Power Tool Switch Heat Sink Lateral Protrusion
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Solution Overview
Problem
Existing electrical switches for power tools face challenges in heat dissipation, particularly under continuous load, which affects operational reliability, and often lack sufficient space for effective cooling and cost-effective design.
Innovation Solution
A heat sink with a wing-like second area that protrudes into the cooling air flow, designed in a stepped manner with increased thickness near the power semiconductor, and featuring slits for enhanced airflow, combined with a resilient contact bearing and a plastic locking mechanism to replace metal bolts, optimizing heat dissipation and reducing component costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional heat sink is used in the housing, then the structure is simple, but heat dissipation is insufficient under continuous load
Solution Approach 1:
The heat sink extends from a conventional planar configuration into a three-dimensional wing-like structure that protrudes laterally from the housing. This dimensional change allows the heat sink to access cooling air flow in multiple directions and increase its effective surface area for heat dissipation without significantly increasing the overall footprint of the device.
Solution Approach 2:
The heat sink is divided into two functional areas: a first area integrated into the housing for mounting the power semiconductor, and a second wing-like area that protrudes laterally to access cooling air flow. This segmentation allows each area to be optimized for its specific function while working together as a unified heat dissipation system.
2Temperature
If the heat sink is extended into the cooling air flow area, then heat dissipation is improved, but the space in the handle is reduced
Solution Approach 1:
Instead of extending the heat sink in the longitudinal direction of the handle (which would consume valuable handle space), the invention utilizes the lateral dimension by allowing the heat sink to protrude from the housing walls. This redirects the heat dissipation path into the lateral cooling air flow without encroaching on the handle's internal volume.
3Reliability
If a metal bolt is used for the locking device, then the locking is reliable, but the cost is high
Solution Approach 1:
The invention replaces the expensive metal bolt with a plastic locking element that is integrated into the housing. While individual plastic locking elements may have shorter service lives than metal, their low cost allows for easy replacement, and their integration into the housing eliminates the need for separate metal fasteners, thereby reducing overall manufacturing costs while maintaining sufficient locking reliability.
Solution Approach 2:
The locking element is merged with the housing structure, forming an integrated assembly rather than a separate metal bolt component. This integration eliminates the need for additional metal fasteners and simplifies the manufacturing process, reducing both material costs and assembly complexity while maintaining the necessary locking function.
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
Improved heat dissipation under continuous load, reduced need for expensive power semiconductors, cost savings, enhanced operational reliability, and a compact, cost-effective switch design suitable for confined spaces.
Implementation Method 1
a heat sink 6 located on the outside of the housing 2, with which the heat-generating component 10 and/or at least parts of the circuit arrangement are in thermally conductive connection
Implementation Method 2
the second area 12 of the heat sink 6 extends into the area of the device cooling air flow
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a control device, particularly an electric switch (1) for use for a hand-held power tool, such as a hand-held power tool using a rechargeable battery and/or mains operation, for example drills, grinders, saws, planes, angle grinders and the like, comprising an electric motor. The switch (1) comprises a housing (2) for receiving at least one heat-generating power element, such as a power transistor, a MS-FET, a triac, or the like, which is particularly arranged in an electric circuit arrangement. The circuit arrangement is used, for example, to control and/or regulate the electric motor through a corresponding control and/or regulation of the electric load current flowing through the power element to the electric motor. The heat-generating power element and/or at least parts of the circuit arrangement are thermally conductively connected to a cooling body (6) disposed on the outside of the housing (2). The cooling body (6) comprises at least two regions, wherein the first region of the cooling body (6) is arranged in the housing (2) such that the heat-generating element and/or at least parts of the circuit arrangement are directly connected to the first region, and wherein the second region (12) of the cooling body (6) protrudes out of the housing (2), particularly in the manner of a lateral emergence on both sides out of the housing (2). Furthermore, an electric switch (1) having a resilient contact bearing is created, wherein the movement of the operating element (3) is deflected approximately in the transversal direction relative to the action on the contact system. Finally, the electric switch (1) can be provided with an on-blocking device (24) having a blocking member, wherein the blocking member comprises a plastic web.