Latch-Spring Interconnect Assembly for Battery Pack Housing
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Solution Overview
Problem
Existing interconnect mechanisms between battery packs and portable communication devices often experience disengagement or intermittent contact due to misassembly, particularly in varying temperature conditions and when dropped, leading to reliability issues and increased manufacturing complexity and cost.
Innovation Solution
A simplified interconnect assembly comprising a spring member and a latch, which are easily assembled and integrated into a housing with a predetermined form factor, providing a reliable interface with minimal components and no need for specialized tools, allowing for secure coupling of sub-assemblies such as battery packs to communication devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional interconnect mechanisms are used between battery packs and portable communication devices, then the connection can be established, but the mechanism is prone to disengagement or intermittent contact under varying temperature conditions and when dropped, leading to reliability issues
Solution Approach 1:
The interconnect mechanism is divided into distinct functional segments: a spring member with first and second ends for applying contact force, and a latch member with specific features for securing the connection. This segmentation allows each component to perform its specialized function reliably while keeping the overall structure manageable and not overly complex.
Solution Approach 2:
The spring member is designed to be resilient and dynamic, capable of deflecting and applying variable contact force to maintain reliable electrical connection. The spring's dynamic properties allow it to compensate for misalignment and maintain connection reliability under varying conditions without requiring an overly complex rigid mechanism.
2Reliability
If complex interconnect mechanisms are used to ensure reliable contact, then connection reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The spring member serves multiple functions simultaneously: it provides resilient contact force, compensates for misalignment, and maintains electrical connection. The latch member also performs multiple functions including securing the battery pack and providing a release mechanism. This multi-functionality reduces the need for additional specialized components, simplifying manufacturing while ensuring reliable contact.
Solution Approach 2:
The spring-latch mechanism is designed to be self-assemblying and self-adjusting. The spring automatically applies contact force and the latch secures itself into position without requiring specialized assembly tools or complex manufacturing processes, thereby improving ease of manufacture while maintaining contact reliability.
3Ease of manufacture
If simplified interconnect mechanisms are used to reduce manufacturing cost, then ease of manufacture improves, but the mechanism may fail to maintain reliable contact under various conditions
Solution Approach 1:
The spring member is designed with specific geometric parameters including a deflected portion with a radius of curvature between 0.06 inches and 0.12 inches, and leg spacing between 0.08 inches and 0.16 inches. These controlled parameter changes optimize the spring's contact force and deflection characteristics to maintain reliable connection while keeping the overall design simple and manufacturable.
4Ease of operation
If traditional assembly methods are used for interconnect mechanisms, then assembly can be completed, but specialized tools and complex procedures are required, increasing manufacturing complexity
Solution Approach 1:
The latch member is designed with a release feature that allows the battery pack to be easily released and reattached without specialized tools. The spring member and latch member are configured to self-align and self-secure during assembly, eliminating the need for complex assembly procedures or specialized tools, thereby improving ease of operation while keeping the mechanism relatively simple.
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 latch-spring assembly ensures reliable contact and easy assembly with minimal cost, maintaining interconnectivity under various conditions and simplifying manufacturing processes, while allowing for secure engagement and disengagement of sub-assemblies.
Implementation Method 1
a spring member and a latch which operably couple to a predetermined form factor of a housing... The spring member has a first end, a second end, and a deflected portion... providing a reliable interface
Data Source
AI summary
An interconnect assembly (100) includes a spring member (200) integrally formed of a first portion (202) having two prongs (208) and a slot (210), the first portion being coupled to a second deflected portion (204) formed of a cantilevered beam (212) with interference fit tabs (214) extending from either side. A latch (400) includes hooks (406) and foot members (408). A housing (600), such as a battery pack housing, includes a side surface (606) having protrusion (602) and pockets (604) formed therein along with vertical side channels (610). The spring, latch and housing (200, 400, 600) are coupled such that the vertical channels (610) capture and guide the interference fit tabs (214) down the side of the housing (600) as the foot members (408) of the latch (400) are inserted into the pockets (604) of the housing (600). As the spring member (200) is pushed downward, the protrusion (602) of the housing (600) captures the slot (210), and the hooks (406) of the latch (400) capture the interference fit tabs (214) of the spring member thereby providing a locked latch-spring assembly (1000).