Battery Pack Secure-Locking and Shock Absorbing System
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Solution Overview
Problem
Current battery packs lack a shock absorbing system and robust locking mechanism, leading to inefficiencies, precision issues, and increased failure rates due to ultrasonic welding and inadequate protection during drops.
Innovation Solution
A shock absorbing system and improved locking mechanism are introduced, utilizing shock-absorbing materials and a secure-locking device that eliminates ultrasonic welding, enhances mechanical robustness, and provides better protection during impacts, with a customizable button feel and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic welding is used to assemble battery pack components, then manufacturing efficiency is improved, but manufacturing precision deteriorates due to welding gaps and potential misalignment
Solution Approach 1:
The patent replaces ultrasonic welding with a mechanical locking mechanism consisting of a lock lever, lock groove, and lock hole system. This mechanical substitution eliminates the need for ultrasonic welding while achieving secure assembly, thereby maintaining manufacturing efficiency without compromising assembly precision.
Solution Approach 2:
The battery pack is divided into modular components (battery cell, shock absorbing housing, cap, locking mechanism) that can be independently manufactured and then assembled through precise mechanical interfaces. This segmentation allows each component to be optimized separately while ensuring precise fit-through during assembly.
2Device complexity
If a simple locking mechanism is used, then device complexity is reduced, but reliability deteriorates due to insufficient protection during drops and shocks
Solution Approach 1:
The patent incorporates a shock absorbing system with damping elements positioned between the battery cell and the housing walls before any impact occurs. This pre-installed cushioning protection absorbs shock and vibration during drops and shocks, enhancing reliability without adding complex active protection mechanisms.
Solution Approach 2:
The locking mechanism is integrated with the shock absorbing housing structure, combining the functions of mechanical retention and shock protection into a unified design. The lock lever and lock groove work together with the shock absorbing elements to provide both securing and protection functions through a coordinated system.
3Reliability
If shock absorbing material is added around the battery cell, then protection during impacts is improved, but device complexity increases due to additional components
Solution Approach 1:
The shock absorbing housing is designed as an integrated structure where the shock absorbing material is incorporated into the housing walls themselves rather than being separate components. This merging of the housing and shock absorption functions reduces the number of discrete parts while maintaining comprehensive impact protection.
Solution Approach 2:
The housing utilizes composite construction with shock absorbing materials integrated into the structural walls, creating a multi-functional component that provides both mechanical support and impact attenuation. This composite approach delivers enhanced protection without proportionally increasing complexity.
4Reliability
If a secure-locking mechanism with multiple components is used, then reliability is improved, but ease of manufacture deteriorates due to increased assembly steps
Solution Approach 1:
The patent replaces complex multi-step locking procedures with a simple lever-based mechanical locking system. The lock lever engages with the lock groove and lock hole in a single motion, providing reliable locking without requiring multiple assembly steps or specialized equipment, thereby maintaining ease of manufacture.
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 field failures, lowers production costs, and enhances user experience by providing better protection and reliability, with a 'green' design that avoids glue and Terostat, while ensuring secure locking and precise coupling.
Implementation Method 1
shock absorbing system and locking mechanism for a battery pack is provided for a handheld device. The shock absorbing system and locking mechanism for the battery pack avoids ultrasonic welding, improves mechanical robustness, provides better protection of the battery cells during drop tests
Implementation Method 2
encasing a battery cell in a shock absorbing material. The shock absorbing material has a cylindrical portion that surrounds the battery cell and functions as a first shock absorber
Data Source
AI summary
An improved battery pack is inserted in a handle portion of a handheld scanner. The battery pack has an integral shock absorbing system where the structure surrounding the battery cell provides advantageous shock protection. The improved battery pack has a locking and unlock mechanism for retention of the battery pack. The locking and unlock mechanism retains the battery pack in the handheld scanner in the event of a shock or impact.