Suspended Power Tool Battery Pack for Shock and Vibration Resilience
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Solution Overview
Problem
Existing batteries for electrically powered and hybrid power tools lack sufficient shock resilience to withstand harsh operating conditions such as strong vibration and mechanical impacts, which can damage the battery cells.
Innovation Solution
A battery design featuring a central housing with gables that support a battery cell pack suspended by resilient members extending diagonally from the mass center, distributing impact forces efficiently and allowing for easy replacement and recycling, while also optimizing cooling efficiency and adaptability to different gable geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are protected from vibration and mechanical shock, then shock resilience is improved, but device complexity increases
Solution Approach 1:
The patent applies beforehand cushioning by pre-installing resilient members (elastic elements) between the battery cell pack and the housing before any shock occurs. These resilient members are positioned to absorb and distribute impact forces from multiple directions, cushioning the battery cells against vibration and mechanical shock during harsh operating conditions without requiring complex active protection systems.
Solution Approach 2:
The patent applies segmentation by dividing the battery assembly into distinct functional modules: the battery cell pack, the housing with gables, and the resilient members as separate shock-absorbing elements. This modular segmentation allows the resilient members to be strategically positioned at critical locations (between gables and cell pack) to provide targeted protection while keeping the overall structure manageable and not excessively complex.
2Reliability
If resilient members are supported by gables instead of central housing, then shock resilience is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies dynamics by making the resilient members non-fixedly supported on the gable portion rims, allowing them to move and adapt dynamically during shock events. This dynamic support arrangement enables the resilient members to absorb impact forces from various directions while accommodating tolerances in gable geometry, as the resilient elements can deform and reposition themselves rather than requiring precise fixed mounting positions.
Solution Approach 2:
The patent applies parameter changes by utilizing the elastic properties of the resilient members, which can change their physical state (deformation) in response to applied forces. This parameter change capability allows the resilient members to absorb shock while accommodating variations in gable dimensions and positioning tolerances, reducing the need for extremely tight manufacturing precision.
3Reliability
If battery cell pack is suspended by resilient members, then shock resilience is improved, but ease of repair decreases
Solution Approach 1:
The patent applies segmentation by designing the resilient members as separate, removable components between the battery cell pack and the housing. This segmentation allows the battery cell pack to be easily separated from the housing by removing or compressing the resilient members, facilitating repair and replacement operations while maintaining shock protection during normal use.
Solution Approach 2:
The patent applies dynamics through the non-fixed support of resilient members on gable portion rims, which allows for easy compression and removal of these elements. This dynamic characteristic enables straightforward disassembly for repair by simply compressing the resilient members to release the battery cell pack, while still providing effective shock resilience 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 enhanced shock resilience, efficient cooling, and adaptability to various power tool applications, enabling the batteries to withstand harsh conditions and maintain performance without requiring changes to the power tool or charger interfaces.
Implementation Method 1
The battery cell pack is arranged suspended in the volume by at least three resilient members, wherein each resilient member extends in a direction diagonally away from a mass center of the battery cell pack
Data Source
AI summary
A battery (400) for a power tool, the battery comprising a central housing (310) terminated by a first gable (320) and a second gable (330), the first gable (320) being arranged opposite to the second gable (330) and facing in an insertion direction (D) of the battery, wherein the gables (320, 330) mate with the central housing (310) along respective gable rims (325, 335), thereby defining a volume (V) delimited by the gables (320, 330) and the central housing (310), the battery further comprising a battery cell pack (410) comprising a plurality of elongated battery cells extending in an elongation direction transversal to the insertion direction (D), wherein the battery cell pack (410) is arranged suspended in the volume (V) by at least three resilient members, wherein the resilient members extend in a direction diagonally away from a mass center of the battery cell pack and transversal to the elongation direction, towards a supporting location on one of the gable portion rims (325, 335).