Battery Pack Insert Structure to Reduce Power Tool Contact Wear
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Solution Overview
Problem
In battery-operated oscillating power tools, the relative movement between the tool and the battery pack due to inertia causes wear and heat build-up at the contact surfaces, leading to bonding issues and difficulty in removing the battery pack.
Innovation Solution
The power tool features a battery pack attachment area with an insert having specific contact surfaces and guide sections, made from materials with different coefficients of friction, to reduce wear and heat build-up, allowing for easier battery pack removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is rigidly attached to eliminate relative movement, then wear and heat build-up are reduced, but manufacturing complexity and cost increase significantly
Solution Approach 1:
An insert element is introduced as an intermediary component between the battery pack and tool housing. This insert has a first contact surface that interfaces with the battery pack and a second contact surface that interfaces with the tool housing, mediating the contact and distributing forces to reduce wear and heat build-up at the primary contact interfaces.
Solution Approach 2:
The coefficient of friction parameter is changed by selecting specific materials for the insert that have appropriate friction characteristics. This material selection modifies the friction parameter at the contact surfaces to reduce wear and heat generation while maintaining secure attachment.
2Temperature
If forced cooling is applied to the contact areas, then heat build-up is reduced, but device complexity and cost increase
Solution Approach 1:
The friction-generated heat, which is normally a harmful effect, is converted into a beneficial bonding mechanism. The insert material is selected so that the heat generated during battery pack insertion causes the material to soften and bond with the battery pack, creating a secure attachment without requiring additional cooling systems.
Solution Approach 2:
The insert material undergoes a phase transition from solid to softened state due to friction-generated heat during insertion, then returns to solid state to maintain the bond. This phase transition mechanism allows the contact surfaces to self-regulate temperature and prevent excessive heat build-up without external cooling.
3Ease of operation
If the battery pack allows relative movement due to inertia, then ease of insertion is improved, but wear and heat build-up increase causing bonding
Solution Approach 1:
The friction coefficient parameter is optimized through material selection to allow sufficient relative movement during insertion for ease of operation, while simultaneously limiting the wear and heat build-up to prevent bonding. The insert material is chosen to have a friction coefficient that balances these competing requirements.
Solution Approach 2:
The insert is made from a composite or specially formulated material that combines properties of low friction for easy insertion with high wear resistance and controlled thermal properties to prevent bonding. This composite material approach allows simultaneous optimization of ease of operation and contact surface durability.
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 reduces wear and heat at the contact surfaces, preventing bonding and making battery pack removal easier, while maintaining tool functionality and safety.
Implementation Method 1
the insert having at least a base segment extending along the end portion and including the at least first contact surface... made from materials with different coefficients of friction, to reduce wear and heat build-up
Data Source
AI summary
A power tool has a housing. The housing includes a battery pack attachment area. The battery pack attachment area comprises a battery pack insertion direction, a battery pack insertion opening and an end portion opposite from the battery pack insertion opening in the battery pack insertion direction. The end portion extends across the battery pack insertion direction and has at least one first contact surface for a forward portion of an inserted battery pack. Battery pack guide sections extend parallel to the battery pack insertion direction between the battery pack insertion opening and the end portion and that are spaced apart from each other. The battery pack attachment area comprises an insert which extends along the end portion and includes the at least first contact surface.