Battery Chassis Shear Stops for Repairable Electronic Devices
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Solution Overview
Problem
Existing electronic device designs that adhere batteries to structural components make battery replacement and internal component access challenging, time-consuming, and potentially damaging, while also complicating manufacturing and increasing costs due to the need for precise adhesive application.
Innovation Solution
A battery chassis with shear stops that mechanically interlocks with the electronic device's mechanical frame, allowing the battery to be removed without severing adhesives, facilitating repair and reducing manufacturing complexity by distributing mechanical forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are adhered to structural components using adhesive, then the battery is securely fixed, but battery replacement and component access become difficult and time-consuming
Solution Approach 1:
The battery assembly is segmented into the battery unit and the chassis, which are separately attachable to the device frame. The chassis acts as an intermediary carrier that holds the battery via adhesive, while the chassis itself is mechanically attached to the frame through shear stops. This segmentation allows the battery to be removed by detaching it from the chassis without disturbing the adhesive bond between the chassis and frame, enabling easy battery replacement while maintaining secure fixation.
Solution Approach 2:
The chassis serves as an intermediary component between the battery and the device frame. It provides a mechanical interface through shear stops that constrain movement in multiple dimensions, while the battery adheres to the chassis. This intermediary structure enables the battery to be securely fixed through the combined mechanical-adhesive system, yet easily replaceable by disconnecting the battery from the chassis without severing the chassis-to-frame adhesive bond.
2Reliability
If adhesive is used to attach battery to structural components, then secure bonding is achieved, but manufacturing complexity and costs increase due to precise adhesive application requirements
Solution Approach 1:
The bonding system is segmented into two distinct interfaces: an adhesive bond between the battery and chassis, and a mechanical connection between the chassis and frame via shear stops. This segmentation allows the adhesive to be applied only to the battery-chassis interface, a controlled and accessible area, rather than requiring precise application across the entire battery-to-frame path. The mechanical shear stops provide additional bonding security without requiring complex adhesive application procedures.
3Strength
If battery is firmly attached to device structure, then structural integrity is maintained, but access to internal components is restricted
Solution Approach 1:
The device internal structure is segmented into modular assemblies: the battery adheres to the chassis, and the chassis mechanically attaches to the frame via shear stops. This segmentation creates a hierarchical attachment system where the battery can be accessed by detaching it from the chassis, while the chassis remains firmly secured to the frame through the shear stop mechanical constraints, maintaining overall structural integrity.
Solution Approach 2:
The attachment system exhibits dynamic characteristics where the degree of fixation can be selectively adjusted. The shear stops provide rigid mechanical constraints for overall structural stability, while the battery-chassis adhesive bond allows for controlled separation during maintenance. This dynamic attachment enables the structure to transition between a firmly integrated state during operation and an accessible state during repair.
Data Source
AI summary
This document describes systems and techniques directed at a battery chassis for electronic devices. In aspects, a battery is attached to a battery chassis that mechanically interlocks with a mechanical frame of an electronic device. The battery chassis includes a plurality of shear stops that constrain a motion of the battery chassis and battery subassembly in at least two dimensions. The battery chassis and battery subassembly can be removed from the electronic device without severing an adhesive, facilitating device repair.