Power Tool Structural Backbone Motor Mount Design

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Solution Overview

Problem

Existing fastening tools, such as cordless nailers, are often cumbersome due to their size and weight, require expensive non-refillable fuel cartridges, and have complex designs that lead to inconsistent performance in setting fasteners into a workpiece.

Innovation Solution

A hand-held fastening tool with a structural backbone, a motor assembly, and a plastic housing that includes an electric motor and flywheel, allowing for efficient kinetic energy transfer to drive fasteners, featuring a driver that translates along an axis and a housing with a handle for improved ergonomics and ease of use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If cordless nailers are designed with larger batteries and motors to improve power and runtime, then the tool becomes more powerful, but the size and weight increase making it cumbersome to work with

Engineering Contradiction:

ImprovepowerVSAvoidweight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The tool is divided into functional modules: a reusable main body containing the motor and control system, and replaceable fuel cartridges containing the power source. This segmentation allows users to swap fuel cartridges quickly without replacing the entire tool, maintaining power while managing weight through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the energy storage parameter from large rechargeable batteries to compact fuel cartridges with high energy density. This parameter change enables sufficient power output with reduced weight and volume, resolving the contradiction between power and portability.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If fastening tools use complex mechanical systems to achieve precise fastener setting, then the tool can perform multiple functions, but the design becomes complex leading to inconsistent performance and higher manufacturing costs

Engineering Contradiction:

ImproveversatilityVSAvoidcomplexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention replaces complex mechanical adjustment systems with a simplified motor-driven mechanism. The motor assembly with eccentric cam and follower provides consistent mechanical advantage for driving fasteners, eliminating the need for complex manual adjustment mechanisms while maintaining versatility through electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The motor assembly is designed to accommodate different fastener types and driving mechanisms through standardized mounting interfaces. The same basic motor unit can drive various fastener styles (nails, screws, staples) by changing the driver component, achieving versatility without increasing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If cordless nailers use non-refillable fuel cartridges to simplify design, then the tool structure is simplified, but users must leave the work site to purchase additional cartridges when fuel is exhausted

Engineering Contradiction:

ImprovesimplicityVSAvoidtime

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The fuel cartridges are designed to be refillable and reusable. When a cartridge is depleted, users can refill it with refuel bottles purchased at the work site, rather than discarding it entirely. This recovering principle eliminates the need to leave the work site and reduces waste, while maintaining the simplicity of the cartridge design.

Inventive Principle:

Principle #34Discarding and recovering

4Reliability

If fastening tools are designed with larger components to ensure robust performance, then the tool can handle demanding applications, but the overall size increases making it less maneuverable

Engineering Contradiction:

ImproverobustnessVSAvoidsize

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The tool housing and structural components use composite materials and optimized alloys that provide high strength-to-weight ratios. This allows robust performance in demanding applications while maintaining a compact size, as the materials provide necessary strength without requiring increased component dimensions.

Inventive Principle:

Principle #40Composite materials

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 tool provides a compact, user-friendly, and cost-effective solution for driving fasteners consistently and efficiently, reducing the need for frequent fuel changes and simplifying operation while maintaining robust performance.

Implementation Method 1

a flywheel, which is driven by the electric motor, and a driver and can be actuatable so that the flywheel transmits kinetic energy to the driver to thereby cause the driver to translate along an axis

Methodology Applied

Scientific EffectKinetic energy: Inertia

Data Source

PatentUS8231039B2Structural backbone/motor mount for a power tool

Publication Date: 2012.07.31 BLACK & DECKER CORP

AI summary

A hand-held tool with a backbone, a motor assembly that is mounted to the backbone, and a plastic housing. The motor assembly can include a driver and can be selectively actuatable to translate the driver along an axis. The plastic housing can be coupled to the backbone and can shroud at least a portion of the backbone.