Battery Pack Terminal Shock Protection via Case Sub-Portion
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Solution Overview
Problem
Existing battery packs are prone to electrode terminal damage or breakage when subjected to shock, especially when in a sideways falling-down state, as the shock is directly applied to the terminal, leading to potential damage or breakage.
Innovation Solution
The battery pack design includes a case with a protruded sub-portion and an electrode terminal positioned on the upper surface of the main portion, interposed between the main and sub-portions, with a cushion member and sealing member to absorb and redirect shock, and a power tool with an accommodation part that securely houses the battery pack, preventing direct shock application to the terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electrode terminal is disposed at an upper end of the battery case, then it is easily connected to the power tool, but it is readily damaged or broken when the battery pack falls sideways
Solution Approach 1:
The electrode terminal is repositioned from the traditional upper end location to the side surface of the battery case, changing its spatial dimension. This dimensional shift allows the terminal to be protected from shock when the battery pack falls sideways, while still maintaining easy connection capability through proper orientation and design of the connection interface.
Solution Approach 2:
A terminal protective member is introduced as an intermediary component between the electrode terminal and the external environment. This protective member absorbs or redirects shock forces, preventing direct transmission to the terminal while allowing electrical connection to occur, thus resolving the contradiction between protection and connectivity.
2Device complexity
If the battery case is L-shaped with terminal at upper end, then structure is simple, but terminal is exposed to direct shock
Solution Approach 1:
The electrode terminal is relocated from the upper end to the side surface of the battery case, changing its spatial positioning. This dimensional repositioning maintains the simplicity of the L-shaped case structure while naturally protecting the terminal from shock forces that occur during sideways falls, as the terminal is no longer at the most vulnerable upper extremity.
3Reliability
If electrode terminal is positioned closer to case sub portion, then shock protection is improved, but connection alignment may be affected
Solution Approach 1:
The battery pack and power tool are equipped with self-aligning connection mechanisms that automatically adjust for positional variations. When the battery pack is inserted, guide structures and toleranced interfaces ensure proper alignment of the electrode terminal with the tool's connection point, eliminating the need for high-precision manual positioning while maintaining protection benefits.
Data Source
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AI summary
According to an aspect of the present invention, there is provided a battery pack to be inserted and attached to a power tool, including: a case; a battery cell accommodated inside the case; and an electrode terminal connected to the battery cell and provided on the case so as to be connectable to a tool-side electrode terminal, wherein the case includes: a case main portion; and a case sub portion which is protruded from the case main portion to be inserted into the power tool, and wherein the electrode terminal is provided on an upper surface of the case main portion at a side of the case sub portion.