Battery Pack Mounting Mechanism Alignment
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Solution Overview
Problem
Existing battery packs face challenges in achieving precise alignment between mechanical and electrical connections, leading to unstable or misaligned contacts, which complicates reliable connection and detachment from battery-powered devices.
Innovation Solution
The battery pack design incorporates a mounting mechanism with a partially exposed latching unit and electrical connection holder on the upper casing, allowing for precise positioning of the pack circuit board and connectors relative to the mechanical and electrical structures, reducing alignment errors and improving connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mechanical connection structure and electrical connection structure are separated, then mechanical connection strength is improved and electrical connection stability is improved, but positioning accuracy between the two structures becomes difficult to achieve
Solution Approach 1:
The patent introduces a positioning pin as an intermediary element that mediates between the mechanical connection structure (latching unit) and electrical connection structure (connector). The positioning pin protrudes from the upper casing and fits into a positioning hole in the connector, ensuring accurate relative positioning of the two separated structures without requiring high-precision manufacturing of each component individually.
2Ease of operation
If the battery pack is designed with detachable mounting mechanism, then ease of attachment and detachment is improved, but connection reliability may be compromised
Solution Approach 1:
The mounting mechanism is segmented into distinct functional components: a latching unit with an engaging hook for mechanical connection, a positioning pin for alignment, and a connector for electrical connection. This segmentation allows each component to perform its specific function optimally while working together to achieve both easy operation and reliable connection.
Solution Approach 2:
The positioning pin performs preliminary action by establishing accurate relative positioning between the mechanical and electrical connection structures before the actual connection is made. This preliminary positioning ensures that when the latching unit engages, the electrical connector is already correctly aligned, guaranteeing connection reliability from the first attachment.
Data Source
AI summary
A battery pack detachably mounted in a device for supplying power to the device to operate the device includes at least one rechargeable secondary battery (1), a battery case (31) housing the rechargeable secondary battery (1), a mounting mechanism for mechanically mounting the battery case (31) in the device, an electrical connection connected electrically to the device for supplying power to the device, and a pack circuit board (74) securing the electrical connection. The battery case (31) is divided into a first casing and a second casing, the pack circuit board (74) is secured to the inside surface of the first casing, and the mounting mechanism is installed so the mounting mechanism is at least partially exposed on the surface of the first casing.