Battery Pin Insulation for Electronic Device Power Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electronic devices with built-in batteries face issues where the insulating sheet between the battery lead terminal and wiring electrode pad can tear, preventing power from being fed to the electronic circuit module due to insufficient pulling force to overcome friction, leading to device defects.
Innovation Solution
The electronic device design incorporates a pin inserted through a casing hole, with a pressure-sensitive adhesive sheet supporting the pin, ensuring it can be easily pulled out without tearing, and the pin's height separates the battery lead terminal from the wiring layer, allowing for electrical insulation and reliable power connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating sheet is disposed between the battery lead terminal and wiring electrode pad, then electrical insulation is achieved, but the insulating sheet may tear when pulling force is applied to activate the battery
Solution Approach 1:
The insulating function is segmented from the adhesive function by using two separate components: an insulating sheet and an adhesive sheet. The insulating sheet provides electrical insulation without bearing pulling forces, while the adhesive sheet provides bonding strength. This segmentation resolves the contradiction by allowing each component to optimize its specific function without compromise.
Solution Approach 2:
The adhesive sheet acts as an intermediary between the insulating sheet and the battery assembly. It transfers the pulling force from the battery to the adhesive sheet itself rather than to the insulating sheet, protecting the insulating sheet from tearing while still enabling the necessary mechanical activation.
2Ease of operation
If pulling force is applied to the insulating sheet to activate the battery, then the battery can be turned ON, but the insulating sheet may tear halfway due to insufficient pulling force margin
Solution Approach 1:
The adhesive sheet serves as a mediator that absorbs and distributes the pulling force during battery activation. By positioning the adhesive sheet between the battery and the insulating sheet, it ensures that the full pulling force is applied to the adhesive sheet rather than directly to the insulating sheet, preventing tears while enabling reliable activation.
Solution Approach 2:
The adhesive sheet provides beforehand cushioning by being positioned to absorb potential excessive pulling forces during battery activation. This pre-positioned protective layer prevents the insulating sheet from experiencing force concentrations that could cause tearing, ensuring reliable activation without damage.
3Reliability
If the pin height is increased to separate the lead terminal from the wiring layer, then electrical insulation is improved, but the device complexity increases
Solution Approach 1:
The pin is designed with multi-functionality, serving both as a mechanical support structure and as an electrical insulation barrier. By positioning the pin to physically separate the lead terminal from the wiring layer, it simultaneously provides mechanical stability and electrical insulation without requiring additional dedicated insulating components, thus reducing overall device complexity.
Solution Approach 2:
The insulating function is merged into the existing pin structure rather than being implemented as a separate component. The pin's physical presence and positioning combine mechanical support with electrical insulation, eliminating the need for additional insulating elements and simplifying the overall device structure while maintaining reliable insulation.
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
This design ensures the electronic device can be powered reliably without tearing the adhesive sheet, improving product reliability and preventing power interruption, allowing continuous operation until the battery is depleted.
Implementation Method 1
a pressure-sensitive adhesive sheet supporting the pin
Data Source
AI summary
An electronic device includes: a casing; a through hole which penetrates a bottom plate of the casing; a pin inserted into the through hole; a battery mounted on the pin inside the casing, wherein the battery includes a first lead terminal connected to an upper face of the battery, and a second lead terminal connected to a lower face of the battery; a first wiring layer disposed inside the casing and connected to the first lead terminal; and a second wiring layer disposed inside the casing to overlap with the second lead terminal in planar view. An upper face of the pin is higher in height than an upper face of the second wiring layer. The pin separates the second lead terminal and the second wiring layer from each other such that the second lead terminal and the second wiring layer are electrically insulated from each other.