Elastomeric Battery Interface for Power Tool Connection Stability
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Solution Overview
Problem
Existing power tools and battery chargers face issues with battery movement and terminal alignment, leading to fretting corrosion and excessive wear due to play or rattle, which affects the reliability and longevity of the components.
Innovation Solution
A modular battery interface or connector system with a support member positioned between the battery and the housing to limit movement, combined with elastomeric materials and angled vents for improved grip and air flow, and a protection device like a free-wheeling diode to manage back emf currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid battery interface is used, then connection stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical state of the battery interface from rigid to compliant by using elastomeric material. This parameter change allows the interface to accommodate manufacturing tolerances while maintaining stable electrical connection, resolving the contradiction between connection stability and manufacturing precision requirements.
Solution Approach 2:
The patent employs an elastomeric battery interface that acts as a flexible component between the battery and tool. This flexible interface compensates for dimensional variations and misalignments, achieving reliable connections without demanding high manufacturing precision.
2Ease of operation
If play or rattle between battery and tool is allowed, then ease of assembly is improved, but terminal wear increases
Solution Approach 1:
The elastomeric battery interface absorbs movement and play between the battery and tool through its compliant nature. This flexible component reduces terminal wear by eliminating rigid contact and friction, while still allowing easy assembly and disassembly of the battery.
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 reduces wear and tear, enhances battery alignment and connection reliability, and protects electronic components from back emf, thereby improving the overall performance and lifespan of power tools and battery chargers.
Implementation Method 1
A material, such as, for example, an elastomeric material, may be molded over portions of the handle and/or of the motor housing
Implementation Method 2
an on/off switch operable to control a supply of power from a battery to the motor and a diode electrically connected between the motor and the battery
Data Source
AI summary
A battery pack for powering a cordless power tool. The battery pack includes at least one battery cell operable to supply a discharge current, a switch operable to control the discharge current and a protection device to protect the switch. The protection device is positioned such that the device absorbs a current traveling in a direction opposite to that of the discharge current supplied from the battery cell.