Foldable Battery Pack Housing for Faster Tool Battery Assembly
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Solution Overview
Problem
Existing battery packs for hand-held power tools require complex assembly processes due to the use of various fasteners like screws or snap-fit connections, which are time-consuming and costly.
Innovation Solution
A battery pack design featuring a hinged hinge that integrates two housing components, allowing for easy assembly and reduced parts through the use of film hinges and snap connections, along with a microcontroller for cell monitoring and flexible circuit boards for simplified electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners like screws or snap-fit connections are used to connect battery pack housing components, then the structural strength and reliability are improved, but the assembly time and manufacturing cost increase
Solution Approach 1:
The patent integrates the cell holder and battery pack housing into a single integral component, eliminating the need for separate fasteners and connections. This merging of components directly reduces assembly time while maintaining structural integrity through the unified design, resolving the contradiction between reliability and assembly efficiency.
Solution Approach 2:
The housing structure is designed to perform multiple functions simultaneously: it provides structural support, contains the battery cells, and serves as the outer protective shell. This multi-functionality eliminates the need for additional fastening components, reducing assembly complexity and time while maintaining overall reliability.
2Adaptability or versatility
If multiple separate housing components are used, then the manufacturing flexibility and adaptability are improved, but the number of parts and assembly complexity increase
Solution Approach 1:
By combining the cell holder and housing into one integral component, the patent reduces the total number of parts that need to be managed, stored, and assembled. This significantly reduces assembly complexity while the design maintains manufacturing flexibility through the ability to produce the integral component in various configurations.
Solution Approach 2:
While the housing and cell holder are integrated, the battery pack maintains functional segmentation through the removable battery cell assembly. This allows the pack to be disassembled for cell replacement or servicing without requiring disassembly of the housing structure itself, maintaining adaptability with reduced complexity.
Data Source
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AI summary
The invention relates to a battery pack for a hand-held power tool, said battery pack comprising a housing and at least one cell holder. The cell holder accommodates at least one battery cell. According to the invention, the housing of the battery pack includes at least one foldable hinge that connects a first element to a second element. The invention is characterized in that the first element and the second element are designed as a single piece and in such a way as to be able to pivot relative to each other.