US20050272401A1 - Environmentally-sealed portable terminal - Google Patents

Abstract

A wearable, mobile and/or portable terminal for use in an inventory management system. The terminal includes a terminal housing, a battery pack removably receivable within an external battery-receiving cavity of the terminal housing, and a battery latching mechanism that secures the battery pack in the battery-receiving cavity in a latched condition. The battery pack has an unlatched condition in which the battery latch mechanism is disengaged from the battery pack. The terminal and battery pack are environmentally sealed to, for example, preclude entry of water into the interior of the terminal when the terminal is immersed.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application is a divisional of application Ser. No. 10/185,334, filed Jun. 27, 2002, the disclosure of which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
• This invention relates generally to wearable, portable and/or mobile computer terminals and peripherals.
BACKGROUND OF THE INVENTION
• Wearable, portable and/or mobile computer terminals are used for a wide variety of tasks. Such terminals allow a worker using them to have mobility, while providing them with desirable computing and data-processing functions. Furthermore, various terminals provide a communication link to a larger, more centralized computer system. Such terminals are being implemented for an ever-increasing number of tasks.
• One illustrative example of a specific use for a wearable or portable terminal is inventory management. Computerized inventory management systems are used in inventory-driven industries for various tasks, such as food and retail product distribution, manufacturing, and quality control. An overall integrated inventory management system involves a combination of a central computer for tracking and management, and the people who use and interface with the computer system in the form of order fillers, pickers and other workers. The workers handle the manual aspects of the integrated management system.
• To provide an interface between the central computer system and the workers, wearable or portable terminals are used by the workers as they complete their numerous tasks. Such wearable terminals, for example, pull information directly from the central system and translate the information into voice or text commands for the workers. Through wireless RF networks, the commands to and responses from the workers are communicated between the system and the terminals. To communicate in a voice driven system, for example, the worker wears a headset which is coupled to their wearable terminal. Through the headset, the workers are able to receive voice instructions, ask questions, report the progress of their tasks, and report working conditions, such as inventory shortages, for example. Using such terminals, the work is done virtually hands-free without equipment to juggle or paperwork to carry around.
• In addition to headsets, other peripherals are often coupled to the terminals depending upon the tasks to be performed. For example, bar code readers and other scanners may be utilized alone or in combination with a headset to communicate back and forth with the system.
• An illustrative example of a job through a system utilizing wearable and/or portable terminals having voice capabilities may involve initially welcoming the worker to the system and defining a particular task or order, for example, a load to be filled for a certain truck to depart from a warehouse. The worker may then answer with a particular area (e.g., freezer) that they will be working in for that order. The system then vocally directs the worker to a particular aisle and bin to pick a particular quantity of an item. The worker then vocally confirms their location and the amount of items that are picked. The system may then direct them to a loading dock or bay for a particular truck to receive the order. As may be appreciated, various different scenarios might be played out through the system using a wearable terminal and attached peripherals.
• The terminals are electronic devices which require a source of power. Therefore, they utilize a portable power source, such as a battery. During a shift, a worker may find that they must replace the battery in their terminal with a new one. This can be a tedious task. Often times a worker will have to stop what they are doing, remove the terminal from their belt or other securing device, disconnect the battery and install/connect a new battery. This usually requires two hands and is a significant disruption to the work schedule.
• A further issue with portable batteries used with wearable and/or portable terminals is that they are susceptible to falling off or out of the terminal during use. As may be appreciated, wearable terminals are subject to rigorous use as the workers scramble around handling various tasks. The terminals are often bumped or otherwise abused in use.
• In the past, batteries have tended to fall off when the terminals or the batteries were bumped. This might cause the battery or its casing to break, particularly on hard, concrete floors, and thereby result in further delays for the worker.
• An additional concern with wearable terminals and also the power supplies therein, is their exposure to harsh environments which may affect their operation. Specifically, many work environments expose the terminals, and therefore the batteries, to moisture. Sometimes such moisture is direct, however, it is often in the form of condensation which may find a pathway into the electrical components of the terminal and also to the battery. For example, in food distribution, the terminals are exposed to the cold of a refrigerator or freezer environment, and then to the ambient warmth or heat and humidity of the rest of the facility. The moisture and condensation may cause electrical shorts and malfunctions in the terminal and in the batteries.
• As such, it is desirable to improve upon the ruggedness of wearable terminals and their power sources. It is also desirable to improve the battery management procedures for active workers and reduce delays associated with power issues. It is further desirable to make workers more efficient and effective.
BRIEF DESCRIPTION OF THE DRAWINGS
• The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.
• FIG. 1 is an illustration of a terminal constructed in accordance with the principles of the invention;
• FIG. 2 is a partially-broken away side view of the terminal ofFIG. 1 showing the battery pack in a latched condition;
• FIG. 3 is a partially-broken away side view of the terminal ofFIG. 1 showing the battery pack in an intermediate condition;
• FIG. 4 is a partially-broken away side view of the terminal ofFIG. 1 showing the battery pack in an unlatched condition;
• FIG. 5 is an exploded view of a portion of the terminal ofFIG. 1 showing the assembly of the battery latch mechanism with the terminal housing; and
• FIG. 5A is an exploded view of the battery latch mechanism of the terminal ofFIG. 1.
DETAILED DESCRIPTION
• Although the invention will be described next in connection with certain embodiments, the invention is not limited to practice in any one specific type of wearable, portable and/or mobile terminal. It is contemplated that the principles of the invention can be used with a variety of electronic devices, including but not limited to wearable terminals for use with computerized inventory systems. The description of the invention is intended to cover all alternatives, modifications, and equivalent arrangements as may be included within the spirit and scope of the invention as defined by the appended claims. In particular, those skilled in the art will recognize that the components of the invention described herein could be arranged in multiple different ways.
• With reference toFIG. 1, a wearable, portable and/ormobile terminal10 of the invention is worn by a worker on abelt12 or is otherwise associated by another securing device associated with the worker's person. Theterminal10 is connected to at least oneperipheral device14, such as a headset or bar code reader, by a length of acord16 electrically coupled to theterminal10. Alternatively, eachperipheral device14 may communicate unidirectionally or bidirectionally with theterminal10 over a wireless communication link, such as a radiofrequency (RF) link or an infrared (IR) link.
• Such terminals10 may be used, for example, in warehouse environments where workers are required to retrieve various items within the warehouse. An interior17 of the terminal10 houses electronics including a transceiver (not shown) that communicates with a remote central computer by transmitting and receiving information regarding the activities performed by the worker.
• For use in a warehouse environment, the terminal10 incorporates aremovable battery pack18 and abattery latch mechanism20 for detachably securing theremovable battery pack18 to the terminal10. Thebattery pack18 supplies electrical power to the electronics of the terminal10 so that the terminal10 is wearable by the worker and is portable. As thebattery pack18 is powered and used in the warehouse environment, the electrical energy stored by thebattery pack18 is necessarily depleted until the battery capacity is expended. The battery capacity of thebattery pack18 may be replenished with a battery charger (not shown) having a power supply that can provide a supply of DC current.
• With reference toFIGS. 2 and 5, the terminal10 includes aterminal housing22 having a curved, convexouter surface23 and a battery-receivingcavity24 recessed below theouter surface23. The battery-receivingcavity24 is dimensioned to receive thebattery pack18 therein and provides a recessed void generally shaped like a cuboid or a parallelepiped that is external to theterminal housing22. Theterminal housing22 includes a pair of opposingside walls25,26, a pair of opposingend walls27,28, and abase wall30 having an outwardly-facing substantially planar,rectangular base surface32 extending transversely between theside walls25,26 and longitudinally between theend walls27,28. Thewalls25,26,27,28 and30 defined the boundaries of the battery-receivingcavity24.End wall28 separates achamber38 provided inside theterminal housing22 from the battery-receivingcavity24. Theterminal housing22 may be molded from a polymer resin. As used herein, inwardly and outwardly directions are referenced relative to thebase surface32 bounding the battery-receivingcavity24. An outwardly direction is directed away from thebase surface32 and an inwardly direction is directed toward thebase surface32.
• A plurality of spring-loadedelectrical contacts34, of which oneelectrical contact34 is shown inFIG. 2, are located within theterminal housing22 and positioned opposite to the location of thebattery latch mechanism20. Each electrical contact includes atang portion36 disposed within thechamber38 and aspring finger40 projecting into the battery-receivingcavity24 from a corresponding one ofmultiple openings42penetrating end wall28. Eachspring finger40 is resiliently deflectable by a force applied in a direction generally toward theend wall28 with a concomitant storage of elastic energy. Alip portion44 of theterminal housing22 projects outwardly fromend wall28 over a portion of the battery-receivingcavity24 so as to overhang thespring fingers40. Eachtang portion36 is coupled electrically by anindividual conductor39 with the electronics housed within theterminal housing22.
• Anencapsulant46, such as an encapsulant selected from among the 1650 Series of encapsulants commercially available from Mereco Technologies Group (West Warwick, R.I.), is injected into thechamber38 to secure theelectrical contacts34 in place and to prevent displacing of theelectrical contacts34 by thebattery pack18 relative to the battery-receivingcavity24 back into theterminal housing22. In one aspect of the invention, theencapsulant46 also provides waterproofing and dustproofing so that the terminal10 is sealed against the entry or infiltration of contaminants, including dust, moisture and other liquids, into the interior17 of theterminal housing22 throughopenings42. The battery-receivingcavity24 is accessible from the exterior of theterminal housing22 for placement of thebattery pack18. As a result, theterminal housing22 is sealed from the ambient environment of the terminal10 and thebattery pack18 can be positioned within the battery-receivingcavity24 without exposing the interior17 of the terminal housing to the ambient environment. In addition, the sealed nature of theterminal housing22 permits the terminal10 to operate in ambient environments entailing exposure to condensation, moisture and other liquids without a significant risk of damage to the electronics housed inside theterminal housing22.
• In certain embodiments, the environmental-sealing ofterminal housing22 may comply with the IP67 standard of the International Protection (IP) rating system which requires that thehousing22 be dust proof and that thehousing22 prevent the entry of water into the interior17 if immersed in room temperature water to a depth of 1 meter for 30 minutes. The International Electrotechnical Commission standardizes classes of environmental protection for industrial equipment using the IP rating system.
• With reference toFIG. 2, thebattery pack18 includes a sealedcase48, preferably molded from a polymer resin and shaped roughly like a parallelepiped or cuboid, and abattery cell47, typically a lithium ion battery cell, housed within the sealed environment of the sealedcase48. The sealedcase48 is provided with a pair of opposing transverse ends50,52, aperipheral edge53 attransverse end52, a contact-containingportion54 protruding outwardly fromtransverse end50, and an outwardly-facingshoulder56 formed by the contact-containingportion54. A convex outwardly-facingsurface58 of the sealedcase48 has a curvature that conforms with the curvature of theouter surface23 of theterminal housing22 when thebattery pack18 is inserted in the battery-receivingcavity24. An inwardly-facingplanar surface60 of thebattery pack18 provides a substantially abutting contact with theplanar base surface32 of the battery-receivingcavity24 when thebattery pack18 is inserted into battery-receivingcavity24.
• A set of cylindricalconductive contacts62, of which oneelectrical contact62 is visible inFIG. 2, is disposed in the contact-containingportion54 of the sealedcase48 ofbattery pack18. Each of theconductive contacts62 is terminated by a disk-shapedflat pad64 facing outwardly fromtransverse end50. The set ofconductive contacts62 participates in electrically coupling the battery cell with the electronics disposed within theterminal housing22 of the terminal10. To that end, eachflat pad64 of thebattery pack18 is electrically coupled with a corresponding one of thespring fingers40 of the terminal10. The physical contact between theflat pads64 andspring fingers40 is operative for supplying a good electrical contact adequate for transferring electrical current with minimal resistive loss. Upon engagement of thebattery pack18 within the battery-receivingcavity24 in a latched condition, the terminal10 operates via electrical power supplied from the battery cell of thebattery pack18.
• The sealedcase48 of thebattery pack18 is sealed against the entry of moisture or other liquids. To that end, the sealedcase48 may be molded as multiple sections and subsequently joined by any suitable technique, such as ultrasonic welding, that provides a water-tight enclosure. Theelectrical contacts62 provide the only external connections withbattery cell47 and have a liquid-tight seal with the corresponding openings in the contact-containingportion54. For example, theelectrical contacts62 may be press-fit into the corresponding openings in the contact-containingportion54 or the sealedcase48 may be molded about theelectrical contacts62.
• In addition, the sealedcase48 of thebattery pack18 is free or any projecting elements, such as tabs or the like, that would otherwise cooperate with a latching mechanism. The absence of such projecting elements makes thebattery pack18 less prone to damage from, for example, being dropped onto a hard surface that would prevent positive engagement withterminal10. As a result, thebattery pack18 is sturdy and robust because the battery-receivingcavity24 that provides the positive engagement with thebattery latch mechanism20 is not susceptible to damage that would result in an inability to mechanically couple thebattery pack18 with the terminal10.
• With continued reference toFIG. 2, theperipheral edge53 of sealedcase48 further includes alip66 and alatch cavity68 with an entrance or opening therein oriented for engagement with thebattery latch mechanism20 when thebattery pack18 is inserted into the battery-receivingcavity24. Thelip66 andlatch cavity68 extend transversely into and out of the plane of the page ofFIG. 2. Thelatch cavity68 has a triangular cross-sectional profile in a transverse direction. Thelip66 includes an outwardly-facingplanar surface70 that defines a lower surface of thelatch cavity68 and an inwardly-facinginclined camming surface72 of thelip66 oriented downwardly toward thebase wall30 of the battery-receivingcavity24 when thebattery pack18 is inserted into the battery-receivingcavity24. Theinclined camming surface72 is coextensive with theplanar surface70 along a sharedtransverse edge74.
• With reference toFIGS. 2, 5 and5A, thebattery latch mechanism20 is positioned within the battery-receivingcavity24 and proximate to endwall27. Thebattery latch mechanism20 is actuatable between to provide a latched condition in which thebattery pack18 is secured within the battery-receivingcavity24 and a latched condition in which thebattery pack18 is readily removable from the battery-receivingcavity24. Thebattery latch mechanism20 includes a latchingmember76 movable between an extended position (FIGS. 2 and 4) and a retracted position (FIG. 3), an actuator orrelease button78 in the form of a pushbutton depressible to cause the latchingmember76 to move between the extended and retracted positions, and abracket member80 pivotally coupling therelease button78 with theterminal housing22 of the terminal10. Thebracket member80 of thebattery latch mechanism20 is secured to theterminal housing22 withconventional fasteners81 or the like.
• The latchingmember76, therelease button78, and thebracket member80 may be molded from a polymer resin. In particular, therelease button78 and thebracket member80 may be molded from any polymer resin having good low temperature characteristics useful when the terminal10 is exposed to a low temperature ambient environment. For example, therelease button78 and thebracket member80 may be formed from a mixture of polycarbonate with either polybutylene terephthalate (PBT) or polyethylene terephthalate (PET), such as the family of such polymer resins available commercially under the tradename XENOY® from GE Plastics (Seven Hills, Ohio).
• With continued reference toFIGS. 2, 5 and5A, a biasingmember82, such as a compression spring, urges or biases the latchingmember76 to the extended position when therelease button78 is not depressed. One end of the biasingmember82 fits over aguide post83 formed on therelease button78. An opposite end of the biasingmember82 abutsend wall27 of theterminal housing22. The biasingmember82 is constrained against lateral movement by a pair of transversely-spacedguides84,85 projecting outwardly from thebase surface32 and a pair of transversely-spacedprongs86,87 projecting inwardly from thebracket member80. While the biasingmember82 is illustrated as a compression spring, the invention contemplates that other types of springs, plastic cantilevers, or elastic members may also be used for biasing the latchingmember76 toward the extended position.
• Therelease button78 is pivotal relative to thebracket member80 about a transverse axis of rotation defined by a transversely-spaced pair of pivot pins88, of which onepivot pin88 is shown, that also secure therelease button78 mechanically with thebracket member80. A pair of transversely-spacedflanges89,90 are provided on therelease button78 and project inwardly toward thebase surface32. The transverse space between theflanges89,90 is dimensioned to receive therebetween theprongs86,87 of thebracket member80. Theflanges89,90 extend into a corresponding pair of transversely-orientedgrooves91,92 provided on the latchingmember76. When therelease button78 is depressed, the angular rotation of therelease button78 about the pivot pins88 is converted by the engagement between theflanges89,90 andgrooves91,92 into a longitudinal displacement of the latchingmember76 that moves the latchingmember76 toward theend wall27 from the extended position to the retracted position. Similarly, when the latchingmember76 is in the retracted position and therelease button78 is released, the angular rotation of therelease button78 in the opposite angular direction about the pivot pins88 is converted into a longitudinal displacement of the latchingmember78 away from theend wall27 due to the engagement between theflanges89,90 andgrooves91,92 and the restoring force supplied by the biasingmember82 so that the latchingmember76 moves from the retracted position (FIG. 3) to the extended position (FIGS. 2 and 4).
• An inwardly-projectingflange93 provided on therelease button78 abuts an upwardly-facing surface of a transversely-oriented, outwardly-facingslot94 provided in the latchingmember76.Flange93 has a longitudinally spaced relationship withflanges89,90. The latchingmember76 is slidingly captured between the tip of theflange93 and thebase surface32 so that the latchingmember76 cannot cantilever outwardly relative to the engagement between theflanges89,90 andgrooves91,92 during movement between the extended and retracted positions.
• With continued reference toFIGS. 2, 5 and5A, a battery-engagingelement96 projects from the latchingmember76 toward the interior of the battery-receivingcavity24 of the terminal10. The battery-engagingelement96 has aplanar surface98 facing thebase surface32 of the battery-receivingcavity24 and aninclined camming surface100 positioned opposite to theplanar surface98. The battery-engagingelement96 is captured within thelatch cavity68 when thebattery pack18 is present in the battery-receivingcavity24 and the latchingmember76 is in the extended position (FIG. 2). In particular, theplanar surface98 of the battery-engagingelement96 contacts theplanar surface70 of thelip66 for securing thebattery pack18 within the battery-receivingcavity24 in the latched condition. The engagement between theplanar surfaces70,98 prevents outward movement of thebattery pack18 relative to theterminal housing22. When the latchingmember76 is in the retracted position (FIG. 3), the battery-engagingelement96 is not captured within thelatch cavity68 and thebattery pack18 is movable within the battery-receivingcavity24 due to the extension of thespring fingers40 and the associated bias force applied again theflat pads64. Theperipheral edge53 of the battery pack also pushed slightly upward out of the battery-receivingcavity24. It is contemplated by the invention that additional springs, plastic cantilevers, or other elastic members may be used to apply motive force to thebattery pack18 in addition to, or instead of, thespring fingers40.
• The inclination angle of theinclined camming surface100 of the battery-engagingelement96 is complementary to the inclination angle of theinclined camming surface72 of thelip66. Thebattery pack18 is placed in the unlatched condition when the latchingmember76 is fully in the extended position and the inclined camming surfaces72,100 are abutting. In the unlatched condition, thebattery pack18 is lifted by the engagement between the inclined camming surfaces72,100 and may be manually removed from the battery-receivingcavity24. Manual removal is facilitated by the outward projection of anupper corner102 ofperipheral edge53 of thebattery pack18 above theouter surface23 of theterminal housing22. Theupper corner102 is readily grasped by a worker for removal of thebattery pack18.
• With continued reference toFIGS. 2, 5 and5A, an outwardly-facingsurface104 of therelease button78 has a convex curvature that generally conforms with the convex curvatures of theouter surface23 of theterminal housing22 and the outwardly-facingsurface58 of the sealedcase48 of thebattery pack18. The portion of theterminal housing22 surrounding therelease button78 operates as a guard to prevent inadvertent latching and unlatching from incidental contact with outwardly-facingsurface104. As a result, a worker is generally required to make a specific and deliberate effort to apply an inward force to pivot therelease button78 for unlatching thebattery pack18. This, therefore, reduces the likelihood of damage to thebattery pack18 from inadvertently falling out of theterminal housing22.
• Provided on therelease button78 is a set of finger grips106 that reduce slippage with the worker's finger when therelease button78 is pressed to actuate thebattery latch mechanism20. The finger grips106 project a short distance outwardly above thesurface104 of therelease button78 that is insufficient to allow inadvertent actuation of therelease button78 and insufficient to significantly interrupt the smooth, curved contour presented collectively bysurfaces23,58,104.
• In use and with reference toFIGS. 2-4, thebattery pack18 is initially in the latched condition shown inFIG. 2 with the battery-engagingelement96 of the latchingmember76 engaged within thelatch cavity68 of the sealedcase48 ofbattery pack18. To remove thebattery pack18 from the battery-receivingcavity24, an inward force is applied to push or depress therelease button78 in a general direction indicated by arrow108 inFIG. 3. The inward force causes therelease button78 to pivot about pivot pins88 relative to thebracket member80. The pivoting of therelease button78 displaces the latchingmember76 towardwall27 in a general direction indicated byarrow110 inFIG. 3 due to the engagement betweenflanges89,90 andgrooves91,92 from the extended position toward the retracted position. The biasingmember82 is compressed for applying a restoring force after the inward force applied to releasebutton78 is removed. When the latchingmember76 is fully in the retracted position, the battery-engagingelement96 is released from thelatch cavity68 and thebattery pack18 is released or freed for movement within the battery-receivingcavity24.
• Thespring fingers40 of theelectrical contacts34, which are compressed when thebattery pack18 is latched, collectively exert a lateral propulsive or motive force against thebattery pack18 that is directed away fromend wall28 as the spring compression is released. The lateral motive force displaces or moves thebattery pack18 toward thebattery latch mechanism20 in a direction generally indicated byarrow112 inFIG. 3. As thebattery pack18 moves away fromend wall28, acamming surface105 on theperipheral edge53 of sealedcase48 engages amating camming surface103 on theterminal housing22, causing the end of thebattery pack18 to elevate in a direction indicated byarrow114 inFIG. 3 so that thecorner102 and elevated end of thebattery pack18 project above theouter surface23 of theterminal housing22 of theterminal housing22 in the unlatched condition. Theopposed end50 of sealedcase48 remains captured between thelip portion44 andbase wall30 of theterminal housing22.
• The cooperating camming surfaces103,105 at the interface betweenbattery pack18 andterminal housing22 work with the propulsive force supplied by theelectrical contacts34 to lift the end of thebattery pack18 partially out of the battery-receivingcavity24 wherebattery pack18 can be grasped using the same finger that actuated therelease button78. Thedepressed release button78 provides a space for the finger to contact thecorner102 and elevated end of thebattery pack18. This makes possible a rapid one-hand removal of thebattery pack18.
• When the inward force applied to therelease button78 is removed as shown inFIG. 4, the restoring force applied by the biasingmember82 pivots therelease button78 to its initial position and the latchingmember76 moves from the retracted position back toward the extended position. As a result, theinclined camming surface100 of the latchingmember76 slidingly engages theinclined camming surface72 of thebattery pack18 and displaces or lifts theperipheral edge53 of thebattery pack18 further outwardly relative to the battery-receivingcavity24 in the general direction ofarrow114. As a result, thecorner102 of theperipheral edge53 projects an additional distance above the contour of theouter surface23 of theterminal housing22 sufficient for removing thebattery pack18 from the battery-receivingcavity24. The continued engagement between the inclined camming surfaces72,100, after the sliding relative movement therebetween ceases, holds thebattery pack18 in the unlatched condition in which thebattery pack18 can be easily disengaged from the battery-receivingcavity24 and removed from the terminal10 by single-handed manual manipulation. The hand of the worker is positioned to cradle thebattery pack18 during removal from terminal10 so that the risk of dropping is reduced. The removal of thebattery pack18 may be accomplished with one hand and while the terminal10 remains secured to belt12.
• Thebattery pack18 is replaced by inserting theend50 of thebattery pack18 into the battery-receivingcavity24 so that theflat pads64 contact thespring fingers40 and theshoulder56 of thebattery pack18 is captured between thelip portion44 andbase surface32 of theterminal housing22. An inward force applied to the sealedcase48 adjacent to end52 toward thebase surface32 causes the latchingmember76 to move from the extended position to the retracted position against the biasing force of the biasingmember82 by sliding contact between the inclined camming surfaces72,100. As thebattery pack18 is further pressed into the battery-receivingcavity24,inclined camming surface100 slides overtransverse edge74 and the latchingmember76 is urged by the biasingmember82 away from theend wall27 so that the battery-engagingelement96 protrudes into the latchingcavity68. Contact betweenplanar surfaces70,98 provides a positive stop to place thebattery pack18 at the proper insertion depth in the battery-receivingcavity24. When thebattery pack18 is thus completely inserted into the battery-receivingcavity24, outward movement of thebattery pack18 is prevented and each of theflat pads64 of thebattery pack18 is electrically coupled with a corresponding one of thespring fingers40 of the terminal10. The installation of thebattery pack18 may be accomplished with one hand and while the terminal10 remains secured to belt12. Thebattery pack18 fits snugly in the battery-receivingcavity24 so that movement of thebattery pack18 is restricted and the engagement between thespring fingers40 andflat pads64 is maintained as the terminal10 is transported by the worker for use in the warehouse environment.
• According to the principles of the invention, the battery pack can be quickly, easily, and effectively attached to the terminal and removed from the terminal. As a result, battery management procedures are simplified for active workers and delays associated with power issues are reduced. The principles of the invention improve worker efficiency and effectiveness. In addition, the principles of the invention act to ruggedize the terminal and battery pack so that operational lifetimes are lengthened.
• The battery latch mechanism and battery pack of the invention cooperate to provide a desired combination of substantial resistance to inadvertent detachment from the terminal and efficient battery replacement. Specifically, the battery pack is not overly susceptible to falling off or out of the terminal during use because of the secure attachment to the terminal. Moreover, the small surface area of the outwardly-facing surface of the release button that makes the release button resistant to actuation by inadvertent applied forces. In addition, the conforming surface contours of the terminal housing, battery pack and release button reduce the likelihood that contact with an object will dislodge the battery pack from the battery-receiving cavity. As a result, delays in worker activities resulting from unintended separation of the battery pack from the terminal are reduced. In addition, the useful lifetime of the battery pack is extended because the battery pack is less likely to be inadvertently separated from the terminal and damaged by impact with, for example, a concrete floor.
• The battery pack is removable from the battery-receiving cavity with a minimal applied force yet is retained with a sufficient retaining force, when the latch mechanism is initially actuated, so that the battery pack does not readily disengage from the terminal during an operation exchanging a depleted battery pack for a charged battery pack. The magnitude of the applied force required to separate the battery pack from the terminal, when the battery latch mechanism is disengaged from the battery pack, permits a worker to replace a depleted battery pack in a one-handed operation while the terminal remains attached to the worker. As a result, the tediousness entailed in the removal and replacement of the battery pack is significantly reduced by the improved ergonomics and the impact to the worker's work schedule is lessened.
• According the principles of the invention, the electronics within the terminal are isolated from exposure to harsh ambient operating environments in which the terminal is being used. In addition, the battery pack provides a sealed environment that isolates the battery cell from the infiltration of moisture and other contaminants from the operating environment or condensation arising from changes in the humidity level and temperature of the operating environment. As a result, the terminal and battery pack are significantly less susceptible to electrical shorts and malfunctions.
• While the present invention has been illustrated by the description of the various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of Applicants' general inventive concept.

Claims (20)

1. A wearable, mobile and/or portable terminal powered by an environmentally-sealed battery pack, comprising:

a terminal housing having an interior and an external battery-receiving cavity configured to removably receive a battery pack, said interior of said terminal housing being sealed from the ambient environment surrounding said terminal housing; and

a latch mechanism within the battery-receiving cavity being operative to latchingly engage and disengage the battery pack within said battery-receiving cavity and mounted such as not to impair said environmental sealing of the terminal interior,

said environmental sealing of said terminal being effective to preclude entry of water into the interior of the terminal when the terminal is immersed.

2. The terminal ofclaim 1 wherein said terminal housing includes a chamber proximate to said battery-receiving cavity, an end wall separating said chamber from said battery-receiving cavity, and a plurality of first electrical contacts extending through a corresponding plurality of openings in the end wall.

3. The terminal ofclaim 2 wherein said openings are sealed to seal said terminal housing from the environment proximate the cavity.

4. The terminal ofclaim 3 further comprising:

an encapsulant filling said chamber to seal said chamber from the environment within said cavity.

5. The terminal ofclaim 1 further comprising a battery pack having a sealed case and a plurality of second electrical contacts sealingly extending through said sealed case to contact said plurality of first electrical contacts when said battery pack is received within said battery-receiving cavity.

6. The terminal ofclaim 5 wherein said battery pack is sealed against the entry of moisture.

7. The terminal ofclaim 1 wherein said terminal housing is sealed from the ambient environment effective to preclude significant entry of water upon immersion to a depth of one meter for thirty minutes.

8. A combination including the terminal ofclaim 1 and an environmentally sealed battery pack configured to mate said cavity and to be latched and unlatched by said latch mechanism.

9. A mobile voice-directed system having a quick-change arrangement for a battery pack with opposite first and second ends, comprising:

a terminal having an environmentally sealed housing with exposed electrical contacts located in a shallow external battery cavity, the battery cavity and electrical contacts being configured to mate with a battery pack having an environmentally sealed casing adapted to conform to the housing cavity and exposed battery contacts adapted to mate with the terminal contacts; and

a battery latch mechanism mounted in the terminal cavity and environmentally isolated from a terminal interior, the battery latch mechanism including a finger-depressible pushbutton and being configured such that depressing the pushbutton releases the battery pack and exposes the battery pack for quick and easy removal with the finger used to depress the pushbutton,

said environmental sealing of said terminal being effective to preclude entry of water into the interior of the terminal when the terminal is immersed.

10. The system ofclaim 9 further comprising:

a battery lifter arrangement configured to elevate the first end of the battery pack when the battery latch mechanism is unlatched.

11. The system ofclaim 10 wherein the battery lifter arrangement includes a battery-elevating camming structure at an interface between the terminal housing and the first end of the battery pack, and a spring biasing arrangement at the location of the second end of the battery pack which cooperates with the camming structure to cause the first end of the battery pack to elevate when the battery latch mechanism is unlatched.

12. The system ofclaim 11 wherein the spring biasing arrangement comprises the terminal electrical contacts.

13. The system ofclaim 8 wherein the latching member is a spring-biased slider mounted to reciprocate.

14. The system ofclaim 8 wherein the pushbutton is pivotally mounted, and the battery latch mechanism includes a linearly reciprocable slider configured to latchingly engage the battery pack, and a motion converter for converting rotary motion of the pushbutton to reciprocatory motion of the latching member.

15. A combination including the system ofclaim 8 and an environmentally sealed battery pack configured to fit said cavity and to be latched and unlatched by said latch mechanism.

16. The system ofclaim 8 wherein the battery latch mechanism includes a member which latchingly engages the battery pack when the battery latch mechanism is latched, which disengages the battery pack when the battery latch mechanism is unlatched by depressing the pushbutton, and which non-latchingly re-engages the battery pack when it is an elevated state to resist its falling back into the battery-receiving cavity.

17. For use with a mobile terminal having an environmentally sealed terminal housing with an external surface, a camming surface, and a shallow external battery cavity with exposed electrical contacts, a quick-change battery pack comprising:

an environmentally sealed casing having exposed electrical contacts configured and located to mate with the exposed electrical contacts in the external battery cavity, the casing having a first surface portion configured to physically mate with the battery cavity, a second surface portion configured to blend with the external surface of the terminal housing such that the battery pack forms part of the terminal exterior, and a camming surface adapted to mate with the camming surface on the terminal housing to assist in elevating a predetermined end of the casing for removal from the battery cavity, the casing having a contour at the predetermined end of the battery pack which is adapted to facilitate removal of the battery pack from the battery cavity.

18. The battery pack ofclaim 17 sealed to preclude significant entry of water upon immersion to a depth of one meter for thirty minutes.

19. The battery pack ofclaim 17 wherein the casing is configured at the predetermined to be engaged by a latch mechanism mounted in the battery cavity of a terminal.

20. A mobile device having a quick-change battery pack arrangement, comprising:

a terminal having an environmentally sealed housing with a shallow external battery cavity and exposed terminal electrical contacts located in the external battery cavity;

a battery pack having an environmentally sealed casing with a first surface portion configured to conform to the battery cavity and exposed battery contacts adapted to mate with the terminal electrical contacts, and a second surface portion configured to blend with an external surface of the terminal housing such that the battery pack casing forms part of the terminal housing exterior; and

a battery latch mechanism mounted in the terminal cavity, the battery latch mechanism including a finger-depressible pushbutton flush with the terminal housing exterior and being configured such that depressing the pushbutton releases the battery pack and creates a recess which exposes the battery pack for quick and easy removal with the finger used to depress the pushbutton,

said environmental sealing of said terminal and of said battery pack each being effective to preclude entry of water when the terminal is immersed to a depth of one meter for thirty minutes.

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