Floating Terminal Block Aligns Battery Pack Connections
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Solution Overview
Problem
Frequent charging of cordless devices leads to weakening and potential damage of connections between battery packs and cordless tools, causing misalignment and adverse effects on mechanical and electrical contact.
Innovation Solution
The design includes a terminal block system with displaceable movement within the housing to align the battery pack and cordless power tool or charger, featuring guide rails and grooves for precise alignment and a terminal block configuration that allows side-to-side displacement to ensure proper electrical connections before engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If frequent charging is performed, then battery pack usage is maintained, but connection strength between battery pack and cordless device deteriorates
Solution Approach 1:
The terminal block is designed with floating capability, allowing it to dynamically adjust its position within the housing. This dynamic adjustment compensates for repeated connection and disconnection cycles, maintaining optimal electrical contact without compromising connection strength. The terminal block can shift laterally to accommodate wear and misalignment that occur during frequent charging operations.
2Manufacturing precision
If terminal blocks are rigidly fixed, then alignment precision is high, but damage risk from frequent connections increases
Solution Approach 1:
The terminal block transitions from a rigid fixed position to a dynamically adjustable floating position. This allows the terminal block to self-align during connection while absorbing mechanical stresses from frequent plugging and unplugging, thereby maintaining alignment precision without increasing damage risk.
Solution Approach 2:
The floating terminal block design provides a cushioning effect by allowing controlled movement and deformation. This cushioning absorbs the shock and stress of repeated connections before they can propagate to critical components, preventing damage while maintaining reliable electrical contact.
3Ease of operation
If terminal blocks are made detachable for charging, then charging convenience is improved, but connection durability deteriorates
Solution Approach 1:
The detachable terminal block with floating capability combines the ease of removal for charging with improved durability. The floating mechanism ensures that each connection cycle maintains optimal contact pressure and alignment, extending the overall connection durability despite frequent detachable operations.
Data Source
AI summary
A battery pack, charger, and terminal blocks for the pack, charger and a cordless power tool are provided. The pack includes battery cells disposed between end caps within a bottom housing of the pack, and a potting boat for housing pack electronics electrically connected to the cells between the end caps and disposed within a pack top housing. A pack terminal block is connected to the potting boat within the top housing. The charger and the power tool each include a terminal block for providing electrical connections between the charger/tool and the battery pack. The terminal block is configured to float side-to-side to provide displaceable movement of the terminal block within the charger housing or tool housing for aligning the battery pack terminal block therein.