Battery Protection Divider for Power Tools

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Solution Overview

Problem

Power tools may draw power from battery packs during shipping due to physical connection, leading to low voltage and inoperability upon receipt.

Innovation Solution

A battery protection system with a divider that includes an outer portion with an indicator and an inner portion with a stem extending from the outer portion, galvanically isolating the battery receptacle terminal and the battery pack terminal, preventing current draw until the power tool is ready for use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the battery pack is physically connected to the power tool during shipping, then the power tool is ready for immediate use, but the battery voltage decreases due to power draw

Engineering Contradiction:
Improvereadiness for useVSAvoidbattery voltage
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

A divider is introduced as an intermediary component between the battery pack terminal and the power tool terminal. This divider includes a stem that galvanically isolates the electrical connection, preventing current flow while maintaining physical connectivity. The indicator on the divider provides visual feedback about the isolation state. This resolves the contradiction by allowing the battery to remain physically connected (maintaining readiness) while blocking electrical current (preserving voltage).

Inventive Principle:
Principle #24Intermediary (Mediator)

2Productivity

If the battery pack is connected to the power tool during storage, then the tool is prepared for operation, but the battery becomes inoperable due to discharge

Engineering Contradiction:
Improveoperational readinessVSAvoidbattery functionality
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The divider is installed in advance during shipping or storage to preemptively prevent battery discharge. By placing the galvanic isolation barrier before the battery can deplete, the system ensures the battery remains charged and functional when actually needed. The indicator provides preliminary visual confirmation that protection is active. This resolves the contradiction by performing protective action beforehand, maintaining both readiness and functionality.

Inventive Principle:
Principle #10Preliminary action

3Power

If electrical connection is maintained between battery and tool, then power is available, but unwanted current draw occurs during transport

Engineering Contradiction:
Improvepower availabilityVSAvoidbattery energy
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The divider acts as an intermediary that selectively blocks unwanted current flow while allowing the electrical connection to remain physically intact. The stem of the divider creates a galvanic barrier that prevents energy drain during transport, yet the connection structure remains in place for quick activation. When needed, removing the divider restores full power availability. This resolves the contradiction by using the intermediary to eliminate energy loss while preserving the capability for power delivery.

Inventive Principle:
Principle #24Intermediary (Mediator)

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

Prevents battery discharge during shipping and storage, ensuring the battery is operational when the power tool is used for the first time.

Implementation Method 1

The stem galvanically isolates the battery receptacle terminal and the battery pack terminal

Methodology Applied
Scientific EffectGalvanic isolation: Electrical Resistance

Data Source

PatentUS10686180B2Battery protection system
Publication Date: 2020.06.16 MILWAUKEE ELECTRIC TOOL CORP
  • US10686180B2 patent drawing
  • US10686180B2 patent drawing
  • US10686180B2 patent drawing

AI summary

A battery protection system for a power tool includes a power tool housing with a battery pack interface. The battery pack interface includes at least one tool electrical terminal. The battery protection system also includes a battery with a battery housing and at least one battery electrical terminal and a divider positioned between the at least one battery electrical terminal and the at least one tool electrical terminal. The divider includes at least one fold.