Adapter for Cordless Power Tool Battery Compatibility

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Cordless power tool systems face limitations in adapting batteries from one platform to another, as existing adapters do not effectively prevent charging of incompatible batteries and do not provide seamless operation with different battery configurations.

Innovation Solution

The system employs mechanical lockout mechanisms and adapters with specific terminal configurations to prevent charging of incompatible batteries while allowing operation with different battery platforms, using adapters with insulating barriers, terminal height and width differences, and electronic identification systems to ensure compatibility and control charging processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If existing adapters are used to convert between battery platforms, then battery compatibility is improved, but charging safety deteriorates because incompatible batteries can be charged

Engineering Contradiction:

Improvebattery compatibilityVSAvoidcharging safety

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The adapter serves as an intermediary device between the battery and tool/charger interfaces. It includes terminal blocks that electrically connect to the battery terminals and interface with the tool or charger, enabling compatibility while maintaining charging safety through controlled electrical connections

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The adapter incorporates insulating barriers at specific locations between adjacent terminals to prevent short circuits. The insulating material is applied selectively between terminals of opposite polarity while maintaining electrical connectivity to the battery, ensuring charging safety without compromising compatibility

Inventive Principle:

Principle #3Local quality

2Reliability

If mechanical lockout mechanisms are implemented to prevent charging of incompatible batteries, then charging safety is improved, but device complexity increases

Engineering Contradiction:

Improvecharging safetyVSAvoidadapter structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The adapter includes protrusions on its outer surface that correspond to recesses in the tool or charger housing. This asymmetric mechanical interface allows the adapter to be inserted only in the correct orientation and prevents incompatible batteries from being charged, providing safety without complex electronic mechanisms

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The charging prevention function is extracted from the battery itself and implemented in the adapter through mechanical lockout features. The adapter's protrusions and the charger's recesses work together to physically prevent charging of incompatible batteries, separating the safety function from the battery platform

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If terminal configurations with insulating barriers are used in adapters, then electrical safety is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveelectrical short circuit preventionVSAvoidterminal spacing tolerance

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

Insulating barriers are positioned beforehand between adjacent terminals during adapter manufacturing. These barriers, made of electrically insulating material, are placed in predetermined locations to prevent short circuits before the adapter is used, ensuring electrical safety while allowing for standard manufacturing tolerances

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Adaptability or versatility

If electronic identification systems are integrated into adapters, then battery compatibility verification is improved, but device complexity and cost increase

Engineering Contradiction:

Improvebattery platform identificationVSAvoidadapter electronics

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Electronic identification systems in the adapter detect the battery platform type through electrical signals rather than mechanical features. This allows for automated compatibility verification and appropriate charging parameter selection, providing enhanced adaptability while keeping the adapter structure relatively simple

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9415499B2Adapter for cordless power tools

Publication Date: 2016.08.16 BLACK & DECKER CORP

AI summary

An electrical combination including a power tool, charger and an adapter separate from and connectable between the battery and the tool housing or battery charger to support the battery on the tool housing or the battery charger, the adapter having adapter leads for electrically coupling the battery to the power tool or the battery charger, the adapter having a mechanical lockout for allowing an electrical coupling between the adapter and the power tool while preventing an electrical coupling between the adapter and the battery charger.