Brushless Power Tool Housing Layout for Circuit Cooling
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Solution Overview
Problem
Power tools employing brushless motors face challenges in effectively cooling circuit elements generating heat, leading to increased size and reduced maintenance, as existing solutions do not adequately address the thermal management of these components.
Innovation Solution
A power tool design incorporating a housing with inlet and exhaust holes to facilitate cooling air flow, supporting a brushless motor and circuit elements, where the circuit elements are cooled by the air flow generated by a fan driven by the motor, and strategic placement of components to optimize cooling efficiency and reduce tool size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brushless motor is employed instead of a motor with brush, then the power tool achieves prolonged life and maintenance-free operation, but circuit elements generate heat requiring effective cooling
Solution Approach 1:
The patent combines the cooling function with the existing housing structure by forming inlet and exhaust holes directly in the housing. The housing serves dual purposes: structural support and thermal management. This integration eliminates the need for separate cooling systems while effectively managing heat from circuit elements.
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: it provides structural support, contains circuit elements, and facilitates cooling air flow through integrated inlet and exhaust holes. This multi-functionality reduces overall system complexity while addressing thermal management requirements.
2Ease of operation
If circuit elements are provided to drive the brushless motor, then the motor can operate, but the power tool becomes large in size due to accommodation of circuit elements
Solution Approach 1:
The patent integrates circuit elements directly into the housing structure, eliminating the need for separate mounting spaces. The housing serves as both the structural enclosure and the mounting platform for circuit elements, thereby reducing overall tool size while maintaining full functionality.
Solution Approach 2:
Circuit elements are disposed inside the housing, with the housing acting as a container that accommodates multiple components. This nesting approach allows circuit elements to be housed within the existing structural envelope rather than requiring additional external space.
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 solution enables efficient cooling of circuit elements, prolonging the tool's life and maintaining its compact size, while ensuring effective thermal management and reduced maintenance.
Implementation Method 1
The fan is driven by rotation of the brushless motor to generate a cooling air flow that flows from the inlet hole to the exhaust hole in the housing
Implementation Method 2
the at least one circuit element is disposed inside the first housing and is cooled by the cooling air flow
Data Source
AI summary
There is provided a power tool including a housing, a brushless motor, a power supply circuit, and a fan. The housing is formed with an inlet hole and an exhaust hole. The brushless motor is supported by the housing. The power supply circuit includes at least one circuit element for supplying electric power of a power source to the brushless motor. The fan is driven by rotation of the brushless motor to generate a cooling air flow that flows from the inlet hole to the exhaust hole in the housing. The housing includes a first housing including a grip portion and supporting the brushless motor. The inlet hole is formed in the first housing. The at least one circuit element is disposed inside the first housing and is cooled by the cooling air flow.