Battery Bridge Activation via Welding Air Gaps
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Solution Overview
Problem
Current methods for activating electronic devices, particularly implants, are inefficient and unreliable due to the complexity of soldering processes, material fatigue in plug-in contacts, and the need for manual handling of temporary insulators, which are time-consuming and not cost-effective.
Innovation Solution
A battery bridge with electrically conductive contact elements and an insulator, where the contact elements are initially separated by a predefined air gap, allowing for automated welding to create a permanent electrical connection, enabling simple and economical activation of electronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If soldering method is used to close the circuit between two adjacent soldering faces, then the circuit can be activated, but the process cannot be reliably automated due to influence from solder amount, temperature, fluxing agent, and surface cleanliness
Solution Approach 1:
The patent replaces the manual soldering process with a mechanical pressing system. A bridge component with conductive elements is pressed onto contact pads, establishing electrical connection through mechanical contact rather than thermal soldering. This eliminates the need for temperature control, flux application, and solder amount management, enabling reliable automation.
2Productivity
If temporary insulator and manual handling method is used for battery bridge activation, then accidental initialization can be avoided, but the process becomes time-consuming and requires fine motor skills that cannot be automated
Solution Approach 1:
The patent removes the temporary insulator entirely from the design. Instead of using insulating material that must be manually removed, the bridge component is designed with conductive elements that are initially separated by air gaps or insulating structures that are already integrated into the component geometry, eliminating the need for separate insulator removal steps.
Solution Approach 2:
The bridge component is designed to be self-activating through the pressing operation itself. The mechanical act of pressing the bridge onto the contact pads simultaneously establishes electrical connection and activates the circuit, without requiring separate manual interventions for insulator removal or additional activation steps.
3Ease of manufacture
If bonding method with friction welding or laser welding is used to close the circuit, then the circuit can be activated, but high forces occur that require adhesives which cannot be used in electronic implants
Solution Approach 1:
The patent uses a pressing force that is sufficient to establish reliable electrical contact through the conductive elements and contact pads, but does not exceed the threshold that would require adhesive bonding. The mechanical connection is designed to achieve the necessary contact pressure for electrical conduction without generating the extreme forces that would necessitate adhesive use.
4Ease of operation
If plug-in contact or spring contact is used for battery bridge, then the circuit can be activated, but material fatigue and contact resistance changes over time reduce product reliability
Solution Approach 1:
The bridge component is designed with conductive elements and geometric features that pre-establish the optimal contact configuration. The pressing operation permanently deforms or sets the conductive elements into their final operational position, eliminating subsequent movement, vibration, or contact resistance changes that would occur with reusable plug-in or spring contacts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for reliable, automated activation of electronic devices, reducing manufacturing time and eliminating the need for manual handling, while ensuring consistent performance over the device's lifespan.
Implementation Method 1
it can be transferred, by welding the first contact element and the second contact element to one another, into a second ('closed') state, in which the air gap between the first contact element and the second contact element is permanently closed electrically conductively
Data Source
AI summary
A battery bridge for an electronic device, preferably for an electronic implant, has an electrically conductive first contact element, an electrically conductive second contact element and an insulator. The first contact element and the second contact element comprise a weldable material. In a first state of the battery bridge, the first contact element is distanced from the second contact element via a predefined air gap and the first contact element is electrically insulated from the second contact element by the air gap and the insulator. The battery bridge is formed in such a way that it can be transferred, by welding the first contact element and the second contact element together, into a second state, in which the air gap between the first contact element and the second contact element is closed electrically conductively, at least in part. A method for activating such an electronic device is also disclosed.