Battery Pack LED Assembly via Snap-Fit Mechanism
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Solution Overview
Problem
The existing battery pack assembly processes for incorporating a light emitting portion are costly and prone to errors due to complex and time-consuming assembly methods, including hot welding, which can lead to thermal deformation and unintentional failures.
Innovation Solution
A battery pack assembly design that simplifies the manufacturing process by using a support portion, elastic connection, button, and observation portion with specific fixing and alignment features, eliminating the need for hot welding and reducing interference between light emitting devices, thereby decreasing processing time and preventing thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot welding is used to assemble the light emitting portion, then the assembly is securely fixed, but thermal deformation and unintentional failures occur
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical snap-fit assembly system. The support portion includes fixing hooks that engage with corresponding grooves in the case, and the observation portion has alignment projections that fit into guide grooves. This mechanical connection achieves secure fixation without thermal deformation, directly resolving the contradiction between strong assembly and avoiding thermal damage.
2Reliability
If complex assembly processes are used to incorporate the light emitting portion, then reliable assembly is achieved, but manufacturing costs increase and processing time is extended
Solution Approach 1:
The patent merges multiple assembly operations into a single snap-fit process. The support portion with fixing hooks and the observation portion with alignment projections are designed to be installed in one straightforward operation, eliminating the need for separate welding, alignment, and securing steps. This integration maintains assembly reliability while dramatically improving manufacturing efficiency by reducing process complexity and time.
Solution Approach 2:
The support portion and observation portion are pre-formed with specific geometric features (fixing hooks, alignment projections, guide grooves) that enable self-alignment and automatic positioning during assembly. This preliminary preparation of structural features ensures reliable assembly without requiring complex real-time adjustment processes, thereby improving productivity while maintaining assembly quality.
3Manufacturing precision
If hot welding equipment and jigs are used, then precise assembly is achieved, but equipment cost and process complexity increase
Solution Approach 1:
The patent designs the support portion and observation portion with self-aligning features where alignment projections automatically fit into guide grooves and fixing hooks engage with case grooves without external equipment. The structure itself provides the alignment and positioning functions that would otherwise require precision jigs and specialized welding equipment, thereby achieving manufacturing precision while eliminating complex equipment requirements.
4Strength
If welding is performed in confined spaces, then the light emitting portion is securely attached, but operational challenges and potential failures increase
Solution Approach 1:
The patent replaces the difficult welding operation in confined spaces with a simple mechanical insertion and snap-fit process. The support portion is designed to be inserted into the case where fixing hooks automatically engage with grooves, and the observation portion is positioned using alignment projections that fit into guide grooves. This mechanical approach is far easier to perform in confined battery pack spaces compared to welding, while achieving secure attachment.
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 reduces manufacturing costs and failure rates by streamlining the assembly process, eliminating the need for a separate hot melting jig, and avoiding the challenges of welding in confined spaces, while ensuring reliable operation and observation of LEDs.
Implementation Method 1
an elastic connection portion (30) extended from one side of the support portion (21)
Data Source
AI summary
A battery pack assembly comprises at least one light emitting device, a switch for operating the light emitting devices, a case, and a battery pack. The battery pack assembly includes a support portion, an elastic connection portion, a button and an observation portion. The support portion is fixed to an inside of the case. The elastic connection portion is extended from one side of the support portion. The button is formed at an end portion of the elastic connection portion. The observation portion is fixed between the support portion and the case, and is configured to allow light emitted from the light emitting devices to pass therethrough. In the battery pack assembly, the button is exposed through the button hole, and light passing through the observation portion is exposed through the observation holes.