ELECTRICAL AND MECHANICAL EXPERTISE
3D Printing is commonly used for prototype versions of injection-molded enclosure.
For each project, Mobile Power Solutions (MPS) creates and assigns a multi-functional team to support your development efforts. This team may consist of electrical and mechanical design resources, as well as project management, account management, testing and approvals experts, cell technologists, and manufacturing engineering (as dictated by the project scope).
Our staff has decades of experience in their respective domains across all aspects of battery system development, assembly, and manufacturing. This experience has enabled them to sucessfully complete over 1900 projects over two decades. This dedicated team is a natural extension of your design and production team, and guides your team through the battery power aspects of your mobile device development.
In addition to BMS Design and Manufacturing expertise, our Electrical experience includes;
- Electrical contacts and connectors,
- Serial communications protocols (SMBus, I2C, HDQ, CANBus),
- Fusing and interconnects within the cell assembly,
- LED/LCD Integration,
- Addition of buck/boost voltage converters and charging electronics, and
- Electrical insulation (internal) and Electro-Magnetic Interference (EMI).
The range of Mechanical enclosures for Lithium-ion battery packs include shrink-wrap subassemblies, formed metal, cast metal, 3D printed, composite/carbon fiber, and plastic injection-molded enclosures. These enclosures can accommodate a wide range of environmental and regulatory standards, all of which can be verified with our Environmental, Safety, Performance, and Regulatory test capabilities.
Beyond the environmental and regulatory requirements, other Mechanical features to be considered in battery design include;
- Latching mechanisms and connector mating,
- Overmold with ThermoPlastic Elastomer (TPE) parts,
- Carriers or interal structures for cell assembly,
- Heat distribution within the enclosure,
- Sealing the enclosure for Ingress Protection (IP) and immersion (i.e. ultrasonic welding, gluing, screwing, and snap-tight seals),
- Plastic material selection (i.e. PC, ABS, PC/ABS blends, and Fire Resistant (FR) additives), and
- Color selection/matching and Industrial Design (ID).
As an integrated member of your development team, MPS delivers a wide range of Electrical and Mechanical expertise in battery power to your development team.
