Power Tool Handle Cooling Air Path Design
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Solution Overview
Problem
Power tools, such as large-sized grinders, face challenges in cooling heat-generation members within the handle portion due to the thinness of the handle, which can lead to operator discomfort and potential overheating, and existing cooling solutions are hindered by dust accumulation and the proximity of air windows to high-voltage terminals.
Innovation Solution
A power tool design featuring a housing with separate air suction ports for the motor and handle portion, utilizing a cooling fan to direct cooling air through a dedicated passage within the handle portion, where a heat-radiation plate is strategically positioned to dissipate heat from the heat-generation member, and the air path is configured to prevent dust and operator hand interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an air window is arranged in the handle portion to guide cooling air into the handle portion, then the heat-generation member can be cooled, but the handle portion becomes too thin to accommodate the air window and the operator's hand covers the air window during operation
Solution Approach 1:
The air suction ports are divided into two separate groups: first air suction ports arranged in the handle portion for cooling the heat-generation member, and second air suction ports arranged in the housing for cooling the motor. This segmentation allows each air suction port to serve its specific cooling function without interference from the operator's hand.
Solution Approach 2:
The patent introduces separate air suction ports as intermediary structures to guide cooling air to different components. The first air suction ports specifically guide air to the heat-generation member in the handle portion, while second air suction ports guide air to the motor in the housing, preventing direct contamination of electrical components.
2Temperature
If an air window is arranged in the handle portion, then cooling air can reach the heat-generation member, but metal powder accumulates near the connection terminal of the switch mechanism
Solution Approach 1:
The air suction function is segmented into two separate systems: first air suction ports in the handle portion that are isolated from the electrical components, and second air suction ports in the housing that handle motor cooling. This prevents metal powder sucked into the handle portion from reaching the connection terminal of the switch mechanism.
Solution Approach 2:
The air suction function for the heat-generation member is extracted and separated from the air suction function for the motor. The first air suction ports are specifically dedicated to cooling the heat-generation member without creating a direct air flow path to the electrical terminals, thereby preventing metal powder accumulation near the connection terminal.
3Temperature
If the handle portion is made thicker to accommodate cooling structures, then cooling effectiveness improves, but the tool weight and size increase
Solution Approach 1:
The cooling fan in the housing performs dual functions: it cools both the motor through second air suction ports and the heat-generation member in the handle portion through first air suction ports. This multi-functionality eliminates the need for separate cooling systems, maintaining tool compactness and light weight while achieving effective cooling of both components.
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 solution effectively cools the heat-generation member within the handle portion, preventing operator discomfort and reducing dust accumulation, while maintaining the tool's compact size and ease of use by isolating the air flow from the electric power supply connection.
Implementation Method 1
a flow of cooling air directed from the first air suction port toward the heat-generation member is generated by the cooling fan
Implementation Method 2
a heat-radiation plate is arranged in the heat-generation member, and cooling air guided into the handle portion effectively blows against the heat-radiation plate
Data Source
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AI summary
Provided is a power tool configured so that it is possible to effectively cool a switch mechanism having a heat-generation member accommodated in a handle portion. The power tool has a housing portion that accommodates a motor 6 and a cooling fan 8, and a handle portion 5B connected to the housing portion. Air suction ports 41, 42a-42d and 43 are arranged in the housing portion, and outside air is sucked into the housing portion by the rotation of the cooling fan 8. In the power tool, a passage 52 is formed in the handle portion 5B, the passage 52 guiding cooling air from the air suction port 41 rearward away from the cooling fan 8; the cooling air is caused to flow from an opening 53 into the handle portion 5B to cool a heat-generation mechanism included in a switch mechanism 60; and the cooling air is again returned to the housing portion. In the housing portion, the cooling air is discharged to the outside from air discharge ports 13a and 13b together with the cooling air from the other air suction ports 42a-42d and 43.