Molded SMD Battery Assembly for Humidity and Chemical Protection
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Solution Overview
Problem
Existing methods for protecting active SMD components from environmental influences, such as humidity and chemical attacks, are inadequate, especially for components with high energy density like rechargeable solid-state batteries, which cannot withstand the high temperatures and pressures of conventional soldering or coating processes.
Innovation Solution
A protective assembly comprising at least one active SMD component, metallic wiring, and a protection element, where the protection element, made of epoxy resin or thermal plastic material, encloses the SMD component and parts of the wiring, forming a molded module that shields the component from environmental factors while maintaining compatibility with standard SMT processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional soldering/coating/molding processes are used to protect SMD components, then protection from environmental influences is achieved, but the high temperature/pressure damages active SMD components with high energy density
Solution Approach 1:
The patent applies preliminary protection by coating the active SMD component with a protective layer (such as conformal coating or encapsulation material) before the component is exposed to environmental influences. This preliminary coating shields the sensitive active component from subsequent environmental damage without requiring the component to withstand high temperature/pressure during operation, thereby resolving the contradiction between achieving protection and maintaining component integrity
Solution Approach 2:
The protective system is segmented into multiple functional layers: the active SMD component itself, an intermediate protective coating layer, and an outer encapsulation or housing structure. This segmentation allows each layer to perform its specific function - the active component generates energy, the intermediate layer provides chemical and moisture protection, and the outer layer provides mechanical protection and environmental sealing, thereby protecting the component without exposing it to damaging conditions
2Reliability
If tight housing with special structure and materials is used for batteries, then protection from environmental influences is achieved, but additional assembling costs and reduced reliability in mechanical/electrical connections are introduced
Solution Approach 1:
The patent merges the protective housing function with the mounting structure by integrating the encapsulation material directly onto the PCB or circuit board. Instead of using a separate tight housing that requires additional assembly steps, the protective coating serves dual purposes: protecting the battery from environmental influences and providing the mechanical connection interface to the circuit board, thereby reducing assembly complexity and maintaining connection reliability
Solution Approach 2:
The protective coating or encapsulation material performs multiple functions simultaneously: it provides moisture and chemical protection, serves as an electrical insulator, acts as a mechanical bond to the circuit board, and provides structural support. This multi-functionality eliminates the need for separate specialized housing components and complex assembly processes, resolving the contradiction between protection and assembly simplicity
Data Source
AI summary
In an embodiment an assembly includes at least one surface mounted device (SMD) component, a metallic wiring configured to lead current from the at least one SMD component to an external circuit and at least one protection element is configured to cover all outer surface of the at least one SMD component and at least parts of the metallic wiring, wherein the assembly has a structure of a molded module, and wherein the at least one SMD component includes a rechargeable all solid-state battery.