Electronics Protection - Spring 2016 - (Page 12)

Feature Designing and Managing Custom Battery Pack Enclosures Anton Beck, Battery Product Manager Epec Engineered Technologies Customers are often unfamiliar with battery regulatory requirements, which can lead to complications during the design of plastic enclosures. Understanding some of the design and management elements will help avoid production process complications. With any enclosure, the most important aspect is that the enclosure must be able to support the battery itself. It must also pass rigorous tests, especially when associated with transportation safety certifications. One of the first steps once a customer has approached a manufacturer is to determine the level of design the customer intends and if it is a full design or partial. A full design would allow the manufacturer to be in full working knowledge of the project from the start. The creation of CAD files, progressive meeting schedules, approval stages, and the production volume will be established based on the need and depth of a full or partial design. The production volume will determine the level of tooling required. Tooling can raise costs and/or extend the time of a project's completion. The intention is to always get the design completed first time through because of time involved, cost, and tooling. Most importantly is meeting the transportation certification requirements and the customer's look and feel of the design. Complete Battery Pack Enclosure Customization The complete customization of a battery pack plastic enclosures is available right down to the plastic grade itself. It is important to understand what type of environment the application will be primarily used in and whether it will be used in extreme or mild conditions. The plastic grade will have to be selected to accommodate the appropriate environment. ABS plastic for an example is less expensive however it becomes very brittle when exposed to certain cold temperatures. There are a lot of plastic grades available and in some cases it is possible to create a Hybrid grade. The focus on determining the best plastic grade for any given application starts with the environmental conditions but drop tests and of course transportation certification requirements should be kept in consideration. Branding Your Enclosure Not as complex but just as important is branding. Any customer looking to add their company's branding to the application can do so. Product branding is available by means of labels, digital printing, or etching specific to the application requirements. Sealing the Plastic Enclosure After the internal components have been secured, the enclosure has to be sealed. Take note that sealing the enclosure is part of the final assembly. Ultrasonic wielding is a method that uses high-frequency acoustic vibrations to generate heat. The heat melts the material voiding any need for screws or bolts. Ultrasonic wielding is a robust and economically sound solution. Using screws or bolts are still a viable option. However, having access to surface screws or bolts may be good for repair but also easy access for end users to alter the application. Lastly, glue is another adequate sealing solution, typically used in lower quantities. Securing Internal Components Concerns with internal components shifting during use have options to ensure parts stay in place. The actual product and how it will be used, handled and stored determines how the enclosure will be created. Once there is an understanding on the actual product details, the enclosure would be designed internally. Procedures for securing internal parts include RTVs, designing ribs, combination of glues and in most cases foam spacing - all of which help hold parts in place and minimize any shifting. 12 Spring 2016 * www.ElectronicsProtectionMagazine.com http://www.ElectronicsProtectionMagazine.com

Table of Contents for the Digital Edition of Electronics Protection - Spring 2016

Editor's Choice
Security Considerations for Data Center Intelligent Rack Power Distribution
Five Misconceptions about DRUPS Systems
Designing and Managing Custom Battery Pack Enclosures
Reducing TCO with the Right UPS Architecture and Operating Mode
Industry News
Calendar of Events

Electronics Protection - Spring 2016