Power Tool Switch Module Heat Dissipation via Segmentation

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Solution Overview

Problem

Cordless power tools with brushless DC motors face challenges in managing heat dissipation and electrical connectivity due to complex wiring and heat generation by power devices, which affects the efficiency and reliability of the motor control system.

Innovation Solution

An electronic switch and control module with a printed circuit board (PCB) housed in a module with encapsulation features, including heat sinks and an input unit, that securely mounts power switches and a controller to manage power flow and heat transfer effectively, using a combination of heat sinks and airflow for cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If power switches are provided within the power tool in close proximity to the motor or within the handle, then the motor control function is achieved, but heat dissipation becomes difficult and wiring complexity increases

Engineering Contradiction:

Improvemotor control functionVSAvoidheat dissipation

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The power switch assembly is segmented into a separate modular unit that can be independently positioned within the power tool. This module contains the power switches mounted on a circuit board, allowing it to be located in optimal positions for both control functionality and heat dissipation, rather than cramming all components into the handle area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A circuit board serves as an intermediary platform that mounts the power switches and provides structured electrical connectivity. This intermediary structure reduces wiring complexity by consolidating electrical connections onto the circuit board traces, while also enabling better thermal management through strategic placement and potential heat sink integration.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If power switches are provided within the power tool in close proximity to the motor or within the handle, then the motor control function is achieved, but wiring complexity increases substantially

Engineering Contradiction:

Improvemotor control functionVSAvoidwiring complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Multiple electrical connections and control functions are merged onto a single circuit board within the power switch assembly. This consolidation integrates the power switches, control circuitry, and connectivity interfaces into one unified module, dramatically reducing the overall wiring complexity compared to distributed component placement.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power switch assembly is designed as a universal modular unit that can be integrated into different power tool configurations. The circuit board provides multi-functional capabilities including power switching, signal processing, and connectivity, allowing a single module to perform multiple functions that would otherwise require separate components and extensive wiring.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If power devices are arranged to transfer heat away effectively, then heat dissipation is improved, but device structure becomes more complex

Engineering Contradiction:

Improveheat dissipationVSAvoiddevice structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Heat dissipation features are applied locally to the power switch assembly where heat generation occurs. The module can incorporate heat sinks, thermal vias, or conductive pathways specifically at the power switch locations on the circuit board, providing targeted thermal management without requiring complex system-wide structural changes.

Inventive Principle:

Principle #3Local quality

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 enhances heat dissipation and reduces electrical complexity, improving the reliability and efficiency of power tool operation by effectively managing heat and power switching within the tool handle, allowing for better motor control and user interface integration.

Implementation Method 1

heat sinks... to transfer heat away from the power switches

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

using a combination of heat sinks and airflow for cooling

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS10497524B2Integrated electronic switch and control module for a power tool

Publication Date: 2019.12.03 BLACK & DECKER CORP

AI summary

An electronic switch and control module for a power tool having an electric motor is provided. The module includes a printed circuit board (PCB), an encapsulation member forming an enclosed compartment enclosing a portion of a surface of the PCB, and power switches mounted on the surface of the PCB outside the enclosed compartment, where the power switches are electrically configured to switchably connect a supply of electric power from a power source to the electric motor. The module further includes an input unit having at least one electro-mechanical element at least partially disposed within the enclosed component and generating a signal for controlling a switching operation of the plurality of power switches.