The battery holder shrapnel becomes loose after frequent plugging and unplugging, which will affect the stable connection between the device and the battery and even cause power outages. Therefore, appropriate reinforcement measures need to be taken. First of all, the cause of the loosening should be clarified. Usually, the elastic fatigue of the shrapnel caused by long-term stress causes the elastic deformation ability of the metal material to decrease, resulting in the weakening of the elastic force of the shrapnel and the inability to fit the battery electrode tightly. In addition, the friction during the plugging and unplugging process may cause the wear of the shrapnel positioning structure, causing its position to shift, which is also a common factor of loosening. In response to these problems, the reinforcement method needs to start from multiple aspects such as restoring the elastic force of the shrapnel, enhancing the structural stability, and improving the contact environment.
Restoring the elastic force of the shrapnel is the core of solving the loosening problem. For shrapnel whose elastic fatigue is not serious, you can try to restore its deformation ability through physical adjustment. For example, use a small tool (such as tweezers or toothpicks) to carefully bend the shrapnel outward to restore its initial bending angle, thereby increasing the pressure between the shrapnel and the battery electrode. During operation, you need to pay attention to uniform strength to avoid excessive force that may cause the shrapnel to break or deform excessively. Especially for shrapnel with thinner materials, you need to be more careful to avoid secondary damage.
If the elastic fatigue of the shrapnel is more serious and physical adjustment is difficult to work, you need to consider replacing the shrapnel. When selecting a new shrapnel, you should ensure that its material is consistent with or better than the original shrapnel. Common shrapnel materials include phosphor bronze, beryllium copper, etc. These materials have good elasticity and wear resistance. When replacing, first use tools to remove the shell of the battery holder, carefully remove the old shrapnel, pay attention to record the installation position and angle of the shrapnel, and then install the new shrapnel in place according to the original structure to ensure that the contact of the shrapnel corresponds accurately to the position of the battery electrode to avoid new contact problems caused by installation deviation.
Enhancing the structural stability of the shrapnel can effectively prevent the recurrence of looseness. One method is to add a reinforcement component to the fixed end of the shrapnel, such as using a high-temperature resistant adhesive (such as epoxy resin glue) to bond the shrapnel to the substrate of the battery holder to reduce the displacement of the shrapnel during the insertion and removal process. Before bonding, the surface of the shrapnel and the substrate should be cleaned to ensure that there is no oil or dust to improve the adhesion of the glue. Another method is to strengthen the shrapnel through mechanical structure, such as adding metal brackets or buckles around the shrapnel to fix the shrapnel in a specific position to limit its unnecessary shaking. This method is suitable for devices with high stability requirements.
Improving the contact environment of the shrapnel can also indirectly play a reinforcing role. Regularly cleaning oxides, dirt and other impurities on the shrapnel contacts and battery electrodes can reduce contact resistance and avoid damage to the shrapnel caused by additional plug-in and pull-out forces due to poor contact. You can use anhydrous alcohol and cotton swabs to gently wipe the contact surface. For stubborn stains, you can use an eraser to gently polish. In addition, applying a layer of conductive paste on the surface of the shrapnel contact can not only enhance the conductive performance, but also reduce the friction resistance during plug-in and pull-out to a certain extent, reduce the wear rate of the shrapnel, and thus extend the service life of the shrapnel.
For some battery holder shrapnels with design defects, the overall structure may need to be optimized. For example, if the fixing method of the shrapnel is too simple and is only fixed by a single solder point, the number of solder points can be increased or a more solid welding process (such as laser welding) can be used without affecting the circuit to improve the connection strength between the shrapnel and the substrate. For another example, if the plug-in and pull-out direction of the shrapnel is unreasonable with the force direction, the installation angle of the shrapnel can be adjusted to make the direction of the plug-in and pull-out force consistent with the elastic deformation direction of the shrapnel, reducing the damage to the shrapnel caused by the lateral stress.
In daily use, reasonable operation can also prevent the shrapnel from loosening. When plugging and unplugging the battery, try to keep the force in the vertical direction and avoid tilting or shaking to reduce the lateral force on the shrapnel. At the same time, avoid frequent plugging and unplugging of batteries. For devices that are not used for a long time, the battery can be removed and stored to reduce the number of times the shrapnel is worn. In addition, during the equipment design stage, select a reliable quality battery holder assembly to ensure that the material and process of the shrapnel meet the use requirements, and reduce the probability of loosening problems from the source.
To solve the problem of battery holder shrapnel loosening after frequent plugging and unplugging, it is necessary to select appropriate reinforcement methods according to the degree of looseness and specific reasons, and pay attention to daily maintenance and reasonable use. Through the comprehensive use of multiple measures such as restoring elastic force, replacing parts, structural reinforcement, improving contact environment, optimizing design and standardizing operation, the stability and reliability of the shrapnel can be effectively improved to ensure the normal operation of the equipment.
