👇 🎥Customer Background：
A Southeast Asian brand sells 20000mAh large-capacity fast-charging power banks on e-commerce platforms. Due to fierce price competition, they chose a low-cost PCBA solution. However, two months after the product was launched, a large number of users reported that the body became hot during charging, and even affected the safety of the mobile phone. The customer return rate soared to more than 10%, seriously affecting the store rating.
📊Problem Analysis：
After receiving the product, we disassembled and analyzed it and found that there were several key problems with the PCBA solution:
1️⃣ The MOS tube is of poor quality, resulting in low conversion efficiency and severe heating.
2️⃣ The temperature monitoring chip is not used, and there is a lack of effective over-temperature protection mechanism during charging.
3️⃣ The power management IC is not designed reasonably, resulting in excessive energy loss during charging and discharging, further exacerbating the heating.
💥 We provide customers with the following optimization solutions:
✅ Replace high-efficiency MOS tube: We use MOS tubes with low on-resistance (Low Rds(on)) to improve conversion efficiency and reduce energy loss.
✅ Add NTC temperature control protection: Add NTC thermistor sensor to the PCBA solution to achieve temperature monitoring and overheating protection. When the temperature is too high, the charging power is automatically reduced to ensure safety.
✅ Upgrade power management IC: Use synchronous rectification IC to increase the conversion efficiency from 85% to 91%, effectively reducing the heating problem.
💯Final result：
After optimization, the new product was put back on the shelves, and the return rate dropped from 10% to 0.8%. The customer successfully restored the brand reputation and completely switched to our PCBA solution in subsequent purchases.
