Battery Pack Connector Automatic Circuit Breaker
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Solution Overview
Problem
High-power battery packs used in hand-held electric tools pose a risk of fire during shipping due to potential short-circuiting, necessitating manual disconnection of circuitry to comply with transport regulations, which is complex and costly.
Innovation Solution
A system with configurable electrical connector members that automatically open or close the circuit path when the battery pack is connected or disconnected from the machine, using primary and secondary electrical circuit paths with switches and actuators to manage power flow, thereby minimizing risk during storage and shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power output capacity of battery packs is increased to meet higher power tool requirements, then the power capability is improved, but the risk of fire during shipping due to potential short-circuiting increases
Solution Approach 1:
The circuit breaker is pre-configured in the battery pack to automatically disconnect the circuit when shipping conditions are detected (such as when the battery pack is not properly installed in a tool). This preliminary safety mechanism is built into the battery pack design, so that no manual intervention is needed to prevent short-circuiting during shipping while maintaining full power capability when in use.
2Object-affected harmful factors
If manual disconnection of circuitry is implemented to comply with transport regulations, then the fire risk during shipping is reduced, but the device complexity and cost increase
Solution Approach 1:
The battery pack performs the safety function automatically through the circuit breaker that detects whether it is properly installed in a power tool. When not installed (shipping condition), the circuit breaker remains open, preventing short-circuiting. When installed (use condition), the circuit breaker closes to enable full power output. This self-service mechanism eliminates the need for manual circuit disconnection or reconnection.
3Object-affected harmful factors
If manual disconnection of circuitry is implemented before shipping, then compliance with transport regulations is achieved, but the time and labor required for reconnection after shipping increase
Solution Approach 1:
The circuit breaker automatically transitions from an open state during shipping to a closed state when the battery pack is installed in a power tool, eliminating the need for manual reconnection. The system self-manages the circuit state based on installation detection, saving time and labor while maintaining safety compliance.
4Productivity
If the circuit path is kept closed for continuous power supply capability, then the power tool operational readiness is improved, but the risk of accidental short-circuiting increases
Solution Approach 1:
The circuit breaker dynamically changes its state based on operational conditions. It remains open during shipping/storage to prevent short-circuiting, and automatically closes when the battery pack is installed in a power tool to enable full power output. This dynamic state change allows the system to maintain operational readiness while preventing accidental short-circuiting.
Data Source
AI summary
A battery pack system for use in connecting a battery pack to a battery pack receiving member of a machine so that the battery pack is operable to supply a suitable amount of power to the machine for operation of the machine via an electrical circuit path that is configurable for electrically connecting the battery pack to the machine, the system including: a first electrical connector member disposed along a first region of the electrical circuit path; and a second electrical connector member; wherein, responsive to the battery pack being connected to the battery pack receiving member of the machine, the second electrical connector member is configured for movement relative to the first electrical connector member to cooperatively form a first configuration which electrically closes the electrical circuit path via which the suitable amount of power is able to be supplied from the battery pack to the machine; and wherein, responsive to the battery pack being disconnected from the battery pack receiving member of the machine, the second electrical connector member is configured for movement relative to the first electrical connector member to cooperatively form a second configuration which electrically opens the electrical circuit path via which the suitable amount of power is not able to be supplied from the battery pack to the machine.