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 their operation and pose safety risks, and existing protection methods like silicone grease and overmoulding are cumbersome.
Innovation Solution
A tool housing design with two cooperating housing elements, each containing a pocket filled with sealing material, encases electrical components, allowing the sealing material to bulge around and encapsulate them, providing effective protection against water and condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone grease or overmoulding is used to protect electrical components from water, then protection reliability is improved, but device complexity and maintenance difficulty increase
Solution Approach 1:
The housing is divided into first and second housing elements that can be separated, with pockets formed in each element. This segmentation allows the electrical components to be accessed by simply separating the housing elements, eliminating the need for complex overmoulding or silicone grease applications while maintaining protection.
Solution Approach 2:
The sealing function is extracted from the housing structure itself and implemented through removable sealing elements and pockets. This allows the electrical components to be easily removed and replaced without affecting the sealing mechanism, reducing device complexity while maintaining protection reliability.
2Reliability
If silicone grease or overmoulding is used to protect electrical components from water, then protection reliability is improved, but ease of maintenance deteriorates
Solution Approach 1:
The housing is segmented into separable first and second housing elements with dedicated pockets for electrical components. This segmentation enables easy access to components for maintenance and repair, while the sealing pockets remain in place to maintain protection reliability.
Solution Approach 2:
The pockets and sealing structures are pre-formed during housing manufacturing, eliminating the need for post-manufacturing sealing applications. This preliminary action ensures consistent sealing performance while allowing easy component access for maintenance.
3Reliability
If existing protection methods are used, then electrical components are sealed, but manufacturing complexity increases
Solution Approach 1:
The sealing function is merged with the housing structure through integrated pockets formed in the housing elements during standard manufacturing processes. This eliminates the need for separate sealing applications like silicone grease or overmoulding, reducing manufacturing complexity while maintaining sealing effectiveness.
Solution Approach 2:
The sealing mechanism transitions from chemical/physical barrier methods (silicone grease, overmoulding) to a mechanical interlocking system with fitted pockets and sealing surfaces. This parameter change simplifies manufacturing by using standard forming processes rather than specialized sealing application processes.
Data Source
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, where the first housing element includes 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 is 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.