Power Tool Battery Pack Isolation for Vibration Durability
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Solution Overview
Problem
Excess vibrational forces from power tools can limit the life cycle of battery packs, as these vibrations are not effectively isolated from the battery packs.
Innovation Solution
A battery pack isolation system that includes an interface member within the power tool housing to electrically couple the battery pack to the motor, and a plurality of isolators coupled between the housing and the interface member to isolate the battery pack from the housing during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is directly coupled to the housing, then the electrical connection is simple and reliable, but the battery pack is exposed to excessive vibrational forces that limit its life cycle
Solution Approach 1:
An interface member is introduced as an intermediary component between the battery pack and the housing. This interface member provides the electrical connection while isolating the battery pack from vibrational forces transmitted through the housing, thus resolving the contradiction between connection reliability and vibration exposure.
Solution Approach 2:
The connection system is segmented into separate functional components: the interface member that provides electrical connection and the isolators that provide vibration isolation. This segmentation allows each component to perform its specific function optimally without compromising the other.
2Duration of action of stationary object
If isolators are added to isolate the battery pack from vibrations, then the battery pack life cycle is extended, but the device complexity increases
Solution Approach 1:
The interface member combines multiple functions into a single component: it provides electrical connection between the battery pack and motor, serves as a mounting structure for the isolators, and acts as a vibration isolation element itself. This merging reduces the number of separate components and simplifies the overall system.
Solution Approach 2:
The interface member is designed as a multi-functional component that simultaneously performs electrical connection, mechanical support, and vibration isolation functions. This multi-functionality reduces the need for separate dedicated components for each function, thereby reducing overall system complexity.
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 isolation system effectively reduces the transfer of vibrations to the battery pack, thereby extending the life cycle of the battery pack and ensuring reliable operation of the power tool.
Implementation Method 1
a plurality of isolators coupled between the housing and the interface member to isolate the battery pack from the housing during operation of the power tool
Data Source
AI summary
A power tool includes a housing, a motor positioned substantially within the housing, a drive mechanism supported by the housing and coupled to the motor, a battery pack electrically coupled to the motor, and an isolation system. The isolation system includes an interface member positioned substantially within the housing. The interface member receives a portion of the battery pack to electrically couple the battery pack to the motor. The isolation system also includes a plurality of isolators coupled between the housing and the interface member to isolate the battery pack from the housing during operation of the power tool.