Battery Cover Spring Mechanism for Compact Electrical Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery-operated appliances face challenges in securely fastening battery covers while ensuring reliable electrical contact, especially in small devices with non-linear seam lines and space constraints.
Innovation Solution
A mechanism using metal spring elements with hooks and slots provides a secure twist-on connection between the battery cover and housing, offering both mechanical retention and electrical contact, with the spring elements applying axial force to compensate for geometry issues and tolerances, and the receiving part making electrical contact with the device's circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mechanical fastening methods (screws, clips) are used to secure the battery cover, then the mechanical connection is reliable, but the device complexity increases and space is consumed
Solution Approach 1:
The patent combines the mechanical fastening function and electrical contact function into a single integrated spring element. The spring element simultaneously secures the battery cover mechanically and provides electrical contact with the battery, eliminating the need for separate fasteners and contact elements, thus reducing part count while maintaining both mechanical strength and electrical reliability
Solution Approach 2:
The spring element serves multiple functions: it acts as a mechanical fastener to secure the battery cover, provides resilient retention force to maintain connection, and simultaneously serves as an electrical contact element. This multi-functionality resolves the contradiction by consolidating multiple components into one universal element
2Reliability
If multiple separate components are used for mechanical fastening and electrical contact, then each function is optimized, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the electrical contact function with the mechanical fastening component into a single spring element. This integration maintains reliable electrical contact while significantly simplifying assembly operations, as the spring element is installed in one piece rather than requiring separate assembly of multiple fasteners and contact elements
Solution Approach 2:
The spring element is designed to be self-retaining through its resilient properties. The hooks engage with slots and the spring force automatically maintains the connection without requiring additional locking mechanisms or complex assembly procedures, making the system easy to manufacture and assemble while ensuring reliable electrical contact
3Stability of the object's composition
If rigid mechanical connections are used, then the structural integrity is maintained, but the ability to compensate for tolerance variations and non-linear seam lines is reduced
Solution Approach 1:
The patent employs a dynamic spring element instead of a rigid connector. The spring's resilient properties allow it to flex and adapt to tolerance variations and non-linear seam lines between the battery cover and housing, while still maintaining secure mechanical retention and stable electrical contact. The spring dynamically adjusts to geometric imperfections while preserving structural integrity
4Strength
If threadedly secured covers are used (as in US 4398238), then the mechanical connection is secure, but the device size increases and space-saving designs are compromised
Solution Approach 1:
The spring element is divided into functional segments (hooks, slots, spring body) that can be compactly integrated into the battery cover and housing structure. This segmentation allows the secure mechanical connection to be achieved within a compact volume, avoiding the bulk associated with threaded connections while maintaining connection security
Solution Approach 2:
The spring element's hooks nest into slots within the housing structure, creating a compact integrated connection system. This nesting arrangement provides secure mechanical retention without requiring additional external space, enabling space-saving device designs while maintaining strong mechanical connections
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
This solution ensures a simple, reliable, and space-efficient mechanical and electrical connection, reducing part count and assembly complexity, and is adaptable to various appliance designs, including those with non-linear seams and tolerances.
Implementation Method 1
The spring elements are designed to apply a spring force axially along the long axis of the housing. In the embodiment shown, the S-shaped profile of the springs (Fig. 4), along with stretching of the springs during operation, generates this spring force.
Implementation Method 2
The spring members and the receiving part are both made of metal, and thus engagement of the hooks with the slots also provides electrical contact between the spring members and the receiving part.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Battery operated appliances are provided. Some appliances include a housing defining a chamber having an interior wall, electronics within the chamber, a battery cover, and a closing system including (a) a first electrically conductive member secured to the battery cover, and (b) a second electrically conductive member secured to the interior wall of the housing and configured to engage the first electrically conductive member and thereby mechanically secure the battery cover to the housing while also establishing electrical contact between the first and second electrically conductive members.