Power Tool Light Unit Impact Protection
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Solution Overview
Problem
Power tools equipped with lights, such as impact drivers, are prone to damage from unanticipated impacts during use or storage, as the light units are not securely mounted, leading to potential damage from collisions or drops.
Innovation Solution
The power tool design incorporates a protector made of lightweight materials like elastomers, which covers the light unit and is fixed to the hammer case using a stopper, and a holder member made of transparent resin that securely mounts the light unit on the hammer case using a rib and screw mechanism, ensuring the light unit is positioned close to the work area for effective illumination and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the light unit is mounted on the front of the housing or hammer case, then the work area can be illuminated in dark locations, but the light unit is vulnerable to unanticipated impacts from collisions or drops
Solution Approach 1:
The patent applies beforehand cushioning by providing a protective cover that surrounds the light unit. This cover is designed to absorb and dissipate impact forces before they can reach the light unit, thereby protecting it from damage during collisions or drops while allowing the light to remain exposed enough to illuminate the work area effectively.
2Reliability
If the light unit is securely mounted to prevent impact damage, then reliability is improved, but the device complexity increases due to additional mounting components
Solution Approach 1:
The patent merges the protective function with the mounting structure by integrating the protective cover into the existing housing or hammer case design. The cover is formed as a single piece that both protects the light unit and attaches to the mounting surface, eliminating the need for separate protective components and reducing overall device complexity.
Solution Approach 2:
The protective cover serves multiple functions simultaneously: it protects the light unit from impact damage, provides a mounting surface for attachment to the housing or hammer case, and maintains the structural integrity of the front assembly. This multi-functionality reduces the need for additional specialized components.
3Reliability
If additional protective components are added to secure the light unit, then impact protection is improved, but manufacturing costs increase
Solution Approach 1:
The patent employs a protective cover made from a resilient material that can be molded into shape and attached to the housing or hammer case. This flexible shell approach provides effective impact protection while being cost-effective to manufacture, as it eliminates the need for multiple rigid protective components and complex assembly procedures.
Data Source
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AI summary
A power tool includes a main housing, a motor, a hammer case, an end-tool holding part, a driving-force transmitting mechanism, a light-unit mounting part, a light unit, and a cover. The motor is accommodated in the main housing and is configured to generate a driving force. The hammer case has an outer peripheral surface. The end-tool holding part is configured to hold an end tool. The driving-force transmitting mechanism is accommodated in the hammer case. The driving-force transmitting mechanism is configured to transmit the driving force to the end-tool holding part. The light-unit mounting part is formed integrally with the hammer case. The light unit is mounted to the light-unit mounting part. The cover covers the outer peripheral surface of the hammer case and accommodates the light-unit mounting part and the light unit.