Battery Pack Water Drainage Pathway Design
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Solution Overview
Problem
Battery packs are susceptible to water ingress through openings in the latch mechanism and terminal access points, leading to potential rusting of batteries and damage to internal electrical components, causing malfunction.
Innovation Solution
The battery pack design incorporates a housing with drain holes and a water discharge pathway that directs infiltrating water from the latch and terminal areas to these holes, preventing damage to internal components and ensuring effective water expulsion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery pack includes openings for latch mechanism and terminal access, then the ease of operation is improved, but water ingress susceptibility increases
Solution Approach 1:
A water discharge pathway acts as an intermediary channel between the latch mechanism area and the exterior environment. This pathway provides a controlled route for water to exit, preventing uncontrolled water ingress while maintaining access to the latch mechanism. The pathway includes a water discharge opening positioned to allow water to escape without compromising the sealing of critical components.
Solution Approach 2:
The water discharge pathway extracts harmful water that enters through the latch mechanism openings and directs it outward through dedicated discharge openings. This separates the water ejection function from the latch mechanism function, allowing the latch openings to remain accessible while water is actively removed from the internal cavity.
2Ease of operation
If the battery pack includes openings for terminal access, then the ease of operation is improved, but water ingress susceptibility increases
Solution Approach 1:
The water discharge pathway serves as an intermediary that manages water near the terminal access openings. By providing a controlled discharge route, it allows terminal openings to remain accessible for electrical connection while preventing water from accumulating or reaching sensitive internal components through these same openings.
Solution Approach 2:
The water discharge pathway converts the potentially harmful effect of water entering through terminal access openings into a beneficial drainage function. Instead of allowing water to damage internal components, the pathway guides water outward through discharge openings, transforming the vulnerability of accessible terminal openings into an opportunity for active water management.
3Reliability
If water is redirected to drain holes, then protection of internal components is improved, but device complexity increases
Solution Approach 1:
The water discharge pathway merges multiple functions into a single integrated structure. It combines the protective function (shielding internal components from water) with the drainage function (redirecting water to discharge openings) and the structural support function (maintaining the spatial relationship between components). This integration reduces the need for separate protective barriers and drainage systems.
Solution Approach 2:
The water discharge pathway structure performs multiple functions simultaneously: it acts as a protective barrier, a water collection channel, and an ejection pathway. By making the structure multi-functional, the patent avoids adding separate dedicated components for each function, thereby limiting the increase in device complexity while achieving comprehensive protection.
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 effectively prevents water damage to the battery pack's internal components by redirecting infiltrating water to drain holes, thereby protecting the batteries and electrical components from rust and malfunction.
Implementation Method 1
A first water discharge pathway extends along the latch cover, downward along a first space between the battery cells and the housing, to the drain holes such that the first water discharge pathway directs water infiltrating the battery pack to the drain holes
Data Source
AI summary
A battery pack including a housing having a first housing portion and a second housing portion. The first housing portion is secured to the second housing portion and defines an interface for receiving a power tool. The battery pack also includes a frame received within the second housing portion, the frame including opening to secure a plurality of battery cells. The battery pack further includes a pair of battery cells of the plurality of battery cells stacked vertically in each of the openings. A wedge is positioned in each of the openings between the pair of battery cells. The battery pack also includes a printed circuit board positioned between the frame and the first housing portion.