Power Tool LED Lighting Module for Multi-Battery Compatibility
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Solution Overview
Problem
Existing power tool lighting systems lack a versatile and efficient solution for integrating LED lighting modules that can be powered by various power tool battery packs, limiting their adaptability and performance across different tools and applications.
Innovation Solution
A power tool light product with a lighting module comprising a printed circuit board, LED, controller, and LED driver, integrated with a battery pack receptacle, allowing for removability and compatibility with different power tool battery packs, and featuring a heat sink and housing for efficient heat dissipation, along with gaskets for protection, enabling flexible configuration and operation across multiple power tool systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a lighting module is integrated with a battery pack receptacle to enable selective powering by various power tool battery packs, then adaptability and versatility are improved, but device complexity increases due to the need for compatible electrical connections and control circuits
Solution Approach 1:
The lighting module is designed with a universal battery pack receptacle that can accept and be powered by various power tool battery packs (e.g., 18V, 36V, 54V), enabling a single lighting device to serve multiple voltage platforms and applications across different power tool systems
Solution Approach 2:
The lighting system is divided into separate functional modules: the lighting module with LED array and control circuitry, the battery pack receptacle, and the power tool battery pack. This modular segmentation allows independent optimization of each component and facilitates compatibility across different voltage systems without redesigning the entire system
2Illumination intensity
If high power LEDs are used to provide sufficient illumination for power tool applications, then illumination intensity is improved, but heat generation increases requiring advanced thermal management
Solution Approach 1:
The heat sink is designed as a separate, dedicated thermal management component that extracts heat away from the LED array and control circuitry on the printed circuit board. This separation allows the lighting module to maintain high illumination output while the heat sink handles thermal dissipation independently
Solution Approach 2:
The control circuit is designed to manage the relationship between power input and heat generation by regulating LED current based on battery voltage levels. Higher voltage batteries (which generate more heat) automatically drive LEDs at higher currents with proportional heat output, optimizing illumination while managing thermal load efficiently
3Ease of operation
If the lighting module is designed to be operably coupled to the battery pack receptacle with removable connection, then ease of operation and maintenance are improved, but reliability may worsen due to potential connection issues
Solution Approach 1:
The electrical connection between the lighting module and battery pack receptacle is designed as a dynamic, removable interface rather than a permanent fixed connection. This allows the lighting module to be easily attached and detached while maintaining reliable electrical contact through spring-loaded or snap-fit connectors that ensure consistent connectivity during operation
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 solution provides a versatile and efficient LED lighting system that can be powered by various power tool battery packs, ensuring adaptability and performance across different tools, with enhanced heat management and protection, thereby addressing the limitations of existing systems.
Implementation Method 1
an LED on the printed circuit board
Implementation Method 2
featuring a heat sink and housing for efficient heat dissipation
Data Source
AI summary
A power tool light product includes a light body including a power tool battery pack receptacle, the power tool battery pack receptacle configured to removably receive a power tool battery pack that is configured to selectively power the power tool light product and at least one of a drill, a saw, a sander, or a concrete tool. The power tool light product also includes a lighting module, the lighting module operably coupled to the power tool battery pack receptacle. The lighting module includes a printed circuit board, an LED on the printed circuit board, and an LED driver on the printed circuit board.