Abstract:
Methods and apparatus for a batter contact assembly having a compact profile for efficient use of space and reliable battery connections. In one embodiment, the assembly is of unitary construction with hinges and engagement mechanism to facilitate installation of the assembly into a device requiring battery power.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims the benefit of U.S. Patent Application No. 60/909,570, filed on Apr. 2, 2007, which is incorporated herein by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
       [0002]    The Government may have certain rights in the invention pursuant to Contract No. W15P7T-04-C-K402. 
     
    
     BACKGROUND 
       [0003]    As is known in the art, many electronic devices and systems have limited space and weight requirements. Such devices can include batteries to provide power. To provide these devices, it is often necessary to fabricate custom batteries and/or battery contact assemblies. These assemblies can have numerous parts requiring significant cost and effort in assembling the final device. In addition, multi-part assemblies may be susceptible to environmental degradation due to leaks, humidity, etc. 
         [0004]      FIGS. 1A and 1B  show a prior art battery contact assembly  10  having angled metal contacts  12  coupled to a plastic insulator  14  with metal holders  16 . The assembly  10  is screwed to another assembly forming a part of a structure to hold one or more batteries. The battery contact assembly  10  also includes a separate metal contact  18  coupled to another plastic insulator  20 . While this configuration may provide a relatively low profile, there are many parts, some of which are quite small and/or thin, that render assembly difficult. In addition, the completed assembly is less than rugged. 
       SUMMARY 
       [0005]    The present invention provides methods and apparatus for a low profile battery contact assembly. In one embodiment, the batter contact assembly is formed from a single piece of insulative material having a first hinge to interconnect first and second portions of the assembly and a second hinge to interconnect the second portion and a third portion. With this arrangement, the battery contact assembly can be readily inserted into a device after which a battery can be installed into the assembly. 
         [0006]    In one aspect of the invention, an apparatus comprises a battery contact assembly including interconnected first, second, and third portions, the battery contact assembly having a first position in which the assembly is generally flat and having a second position in which the assembly is generally U-shaped, the first portion including a positive battery contact and the third portion including a negative battery contact. 
         [0007]    In another aspect of the invention, a device powered by a battery comprises a battery contact assembly including interconnected first, second, and third portions, the battery contact assembly having a first position in which the assembly is generally flat and having a second position in which the assembly is generally U-shaped, the first portion including a positive battery contact and the third portion including a negative battery contact. 
         [0008]    In a further aspect of the invention, a method comprises forming a battery contact assembly including interconnected first, second, and third portions, the battery contact assembly having a first position in which the assembly is generally flat and having a second position in which the assembly is generally U-shaped, the first portion including a positive battery contact and the third portion including a negative battery contact. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The foregoing features of this invention, as well as the invention itself, may be more fully understood from the following description of the drawings in which: 
           [0010]      FIGS. 1A and 1B  show pictorial representations of a prior art assembly to contact a battery; 
           [0011]      FIGS. 2A and 2B  are pictorial representations of a battery contact assembly in accordance with exemplary embodiments of the invention; 
           [0012]      FIG. 3A  is a pictorial representation of the battery contact assembly of  FIG. 2  in a first position; 
           [0013]      FIG. 3B  is a top view of the battery contact assembly of  FIG. 3A ; 
           [0014]      FIG. 3C  is a side view of the battery contact assembly of  FIG. 3A ; 
           [0015]      FIG. 4A  is a side view of the battery contact assembly of  FIGS. 2A and 2B   
           [0016]      FIG. 4B  is a front view of the battery contact assembly of  FIGS. 2A and 2B ; 
           [0017]      FIGS. 5A and 5B  are a pictorial representation of a device having a battery contact assembly in accordance with exemplary embodiments of the invention; 
       
    
    
     DETAILED DESCRIPTION 
       [0018]      FIGS. 2A and 2B  show a low profile battery contact assembly  100  having a first contact mechanism  102  and a second contact mechanism  104  for providing electrical connections for a battery in accordance with exemplary embodiments of the invention. In one embodiment, the first contact  102  provides an electrical connection to a first, e.g., positive, terminal of a battery and the second contact  104  provides an electrical connection to a second, e.g., negative, terminal of a battery. 
         [0019]    In the illustrated embodiment, the battery contact assembly  100  includes a housing  108  having first, second and third portions  110 ,  112 ,  114 , interconnected at respective first and second pivot regions  116 ,  118 . It is understood that the pivot regions  116 ,  118  should be construed to allow movement of one portion of the housing with respect to a connected portion. 
         [0020]    In one particular embodiment, the housing  108  is formed from a single piece of material, such as from a mold. The housing  102  material is a flexible insulator, such as plastic, in which hinges can be formed to provided the respective first and second pivot regions  116 ,  118 . With this arrangement, the housing  108  can be molded as a generally flat piece of material that can be folded at the pivot regions  116 ,  118  to provide a three-sided enclosure to securely contain the battery/batteries. The contacts  102 ,  104  can be secured to the housing  108  using a variety of techniques well known to one of ordinary skill in the art. In one particular embodiment, the contacts are hot-staked to the plastic housing. In an alternative embodiment, the contacts can be snapped onto the housing. 
         [0021]      FIGS. 3A ,  3 B, and  3 C show the battery contact assembly in a flat, non-use position. It will be readily appreciated that this position facilitates shipping and storage of the assembly  100 .  FIGS. 4A and 4B  shows the battery contact assembly  100  in a use position configured to receive a battery. In the illustrated embodiment, the first, second, and third housing portions  110 ,  112 ,  114  provide three sides of a rectangular shape about the battery. The first portion  110  manipulated to be generally perpendicular to the second portion  112 . Similarly, the third portion  114  is manipulated to be generally perpendicular to the second portion  112 , such that a U-shape is formed. 
         [0022]    In an exemplary embodiment, the second portion  112  includes first and second stops  120 ,  122  to prevent the first and third portions  110 ,  114  from folding in more than about ninety degrees with respect to the second portion  112 . In the use position, where the first, second, and third portions generally form a U-shape, the assembly can be inserted into a device with relative ease, as described more fully below. 
         [0023]    In an exemplary embodiment, the first contact  102  is a generally flat conductor, such as metal, secured to the third housing portion  114 . The second conductor  104  is a generally arcuate conductor, such as metal secured to the first housing portion  110 . The arcuate shape of the contact  102  enables a battery to be inserted into the assembly  100  with reliable electrical connections between the battery ends and the first and second contacts  102 ,  104 . The second contact  104  deforms and biases the battery to the first contact  102 . 
         [0024]    It is understood that a variety of geometries and dimensions for the contacts can be used to meet the needs of a particular application. In addition, any practical number of contacts can be provided to receive corresponding batteries. 
         [0025]    In another aspect of the invention, and referring again to  FIGS. 2A and 2B , the housing includes at least one attachment mechanism to engage a complementary mechanism on the device to secure the battery contact housing  100  to the device. In one embodiment, the attachment mechanism includes first and second protrusions  202   a,b  on an outer surface of the third housing portion  114  and third and fourth protrusions  204   a,b  on an outer surface of the first housing portion  110 . The protrusions  202 ,  204  snap into undercuts in a corresponding structure in the device. The protrusions  202 ,  204  provide uni-directional movement of the assembly into the device. That is, the snap-fit of the assembly  100  into the device in a first direction is not readily reversible due to the configuration of the protrusions  202 ,  204  and the undercuts. In alternative embodiments, slots and/or holes can be used in place of undercuts. With this arrangement, the attachment mechanism securely engages the battery contact assembly  100  to the device without the need of any additional hardware. 
         [0026]      FIGS. 5A and 5B  show a pictorial representation of a battery contact assembly  100  captured in a device  300  that requires battery power. The battery contact assembly  100  is configured to the U-shape position and pushed into the device  300  until the attachment mechanism, such as protrusions  202 ,  204 , engage a corresponding structure, such as undercuts  350 , in the device housing. 
         [0027]    It is understood that a variety of suitable attachment mechanisms can be used to couple the battery contact assembly to the device will be apparent to one of ordinary skill in the art. Exemplary alternative mechanisms include snaps, detents, hook and loop, and the like. 
         [0028]    While exemplary embodiments of the invention are shown and described herein, it is understood that various modifications to meet the needs of a particular application will be readily apparent to one of ordinary skill in the art. For example, while a U-shape position is shown, it is understood that other shapes can be provided in further embodiments, such as C-shapes, and other suitable configurations that can effectively receive a battery. Alternative insulator materials to plastic will be readily apparent for the housing portions. Materials can be selected for rigidity, cost, environmental conditions, and other factors. 
         [0029]    The exemplary embodiments of the invention provide a battery contact assembly having a low profile that can be assembled and inserted into a device with relative ease. An integral housing, for example, can be injection molded with living hinges provided to allow the assembly to easily manipulated for facilitating insertion into a device. As described above, an exemplary battery contact assembly can be inserted into a device without the need for an installation tool. 
         [0030]    Having described exemplary embodiments of the invention, it will now become apparent to one of ordinary skill in the art that other embodiments incorporating their concepts may also be used. The embodiments contained herein should not be limited to disclosed embodiments but rather should be limited only by the spirit and scope of the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety.