Headlamp Battery Case Double-Rotation Lock for Waterproof Sealing
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Solution Overview
Problem
Existing portable headlamps face challenges in securing and waterproofing their battery compartments, especially as batteries become heavier and operating conditions become harsher, requiring an improved locking system for a perfectly sealed battery compartment.
Innovation Solution
A battery housing for a headlamp featuring a double rotation mechanism for the cover, utilizing a locking lever with cam-shaped branches that insert into circular grooves when the cover is closed, ensuring a secure and waterproof seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional locking mechanism with rotation axis at the bottom and clip at the top is used, then the structure is simple, but the closing force is concentrated causing deformation of rigid parts (banana effect)
Solution Approach 1:
The locking mechanism is segmented into multiple locking points distributed along the cover perimeter. Instead of a single concentrated locking point, the invention uses multiple discrete locking elements that distribute the closing force across several locations, preventing localized deformation while maintaining structural integrity.
Solution Approach 2:
The invention transitions from a single-plane locking mechanism to a three-dimensional distributed locking system. The locking elements are arranged in multiple dimensions along the cover perimeter, creating a spatial distribution of closing forces that eliminates the banana effect caused by concentrated single-plane locking.
2Strength
If the cover is oversized to prevent deformation, then the strength is improved, but the device complexity and weight increase
Solution Approach 1:
Instead of uniformly oversizing the entire cover to prevent deformation, the invention applies localized reinforcement only at critical stress points where locking forces are concentrated. This allows the cover to maintain adequate strength and rigidity while minimizing overall material usage and complexity.
Solution Approach 2:
The locking mechanism is designed to pre-distribute closing forces before the cover is fully closed, preventing deformation from occurring in the first place. This preliminary force distribution eliminates the need for excessive cover sizing, as the structural integrity is maintained through proactive force management rather than reactive oversizing.
3Reliability
If a secure and waterproof lock is implemented, then the reliability is improved, but the ease of operation decreases due to multiple manual movements required
Solution Approach 1:
The locking mechanism incorporates self-aligning features that automatically guide the locking elements into their correct positions during the closing operation. This self-service capability reduces the precision required from the user, making the multi-movement locking procedure easier to perform correctly while maintaining the reliability of the waterproof seal.
Solution Approach 2:
The locking mechanism is designed with a rhythmic, periodic closing sequence that guides the user through the multiple manual movements in a predictable pattern. This periodic action structure makes the complex locking procedure more intuitive and easier to remember, improving ease of operation while maintaining sealing effectiveness.
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 double rotation mechanism provides a better distribution of closing force, reducing deformation of rigid parts and ensuring a tight, waterproof seal, which is more effective than conventional mechanisms that may suffer from deformation issues.
Implementation Method 1
a lid mobile in rotation around a first axis of rotation defined by the hinge
Implementation Method 2
a locking lever comprising two left and right branches, in which the inner face of the left branch comprises a first perpendicular pin and the inner face of the right branch comprises a second pin; in which said first and second pins are configured to be inserted into the blind holes of the cover so as to allow rotation of the lever relative to the cover; in which the U-shaped lever further comprises, on each of the two outer faces of the left and right branches, a cam having a substantially circular shape centered around the second axis of rotation
Implementation Method 3
configured to receive the passage of said circular cams, respectively, when the cover is in the closed position with the lever in the deployed position and the lever is pivoted to insert the circular cams into their respective circular grooves ensuring force locking
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A battery housing case for a headlamp, comprising: a case body (10) having a front face, a rear face provided with a hinge (19) and two left and right side faces; a cover (20) rotatable about the hinge defining a first rotation axis; a second rotation axis being defined at the front of the cover for rotation of a locking lever relative to the cover; a locking lever (30) having two left (31) and right (32) arms, wherein the inner face of the left arm (31) has a first perpendicular pin (33) and the inner face of the right arm (32) has a second pin (34); wherein said first and second pins (33, 34) are configured to be inserted into blind holes (23, 24) of said cover (20) so as to effect rotation of the lever relative to the cover (20);wherein said U-shaped lever (30) further comprises, on each of the two external faces of the left and right branches (31, 32), a cam (35, 36) having a substantially circular shape centered around an axis common with said second axis of rotation; wherein said lateral faces (13, 14) of said housing (10) comprise, at the front part, two circular grooves (15, 16) configured to receive the passage of said circular cams (35, 36), respectively, when the cover is in the closed position with the lever in the deployed position and the lever is pivoted to insert the circular cams (35, 36) into their respective circular grooves (15, 16) ensuring force locking.;