Flashlight Battery Cartridge With Integrated Switch
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Solution Overview
Problem
Existing battery cartridges for flashlights require costly and laborious replacement of the high-quality housing when the push-button switch wears out, as the entire end piece must be replaced, and internal contact replacement is difficult due to inaccessible mounting locations.
Innovation Solution
A battery cartridge design with a casing that holds batteries, external contacts, and internal circuitry, featuring a push-button switch integrated into the cartridge, allowing independent replacement of the switch without needing to replace the high-quality end cap, and enabling easy access to replace worn-out contacts by swapping the entire cartridge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the push-button switch is integrated into the end cap, then the switch is protected and structurally stable, but the replacement cost increases significantly when the switch wears out
Solution Approach 1:
The invention separates the push-button switch from the end cap by integrating it into a battery cartridge that can be independently removed. The battery cartridge (containing switch, contacts, and battery) becomes a modular unit that can be replaced without affecting the end cap or housing, thus reducing replacement costs while maintaining switch stability during use.
Solution Approach 2:
The design transitions from a static integration (switch permanently fixed in end cap) to a dynamic configuration where the switch moves with the battery cartridge. This allows the switch assembly to be easily exchanged by simply removing the battery cartridge, converting a high-cost repair scenario into a low-cost replacement operation.
2Reliability
If the contacts are mounted inside the housing, then they are protected from damage, but their replacement becomes laborious due to difficult accessibility
Solution Approach 1:
The contacts are integrated into the battery cartridge as a complete sub-assembly, separated from the main housing. This segmentation allows the contacts to remain protected within the cartridge structure while enabling easy replacement by simply removing the entire battery cartridge unit, eliminating the need for complex disassembly of the housing.
3Ease of repair
If the battery cartridge is designed to be replaceable, then maintenance becomes easier, but the device complexity increases
Solution Approach 1:
The invention combines multiple components (battery, push-button switch, contacts, and spring mechanism) into a single integrated battery cartridge unit. This merging simplifies the overall system by creating a self-contained module that handles both power supply and switching functions, making maintenance easier despite the internal complexity of the cartridge itself.
Data Source
AI summary
A battery cartridge has a casing adapted to releasably hold at least one battery, externally accessible contacts on the casing, and internal circuitry in the casing between the contacts and poles of the battery. A switch is mounted in the casing and connected to the circuitry between one of the poles and the respective contacts for controlling current flow therebetween.