Power Tool Battery Locking Interface With Wear-Resistant Contact Regions
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Solution Overview
Problem
Existing interfaces for connecting energy supply devices to power tools are prone to wear and tear, leading to reduced durability and service life, with some mechanisms requiring large construction space and being susceptible to dust and moisture ingress, while others have individual elements that do not interact effectively or are made from materials that wear easily.
Innovation Solution
The use of a hybrid locking mechanism with contact materials of different densities, where one connection partner has a locking element with a base material and a contact region made from a material with a higher density than the other, providing a robust and durable connection between the energy supply device and the power tool without increasing actuation forces for unlocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional locking mechanisms are used, then the interface can be manufactured easily and inexpensively, but the service life is reduced due to wear and abrasion
Solution Approach 1:
The locking element is constructed as a composite structure combining a plastic base material with a metal contact region. The metal contact region (made of wear-resistant material such as steel or brass) is integrated into the plastic body through injection molding or insert molding processes. This composite construction allows the locking element to maintain ease of manufacture while significantly improving wear resistance and service life at the critical contact interface.
Solution Approach 2:
The locking element features heterogeneous material properties distributed spatially: the plastic base material provides structural integrity and ease of manufacturing, while the metal contact region provides enhanced wear resistance specifically at the interface where contact with the counterpart contour occurs. This local differentiation of material quality addresses the contradiction by applying enhanced material properties only where needed.
2Stability of the object's composition
If robust locking mechanisms are used, then the connection stability is improved, but the construction space required increases
Solution Approach 1:
The locking element integrates multiple functions into a single compact component: the plastic base material provides structural support and positioning features, while the metal contact region provides locking engagement and wear resistance. By merging these functions into one integrated element rather than using separate components, the design achieves robust connection stability without increasing construction space.
3Duration of action of stationary object
If material with high wear resistance is used, then the service life is extended, but the actuation forces increase
Solution Approach 1:
The invention changes the material parameter (density/wear resistance) locally at the contact region rather than throughout the entire locking element. The metal contact region has higher density and wear resistance, while the plastic base material maintains lower density and requires lower actuation forces. This localized parameter change extends service life without significantly increasing the forces needed to actuate the locking mechanism.
Data Source
AI summary
A system that includes a power tool and an energy supply device, wherein the power tool can be detachably connected to the energy supply device via an interface, and wherein the energy supply device and the power tool are connection partners of the interface. One of the connection partners may have a locking element, whilst the respective other connection partner has a counterpart contour as a stop for the locking element, wherein the locking element and the counterpart contour have a base material with a first density. The locking element and the counterpart contour each have a contact region with contact materials, wherein at least one of the contact materials has a second density that may be higher than the first density of the base material. An energy supply device, wherein power tools and locking elements are also disclosed in the context of the invention.