Power Tool Battery Pack Housing for Drop Impact Protection
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Solution Overview
Problem
Rechargeable battery packs for hand-held power tools experience mechanical stress and potential damage due to their high weight and inertia, leading to non-reversible damage at the mechanical interface when dropped, which can compromise the system's functionality and longevity.
Innovation Solution
The design incorporates a sealing element to protect radial openings, a two-component sealing element carrier with hard and soft plastic components, and a protective element made of metal to reinforce the housing, along with a predetermined breaking point in the mechanical interface to prevent damage during falls and overloads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery pack housing is made robust to withstand mechanical stress and drops, then the strength and durability are improved, but the weight increases
Solution Approach 1:
The housing is divided into multiple components (first housing part, second housing part, cell holder) that can be separately optimized. The cell holder is a separate component that can be designed with minimal material while providing necessary support, reducing overall weight while maintaining structural integrity through the assembled configuration of parts.
Solution Approach 2:
The patent employs different materials for different housing components - the first and second housing parts use one material while the cell holder uses another material. This allows each component to be optimized for its specific function, using lighter materials where sufficient strength is achieved through design rather than material alone.
2Object-affected harmful factors
If sealing elements are added to protect radial openings, then the protection against contaminants is improved, but the device complexity increases
Solution Approach 1:
The sealing element is integrated with the cell holder or housing structure rather than being a separate assembly. The sealing function is merged into the existing structural components, so that the same elements that provide mechanical support also provide sealing, avoiding additional complexity while achieving contaminant protection.
Solution Approach 2:
The sealing element uses a flexible sealing ring or lip that can be molded directly into the housing or cell holder. This thin film approach provides effective sealing against contaminants without requiring complex mechanical structures, maintaining simplicity while achieving the protective function.
Data Source
AI summary
A rechargeable battery pack, in particular a rechargeable battery pack for a hand-held power tool. The rechargeable battery pack includes a housing in which at least one rechargeable battery cell is accommodated. It is provided that the rechargeable battery pack includes at least one protective element that is connected to the housing.