Lead Holding Structure for Battery Wire Pinch Prevention
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Solution Overview
Problem
In power supply devices, the excess length of lead wires often causes them to wobble and get pinched when the lid closes, leading to increased risk of damage and requiring additional time and resources for securing the lead wire with cable ties.
Innovation Solution
A power supply device with a lead holding structure that includes a circuit board with a cut-out and a pull-out blocker on the lead wire, which restricts the lead wire's length and position to prevent pinching and ensure proper connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lead wire is made sufficiently long to ensure ease of work when connecting connectors, then the workability is improved, but the lead wire is likely to wobble and get pinched when the lid closes
Solution Approach 1:
The patent applies preliminary action by pre-positioning the lead wire within the housing using a lead holder before the lid is closed. The lead holder is installed in advance to guide and secure the lead wire, preventing it from moving or getting pinched during subsequent operations. This advance preparation eliminates the need for cable ties and manual securing while maintaining sufficient lead wire length for connector connection workability.
2Object-affected harmful factors
If the lead wire is tied with a cable tie to prevent wobbling and pinching, then the risk of pinching is reduced, but the device complexity and manufacturing time increase
Solution Approach 1:
The lead holder is designed to automatically secure the lead wire through its own structure without requiring additional components like cable ties or screws. The holder's geometry itself provides the securing function, making the system self-sufficient. This eliminates the need for separate fastening elements and reduces assembly steps while effectively preventing lead wire movement and pinching.
Solution Approach 2:
The patent merges the lead wire securing function into the existing lead holder structure rather than using a separate cable tie system. The lead holder combines multiple functions: guiding the lead wire, securing it in position, and preventing movement during lid closure. This integration eliminates additional components and simplifies the overall structure.
3Object-affected harmful factors
If the lead wire is shortened to avoid pinching, then the pinching risk is reduced, but the amount of stroke of the board-side connector is reduced, hardly performing the work
Solution Approach 1:
The lead holder is installed in advance to pre-position the lead wire within the housing, ensuring it has sufficient length and proper positioning for connector connection operations. This preliminary arrangement allows the lead wire to maintain adequate stroke for workability while being secured to prevent pinching during lid closure.
Data Source
AI summary
A power supply device includes a battery cell, a circuit board including a board-side connector, a lead wire connected to the board-side connector, an open case accommodating the battery cell, the lead wire, and the circuit board therein, a lid case closing an opening surface of the open case, and a pull-out blocker disposed on the lead wire. The circuit board has a first main surface, a second main surface opposite to the first main surface, and a side surface connected to the and second main surfaces. The side surface has a cut-out therein. The lead wire extends from a first tip end to a second tip end through the cut-out of the circuit board. The first tip end is connected to the board-side connector. The pull-out blocker is disposed at an intermediate position of the lead wire between the first and second tip ends. The pull-out blocker protrudes from the lead wire to be prevented from passing through the cut-out. The pull-out blocker is configured to prevent a portion of the lead wire extending from the first tip end to the cut-out of the circuit board from being greater than or equal to a predetermined length.