Mains Plug Circuit Board for Power Tool Thermal Management
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Solution Overview
Problem
Conventional power tools require significant installation space for electronic circuits used to control motors, increasing their overall dimensions and necessitating additional components for housing and cooling.
Innovation Solution
Integrating a circuit board with an electronic power component into the mains plug, allowing for a data connection to power tool components and incorporating thermal management features such as thermally conductive connections to the mains cable and heat sinks, which reduces the need for external components and minimizes overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electronic circuits are arranged inside the power tool, then motor control functionality is achieved, but installation space is consumed and overall dimensions increase
Solution Approach 1:
The control device is extracted from the power tool housing and relocated to the mains plug. The circuit board with electronic components is positioned in the mains plug body, utilizing the plug's internal space instead of the tool's housing space. This extraction resolves the space conflict by moving the electronic system to an external location that does not constrain the tool's overall dimensions.
Solution Approach 2:
The mains plug is transformed from a simple power connection device into a multi-functional unit that combines power delivery with electronic control capabilities. The plug now houses both the electrical connection elements and the control circuitry, allowing a single component to serve multiple functions: power transmission, motor control, and potentially data communication.
2Adaptability or versatility
If surrounding components for the control device are included, then complete control functionality is achieved, but device complexity and cost increase
Solution Approach 1:
Multiple previously separate components are merged into the mains plug structure. The circuit board, housing elements, and thermal management features are integrated into a single unified assembly within the plug. This consolidation reduces the total component count and simplifies the overall system architecture while maintaining full control functionality.
Solution Approach 2:
The mains plug serves multiple functions simultaneously: it provides electrical power connection, houses the control electronics, and incorporates thermal management capabilities. This multi-functionality eliminates the need for separate dedicated components for each function, thereby reducing overall device complexity.
3Volume of stationary object
If power component is placed in the mains plug, then space saving is achieved, but thermal energy dissipation becomes challenging
Solution Approach 1:
A thermally conductive intermediary material or structure is introduced between the power component and the mains plug housing. This intermediary facilitates efficient heat transfer from the concentrated heat source (power component) to the larger thermal mass of the plug housing, enabling effective passive heat dissipation without requiring additional active cooling components.
Solution Approach 2:
The mains plug housing is designed to serve dual purposes: electrical insulation and thermal management. The housing material and structure are selected or designed to provide both electrical isolation and adequate thermal conduction pathways, allowing the same component to address both safety and thermal dissipation requirements.
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
This approach results in a compact, cost-effective control device that effectively dissipates heat and provides functional communication, enabling smaller power tool designs and optimized production costs.
Implementation Method 1
the power component is connected, at least in sections, directly or by means of a thermally conductive connection to a stranded wire of a mains cable. In this way, thermal energy can be easily dissipated from the power component into the mains cable of the power tool.
Implementation Method 2
a heat sink is arranged on the power component. As a result, thermal energy can advantageously be dissipated to an increased extent by the control device.
Implementation Method 3
the mains plug has a thermally conductive plastic. In this way it is possible, for example, to implement a heat dissipation device in an injection molding process for the mains plug.
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
Control device (100) for a power tool (200), comprising a circuit board (10) with an electronic power component (20) arranged thereon, characterized in that the circuit board (10) is arranged in a mains plug (30) of the power tool (200).