Molded Battery Pack Button Assembly for Faster Manufacturing
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Solution Overview
Problem
Complex assemblies in battery packs, such as those required for power tools, slow down manufacturing processes due to the intricate steps involved in assembling, fastening, and testing multiple components, necessitating a simplified approach to housing and peripheral component integration.
Innovation Solution
A battery pack design featuring a housing with a flexible button and switch, and an integrated light pipe system with a retention member and LED, where the flexible button is molded onto the housing with a user engagement portion, sidewall, lip, and post, and the light pipe is retained by a protrusion, allowing for easier assembly and enhanced user interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components are assembled and fastened together, then functional requirements are met, but manufacturing complexity and time increase
Solution Approach 1:
The button assembly is integrated directly into the housing through molding, combining what would traditionally be separate components (button, housing, mounting structure) into a single molded part. This eliminates the need for separate assembly and fastening steps while maintaining all necessary functions.
Solution Approach 2:
The housing serves multiple functions: it provides structural support, contains internal components, and integrates the button assembly directly into its structure. This multi-functionality reduces the overall number of components needed in the battery pack.
2Productivity
If traditional assembly methods are used with multiple fastening steps, then component retention is ensured, but manufacturing productivity decreases
Solution Approach 1:
The button assembly is pre-integrated into the housing during the molding process itself, rather than being attached separately after housing fabrication. This preliminary integration eliminates subsequent assembly steps and significantly reduces manufacturing time.
3Reliability
If complex fastening and testing steps are required, then component reliability is ensured, but manufacturing complexity increases
Solution Approach 1:
The retention features are built directly into the molded housing structure, ensuring reliable component retention through the inherent strength of the molded joint rather than separate fasteners. This integration simplifies the assembly process while maintaining or improving reliability.
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 design simplifies the assembly process, enhances user engagement, and provides a visually appealing and functional battery pack that can power various power tools and electronic devices, improving manufacturing efficiency and user experience.
Implementation Method 1
The LED is disposed in the housing. The LED is positioned to emit light into the base of the light pipe.
Data Source
AI summary
A battery pack includes a housing, a flexible button, and a switch. The housing includes an opening and a groove. The groove is disposed at least partially about the opening. The flexible button is molded onto the housing in the opening. The flexible button includes a user engagement portion, a sidewall, a lip, and a post. The sidewall extends from the user engagement portion into the housing. The lip extends laterally from the sidewall. The lip includes a ridge protruding into the groove of the housing. The post extends from the user engagement portion. The switch is disposed in the housing. The switch is positioned to be engaged by the post.