Sealing Pocket Housing for Tool Electrical Components

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Solution Overview

Problem

Electrical components in tools are vulnerable to water ingress and condensation, which can affect operation and pose safety risks, and existing protection methods like silicone grease and overmoulding are cumbersome.

Innovation Solution

A tool housing design featuring a pocket in one housing element filled with sealing material and a cooperating sealing portion in another element that encapsulates electrical components when assembled, using non-adhesive elastomeric gels to form a resilient seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If silicone grease or overmoulding is used to protect electrical components from water, then protection from water ingress is improved, but maintenance difficulty increases

Engineering Contradiction:

Improveprotection from water ingressVSAvoidmaintenance difficulty

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The housing is divided into two separable elements that can be detached to access the electrical component. The first housing element contains a pocket with sealing material, while the second housing element has a sealing portion that engages with the first element. This segmentation allows the housing to be opened for maintenance while maintaining water protection when closed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A non-adhesive sealing material (such as silicone grease or elastomeric gel) is introduced as an intermediary substance between the electrical component and the housing elements. This sealing material provides water protection without permanently bonding the component to the housing, enabling easy removal and reinstallation during maintenance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If UV-cured glue is used to protect electrical components, then sealing effectiveness is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improvesealing effectivenessVSAvoidease of manufacture

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealing material is designed to be self-containing within the housing structure. The pocket in the first housing element and the sealing portion in the second housing element work together to automatically contain and position the sealing material during assembly, eliminating the need for additional curing processes or complex manufacturing steps.

Inventive Principle:

Principle #25Self-service

3Reliability

If adhesive sealing material is used to seal electrical components, then sealing effectiveness is improved, but maintenance ease deteriorates

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmaintenance ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4674572A1A tool having a sealing pocket for an electrical component

Publication Date: 2026.01.07 BLACK & DECKER CORP

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Figure 5A~5B

AI summary

A tool comprising: a housing for housing components of the tool, the housing comprising a first housing element and a second housing element, the first and second housing elements being configured to cooperate with each other to form the housing; the first housing element comprising a pocket; a sealing material disposed in the pocket; an electrical component disposed at least partially in the pocket; and a further component located exterior to the pocket within the housing; the tool being configured such that, where the first housing element and the second housing element are in cooperative engagement, a sealing portion of the second housing element abuts the electrical component whereby the electrical component is sealed by the sealing material.