Battery Lead Insulator Structure for Vaporizer Short-Circuit Isolation
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Solution Overview
Problem
Vaporizer devices are susceptible to short circuits due to exposed battery terminals, which can lead to safety issues and device malfunction.
Innovation Solution
A vaporizer device with a power source and printed circuit board (PCB) is designed to include an insulator surrounding the power source lead, mechanically coupled to the PCB, to prevent short circuits by electrically isolating the battery terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If exposed battery terminals are used in the vaporizer device, then the device structure is simpler and easier to manufacture, but the device becomes susceptible to short circuits and safety issues
Solution Approach 1:
An insulator is introduced as an intermediary component between the battery terminals and the PCB/tray assembly. This insulator mechanically couples to both the battery and the tray/PCB, providing electrical isolation while maintaining structural connection. The insulator prevents direct contact between exposed battery terminals and conductive components, thereby eliminating the short circuit risk while preserving the simple manufacturing approach of using exposed terminals.
2Reliability
If an insulator is added to surround the power source lead, then short circuit protection is improved, but the device complexity increases
Solution Approach 1:
The insulator is designed to mechanically couple to both the battery and the tray/PCB assembly, merging multiple functions into a single component. It simultaneously provides electrical isolation, structural support, and mechanical coupling between components. This integration approach minimizes the increase in device complexity while achieving reliable short circuit protection.
Solution Approach 2:
The insulator is implemented as a shell-like structure that surrounds the power source lead and battery terminals. This shell configuration provides comprehensive electrical isolation without requiring complex internal structures or multiple separate components, thereby limiting the increase in device complexity.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
Aspects of the current subject matter relate to methods and system for protecting a battery cell and/or a /pack of multiple battery cells serving as a power source of a vaporizer device from developing a short-circuit in a vaporizer device. In one aspect, a vaporizer device (100) is provided. The vaporizer device may include a power source (112) including a battery and a power source lead extending outward from a distal end of the battery. The vaporizer device may further include a printed circuit board (PCB) (104) electrically coupled to the power source via the power source lead extending outward from the battery. The vaporizer device may further include an insulator (202) at least partially surrounding the power source lead. The insulator may be mechanically coupled to at least one of the power source and the PCB.