Vertical Terminal Assembly Layout for Compact Power Tool Batteries
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Solution Overview
Problem
Existing terminal assemblies for power tools are bulky due to the increased number of electrical terminals required for different power outputs, leading to a larger width and bulkier batteries, which complicates the manufacturing process and increases costs.
Innovation Solution
A method of manufacturing a terminal assembly where first and second terminals are positioned vertically above and below each other, supported by cantilevered support portions, allowing for a single-step injection molding process that reduces complexity and saves time and costs by filling the space between terminals with material, thus reducing the overall width of the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of terminals is increased to accommodate different power outputs and communication functions, then the functionality and versatility of the terminal assembly is improved, but the width of the terminal assembly must be increased to accommodate enough space between each adjacent terminal
Solution Approach 1:
The patent applies dimensional change by transitioning from a horizontal arrangement of terminals to a vertical arrangement. Multiple terminals are stacked vertically within the same horizontal footprint, allowing the terminal assembly to accommodate more terminals without increasing width. The terminals extend in the vertical direction rather than horizontally, effectively using the third dimension (height) to resolve the contradiction between functionality and width.
2Adaptability or versatility
If the width of the terminal assembly is increased to accommodate more terminals with proper spacing, then the number of terminals and functionality are improved, but the battery becomes bulky in comparison to the power tool
Solution Approach 1:
The patent reduces battery volume by changing the spatial arrangement of terminals from horizontal to vertical stacking. This dimensional change allows multiple terminals to be packed into a smaller horizontal footprint, reducing the overall width and volume of the battery assembly while maintaining the same number of terminals and functionality.
3Ease of manufacture
If traditional terminal positioning methods are used without support portions, then the manufacturing process is simpler, but the vertical positions of terminals cannot be precisely controlled and the region between terminals cannot be efficiently utilized
Solution Approach 1:
The patent introduces support portions as intermediary elements between the terminals and the surrounding structure. These support portions serve as positioning features that precisely control the vertical positions of terminals during manufacturing. The support portions act as mediators that transfer and maintain the required vertical spacing, enabling precise positioning while simplifying the manufacturing process through integrated support structures.
Data Source
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AI summary
There is provided a method of manufacturing a terminal assembly for an electrical device. The method comprises providing a die defining a mould cavity; providing a first terminal defining a first terminal axis and having a first support portion extending away from the first terminal axis; providing a second terminal defining a second terminal axis and having a second support portion extending away from the second terminal axis; arranging the first terminal in a first vertical position by supporting the first support portion on the die; and arranging the second terminal in a second vertical position above the first vertical position by supporting the second support portion on the die.