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Samsung Note 7 Investigation Will Blame 'Irregularly Sized' Batteries and Manufacturing Flaws, Says WSJ (theverge.com)

Samsung's official investigation into the cause of widespread faults with the Galaxy Note 7 will blame "irregularly sized" batteries and manufacturing faults, according to a report from The Wall Street Journal. The company is set to announce the results of its inquiry this weekend, but the WSJ claims to have revealed its conclusions early, citing information from "people familiar with the matter." From the report: The WSJ says Samsung hired three independent "quality-control and supply-chain analysis firms" to conduct its investigation, with these firms concluding that two separate faults affected the Note 7. The first fault relates to devices that used batteries made by Samsung subsidiary Samsung SDI. These batteries didn't fit inside the phone properly, which led to overheating and, in some cases, explosions. When reports of the Note 7 fault first emerged last August, executives initially believed the problem was confined to these particular devices. In response, they increased production of the Note 7 using batteries made by Hong Kong-based firm Amperex Technology. According to the official investigation, this rush to ensure there was an adequate supply of Note 7 devices for the market led to the second fault -- with the increased pressure on production creating unknown "manufacturing issues."

11 of 87 comments (clear)

  1. Agrument in favor of modularity by TWX · · Score: 4, Insightful

    Well this is definitely an argument in favor of having some modular components inside of compact electronics like phones. It's understandable that the old PC model with sockets for the electronic parts like memory and microprocessors is not practical in miniaturized devices this small, but it definitely makes sense for devices like batteries, which are not nearly so integrated into the electronics as many other devices, to be removable.

    Had the batteries been removable, Samsung could have recalled these units by correcting battery manufacturing problems and then shipping batteries to the carriers to distribute via store, or directly to consumers in cases where the store might not be an option.

    A couple of coworkers had these phones and basically used them until they were bricked, they loved them so much. A lot of people would have been much less unhappy if a simple battery swap had been an option.

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    Do not look into laser with remaining eye.
    1. Re:Agrument in favor of modularity by hey! · · Score: 5, Interesting

      How much thickness do you think the extra outer layer of plastic adds to the phone? If it has to be more than a millimeter I would be surprised.

      Personally, I think it has more to do with the fact the lithium ion batteries have a finite shelf-life than it does with thickness. That means in two years you need a new phone even if you never added any software to it and managed the battery recharging perfectly. Even if the phone had been sitting in a box all that time it'd have significantly less battery life.

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      Post may contain irony: discontinue use if experiencing mood swings, nausea or elevated blood pressure.
    2. Re:Agrument in favor of modularity by Anonymous Coward · · Score: 2, Interesting

      For the battery to be truly removable and replaceable it would either need to be significantly larger not because of the battery but because there needs to be a frame rigid enough to accept the battery. When the battery is built in this is no longer a consideration. The only other option is to make the battery replacement part a component of the phone frame which is likely to mean only official batteries can be used and they will be expensive.

      As for a recall-and-fix being less expensive - HAHA. It is way easier to just make new phones. #1 collection, shipping, and ensuring the *same* phone makes it back to the customer would be a costly nightmare in and of itself. You would need to start what amounts to an entire logistics company just to complete the process. Then you have to send all the phones to a facility that can make this repair on millions of phones with little time to train employees. You basically still have the labor cost and battery materials cost. Remember Samsung doesn't pay what you do for the parts so they are not losing $600 per phone. They may even be able to negotiate down some of the costs that are "licensing" based in a situation like this and "transfer" that licensing to the replacement phone. The actual "materials" cost of a phone is fairly small. Tons of the cost is IP + there is gross margin.

      The ability to take advantage of bulk services from labor to facility time to shipping is reduced which increases costs significantly compared to the fine tuned "new build" production runs. For phones you can fill an airplane with a batch of complete phones - one flight from china and bam - done. For a recall process you are at the whim of the consumer. Daily -1/10th full planes? Market rate shipping?

  2. OK, so by Anonymous Coward · · Score: 2, Insightful

    the decision to dump the removable battery really was as brain-dead as it looked.

  3. An anecdote by Anonymous Coward · · Score: 3, Interesting

    I work in print

    Certain professions (architects and some flavors of engineer) have a bad habit of giving very very specific dimensions, like to within 10um over ~1m which promptly get ignored. Not only are they unimportant and unatainable, but the substrates themselves aren't anything like that dimensionaly stable. Sometimes when I point this out to them they get a little bit upset, and give the impression that they feel I am some sort of slap-dash cowboy who couldn't give a fuck about their requirements.

    Now my understanding of prismatic lithium cells is that they are made my laminating foil and plastic together, and then rolling it up into a battery, I'd guess that this is quite a repeatable process but not uber-precise when it comes to finished size. Combine this with the electrodes tendency to expand and contract with charge / discharge cycle then all you need is one over optimistic design engineer to spell disaster.

  4. To thin! by Joe_Dragon · · Score: 3, Insightful

    I don't want an super thin phone, why not make it bit bigger to have an better battery / one you can swap!

  5. Would the trendy customer please stand up? by Opportunist · · Score: 4, Interesting

    I actually started going out of my way to ask around among people that I run into (at meetings, conferences, etc) whether they want slimmer phones. Even the markedroids didn't give a shit.

    Who the hell wants those phones thinner? Nobody I know cares. Yes, we don't want the inch-thick bricks from the 1990, no doubt about this, but phones have been "thin enough" for well over 5 years now.

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    We used to have a Bill of Rights. Now, with the rights gone, all we have left is the bill.
  6. It's that time again... by nightfire-unique · · Score: 2

    I've got upwards of $1000USD to spend on my next phone. It will not be spent on any device which has a battery glued in.

    Wany my money, Samsung? Stop gluing batteries into your flagship phones.

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    A government is a body of people notably ungoverned - AC
  7. Probably why Apple only has a $600B market cap. by Brannon · · Score: 2

    If they would just make some thicker phones then they could finally make some money.

  8. Out-of-the-box solution: battery in protector. by aussersterne · · Score: 2

    Instead of placing the battery inside the handset, make a handset that just has a connector on it (wouldn't have to be a bulky, thick connecter like the USB series, could be done in any number of ways, including contacts on the back.

    Open up the design, then let case manufacturers include batteries in their cases, since people overwhelmingly use cases anyway. Now the phone is very thin, so the case can be thicker to accommodate a battery.

    Consumers needing long, long battery life can choose a wacky big case. Consumers needing very little battery life can choose a case with a battery that gets them close to current thickness levels. Need a new battery? Replace your $60 case instead of your $700 phone. Going on vacation? Get a fat silicone case with a fat, fat battery in it, just for the trip.

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    STOP . AMERICA . NOW
    1. Re:Out-of-the-box solution: battery in protector. by Jaime2 · · Score: 4, Insightful

      So you want someone to invent the Moto Z?