Active cooling and heat dissipation system for electric tool battery

Abstract

The invention relates to the technical field of electric tool battery thermal management, and discloses an active cooling system for an electric tool battery. According to the invention, the air cooling intensity can be optimized in real time according to the temperature change of the battery by matching the double-vortex fan with self-adaptive rotating speed adjustment and combining with the internally precisely designed closed air guide channel, the air flow is forced to uniformly penetrate through the gaps of the battery, the accumulated hot air flow is quickly discharged, and the problems of local overheating and heat accumulation are effectively eliminated; meanwhile, the air outlet below the side edge of the shell is integrated with the waterproof and dustproof breathable film, so that the dustproof and waterproof sealing performance is realized on the premise of ensuring efficient heat dissipation, the system can reliably adapt to outdoor dust, moisture and other harsh working conditions, the working stability and the safety protection level of the battery pack are remarkably improved, and the overall service life of the battery pack is remarkably prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of thermal management of power tool batteries, and in particular to an active cooling and heat dissipation system for power tool batteries. Background Art

[0002] As power tools (such as electric drills, angle grinders, and electric saws) accelerate their evolution toward higher power and longer battery life, lithium batteries, with their high energy density and lightweight advantages, have become a core power source. However, under high-current charging and discharging conditions and high-temperature environments, electrochemical polarization and ohmic internal resistance combine to rapidly accumulate Joule heat. If the battery temperature exceeds the safety threshold, it can not only cause irreversible damage such as electrolyte decomposition and SEI membrane rupture, significantly shortening the cycle life, but can also trigger a chain reaction of exothermic reactions due to thermal runaway, resulting in serious safety accidents such as fire and explosion.

[0003] Current industry standards are increasingly stringent on limiting battery temperature rise, and users' demand for battery life is also driving technological upgrades. Traditional passive cooling solutions (such as natural convection and metal heat sinks) are limited by confined spaces and heat dissipation efficiency, making it difficult to cope with the temperature rise challenges under high-load conditions. Existing active cooling systems mostly use fixed threshold control and lack dynamic response capabilities, which can easily lead to heat dissipation lag or energy waste. For this reason, the technology that integrates real-time temperature monitoring, dynamic prediction algorithms, and multi-mode collaborative heat dissipation has become a research hotspot. Its core lies in achieving coordinated optimization of safety, life, and energy efficiency through precise thermal management to meet the development needs of intelligent and high-reliability power tools. To this end, an active cooling and heat dissipation system for power tool batteries is proposed. Summary of the Invention

[0004] In view of the deficiencies in the prior art, the present invention provides an active cooling and heat dissipation system for a power tool battery to solve the background technical problems.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an active cooling and heat dissipation system for a power tool battery, comprising:

[0006] Temperature detection module, used to monitor the temperature inside or on the surface of the battery pack in real time;

[0007] A heat dissipation execution module, including a vortex fan, is used to force air cooling for the battery pack and is located directly below the battery pack;

[0008] The circuit board is electrically connected to the eddy current fan and integrates a control module, a power management module, and a signal processing circuit. Specifically:

[0009] The control module is in communication with the temperature detection module and the heat dissipation execution module, and dynamically adjusts the start and stop and power of the heat dissipation execution module according to the temperature signal;

[0010] The power management module is used to provide power to the heat dissipation system and distribute power consumption;

[0011] The signal processing circuit is used to convert the analog signal detected by the temperature detection module into a digital signal and transmit it to the control module;

[0012] The shell has an air guide channel formed inside, which covers the battery pack, circuit board and heat dissipation execution module. The shell is provided with an air outlet corresponding to the air outlet end of the vortex fan for air outlet and heat dissipation.

[0013] Preferably, the temperature detection module includes:

[0014] The thermistor is integrated on the circuit board and sends an analog signal to the control module through the signal processing circuit.

[0015] Preferably, the vortex fan adopts side air outlet, the air outlet is located below the inner side of the shell, and a waterproof, dustproof and breathable membrane is laid on the side of the air outlet close to the inside of the shell.

[0016] Preferably, a support guide plate is installed in the shell, and the support guide plate is located between the vortex fan and the battery pack. The support guide plate supports the battery pack, and a guide hole corresponding to the air inlet of the vortex fan is opened on the support guide plate.

[0017] Preferably, the temperature control strategy of the control module is:

[0018] The rotation speed of the eddy current fan is controlled according to the temperature value detected by the thermistor, and the rotation speed increases as the temperature rises.

[0019] Preferably, the control module further includes a dynamic prediction function, which calculates the temperature rise rate based on historical temperature data, and increases the heat dissipation intensity in advance if the predicted temperature will exceed a threshold within a set time.

[0020] Preferably, the power management module draws power from the remaining discharged power of the battery pack through a DC-DC step-down circuit.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] The present invention uses a dual-vortex fan with adaptive speed regulation, combined with a precisely designed internal closed air guide channel, to optimize the air cooling intensity in real time according to battery temperature changes, force the airflow to evenly penetrate the battery gaps, quickly discharge accumulated hot air, and effectively eliminate local overheating and heat accumulation problems; at the same time, the air outlet on the lower side of the shell is integrated with a waterproof and dustproof breathable membrane, which achieves dustproof and waterproof sealing performance while ensuring efficient heat dissipation, so that the system can reliably adapt to harsh working conditions such as outdoor dust and humidity, and significantly improve the working stability, safety protection level and overall service life of the battery pack.

[0023] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the battery structure of the power tool of the present invention;

[0025] Figure 2 for Figure 2 A partial enlarged view of point A in the middle;

[0026] Figure 3 This is a schematic diagram of the exploded structure of the power tool battery of the present invention;

[0027] Figure 4 This is a schematic diagram of the specific structure of the temperature detection module, heat dissipation execution module and circuit board of the present invention;

[0028] Figure 5 This is a connection block diagram of the active cooling and heat dissipation system for the power tool battery of the present invention;

[0029] Figure 6 This is a functional diagram of the signal processing circuit of the present invention.

[0030] In the figure: 1. Housing; 2. Circuit board; 3. Vortex fan; 4. Support guide vane; 5. Air guide hole; 6. Air outlet; 7. Waterproof, dustproof and breathable membrane. DETAILED DESCRIPTION

[0031] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, other embodiments obtained by ordinary technicians in this technical field without making any creative efforts shall fall within the scope of protection of the present invention.

[0032] See also Figure 1-6 The present invention relates to an active cooling and heat dissipation system for power tool batteries. Its core components include a temperature detection module, a heat dissipation execution module, a circuit board 2 with integrated control functions, and a housing 1. The following is a detailed implementation of each module and the collaborative workflow:

[0033] 1. Shell 1

[0034] The housing 1 is composed of two shell parts, which form an air guide channel inside the combination. The housing 1 protects structures such as the battery pack and the circuit board 2.

[0035] The air outlet 6 is located at the lower inner side of the housing 1 and adopts a side air outlet design for exhausting hot air to facilitate heat dissipation;

[0036] Waterproof and dustproof breathable membrane 7: It is laid close to the side of the air outlet 6 close to the inside of the housing 1, achieving IP54 protection level, preventing external dust and liquid intrusion while allowing air circulation;

[0037] The support guide plate 4 is installed in the housing 1 and is located below the battery pack. It is used to support the battery pack and is made of flame-retardant plastic material. A guide hole 5 is opened on it.

[0038] 2. Heat dissipation execution module

[0039] The vortex fan 3 is fixed at the bottom of the cavity of the shell 1 and is located directly below the battery pack. Its air inlet end faces upward, and the air outlet end is located on the side and corresponds to the air outlet 6. The vortex fan 3 discharges the heat of the battery pack through the air outlet 6.

[0040] 3. Support guide plate 4

[0041] It is fixed in the housing 1, located between the vortex fan 3 and the battery pack, and is made of flame-retardant plastic material to support the battery pack above;

[0042] The housing 1 is provided with a plurality of guide holes 5 , which correspond to the air inlets of the eddy current fan 3 . The eddy current fan 3 draws away the heat in the battery pack through the guide holes 5 .

[0043] 4. Circuit board 2 and temperature detection module

[0044] The circuit board 2 is installed on the battery pack and integrates the control module, power management module, and signal processing circuit;

[0045] The temperature detection module includes a thermistor, which is integrated on the circuit board 2, detects the temperature of the battery pack inside the housing 1, and sends an analog signal to the control module through the signal processing circuit;

[0046] Signal processing circuit: Connects to the thermistor, receives analog signals, integrates a multi-channel ADC chip (ADS1115), and converts them into digital signals at a sampling rate of ≥10Hz.

[0047] Control module (MCU, such as STM32 series): through I 2 The C bus receives the ADC digital signal, and its temperature control strategy is:

[0048] Temperature ≥ T1: Start eddy current fan 3 at low speed (30% PWM duty cycle);

[0049] Temperature ≥ T2: switch eddy current fan 3 to high speed operation (70% PWM duty cycle);

[0050] Temperature ≤ T1: turn off eddy current fan 3;

[0051] Among them, T1 <T2。

[0052] Dynamic prediction function:

[0053] The speed increases linearly / step by step with the temperature value;

[0054] Calculate the temperature rise rate (dT / dt) based on historical temperature data;

[0055] If the temperature is predicted to be ≥ T2 within 5 seconds, the speed of the eddy current fan 3 is increased to 80% duty cycle in advance.

[0056] Power management module:

[0057] Main power supply: Take power from the positive and negative terminals of the battery pack through a DC-DC step-down circuit (LM2596) and step down the voltage to 12V;

[0058] Power consumption management: power consumption <0.1W in standby mode (temperature <40°C).

[0059] Power consumption optimization: In standby mode (temperature < T3, T1 > T3), only the temperature detection module is kept running, and the power consumption is less than 0.1W.

[0060] Cooling system workflow:

[0061] Temperature sensing: The thermistor integrated on the circuit board 2 senses the temperature of the battery pack in the housing 1 in real time and generates an analog signal;

[0062] Signal processing: The analog signal is transmitted to the signal processing circuit on the circuit board 2 and converted into a digital signal by the ADC chip.

[0063] Control decision: Digital temperature signal is transmitted through I 2 The C bus transmits the data to the control module. The control module determines the start and stop and speed of the eddy current fan 3 according to the current temperature value and the preset temperature control strategy;

[0064] At the same time, the dynamic prediction function runs, analyzing historical temperature data to calculate the temperature rise rate. If it is predicted that the temperature will exceed the threshold in the short term, the speed of vortex fan 3 will be increased to a higher level in advance.

[0065] Heat dissipation execution (forced air cooling): The control module issues a command to drive the eddy current fan 3 to run at the set speed:

[0066] The vortex fan 3 runs to extract heat from the battery pack. The heat enters the vortex fan 3 along the guide holes 5 in the support guide plate 4. The vortex fan 3 discharges the heat from the side through the air outlet 6 to the outside of the housing 1 to achieve heat dissipation.

[0067] Heat dissipation termination and standby: When the temperature detection module detects that the temperature drops to the shutdown threshold, the control module turns off the eddy current fan 3 and the system enters a low-power standby mode, keeping only the temperature detection and basic control circuits running.

[0068] Power supply: The power required for the entire system to operate is provided by the power management module, with priority given to using the battery pack to discharge the remaining power.

[0069] Effect of the embodiment:

[0070] Tested at 25°C ambient temperature:

[0071] When the battery pack is operating continuously at full power, after activating this active cooling and heat dissipation system, its operating temperature can be stably controlled below 50°C. Compared with the case without a heat dissipation system, the operating temperature is significantly reduced. Effective temperature control helps to extend the battery cycle life.

[0072] This embodiment provides an active cooling and heat dissipation system for power tool batteries. Its core comprises: a housing 1 forming a sealed cavity with an air outlet 6 covered with a waterproof, dustproof, and breathable membrane 7 at the lower side; a vortex fan 3 fixed to the bottom mounting position of the housing 1 to deliver air outward; a support guide vane 4 mounted directly above the fan, which directs heat away from the battery pack gap through a guide hole 5; a circuit board 2 mounted within the housing 1 and integrating a thermistor, signal processing circuitry, a control module, and a power management module; the control module dynamically adjusts the fan speed based on temperature signals and supports temperature rise prediction, while the power management module draws power from the battery. The system employs an intelligent temperature control strategy and dynamic prediction capabilities to achieve a balance between efficient heat dissipation and energy consumption. The housing 1 is also designed to be both waterproof, dustproof, and breathable, significantly improving battery life and safety, and meeting the requirements for stable operation under complex operating conditions.

Claims

1. An active cooling and heat dissipation system for a power tool battery, characterized in that: include: Temperature detection module, used to monitor the temperature inside or on the surface of the battery pack in real time; A heat dissipation execution module, including a vortex fan (3), is used for forced air cooling of the battery pack and is located directly below the battery pack; The circuit board (2) is electrically connected to the eddy current fan (3) and integrates a control module, a power management module, and a signal processing circuit. Specifically: The control module is in communication with the temperature detection module and the heat dissipation execution module, and dynamically adjusts the start and stop and power of the heat dissipation execution module according to the temperature signal; The power management module is used to provide power to the heat dissipation system and distribute power consumption; The signal processing circuit is used to convert the analog signal detected by the temperature detection module into a digital signal and transmit it to the control module; The housing (1) has an air guide channel formed therein, which covers the battery pack, the circuit board (2) and the heat dissipation execution module. The housing (1) is provided with an air outlet (6) corresponding to the air outlet end of the vortex fan (3) for air discharge and heat dissipation.

2. The active cooling and heat dissipation system for a power tool battery according to claim 1, characterized in that: The temperature detection module includes: The thermistor is integrated on the circuit board (2) and sends an analog signal to the control module through the signal processing circuit.

3. The active cooling and heat dissipation system for a power tool battery according to claim 1, characterized in that: The vortex fan (3) adopts side air outlet, the air outlet (6) is located below the inner side of the shell (1), and a waterproof, dustproof and breathable membrane (7) is laid on the side of the air outlet (6) close to the inside of the shell (1).

4. The active cooling and heat dissipation system for a power tool battery according to claim 1, characterized in that: A support guide plate (4) is installed in the housing (1), the support guide plate (4) is located between the vortex fan (3) and the battery pack, the support guide plate (4) supports the battery pack, and a guide hole (5) corresponding to the air inlet of the vortex fan (3) is opened on the support guide plate (4).

5. The active cooling and heat dissipation system for a power tool battery according to claim 2, characterized in that: The temperature control strategy of the control module is: The rotation speed of the eddy current fan (3) is controlled according to the temperature value detected by the thermistor, and the rotation speed increases as the temperature rises.

6. The active cooling and heat dissipation system for a power tool battery according to claim 1, characterized in that: The control module also includes a dynamic prediction function, which calculates the temperature rise rate based on historical temperature data. If the predicted temperature will exceed a threshold within a set time, the heat dissipation intensity is increased in advance.

7. The active cooling and heat dissipation system for a power tool battery according to claim 1, characterized in that: The power management module draws power from the remaining power of the battery pack through a DC-DC step-down circuit.

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