Dual-Material Battery Pack Housing for Fire and Impact Protection
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Solution Overview
Problem
Existing battery packs lack effective protection against fire and impact, and there is a need for improved design that allows for user-replaceable and portable battery systems for electrically driven working tools.
Innovation Solution
A battery pack design featuring a flame-retardant housing component and an impact-resistant housing component, with power contacts positioned within the flame-retardant region, providing dual protection against fire and impact, and allowing for user-replaceable connection to working tools without tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single housing material is used for the battery pack, then the manufacturing process is simple, but the battery pack lacks protection against both fire and impact
Solution Approach 1:
The housing is divided into two separate components: a flame-retardant housing component and an impact-resistant housing component. This segmentation allows each component to be optimized for its specific protective function while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
The housing combines two different materials with distinct properties: a flame-retardant material for fire protection and an impact-resistant material for mechanical protection. This composite approach enables the battery pack to simultaneously achieve both fire resistance and impact resistance without compromising manufacturing ease
2Reliability
If power contacts are positioned in the impact-resistant housing region, then impact protection is improved, but fire protection is compromised
Solution Approach 1:
The power contacts are positioned in the flame-retardant housing component region, which has different material properties (fire resistance) compared to the impact-resistant region. This local quality differentiation ensures that electrically conductive components are located in the fire-resistant zone, protecting against fire while the impact-resistant component provides mechanical protection
3Weight of moving object
If the battery pack is designed for portability, then user mobility is improved, but protection against fire and impact may be compromised
Solution Approach 1:
The housing is segmented into two thin but functional components that can be closely integrated, minimizing the overall volume and weight added by the dual-protection structure while maintaining both fire and impact resistance
Solution Approach 2:
The use of composite materials allows for thin-walled construction that provides both fire and impact protection without significantly increasing weight, enabling the battery pack to remain portable while achieving reliable dual protection
Data Source
AI summary
A battery pack has a plurality of pack power contacts, the pack power contacts having touch points for the user-releasable touching of tool power contacts of an electrically powered tool for supplying the tool with electric drive power from the battery pack, and a pack housing. The pack housing has at least one flame-retardant housing component and at least one impact-protection housing component. The at least one flame-retardant housing component has at least one flame-retardant material acting as a flame retardant for the battery pack. The least one impact-protection housing component has at least one impact-protection material that differs from the flame-retardant material for providing impact protection for the battery pack. The touch points are located in the region of the at least one flame-retardant housing component and not in the region of the at least one impact-protection housing component.