Battery Textured Surface Mechanical Interlocking for Medical Devices
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Solution Overview
Problem
The challenge in medical devices is to establish a secure, non-toxic, and cost-effective electrical connection between batteries and circuit boards, particularly in environments where traditional bonding agents may be harmful and manufacturing costs are high.
Innovation Solution
A textured conductive surface on the battery, featuring protrusions that partially penetrate the contact surface, providing both physical and electrical connections without the need for harmful bonding agents, which can be integral to the battery casing or applied separately, and can be enhanced with adhesives or deformation to secure the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bonding agents are used to connect battery to circuit board, then connection strength is improved, but toxicity and safety concerns arise
Solution Approach 1:
The patent removes harmful bonding agents from the connection system entirely. Instead of using adhesive layers between the battery and circuit board, the invention extracts the bonding function and replaces it with mechanical interlocking through textured surfaces that directly engage with contact pads, eliminating toxic materials while maintaining connection strength
Solution Approach 2:
The textured surface acts as an intermediary mechanism between the battery and circuit board. Rather than relying on chemical bonding agents, the patent introduces a physical intermediary structure (textured surface with protrusions) that mediates the connection by mechanically engaging with the contact pad, providing both electrical conductivity and mechanical strength without toxicity
2Reliability
If textured surface with protrusions is used to penetrate contact surface, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into the textured surface structure. The same protrusions that provide mechanical interlocking also serve as electrical contacts, eliminating the need for separate bonding agents and simplifying the overall manufacturing process despite the textured surface complexity
Solution Approach 2:
The patent changes the surface parameter of the battery contact area from smooth to textured. This parameter change enables the protrusions to penetrate and engage with the contact pad, improving connection reliability through mechanical interlocking while the texturization process itself can be integrated into existing manufacturing workflows
3Strength
If adhesive layers are applied to enhance connection, then connection strength is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent extracts and eliminates adhesive layers from the manufacturing process. By using textured surfaces that mechanically interlock with contact pads, the invention removes the time-consuming steps of applying, positioning, and curing adhesives, thereby reducing manufacturing time while maintaining connection strength through pure mechanical engagement
Data Source
AI summary
A method of establishing a physical and electrical connection between a battery and a circuit board are described. The methods include applying a texture formed from conductive material to a portion of a battery exterior surface. The texture is a region populated by a plurality of protrusions. Protrusions may be configured to partially perforate and lodge within a contact surface secured to a circuit board. The battery with a texture surface may be pressed against the circuit board resulting in perforation of the contact surface by the region of protrusions. The methods may result in a battery and circuit board in electrical communication, and suitable for use within a variety of medical devices.