Retrofit Battery Pack Enclosure for Dust-Protected Tool Access
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Solution Overview
Problem
Cordless power tools often expose battery packs to contamination from dust, moisture, and other substances due to their partial exposure, which can affect performance and longevity.
Innovation Solution
A modular battery pack enclosure system that can be retrofitted onto power tools, featuring clamshell members and a door to fully enclose the battery pack, providing protection while allowing easy insertion and removal, and accommodating various battery sizes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery pack is partially exposed from the power tool, then the battery pack can be easily accessed and removed, but the battery pack is subjected to contamination from dust, moisture, and other substances
Solution Approach 1:
The enclosure is divided into a first enclosure member and a second enclosure member that can be separated. The first enclosure member remains attached to the power tool while the second enclosure member can be removed to access the battery pack, allowing users to access the battery without removing the entire enclosure structure.
Solution Approach 2:
The enclosure acts as an intermediary structure between the battery pack and the contaminated environment. It provides a protective barrier that shields the battery pack from dust, moisture, and other harmful substances while still allowing controlled access when needed.
2Object-affected harmful factors
If an enclosure is added to protect the battery pack, then contamination is reduced, but the device complexity increases
Solution Approach 1:
The enclosure is segmented into two main parts: a first enclosure member that attaches to the power tool and a second enclosure member that covers the battery pack. This segmentation allows the enclosure to be installed in a straightforward manner without requiring complex assembly procedures.
Solution Approach 2:
The enclosure is designed to be compatible with multiple power tool models within a family, providing universal protection across different tools. The first enclosure member can be attached to various power tools while maintaining the same protective function.
3Adaptability or versatility
If the enclosure is designed to be retrofitted onto existing power tools, then adaptability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The first enclosure member is designed with universal attachment features that can be mounted on various power tool models within a family. It includes a mounting structure that can accommodate different battery pack receptacle configurations while maintaining consistent protection standards.
Solution Approach 2:
The enclosure design allows for parameter adjustments in the mounting configuration to accommodate different power tool models. The first enclosure member can be positioned and secured at various locations on the power tool housing to fit different tool geometries while maintaining the same protective enclosure function.
Data Source
AI summary
A power tool battery pack enclosure is configured to be retrofittedly coupled to battery pack receptacles of a plurality of power tools, each battery pack receptacle configured to removably receive a plurality of power tool battery packs. The enclosure includes a first clamshell member and a second clamshell member configured to be coupled around at least a portion of an exterior surface of each battery pack receptacle. Each of the first and second clamshell members have a top wall portion configured to be received over the exterior surface of the battery pack receptacle and a sidewall portion that extends downward from the top wall portion over at least a portion of the battery pack housing when the battery pack is received in the battery pack receptacle. The first and second enclosure members cover at least a portion of the battery back receptacle and at least a portion of the portion of a battery pack housing while allowing the battery pack to be removed from the battery pack receptacle while the enclosure remains coupled to the battery pack receptacle.