Battery Interface Assembly Wiping Contacts Radial Seal
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Solution Overview
Problem
Existing battery interfaces for communication devices face challenges in maintaining reliable physical and electrical connections, especially in harsh environments, where power interruptions can occur due to weak connections and water exposure, leading to reboot requirements.
Innovation Solution
A battery interface assembly featuring a battery contact extension with an o-ring and cantilevered contacts on the communication device side, surrounded by a compressible seal, providing both radial and compressible sealing to ensure a secure connection, with the battery contacts wiping over cantilevered contacts to establish a robust electrical link.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery interfaces are used, then the device structure remains simple, but the connection reliability deteriorates in harsh environments due to weak physical and electrical connections
Solution Approach 1:
The battery interface is divided into separate functional components: a battery contact extension with o-ring seal, a radio contact block with cantilevered contacts, and a compressible seal. This segmentation allows each component to be optimized independently for its specific function while maintaining overall reliability in harsh environments.
Solution Approach 2:
The cantilevered contacts are pre-positioned and spring-loaded to protrude through the radio aperture before battery insertion. The compressible seal is pre-installed to provide immediate sealing when pressure is applied. This preliminary positioning ensures reliable contact and sealing from the moment of connection without requiring additional adjustment steps.
2Object-affected harmful factors
If sealed battery interfaces are implemented, then water intrusion prevention improves, but manufacturing complexity increases due to additional sealing components
Solution Approach 1:
The o-ring seal on the battery contact extension and the compressible seal in the radio contact block act as intermediary sealing elements between the battery and radio components. These seals create water-tight barriers without requiring complex integrated sealing structures, simplifying the manufacturing process while effectively preventing water intrusion.
Solution Approach 2:
The o-ring and compressible seal utilize flexible elastomeric materials that can deform to accommodate manufacturing tolerances and assembly variations. This flexibility provides reliable sealing without requiring precision machining or complex rigid sealing structures, maintaining ease of manufacture while achieving water intrusion prevention.
3Reliability
If cantilevered contacts with wiping action are used, then electrical connection reliability improves, but contact wear increases over time
Solution Approach 1:
The cantilevered contacts are pre-loaded with spring force to maintain constant pressure against the battery contacts. This preliminary spring loading ensures continuous electrical connection and compensates for contact wear over time, extending the operational lifespan while maintaining reliable electrical connection throughout the device lifecycle.
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 ensures uninterrupted power supply and prevents water intrusion, maintaining a reliable physical and electrical connection across various environments, including drops, vibrations, and water exposure, by combining wiping contacts and radial sealing for enhanced reliability.
Implementation Method 1
the o-ring of the battery extension forms a radial seal about a perimeter of the other aperture
Implementation Method 2
a compressible seal compressibly couples about a perimeter of one of the apertures
Implementation Method 3
the battery contacts wipe over and mate with the cantilevered contacts of the PCB
Data Source
AI summary
A battery interface assembly for a communication device (100), such as a portable radio, is provided to ensure a reliable interconnection between battery contacts (230) and radio contacts (108). Communication device (100) includes a casting (110) having a cavity (112) with two apertures formed therein (114, 228). The two apertures (114, 228) open into the cavity (112) to provide a point of contact for mating radio contacts (108) to the battery contacts (230). The battery contacts (230) are wiping contacts which mate with the radio contacts (108) as the battery is slid into the casting (110). A compression seal (126) is provided to the radio contacts (108) while a radial seal (120) is provided about the battery contacts (230) to ensure reliable electrical and physical connection under a variety of environments.