Battery Pack Charger Interface with Non-Conductive Carrier
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Solution Overview
Problem
Existing battery packs for portable communication devices face challenges in creating a robust, watertight, high current flow charging interface that can withstand water, extreme temperatures, and drop conditions without compromising the water seal integrity, as traditional ultrasonic welding methods are prone to failure.
Innovation Solution
A battery pack with a charger interface featuring tooled contacts supported on multiple surfaces, utilizing a non-conductive contact carrier assembly that aligns and retains charger contacts across perpendicular surfaces, and employs laser welding for metal tabs to ensure a compact, watertight seal without ultrasonic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic welding is used to attach charger contacts, then the charging interface can be manufactured, but the water seal integrity is compromised during drop impact
Solution Approach 1:
The charger contact assembly is segmented into separate components: a non-conductive carrier and individual charger contacts. This segmentation allows the carrier to be molded as a single piece that integrates multiple contact holders, providing structural support without requiring ultrasonic welding of the contacts themselves to the housing.
Solution Approach 2:
A non-conductive carrier acts as an intermediary component between the charger contacts and the battery pack housing. The carrier is molded directly into the housing, providing a secure mechanical attachment point for the contacts while maintaining the waterproof seal, thereby eliminating the need for ultrasonic welding.
2Ease of operation
If charger contacts are left exposed during normal operation, then charging function is accessible, but the contacts are subjected to water, extreme temperatures and drop conditions
Solution Approach 1:
The charger contacts are nested within recessed openings in the battery pack housing. The non-conductive carrier positions each contact within its own recessed opening, allowing the contacts to be accessible for charging while being physically protected from environmental factors such as water and extreme temperatures.
Solution Approach 2:
A waterproof seal (thin film) is applied over the charger contact assembly, covering the contacts and recessed openings. This seal protects the contacts from water and environmental exposure while allowing the charging function to remain accessible when the seal is engaged with the charging cable.
3Reliability
If a robust watertight charging interface is created, then water seal integrity is maintained, but the structural strength against drop impact is compromised
Solution Approach 1:
The charger contact assembly uses composite materials: a non-conductive carrier material that provides mechanical strength and insulation, combined with conductive contact materials. The non-conductive carrier is molded directly into the housing, creating a composite structure that maintains both waterproof integrity and drop impact resistance.
Solution Approach 2:
The charger contacts are positioned to extend across perpendicular back and bottom surfaces of the housing, utilizing three-dimensional space. This multi-dimensional arrangement allows the contacts to be supported on multiple surfaces, distributing mechanical stress during drop impact while maintaining waterproof sealing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a robust, compact, and watertight charging interface capable of withstanding harsh conditions such as water, extreme temperatures, and drops, while maintaining high current flow without the risks associated with ultrasonic welding.
Implementation Method 1
The non-conductive contact carrier aligns and retains a plurality of charger contacts. The carrier aligns a first portion of each charger contact within recessed openings along a back surface of the battery pack housing and further facilitates another portion of each charger contact within bottom apertures of the housing
Implementation Method 2
employs laser welding for metal tabs
Implementation Method 3
The battery pack is provided with an improved charger interface through the use of an improved contact carrier assembly... provides a robust, compact, and watertight charging interface capable of withstanding harsh conditions such as water, extreme temperatures, and drops
Data Source
AI summary
A battery pack is provided with an improved charger interface through the use a contact carrier assembly. The non-conductive contact carrier aligns and retains a plurality of charger contacts. The carrier aligns a first portion of each charger contact along a back surface of the battery pack housing and further facilitates alignment of another portion of each charger contact within bottom apertures of the housing thereby allowing each contact to extend across perpendicular back and bottom surfaces of the housing with improved ruggedness. Improved sealing is also provided by sealing the back of the carrier.