High current intrinsically safe battery arrangement

Abstract

An intrinsically safe battery arrangement for an electronic device includes a battery enclosure including a battery cavity, positive and negative terminal connectors each fixedly disposed within the battery enclosure and including one or more contacts, and a removable battery positioned within the battery enclosure. The removable battery includes positive and negative terminals each with one or more corresponding contacts to engage the one or more contacts of the respective positive and negative terminal connectors. Each of the one or more contacts of the positive and negative terminal connectors within the battery enclosure and the one or more corresponding contacts of the positive and negative terminals of the battery are configured relative to each other to guarantee continuous contact therebetween irrespective of movement of the battery in a lateral direction, a longitudinal direction and a vertical direction within a confines of the battery cavity of the battery enclosure.

Description

HIGH CURRENT INTRINSICALLY SAFE BATTERY ARRANGEMENTBACKGROUNDTechnical Field

[0001] The present disclosure generally relates to battery connection arrangements, such as, for example, intrinsically safe battery connection arrangements for use with removable, high- current batteries.Description of the Related Art

[0002] It is well-known that intrinsically safe battery arrangements are utilized to protect electronic equipment and people in potentially dangerous situations, such as hazardous environments and high-current applications. For example, electricians, line workers, and construction workers, among others, may use devices and tools featuring high voltage and currents as part of their ordinary job responsibilities in environments with flammable gasses in the atmosphere. Without an intrinsically safe design, electronic devices providing a high current are at risk of a circuit shorting and causing a spark, which may ultimately ignite surrounding gases. Such short circuits and / or sparks may be caused by momentary disconnection of the battery from its associated contacts in a host electronic device. For example, a disconnection may be caused by dropping and / or shaking of the electronic device. To prevent a disconnection, intrinsically safe designs designed to supply a high current commonly include soldered wired connections or other fixed connections, which prevents the possibility of removing the battery or batteries. Without the ability to remove a battery from a host electronic device, the life of the electronic device may be dictated by the life of the battery, or servicing or replacement of the battery may be cumbersome and laborious.

[0003] As a result, Applicant believes it would be advantageous to have intrinsically safe battery arrangements that overcome the disadvantages of known solutions.BRIEF SUMMARY

[0004] Embodiments described herein provide intrinsically safe battery arrangements for use in a variety of applications, including high-current lighting, communication devices, and power tools. The intrinsically safe battery arrangements allow removable batteries to be utilized in high-current applications while greatly reducing or eliminating the risk of a circuit interruptingand sparking (arcing). Moreover, the intrinsically safe battery arrangements may provide redundancy in the connections between the electronic device and the removable battery to prevent a circuit arcing if contact is lost at one point between the electronic device and the battery. The battery enclosure may provide limited space for the battery to be displaced, further solidifying the connection between the electronic device and the battery.

[0005] In one embodiment, an intrinsically safe battery arrangement for an electronic device may be summarized as including: a battery enclosure including a battery cavity; a positive terminal connector fixedly disposed within the battery enclosure and including one or more contacts; a negative terminal connector fixedly disposed within the battery enclosure and including one or more contacts; and a removable battery positioned within the battery enclosure including a positive terminal with one or more corresponding contacts to engage the one or more contacts of the positive terminal connector and a negative terminal with one or more corresponding contacts to engage the 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 enclosure and the one or more corresponding contacts of the positive and negative terminals of the battery may be configured relative to each other to guarantee continuous contact therebetween irrespective of movement of the battery in a lateral direction, a longitudinal direction and a vertical direction within a confines of the battery cavity of the battery enclosure.

[0006] In some embodiments, the one or more contacts of the positive and negative terminal connectors may be blade contacts and the corresponding contacts of the positive and negative terminals of the battery may comprise corresponding opposing spring-biased contacts extending into a respective contact receiving channel. Each of the blade contacts of the positive and negative terminal connectors within the battery enclosure and the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery may be configured relative to each other to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts irrespective of movement of the battery in the lateral direction within the confines of the battery cavity. Each of the positive and negative terminal connectors may include at least three blade contacts, and each of the positive and negative terminals of the battery may include at least three corresponding contact receiving channels with opposing spring-biased contacts extending into each respective contact receiving channel. Each of the at least three blade contacts of the positive terminal connector may be redundant and each of the at least three blade contacts of the negative terminal connector may be redundant. Each of the opposing spring-biased contacts of the positive terminal of the batterymay be redundant and each of the opposing spring-biased contacts of the negative terminal of the battery may be redundant. The battery enclosure may be configured to limit maximum travel of the battery in the lateral direction, to limit maximum travel of the battery in the longitudinal direction, and to limit maximum travel of the battery in the vertical direction.

[0007] The blade contacts of the positive and negative terminal connectors may be configured relative to the positive and negative terminals of the battery and the maximum travel of the battery in the longitudinal direction to be of sufficient length to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery at the maximum travel of the battery in the longitudinal direction. The blade contacts of the positive and negative terminal connectors may be configured relative to the positive and negative terminals of the battery and the maximum travel of the battery in the vertical direction to be of sufficient height to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery at the maximum travel of the battery in the vertical direction.

[0008] In response to displacement of the battery in the longitudinal direction, a 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 changes in the vertical direction. Contact between each of the one or more blade contacts of the positive and negative terminal connectors and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery may occur at the contact point. In response to displacement of the battery in the lateral direction, at least one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery may change a position in the lateral direction. The blade contacts of the positive and negative terminal connectors may maintain contact with at least one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery in response to displacement of the battery in at least one of the longitudinal direction, the vertical direction, and the lateral direction. In response to displacement of the battery to the maximum travel of the battery in the lateral direction, contact between each of the one or more blade contacts of the positive and negative terminal connectors and both of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery may transition to contact between each of the one or more blade contacts of the positive and negativeterminal connectors and only one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery.

[0009] In some embodiments, the one or more contacts of the positive and negative terminal connectors each may comprise opposing spring-biased contacts extending into a respective contact receiving channel and each of the one or more corresponding contacts of the positive and negative terminals of the battery may include blade contacts. Each of the blade contacts of the positive and negative terminals of the battery and the corresponding opposing spring-biased contacts of the positive and negative terminal connectors within the battery enclosure may be configured relative to each other to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts irrespective of movement of the battery in the lateral direction within the confines of the battery cavity. Each of the positive and negative terminals of the battery may include at least three blade contacts and each of the positive and negative terminal connectors may include at least three corresponding contact receiving channels with opposing spring-biased contacts extending into each respective contact receiving channel. Each of the at least three blade contacts of the positive terminals of the battery may be redundant and each of the at least three blade contacts of the negative terminals of the battery may be redundant. Each of the opposing spring-biased contacts of the positive terminal connector may be redundant and each of the opposing spring-biased contacts of the negative terminal connector may be redundant.

[0010] The battery enclosure may be configured to limit maximum travel of the battery in the lateral direction, to limit maximum travel of the battery in the longitudinal direction, and to limit maximum travel of the battery in the vertical direction. The blade contacts of the positive and negative terminals of the battery may be configured relative to the positive and negative terminal connectors and the maximum travel of the battery in the longitudinal direction to be of sufficient length to guarantee continuous contact between the blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors at the maximum travel of the battery in the longitudinal direction. The blade contacts of the positive and negative terminals of the battery may be configured relative to the positive and negative terminal connectors and the maximum travel of the battery in the vertical direction to be of sufficient height to guarantee continuous contact between the blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors at the maximum travel of the battery in the vertical direction.

[0011] In response to displacement of the battery in the longitudinal direction, a 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 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 opposing spring-biased contacts of the positive and negative terminal connectors may occur at the contact point. In response to displacement of the battery in the lateral direction, at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors may change a position in the lateral direction. The blade contacts of the positive and negative terminals of the battery may maintain contact with at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors in response to displacement of the battery in at least one of the longitudinal direction, the vertical direction, and the lateral direction. In response to displacement of the battery to the maximum travel of the battery in the lateral direction, contact between each of the one or more blade contacts of the positive and negative terminals of the battery and both of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors may transition to contact between each of the one or more blade contacts of the positive and negative terminals of the battery and only one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors.

[0012] In some embodiments, the battery enclosure may include a battery enclosure cover and a compression member configured to limit maximum vertical travel of the battery when the cover is secured over the battery cavity.

[0013] In some embodiments, the battery may include an external casing having a notch configured to receive an extension of the battery enclosure of the electronic device during insertion of the battery in the electronic device. The notch may be configured to assist in limiting maximum longitudinal travel of the battery.

[0014] In some embodiments, the electronic device may be light-emitting headgear and the battery may be secured within the light-emitting headgear to provide an intrinsically safe lighting device.

[0015] In some embodiments, the removable battery may be configured to discharge electric charge at a current of at least 13 amps, at least 8 amps, or at least 3.3 amps.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0016] Figure 1 is a perspective view of an example of light-emitting headgear, which is provided as a non-limiting example of the types of applications that may be used in connection with disclosed embodiments of the intrinsically safe battery arrangements described herein.

[0017] Figure 2 is a side view of an intrinsically safe battery arrangement within the light-emitting headgear of Figure 1.

[0018] Figure 3 is a top view of the intrinsically safe battery arrangement of Figure 2.

[0019] Figure 4 is a perspective view of battery terminal connectors of the intrinsically safe battery arrangement of Figure 2.

[0020] Figure 5 is a top view of terminals of a battery of the intrinsically safe battery arrangement of Figure 2.

[0021] Figure 6 is a perspective view of terminals of the battery of the intrinsically safe battery arrangement of Figure 2.

[0022] Figure 7 is a top view of battery terminal connectors in contact with the terminals of the battery of the intrinsically safe battery arrangement of Figure 2.

[0023] Figures 8-15 show additional aspects of an example embodiment of light-emitting headgear including an intrinsically safe battery arrangement described herein.DETAILED DESCRIPTION

[0024] Persons of ordinary skill in the relevant art will understand that the present disclosure is illustrative only and not in any way limiting. Other embodiments of the presently disclosed systems and methods readily suggest themselves to such skilled persons having the assistance of this disclosure.

[0025] Each of the features and teachings disclosed herein can be utilized separately or in conjunction with other features and teachings to provide detection devices, systems, and methods. Representative examples utilizing many of these additional features and teachings, both separately and in combination, are described in further detail with reference to attached Figures 1-7. This detailed description is merely intended to teach a person of ordinary skill in the relevant art further details for practicing aspects of the present teachings and is not intended to limit the scope of the claims. Therefore, combinations of features disclosed in the detailed description may not be necessary to practice the teachings in the broadest sense, and are instead taught merely to describe particularly representative examples of the present teachings.

[0026] Moreover, the various features of the representative examples and the dependent claims may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings. It is also expressly noted that all value ranges or indications of groups of entities disclose every possible intermediate value or intermediate entity for the purpose of original disclosure, as well as for the purpose of restricting the claimed subject matter. It is also expressly noted that the dimensions and the shapes of the components shown in the figures are designed to help understand how the present teachings are practiced, but are not intended to limit the dimensions and the shapes shown in the examples in some embodiments. In some embodiments, the dimensions and the shapes of the components shown in the figures are exactly to scale and intended to limit the dimensions and the shapes of the components.

[0027] Intrinsically safe battery arrangements must be incapable of generating heat or sparks to ignite flammable atmospheres. Heat and sparks may be avoided by ensuring a continuous connection between contacts of the intrinsically safe battery arrangement. This is accomplished in the present disclosure by a design configured to guarantee continuous contact between a battery and the device the battery is powering (also referred to herein as a host device or host electronic device).

[0028] The intrinsically safe battery arrangements 102 described herein may be advantageously included in host electronic devices 100, such as, for example, the light-emitting headgear shown in Figure 1. An electronic device 100 may include an intrinsically safe battery arrangement 102 therein, as explained further below. When the battery is secured in the electronic device 100 with an intrinsically safe battery arrangement 102, as explained herein, the electronic device 100 may act as an intrinsically safe device. Although Figure 1 shows lightemitting headgear as the electronic device 100, the electronic device 100 can be any electronic device utilizing an intrinsically safe battery arrangement 102, including, but not limited to, power tools, communication devices, and lighting devices.

[0029] Figure 2 is a side cross-sectional view of the electronic device 100 showing an intrinsically safe battery arrangement 102 therein. Figure 3 is a top cross-sectional view of the electronic device 100 showing an intrinsically safe battery arrangement 102 therein. The electronic device 100 may include a battery enclosure 104, a positive terminal connector 108, and a negative terminal connector 112. The battery enclosure 104 may include a battery cavity 120 therein.

[0030] A removable battery 116 may be positioned within the battery cavity 120 of the battery enclosure 104. In some embodiments, the removable battery 116 may comprise 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 electricity at a high current. In some embodiments, the removable battery 116 may discharge electricity at a current of at least 13 amps, at least 8 amps, or at least 3.3 amps.

[0031] The battery cavity 120 may limit a maximum travel of the removable battery 116 in a lateral direction DI (z.e., parallel to a width of the battery cavity 120), a longitudinal direction D2 (z.e., parallel to a length of the battery cavity 120), and a vertical direction D3 (z.e., parallel to a height of the battery cavity 120). Interior walls 124 of the battery cavity 120 (which may include an interior facing surface of a battery enclosure cover 128) may define maximum travel of the removable battery 116 by physically restraining where the removable battery 116 may be displaced in all orthogonal directions DI, D2, D3. It is appreciated that in doing so the interior walls 124 of the battery cavity 120 also constrain rotational motion (e.g., roll, yaw and pitch) of the removable battery 116.

[0032] The battery enclosure 104 may include a battery enclosure cover 128 which may cover the battery cavity 120 when the battery enclosure cover 128 is placed in a closed position, as shown in Figure 1. In some embodiments, the battery enclosure cover 128 may be restrained in the closed position by the use of a fastener, a retaining clip, or the like (not shown). The fastener, the retaining clip, or the like may be configured to require the use of a tool to operate and unlock the battery enclosure cover 128 to open the battery enclosure cover 128 and reveal the underlying removable battery 116. This may discourage or prevent unintentional access and exposure of the removable battery 116 to a surrounding hazardous environment. The battery enclosure 104 may include a compression member 132 disposed on an internal face 136 of the battery enclosure cover 128. When the battery enclosure cover 128 is placed in the closed position over the battery cavity 120, the compression member 132 is configured to at least partially compress in a space between the battery enclosure cover 128 and the removable battery to assist in physically limiting maximum vertical travel of the removable battery 116. The compression member 132 may also be configured to assist in physically limiting maximum travel of the removable battery 116 in other directions.

[0033] In some embodiments, the removable battery 116 may include an external casing 136 surrounding a battery cell or battery cells (not shown). The external casing 136 may define a notch 140 configured to receive an extension 144 defined by the battery enclosure 104 of theelectronic device 100 during insertion of the removable battery 116 in 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 DI, the longitudinal direction D2, and / or the vertical direction D3. For example, this may be accomplished by faces 148 (e.g., end face, side faces, top and bottom faces) of the extension 144 being in contact with the notch 140 of the external casing 136 minimizing the maximum travel of the removable battery 116 in the lateral direction DI, the longitudinal direction D2, and / or the vertical direction D3. It is appreciated that the extension 144 and notch 140 may also assist in limiting travel of the removable battery 116 to constrain rotational motion (e.g., roll, yaw and pitch) of the removable battery 116. Further, although the example embodiment shown in Figures 3 and 4 show the external casing 136 of the removable battery 116 having the notch 140 and the battery enclosure 104 having the corresponding extension 144, it is appreciated that in other embodiments the structures may be reversed with the external casing 136 of the removable battery 116 having an extension that, during installation of the removable battery 116, is insertable in a corresponding cavity formed in the battery enclosure 104.

[0034] The positive terminal connector 108 and the negative terminal connector 112 of the host device 100, shown in more detail in Figure 4, may each be fixedly disposed within the battery enclosure 104. The positive and negative terminal connectors 108, 112 may be electrically coupled to a printed circuit board 150 of the electronic device 100. The positive terminal connector 108 may include one or more contacts 152 for interfacing with the removable battery 116. Likewise, the negative terminal connector 112 may include one or more contacts 156 for interfacing with the removable battery 116.

[0035] With reference to Figure 5 and 6, the removable battery 116 may include a positive terminal 160 and a negative terminal 164 coupled 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 the 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 the one or more contacts 156 of the negative terminal connector 112.

[0036] With reference to Figures 4 through 6, each of the one or more contacts 152 of the positive terminal connector 108 within the battery enclosure 104 and the one or more corresponding contacts 168 of the positive terminal 160 of the removable battery 116 may be configured relative to each other to guarantee continuous contact therebetween irrespective ofmovement of the removable battery 116 in the lateral direction DI, the longitudinal direction D2, and the vertical direction D3 within the confines of the battery cavity 120 of the battery enclosure 104. In other words, the removable battery 116 may be displaced during use of the host device 100 within the limits or confines of the battery cavity 120 to move in each of orthogonal directions DI, D2, and D3; however, irrespective of such movement, continuous contact between the one or more contacts 152 of the positive terminal connector 108 within the battery enclosure 104 and the one or more corresponding contacts 168 of the positive terminal 160 of the removable battery 116 is guaranteed.

[0037] Similarly, each of the one or more contacts 156 of the negative terminal connector 112 within the battery enclosure 104 and the one or more corresponding contacts 172 of the negative terminal 164 of the removable battery 116 may be configured relative to each other to guarantee continuous contact therebetween irrespective of movement of the removable battery 116 in the lateral direction DI, the longitudinal direction D2, and the vertical direction D3 within the confines of the battery cavity 120 of the battery enclosure 104. In other words, the removable battery 116 may be displaced during use of the host device 100 within the limits or confines of the battery cavity 120 to move in each of orthogonal directions DI, D2, and D3; however, irrespective of such movements, continuous contact between the one or more contacts 156 of the negative terminal connector 112 within the battery enclosure 104 and the one or more corresponding contacts 172 of the negative terminal 164 of the removable battery 116 is guaranteed.

[0038] Figure 4 is an exemplary perspective view of the positive terminal connector 108 and the negative terminal connector 112 of the battery enclosure 104. Figure 6 is an exemplary top view of the positive terminal 160 and the negative terminal 164 of the removable battery 116. Figure 7 is an exemplary perspective view of the positive terminal 160 and the negative terminal 164 of the removable battery 116. In some embodiments, such as the embodiment shown in Figure 4, the one or more contacts 152 of the positive terminal connector 108 may be blade contacts 176. Similarly, in some embodiments, the one or more contacts 156 of the negative terminal connector 112 may be blade contacts 180. In such embodiments, the one or more corresponding contacts 168 of the positive terminal 160 of the removable battery 116 may comprise corresponding opposing spring-biased contacts 184 extending into a respective contact receiving channel 192 as shown in Figures 5 and 6. Similarly, in such embodiments, the one or more corresponding contacts 172 of the negative terminal 164 of the removable battery 116 may comprise corresponding opposing spring-biased contacts 188 extending into a respective contactreceiving channel 196. The opposing spring-biased contacts 184, 188 may each be biased into the respective contact receiving channels 192, 196 by the use of coil springs, leaf springs or other biasing elements (not shown) within the positive and negative terminals 160, 164 of the removable battery 116.

[0039] Figure 7 shows a top view of the blade contacts 176, 180 in contact with the corresponding opposing spring-biased contacts 184, 188 when the removable battery 116 is inserted in the battery enclosure 104 of the electronic device 100. Each of the blade contacts 176 of the positive terminal connector 108 and the corresponding opposing spring-biased contacts 184 of the positive terminal 160 of the removal battery 116 may be configured relative to each other to guarantee continuous contact between each blade contact 176 of the positive terminal connector 108 and at least one of the corresponding opposing spring-biased contacts 184 of the positive terminal 160 of the removable battery 116 irrespective of movement of the removable battery 116 in the lateral direction DI, the longitudinal direction D2 and the vertical direction D3 within the confines of the battery cavity 120. Similarly, each of the blade contacts 180 of the negative terminal connector 112 and the corresponding opposing spring-biased contacts 188 of the negative terminal 164 of the removal battery 116 may be configured relative to each other to guarantee continuous contact between each blade contact 180 of the negative terminal connector 112 and at least one of the corresponding opposing spring-biased contacts 188 of the negative terminal 164 of the removable battery 116 irrespective of movement of the removable battery 116 in the lateral direction DI, the longitudinal direction D2 and the vertical direction D3 within the confines of the battery cavity 120.

[0040] In some embodiments, the blade contacts 176, 180 may be present on the positive and negative battery terminals 160, 164 of the removable battery 116 and the corresponding opposing spring-biased contacts 184, 188 and the respective contact receiving channels 192, 196, may be included on the positive and negative terminal connectors 108, 112. In such an embodiment, the mating between the blade contacts 176, 180 and the corresponding opposing spring-biased contacts 184, 188 will function similarly to the embodiment described above and below with the location of the blade contacts 176, 180 and the corresponding opposing spring- biased contacts 184, 188 being switched with one another.

[0041] As the removable battery 116 moves within the battery cavity 120, contact is maintained between each of the blade contacts 176, 180 and the corresponding opposing spring- biased contacts 184, 188, including in situations in which the removable battery 116 is displacedto the maximum travel possible in at least one of the lateral direction DI, the longitudinal direction D2, and the vertical direction D3.

[0042] The blade contacts 176 of the positive terminal connector 108 may be configured 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 be of sufficient length to guarantee continuous contact between each blade contact 176 and at least one of the corresponding opposing spring-biased contacts 184 of the positive terminal 160 of the removable battery 116 at the maximum travel of the battery in the longitudinal direction D2. In other words, the length of the blade contacts 176 in the longitudinal direction D2 may be greater than the total possible displacement of the removable battery 116 within the battery cavity 120 in the longitudinal direction D2. Put another way, the length of the blade contacts 176 in the longitudinal direction D2 may be such that the blade contacts 176 extend in each of opposite longitudinal directions from a nominal position a length greater than the possible displacement of the removable battery 116 within the battery cavity 120 in the longitudinal direction D2 to ensure that the opposing spring-biased contacts 184 remain positioned adjacent the blade contacts 176. Additionally, the blade contacts 176 of the positive terminal connector 108 may be configured 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 be of sufficient height to guarantee continuous contact between each blade contact 176 and at least one of the corresponding opposing spring-biased contacts 184 of the positive terminal 160 of the removable battery 116 at the maximum travel of the battery in the vertical direction D3. In other words, the height of the blade contacts 176 in the vertical direction D3 may be greater than the total possible displacement of the removable battery 116 in the vertical direction D3 within the battery cavity 120 in the vertical direction D3. Put another way, the height of the blade contacts 176 in the vertical direction D3 may be such that the blade contacts 176 extend in each of opposite vertical directions from a nominal position a height greater than the possible displacement of the removable battery 116 within the battery cavity 120 in the vertical direction D3 to ensure that the opposing spring-biased contacts 184 remain positioned adjacent the blade contacts 176.

[0043] Similarly, the blade contacts 180 of the negative terminal connector 112 may be configured 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 be of sufficient length to guarantee continuous contact between each blade contact 180 and at least one of the corresponding opposing spring-biased contacts 188 of the negative terminal 164 of theremovable battery 116 at the maximum travel of the battery 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 within the battery cavity 120 in the longitudinal direction D2. Put another way, the length of the blade contacts 180 in the longitudinal direction D2 may be such that the blade contacts 180 extend in each of opposite longitudinal directions from a nominal position a length greater than the possible displacement of the removable battery 116 within the battery cavity 120 in the longitudinal direction D2 to ensure that the opposing spring-biased contacts 188 remain positioned adjacent the blade contacts 180. Further, the blade contacts 180 of the negative terminal connector 112 may be configured 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 be of sufficient height to guarantee continuous contact between each blade contact 180 and at least one of the corresponding opposing spring-biased contacts 188 of the negative terminal 164 of the removable battery 116 at the maximum travel of the battery in the vertical direction D3. In other words, the height of the blade contacts 180 in the vertical direction D3 may be greater than the total possible displacement of the removable battery 116 in the vertical direction D3 within the battery cavity 120 in the vertical direction D3. Put another way, the height of the blade contacts 180 in the vertical direction D3 may be such that the blade contacts 180 extend in each of opposite vertical directions from a nominal position a height greater than the possible displacement of the removable battery 116 within the battery cavity 120 in the vertical direction D3 to ensure that the opposing spring-biased contacts 188 remain positioned adjacent the blade contacts 180.

[0044] In some embodiments, the maximum travel distance of the removable battery 116 in 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 in the longitudinal direction D2 may be between 1 mm and 0.6 mm, or between 0.9 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 in 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 in 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, a contact point on each blade contact 176, 180 may change. The contact point is a point where contact between each blade contact 176, 180 and the corresponding opposing spring-biased contacts 184, 188 occurs. Regardless of a change of position of the contact point, contact between each blade contact 176, 180 and corresponding opposing spring-biased contacts 184, 188 will be maintained allowing an unbroken circuit between the removable battery 116 and the electronic device 100.

[0047] Contact between the blade contacts 176, 180 and the corresponding opposing spring-biased contacts 184, 188 may be maintained when each blade contact 176, 180 is in contact with both of the corresponding opposing spring-biased contacts 184, 188 or when each blade contact 176, 180 is in contact with only one of the corresponding opposing spring-biased contacts 184, 188. Such a change in the number of corresponding opposing spring-biased contacts 184, 188 being contacted by each blade contact 176, 180 may occur due to lateral displacement of the removable battery in the lateral direction DI. For example, each of the blade contacts 176, 180 may be in contact with only a first spring-biased contact of the corresponding opposing spring-biased contacts 184, 188 when the removable battery 116 is experiencing the maximum travel in the lateral direction DI. When the removable battery 116 is in a nominal or center position with respect to the lateral direction DI (z.e., a position between the maximum travel in the lateral direction DI between a first side 201 and a second side 202 of the battery cavity 120) both spring-biased contacts of the 184, 188 simultaneously maintain contact. However, as the removable battery 116 is displaced in the lateral direction DI toward the maximum travel in the lateral direction DI, each blade contact 176, 180 may disengage one opposing spring-biased contact of the corresponding opposing spring-biased contacts 184, 188, while maintaining contact with the other opposing spring-biased contacts of the corresponding opposing spring-biased contacts 184, 188 to ensure continuous contact with at least one of the opposing spring-biased contacts 184, 188. Each blade contact 176, 180 will thus maintain an electrical connection in the event of connection to both corresponding opposing spring-biased contacts 184, 188 or only one spring-biased contact of the corresponding opposing spring-biased contacts 184, 188. The blade contacts 176 and the corresponding opposing spring-biased contacts 184, 188 are configured such that each blade contact 176, 180 is continuously in contact with at least one spring-biased contact 184, 188 regardless of a lateral position of the removable battery 116 within the confines of the battery cavity 120.

[0048] In some embodiments, the maximum travel distance of the removable battery 116 in the lateral direction DI 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 DI may be between 1 mm and 0.8 mm, or between 0.95 mm and 0.85 mm. In some embodiments, maximum travel 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 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 and negative terminal connectors 108, 112 may each include a plurality of blade contacts 176, 180. In some embodiments, each of the positive and negative terminal connectors 108, 112 may each include two, three or more of each of the blade contacts 176, 180. Similarly, each of the positive and negative terminals 160, 164 of the removable battery 116 may each include a plurality of corresponding opposing spring-biased contacts 184, 188 and a plurality of contact receiving channels 192, 196. In some embodiments, each of the positive and negative terminals 160, 164 of the removable battery 116 may each include two, three or more corresponding opposing spring-biased contacts 184, 188 and two, three or more contact receiving channels 192, 196.

[0050] In some embodiments, each of the plurality of blade contacts 176 of the positive terminal connector 108 may be redundant with remaining blade contacts of the plurality of blade contacts 176. In some embodiments, each of the plurality of blade contacts 180 of each of the negative terminal connector 112 may be redundant with remaining blade contacts of the plurality of blade contacts 180. In some embodiments, each of the plurality of opposing spring-biased contacts 184 of the positive terminals 160 of the removable battery 116 may be redundant with remaining opposing spring-biased contacts of the plurality of opposing spring-biased contacts 184. In some embodiments, each of the plurality of opposing spring-biased contacts 188 of each of the negative terminals 164 of the removable battery 116 may be redundant with remaining opposing spring-biased contacts of the plurality of opposing spring-biased contacts 188. In embodiments including redundant blade contacts 176, 180 and redundant corresponding opposing spring-biased contacts 184, 188, the redundant contacts 176, 180, 184, 188 allow continued safe operation of the electrical device in the event of disconnection of less than all of the redundant blade contacts 176, 180 and redundant corresponding opposing spring-biased contacts 184, 188.

[0051] It should be understood that that the continuous contact described above with respect to the blade contacts 176, 180 and the corresponding opposing spring-biased contacts 184, 188 will also be maintained in the event of a “twisting” or “rotation” of the removable battery 116 within the battery enclosure 104. For example, should the removable battery 116 twist about a corner of the removable battery 116, such as after an impact on a comer of the battery enclosure 104, the blade contacts 176, 180 and the corresponding opposing spring-biased contacts 184, 188 are configured to maintain contact and electrical connection after such impact.

[0052] Other aspects and features of an intrinsically safe electronic device will be appreciated from a detailed review of the additional drawings provided in Figures 8-15.

[0053] Moreover, as previously indicated, aspects of the various embodiments described above can be combined to provide yet further embodiments.

[0054] In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled.

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

Claims

CLAIMS1. An intrinsically safe battery arrangement for an electronic device, the intrinsically safe battery arrangement comprising: a battery enclosure including a battery cavity; a positive terminal connector fixedly disposed within the battery enclosure and including one or more contacts; a negative terminal connector fixedly disposed within the battery enclosure and including one or more contacts; and a removable battery positioned within the battery enclosure, the removable battery including a positive terminal with one or more corresponding contacts to engage the one or more contacts of the positive terminal connector and a negative terminal with one or more corresponding contacts to engage the one or more contacts of the negative terminal connector, wherein each of the one or more contacts of the positive and negative terminal connectors within the battery enclosure and the one or more corresponding contacts of the positive and negative terminals of the battery are configured relative to each other to guarantee continuous contact therebetween irrespective of movement of the battery in a lateral direction, a longitudinal direction and a vertical direction within a confines of the battery cavity of the battery enclosure.

2. The intrinsically safe battery arrangement of claim 1, wherein the one or more contacts of the positive and negative terminal connectors are blade contacts, the corresponding contacts of the positive and negative terminals of the battery comprise corresponding opposing spring-biased contacts extending into a respective contact receiving channel, and each of the blade contacts of the positive and negative terminal connectors within the battery enclosure and the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery are configured relative to each other to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts irrespective of movement of the battery in the lateral direction within the confines of the battery cavity.

3. The intrinsically safe battery arrangement of claim 2, wherein each of the positive and negative terminal connectors include at least three blade contacts, and each of the positive and negative terminals of the battery include at least three corresponding contact receivingchannels with opposing spring-biased contacts extending into each respective contact receiving channel.

4. The intrinsically safe battery arrangement of claim 3, wherein each of the at least three blade contacts of the positive terminal connector is redundant, each of the at least three blade contacts of the negative terminal connector is redundant, each of the opposing spring- biased contacts of the positive terminal of the battery is redundant, and each of the opposing spring-biased contacts of the negative terminal of the battery is redundant.

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

6. The intrinsically safe battery arrangement of claim 5, wherein the blade contacts of the positive and negative terminal connectors are configured relative to the positive and negative terminals of the battery and the maximum travel of the battery in the longitudinal direction to be of sufficient length to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery at the maximum travel of the battery in the longitudinal direction, and wherein the blade contacts of the positive and negative terminal connectors are configured relative to the positive and negative terminals of the battery and the maximum travel of the battery in the vertical direction to be of sufficient height to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery at the maximum travel of the battery in the vertical direction.

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

8. The intrinsically safe battery arrangement of claim 6, wherein in response to displacement of the battery to the maximum travel of the battery in the lateral direction, contact between each of the one or more blade contacts of the positive and negative terminal connectors and both of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery transitions to contact between each of the one or more blade contacts of the positive and negative terminal connectors and only one of the corresponding opposing spring-biased contacts of the positive and negative terminals of the battery.

9. The intrinsically safe battery arrangement of claim 1, wherein the one or more contacts of the positive and negative terminal connectors each comprise opposing spring-biased contacts extending into a respective contact receiving channel and each of the one or more corresponding contacts of the positive and negative terminals of the battery include blade contacts, and each of the blade contacts of the positive and negative terminals of the battery and corresponding opposing spring-biased contacts of the positive and negative terminal connectors within the battery enclosure are configured relative to each other to guarantee continuous contact between each blade contact and at least one of the corresponding opposing spring-biased contacts irrespective of movement of the battery in the lateral direction within the confines of the battery cavity.

10. The intrinsically safe battery arrangement of claim 9, wherein each of the positive and negative terminals of the battery include at least three blade contacts and each of the positiveand negative terminal connectors include at least three corresponding contact receiving channels with opposing spring-biased contacts extending into each respective contact receiving channel.

11. The intrinsically safe battery arrangement of claim 10, wherein each of the at least three blade contacts of the positive terminals of the battery is redundant, each of the at least three blade contacts of the negative terminals of the battery is redundant, each of the opposing spring- biased contacts of the positive terminal connector is redundant, and each of the opposing spring- biased contacts of the negative terminal connector is redundant.

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

13. The intrinsically safe battery arrangement of claim 12, wherein the blade contacts of the positive and negative terminals of the battery are configured relative to the positive and negative terminal connectors and the maximum travel of the battery in the longitudinal direction to be of sufficient length to guarantee continuous contact between the blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors at the maximum travel of the battery in the longitudinal direction, and wherein the blade contacts of the positive and negative terminals of the battery are configured relative to the positive and negative terminal connectors and the maximum travel of the battery in the vertical direction to be of sufficient height to guarantee continuous contact between the blade contact and at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors at the maximum travel of the battery in the vertical direction.

14. The intrinsically safe battery arrangement of claim 13, wherein in response to displacement of the battery in the longitudinal direction, a contact point on each of the one or more blade contacts changes in the longitudinal direction, wherein in response to displacement of the battery in the vertical direction, the contact point on each of the one or more blade contacts changes in the vertical direction,wherein contact 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 opposing spring-biased contacts of the positive and negative terminal connectors occurs at the contact point, wherein in response to displacement of the battery in the lateral direction, at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors changes a position in the lateral direction, and wherein the blade contacts of the positive and negative terminals of the battery maintain contact with at least one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors in response to displacement of the battery in at least one of the longitudinal direction, the vertical direction, and the lateral direction.

15. The intrinsically safe battery arrangement of claim 13, wherein in response to displacement of the battery to the maximum travel of the battery in the lateral direction, contact between each of the one or more blade contacts of the positive and negative terminals of the battery and both of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors transitions to contact between each of the one or more blade contacts of the positive and negative terminals of the battery and only one of the corresponding opposing spring-biased contacts of the positive and negative terminal connectors.

16. The intrinsically safe battery arrangement of claim 1, wherein the battery enclosure includes a battery enclosure cover and a compression member configured to limit maximum vertical travel of the battery when the cover is secured over the battery cavity.

17. The intrinsically safe battery arrangement of claim 1, wherein the battery includes an external casing having a notch configured to receive an extension of the battery enclosure of the electronic device during insertion of the battery in the electronic device, and wherein the notch is configured to assist in limiting maximum longitudinal travel of the battery.

18. The intrinsically safe battery arrangement of claim 1, wherein the electronic device is light-emitting headgear and the battery is secured within the light-emitting headgear to provide an intrinsically safe lighting device.

19. The intrinsically safe battery arrangement of claim 1, wherein the removable battery is configured to discharge electric charge at a current of at least 3.3 amps.

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