Snap-On Battery Clip Assembly for Balanced PCB Contact Stress
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery clips for medical devices impose asymmetrical mechanical stresses on circuit carriers, require complex processes like heat staking, and lack independent adjustment of contact normal forces, leading to deformation and inconsistent connections.
Innovation Solution
A battery clip with a conductive housing and flexible fingers that securely retains a battery to circuit carriers without soldering, allowing for easy replacement and reliable electrical contact through a snap-on mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single-sided contacting is used to connect battery to circuit carrier, then the structure is simplified, but asymmetrical mechanical stresses occur on PCBA tracks and components
Solution Approach 1:
The patent applies asymmetry principle by designing a dual-sided contacting structure where contact points are distributed on both sides of the circuit carrier. This symmetric arrangement of contact points balances the mechanical stress distribution, preventing the asymmetrical stresses that would occur with single-sided contacting while maintaining structural simplicity.
2Ease of manufacture
If frictional connection via plastic housing is used, then assembly is simplified, but a long tolerance chain is created leading to higher contact normal forces and deformation
Solution Approach 1:
The patent replaces the frictional mechanical connection via plastic housing with a direct electrical contact mechanism. The contacting structure establishes reliable electrical connections through controlled contact points that bypass the plastic housing friction path, thereby eliminating the long tolerance chain and its associated issues with contact normal force variations and deformation.
3Strength
If plastic pins with heat staking are used to secure battery, then mechanical retention is achieved, but complex thermal processes introduce thermal stresses
Solution Approach 1:
The patent extracts the heat staking process and thermal stress introduction from the battery securing mechanism. The design achieves mechanical retention through the structural integration of the contacting elements with the circuit carrier, eliminating the need for plastic pins and heat staking while maintaining secure battery retention without complex thermal processes.
4Reliability
If three contact points are used for power supply, then electrical connection is established, but independent adjustment of contact normal force is not possible
Solution Approach 1:
The patent applies segmentation by designing multiple independent contact points that can be individually optimized. Each contact point is structurally independent, allowing for independent adjustment of contact normal force at each point. This segmented approach maintains reliable electrical connection while providing the adaptability to adjust contact forces independently according to specific requirements.
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
The solution provides a cost-effective, reliable, and scalable connection that minimizes stress on circuit carriers, reduces device thickness, and ensures consistent electrical contact without relying on custom batteries or complex manufacturing processes.
Implementation Method 1
the at least one flexible conductive finger is configured for contacting the battery being arranged on a first side of the circuit carrier being inserted into the receptacle
Data Source
AI summary
A battery clip for retaining a battery to a circuit carrier is disclosed along with an assembly including a circuit carrier having a plurality of flexible tabs. The battery clip includes a plurality of slots configured to mate with and receive the flexible tabs of the circuit carrier such that the battery clip and the circuit carrier are secured together such that a first terminal of a retained battery physically contacts and is in electrical communication with the circuit carrier's first pad, the battery clip further comprising one or more flexible conductive fingers configured to contact a second terminal of a retained battery to establish an electrical communication between the fingers and the second terminal, and wherein the battery clip includes an electrically conductive material and establishes electrical communication between the fingers and the circuit carrier's second pad.