OEM Power Bank Function Bicycle Front Light

This product integrates a high‑capacity lithium‑ion power bank with a front‑mounted LED illumination unit, allowing cyclists to charge portable devices while maintaining visibility. The design targets OEMs that require a sealed, vibration‑resistant module compatible with standard handlebar mounts and DIN‑rail power‑distribution systems.

Electrical Performance

The built‑in power bank delivers a nominal capacity of 10 Ah at 3.7 V, providing up to 37 Wh of stored energy. Output ports support 5 V/2.4 A USB‑A and 5 V/3 A USB‑C, enabling simultaneous charging of a smartphone and a GPS unit.

The LED driver operates at a constant current of 350 mA, producing a luminous flux of 800 lumens with a color temperature of 6000 K. Efficiency exceeds 85 % at full load, minimizing heat generation and extending battery life.

Mechanical & Environmental Specs

The housing is constructed from CNC‑machined aluminum alloy 6061‑T6, providing a tensile strength of 310 MPa and a weight of 180 g. Mounting interface uses a standard 31.8 mm handlebar clamp with a torque rating of 5 Nm.

Ingress protection is rated IP65, ensuring resistance to dust ingress and low‑pressure water jets from any direction. Operating temperature range spans –20 °C to +55 °C, with storage limits of –30 °C to +70 °C.

Vibration testing follows IEC 60068‑2‑6, confirming functionality after 10 g RMS sweep from 5 Hz to 500 Hz for 30 minutes per axis.

Applications

Urban commuting bicycles benefit from the dual‑function design, as riders can power navigation lights and charge a phone without adding separate battery packs.

Off‑road and mountain‑bike platforms utilize the rugged housing and vibration resistance to maintain illumination during rough terrain while keeping essential electronics powered.

Fleet operators of e‑bike sharing services adopt the module to reduce maintenance points, combining lighting and auxiliary power in a single serviceable unit.

Customization Options

• Battery capacity adjustable from 5 Ah to 20 Ah in 2.5 Ah increments.
• LED flux configurable between 400 lm and 1200 lm with optional programmable flashing modes.
• Connector types include USB‑A, USB‑C, Micro‑USB, and proprietary DC barrels.
• Housing finishes available in matte black, anodized silver, or custom powder‑coat colors.
• Mounting adapters for 25.4 mm, 31.8 mm, and 35 mm handlebar diameters.

Quality Control Philosophy

Each unit undergoes incoming material verification, where aluminum alloy composition is checked via spectrometer and lithium‑ion cells are screened for internal resistance below 30 mΩ.

In‑process inspections include dimensional CMM checks of the housing (±0.02 mm tolerance) and functional tests of LED driver regulation at 10 %, 50 %, and 100 % load.

Final validation consists of a 48‑hour burn‑in cycle at 40 °C ambient temperature, followed by IP65 spray testing and a 500‑charge‑discharge cycle to confirm capacity retention above 90 %.

Typical Specifications

Frequently Asked Questions

• Can the battery capacity be scaled for higher‑range e‑bikes? Yes, the lithium‑ion pack can be increased up to 20 Ah while maintaining the same housing dimensions.
• What information is required to obtain a quotation? Required details include desired capacity, LED flux, connector types, mounting diameter, order quantity, and any specific environmental certifications.
• Which materials are available for the housing? Standard is 6061‑T6 aluminum; alternatives include ABS‑PC blend for weight‑critical applications or stainless steel for corrosion‑prone environments.
• How is quality inspected before shipment? Each lot receives 100 % functional test, IP65 verification, and a sample‑based life‑cycle test (500 cycles) with results documented in the batch report.
• What packaging options protect the units during transit? Units are packed in anti‑static foam inserts within double‑wall corrugated cartons; palletization with stretch wrap and corner boards is available for large orders.
• What is the typical production lead time? Lead time ranges from 3 to 6 weeks depending on customization complexity and current capacity; exact schedule is confirmed upon receipt of the technical datasheet.

Get in Touch

To discuss your OEM requirements for a power‑bank‑integrated bicycle front light, please share your technical specifications and target volume. Our engineering team will review the details and provide a feasibility assessment, sample plan, and detailed quotation.

Request a quotation or technical consultation