Power Tool Battery Locking Lever Mechanism
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Solution Overview
Problem
Existing power tools with rechargeable battery packs face difficulties in securely locking larger and heavier battery packs, which can fall out during release due to the cumbersome two-handed operation required to disengage the sliding lock.
Innovation Solution
A device featuring a locking bar held in place by spring force, with a pivotally supported lever acting as both a locking mechanism and release mechanism, allowing single-finger operation and preventing the battery pack from falling by using a dual-arm lever design that engages with recesses on the battery pack, and an oblique contact face to facilitate easy insertion and secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sliding lock mechanism is used to secure the battery pack, then the battery pack can be locked in place, but the operator must use two hands to remove it (one to hold the tool and one to actuate the lock), which becomes difficult when the battery pack is large and heavy
Solution Approach 1:
The locking bar and release mechanism are merged into a single integrated lever component. This unified structure allows the operator to actuate the release mechanism with one hand while the tool remains stable, eliminating the need for two-handed operation while maintaining secure locking during use.
Solution Approach 2:
The spring-loaded locking bar acts as an intermediary between the battery pack and the guide. The spring provides automatic engagement force to secure the battery pack, while the lever mechanism provides controlled release, mediating the interaction between the operator and the heavy battery pack.
2Reliability
If the locking bar is made robust to handle heavy battery packs, then locking reliability improves, but the mechanism becomes more complex and heavier
Solution Approach 1:
The locking mechanism is segmented into distinct functional elements: a locking bar for engagement, a lever for actuation, and a spring for providing engagement force. This segmentation allows each component to be optimized for its specific function while keeping the overall design simple and manageable.
Solution Approach 2:
The lever serves multiple functions: it acts as both the release mechanism and a structural component of the locking system. This multi-functionality reduces the total number of parts needed while maintaining robust locking capability for heavy battery packs.
3Power
If the battery pack size is increased to provide greater output and operating time, then power capacity improves, but the battery pack becomes heavier and more difficult to handle during removal
Solution Approach 1:
The spring-loaded locking bar provides automatic engagement when the battery pack is inserted, securing it without requiring operator intervention. The lever mechanism enables easy one-handed release, allowing the operator to remove even heavy battery packs with minimal effort.
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 secure locking and easy release of the battery pack with single-finger operation, reducing the weight burden on the locking mechanism, enhancing reliability and simplifying the design while preventing the battery pack from falling out during release.
Implementation Method 1
a locking bar installable on a housing of the power tool and held in locking engagement with the rechargeable battery pack via spring force
Implementation Method 2
said locking bar and said release mechanism forming a lever that is pivotally supportable in a rocker pivot on the housing
Implementation Method 3
releasable by pivoting said lever from the lock engagement via a compression force applied to said release mechanism
Data Source
AI summary
A device for locking a power tool and a rechargeable battery pack that is insertable in a guide of the power tool has a locking bar installable on a housing of the power tool and held in locking engagement with the rechargeable battery pack via spring force, a release mechanism that acts on the locking bar for manually releasing the locking bar from the locking engagement, the locking bar and the release mechanism forming a lever that is pivotally supportable in a rocker pivot on the housing, the locking bar being fixedly held via spring force and a recess formed at a top side of the rechargeable battery pack and is releasable by pivoting the lever from the locking engagement via a compression force applied to the release mechanism, which extends upwardly across a front base end of the housing.