I’m building a portable electronics product that I want to have mass-produced and sold to consumers. Besides the obvious electronic protection (overtemperature, over-/undercharge), I’m worried about physical protection.
For example, it seems li-ion batteries can in rare circumstances swell up. Should I leave some extra space to allow the battery to swell and if yes, how much? I plan on covering all sharp edges (from through holes sticking through the pcb) so they can’t cut the battery. Any other measures that I should be thinking of? Any advice or pointers to information would be greatly appreciated.
Different batteries expand different amount, depends on their surface area vs volume among the other things. You can usually get this data from the battery supplier for the specific battery. Numbers like 10% of thickness can often be seen.
Oh, and it is not “in rare circumstances” it is “always”.