Battery Pack Terminal Sealing with Elastic Rubber Covers
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Solution Overview
Problem
Battery packs for electric power tools are vulnerable to damage from foreign materials like water and dust when removed and placed alone, as terminal-connection openings are exposed, leading to potential damage of connection terminals.
Innovation Solution
Incorporating foreign-material entry-regulating members, such as elastic rubber cover bodies or elastic opening-closing members, into the battery pack's terminal-connection openings that can close when the pack is not mounted, preventing foreign material entry while allowing seamless connection when slid onto the tool body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If terminal-connection openings are provided to enable slide mounting connection, then electrical connection between battery-side and body-side connection terminals is achieved, but foreign materials such as water or dust can enter the housing case and damage the connection terminals when the battery pack is removed and placed alone
Solution Approach 1:
The foreign-material entry-regulating members are preliminarily positioned to close the terminal-connection openings when the battery pack is not mounted. This preliminary protective action prevents foreign material entry before any damage can occur, while still allowing the slide mounting connection to be established when needed.
Solution Approach 2:
The foreign-material entry-regulating members are designed to dynamically change their state between closed (when battery pack is removed) and open (when battery pack is mounted). This dynamic behavior allows the same structure to provide both protection during storage and electrical connection during operation.
2Object-affected harmful factors
If foreign-material entry-regulating members are added to close terminal-connection openings, then protection against foreign material entry is improved, but device complexity increases
Solution Approach 1:
The foreign-material entry-regulating members utilize flexible elastic bodies that can deform and recover. This approach provides effective sealing protection against foreign materials while maintaining a relatively simple structural form that integrates well with the existing terminal-connection opening design.
Solution Approach 2:
The elastic foreign-material entry-regulating members are designed to automatically open when the battery pack is mounted and automatically close when removed, without requiring external control mechanisms. This self-service behavior reduces the overall device complexity while maintaining effective protection.
3Reliability
If foreign-material entry-regulating members are provided, then connection terminals are protected from damage, but manufacturing complexity increases
Solution Approach 1:
The use of elastic foreign-material entry-regulating members as simple flexible components allows for relatively straightforward manufacturing processes. These elastic bodies can be produced using standard molding techniques and integrated into the housing case without requiring complex assembly procedures.
Solution Approach 2:
The foreign-material entry-regulating members are designed as simple elastic components that can be manufactured cost-effectively. While they serve a critical protective function, their relatively simple construction allows for economical production and potential replacement if needed.
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
Protects the battery-side connection terminals from damage by preventing foreign material entry when the pack is not in use and ensures uninterrupted electrical connection during slide mounting, while also simplifying manufacturing and assembly processes and extending product lifespan by resisting heat degradation.
Implementation Method 1
the foreign-material entry-regulating members have elasticity and are formed in a shape that can close the opening shapes of the terminal-connection openings
Implementation Method 2
When the body-side connection terminals are connected to the battery-side connection terminals, the foreign-material entry-regulating members themselves are deformed due to elasticity according to the slide movement of the body-side connection terminals that come into contact with the foreign-material entry-regulating members
Data Source
Figure 1
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AI summary
Rubber cover main bodies (42) close opening shapes of terminal-connection openings when a battery pack (10) is placed alone without being mounted on a tool body. When the battery pack (10) is removed from the tool body and is placed alone, it is possible to regulate the entry of foreign materials, such as water or dust, by the rubber cover main bodies (42). Further, when body-side connection terminals (91, 92, and 93) are connected to battery-side connection terminals (36), the rubber cover main bodies (42) themselves can be deformed due to elasticity according to the slide movement of the body-side connection terminals (91, 92, and 93) such that the body-side connection terminals (91, 92, and 93) can be inserted into the rubber cover main bodies (42). Accordingly, it is possible to protect the battery-side connection terminals (36) in the terminal-connection openings such that the battery-side connection terminals (36) are not damaged by regulating the entry of foreign materials, such as water or dust, from the terminal-connection openings without hindering electrical connection caused by slide mounting.