Battery Pack Interface Secondary Support for Drop Impact
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Solution Overview
Problem
Hand-held power tools with rechargeable battery packs face damage from accidental drops due to inadequate support during shock pulses, leading to potential destruction of the tool and loss of electrical contact.
Innovation Solution
The integration of at least two intermediate elements on the housing near the rechargeable battery pack interface, which act as a secondary support by redirecting impact energy and maintaining electrical contact through a spring-decoupled contact holder, combined with a primary support, to absorb and distribute the force of accidental drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only a primary support is provided at the rechargeable battery pack interface, then the structure remains simple, but the tool is vulnerable to damage from accidental drops
Solution Approach 1:
The patent applies beforehand cushioning by providing intermediate elements that are pre-positioned to absorb and redirect impact energy before it reaches critical components. These elements create a progressive support system that activates during shock events, cushioning the battery pack interface against drop damage while maintaining a relatively simple overall structure.
Solution Approach 2:
The support function is segmented into multiple levels: a primary support at the rechargeable battery pack interface and secondary support through intermediate elements. This segmentation allows the system to handle impact forces at different stages, improving reliability without requiring complete structural redesign.
2Reliability
If intermediate elements are added to form secondary support, then protection against drop damage improves, but the device complexity increases
Solution Approach 1:
The intermediate elements act as mediators between the external impact force and the rechargeable battery pack interface. These elements redirect impact energy away from critical components, providing enhanced protection while adding only a limited number of intermediate structural elements rather than completely redesigning the support system.
3Reliability
If the rechargeable battery pack moves from mechanical receptacle into primary and secondary support during shock pulse, then electrical contact is maintained, but the contact holder must be spring-decoupled adding complexity
Solution Approach 1:
The contact holder employs spring decoupling to create a dynamic connection that can accommodate movements of the rechargeable battery pack during shock events. This dynamic design allows the electrical contact to be maintained even as the battery pack moves between primary and secondary support positions, ensuring continuous electrical connection without rigid constraints.
4Reliability
If a specified distance is provided between intermediate elements and battery pack, then impact energy is gradually redirected, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a distance range (2.5 mm ± 1 mm) between intermediate elements and the battery pack, allowing for parameter variation that facilitates gradual impact energy redirection. This parameter specification balances the need for controlled energy distribution with practical manufacturing capabilities, avoiding overly tight tolerances while ensuring functional performance.
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
This configuration effectively prevents destruction of the hand-held power tool by redistributing impact energy and maintaining electrical contact, ensuring reliable operation even when dropped from heights over one meter.
Implementation Method 1
the at least two intermediate elements and a rechargeable battery pack disposed at the rechargeable battery pack interface is provided which decreases in the direction of the at least two intermediate elements in the event of a shock pulse to the rechargeable battery pack
Implementation Method 2
The rechargeable battery pack interface is preferably associated with a spring-decoupled contact holder to maintain electrical contact of the rechargeable battery pack at the rechargeable battery pack interface in the event of a shock pulse
Data Source
AI summary
A hand-held power tool includes a housing in which at least one drive motor for driving a tool holder is disposed. The hand-held power tool further includes a rechargeable battery pack interface for placing a rechargeable battery pack for supplying power to the drive motor. The rechargeable battery pack interface forms a primary support for the rechargeable battery pack. At least two intermediate elements for forming a secondary support are disposed on the housing in the region of the rechargeable battery pack interface. The at least two intermediate elements are disposed in such a way that a specified distance between the at least two intermediate elements and a rechargeable battery pack disposed at the rechargeable battery pack interface is provided which decreases in the direction of the at least two intermediate elements in the event of a shock pulse to the rechargeable battery pack and forms the secondary support when the rechargeable battery pack abuts the at least two intermediate elements.