Integrated Battery Interface Module for Compact Power Tool Inverters
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Solution Overview
Problem
Modern power tools require compact and efficient power modules that can efficiently supply power to brushless DC motors while accommodating the increasing demand for higher power density and compactness, which existing designs struggle to achieve effectively.
Innovation Solution
An integrated power module with a module housing that includes a base body, terminal support body, and a circuit board with an inverter circuit, where conductive connectors extend from the battery terminal block through the terminal support body and base body to the circuit board, providing a robust and efficient electrical connection, and a vibration isolation element is used to absorb impact and vibration, enhancing the module's stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery terminal block is coupled to the power module via wires, then the power module can be positioned separately from the battery receptacle, but the device complexity and space requirements increase
Solution Approach 1:
The battery terminal block is integrated directly into the power module housing, eliminating separate wire connections between the battery receptacle and power module. This merging of components reduces device complexity while maintaining modular assembly capabilities, as the terminal block becomes an inherent part of the power module structure rather than a separate component requiring wiring.
Solution Approach 2:
The power module housing serves multiple functions: it encloses the circuit board, provides structural support, and integrates the battery terminal block for electrical connections. This multi-functionality eliminates the need for separate terminal block housings and wiring structures, reducing overall device complexity while maintaining operational modularity.
2Productivity
If the power module is positioned away from the battery receptacle, then the motor and power electronics can be optimized separately, but the device size and wiring requirements increase
Solution Approach 1:
The power module is nested within the tool housing adjacent to the battery receptacle, with the terminal block integrated into the module housing. This nesting arrangement allows the power electronics to be positioned optimally for motor control while minimizing overall device volume, as components are arranged in a compact configuration rather than distributed throughout the housing.
3Ease of manufacture
If conventional power module designs are used, then existing manufacturing processes can be maintained, but compactness and power density requirements are not met
Solution Approach 1:
The battery terminal block is merged with the power module housing as an integrated component, eliminating the need for separate terminal block assemblies and their associated mounting hardware. This integration maintains manufacturing simplicity while significantly reducing the overall module volume, enabling compact designs that meet modern power density requirements.
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A power tool (10) is provided including a battery receptacle disposed at a foot of a handle portion, and an integrated power module (100) disposed at or proximate the foot of the handle portion. The integrated power module includes: a module housing (102) having a base body and a terminal support body (122) extending substantially perpendicularly and integrally from an end of the base body in a downward direction; a circuit board (110) mounted within the module housing over the base body and including an inverter circuit electrically coupled to the motor; a battery terminal block supported by the terminal support body to make a connection with a removable battery pack; and conductive connectors extending from the battery terminal, through the terminal support body and the base body of the module housing, to the circuit board, to supply power from the battery pack to the inverter circuit.