Battery Pack Terminal Structure for Flexible Tool Connection
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Solution Overview
Problem
Existing battery packs for power tools lack efficient and reliable terminal designs that facilitate secure and easy electrical connections, leading to potential issues with power transfer and tool compatibility.
Innovation Solution
A battery pack design featuring a terminal with a spine, arms, and a base that deform to securely connect with tool terminals, allowing for efficient electrical coupling and varying materials for optimal force and strain characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid terminal design is used, then structural strength is improved, but adaptability to different tool terminals deteriorates
Solution Approach 1:
The terminal arms are designed to be flexible rather than rigid, allowing them to deform elastically during connection and disconnection. This dynamic behavior enables the terminal to adapt to different tool terminal geometries while maintaining sufficient contact force for reliable electrical connection.
Solution Approach 2:
The terminal structure incorporates varying material properties along its length, with the arms having different flexibility characteristics compared to the base. This parameter variation allows the terminal to provide both adaptability at the contact points and structural strength at the connection points.
2Adaptability or versatility
If a flexible terminal design is used, then adaptability to different tool terminals is improved, but connection force deteriorates
Solution Approach 1:
The terminal arms are designed to be flexible rather than rigid, allowing them to deform elastically during connection and disconnection. This dynamic behavior enables the terminal to adapt to different tool terminal geometries while maintaining sufficient contact force for reliable electrical connection.
Solution Approach 2:
The terminal arms incorporate curved geometries that allow for controlled deformation paths. The curvature enables the arms to bend in specific directions to accommodate different tool terminals while maintaining optimal contact force through elastic recovery.
3Reliability
If high connection force is applied, then electrical connection reliability is improved, but risk of permanent deformation deteriorates
Solution Approach 1:
The terminal structure incorporates varying material properties along its length, with the arms having different flexibility characteristics compared to the base. This parameter variation allows the terminal to provide both adaptability at the contact points and structural strength at the connection points.
Solution Approach 2:
The terminal is designed as a composite structure with the base and arms potentially made from different materials or with different structural configurations. This allows the base to provide high strength and stiffness for reliable electrical connection, while the arms provide flexibility for adaptation without permanent deformation.
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 design ensures reliable and efficient electrical connections between the battery pack and power tools, accommodating different tool terminals with varying force requirements and materials to prevent permanent deformation, enhancing compatibility and performance.
Implementation Method 1
the first arm and the second arm are configured to receive a tool terminal of the tool therebetween
Data Source
AI summary
A battery pack may include a housing supporting a plurality of battery cells. A battery pack may include a battery terminal for electrically connecting the battery pack to the tool, the battery terminal including, a spine extending along an axis, a first arm coupled to the spine, a second arm coupled to the spine, wherein the first arm and the second arm are configured to receive a tool terminal of the tool therebetween, and wherein the first arm and the second arm extend along a direction perpendicular to the axis, and a base coupled to the first arm and/or the second arm, the base electrically connected to the plurality of battery cells.