Dual-Orientation Battery Pack Alignment for Secure Coupling
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Solution Overview
Problem
Conventional battery packs lack a standardized mechanism for secure and directional insertion into electronic devices, leading to potential misalignment and improper coupling, which can result in inefficient power transfer and device damage.
Innovation Solution
The battery pack design incorporates dual insertion alignment members, one for radial and one for axial insertion, which cooperate with complementary alignment and lockout members on electronic devices to ensure proper alignment and secure coupling, preventing improper insertion and ensuring efficient electromechanical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery packs use simple insertion mechanisms without alignment members, then the device complexity is reduced, but the reliability of coupling and power transfer deteriorates due to potential misalignment and improper coupling
Solution Approach 1:
The alignment members (protrusions and grooves) are pre-configured on the battery pack and device housing to automatically guide and align the battery pack during insertion before electrical coupling occurs. This preliminary alignment action ensures proper positioning and prevents misconnection, thereby improving coupling reliability without requiring complex active control systems.
2Adaptability or versatility
If dual insertion alignment members are added to support both radial and axial insertion, then the adaptability of the battery pack to different electronic devices is improved, but the device complexity increases
Solution Approach 1:
The battery pack is designed with both radial and axial alignment members, allowing it to function with electronic devices that have different insertion orientations. The same battery pack housing incorporates multiple alignment features that can accommodate various device configurations, achieving multi-functionality and broad compatibility without requiring different battery pack designs for different devices.
Solution Approach 2:
The alignment mechanism is segmented into distinct radial and axial components, each handling a specific insertion direction. This segmentation allows each alignment member to be optimized for its specific function while maintaining overall system compatibility. The modular alignment features can be independently configured to match different device requirements.
3Reliability
If alignment members with lockout features are implemented, then the reliability and safety are improved by preventing improper insertion, but the ease of operation deteriorates due to more complex insertion procedures
Solution Approach 1:
The lockout features (complementary protrusions and grooves that interlock) are designed to passively prevent improper insertion attempts before they can cause damage. The mechanical interlocking geometry inherently blocks misaligned insertion paths, providing preliminary protection against incorrect coupling without requiring active sensing or control systems. This passive prevention mechanism improves reliability while maintaining operational simplicity for correct insertions.
Data Source
AI summary
A battery pack and a method for connecting a battery pack to an electronic device to power to the electronic device (e.g., a headlamp, a flashlight, a flood light, a drill, a driver, etc.). The battery pack includes a generally cylindrical housing defined by an arcuate sidewall extending between a first end surface and a second end surface and defining an interior cavity configured to support at least one battery cell (e.g., a lithium-ion battery cell). The battery pack includes a first insertion alignment member engageable with a first battery alignment member of the electronic device in order to facilitate insertion into a receiving portion of the electronic device in a first direction and a second insertion alignment member engageable with a second battery alignment member of another electronic device in order to facilitate insertion into a receiving portion of the other electronic device in a second direction.