Clamshell Battery Pack Enclosure for Contamination Protection
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Solution Overview
Problem
Cordless power tools with exposed battery packs are susceptible to contamination from dust, moisture, and metal shavings, posing a risk of damage and reduced performance.
Innovation Solution
A modular battery pack enclosure system comprising first and second clamshell members that can be retrofitted onto the battery pack receptacle, covering the battery pack while allowing easy insertion and removal, and featuring elastomeric seals and snap-fit or threaded attachments for compatibility with various power tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery pack is partially exposed from the power tool, then the battery pack can be easily accessed and removed, but the battery pack is subjected to contamination from dust, moisture, and other substances
Solution Approach 1:
The enclosure is divided into a first enclosure member and a second enclosure member that can be separately coupled to the battery pack receptacle, allowing the enclosure to be assembled in parts and providing a modular protection system that doesn't interfere with battery access
Solution Approach 2:
The enclosure acts as an intermediary structure between the battery pack receptacle and the external environment, providing a protective barrier that filters out harmful contaminants while still allowing the battery pack to be inserted and removed through the door mechanism
2Object-affected harmful factors
If an enclosure is added to protect the battery pack, then contamination is prevented, but the device complexity increases
Solution Approach 1:
The enclosure is segmented into two main members (first and second enclosure members) that can be separately manufactured and coupled to the battery pack receptacle, simplifying the manufacturing process and reducing the complexity of assembling a complete enclosure
Solution Approach 2:
The enclosure members are designed to be retrofitted onto existing battery pack receptacles, making the protection system universally applicable to multiple power tool models without requiring complete redesign of the original structure
3Object-affected harmful factors
If the enclosure is designed to fully enclose the battery pack, then maximum protection is achieved, but the ease of battery removal is reduced
Solution Approach 1:
The enclosure incorporates a movable door that can open and close, transforming the enclosure from a static fully-enclosed structure to a dynamic system that provides full protection when closed but allows easy battery access when opened
Solution Approach 2:
The door mechanism replaces the need for complete disassembly of the enclosure to access the battery pack, using a simple hinge and latch system instead of requiring removal of multiple enclosure components
4Object-affected harmful factors
If the enclosure is customized for specific battery pack sizes, then optimal protection is provided, but the adaptability to different battery sizes is reduced
Solution Approach 1:
The enclosure members are designed with universal mounting features that can accommodate multiple battery pack sizes and configurations, allowing the same enclosure structure to protect different types of battery packs without customization
Solution Approach 2:
The enclosure design allows for adjustment of internal dimensions and configuration to accommodate different battery pack sizes, enabling the same basic enclosure structure to adapt to various battery capacities and form factors
Data Source
AI summary
A power tool battery pack enclosure is configured to be coupled to battery pack receptacles of a plurality of power tools, each battery pack receptacle configured to removably receive a plurality of power tool battery packs. The enclosure includes a first clamshell member and a second clamshell member configured to be coupled around at least a portion of an exterior surface of each battery pack receptacle. Each of the first and second clamshell members have a top wall portion configured to be received over the exterior surface of the battery pack receptacle and a sidewall portion that extends downward from the top wall portion over at least a portion of the battery pack housing when the battery pack is received in the battery pack receptacle. The first and second enclosure members cover at least a portion of the battery back receptacle and at least a portion of the portion of a battery pack housing while allowing the battery pack to be removed from the battery pack receptacle while the enclosure remains coupled to the battery pack receptacle.