank will last, but reducing how often you use your power bank can make it last longer.

What Can a Power Bank Charge?

A power bank can charge just about any electronic device that has a rechargeable battery. Devices that normally use a USB charger can be charged with a power bank!

A power bank can charge the following electronics:

  • Smartphones
  • Cameras
  • GPS systems
  • Gaming devices
  • Laptops
  • GoPros
  • MP3 players
  • Tablets

If your device does not have a USB interface, you might still be able to use a power bank if wireless charging is a feature of both the device and charger. Before using your power bank, make sure that it provides proper voltage to adequately charge your device. You can always check with the manufacturer of your device if you are uncertain.

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Can a Power Bank Charge a Laptop?

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Yes, a power bank can charge a laptop, but only if it is the right kind! Unfortunately, you won’t be able to charge your laptop with just any power bank, but there are certain types that can keep your battery charged.

Most laptops can be charged with a USB-C port. If the charging cord provided with your laptop has a USB-C, then you can use a power bank that also has a USB-C output to charge it.

Once you have the correct cables, you’ll want to make sure your power bank will deliver 30W of power in order to charge your laptop. If your power bank has less watts, it won’t be powerful enough to charge your laptop and could potentially drain your battery.

The following manufacturers make laptops that are USB-C compatible:

  • Dell
  • Apple
  • Asus
  • HP
  • Lenovo
  • Microsoft
  • LG

If your laptop does not support USB-C charging, you’ll need a power bank with a 12V output and a cable that fits the laptop’s charging port. If you are unsure if your power bank can charge your laptop, you can always reach out to the manufacturer!

Why Are Some Power Banks More Expensive?

Not all power banks are created equal, especially when it comes to price. Some power banks are more expensive than others because of how they are made and their charging capacity.

Higher quality power banks are more expensive because they last longer, have a more powerful battery, and are made with high quality materials. A more budget-friendly power bank will still charge your battery, but it may be smaller or not hold a charge as long.

Do Power Banks Ruin Your Phone?

It is possible to damage your phone’s battery from using a power bank. However, if you are using your power bank correctly, you significantly decrease the odds of ruining your phone.

Here are some of the ways a power bank can ruin your phone:

  • Using a low-quality power bank
  • Power banks with insufficient voltage
  • Overcharging your phone

1. Using a Low-Quality Power Bank

Low-quality power banks aren’t all guaranteed to ruin your smartphone battery. However, if you are using it frequently and for long periods of time, it can cause damage to your phone’s battery by making it lose its charge faster. The best way to avoid this is to make sure you have a high-quality power bank, or to use your lower quality charger only when you need it most. Lower-quality power banks usually have small batteries, are low-cost, and provide insufficient power to your devices.

2. A Power Bank with Insufficient Voltage

The power bank you use to charge your phone should have 5V. If your power bank has less voltage, it can drain your battery instead. If your power bank has a voltage greater than 5V, it can damage your phone by overloading the battery. Be sure to check the voltage of your power bank before using it to charge your phone.

3. Overcharging Your Phone

Power banks aren’t designed to be constantly plugged into your phone to keep it at 100% battery life. If you constantly charge your phone, your battery will not be able to hold its charge for long periods of time. It is best to use your power bank sparingly and to unplug it from your phone when it’s close to being fully charged.

Following these tips will allow you to use your power bank without fear of damaging your smartphone! The best rule of thumb is to use your power bank only when you absolutely need it, and to unplug your phone after it has enough battery.

The Bottom Line

Power banks will always be a necessity because they provide the energy our phones, laptops, and tablets need each day. Through their simple manufacturing process and their capacity to charge a variety of devices, power banks are the ultimate tech accessory!

References

Kishore, Aseem. (2019, July 20). Everything You Should Know About Power Banks. Retrieved on March 9, 2020, from,
https://helpdeskgeek.com/reviews/everything-you-should-know-about-power-banks/

Dealna. (2020). Power Banks – What Impact They Have On Your Phone’s Battery. Retrieved on March 10, 2020, from
https://dealna.com/Article/Post/20822/Power-Banks-What-Impact-They-Have-On-Your-Phone-s-Battery

Tespack. (2016, August 10). 7 facts you didn’t know about power banks. Retrieved on March 10, 2020, from
https://www.tespack.com/7-facts-dont-know-power-banks/

Electronics Notes. (2020). What is a Power Bank – portable charger. Retrieved on March 11, 2020, from,
https://www.electronics-notes.com/articles/equipment-items-gadgets/powerbank/what-is-a-powerbank-battery-store.php

About the author

Gianna Petan

Meet Gianna - no stranger to all things promo products. Her background in research-based writing, linguistics, and advertising gives her an edge in blogging about the marketing industry.