7.2V Li-ion Battery Pack – A Complete Technical & Application Guide

Q: Is a 7.4V battery the same as 7.2V?

Yes. The difference is a naming convention. Both refer to 2-cell lithium-ion battery packs with similar nominal and fully charged voltages.

Q: Can I replace NiMH 7.2V with Li-ion?

Yes, but the charging circuit and protection system must be redesigned. Lithium-ion batteries require dedicated CC/CV charging and a proper battery management system.

Q: Do I need a custom charger?

Absolutely. A lithium-ion charger must follow CC/CV charging and support a maximum charge voltage of 8.4V for a 2S battery pack.

Q: What is the MOQ for custom packs?

Most OEM manufacturers start from 100–500 units, depending on design complexity, cell selection, and certification requirements.

March 2026-02-09 11:16:11

7.2V Li-ion Battery Pack – A Complete Technical & Application Guide

When customers ask us for a 7.2V Li-ion battery pack, they are usually not just looking for a voltage rating. They are looking for a stable, rechargeable, long-life power source that fits their device, meets safety regulations, and can be reliably manufactured at scale.

In this guide, I’ll break down how 7.2V lithium-ion battery packs are designed, where they are used, what specifications really matter, and how OEM customization works in real production scenarios—not theory.

What Is a 7.2V Li-ion Battery Pack?

7-2v-li-ion-battery-pack-structure

A 7.2V Li-ion battery pack is typically built by connecting two lithium-ion cells in series (2S configuration). Since a single Li-ion cell has:

Nominal voltage: 3.6–3.7V
Fully charged voltage: 4.2V

A 2S pack delivers:

Nominal voltage: ~7.2–7.4V
Fully charged voltage: 8.4V

This voltage level is extremely popular because it balances power capability, compact size, and electronic compatibility.

Common Cell Configurations for 7.2V Battery Packs

7.2V Battery Cell Configuration Comparison Chart (2S1P 2S2P)

2S1P, 2S2P, and Beyond

Configuration	Nominal Voltage	Typical Capacity Range	Use Case
2S1P	7.2V	1500–3500 mAh	Compact electronics
2S2P	7.2V	3000–7000 mAh	Longer runtime devices
2S3P+	7.2V	7000 mAh+	High-capacity equipment

From our production experience, 2S1P and 2S2P are by far the most requested formats, especially in portable industrial tools, medical devices, and handheld electronics.

Key Electrical Specifications That Matter

When evaluating or sourcing a 7.2V Li-ion battery pack, these are the parameters engineers and buyers should focus on:

Voltage Profile

Nominal: 7.2V / 7.4V
Charge cut-off: 8.4V
Discharge cut-off: typically 5.0–6.0V (depends on BMS design)

Capacity (mAh / Wh)

Capacity directly affects runtime. In OEM projects, we always calculate Wh (Watt-hours) instead of mAh to compare energy fairly.

Example:

7.2V × 2600 mAh ≈ 18.7 Wh

Discharge Rate and Load Matching

Not all 7.2V Li-ion battery packs are designed for the same current output.

Discharge Type	Typical C-Rate	Applications
Standard	0.5C–1C	Sensors, controllers
Medium	2C–3C	Medical handhelds
High-drain	5C+	Power tools, robotics

Selecting the wrong discharge profile is one of the most common reasons for premature battery failure we see in customer prototypes.

Battery Management System (BMS) for 7.2V Packs

7-2v-lithium-ion-battery-bms

A BMS is not optional—it is mandatory for safety, compliance, and lifespan.

Core BMS Functions

Overcharge protection
Over-discharge protection
Overcurrent protection
Short-circuit protection
Cell balancing (recommended)

In higher-end designs, we also integrate:

NTC temperature monitoring
SMBus / I²C communication
Fuel gauge ICs

Safety Standards and Certifications

For global markets, a 7.2V Li-ion battery pack typically needs:

UN 38.3 – Transportation safety
IEC 62133 – International safety standard
UL 2054 / UL 1642 – North American markets
CE / RoHS / REACH – EU compliance

Typical Applications of 7.2V Li-ion Battery Packs

Diagram showing the application of a 7.2V battery in medical equipment

From real customer projects, the most common applications include:

Medical diagnostic equipment
Portable monitoring devices
Barcode scanners
Industrial handheld terminals
Test & measurement instruments
Consumer electronics requiring higher stability than 3.7V

7.2V battery application diagram in industrial handheld devices

Why 7.2V Is Often Chosen Over 3.7V or 12V

Voltage	Pros	Cons
3.7V	Simple, cheap	Limited power
7.2V	Balanced power & size	Requires 2 cells
12V	High power	Larger, heavier

In many designs, 7.2V becomes the “sweet spot”—enough voltage headroom without the inefficiency of step-up converters.

OEM & Customization Options

From an OEM perspective, customization usually includes:

Cell type (18650, 21700, Li-polymer)
Capacity matching
BMS logic customization
Connector type (JST, Molex, custom)
Cable length and gauge
Housing (PVC, shrink wrap, hard case)
Labeling & branding

This is where battery pack manufacturers create real value, not just selling cells.

Battery Lifespan and Cycle Performance

Conceptual diagram of 7.2V battery capacity and lifespan

A properly designed 7.2V Li-ion battery pack typically delivers:

500–800 cycles at 80% capacity retention
More than 3–5 years of calendar life

Factors affecting lifespan:

Depth of discharge
Operating temperature
Charge current
BMS balancing quality

Typical 7.2V Li-ion Pack Performance

Parameter	Typical Value
Nominal Voltage	7.2–7.4V
Max Charge Voltage	8.4V
Capacity Range	1500–10000 mAh
Cycle Life	500–800 cycles
Operating Temp	-20°C to +60°C

FAQ – 7.2V Li-ion Battery Pack

Is a 7.4V battery the same as 7.2V?

Yes. The difference is naming convention. Both refer to 2-cell Li-ion packs.

Can I replace NiMH 7.2V with Li-ion?

Yes, but charging circuit and protection must be redesigned.

Do I need a custom charger?

Absolutely. A Li-ion charger must follow CC/CV charging at 8.4V.

What is the MOQ for custom packs?

Most OEM manufacturers start from 100–500 units, depending on design complexity.

7.2V Li-ion Battery Pack – A Complete Technical & Application Guide

What Is a 7.2V Li-ion Battery Pack?