Battery Pack Interface With UV Glue Dam and Spring Contacts
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Solution Overview
Problem
Portable communication devices used in public safety operations require a robust battery pack interface that can withstand extreme temperatures, water exposure, and high currents during push-to-talk transmissions, while maintaining impact resistance and efficient power transfer.
Innovation Solution
The battery pack interface features a spring contact connector with a UV-glued endcap and potting compound flow directors, providing a sealed and robust connection that handles high currents and protects sensitive components from water and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robust sealed interface is used to protect against water and impact, then reliability under harsh conditions is improved, but device complexity increases
Solution Approach 1:
The connector is nested within a walled aperture in the endcap, which is itself nested within the battery pack housing. The potting compound is injected through a fill port that penetrates the endcap, creating a nested structure where each component is housed within the previous one. This nesting approach provides robust sealing and protection while maintaining a compact, integrated design rather than requiring separate external sealing components.
Solution Approach 2:
A dam formed from UV glue creates a flexible barrier that seals the walled aperture around the connector. This UV glue dam acts as a flexible film that prevents potting compound and moisture from entering the connector area, providing sealing functionality without requiring rigid, complex sealing mechanisms. The flexible nature of the UV glue dam allows it to conform to the connector geometry while maintaining the seal.
2Power
If high current handling capability is improved for push-to-talk transmissions, then power transfer capability is improved, but contact bounce and reliability issues may worsen
Solution Approach 1:
The connector contacts are spring-loaded, providing pre-compression and cushioning force before high current flows through them. This spring mechanism absorbs mechanical shocks and maintains consistent contact pressure during operation, preventing contact bounce that would occur with rigid contacts under high current loads. The spring cushioning is built into the connector design beforehand to handle the demanding push-to-talk transmission currents.
Solution Approach 2:
The battery pack uses a composite sealing approach combining multiple materials: UV glue (polymer adhesive), potting compound (epoxy or similar encapsulant), and spring contacts (metallic material). This composite structure provides both electrical conductivity for high current handling and mechanical compliance for contact stability. The different materials complement each other to achieve both power handling and reliability requirements.
3Area of stationary object
If the battery pack interface is made more compact with a smaller footprint, then space efficiency is improved, but sealing effectiveness and robustness may worsen
Solution Approach 1:
The endcap serves multiple functions simultaneously: it provides the top surface of the battery pack housing, contains the walled aperture for the connector, forms the dam with UV glue for sealing, and includes the fill port for potting compound injection. By merging these functions into a single integrated component rather than using separate parts, the design achieves compact footprint while maintaining effective sealing through the combined structural features of the endcap.
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 reliable high-power transfer and enhanced durability under harsh conditions, reducing the risk of contact bounce and allowing for a smaller footprint, while maintaining structural integrity and sealing effectiveness.
Implementation Method 1
A dam of UV glue surrounds a perimeter of the connector. The walled aperture is sealed to the dam of UV glue surrounding the connector.
Implementation Method 2
The connector along with electronic circuitry being disposed on a printed circuit board located beneath the endcap... the battery interface must be able to handle high currents, such as those associated with a transceiver that occur during push-to-talk (PTT) transmissions.
Implementation Method 3
An endcap perimeter rim of UV glue seals the endcap to the housing... allowing for a smaller footprint, while maintaining structural integrity and sealing effectiveness.
Data Source
AI summary
A battery pack is provided with an improved interface through the use of an endcap which forms a top surface of a battery pack housing. The endcap includes a walled aperture for a connector. The connector along with electronic circuitry is disposed on a printed circuit board located beneath the endcap. A dam of UV glue surrounds a perimeter of the connector preventing the potting compound from intruding into contacts. An endcap perimeter rim of UV glue seals the endcap to the housing. The endcap further includes an injection port and flow directors for guiding a potting compound into the endcap to form a water tight seal.