Abstract: A fuel cell device (100) has a configuration for easy activation to quickly achieve steady-state operation performance. The fuel cell device (100) has a membrane electrode assembly (MEA) (120) and fuel (115) housed in separate sealed compartments (112, 114). The MEA (120) is pre-hydrated to have a predetermined water content selected for proper steady-state operation of the fuel cell. Prior to activation, the MEA (120) is sealed from air and sealed from the fuel (115). An integral fuel cell activator mechanism (105, 106, 140) is provided to unseal the MEA compartment (112) and expose the MEA (120) to air, and to initiate a flow of fuel (115) from the fuel compartment (114) to the MEA (120).

Abstract: A manufacturing process, such as that used for ultrasonic welding, employs a self-leveling fixture (20) including a base (12) and an operation stage (14) that are separated by leveling devices (16) and 18). The leveling devices include a centrally located spherical plane bearing (16) and one or more spring members (18) disposed about the periphery of the operation stage. In this way, the operation stage can react in response to pressure applied thereto complying to the applied pressure, thus providing a realistic self-leveling feature. After the pressure is removed, the return to a normal position via the spring action of spring (18).

Abstract: A battery pack containing a battery of cells includes an outer casing (402) adapted to receive a battery of cells (404); a bonding surface (410) positioned along the outer casing (402); an inner casing (408) adapted to encapsulate the battery of cells (404) and having a surface for bonding to the bonding surface of the outer casing (402); and a bond provided at the bonding surface to bond the inner casing (408) to the outer casing (402). Also, a method for forming a battery pack comprises steps of positioning a battery of cells within a bonding surface of an outer casing of the battery pack; encapsulating the battery of cells with an inner casing, the inner casing having a surface corresponding to the bonding surface of the outer casing; and bonding the corresponding surface of the inner casing to the bonding surface of the outer casing. The battery pack and method for forming the battery pack reduce the weight and complexity in manufacturing.

Abstract: A contact array (10) for electrically connecting an energy source (20) to a radio (12) and a charger comprising a circuit assembly (31) having a plurality of integral radio and charger contacts (38, 40) extending from one end of the circuit assembly (31). Two terminals (34) extend from a second end of the circuit assembly (32) for connecting to the energy source (20), and means for attaching (42) a component (44) to the top side (32) of the assembly (31). The means for attaching (42) are integral to the circuit assembly (31).

Abstract: A circuit assembly (100) includes a circuit carrier (102) and a solder pad (104). Circuit carrier (102) further includes at least one vent (108) formed in the circuit carrier (102) for venting gases developed during the process of soldering a component or contact (110) to solder pad (104). The one or more vents (108) prevent solder gases to get trapped in the solder joint during the soldering process. Without vent(s) (108) if the contact (110) to be mounted is substantially the size of the solder pad (104) or larger, gases would tend to be trapped and cause the solder joint to weaken.

Abstract: A configurable flexible circuit substrate (100) is disclosed. The substrate (100) has an electrical circuit pattern (120) and an integral separable segment (130) containing a portion (132) of the circuit pattern (120). The substrate (100) also includes an integral extraction initiator portion (132), which is pivotable between a first position substantially planar with the surface of the substrate (100), and a second position away from the surface of the substrate (100). The extraction initiator portion (132) develops stress raisers (137) when pivoted toward the second position, and the extraction initiator portion (132) also effects a removal of the separable segment (130) from the substrate (100) when the extraction initiator portion (132) is pulled across the separable segment (130).

Abstract: A battery pack (10), comprises at least one cell (16) having a positive (15) and a negative terminal (17), and a header (18) for mounting the cell. The header has at least one wiping contact (20) for connection to either the positive or negative terminal of the cell or cells. The battery pack further comprises a first housing member (30) for receiving the header and the cell or cells, a second housing member (12) mounted above the header and coupled to the first housing member, and a scheme for wiping the wiping contact while the cell (or cells) is enclosed within the first and second housing members.

Abstract: A consumer insertable battery pack assembly (70) comprises a plurality of substantially parallelipiped shaped rechargeable cells (61, 62, and 63) having a positive terminal (68) and a negative terminal (66). The positive terminal of one cell is coupled to the negative terminal of an adjacent cell. Insulation (17) is used on at least one of the terminals of the cells to offset the terminal location to prevent the charging of consumer insertable primary cells. The cells are within a housing (74) having contacts (76 and 86) for charging being arranged and constructed to mate with the offset terminals (68 and 66 respectively) of the cells. In this manner, the cells are unable to mate with the terminals of consumer inserted primary cells having centrally located terminals.

Abstract: A battery pack comprises a first housing member (104) having an integrated latch feature (103), a header frame (111) detachably mounted to the first housing member, a plurality of cells (112) for insertion into the header frame and first housing member, circuitry on the header for coupling the plurality of cells and providing charger and power contacts, and a second housing member (102) being substantially laminar and being adhesively attached to said first housing member.

Abstract: An electrical contact (150) in a housing (110) is created by forming an opening (112) in a wall of the housing. A circuit assembly (130) situated inside the housing (110) has a conductive member (140) that is formed to be of substantially the same shape as the opening (112) in the housing. A portion (150) of the conductive member (140) fits into the opening (112) and a second portion is adhesive bonded to the circuit assembly (130). The electrical interconnection (145) between the conductive member (140) and a copper circuit pattern (134) on the circuit assembly (130) is made by creating a hole or via (145) through the conductive member down to the copper circuit pattern and plating copper (147) into the hole or filling the hole with conductive polymers. A battery package (100) is made by adding additional electrical components to the circuit assembly (130) and connecting a plurality of cells (120) to the circuit assembly.

Abstract: A battery pack (10) comprises a housing having two members (2 and 4), a header frame (11), detachably mounted on at least one of the members of the housing, a plurality of cells (12) for insertion into the header frame, a plurality of leaded electronic components (30 and 40) on the header frame, and circuitry (21 and 22) on the header frame for providing intercell connections, battery contacts, charger contacts and for providing weldless circuit connections for the plurality of leaded electronic components.

Abstract: The present invention provides for a battery pack (50) comprising a plurality of cells (58) within a housing (52), each cell having a positive and negative terminals (57 and 59). The battery pack (50) further comprises molded-in circuitry means (54) on the surface of the housing (52) for providing interconnection between the plurality of cells (58). Optionally, the housing (52) further comprises molded-in or integral spring fingers (56). The spring fingers (56) are preferably biased toward the positive and negative terminals and provide at least some interconnection for the plurality of cells (58).

Abstract: The present invention provides for a battery pack (30) comprising a housing (31) and a plurality of cells (46) within the housing (41), each cell having a positive and negative terminal. A flex circuit (48) is provided for interconnecting between the plurality of cells (46). The battery pack (30) additionally comprises biasing means (38) for providing sufficient contact pressure between the flex circuit (48) and the cell terminals.

Abstract: A mechanical rotational control assembly (100) is provided having a knob (20) engaged to a potentiometer's rotating shaft (55). A friction element (40), such as a washer made of a material having similar temperature characteristics to the knob (20), is interlocked to the stationary portion (57) of the potentiometer. The peripheral boundary (47) of the friction element (40) is engaged to the skirt portion (25) of the knob (20), so as to produce a fricional force when the knob (20) is rotated, and thereby increasing the rotational torque of the rotational control assembly.

Abstract: An electrical connector is provided for making electrical connection to a mating connector. The connector includes a body portion that has a substantially cylindrical cavity. A contact block is located in the cavity and carries three contacts. A spring engages the contact block for applying biasing force to the contact block and contacts for providing electrical connection of the contacts to the mating connector. A peripheral resilient seal is located above the contact block and provides a seal between the contact block and a cylindrical cavity. The peripheral seal includes a bead portion that engages the mating connector for providing a water seal about the contacts.

Abstract: An RF interconnect between a printed circuit board and a coaxial connector mounted in a housing is self-aligning along all three major axes. The coaxial connector has a pin connected to its inner conductor that extends beyond the edge of the outer conductor. The outer conductor has an external circumferential groove. The interconnect includes two terminals wherein the first terminal includes a substantially "M" shaped wire formed conductor having five functional segments: two flexible attaching segments near the ends of the wire, two substantially parallel pin contact segments, and a joining segment connecting the pin contact segments. The coaxial connector pin is inserted between the parallel pin contact segments of the wire formed conductor and a clamping force is generated on the pin by the joining segment. The second terminal includes a flat flexible conductor that has a "U" shaped lug at one end and a snap ring at the other end which is inserted into the groove of the coaxial connector.

Abstract: A sealed container having a test port with a membrane which is pervious to gas and impervious to liquid may be tested by connecting a pressure device such as a vacuum pump or pressure pump to the test port and creating a pressure differential between the container side of the membrane and the pump side of the membrane, allowing the pressure differential to equalize through the membrane and monitoring the equalized pressure to detect whether or not the equalized pressure changes, which utilmately allows the observer to determine whether the sealed container has any leaks. If the pressure equalization time is substantially zero, the membrane and/or membrane seal is defective. In the event a leak is determined, the inside of the radio device may be pressurized to a selected pressure, by use of a pressure pump or the like, and then immersed in a liquid such as water. The location of the leak may then be detected by observing the emanation of air bubbles from that portion of the device in which the leak exists.

Abstract: A rotatable control with an integral switch comprises conductive inner and outer shaft in a concentric configuration. The inner and outer shaft are electrically insulated from one another and frictionally coupled to allow concentric simultaneous rotation. The assembly is covered with a flexible insulating shroud which has a switch contact located on the upper interior surface thereof. Conductive spring members are clipped around the lower portion of the inner and outer shaft to allow electrical connection to a circuit board.