Optical Charge Indicator for Battery Packs

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Solution Overview

Problem

Mechanical and electrical connections in hand-held power tool battery packs are prone to wear and failure due to vibrations during operation, affecting the reliability of charge level indicators.

Innovation Solution

Incorporating light-guiding elements that spatially separate light sources from light emitting devices, allowing for flexible arrangement and decoupling from vibrations, with a gap to minimize wear and using LEDs with synthetic materials for reduced susceptibility to failure and cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If mechanical and electrical connections are used for charge level indicators, then the indicator can be integrated into the battery pack structure, but the connections are prone to wear and failure due to vibrations during operation

Engineering Contradiction:

Improveintegration of charge level indicatorVSAvoidsusceptibility to wear and failure

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces mechanical and electrical connections with an optical system using light guides and light sources. The charge level indicator is implemented through light guides that transmit light from LED sources embedded in the battery cells, eliminating mechanical contacts and electrical connections that are susceptible to vibration-induced wear and failure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces light guides as intermediary elements between the light sources (LEDs) and the external environment. These light guides transmit optical signals without requiring direct mechanical or electrical contact, thereby serving as a mediator that eliminates the wear and failure problems associated with traditional mechanical and electrical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If light sources are directly connected to light emitting devices, then the arrangement is simple, but the mechanical connection is susceptible to wear and failure from vibrations

Engineering Contradiction:

Improvearrangement simplicityVSAvoidmechanical susceptibility to failure

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the direct mechanical connection between light sources and light emitting devices with an optical coupling system using light guides. The light guides are inserted into recesses in the battery housing and optically couple the LED sources to the external environment without requiring mechanical fastening or direct contact, thereby eliminating vibration-induced wear.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a gap is provided between light source and light-guiding element to reduce vibration wear, then mechanical susceptibility is reduced, but light losses increase

Engineering Contradiction:

Improvereduced mechanical susceptibilityVSAvoidlight losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent maintains a gap between the light source and light-guiding element to eliminate mechanical contact and vibration wear, while compensating for light losses through optimized optical design of the light guides and proper positioning of the LED sources to ensure efficient light coupling across the gap.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a flexible and durable charge level indicator with reduced mechanical and electrical stress, enhancing reliability and reducing manufacturing costs by decoupling components and using LEDs with synthetic light-guiding elements.

Implementation Method 1

The electronics unit (16) includes one or more light sources (18) and where in the battery housing (10) a first light-guiding element (28) can be inserted that interacts with the at least one light source (18) in such a manner that the light emitted by the at least one light source (18) can be injected into the first light-guiding element (28)

Methodology Applied

Scientific EffectLight Emitting Diode: Light Emitting Diode

Implementation Method 2

the first light-guiding element (28) is made of a fully light-guiding synthetic material

Methodology Applied

Scientific EffectTotal Internal Reflection: Total Internal Reflection

Data Source

PatentUS8211560B2Battery pack and hand-held power tool

Publication Date: 2012.07.03 METABOWERKE

AI summary

The invention relates to a battery pack, especially for a hand-held power tool. Said battery pack comprises a battery housing (10) and an electronic unit (16) housed in said battery housing (10). The electronic unit (16) has one or more light sources (18). A first light-guiding element (28) can be inserted into the battery housing (10) and interacts with the at least one light source (18) in such a manner that the light emitted by the at least one light source (18) can be injected into the first light-guiding element (28).