High current intrinsically safe battery device

Abstract

An intrinsically safe battery device for an electronic device includes: a battery housing including a battery cavity; a positive terminal connector and a negative terminal connector, each fixedly disposed within the battery housing and including one or more contacts; and a removable battery disposed within the battery cavity. The removable battery includes a positive terminal and a negative terminal, each having one or more corresponding contacts for engaging with one or more contacts of the corresponding positive and negative terminal connectors. Each of the one or more contacts of the positive and negative terminal connectors within the battery housing, and each of the one or more corresponding contacts of the battery's positive and negative terminals, is configured relative to each other to ensure continuous contact is maintained between each of the one or more contacts of the positive and negative terminal connectors within the battery housing, and each of the one or more corresponding contacts of the battery's positive and negative terminals, regardless of how the battery moves within the battery cavity of the battery housing in the lateral, longitudinal, and vertical directions.

Description

Technical Field

[0001] This disclosure generally relates to battery connection devices, such as intrinsically safe battery connection devices for removable high-current batteries. Background Technology

[0002] As is well known, intrinsically safe battery devices are used to protect electronic equipment and personnel in potentially hazardous situations such as dangerous environments and high-current applications. For example, electricians, linemen, and construction workers may use equipment and tools with high voltage and high current in their daily work, in environments where flammable gases may be present. Without intrinsically safe design, high-current electronic equipment is at risk of short circuits and sparks, which could eventually ignite surrounding gases. Such short circuits and / or sparks can be caused by the momentary disconnection of corresponding contacts between the battery and the main electronic device. For example, dropping and / or shaking the electronic device can cause a disconnection. To prevent disconnection, intrinsically safe designs for high-current power supplies typically employ soldered wire connections or other fixed connections that prevent the removal of one or more batteries. If the battery cannot be removed from the main electronic device, the lifespan of the electronic device will be determined by the battery's lifespan, or battery maintenance and replacement will be cumbersome and laborious.

[0003] Therefore, the applicant believes that it would be advantageous to provide an intrinsically safe battery device that can overcome the shortcomings of known solutions. Summary of the Invention

[0004] The embodiments described herein provide intrinsically safe battery devices suitable for a variety of applications, including high-current lighting equipment, communication equipment, and power tools. These intrinsically safe battery devices allow for the use of removable batteries in high-current applications while significantly reducing or eliminating the risk of circuit interruption and sparks (arcs). Furthermore, the intrinsically safe battery device provides redundancy in the connection between the electronic device and the removable battery to prevent arcing in the event of a contact failure at some point between the electronic device and the battery. The battery casing provides limited space for battery displacement, further reinforcing the connection between the electronic device and the battery.

[0005] In one embodiment, an intrinsically safe battery device for an electronic device may be generally defined as including: a battery housing including a battery cavity; a positive terminal connector fixedly disposed within the battery housing and including one or more contacts; a negative terminal connector fixedly disposed within the battery housing and including one or more contacts; and a removable battery disposed within the battery cavity, the battery including a positive terminal and a negative terminal, the positive terminal having one or more corresponding contacts for engaging with one or more contacts of the positive terminal connector, and the negative terminal having one or more corresponding contacts for engaging with one or more contacts of the negative terminal connector. Each of the one or more contacts of the positive and negative terminal connectors within the battery housing, and the one or more corresponding contacts of the positive and negative terminals of the battery, may be configured relative to each other to ensure continuous contact between the contacts regardless of how the battery moves within the battery cavity of the battery housing in the lateral, longitudinal, and vertical directions.

[0006] In some embodiments, one or more contacts of the positive and negative terminal connectors may be blade contacts, and corresponding contacts of the positive and negative battery terminals may include opposing spring-biased contacts extending into corresponding contact receiving channels. Each of the blade contacts of the positive and negative terminal connectors within the battery housing, and the corresponding opposing spring-biased contacts of the positive and negative battery terminals, may be configured relative to each other to ensure continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts regardless of how the battery moves laterally within the battery cavity. The positive and negative terminal connectors may each include at least three blade contacts, and each of the positive and negative battery terminals may each include at least three corresponding contact receiving channels, wherein opposing spring-biased contacts extend into each corresponding contact receiving channel. The at least three blade contacts of the positive terminal connector and the at least three blade contacts of the negative terminal connector may be redundant. The opposing spring-biased contacts of the battery's positive terminal and the opposing spring-biased contacts of the battery's negative terminal can be redundant. The battery casing can be configured to limit the battery's maximum travel in the lateral direction, the maximum travel in the longitudinal direction, and the maximum travel in the vertical direction.

[0007] The blade contacts of the positive and negative terminal connectors are configured with sufficient length relative to the positive and negative terminals of the battery, and to the battery's maximum stroke in the longitudinal direction, to ensure continuous contact between each blade contact and at least one corresponding spring-biased contact of the positive and negative terminals when the battery reaches its maximum stroke in the longitudinal direction. The blade contacts of the positive and negative terminal connectors are also configured with sufficient height relative to the positive and negative terminals of the battery, and to ensure continuous contact between each blade contact and at least one corresponding spring-biased contact of the positive and negative terminals when the battery reaches its maximum stroke in the vertical direction.

[0008] In response to battery displacement in the longitudinal direction, the contact point on each of the one or more blade contacts may change in the longitudinal direction. In response to battery displacement in the vertical direction, the contact point on each of the one or more blade contacts may change in the vertical direction. Contact may occur at the contact point between one or more blade contacts of the positive and negative terminals of the battery and at least one corresponding spring-biased contact of the positive and negative terminals. In response to battery displacement in the lateral direction, at least one corresponding spring-biased contact of the positive and negative terminals of the battery may change position in the lateral direction. In response to battery displacement in at least one of the longitudinal, vertical, and lateral directions, the blade contacts of the positive and negative terminals of the connector may maintain contact with at least one corresponding spring-biased contact of the positive and negative terminals of the battery. In response to the battery displacing in the lateral direction to its maximum travel, the contact between each of one or more blade contacts of the positive and negative terminals of the battery and the two corresponding spring-biased contacts of the positive and negative terminals can be transformed into contact between each of one or more blade contacts of the positive and negative terminals and only one of the corresponding spring-biased contacts of the positive and negative terminals of the battery.

[0009] In some embodiments, one or more contacts of the positive and negative terminal connectors may each include opposing spring-biased contacts extending into corresponding contact receiving channels, and each of one or more corresponding contacts of the battery positive and negative terminals may include blade contacts. Each of the blade contacts of the battery positive and negative terminals, and the corresponding opposing spring-biased contacts of the positive and negative terminal connectors within the battery housing, may be configured relative to each other to ensure continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts regardless of how the battery moves laterally within the battery cavity. The battery positive and negative terminals may each include at least three blade contacts, and the positive and negative terminal connectors may each include at least three corresponding contact receiving channels, wherein opposing spring-biased contacts extend into each contact receiving channel. The at least three blade contacts of the battery positive terminal may be redundant, and the at least three blade contacts of the battery negative terminal may be redundant. The opposing spring-biased contacts of the positive terminal connector can be redundant, as can the opposing spring-biased contacts of the negative terminal connector.

[0010] The battery casing can be configured to limit the maximum travel of the battery in the lateral direction, the maximum travel of the battery in the longitudinal direction, and the maximum travel of the battery in the vertical direction. The blade contacts of the battery's positive and negative terminals can be configured with sufficient length relative to the positive and negative terminal connectors and the maximum travel of the battery in the longitudinal direction to ensure continuous contact between the blade contacts and at least one of the corresponding spring-biased contacts of the positive and negative terminal connectors when the battery reaches its maximum travel in the longitudinal direction. The blade contacts of the battery's positive and negative terminals can be configured with sufficient height relative to the positive and negative terminal connectors and the maximum travel of the battery in the vertical direction to ensure continuous contact between the blade contacts and at least one of the corresponding spring-biased contacts of the positive and negative terminal connectors when the battery reaches its maximum travel in the vertical direction.

[0011] In response to displacement of the battery in the longitudinal direction, the contact point on each of the one or more blade contacts may change in the longitudinal direction. In response to displacement of the battery in the vertical direction, the contact point on each of the one or more blade contacts may change in the vertical direction. Contact may occur at the contact point between each of the one or more blade contacts of the positive and negative terminals of the battery and at least one of the corresponding spring-biased contacts of the positive and negative terminals of the connector. In response to displacement of the battery in the lateral direction, at least one of the corresponding spring-biased contacts of the positive and negative terminals of the connector may change position in the lateral direction. In response to displacement of the battery in at least one of the longitudinal, vertical, and lateral directions, the blade contacts of the positive and negative terminals of the battery may maintain contact with at least one of the corresponding spring-biased contacts of the positive and negative terminals of the connector. In response to the battery displacing in the lateral direction to its maximum travel, the contact between each of one or more blade contacts of the positive and negative terminals of the battery and the two corresponding spring-biased contacts of the positive and negative terminals can be transformed into contact between each of one or more blade contacts of the positive and negative terminals and only one of the corresponding spring-biased contacts of the positive and negative terminals of the battery.

[0012] In some embodiments, the battery housing may include a battery housing cover and a clamping member configured to limit the maximum vertical travel of the battery when the battery housing cover securely covers the battery cavity.

[0013] In some embodiments, the battery may include a housing having a recess configured to receive an extension of the battery housing of the electronic device when the battery is inserted into the electronic device. The recess may be configured to further limit the maximum longitudinal travel of the battery.

[0014] In some implementations, the electronic device may be a light-emitting head-mounted device, and the battery may be fixed inside the light-emitting head-mounted device to provide intrinsically safe lighting.

[0015] In some implementations, the removable battery may be configured to discharge at a current of at least 13 amps, at least 8 amps, or at least 3.3 amps. Attached Figure Description

[0016] Figure 1 This is a perspective view of an example of a light-emitting head-mounted device, which is a non-limiting example of an application type that can be used in conjunction with the disclosed embodiments of the intrinsically safe battery device described herein.

[0017] Figure 2 for Figure 1 A side view of the intrinsically safe battery device inside the light-emitting head-mounted device shown.

[0018] Figure 3 for Figure 2 The top view of the intrinsically safe battery device shown.

[0019] Figure 4 for Figure 2 A perspective view of the battery terminal connector of the intrinsically safe battery device shown.

[0020] Figure 5 for Figure 2 A top view of the battery terminals of the intrinsically safe battery device shown.

[0021] Figure 6 for Figure 2 A perspective view of the battery terminals of the intrinsically safe battery device shown.

[0022] Figure 7 shows the relationship with Figure 2 A top view of the battery terminal connector that contacts the battery terminal of the intrinsically safe battery device.

[0023] Figures 8 to 15 Further aspects of example embodiments of a light-emitting head-mounted device including the intrinsically safe battery device described herein are shown. Detailed Implementation

[0024] It will be understood by those skilled in the art that this disclosure is merely illustrative and is not intended to be limiting in any way. Other embodiments will readily be conceived by such those skilled in the art based on the teachings of this disclosure.

[0025] The features and teachings disclosed herein can be used alone or in combination with other features and teachings to provide detection devices, systems, and methods. (See Appendix) Figure 1 Figure 7 details representative examples employing multiples of these additional features and teachings, whether used individually or in combination. This detailed description is intended only to teach those skilled in the art further details for implementing various aspects of this disclosure and is not intended to limit the scope of the claims. Therefore, the combinations of features disclosed in the detailed description are not necessary for implementing this disclosure in the broadest sense, but are merely for teaching specific representative examples of this disclosure.

[0026] Furthermore, the various features of the representative examples and dependent claims may be combined in ways not explicitly enumerated to provide additional useful embodiments of this disclosure. It is also explicitly stated that all indications of numerical ranges or groups of entities are for the purpose of the original disclosure and to limit the scope of the claimed subject matter, disclosing all possible intermediate values ​​or intermediate entities. It is also explicitly stated that the dimensions and shapes of the components shown in the figures are intended to aid in understanding how this disclosure is implemented, but are not intended to limit the dimensions and shapes shown in the examples in some embodiments. In some embodiments, the dimensions and shapes of the components shown in the figures are to precise scale and are intended to limit the dimensions and shapes of the components.

[0027] Intrinsically safe battery devices must not generate heat or sparks that could ignite a flammable environment. Heat and sparks are avoided by ensuring a continuous connection between the contacts of the intrinsically safe battery device. This disclosure achieves this effect through a design configured to ensure continuous contact between the battery and the battery-powered device (also referred to herein as a host device or host electronics).

[0028] The intrinsically safe battery device 102 described herein can be advantageously included in the host electronic device 100, for example... Figure 1 The illustrated head-mounted device. The electronic device 100 may include an intrinsically safe battery device 102, as further described below. When the battery is secured in the electronic device 100 having the intrinsically safe battery device 102 in the manner described herein, the electronic device 100 can operate as an intrinsically safe device. Although Figure 1 The luminous head-mounted device is shown as electronic device 100, but electronic device 100 can be any electronic device employing intrinsically safe battery device 102, including but not limited to power tools, communication devices and lighting devices.

[0029] Figure 2 A side sectional view is shown of an electronic device 100 having an intrinsically safe battery device 102. Figure 3 This is a top view illustrating an electronic device 100 having an intrinsically safe battery device 102. The electronic device 100 may include a battery housing 104, a positive terminal connector 108, and a negative terminal connector 112. The battery housing 104 may include a battery cavity 120.

[0030] The removable battery 116 may be located within the battery cavity 120 of the battery housing 104. In some embodiments, the removable battery 116 may include one or more battery cells. In some embodiments, the removable battery 116 may be a lithium-ion battery. In some embodiments, the removable battery 116 may be capable of discharging with a high current. In some embodiments, the removable battery 116 may discharge with a current of at least 13 amps, at least 8 amps, or at least 3.3 amps.

[0031] The battery cavity 120 can limit the maximum travel of the removable battery 116 in the lateral direction D1 (i.e., parallel to the width of the battery cavity 120), the longitudinal direction D2 (i.e., parallel to the length of the battery cavity 120), and the vertical direction D3 (i.e., parallel to the height of the battery cavity 120). The inner wall 124 of the battery cavity 120 (which may include the inner surface of the battery casing cover 128) can limit the maximum travel of the removable battery 116 by physically constraining the displacement of the removable battery 116 in all orthogonal directions D1, D2, and D3. It should be understood that, in this way, the inner wall 124 of the battery cavity 120 also constrains the rotational movement (e.g., rolling, yaw, and pitch) of the removable battery 116.

[0032] The battery housing 104 may include a battery housing cover 128, which, when in the closed position, covers the battery cavity 120. Figure 1 As shown. In some embodiments, the battery housing cover 128 may be secured in a closed position by fasteners, clamps, etc. (not shown). The fasteners, clamps, etc., may be configured to require the use of tools to operate and unlock the battery housing cover 128 to open it and expose the removable battery 116 underneath. This arrangement prevents or avoids unintentional contact with the removable battery 116 and exposure to the surrounding hazardous environment. The battery housing 104 may include a clamping member 132 disposed on the inner surface 136 of the battery housing cover 128. When the battery housing cover 128 is in the closed position covering the battery cavity 120, the clamping member 132 is configured to at least partially compress within the space between the battery housing cover 128 and the removable battery to assist in physically limiting the maximum vertical travel of the removable battery 116. The clamping member 132 may also be configured to assist in physically limiting the maximum travel of the removable battery 116 in other directions.

[0033] In some embodiments, the removable battery 116 may include a housing 136 that surrounds one or more battery cells (not shown). The housing 136 may define a recess 140 configured to receive an extension 144 defined by the battery housing 104 of the electronic device 100 during insertion of the removable battery 116 into the electronic device. The extension 144 may be configured to assist in limiting the maximum travel of the removable battery 116 in the lateral direction D1, longitudinal direction D2, and / or vertical direction D3. For example, this effect can be achieved by the surfaces 148 (e.g., end faces, side faces, top faces, and bottom faces) of the extension 144 contacting the recess 140 of the housing 136, thereby minimizing the maximum travel of the removable battery 116 in the lateral direction D1, longitudinal direction D2, and / or vertical direction D3. It should be understood that the extension 144 and the recess 140 may also assist in limiting the travel of the removable battery 116 to constrain rotational movements (e.g., rolling, yaw, and pitch) of the removable battery 116. Additionally, although... Figure 3 and Figure 4 The illustrated embodiment shows that the outer casing 136 of the removable battery 116 has a groove 140 and the battery housing 104 has a corresponding extension 144. However, it should be understood that in other embodiments, the structure may be reversed, i.e., the outer casing 136 of the removable battery 116 has an extension that can be inserted into a corresponding cavity formed on the battery housing 104 when the removable battery 116 is installed.

[0034] like Figure 4 As shown in more detail, the positive terminal connector 108 and the negative terminal connector 112 of the host device 100 can each be securely disposed within the battery housing 104. The positive terminal connector 108 and the negative terminal connector 112 can be electrically connected to the printed circuit board 150 of the electronic device 100. The positive terminal connector 108 may include one or more contacts 152 for mating with the removable battery 116. Similarly, the negative terminal connector 112 may include one or more contacts 156 for mating with the removable battery 116.

[0035] Reference Figure 5 and Figure 6 The removable battery 116 may include a positive terminal 160 and a negative terminal 164, which are connected to a printed circuit board 166 of the removable battery 116. The positive terminal 160 of the removable battery 116 may include one or more corresponding contacts 168 to engage with one or more contacts 152 of the positive terminal connector 108. The negative terminal 164 of the removable battery 116 may include one or more corresponding contacts 172 to engage with one or more contacts 156 of the negative terminal connector 112.

[0036] Reference Figures 4 to 6 Each of one or more contacts 152 of the positive terminal connector 108 within the battery housing 104 and one or more corresponding contacts 168 of the positive terminal 160 of the removable battery 116 can be configured relative to each other to ensure continuous contact between contacts 152 and contacts 168 regardless of how the removable battery 116 moves within the battery cavity 120 of the battery housing 104 in the lateral direction D1, longitudinal direction D2, and vertical direction D3. In other words, the removable battery 116 can be displaced within the limitations or range of the battery cavity 120 during use of the host device 100 to move along the orthogonal directions D1, D2, D3; but regardless of this movement, continuous contact is ensured between one or more contacts 152 of the positive terminal connector 108 within the battery housing 104 and one or more corresponding contacts 168 of the positive terminal 160 of the removable battery 116.

[0037] Similarly, each of one or more contacts 156 of the negative terminal connector 112 within the battery housing 104, and one or more corresponding contacts 172 of the negative terminal 164 of the removable battery 116, can be configured relative to each other to ensure continuous contact between contacts 156 and contacts 172 regardless of how the removable battery 116 moves within the battery cavity 120 of the battery housing 104 in the lateral direction D1, longitudinal direction D2, and vertical direction D3. In other words, the removable battery 116 can be displaced within the limitations or range of the battery cavity 120 during use of the host device 100 to move along the orthogonal directions D1, D2, D3; but regardless of this movement, continuous contact is ensured between one or more contacts 156 of the negative terminal connector 112 within the battery housing 104 and one or more corresponding contacts 172 of the negative terminal 164 of the removable battery 116.

[0038] Figure 4 An exemplary perspective view of the positive terminal connector 108 and the negative terminal connector 112 of the battery housing 104. Figure 6 Figure 7 is an exemplary top view of the positive terminal 160 and negative terminal 164 of the removable battery 116. Figure 8 is an exemplary perspective view of the positive terminal 160 and negative terminal 164 of the removable battery 116. In some embodiments, such as... Figure 4 In the illustrated embodiment, one or more contacts 152 of the positive terminal connector 108 may be blade contacts 176. Similarly, in some embodiments, one or more contacts 156 of the negative terminal connector 112 may be blade contacts 180. In these embodiments, one or more corresponding contacts 168 of the positive terminal 160 of the removable battery 116 may include corresponding spring-biased contacts 184, the spring-biased contacts 184 extending into corresponding contact receiving channels 192, such as... Figure 5 and Figure 6 As shown. Similarly, in these embodiments, one or more corresponding contacts 172 of the negative terminal 164 of the removable battery 116 may include corresponding opposing spring-biased contacts 188 extending into corresponding contact receiving channels 196. The opposing spring-biased contacts 184, 188 may be biased into corresponding contact receiving channels 192, 196 by means of a coil spring, leaf spring, or other biasing element (not shown) within the positive terminal 160 and negative terminal 164 of the removable battery 116.

[0039] Figure 7 shows a top view of the contact between blade contacts 176, 180 and corresponding spring-biased contacts 184, 188 when the removable battery 116 is inserted into the battery housing 104 of the electronic device 100. Each of the blade contacts 176 of the positive terminal connector 108 and the corresponding spring-biased contact 184 of the positive terminal 160 of the removable battery 116 can be configured relative to each other to ensure that regardless of how the removable battery 116 moves within the battery cavity 120 of the battery housing 104 in the lateral direction D1, longitudinal direction D2, and vertical direction D3, continuous contact is maintained between each blade contact 176 of the positive terminal connector 108 and at least one corresponding spring-biased contact 184 of the positive terminal 160 of the removable battery 116. Similarly, each of the blade contacts 180 of the negative terminal connector 112 and the corresponding opposing spring-biased contact 188 of the negative terminal 164 of the removable battery 116 can be configured relative to each other to ensure that regardless of how the removable battery 116 moves within the battery cavity 120 of the battery housing 104 along the lateral direction D1, longitudinal direction D2, and vertical direction D3, the blade contacts 180 of the negative terminal connector 112 and at least one corresponding opposing spring-biased contact 188 of the negative terminal 164 of the removable battery 116 maintain continuous contact.

[0040] In some embodiments, blade contacts 176, 180 may be disposed on the positive terminal 160 and the negative terminal 164 of the removable battery 116, and corresponding spring-biased contacts 184, 188 and corresponding contact receiving channels 192, 196 may be disposed on the positive terminal connector 108 and the negative terminal connector 112. In this embodiment, the engagement between the blade contacts 176, 180 and the corresponding spring-biased contacts 184, 188 can operate similarly to the embodiments described above and below, except that the positions of the blade contacts 176, 180 and the corresponding spring-biased contacts 184, 188 are interchanged.

[0041] When the removable battery 116 moves within the battery cavity 120, each blade contact 176, 180 remains in contact with the corresponding spring-biased contacts 184, 188, including when the removable battery 116 is displaced to its maximum possible travel in at least one of the lateral direction D1, longitudinal direction D2, and vertical direction D3.

[0042] The blade contacts 176 of the positive terminal connector 108 are configured with sufficient length relative to the positive terminal 160 of the removable battery 116 and the maximum travel of the removable battery 116 in the longitudinal direction D2 to ensure continuous contact between each blade contact 176 and at least one corresponding opposing spring-biased contact 184 of the positive terminal 160 of the removable battery 116 when the battery reaches its maximum travel in the longitudinal direction D2. In other words, the length of the blade contacts 176 in the longitudinal direction D2 is greater than the total possible displacement of the removable battery 116 in the longitudinal direction D2 within the battery cavity 120. In other words, the length of the blade contacts 176 in the longitudinal direction D2 is configured such that the blade contacts 176 extend from their nominal positions in opposite longitudinal directions by a length greater than the possible displacement of the removable battery 116 in the longitudinal direction D2 within the battery cavity 120, to ensure that the opposing spring-biased contact 184 remains near the blade contacts 176. Additionally, the blade contacts 176 of the positive terminal connector 108 can be configured with sufficient height relative to the positive terminal 160 of the removable battery 116 and the maximum travel of the removable battery 116 in the vertical direction D3 to ensure continuous contact between each blade contact 176 and at least one corresponding opposing spring-biased contact 184 of the positive terminal 160 of the removable battery 116 when the battery reaches its maximum travel in the vertical direction D3. In other words, the height of the blade contacts 176 in the vertical direction D3 can be greater than the total possible displacement of the removable battery 116 in the vertical direction D3 within the battery cavity 120. In other words, the height of the blade contacts 176 in the vertical direction D3 can be set such that the blade contacts 176 extend a certain height from their nominal position in the opposite vertical direction, a height greater than the possible displacement of the removable battery 116 in the vertical direction D3 within the battery cavity 120, to ensure that the opposing spring-biased contact 184 remains near the blade contacts 176.

[0043] Similarly, the blade contacts 180 of the negative terminal connector 112 may be configured with sufficient length relative to the negative terminal 164 of the removable battery 116 and the maximum travel of the removable battery 116 in the longitudinal direction D2 to ensure continuous contact between each blade contact 180 and at least one corresponding spring-biased contact 188 of the negative terminal 164 of the removable battery 116 when the battery reaches its maximum travel in the longitudinal direction D2. In other words, the length of the blade contacts 180 in the longitudinal direction D2 may be greater than the total possible displacement of the removable battery 116 in the longitudinal direction D2 within the battery cavity 120. In other words, the length of the blade contacts 180 in the longitudinal direction D2 may be configured such that the blade contacts 180 extend from their nominal positions in opposite longitudinal directions by a length greater than the possible displacement of the removable battery 116 in the longitudinal direction D2 within the battery cavity 120, to ensure that the opposing spring-biased contact 188 remains in proximity to the blade contacts 180. Additionally, the blade contacts 180 of the negative terminal connector 112 can be configured with sufficient height relative to the negative terminal 164 of the removable battery 116 and the maximum travel of the removable battery 116 in the vertical direction D3 to ensure continuous contact between each blade contact 180 and at least one corresponding opposing spring-biased contact 188 of the negative terminal 164 of the removable battery 116 when the battery reaches its maximum travel in the vertical direction D3. In other words, the height of the blade contacts 180 in the vertical direction D3 can be greater than the total possible displacement of the removable battery 116 in the vertical direction D3 within the battery cavity 120. In other words, the height of the blade contacts 180 in the vertical direction D3 can be set such that the blade contacts 180 extend a certain height from their nominal position in the opposite vertical direction, a height greater than the possible displacement of the removable battery 116 in the vertical direction D3 within the battery cavity 120, to ensure that the opposing spring-biased contact 188 remains near the blade contacts 180.

[0044] In some embodiments, the maximum travel distance of the removable battery 116 along the longitudinal direction D2 may be less than 1 mm, less than 0.8 mm, or less than 0.6 mm. In some embodiments, the maximum travel distance of the removable battery 116 along the longitudinal direction D2 may be between 1 mm and 0.6 mm, or between 0.9 mm and 0.7 mm. In some embodiments, the length of each blade contact 176, 180 may be at least 2.1 mm, at least 1.7 mm, or at least 1.3 mm. In some embodiments, the length of each blade contact 176, 180 may be between 2.1 mm and 1.3 mm, or between 1.9 mm and 1.5 mm.

[0045] In some embodiments, the maximum travel distance of the removable battery 116 along the vertical direction D3 may be less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm. In some embodiments, the maximum travel distance of the removable battery 116 along the vertical direction D3 may be between 0.3 mm and 0.1 mm, or between 0.25 mm and 0.15 mm. In some embodiments, the height of each blade contact 176, 180 may be at least 0.7 mm, at least 0.5 mm, or less than 0.3 mm. In some embodiments, the height of each blade contact 176, 180 may be between 0.7 mm and 0.3 mm, or between 0.6 mm and 0.4 mm.

[0046] As the removable battery 116 moves within the battery cavity 120, the contact points on each blade contact 176, 180 can change. The contact point is the position where each blade contact 176, 180 makes contact with its corresponding spring-biased contact 184, 188. Regardless of the change in contact point position, contact between each blade contact 176, 180 and its corresponding spring-biased contact 184, 188 is maintained, thereby ensuring an uninterrupted circuit between the removable battery 116 and the electronic device 100.

[0047] The contact between the blade contacts 176, 180 and their corresponding spring-biased contacts 184, 188 can be maintained when each blade contact 176, 180 is in contact with both corresponding spring-biased contacts 184, 188, or when each blade contact 176, 180 is in contact with only one corresponding spring-biased contact 184, 188. The number of corresponding spring-biased contacts 184, 188 contacted by each blade contact 176, 180 can vary due to the displacement of the removable battery along the lateral direction D1. For example, when the removable battery 116 reaches its maximum travel along the lateral direction D1, each blade contact 176, 180 may only be in contact with the first spring-biased contact of the corresponding spring-biased contacts 184, 188. When the removable battery 116 is in its nominal or central position relative to the lateral direction D1 (i.e., between the first side 201 and the second side 202 of the battery cavity 120 and the maximum travel along the lateral direction D1), the two spring-biased contacts 184 and 188 remain in contact simultaneously. However, when the removable battery 116 is displaced along the lateral direction D1 towards the maximum travel along the lateral direction D1, each blade contact 176 and 180 can disengage from one of the corresponding spring-biased contacts 184 and 188 while maintaining contact with the other spring-biased contact 184 and 188 to ensure continuous contact with at least one of the corresponding spring-biased contacts 184 and 188. Therefore, whether connected to both corresponding spring-biased contacts 184 and 188 or only one corresponding spring-biased contact 184 and 188, each blade contact 176 and 180 remains electrically connected. Blade contacts 176 and corresponding spring-biased contacts 184, 188 are configured such that each blade contact 176, 180 remains in contact with at least one spring-biased contact 184, 188 regardless of the lateral position of the removable battery 116 within the battery cavity 120.

[0048] In some embodiments, the maximum travel distance of the removable battery 116 in the lateral direction D1 may be less than 1 mm, less than 0.9 mm, or less than 0.8 mm. In some embodiments, the maximum travel distance of the removable battery 116 in the lateral direction D1 may be between 1 mm and 0.8 mm, or between 0.95 mm and 0.85 mm. In some embodiments, the maximum travel distance of each opposing spring-biased contact 184, 188 may be at least 0.5 mm, at least 0.4 mm, or less than 0.3 mm. In some embodiments, the maximum travel distance of each opposing spring-biased contact 184, 188 may be between 0.5 mm and 0.3 mm, or between 0.45 mm and 0.35 mm.

[0049] In some embodiments, each of the positive terminal connector 108 and the negative terminal connector 112 may each include a plurality of blade contacts 176, 180. In some embodiments, each of the positive terminal connector 108 and the negative terminal connector 112 may each include two, three, or more of each of the blade contacts 176, 180. Similarly, each of the positive terminal 160 and the negative terminal 164 of the removable battery 116 may each include a plurality of corresponding spring-biased contacts 184, 188 and a plurality of contact receiving channels 192, 196. In some embodiments, each of the positive terminal 160 and the negative terminal 164 of the removable battery 116 may each include two, three, or more corresponding spring-biased contacts 184, 188 and two, three, or more contact receiving channels 192, 196.

[0050] In some embodiments, the plurality of blade contacts 176 of the positive terminal connector 108 may each be redundant with the remaining blade contacts among the plurality of blade contacts 176. In some embodiments, each of the plurality of blade contacts 180 of each of the negative terminal connectors 112 may be redundant with the remaining blade contacts among the plurality of blade contacts 180. In some embodiments, each of the plurality of opposing spring-biased contacts 184 of the positive terminal 160 of the removable battery 116 may be redundant with the remaining opposing spring-biased contacts among the plurality of opposing spring-biased contacts 184. In some embodiments, each of the plurality of opposing spring-biased contacts 188 of the negative terminal 164 of the removable battery 116 may be redundant with the remaining opposing spring-biased contacts among the plurality of opposing spring-biased contacts 188. In embodiments including redundant blade contacts 176, 180 and redundant corresponding spring-biased contacts 184, 188, the redundant contacts 176, 180, 184, 188 enable the electronic device to continue operating safely even when all redundant blade contacts 176, 180 and redundant corresponding spring-biased contacts 184, 188 are not completely disconnected.

[0051] It should be understood that the aforementioned continuous contact between the blade contacts 176, 180 and the corresponding spring-biased contacts 184, 188 can be maintained even if the removable battery 116 is "twisted" or "rotated" within the battery casing 104. For example, if the removable battery 116 is twisted around one corner, and if a corner of the battery casing 104 is impacted, the blade contacts 176, 180 and the corresponding spring-biased contacts 184, 188 are configured to maintain contact and electrical connection after such an impact.

[0052] Those skilled in the art, through detailed review Figures 8 to 15 The accompanying drawings illustrate other aspects and features of intrinsically safe electronic devices.

[0053] Furthermore, as mentioned above, various aspects of the above-described embodiments can be combined to provide more embodiments.

[0054] In general, the terminology used in the appended claims should not be construed as limiting the claims to the specific embodiments disclosed in the specification and claims, but should be construed as including all possible embodiments and the full scope of equivalents claimed by the claims.

[0055] This application claims priority to U.S. Provisional Patent Application No. 63 / 583,149, filed September 15, 2023, which is incorporated herein by reference in its entirety.

Claims

1. An intrinsically safe battery device for use in electronic devices, the intrinsically safe battery device comprising: Battery casing, including battery cavity; The positive terminal connector is fixedly disposed inside the battery housing and includes one or more contacts; The negative terminal connector is fixedly disposed within the battery housing and includes one or more contacts; and A removable battery is placed within the battery cavity. The removable battery includes a positive terminal and a negative terminal. The positive terminal has one or more corresponding contacts to engage with one or more contacts of the positive terminal connector, and the negative terminal has one or more corresponding contacts to engage with one or more contacts of the negative terminal connector. Each of one or more contacts of the positive terminal connector and the negative terminal connector within the battery housing, and one or more corresponding contacts of the positive terminal and the negative terminal of the battery, are configured relative to each other to ensure that continuous contact is maintained between the one or more contacts of the positive terminal connector and the negative terminal connector within the battery housing, and between the one or more corresponding contacts of the positive terminal and the negative terminal of the battery, regardless of how the battery moves in the lateral, longitudinal, and vertical directions within the battery cavity of the battery housing.

2. The intrinsically safe battery device according to claim 1, wherein, One or more contacts of the positive and negative terminals are blade contacts. The corresponding contacts of the positive and negative terminals of the battery include opposing spring-biased contacts extending into the corresponding contact receiving channels. Each of the blade contacts of the positive and negative terminals within the battery housing, and the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery, are configured relative to each other to ensure that each blade contact maintains continuous contact with at least one of the corresponding opposing spring-biased contacts regardless of how the battery moves in the lateral direction within the battery cavity.

3. The intrinsically safe battery device according to claim 2, wherein, The positive terminal connector and the negative terminal connector each include at least three blade-type contacts, and the positive terminal and the negative terminal of the battery each include at least three corresponding contact receiving channels, with the opposing spring-biased contacts extending into each contact receiving channel.

4. The intrinsically safe battery device according to claim 3, wherein, The positive terminal connector has at least three blade contacts that are redundant, the negative terminal connector has at least three blade contacts that are redundant, the opposing spring-biased contacts of the positive terminal of the battery are redundant, and the opposing spring-biased contacts of the negative terminal of the battery are redundant.

5. The intrinsically safe battery device according to claim 2, wherein, The battery casing is configured to limit the maximum travel of the battery in the lateral direction, limit the maximum travel of the battery in the longitudinal direction, and limit the maximum travel of the battery in the vertical direction.

6. The intrinsically safe battery device according to claim 5, wherein, The blade contacts of the positive and negative terminal connectors are configured with sufficient length relative to the positive and negative terminals of the battery and the maximum travel of the battery in the longitudinal direction to ensure continuous contact between each blade contact and at least one of the corresponding spring-biased contacts of the positive and negative terminals of the battery when the battery reaches its maximum travel in the longitudinal direction. The blade contacts of the positive and negative terminals are configured with sufficient height relative to the positive and negative terminals of the battery and the maximum travel of the battery in the vertical direction to ensure that each blade contact maintains continuous contact with at least one of the corresponding spring-biased contacts of the positive and negative terminals of the battery when the battery reaches its maximum travel in the vertical direction.

7. The intrinsically safe battery device according to claim 6, wherein, In response to displacement of the battery along the longitudinal direction, the contact point on each of the one or more blade contacts changes along the longitudinal direction. In response to the displacement of the battery along the vertical direction, the contact point on each of the one or more blade contacts changes along the vertical direction. The contact between each of one or more blade contacts of the positive and negative terminals of the battery and at least one of the corresponding spring-biased contacts of the positive and negative terminals occurs at the contact point. In response to the displacement of the battery along the lateral direction, at least one of the corresponding spring-biased contacts of the positive and negative terminals of the battery changes position along the lateral direction. In response to displacement of the battery along at least one of the longitudinal direction, the vertical direction, and the transverse direction, the blade contacts of the positive terminal connector and the negative terminal connector maintain contact with at least one of the corresponding spring-biased contacts of the positive and negative terminals of the battery.

8. The intrinsically safe battery device according to claim 6, wherein, In response to the battery displacing to its maximum travel in the lateral direction, the contact between each of one or more blade contacts of the positive and negative terminals of the battery and the two corresponding spring-biased contacts of the positive and negative terminals is transformed into contact between each of one or more blade contacts of the positive and negative terminals of the battery and only one of the corresponding spring-biased contacts of the positive and negative terminals of the battery.

9. The intrinsically safe battery device according to claim 1, wherein, One or more contacts of the positive terminal connector and the negative terminal connector each include opposing spring-biased contacts extending into the corresponding contact receiving channel, and each of one or more corresponding contacts of the positive and negative terminals of the battery includes a blade contact, and each of the blade contacts of the positive and negative terminals of the battery, as well as the opposing opposing spring-biased contacts of the positive and negative terminal connectors within the battery housing, are configured relative to each other to ensure that each blade contact maintains continuous contact with at least one of the opposing spring-biased contacts regardless of how the battery moves in the lateral direction within the battery cavity.

10. The intrinsically safe battery device according to claim 9, wherein, The positive and negative terminals of the battery each include at least three blade-type contacts, and the positive terminal connector and the negative terminal connector each include at least three corresponding contact receiving channels, and opposing spring-biased contacts extend into each contact receiving channel.

11. The intrinsically safe battery device according to claim 10, wherein, The positive terminal of the battery has at least three blade contacts that are redundant, the negative terminal of the battery has at least three blade contacts that are redundant, the opposing spring-biased contacts of the positive terminal connector are redundant, and the opposing spring-biased contacts of the negative terminal connector are redundant.

12. The intrinsically safe battery device according to claim 9, wherein, The battery casing is configured to limit the maximum travel of the battery in the lateral direction, limit the maximum travel of the battery in the longitudinal direction, and limit the maximum travel of the battery in the vertical direction.

13. The intrinsically safe battery device according to claim 12, wherein, The blade contacts of the positive and negative terminals of the battery are configured with sufficient length relative to the positive and negative terminal connectors and the battery's maximum travel in the longitudinal direction to ensure continuous contact between the blade contacts and at least one of the corresponding spring-biased contacts of the positive and negative terminal connectors when the battery reaches its maximum travel in the longitudinal direction. The blade contacts of the positive and negative terminals of the battery are configured with sufficient height relative to the positive and negative terminal connectors and the battery's maximum travel in the vertical direction to ensure that the blade contacts maintain continuous contact with at least one of the corresponding spring-biased contacts of the positive and negative terminal connectors when the battery reaches its maximum travel in the vertical direction.

14. The intrinsically safe battery device according to claim 13, wherein, In response to displacement of the battery along the longitudinal direction, the contact point on each of the one or more blade contacts changes along the longitudinal direction. In response to the displacement of the battery along the vertical direction, the contact point on each of the one or more blade contacts changes along the vertical direction. The contact between each of one or more blade contacts of the positive and negative terminals of the battery and at least one of the corresponding spring-biased contacts of the positive and negative terminals occurs at the contact point. In response to the displacement of the battery along the lateral direction, at least one of the corresponding spring-biased contacts of the positive and negative terminals of the connector changes position along the lateral direction. In response to displacement of the battery along at least one of the longitudinal direction, the vertical direction, and the transverse direction, the blade contacts of the positive and negative terminals of the battery remain in contact with at least one of the corresponding spring-biased contacts of the positive and negative terminals of the connector.

15. The intrinsically safe battery device according to claim 13, wherein, In response to the battery being displaced to its maximum travel in the lateral direction, the contact between each of one or more blade contacts of the positive and negative terminals of the battery and the two corresponding spring-biased contacts of the positive and negative terminals is transformed into contact between each of one or more blade contacts of the positive and negative terminals of the battery and only one of the corresponding spring-biased contacts of the positive and negative terminals of the battery.

16. The intrinsically safe battery device according to claim 1, wherein, The battery housing includes a battery housing cover and a clamping member, the clamping member being configured to limit the maximum vertical travel of the battery when the battery housing cover securely covers the battery cavity.

17. The intrinsically safe battery device according to claim 1, wherein, The battery includes a housing having a recess configured to receive an extension of the battery housing of the electronic device when the battery is inserted into the electronic device. The groove is configured to help limit the maximum longitudinal travel of the battery.

18. The intrinsically safe battery device according to claim 1, wherein, The electronic device is a light-emitting head-mounted device, and the battery is fixed inside the light-emitting head-mounted device to provide intrinsically safe lighting.

19. The intrinsically safe battery device according to claim 1, wherein, The removable battery is configured to discharge at a current of at least 3.3 amps.

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