Battery Flange Layout for Compact Wearable Component Integration
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Solution Overview
Problem
Existing wearable electronic devices face limitations in performance due to the inclusion of multiple components, which can compromise the functionality and efficiency of individual components, especially when designed for portability, as larger batteries and additional features require optimized component arrangement without increasing undesirable device properties.
Innovation Solution
A portable electronic device design featuring a battery with a flange extending beyond the housing, allowing for a larger battery capacity and optimized component placement, including a controller overmolded with polymer material, and flexible electrical connectors to enhance performance and space utilization, while maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components are included to enhance functionality, then device versatility is improved, but component performance and device portability deteriorate
Solution Approach 1:
The patent combines the battery controller with the battery assembly by overmolding the controller onto the battery housing. This integration reduces the number of separate components, minimizes space requirements, and eliminates the need for additional mounting structures, thereby maintaining component performance while enhancing device versatility
Solution Approach 2:
The battery housing serves multiple functions: it contains the battery cells, provides structural support, houses the controller through overmolding, and offers protection through integrated sealing features. This multi-functionality allows enhanced device capabilities without adding separate components that would compromise performance
2Duration of action of moving object
If battery capacity is increased to improve duration of action, then device volume increases
Solution Approach 1:
The controller is nested within the battery assembly through overmolding, where the controller is molded directly onto the battery housing. This nesting approach allows the controller to occupy space within the existing battery volume rather than requiring additional external space, enabling larger battery capacity without proportionally increasing device volume
Solution Approach 2:
The battery housing includes a flange that extends beyond the sidewall in a different dimension, allowing the battery to be mounted optimally within the device. This dimensional extension enables better space utilization and allows for larger battery capacity while maintaining compact device form factor
3Length of moving object
If component arrangement is optimized to maintain portability, then manufacturing complexity increases
Solution Approach 1:
The controller is pre-integrated with the battery housing through overmolding before final device assembly. This preliminary integration ensures optimal component arrangement is achieved during manufacturing rather than requiring complex post-assembly adjustments, maintaining device compactness while simplifying the overall assembly process
Solution Approach 2:
The battery housing uses composite construction with integrated sealing features and flange structures that provide both mechanical support and optimized component arrangement. These composite design elements are incorporated during manufacturing to achieve compact device form factor without requiring complex assembly operations
Data Source
AI summary
A portable electronic device can include a housing at least partially defining an internal volume and a battery disposed in the internal volume. The battery can include sidewalls and a top portion extending past the sidewalls to define a flange. A component can be positioned in the internal volume adjacent to the battery, and at least a portion of the component can extend beyond an edge of the flange toward the sidewall of the battery.