Hand-Held Tool Rigid Connector Design to Reduce Wiring Complexity
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Solution Overview
Problem
Existing tools, such as cordless vacuums and screwdrivers, have complex designs that complicate manufacturing and increase costs due to the use of multiple wires and circuit boards for power and charging systems, making them less reliable and more expensive to produce.
Innovation Solution
A simplified design for hand-held tools that eliminates the need for printed circuit boards and cell monitors by using stamped metal connectors and enameled or uninsulated wires for electrical connections, allowing for a more straightforward assembly process and reduced component count, with charging systems integrated into a charger unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If printed circuit boards and cell monitors are used for power and charging systems, then electrical connections can be established, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the printed circuit board and cell monitor components from the power system, replacing them with direct wire connections between battery terminals and motor terminals. This elimination of unnecessary components simplifies the device structure while maintaining electrical connection functionality.
Solution Approach 2:
The patent makes the housing serve multiple functions: it provides structural support and simultaneously acts as an electrical conductor for power transmission. The housing includes conductive portions that directly connect battery terminals to motor terminals, eliminating the need for separate wiring systems.
2Reliability
If multiple wires and circuit boards are used for power transfer, then electrical connections are established, but manufacturing cost increases
Solution Approach 1:
The patent merges the structural housing with the electrical connection function by incorporating conductive portions directly into the housing. This integration eliminates separate wiring components and reduces the number of assembly steps, thereby simplifying manufacturing while ensuring reliable power transfer.
Solution Approach 2:
The housing is designed to perform dual functions: providing mechanical support and enabling electrical power transmission. The conductive portions of the housing serve as both structural elements and electrical conductors, reducing component count and manufacturing complexity.
3Reliability
If cell monitors and independent charge shut-off are integrated into the tool, then charging control is improved, but device complexity increases
Solution Approach 1:
The patent extracts the cell monitor and independent charge shut-off functions from the tool itself and relocates them to the charging system. This separation allows the tool to maintain simple wiring while the charging system provides sophisticated charging control through external monitoring components.
Data Source
Figure 1
Figure 2~3
Figure 4A
AI summary
A hand-held tool that includes a housing. The housing includes a handle. A tool also includes a motor assembly, a battery assembly and a circuit board. The motor assembly includes a motor, the motor including a rotatable motor output shaft, a motor positive terminal and a motor negative terminal. The motor assembly also includes a first rigid conductive electrical connector having a first end fixed to the motor positive terminal and a second end fixed to the circuit board. The battery assembly includes a battery cell with a battery cell positive terminal and a battery cell negative terminal. The battery assembly further includes a second rigid conductive electrical connector having a first end fixed to the battery cell positive terminal and a second end fixed to the circuit board.