Battery Pack Integral Coupling Mechanism for Secure Attachment
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Solution Overview
Problem
Existing battery packs for portable external devices lack a secure and cost-effective mechanism for attachment and detachment from external devices, leading to complex assembly structures and higher manufacturing costs.
Innovation Solution
A battery pack design featuring integral coupling parts with handle and protrusion mechanisms, including recesses and protrusions, guide holes, and elastic members, which simplify the attachment and detachment process while reducing manufacturing costs through a simplified assembly structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secure attachment mechanism is added to the battery pack, then the reliability of attachment is improved, but the device complexity increases
Solution Approach 1:
The coupling part is formed as an integral structure combining the handle part and protrusion part into a single component. This merging reduces the number of separate parts and assembly steps while maintaining the secure attachment function through the integrated design of coupling elements.
Solution Approach 2:
The coupling part serves multiple functions: it provides attachment security through protrusions and recesses, guides alignment via guide holes and guide protrusions, and enables user operation through the handle part. This multi-functionality reduces the need for separate components for each function.
2Reliability
If multiple coupling components are added to ensure secure attachment, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The handle part and protrusion part are integrally formed as a single coupling part, reducing the number of manufacturing steps and assembly operations. This integration lowers manufacturing costs while maintaining attachment security through the combined functional elements.
Solution Approach 2:
The coupling part is designed with distinct functional segments (handle part for operation, protrusion part for coupling) that are integrally formed. This segmentation within integration allows each function to be optimized while maintaining cost-effectiveness through single-component manufacturing.
3Ease of manufacture
If an integral coupling structure is used, then the manufacturing cost is reduced and assembly is simplified, but the ease of operation may be affected
Solution Approach 1:
The handle part features a rough part at its upper portion, providing localized enhanced grip for user operation. This local quality improvement ensures ease of operation despite the integral structure, allowing users to easily grasp and manipulate the coupling part.
4Reliability
If guide mechanisms are added to fix the position of coupling parts, then the reliability of positioning is improved, but the device complexity increases
Solution Approach 1:
The guide protrusion fits within the guide hole, creating a nested guiding mechanism. This nested design provides precise positioning and alignment while maintaining a compact structure, reducing overall complexity compared to separate external guides.
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 battery pack achieves secure coupling and uncoupling from external devices with reduced manufacturing costs, enhancing ease of assembly and physical reinforcement through a simplified, integral coupling mechanism.
Implementation Method 1
The elastic member may be compressed according to a movement of the handle part to horizontally apply an elastic force to the protrusion part
Data Source
AI summary
A battery pack that can reduce manufacturing costs and simplify an assembly structure. The battery pack includes a first case having an inner space, at least one battery cell arranged in the inner space of the first case, a second case coupled to the first case to accommodate the battery cell, and a coupling part arranged inside the coupled first and second cases. The coupling part includes a handle part and a protrusion part that is integrally formed with the handle part and protrudes outward according to a movement of the handle part.