Battery Pack Interface With Stepped Rails and Ejector Latch
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Solution Overview
Problem
Existing battery pack interfaces and electrical devices face challenges in secure and efficient power transfer, relative movement inhibition, and easy disengagement, with existing solutions often resulting in complex mechanisms and potential for unintended power transfer or disconnection.
Innovation Solution
A battery pack interface featuring a stepped rail configuration and latching mechanism with a switch, allowing for secure engagement and disengagement, and an ejector mechanism with a biasing member to facilitate easy removal, ensuring secure power transfer and preventing unintended power disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a latching mechanism is added to secure the battery pack, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The latch member is spring-biased to automatically engage with the battery pack upon insertion, securing the connection without requiring user intervention. The mechanism serves itself by using the insertion motion to trigger latch engagement, eliminating the need for separate actuation steps while maintaining secure connection.
Solution Approach 2:
The ejector member is pre-loaded with a spring to provide ejection force before the battery pack needs to be removed. This preliminary energizing of the spring during normal operation enables quick and easy battery pack removal when needed, without requiring complex manual release mechanisms.
2Ease of operation
If an ejector mechanism is added for easy removal, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The ejector member uses a pre-compressed spring to automatically push the battery pack out when triggered. The spring stores energy during normal operation and releases it to perform the ejection action, making the removal process simple and intuitive without requiring complex multi-step mechanisms.
Solution Approach 2:
The ejector mechanism transitions from a static spring-loaded design to a dynamic system where the spring force is selectively applied. The spring remains compressed during operation and only releases force when the battery pack needs to be removed, providing dynamic responsiveness that simplifies the user interaction.
3Reliability
If a switch is added to control power transfer, then reliability is improved by preventing unintended power transfer, but device complexity increases
Solution Approach 1:
The switch is positioned and configured to automatically change state when the battery pack transitions between inserted and removed positions. This preliminary positioning of the switch mechanism ensures that power transfer is controlled based on the physical state of the battery connection, preventing unintended power transfer without requiring complex sensing or control logic.
4Ease of operation
If the interface design is simplified for easy insertion, then ease of operation is improved, but connection reliability may worsen
Solution Approach 1:
The interface is segmented into distinct functional zones: the body provides the main structural interface, the rail provides lateral guidance and positioning, and the latch member provides secure engagement. This segmentation allows each component to be optimized for its specific function while working together to achieve both easy insertion and reliable connection.
Solution Approach 2:
Different portions of the interface have different properties optimized for their local function. The body surface provides a smooth interface for insertion, the rail provides precise lateral positioning, and the latch member provides secure mechanical engagement. This local optimization of properties ensures both ease of operation and connection reliability.
Data Source
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AI summary
An interface for a battery pack and an electrical combination. The interface may include a battery-receiving portion configured to receive a battery pack and including a cavity. The cavity is defined by a pair of sidewalls with rails defining a groove between the rails and a lower surface of the cavity. The rails are stepped or angled along a battery insertion axis and are configured to guide the sliding engagement of a battery pack within the battery-receiving portion.