Power Tool Battery Terminal Block Cooling for High-Current Heat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat generated by electrical current in power tool battery terminals increases with higher current supply, leading to potential overheating and inefficiencies.
Innovation Solution
Incorporation of a heat sink with thermally conductive material and a dedicated terminal block fan to transfer heat away from the battery terminals, combined with a temperature sensor to monitor and manage thermal conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher current is supplied to increase power output, then power delivery is improved, but heat generation increases causing overheating
Solution Approach 1:
The patent applies the 'Blessing in disguise' principle by converting the harmful heat generated by high current into a manageable thermal management challenge. The heat sink and cooling system transform the waste heat into a controlled thermal flow, allowing the system to maintain high power delivery without overheating. The cooling airflow converts the harmful thermal energy into a dissipatable form, enabling sustained high-current operation.
Solution Approach 2:
The patent introduces a heat sink as an intermediary component between the battery terminals and the environment. This heat sink acts as a thermal mediator that receives heat from the high-current terminals and transfers it to the cooling airflow, preventing direct heat accumulation at the terminals while enabling continuous high power delivery.
2Loss of energy
If larger battery terminals are used to reduce resistance, then electrical efficiency is improved, but device size increases
Solution Approach 1:
The patent applies 'Parameter changes' by modifying the thermal parameters of the terminal block through the addition of a heat sink. Instead of increasing terminal size to reduce resistance, the invention changes the thermal dissipation parameters by introducing active cooling, allowing smaller terminals to achieve the same thermal management performance.
Solution Approach 2:
The patent replaces the mechanical approach of using larger terminals (physical size increase) with a thermal management system. Instead of mechanically enlarging the terminals to reduce resistance, the invention uses a heat sink and cooling airflow to manage the thermal consequences, allowing smaller terminals to function effectively.
3Temperature
If active cooling system is added to manage heat, then thermal management is improved, but device complexity increases
Solution Approach 1:
The patent applies 'Self-service' by designing a cooling system that utilizes the device's own operational characteristics. The cooling airflow is integrated into the existing device architecture, using natural convection and the device's operational airflow paths to provide self-sustaining thermal management without requiring external active cooling components.
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
Effectively cools the battery terminals, preventing overheating and ensuring efficient operation by managing thermal conditions and current draw.
Implementation Method 1
The heat sink comprises a thermally conductive material configured to transfer heat away from the tool-side battery terminal
Implementation Method 2
Incorporation of a heat sink with thermally conductive material and a dedicated terminal block fan to transfer heat away from the battery terminals
Data Source
AI summary
A power tool includes a motor configured to drive a working element and a battery receptacle. The battery receptacle is configured to receive a battery and includes a tool-side battery terminal, a tool-side terminal block, and a heat sink. The tool-side battery terminal is electrically coupled to the motor and configured to transfer electrical current from the battery to the motor. The tool-side terminal block is mounted to the tool-side battery terminal. The heat sink is in thermal communication with at least one of the tool-side terminal block or the tool-side battery terminal. The heat sink comprises a thermally conductive material configured to transfer heat away from the tool-side battery terminal.