Redefine the standards for battery protection in headphones

1. Ultimate lightweight, no burden to wear

It adopts aerospace-grade carbon fiber composite material with a density of only 1.6g/cm³, reducing the weight by 40% to 50% compared to traditional aluminum alloy battery shells. Take in-ear headphones as an example. The weight of a single battery case can be controlled within 0.8g. Combined with ergonomic design, it remains light and seamless even after long-term wearing, completely saying goodbye to the “ear-dropping sensation”.

2. Military-grade protection, ensuring no blind spots in safety

The high-strength structure is constructed through three-dimensional weaving technology, with a tensile strength exceeding 7000MPa, which is more than ten times that of aluminum alloy. The innovative “sandwich” sandwich structure features a high-modulus carbon fiber pre-impregnated surface layer that can withstand daily drop impacts, while the core layer’s honeycomb structure can buffer compressive stress. Tests have shown that it remains structurally intact even when dropped from a height of 1.5 meters onto a cement floor, effectively protecting the internal battery cells.

3. Intelligent thermal management ensures more stable battery life

By taking advantage of the axial thermal conductivity of carbon fiber and in combination with the built-in phase change microcapsules, the local hot spot temperature generated by fast charging can be reduced by 40℃ within 10 seconds. In extreme environments ranging from -30 ℃ to 60℃, the battery capacity retention rate still exceeds 85%, solving the problem of battery life attenuation caused by uneven heat dissipation in traditional metal shells and extending the continuous usage time of the headphones by 2 to 3 hours.

4. Long-lasting weather resistance and upgraded durability

The carbon fiber matrix has excellent corrosion resistance. It has passed the 1000-hour salt spray test without any signs of aging, far exceeding the oxidation loss problem of aluminum alloy. The surface nano-coating can resist sweat erosion and daily scratches. It still maintains stable performance after 5,000 bending tests, and its service life is more than twice as long as that of the metal shell.

Exterior design: Fully showcases the original texture of carbon fiber

Texture presentation: It retains the unique twill weave texture of carbon fiber. By precisely controlling the weave density (12 stitches per inch), the texture is uniform and fine. Under the light, it presents an alternating metallic luster of light and dark, which not only showcases the technological feel of the material but also avoids the cheap impression of traditional plastic shells. At the same time, two texture options are provided – the classic 2×2 twill and the fine 1×1 plain texture, to meet the style requirements of different products and be suitable for various scenarios such as high-end headphones and smart wearable devices.

Color matching: Based on the natural color of carbon fiber (dark gray), combined with the transparent texture of the nano-ceramic coating, it creates a “low-key and high-end” visual effect. Meanwhile, it supports customized colors. By adding inorganic pigments, various color combinations such as matte black, deep space gray, and silver gray can be achieved. Moreover, the pigments have a high degree of integration with the coating and will not affect the corrosion resistance and wear resistance of the coating, ensuring that the colors do not fade or fade over long-term use.

Edge treatment: CNC precision numerical control processing is adopted to control the chamfering of the battery shell edge within the range of R0.2-R0.5mm. This not only avoids the risk of scratches caused by sharp edges but also maintains the neat lines of the product. For irregular-shaped battery casings (such as arc-shaped and trapezoidal ones), through 5-axis linkage processing technology, the edge curvature is ensured to be smooth and natural, seamlessly integrating with the overall shape of the product.

Structural design: Balancing performance and practicality

Compact design Based on the high strength characteristics of carbon fiber material, while ensuring protective performance, the wall thickness of the battery shell is controlled between 0.5 and 1mm (the wall thickness of traditional ABS plastic shells needs to be 1.5 to 2mm, and that of aluminum alloy shells needs to be 1 to 1.2mm), significantly saving internal space and being compatible with smaller batteries Help electronic products achieve “thin and light” design. Take the battery case of a smartwatch as an example. After adopting this design, the space occupied by the battery case is reduced by 30%, leaving more installation space for other internal components of the watch, such as sensors and displays.

Modular interface: Standardized interface slots (such as charging interfaces and data transmission interfaces) are reserved on the surface of the battery shell. The edges of the interface slots are designed with a combination of “reinforcing ribs + sealing strips”. The reinforcing ribs are integrally formed from carbon fiber to enhance the structural strength at the interface and prevent interface loosening caused by frequent plugging and unplugging. The sealing rubber strip is made of anti-aging silicone material and precisely adheres to the interface groove, achieving an IP68 protection level at the interface and effectively preventing dust and moisture from entering.

Easy disassembly design: For products that require regular battery replacement, a dual fixation structure of “snap + screw” is designed. The snap is made of elastic carbon fiber material, which has good toughness and can be disassembled more than 500 times without damage. The screw hole is equipped with a built-in metal insert, which is tightly combined with the carbon fiber shell through a high-temperature pressing process, avoiding the problem of thread slipiness caused by repeated screwing of the screw, and balancing the convenience of disassembly and structural stability.

Adaptive design: Meeting diverse product requirements

Customized styling: Relying on the excellent formability of carbon fiber composite materials, battery shells of various shapes can be customized according to the battery size and appearance requirements of different electronic products, such as round, square, oval, and irregular shapes. Through 3D modeling and rapid prototyping technology, customized sample development can be completed within 72 hours, shortening the product research and development cycle. For instance, the arc-shaped battery case custom-made for in-ear headphones can perfectly fit the curves of the earphone body, reduce the protrusion of the body, and enhance the wearing comfort.

Multi-scenario adaptation: Optimize the design details of the battery case for different usage scenarios. In motion scenarios, add anti-slip textures on the surface (with a texture depth of 0.1mm) to enhance the grip friction and prevent the product from slipping during movement. In outdoor scenarios, adding an anti-ultraviolet coating to the surface of the battery shell can resist UVA and UVB ultraviolet radiation, preventing material aging and appearance discoloration. In the context of medical equipment, the application of antibacterial nano-ceramic coatings (with an antibacterial rate of ≥99%) can inhibit the growth of common bacteria such as Escherichia coli and Staphylococcus aureus, meeting the hygiene requirements of medical equipment.