Battery Pack Terminal Structure With Coil Spring Contact Coupling
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Solution Overview
Problem
Existing battery pack terminal connections for power tools lack efficient and reliable electrical coupling mechanisms, leading to inconsistent power transfer and potential for short circuits due to inadequate contact points and mechanical retention.
Innovation Solution
The battery pack incorporates a unique terminal design featuring a coil spring positioned between spaced terminal walls, which engages with the power tool's connector to ensure secure electrical coupling, and a nested prong configuration to enhance contact area and retention, reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional terminal connections are used, then the device complexity is low, but the reliability of electrical connection deteriorates due to inadequate contact points and mechanical retention
Solution Approach 1:
The terminal connection system is segmented into multiple independent contact points (first terminal, second terminal, third terminal, fourth terminal) rather than using a single monolithic connector. Each terminal provides separate electrical contact, distributing the connection function across multiple elements to improve overall reliability while maintaining manageable complexity through modular design
Solution Approach 2:
The terminal structure employs nesting where the second terminal is positioned within the gap formed by the first terminal's spaced-apart walls, and additional terminals are integrated into the same structural envelope. This nested arrangement maximizes contact points within a compact form factor, improving reliability without proportionally increasing external dimensions or complexity
2Reliability
If more contact points are added to improve electrical coupling, then the reliability improves, but the device complexity increases
Solution Approach 1:
The first terminal structure serves multiple functions simultaneously: it provides both mechanical retention (through spaced-apart walls forming a gap) and electrical contact (through the terminal itself and nested terminals). The circuit board also serves dual purposes as both the mounting substrate and an electrical conductor. This multi-functionality increases reliability through multiple contact paths without adding separate dedicated components for each function
Solution Approach 2:
Multiple terminal functions are merged into a single integrated assembly where the first terminal, second terminal, third terminal, and fourth terminal work together as a unified connection system. The spaced-apart walls of the first terminal serve as both structural support and electrical isolation, while the nested second terminal provides additional contact within the same structural envelope, combining multiple functions into a compact integrated design
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 provides a reliable and efficient electrical connection with increased contact points and mechanical retention, ensuring stable power transfer and improved safety by minimizing the risk of short circuits.
Implementation Method 1
a coil spring at least partially positioned within the gap. Where the coil spring is configured to selectively engage and form an electrical connection with the electric connector
Implementation Method 2
a first terminal in electrical communication with the battery cells, the first terminal including a pair of spaced apart terminal walls forming a gap therebetween
Data Source
AI summary
A battery pack for use with a power tool having an electric connector. The battery pack including a housing containing one or more battery cells, a first terminal in electrical communication with the battery cells, the first terminal including a pair of spaced apart terminal walls forming a gap therebetween and a coil spring at least partially positioned within the gap. Where the coil spring is configured to selectively engage and form an electrical connection with the electric connector of the power tool when the electric connector is at least partially positioned within the gap.