Battery Contact Segmentation for Underwater Rescue Tools
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Solution Overview
Problem
Existing battery-operated electromechanical and electrohydraulic tools face challenges in operating underwater due to corrosion from conductive salt water, which can lead to operational failures, especially in rescue and emergency situations.
Innovation Solution
The tool design includes a contact surface with a nonconductive surface protective layer on one region and a bare surface region for contact with the battery, allowing current flow while preventing corrosion, and the battery has a sealed housing with a resilient closure device and nonconductive gel-like compound to prevent water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact surface is covered with a nonconductive surface protective layer, then corrosion resistance is improved, but electrical conductivity deteriorates
Solution Approach 1:
The contact surface is divided into two distinct regions: a first surface region covered with a nonconductive protective layer for corrosion protection, and a second surface region left bare for electrical contact. This segmentation allows each region to fulfill its specific function without compromising the other.
Solution Approach 2:
Different surface properties are applied to different regions of the contact surface. The first region has a nonconductive protective layer for corrosion resistance, while the second region maintains bare metal conductivity for electrical contact. This local differentiation resolves the contradiction between protection and conductivity.
2Reliability
If complex sealing measures are implemented to prevent water ingress, then reliability underwater is improved, but device complexity increases
Solution Approach 1:
The harmful effect of water is extracted or excluded from the critical electrical contact region by using a nonconductive protective layer that prevents water contact, eliminating the need for complex sealing structures while maintaining reliability.
Solution Approach 2:
The nonconductive surface protective layer acts as an intermediary barrier between the metal contact surface and the conductive salt water environment. This intermediary prevents harmful electrochemical processes without requiring complex sealing mechanisms.
3Use of energy by moving object
If the contact surface is left bare for electrical contact, then electrical conductivity is improved, but corrosion resistance deteriorates
Solution Approach 1:
The contact surface is segmented into protective and conductive zones, allowing the bare metal second region to provide electrical conductivity while the first region with protective layer provides corrosion resistance.
Solution Approach 2:
The bare metal surface is localized to the second contact region where conductivity is needed, while the first region receives corrosion protection. This local quality differentiation allows both properties to coexist in different areas.
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
Enables the tool to operate underwater without significant corrosion, ensuring high current flow and mechanical stability, even in harsh environments like salt water, without complex sealing measures.
Implementation Method 1
The surface protective layer isolates the first surface region of contact from water, in particular from highly conductive salt water. Despite a very high electrical conductivity of salt water, the first surface region covered with a surface protective layer with the water does not cause any, at least no substantial, current flow
Implementation Method 2
the battery has a sealed housing with a resilient closure device and nonconductive gel-like compound to prevent water ingress
Data Source
AI summary
A portable tool for mobile use includes a housing, an electric motor located in the housing, an insert shaft on the tool, and a battery. The battery or a terminal for connecting to an external energy source is located in the insert shaft. A mechanically or hydraulically driven movable piston rod is for performing spreading, cutting, lifting, and/or pressing. An electronic device controls and/or regulates the electric motor and includes a printed circuit board with a potting compound on which electronic components are arranged. An electrically conductive on the insert shaft allows a releasable electric contact between the battery and the electronic device of the tool by inserting the battery into the insert shaft. The contact is divided into a first and second surface regions. The first surface region is covered with a nonconductive protective layer, and the second surface region is free of the protective layer.