Battery Retention System with Backup Latch for Power Tools
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Solution Overview
Problem
Battery retention systems in power tools are prone to failure due to fatigue, especially when subjected to vibrations, as the latch mechanisms are not adequately secured.
Innovation Solution
A battery retention system that includes a primary locking mechanism using spring arms and rails, and a secondary locking mechanism with latch contact surfaces, providing a backup in case the primary mechanism fails, ensuring secure retention of the battery pack even during tool vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a latch mechanism is used to retain the battery pack, then the battery pack can be securely held during operation, but the latch mechanism is subject to fatigue and possible failure due to vibrations
Solution Approach 1:
The patent implements a backup latch mechanism that is pre-positioned and ready to engage if the primary latch fails. This backup system includes a second latch arm and corresponding latch feature that can independently secure the battery pack, providing a safety net against primary latch failure due to fatigue or vibration damage.
Solution Approach 2:
The patent applies different retention strategies at different locations: the primary latch mechanism provides strong, active retention during normal operation, while the backup latch mechanism provides passive, fail-safe retention. The spring arms also provide distributed retention force at multiple contact points along the battery pack interface.
2Reliability
If a complex latch mechanism is used to prevent battery disengagement, then retention security is improved, but the mechanism becomes more complex and harder to manufacture
Solution Approach 1:
The patent divides the retention system into separate, modular components: a primary latch mechanism with latch arm and latch feature, and a backup latch mechanism with a second latch arm and second latch feature. These segmented components can be manufactured independently and assembled, reducing overall system complexity while maintaining high retention security through redundant functionality.
3Reliability
If the battery pack is tightly secured to prevent vibrations, then retention reliability is improved, but removal and reinsertion becomes more difficult
Solution Approach 1:
The patent employs spring arms that provide dynamic retention force. The springs maintain constant contact pressure to secure the battery pack during vibration, but can be easily compressed by user force to allow quick removal. The latch mechanisms are designed with sufficient clearance and mechanical advantage to be easily actuated by hand, balancing secure retention with ease of operation.
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 system effectively secures the battery pack to the power tool, preventing disengagement due to vibrations and allowing for easy removal and reinsertion, enhancing the reliability and usability of battery-powered tools.
Implementation Method 1
The spring arms are configured to deform in engagement with the respective rails of the battery pack when the battery pack is inserted into the cavity
Implementation Method 2
a latch mechanism. The latch mechanism is subject to possible failure due to fatigue, particularly when used in tools that generate vibrations
Data Source
AI summary
A battery retention system for a power tool having a motor, a drive mechanism coupled to the motor, an output element coupled to the drive mechanism, and latch-receiving recesses for receiving battery pack latches. The battery retention system includes a battery pack for powering the motor. The battery pack is removably coupled to the power tool and includes latches and elongated rails. The system includes a cavity in the power tool for receiving the battery pack in a direction of insertion. Spring arms extend generally in the direction of insertion and each have a projection extending into the cavity for coupling the battery pack to the power tool. The spring arms are configured to deform in engagement with the respective rails of the battery pack when the battery pack is inserted into the cavity. The rails are elongated generally in the direction of insertion.