Battery Pack Bracket Reduces Mechanical Interface Stress
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Solution Overview
Problem
Cordless power tools are limited by the weight and size of more powerful battery packs, which increase stress on the mechanical interface, leading to ergonomic disadvantages and potential damage during use.
Innovation Solution
Incorporating a metal U-shaped bracket within the battery pack housing, positioned within the rail and adjacent to the sliding surface, to provide additional support and reduce stress on the mechanical interface, while also maximizing surface area for heat conduction and minimizing wear and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If larger format cells or additional cells are added to the battery pack to increase power output, then the power and runtime of cordless tools are improved, but the battery pack size and weight increase, placing additional strain on the housing and mechanical interface system
Solution Approach 1:
The patent combines plastic housing material with metal reinforcement elements (brackets or ribs) to create a composite structure. The metal components provide enhanced mechanical strength and stress distribution at the mechanical interface, allowing the battery pack to support higher power outputs without increasing overall size excessively.
Solution Approach 2:
The mechanical interface is segmented into distinct functional zones: the plastic housing provides basic structure, while embedded metal brackets or ribs provide localized reinforcement at high-stress areas. This segmentation allows each material to perform its optimal function without unnecessary weight addition throughout the entire housing.
2Power
If larger format cells or additional cells are added to the battery pack to increase power output, then the power and runtime of cordless tools are improved, but the battery pack weight increases, creating ergonomic disadvantages
Solution Approach 1:
Instead of uniformly increasing housing thickness or adding material throughout the battery pack, the patent applies reinforcement (metal brackets or ribs) only at specific locations where mechanical stress is highest - namely at the mechanical interface. This localized approach provides necessary structural support while minimizing overall weight increase.
3Strength
If the mechanical interface is designed to accommodate higher power battery packs, then the structural support and stress distribution are improved, but the device complexity increases
Solution Approach 1:
The patent integrates the reinforcement elements (metal brackets or ribs) directly into the plastic housing structure during manufacturing. This merging of components creates a unified structural system that provides enhanced strength without adding separate, complex assemblies. The reinforcement becomes an inherent part of the housing rather than an attached component.
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 solution enhances the structural integrity and support of the battery pack, reducing the likelihood of cracking and wear, and improves ergonomics by distributing stress more evenly, thus enhancing the performance and durability of the battery pack.
Implementation Method 1
maximizing surface area for heat conduction
Implementation Method 2
minimizing wear and friction
Data Source
AI summary
The present invention includes a battery pack for a cordless power tool including a plastic housing including a mechanical interface for mechanically coupling the battery pack to a corresponding mechanical interface of a cordless power tool. The mechanical interface includes a rail, a groove and a sliding surface. The battery pack also includes a bracket encased within the plastic housing wherein the bracket includes a first portion positioned within the rail of the mechanical interface.