Power Tool Housing with Segmented Grip and Fan Cooling
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Solution Overview
Problem
Power tools with battery power supplies often have uncomfortable grip designs and inadequate cooling for controllers and terminal blocks, making them difficult to hold and use, especially for users with smaller hands, and leading to temperature issues.
Innovation Solution
A power tool design featuring a brushless motor with a fan-cooled housing that includes a smaller diameter grip section for ergonomic comfort, effective air suction ports for cooling the controller and terminal block, and a tilted display for battery capacity indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tool housing has a uniform cross-section in the longitudinal direction, then the structure is simple and easy to manufacture, but the power tool becomes difficult and uncomfortable to hold, especially for users with smaller hands
Solution Approach 1:
The housing is divided into multiple sections with different cross-sectional dimensions along the longitudinal direction. The first housing section has a larger outer diameter while the second housing section has a smaller outer diameter, creating distinct grip areas that improve ergonomics without complicating the overall manufacturing process
Solution Approach 2:
Different portions of the housing are given different dimensional characteristics to serve specific functions. The first housing section maintains a larger diameter for structural support and component housing, while the second housing section is reduced in diameter specifically to provide an ergonomic grip area for users with smaller hands
2Device complexity
If the controller is mounted in or near the battery-mount part, then the structure is compact, but the temperature of the controller rises together with that of the battery pack
Solution Approach 1:
The controller is extracted from the battery-mount part and relocated to the first housing section. This spatial separation allows the controller to be positioned in a region with better air circulation and away from the heat-generating battery pack, enabling effective cooling without increasing device complexity
Solution Approach 2:
Cooling air acts as an intermediary medium between the external environment and the controller. Air-suction ports are provided in the first housing section to draw cooling air that passes through the controller, effectively removing heat while maintaining the compact overall structure
3Ease of operation
If the terminal block is provided on the battery-mount part, then the electrical connection is convenient, but the temperature of the terminal block rises together with that of the battery pack
Solution Approach 1:
The terminal block is extracted from the battery-mount part and relocated to the second housing section. This separation places the terminal block in a region with better heat dissipation characteristics, allowing convenient electrical connection while preventing temperature rise that would occur if it remained attached to the battery-mount part
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 design enhances user comfort by providing a more ergonomic grip and effective cooling of critical components, improving handling and performance.
Implementation Method 1
A fan is provided on a rotary shaft of the motor and sucks in outside air, by the rotation of the motor (i.e. when the motor shaft rotates), through one or more air-suction ports provided (defined) in the housing, the outside air being caused to pass or flow through the motor
Implementation Method 2
The controller and the terminal block are disposed in the first housing section. The air-suction port(s) is (are) provided between the controller and the terminal block
Data Source
AI summary
A power tool includes a brushless motor having a stator and a rotor, which includes a rotary shaft extending in a front-rear direction of the power tool. The rotary shaft rotates a spindle that extends in an up-down direction of the power tool. A fan is fixedly coupled to the rotary shaft and rotates therewith. A switch is disposed rearward of the brushless motor and a controller is disposed rearward of the switch in the front-rear direction. A battery pack is disposed rearward of the controller. A main-body housing houses the brushless motor, the switch and the controller. The main-body housing includes a first tubular part, which houses the brushless motor, and a second tubular part, which houses the switch. The diameter of the second tubular part is smaller than the diameter of the first tubular part.