Compliant Battery Supports for PSA Bonding and Repair
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Solution Overview
Problem
Existing systems for mobile computing devices face challenges in removing and repairing batteries bonded with pressure sensitive adhesive (PSA), as it becomes difficult to do so without damaging the battery, device enclosure, or other components, leading to high re-work costs and material waste.
Innovation Solution
The use of compliant supports applied on the battery enclosure to hover the battery above the PSA, allowing for translational and rotational movement during testing, and subsequent bonding by applying a downward force to overcome the upward force exerted by the compliant supports, enabling easy removal and reinstallation without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery is bonded directly to the device enclosure using PSA, then the bonding strength and structural stability are improved, but the ease of repair deteriorates because the battery cannot be removed without damaging components
Solution Approach 1:
A release liner is introduced as an intermediary layer between the battery and the PSA. The release liner has a first adhesive layer that bonds to the battery and a second adhesive layer that bonds to the PSA, allowing the battery to be securely attached during operation but easily removed by peeling off the release liner when repair is needed
Solution Approach 2:
The bonding system is segmented into multiple functional layers: the PSA layer on the enclosure, the release liner with dual adhesive layers, and the battery. This segmentation allows the release liner to serve as a removable interface that provides both secure bonding and easy removal capabilities
2Ease of repair
If removable fixtures with temporary adhesive are used to hold the battery during testing, then the ease of repair is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The release liner combines multiple functions into a single component: it serves as both the bonding interface and the removal mechanism. The dual-adhesive release liner eliminates the need for separate removable fixtures, positioning aids, and temporary bonding systems that would otherwise be required
Solution Approach 2:
The release liner performs multiple functions: providing adhesive bonding during assembly, maintaining battery position during testing, and enabling easy removal for repair. This multi-functional design replaces what would otherwise require multiple separate components and operations
3Ease of operation
If the battery FPC is made longer to allow battery lifting during fixture removal, then the ease of operation is improved, but the product cost increases
Solution Approach 1:
The release liner acts as an intermediary that enables battery removal without requiring the battery to be physically lifted. By peeling the release liner, the battery can be detached while remaining in its original position, eliminating the need for extended FPC to provide lifting leverage
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 method reduces the cost of repairs by allowing for easy removal and reinstallation of the battery without damaging the components, eliminating the need for removable fixtures and temporary adhesives, and streamlining the testing and assembly process.
Implementation Method 1
The compliant supports apply an upwards force to hover a battery above the PSA while preventing the battery from coming in contact with the PSA. The compliant supports compress and/or collapse to enable the battery to bond to the battery enclosure via the PSA.
Implementation Method 2
The compliant supports compress and/or collapse to enable the battery to bond to the battery enclosure via the PSA. For example, a downwards force may be applied to the battery to overcome the upwards force to bond the battery to the PSA while retaining at least one of the one or more compliant supports.
Data Source
AI summary
Compliant supports hover a battery above pressure sensitive adhesive (PSA) when testing a computing device and before the battery is bonded to an enclosure. The compliant supports are placed along a surface of the enclosure such that at least a portion of each of the compliant supports extends above the PSA. The compliant supports apply an upwards force on the battery to maintain a gap between the battery and the PSA. After electrical testing of the computing device, the battery is brought into contact with the PSA while retaining at least one of the compliant supports in the enclosure. In some embodiments, a downwards force is applied to the battery to overcome the upwards force from the compliant supports.