Battery Pack Ejection Mechanism for Flush-Mount Handheld Tools
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Solution Overview
Problem
Existing lithium battery packs for cordless handheld tools have a closed cover with a locking structure that limits adaptability to specific tools, are cumbersome to mount and remove, and have a raised outer housing making them inconvenient for use.
Innovation Solution
A battery pack with a smooth surface and no raised portions, featuring a battery ejection mechanism and fool-proof structure, allowing easy mounting and removal, and a locking mechanism that prevents reverse insertion, integrated with a handheld tool for improved usability and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed cover with locking structure is used in the battery pack, then the battery pack can be securely locked in the tool, but the battery pack has a raised outer housing making it inconvenient for use and reducing adaptability
Solution Approach 1:
The patent removes the traditional closed cover with locking structure from the battery pack exterior. Instead, a locking mechanism is integrated inside the battery compartment of the tool, which locks the battery pack from the interior side. This extraction of the locking structure from the battery pack surface eliminates the raised outer housing while maintaining secure locking functionality.
Solution Approach 2:
The locking mechanism is nested within the battery compartment structure of the tool. The locking component is integrated into the tool's housing rather than being an external feature of the battery pack, allowing the battery pack to maintain a smooth, compact form factor while still achieving reliable locking when inserted into the tool.
2Reliability
If a closed cover with locking structure is used in the battery pack, then the battery pack can be securely locked in the tool, but the battery pack is adapted to only specific types of tools
Solution Approach 1:
The locking mechanism is designed as a universal solution integrated into the tool's battery compartment rather than being specific to particular battery pack models. The standardized locking interface and smooth battery pack design allow the same battery pack to be used across different tool types, enhancing versatility while maintaining secure locking through the integrated mechanism.
3Ease of operation
If manual removal of the battery pack is required, then the user can control battery removal, but the operation is time-consuming and labor-consuming
Solution Approach 1:
The battery ejection mechanism is designed to be automatically triggered by the user's insertion action. When the battery pack is inserted into the tool, it automatically activates the ejection mechanism through the interaction between the battery pack's positioning structure and the tool's locking mechanism, enabling quick one-handed operation without requiring separate manual ejection steps.
4Ease of manufacture
If the battery pack has a raised outer housing, then the locking structure can be provided, but the surface of the battery pack is not smooth and the tool size is elongated
Solution Approach 1:
The locking structure is extracted from the battery pack's outer housing and relocated to the tool's battery compartment. This removes the need for a raised outer housing on the battery pack, resulting in a smooth surface and more compact overall tool design, while the locking functionality is preserved through the integrated mechanism in the tool.
Data Source
AI summary
Disclosed is a handheld tool using a battery pack (1). A positioning hole (118) is provided on the surface of the battery pack, a locking mechanism (31) matching the positioning hole is provided inside the handheld tool for locking or unlocking the battery pack, and an ejection mechanism (32) is further provided inside the handheld tool to work in conjunction with the locking mechanism to eject the battery pack when the battery pack is unlocked. The battery pack of the handheld tool can be completely inserted into a holding portion of the handheld tool, such that the tool can be made smaller. Moreover, the battery pack has a smooth surface and is convenient to carry, such that assembly/disassembly of the battery pack into/from the tool is more convenient. In addition, there is no detached gap between a tool housing and the battery pack on the surface of the tool, such that the appearance of the tool is more aesthetic.