Battery pack

Abstract

Disclosed is a battery pack comprising: a battery case; a core case disposed within the battery case; and at least one pouch cell disposed within the cell housing, the pouch cells comprising at least one corner, where the cell housing comprises a base plate, at least one side wall extending from the base plate, and a rear wall extending from the base plate to the side wall, where the rear wall meets the side wall at a partially cylindrical corner, and where the rear wall is located at a partially cylindrical corner, where the at least one pouch cell is located within the cell housing, and where the at least one pouch cell is located within the cell housing. And the local cylindrical corner provides a clearance for the corner of the soft package battery cell.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 430,569, filed on December 6, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to cordless power tools and, more particularly, to batteries for cordless power tools. Background Art

[0004] From do-it-yourself projects at home to large commercial construction projects, cordless power tools are everywhere. These tools increase productivity and efficiency. These tools require battery packs that continue to improve. Utility Model Content

[0005] In one aspect, the present disclosure provides a battery pack comprising: a battery case; a core shell disposed within the battery case; and at least one soft-pack battery cell disposed within the core shell, the soft-pack battery cells comprising at least one corner, wherein the core shell comprises a bottom plate, at least one side wall extending from the bottom plate, and a rear wall extending from the bottom plate to the side wall, wherein the rear wall meets the side wall at a local cylindrical corner, and wherein the local cylindrical corner provides clearance for the corner of the soft-pack battery cell.

[0006] On the other hand, the present disclosure provides a battery pack, comprising: a battery case having an upper battery case portion and a lower battery case portion; a core shell disposed within the battery case; at least one soft-pack battery cell disposed within the core shell; and at least one mortise and tenon assembly comprising a tenon extending from an inner surface of the lower battery case portion and a groove extending into an outer surface of the core shell, wherein the tenon of the lower battery case portion fits into the groove on the core shell.

[0007] On the other hand, the present disclosure provides a battery pack, comprising: a battery housing having a battery housing upper portion and a battery housing lower portion; a core housing disposed within the battery housing, the core housing including at least one printed circuit board assembly (PCBA) alignment protrusion extending therefrom; at least one soft-pack battery cell disposed within the core housing; and at least one PCBA disposed on the core housing, wherein the PCBA includes at least one alignment slot that fits around the PCBA alignment protrusion on the core housing.

[0008] Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 It is a three-dimensional diagram of a battery pack.

[0010] Figure 2 yes Figure 1 A top plan view of a battery pack.

[0011] Figure 3 yes Figure 1 A bottom plan view of a battery pack.

[0012] Figure 4 yes Figure 1 A side plan view of a battery pack.

[0013] Figure 5 yes Figure 1 Rear plan view of the battery pack.

[0014] Figure 6 yes Figure 1 Front plan view of a battery pack.

[0015] Figure 7 The lower part of the battery case is removed. Figure 1 A side plan view of a battery pack.

[0016] Figure 8 The lower part of the battery case and the core case are removed. Figure 1 A side plan view of a battery pack.

[0017] Fig. 9 yes Figure 1 A front perspective view of a core housing of a battery pack.

[0018] Fig.10 yes Figure 1 The battery pack along Figure 4 A cross-sectional view taken along line 10-10 in FIG.

[0019] Fig.11 yes Figure 1 The battery pack is Fig.10 Detailed view taken at box 11 in FIG.

[0020] Fig.12 The upper part of the battery case is removed. Figure 1 A top plan view of a battery pack.

[0021] Fig.13 The battery case is removed. Figure 1 A front perspective view of a battery pack.

[0022] Fig.14 The battery case is removed. Figure 1 A rear perspective view of a battery pack.

[0023] Fig.15 yes Figure 1 A bottom plan view of a printed circuit board assembly (PCBA) of a battery pack.

[0024] Fig.16 yes Figure 1 A front plan view of the front end panel of a battery pack.

[0025] Fig.17 yes Fig.16 A bottom plan view of the front end plate.

[0026] Before explaining any embodiments of the present disclosure in detail, it should be understood that the application of the present disclosure is not limited to the details of the construction and arrangement of the components set forth in the following specification or illustrated in the following figures. The present disclosure can have other embodiments and can be practiced or performed in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered restrictive.

[0027] Features illustrated or described as part of one embodiment may be used with another embodiment to yield yet another embodiment. It is therefore contemplated that the present disclosure covers such modifications and variations as fall within the scope of the appended claims and their equivalents. Numerals and letter designations are used in the detailed description to refer to features in the figures. The same or similar designations have been used in the drawings and description to refer to the same or similar parts of the present disclosure.

[0028] As used herein, the terms "first", "second" and "third" can be used interchangeably to distinguish one component from another, without intending to specify the position or importance of each component. Unless the context clearly indicates otherwise, the singular forms of "a", "one" and "the" include plural referents. Unless otherwise specified herein, the terms "connect", "fix", "attach to" and the like refer to both direct connection, fixing or attachment, and also refer to indirect connection, fixing or attachment through one or more intermediate components or features. As used herein, the terms "comprises, comprising", "includes, including", "has, having" or any other variation thereof are intended to cover non-exclusive inclusion. For example, a process, method, article or device including a list of features need not be limited to those features, but may include other features that are not explicitly listed or inherent to such a process, method, article or device. Further, unless otherwise clearly stated to the contrary, "or" refers to an inclusive "or" rather than an exclusive "or". For example, any of the following situations satisfies condition A or B: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0029] Approximate terms such as "substantially," "approximately," or "substantially" include values ​​within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include values ​​within ten degrees greater or less than the stated angle or direction. For example, "substantially vertical" includes directions within ten degrees of vertical in any direction (e.g., clockwise or counterclockwise).

[0030] Benefits, other advantages, and solutions to problems are described below with respect to specific embodiments. However, benefits, advantages, solutions to problems, and any one or more features that may make any benefit, advantage, or solution appear or become more apparent should not be construed as key, required, or essential features of any or all claims. DETAILED DESCRIPTION

[0031] refer to Figures 1 to 6, a battery pack 100 is illustrated. As shown, the battery pack 100 includes a battery housing 102, the battery housing upper portion 104 of which is coupled to a battery housing lower portion 106 along a seam 108 or interface via a plurality of threaded fasteners 110 (e.g., screws). The battery housing upper portion 104 includes an upper surface 112 and a tool body engagement assembly 114 extending from the upper surface. The tool body engagement assembly 114 includes a latch assembly housing 116 disposed on the battery housing upper portion 104 adjacent to a first end 118 of the battery housing upper portion 104. A rail assembly 120 extends from the latch assembly housing 116 along the upper surface 112 of the battery housing upper portion 104 to near a second end 122 of the battery housing upper portion 104. The track assembly 120 includes a first track 124 and a second track 126 extending along the length of the track assembly 120 from a first end 128 of the track assembly 120 to a second end 130 of the track assembly 120 .

[0032] As shown, the rails 124, 126 extend outwardly from the center portion 132 of the rail assembly 120 away from the center axis 134 of the battery pack 100, so that the rails 124, 126 are parallel to the center axis 134. Each rail 124, 126 is generally inverted "L" shape, and its size and shape are configured to fit into a complementary shaped feature on the battery receptacle of the cordless power tool. The tool body engagement assembly 114 further includes a recess 136 that extends into the second end 130 of the rail assembly 120 and terminates with a plurality of terminal openings 138. When the battery pack 100 is engaged with the battery receptacle on the cordless power tool, the terminal openings 138 will fit around one or more terminals in the cordless power tool, and the battery terminals in the terminal openings 138 will be operably connected to each other to transmit direct current (DC) power from the battery pack 100 to the cordless power tool, thereby providing DC power to the motor and other electrical components in the cordless power tool.

[0033] The tool body engagement assembly 114 also includes a first latch 140 and a second latch 142, which are disposed in the latch assembly housing 116 and partially extend into the first end 128 of the rail assembly 120. The first latch 140 includes a hook 150 and a release button 152. The second latch 142 also includes a hook 154 and a release button 156. The first latch 140 and the second latch 142 are biased outwardly relative to the central axis 134 via one or more springs. During use, when the battery pack 100 is engaged with the battery receptacle of the cordless power tool, the hooks 150, 154 engage with complementary features of the battery receptacle to keep the battery pack 100 engaged with the cordless tool. When the release buttons 152, 156 are pressed by the user, the hooks 150, 154 retract, and the battery pack 100 can be removed from the cordless power tool by sliding the battery pack 100 away from the battery receptacle.

[0034] refer to Figure 7 , the battery pack 100 includes a core housing 200 disposed in a battery housing 102. Further, as Figure 8 As shown, a plurality of soft-pack battery cells 202 are disposed in a core case 200. The soft-pack battery cells 202 are electrically coupled to each other. Adjacent soft-pack battery cells 202 are separated by plates 204 or spacers. Fig. 9 The core housing 200 is shown to include a bottom plate 210. A first side wall 212 and a second side wall 214 extend vertically from the bottom plate 210. The side walls 212, 214 are parallel to each other. A rear wall 216 extends vertically from the bottom plate 210 between the side walls 212, 214. The rear wall 216 extends along the entire height of the side walls 212, 214 and is perpendicular to the side walls 212, 214. A front wall 218 also extends vertically from the bottom plate 210 opposite the rear wall 218. The front wall 218 is parallel to the rear wall 216. In addition, the front wall 218 extends along only a portion of the height of the side walls 212, 214, so that an opening 220 is formed on the front wall 218, located between the side walls 212, 214.

[0035] As shown, each side wall 212, 214 and rear wall 216 has a height H1, and the front wall has a height H2. Further, the height H2 is less than the height H1. In particular, H2 is less than or equal to 0.20H1, such as less than or equal to 0.19H1, less than or equal to 0.18H1, less than or equal to 0.17H1, less than or equal to 0.16H1, less than or equal to 0.15H1, or less than or equal to 0.14H1. In addition, H2 is greater than or equal to 0.07H1, such as greater than or equal to 0.08H1, greater than or equal to 0.09H1, greater than or equal to 0.10H1, greater than or equal to 0.11H1, greater than or equal to 0.12H1, or greater than or equal to 0.13H1. It should be understood that H2 can be within a range between and including any of the maximum and minimum values ​​of H2 disclosed herein.

[0036] Fig.10 The first side wall 212 is shown meeting the rear wall 216 at a first partial cylindrical corner 222. In addition, the second side wall 214 also meets the rear wall 216 at a second partial cylindrical corner 224 opposite the first partial cylindrical corner 222. Although not shown, it is understood that the front wall 218 may also meet the side walls 212, 214 at a partial cylindrical corner. The partial cylindrical corners 222, 224 are identical mirror images of each other.

[0037] like Fig.11 As shown in the detailed view of FIG. 2 , the first partial cylindrical corner 222 extends on an arc A. In certain aspects, the arc A is greater than or equal to one hundred twenty degrees (120°), such as greater than or equal to one hundred twenty five degrees (125°), greater than or equal to one hundred thirty degrees (130°), greater than or equal to one hundred thirty five degrees (135°), greater than or equal to one hundred forty degrees (140°), greater than or equal to one hundred forty five degrees (145°), greater than or equal to one hundred fifty degrees (150°), and greater than or equal to one hundred fifty five degrees (155°). On the other hand, arc A is less than or equal to two hundred degrees (200°), such as less than or equal to one hundred ninety five degrees (195°), less than or equal to one hundred ninety degrees (190°), less than or equal to one hundred eighty five degrees (185°), less than or equal to one hundred eighty degrees (180°), less than or equal to one hundred seventy five degrees (175°), less than or equal to one hundred seventy degrees (170°), less than or equal to one hundred sixty five degrees (165°), or less than or equal to one hundred sixty degrees (160°). It should be understood that arc A can be within a range between and including the values ​​of A disclosed herein. Further, it should be understood that the second partial cylindrical corner 224 has an arc that is the same or similar to arc A of the first partial cylindrical corner 222.

[0038] Further, if Fig.11As depicted, the first partial cylindrical corner 222 includes a radius R. In addition, the soft-pack battery 202 defines a corner distance D measured from the center C of the partial cylindrical corner 222 to the vertex V of the corner of the soft-pack battery 202. In a particular aspect, the corner distance D is less than the radius R, so that a gap G is formed between the inner wall of the partial cylindrical corner 222 and the vertex V of the corner of the soft-pack battery 202. In a particular aspect, the gap G is equal to the radius R minus the corner distance D. Further, the gap G is greater than or equal to 0.150R, such as greater than or equal to 0.155R, greater than or equal to 0.160R, greater than or equal to 0.165R, greater than or equal to 0.170R, and greater than or equal to 0.175R. On the other hand, the gap G is less than or equal to 0.200R, such as less than or equal to 0.195R, less than or equal to 0.190R, less than or equal to 0.185R, or less than or equal to 0.180R. It will be appreciated that the gap G can be within a range between and including the minimum and maximum values ​​disclosed herein for G. Further, it will be appreciated that the size and shape of the second partial cylindrical corner 224 is similar or identical to the first partial cylindrical corner 222 .

[0039] In certain aspects, the partial cylindrical corners 222, 224 substantially minimize or eliminate stress concentrations that would otherwise exist if the side walls 214, 214 met the back wall 216 at a sharp corner. Further, the partial cylindrical corners 222, 224 provide sufficient clearance for the corners of the soft pack cell 202. Additionally, the partial cylindrical corners 222, 224 provide protection for the corner "corners" of the soft pack cell 202.

[0040] As shown, the rear wall 216 further includes a first mounting cylinder 226 on a first side of the central axis 134 and a second mounting cylinder 228 on a second side of the central axis 134 opposite the first mounting cylinder 226. Each mounting cylinder 226 includes a central hole configured to receive a screw. During assembly of the battery pack 100, the mounting cylinders 226, 228 receive screws to hold the lower plate of the printed circuit board assembly.

[0041] Fig.10 It is further indicated that the battery pack 100 includes a first tongue-and-groove component 230 on a first side of the central axis 134 and a second tongue-and-groove component 232 on a second side of the central axis 134 opposite the first tongue-and-groove component 232. The tongue-and-groove components 230, 232 are aligned along a transverse axis 234 that is perpendicular to the central axis 134. The tongue-and-groove components 230, 232 are substantially identical to each other. In addition, as Fig.11As indicated, the first tongue and groove assembly 230 includes a slot 240 formed on the first side wall 212 of the core housing 200. The slot 240 extends at least partially along the height of the first side wall 212. As shown, the channel 240 is flanked by a first side wall 242 and a second side wall 244.

[0042] In certain aspects, the groove 240 has a depth D measured from the outer surface 246 of the first sidewall 212 to the bottom of the groove 240. And, the first sidewall 212 has a thickness T measured from the outer surface 246 of the first sidewall 212 to the inner surface 248 of the first sidewall 212. In certain aspects, the depth D of the groove 240 is greater than or equal to 0.150T, such as greater than or equal to 0.155T, greater than or equal to 0.160T, greater than or equal to 0.165T, greater than or equal to 0.170T, and greater than or equal to 0.175T. In another aspect, the depth D is less than or equal to 0.200T, such as less than or equal to 0.195T, less than or equal to 0.190T, less than or equal to 0.185T, or less than or equal to 0.180T. It should be understood that the depth D can be within a range between and including the minimum and maximum values ​​of D disclosed herein.

[0043] Fig.11 It is further shown that the first tongue and groove assembly 230 has a tongue 250 extending from the inner surface 252 of the lower portion 106 of the battery housing. The tongue 250 extends at least partially along the height of the inner surface 252 of the lower portion 106 of the battery housing. The tongue 250 includes a length L measured from the inner surface 252 of the lower portion 106 of the battery housing to the inner surface 254 of the tongue 250. The lower portion 106 of the battery housing includes a wall thickness TW measured from the outer surface 256 of the lower portion 106 of the battery housing to the inner surface 252 of the lower portion 106 of the battery housing. In particular, the length L is less than the wall thickness TW. Specifically, the length L is less than or equal to 0.95TW, such as less than or equal to 0.90TW or less than or equal to 0.85TW. In addition, L is greater than or equal to 0.65TW, such as greater than or equal to 0.70TW, greater than or equal to 0.75TW, or greater than or equal to 0.80TW. It should be understood that L can be within a range between and including any value in the maximum and minimum values ​​of L disclosed herein. It should be further understood that the second tongue and groove assembly 232 is substantially an identical mirror-image replica of the first tongue and groove assembly 232, including the same features and dimensions as the first tongue and groove assembly 230.

[0044] like Fig.12As shown, when the core housing 200 is installed in the battery housing lower portion 106, the tongue 250 fits into the groove 240. Each of the plurality of screws 260 extends through a corresponding screw boss 262 on a printed circuit board assembly (PCBA) 264 to hold the PCBA 264 in place relative to the battery housing lower portion 106. The tongue and groove assemblies 230, 232 substantially limit the relative movement between the core housing 200 and the battery housing lower portion 106. Further, the tongue and groove assemblies 230, 232 significantly reduce any loads transmitted through the screw boss 262. When the screw 260 directly engages the PCBA 264, the load bypasses the PCBA 264 and is transmitted to the core housing 200. The front end plate 266 is disposed within the opening 220 of the front wall 218 of the core housing 200. The front end plate 266 includes one or more components that are electrically and operably coupled to the pouch cells 202 within the core housing 200 and electrically and operably coupled to the PCBA 264 .

[0045] Fig. 9 and Figure 12 to Figure 14 The core housing 200 is shown to further include a first PCBA retaining clip 270 and a second PCBA retaining clip 272 on a first side of the central axis 134. In addition, the core housing 200 includes a third PCBA retaining clip 274 and a fourth PCBA retaining clip 276 on a second side of the central axis 134 opposite the first and second retaining clips 270, 272. Fig. 9 As best shown in FIG. 1 , each PCBA retaining clip 270, 272, 274, 276 extends from a corresponding side wall 212, 214 of the core housing 200 in a generally upward direction and includes a retaining wall 278 having a distal clip 280. The distal clip 280 is generally triangular in shape and increases in width from top to bottom. Thus, the PCBA 264 can be slid over the distal clip 280 of the PCBA retaining clips 270, 272, 274, 276 and, as shown, Figure 12 to Figure 14 Depicted snapped into place on top of core housing 200 .

[0046] Fig. 9 and Figure 12 to Figure 14 As indicated, the core housing 200 further includes a first PCBA alignment protrusion 290, a second PCBA alignment protrusion 292, and a third PCBA alignment protrusion 294 on a first side of the central axis 134. Further, the core housing 200 includes a fourth PCBA alignment protrusion 296, a fifth PCBA alignment protrusion 298, and a sixth PCBA alignment protrusion 300 on a second side of the central axis 134 opposite to the first, second, and third PCBA alignment protrusions 290, 292, 294. Fig. 9As best shown in FIG. 1 , the first and fourth PCBA alignment tabs 290, 296 extend from the rear wall 216 of the core housing 200 in a generally upward direction and are coplanar with the rear wall 216. The second and third PCBA alignment tabs 292, 294 extend from the first side wall 212 of the core housing 200 in a generally upward direction and are coplanar with the first side wall 212. The fifth and sixth PCBA alignment tabs 298, 300 extend from the second side wall 214 of the core housing 200 in a generally upward direction and are coplanar with the second side wall 214. As shown, the first and fourth PCBA alignment tabs 290, 296 are perpendicular to the second, third, fifth, and sixth PCBA alignment tabs 292, 294, 298, 300. Further, the alignment projections 290 , 292 , 294 , 296 , 298 , 300 extend in the same direction as the retention clips 270 , 272 , 274 , 276 .

[0047] Fig. 9 It is further shown that the core housing 200 also includes a first front end board alignment projection 310 extending from the first side wall 212 in a forward direction (i.e., in a direction perpendicular to the second and third PCB alignment projections 292, 294). The first front end board alignment projection 310 is coplanar with the first side wall 212. The core housing 200 also includes an end plate clip receiving slot 314 formed adjacent to each front end board alignment projection 310, 312 on the respective side wall 212, 214.

[0048] Fig.15 Details of PCBA 264 are illustrated. As shown, PCBA 264 includes an upper plate 320 and a lower plate 322. Lower plate 320 includes a first end 324 and a second end 326. Lower plate 320 includes a first attachment slot 330 adjacent to first end 324 and a second attachment slot 332 adjacent to second end 326, both of which are formed on an edge of PCBA 264 on a first side of central axis 134. Lower plate 320 also includes a third attachment slot 334 adjacent to first end 324 and a fourth attachment slot 336 adjacent to second end 326, both of which are formed on an edge of PCBA 264 on a second side of central axis 134.

[0049] Fig.15The lower plate 320 is further shown to include a first alignment slot 340 adjacent to the first end 324 on the first side of the central axis 134. The lower plate 320 also includes a second alignment slot 342 and a third alignment slot 344 between the first and second attachment slots 330, 332 on the first side of the central axis 134. As shown, the lower plate 320 further includes a fourth alignment slot 346 adjacent to the first end 324 on the second side of the central axis 134. In addition, the lower plate 320 includes a fifth alignment slot 348 and a sixth alignment slot 350 between the third and fourth attachment slots 334, 336 on the second side of the central axis 134.

[0050] When the PCBA 264 is installed on the core housing 200, the first alignment slot 340 fits on the first PCBA alignment protrusion 290. The second alignment slot 342 fits around the second PCBA alignment protrusion 292. The third alignment slot 344 fits around the third PCBA alignment protrusion 294. In addition, the fourth alignment slot 346 fits on the fourth PCBA alignment protrusion 296. The fifth alignment slot 348 fits around the fifth PCBA alignment protrusion 298. The sixth alignment slot 350 fits around the sixth PCBA alignment protrusion 300. As described herein, the cooperation of the protrusions 290, 292, 294, 296, 298, 300 and the slots 340, 342, 344, 346, 348, 350 controls the placement of the PCBA 264 on the core housing 200 to assist in assembling the battery pack 100 when the PCBA 264 is snapped onto the core housing 200.

[0051] When installing the PCBA 264, the first attachment slot 330 slides over the first PCBA retaining clip 270 and snaps into place under its distal clip 280, guided by the protrusions 290, 292, 294, 296, 298, 300 and the slots 340, 342, 344, 346, 348, 350. The second attachment slot 332 slides over the second PCBA retaining clip 272 and snaps into place under its distal clip 280. The third attachment slot 334 slides over the third PCBA retaining clip 274 and snaps into place under its distal clip 280. Finally, the fourth attachment slot 336 slides over the fourth PCBA retaining clip 276 and snaps into place under its distal clip 280. The retaining clips 270 , 272 , 274 , 276 cooperate and engage with the attachment slots 330 , 332 , 334 , 336 to retain the PCBA 264 on top of the core housing 200 and can substantially withstand the forces generated by the expansion of the pouch cell 202 within the core housing 200 .

[0052] Fig.16 and Fig.17Details of the front end plate 266 are illustrated. As shown, the front end plate 266 includes a generally flat body 400 having a first end 402 and a second end 404. The front end plate 266 includes a first end plate alignment slot 406 adjacent to the first end 402 and a second end plate alignment slot 408 adjacent to the second end 404. The front end plate 266 also includes a third mounting cylinder 410. The third mounting cylinder 410 includes a central hole configured to receive a screw. During assembly of the battery pack 100, the third mounting cylinder 410 receives the screw 260 to retain the lower plate 320 of the PCBA 264 on the core housing 200.

[0053] The front end plate 266 further includes a first end plate retaining clip 412 adjacent to the first end plate alignment slot 406 and a second end plate retaining clip 414 adjacent to the second end plate alignment slot 406. Each end plate retaining clip 412, 414 includes a retaining wall 416 and a distal clip 418. Fig.13 When installed on the core housing 200, the first end plate alignment slot 406 is first on the first front end plate alignment protrusion 310. The second end plate alignment slot 408 fits on the second front end plate alignment protrusion 312. The end plate retaining clips 412, 414 on the front end plate 266 fit into the corresponding end plate clip receiving slots 314 on the core housing 200. As described herein, the cooperation of the protrusions 310, 312 and the slots 404, 406 controls the placement of the front end plate 266 on the core housing 200 to assist in assembling the battery pack 100 when the front end plate 266 is snapped onto the core housing 200. The end plate retaining clips 412, 414 cooperate and engage with the end plate clip receiving slots 314 to retain the front end plate 266 on the front of the core housing 200 and can substantially withstand the forces generated by the expansion of the soft pack battery cells 202 within the core housing 200.

[0054] Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure described.

Claims

1. A battery pack comprising: Battery housing; a core housing disposed within the battery housing; as well as At least one soft-pack battery cell is disposed in the core housing, and the soft-pack battery cells include at least one corner, The core shell includes Base plate; at least one side wall extending from the base plate; and A rear wall extending from the bottom plate to the side wall, wherein the rear wall meets the side wall at a partially cylindrical corner, And wherein, the local cylindrical corner provides clearance for the corner of the soft-pack battery cell.

2. The battery pack according to claim 1, wherein: Each of the partial cylindrical corners defines an arc A that is greater than or equal to one hundred twenty degrees.

3. The battery pack according to claim 2, wherein: The arc A is less than or equal to 200 degrees.

4. The battery pack according to claim 1, wherein: The local cylindrical corner includes a radius R and a center C, wherein the soft-pack battery cell defines a corner distance D measured from the center C to a vertex V of the corner of the soft-pack battery cell, and wherein the corner distance D is less than the radius R, such that a gap G is formed between an inner wall of the local cylindrical corner and the vertex V of the corner of the soft-pack battery cell.

5. The battery pack according to claim 4, wherein: The gap G is greater than or equal to 0.150R.

6. The battery pack according to claim 5, wherein: The gap G is less than or equal to 0.200R.

7. A battery pack comprising: a battery housing having a battery housing upper portion and a battery housing lower portion; a core housing disposed within the battery housing; At least one soft-pack battery cell, the at least one soft-pack battery cell being disposed in the core housing; as well as At least one tongue and groove assembly, the at least one tongue and groove assembly comprising A tenon extends from the inner surface of the battery housing lower portion and a groove extends into the outer surface of the core housing, wherein the tenon of the battery housing lower portion fits into the groove on the core housing.

8. The battery pack according to claim 7, wherein: The tongue and groove assembly limits relative movement between the core housing and the battery housing lower portion.

9. The battery pack according to claim 8, wherein: The tongue and groove assembly reduces loads transmitted through one or more screw bosses on a printed circuit board assembly disposed on the core housing.

10. A battery pack comprising: A battery housing having an upper battery housing portion and a lower battery housing portion part; A core housing is disposed in the battery housing, the core housing comprising at least one PCB assembly alignment projection extending therefrom; At least one soft-pack battery cell, the at least one soft-pack battery cell being disposed in the core housing; as well as At least one printed circuit board assembly is disposed on the core housing, wherein the printed circuit board assembly comprises At least one alignment slot fits around the printed circuit board assembly alignment projection on the core housing.

11. The battery pack according to claim 10, wherein: The core housing further includes a PCB assembly retaining clip extending from the core housing in the same direction as the PCB assembly alignment projection.

12. The battery pack according to claim 11, wherein: The PCB assembly includes at least one attachment slot formed on an edge of the PCB assembly, wherein the PCB assembly retention clip engages the attachment slot to maintain the PCB assembly on the core housing.

13. The battery pack according to claim 10, wherein: The core housing includes at least one front end plate alignment protrusion extending in a direction perpendicular to the printed circuit board assembly alignment protrusion.

14. The battery pack according to claim 13, further comprising an end plate provided on one end of the core case, wherein The end plate includes an end plate alignment slot that fits over the end plate alignment projection.

15. The battery pack according to claim 13, wherein: The core housing further includes an end plate clip receiving slot adjacent to the end plate alignment tab.

16. The battery pack according to claim 15, wherein: The end plate further includes an end plate retaining clip adjacent to the end plate alignment slot, and the end plate retaining clip fits into the end plate clip receiving slot on the core housing.

Images