Electronics Protection - Spring 2016 - (Page 12)
Designing and Managing Custom Battery
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.
Spring 2016 * www.ElectronicsProtectionMagazine.com
Table of Contents for the Digital Edition of Electronics Protection - Spring 2016
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
Calendar of Events
Electronics Protection - Spring 2016