For toys that involve frequent voice interaction, LED lighting, intermittent Bluetooth use, or motor movement, selecting
the right battery chemistry, capacity, and protection system is crucial for safety, runtime, user satisfaction, and
global compliance.

At PKNERGY, we support OEM/ODM teams in the toy industry worldwide. Through hundreds of projects, we’ve summarized key
engineering insights to help you avoid common pitfalls and create safer, longer-lasting, and more competitive AI toys.

1. Choosing the Right Battery Chemistry

For small to medium-power AI toys, the most suitable choice is typically a 3.7 V Lithium Polymer (LiPo) cell
with a built-in PCM protection board. LiPo batteries offer excellent energy density, lightweight structure, and flexible
size customization—making them ideal for toys with limited space and creative industrial design. :contentReference[oaicite:2]{index=2}

1.1 Why LiPo Is Ideal for AI Voice Assistant Toys

Key advantages of LiPo batteries in AI toys include:

• Stable discharge curve for consistent audio & speaker performance
• Thin, lightweight, customizable formats (e.g., 402030, 502540, 702030)
• High safety when paired with PCM (OVP/UVP/SCP protection)
• Easily integrated into curved or compact plastic housings

AA/AAA alkaline batteries remain common for simple low-power toys, but for any AI-enabled product, LiPo is far superior in
runtime, safety control, and user experience.

For projects that require fully customized thickness, width, length or wiring harness, PKNERGY provides dedicated

Custom Lithium Polymer Battery

development to match your toy structure and electrical profile.

2. Internal Space and Custom Cell Dimensions

AI toys often have irregular inner structures because of acoustic cavities, PCBA shape, speaker chambers, and design
aesthetics. Off-the-shelf cells often don’t fit optimally, leading to wasted space or mechanical stress on the battery.
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This is why PKNERGY frequently provides custom LiPo dimensions, matching the toy’s internal layout
precisely. Even a 1–2 mm adjustment can significantly improve space usage, avoid squeezing the cell, and
enhance safety.

PKNERGY supports custom sizes across a wide range, for example:

• Thickness: 3–12 mm
• Width: 20–50 mm
• Length: 20–70 mm

Early in the design phase, sharing your 3D models and internal structure with our engineering team helps ensure that
battery shape, wiring route, and connector position fit perfectly with your toy’s mechanical design.

3. Safety Requirements for Children’s Products

Battery safety in children’s toys is far more demanding than in general consumer electronics. A toy must withstand:

• Drops and impact from everyday play
• Chewing pressure and squeezing
• Rough usage and occasional misuse
• Repeated charging cycles over its lifetime

Therefore, we recommend a robust battery and pack design including: :contentReference[oaicite:4]{index=4}

• Built-in PCM for over-charge, over-discharge, and short-circuit protection
• Optional NTC temperature sensor for real-time temperature monitoring
• Insulation tape plus PVC or aluminum-laminated wrapping
• Reinforced wiring and secure connectors designed to resist pulling
• Options for UL94-V0 flame-retardant materials for premium safety

For export products, compliance such as UN38.3, IEC 62133, EN 62115,
and EMC standards may also be required, depending on your target markets.

If your AI toy combines multiple functions (e.g., motion, sound, wireless connectivity), PKNERGY’s

Consumer Electronics Power Solution

framework can be used as a reference for designing a safe, certifiable power system.

4. Realistic Runtime Analysis (Not Just mAh Numbers)

AI toys typically operate in mixed power-consumption modes, not at a single fixed current. A realistic usage profile may
include: :contentReference[oaicite:5]{index=5}

• Standby with wake-word listening
• Audio playback (0.5–1.2 W peaks) through speakers
• Idle mode with LEDs or small light effects
• Occasional wireless connectivity (e.g., Bluetooth)

Instead of relying only on nominal capacity (mAh), PKNERGY helps engineering teams evaluate true usage cycles.
This includes:

• Defining typical daily playtime windows (e.g., 30–60 minutes per day)
• Calculating average current across mixed modes
• Simulating realistic duty cycles (listening vs. active interaction)
• Adding safety margins to cover peak loads and battery aging

This approach ensures the product meets parent expectations (e.g., “charge once, play for several days”) while keeping the
battery size and cost under control.

5. From Prototype to Scalable Mass Production

Whether you need rapid samples for function testing, engineering validation, or stable mass production up to tens of
thousands of units per month, PKNERGY provides a complete service chain: :contentReference[oaicite:6]{index=6}

• Custom pack design and cell selection
• Electrical performance matching to your PCBA and load profile
• Reliability testing under toy-specific conditions (drop, vibration, cycling)
• Safety documentation for certification and shipment
• Consistent delivery capability for long-term toy programs

For more advanced smart toys or companion robots, PKNERGY can also support higher-capacity packs and additional functions
such as heating films, smart fuel-gauging, or multiple voltage rails.

6. PKNERGY Custom Battery & Toy Power Solutions

PKNERGY focuses on custom lithium battery packs for OEM/ODM clients across smart toys, robotics, and
interactive children’s devices. For children’s AI voice assistant toys, you can leverage our existing solution platforms:

• 
  Custom Lithium Polymer Battery
  
  for ultra-thin, lightweight packs tailored to your toy’s inner structure.
• 
  Ultra-thin Battery for Wearables
  
  as a reference for slim, body-contact or wearable-type children’s toys.
• 
  Consumer Electronics Power Solution
  
  for desktop, companion, and smart-home-connected AI toys.
• 
  PKNERGY Battery FAQ
  
  for common questions about customization, safety, and shipping of lithium packs.
• 
  Contact Us
  
  to start a new toy battery project or request samples.

By involving PKNERGY early in your project, you can ensure that battery selection, structure design, and safety compliance
all move in the same direction—reducing redesign risk and shortening time-to-market for your AI toys.