Single PCB Battery Pack for Electro-Optical Reader

The patent combines multiple separate PCBs and contact blocks into a single integrated PCB assembly. The electrical connector is formed as an integrated structure where contacts are directly mounted on the PCB, eliminating the need for separate contact blocks. This merging reduces the number of components while maintaining electrical connection reliability through proper contact design and PCB trace routing.

The single PCB serves multiple functions simultaneously: it acts as the circuit board for electrical connections, the mounting structure for contacts, the structural support element, and the alignment reference for mating with reader contact blocks. This multi-functionality eliminates the need for separate dedicated components for each function, reducing overall complexity.

By merging multiple separate components (multiple PCBs, contact blocks, mounting hardware) into a single integrated PCB assembly, the patent reduces the total component count. This leads to lower material costs, reduced assembly steps, fewer fasteners, and simplified inventory management, all of which directly reduce manufacturing cost while maintaining the necessary electrical connection reliability.

The integrated PCB design uses standard, readily available PCB manufacturing processes and common electrical contact components that can be efficiently produced at scale. The design accepts that the battery pack is a consumable item with limited lifetime, optimizing for cost-effective manufacturing rather than extreme durability, allowing the use of economical materials and assembly methods.

The PCB is pre-designed with built-in alignment features such as positioning pins, recesses, or keyed slots that automatically guide the battery pack into correct alignment with the reader contact block during assembly. The electrical contacts are pre-positioned and pre-soldered to the PCB in precise locations during PCB manufacturing, eliminating the need for field adjustment and reducing assembly precision requirements.

The design incorporates tolerance compensation through PCB flexibility, elastic contact elements, or adjustable contact pressure mechanisms that can accommodate variations in assembly precision. By changing the physical parameters of the contact interface (such as making contacts slightly elastic or allowing for positional variation), the design becomes more robust to assembly tolerances while maintaining reliable electrical connections.