As we know Samsung has been investigating the explosion of Note 7 since the recall of devices, however could not locate the problems yet. And the manufacturing engineering company Instrumental has performed a teardown of the device, and found that the battery simply did not have enough physical room for error.
The company suggests Samsung was too aggressive in its internal design margins. This had left no room for the phone’s battery, which, as Instrumental points out, swells up even in normal usage.
Samsung had the tough task for the Note7 to offer better battery life than its predecessor all the while having a slimmer design. The Note7’s Li-Po battery is a “jelly-roll” model, which consists of a positive and a negative layer separated by polymer. It’s what allows energy to flow between the two layers without them touching, because once that happens, the battery explodes due to the increased heat and greater energy transfer because of it.
When batteries are charged, they swell a little. Around 10 percent extra space is required, but the battery entirely filled its 5.2-millimetre-deep pocket, with very little space around the edges. Add the normal pressures of day-to-day handling, and the risk of explosion goes up.
“Looking at the design, Samsung engineers were clearly trying to balance the risk of a super-aggressive manufacturing process to maximize capacity, while attempting to protect it internally,” the teardown reads. “Samsung took a deliberate step toward danger, and their existing test infrastructure and design validation process failed them.”
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