Battery pack

Abstract

A battery pack is disclosed and includes a core shell, an outer shell, and a fastener. The core includes an internal cavity and at least two lobes. The lobes protrude outwardly away from the internal cavity. The outer shell surrounds the core shell and includes a set of protrusions that fit between the two lobes of the core shell. A fastener extends through the lobes and the protrusions.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 430,598, filed on December 6, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to battery packs and, more particularly, to battery packs configured to interface with a power tool. Background Art

[0004] Typically, a battery pack for a power tool includes a plurality of battery cells. During operation, the battery cells may become easily damaged if they are not properly secured and protected. One method of protecting the battery cells is to provide an additional battery cell housing disposed within the outer housing of the battery pack. The battery cell housing will be secured to prevent the battery cells from moving within the outer housing. Utility Model Content

[0005] In an independent aspect, the present disclosure provides a battery pack comprising a core shell, an outer shell, and a fastener. The core comprises an internal cavity and at least two lobes. The lobes protrude outwardly away from the internal cavity. The outer shell surrounds the core shell and comprises a set of protrusions that fit between the two lobes of the core shell. The fastener extends through the lobes and the protrusions.

[0006] In another independent aspect, the present disclosure provides a battery pack having a core shell, an outer shell, and a fastener. The core shell defines an internal cavity and an outwardly protruding horn, the outwardly protruding horn having a hole. The outer shell surrounds the core shell and includes an inwardly facing protrusion. The protrusion has a hole aligned with the hole of the horn. The outer shell also includes a guide rail for mounting the battery pack to an electric device. The fastener extends through the hole of the protrusion and the hole of the horn in a direction similar to the guide rail.

[0007] In another independent aspect, the present disclosure also provides a battery pack housing having a base, a band, and a rod. The base has an outer surface and an inner surface and comprises a first material. The band is molded into the outer surface of the base and has a plurality of protrusions formed on the inner surface of the base. The rod is molded into the inner surface of the base and contacts the band. The rod and the band comprise a material different from the first material. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a perspective view of a battery pack according to one configuration.

[0009] Figure 2 yes Figure 1 A three-dimensional view of the core shell of a battery pack in which the outer shell is transparent.

[0010] Figure 3 is from Figure 1 A three-dimensional cross-sectional view of the section taken along line 3-3 in FIG.

[0011] Figure 4 is from Figure 1 A three-dimensional cross-sectional view of a section taken along line 5-5 in FIG.

[0012] Figure 5 is a perspective view of a bottom cover of a battery pack according to another configuration. DETAILED DESCRIPTION

[0013] Before explaining any independent configuration 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 description or shown in the following figures. The present disclosure can have other independent configurations 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.

[0014] As used herein, "including" and "comprising" and variations thereof are intended to encompass the items listed below and equivalents thereof as well as additional items. As used herein, "consisting of" and variations thereof are intended to encompass only the items listed below and equivalents thereof.

[0015] Figure 1 to Figure 2 An embodiment of a battery pack 10 is illustrated. The battery pack 10 is configured to power various power tools and be charged by a charger. The battery pack 10 includes a core shell 12, an outer shell 14, and a plurality of fasteners 16. In the current embodiment, the outer shell 14 of the battery pack 10 includes a battery pack interface 15, which defines a plane along which a power tool or other suitable electrical device can be mounted. The battery pack interface 15 includes a plurality of terminals 18 located on a guide rail 20, which are configured to releasably couple and electrically connect the battery pack 10 to a corresponding electric device. The battery pack 10 further includes a release button 22, which is configured to separate the battery pack 10 from the connected electric device.

[0016] Specific reference Figure 2, the core shell 12 of the battery pack 10 has a generally box-like shape and is used to accommodate a plurality of battery cells in an internal cavity defined in the core shell. In the current embodiment, three side walls cooperate with a front plate (not shown) and a circuit board to enclose the battery cells. In the illustrated embodiment, each of the two opposing walls 26 has a plurality of lobes 28 extending outwardly in pairs away from the internal cavity. In other embodiments, the core shell 12 includes only a single lobes 28. A lobes hole 30 is provided in each lobes 28, and each lobes hole 30 has a circular shape. In some embodiments, the lobes 28 may extend from adjacent walls instead of extending outwardly from opposing walls or in addition to extending outwardly from opposing walls. In some embodiments, each lobes 28 may be formed integrally as a unitary piece of the core shell 12.

[0017] Continue to refer Figure 2 In the illustrated embodiment, each lobe 28 receives a fastener 16 within a lobe hole 30. In the illustrated embodiment, the fastener 16 passes through the outer shell 14 and the corresponding lobe 28 in a direction parallel to the plane defined by the battery pack interface 15. In other words, the fastener 16 extends transversely to the height of the core shell 12. For example, in the illustrated embodiment, a plurality of fasteners 16 extend through the outer shell 14 and the lobe 28 between the front side and the opposite rear side of the core shell 12 in a direction parallel to the guide rails. In this embodiment, at least one fastener 16 is partially disposed below the release button 22.

[0018] refer to Figure 3 , the current embodiment of the outer shell 32 of the battery pack 10 includes a top cover 34 and a bottom cover 36. The top cover 34 includes a battery pack interface 15 and a release button 22, and is configured to releasably connect the battery pack 10 to an appropriate electric device (such as a power tool or a charger). In addition, the top cover 34 extends across the front side of the core shell 12, thereby allowing the fastener 16 to extend through the outer surface of the top cover 34. In other words, the top cover 34 can have a barrel shape. A plurality of top outer holes 35 are also provided in the top cover 34. In the current embodiment, the outer holes are recessed to protect the heads of the corresponding inserted fasteners 16.

[0019] The top cover 34 further includes a plurality of top inwardly facing protrusions 38, each of which has a top protrusion hole 39 disposed therein. In the current embodiment, the top protrusion 38 extends between a pair of lobes 28 and spans the entire width defined between the pair of lobes. In the current embodiment, each protrusion hole 39 is concentric with the lobes holes 30 of the two surrounding lobes 28, respectively. Other embodiments may have fewer protrusions, and the protrusions may not span the entire width between the pair of lobes 28.

[0020] The bottom cover 36 may also have a barrel shape extending across the front side of the core shell 12. In some embodiments, the top cover 34 and the bottom cover 36 may overlap so that the top cover 34 and the bottom cover 36 may be coupled together. In some embodiments, the top cover 34 and the bottom cover 36 may be coupled together by mutual coupling with the core shell 12. In some embodiments, the top cover 34 and the bottom cover 36 may be coupled together by overlapping fasteners 16. In still other embodiments, the top cover 34 and the bottom cover 36 may be coupled together by the opposing forces of opposing fasteners 16 inserted into both the top cover 34 and the bottom cover 36.

[0021] Returning to the bottom cover 36, the bottom cover 36 may also include a plurality of bottom outer holes 37. In the current embodiment, the bottom outer holes 37 are recessed to protect the heads of the corresponding inserted fasteners 16. The bottom cover 36 further includes a plurality of bottom inwardly facing protrusions 41, each of which has a bottom protrusion hole 44 disposed therein. In the current embodiment, two bottom protrusions 41 each extend between a pair of bottom lobes 28. In the current embodiment, each of the bottom protrusions 41 is adjacent to its corresponding bottom lobes 28, so that the space between the bottom protrusions 41 plus the width of the protrusion constitutes the entire space between the two lobes 28. The bottom protrusion holes 44 of the current embodiment are also concentric with the lobes holes 30 of the two surrounding lobes 28, respectively. The configuration of the bottom lobes 28 and the bottom protrusion holes 44 may also be reflected in the top protrusions 38 and the top lobes 28. In the illustrated embodiment, the fastener 16 is inserted through the hole defined by the corresponding alignment of the concentric lobes holes 30 and the protrusion holes 39, 44.

[0022] Additionally, in the illustrated embodiment, the width of the gap between the lobes 28 is similar between the protrusions 38 of the top and bottom caps 34, 36. Other embodiments may not span the entire width between a pair of lobes 28. The width between the lobes 28 may also be different between different pairs of lobes 28. In still other embodiments, the bottom protrusions 41 may be aligned with the top protrusions 38.

[0023] Continue to refer Figure 3 , the bottom cover 36 covers most of the core shell, and the top cover 34 covers a small part of the core shell accordingly. Both the top cover 34 and the bottom cover 36 include an interface for nesting the top cover 34 in the bottom cover 36. Other embodiments may involve nesting the bottom cover 36 in the top cover 34 or connecting the top cover 34 and the bottom cover 36 using a defined interface.

[0024] Both the top cover 34 and the bottom cover 36 of the outer shell 14 include a plurality of protrusions 38, 41 extending from the outer shell 14 toward the core shell 12, such that at least one protrusion 38, 41 fits between a pair of lobes 28. The protrusions 38, 41 include protrusion holes 44 defined therein that align with the lobes holes 30 of the core shell 12. In the current embodiment, inserting the protrusions 38 between the pair of lobes 28 allows the core shell 14 to be fixed relative to the protrusion holes 44. In some embodiments, the protrusions 38 of the top cover 34 are integrally formed with the top cover 34 as a unitary piece. In some embodiments, the protrusions 41 of the bottom cover 36 are integrally formed with the bottom cover 36 as a unitary piece.

[0025] In the current embodiment, the contact between the lobes 28 and the protrusions 38 of the outer shell 14 is combined with the fasteners 16 to prevent the core shell from moving. There are eight fasteners 16 per group consisting of the upper outer shell protrusions 38 and lobes 28; four are disposed in the top outer holes 35 and four are disposed in the bottom outer shell holes. In other cases, only the connection between the fasteners 16, the lobes holes 30 and the protrusion holes 44 is used to secure the core shell 12 within the shell 14. The fasteners 16 extend through the surface 46 of the outer shell, the lobes 28 and the protrusions of the core shell 12. In some embodiments, the fasteners 16 can extend beyond the lobes holes 30 and the protrusion holes 44.

[0026] In some embodiments, the space between a pair of lobes 28 may not be filled by a single protrusion 38. Instead, a group of multiple protrusions 38 may occupy a portion of the available space. In yet another embodiment, the lobes 28 may extend between the surface 46 of the outer shell and the protrusions 38.

[0027] refer to Figure 4 , the lobes 28 can also define the outermost surface 50 to which the top cover 34 and the bottom cover 36 can be mounted, respectively, thereby allowing the core housing 12 to be aligned within the outer housing 14 without the fasteners 16. The interface will not have to be a press fit, because the fasteners 16 can still be used to secure the interface in place. In this embodiment, the core housing 12 has a set of upper lobes 28 and a set of lower lobes. Both are partially enclosed below the release button 22.

[0028] Reference Figure 5 , the bottom cover 36 includes a rectangular base 38, a stem 40 integrally formed as a single piece on the side of the base 38 facing the cavity, and at least one band 42 molded to the base on the opposite side of the stem 40. In other words, the stem 40 is molded on the inner surface of the base 38, opposite the band 42 molded on the outer surface of the base 38. The band 42 further includes a plurality of protrusions 44 extending into the side of the base 38 facing the cavity. The band 42 and the stem 40 are physically connected within the base 38 and are each made of a different material than the base 38. The band 42 and the stem 40 can serve as an interface for contacting and aligning the core shell 12 supported within the bottom cover 36.

Claims

1. A battery pack comprising: a core housing defining an interior cavity for receiving a plurality of battery cells, the core housing including at least two lobes, each lobed protruding outwardly away from the interior cavity; an outer shell surrounding the core shell and mounted to the core shell, the outer shell including an inwardly facing protrusion disposed between the two lobes; as well as A fastener extends through the two lobes and the inwardly facing protrusion.

2. The battery pack according to claim 1, wherein: Each lobe of the core housing defines a hole that receives the fastener therethrough.

3. The battery pack according to claim 2, wherein: The outer shell defines a hole that receives the fastener therethrough.

4. The battery pack according to claim 3, wherein: The hole defined in the outer housing is concentric with the holes of the two lobes.

5. The battery pack according to claim 1, wherein: The outer housing further includes another inwardly facing protrusion disposed between the two lobes.

6. The battery pack according to claim 1, wherein: The outer housing further includes a guide rail configured to mount the battery pack to an electric device.

7. The battery pack according to claim 6, wherein: The fastener extends parallel to the guide rail.

8. The battery pack according to claim 1, wherein: The outer shell includes a top cover and a bottom cover coupled together.

9. The battery pack according to claim 8, wherein: The top cover of the outer shell partially extends across one side of the core shell.

10. A battery pack comprising: a core housing defining an interior cavity for receiving a plurality of battery cells, the core housing including a lobed corner projecting outwardly away from the interior cavity, the lobed corner including an aperture defined therein; an outer shell surrounding the core shell and mounted to the core shell, the outer shell comprising: an inwardly facing protrusion including an aperture defined therein, the aperture of the protrusion being aligned with the aperture of the lobe, and A guide rail for mounting the battery pack to an electric device; as well as A fastener extends through the hole of the protrusion and the hole of the horn in a direction along the guide rail.

11. The battery pack according to claim 10, wherein: The core housing includes a plurality of lobes protruding away from the interior cavity.

12. The battery pack according to claim 10, wherein: The outer shell further includes an additional inwardly facing protrusion including an aperture defined therein that is aligned with the aperture of the lobe.

13. The battery pack according to claim 10, wherein: The core housing further includes a second convex corner protruding outwardly away from the interior cavity, and The outer housing further includes another inwardly facing protrusion disposed between the lobe and the second lobe.

14. The battery pack according to claim 10, wherein: The lobe is formed as an integral piece of the core housing.

15. The battery pack according to claim 14, wherein: The inwardly facing projection is formed as an integral piece of the outer housing.

16. The battery pack according to claim 10, wherein: The outer shell includes a top cover, The top cover includes the inwardly facing protrusion, the inwardly facing protrusion is a top inwardly facing protrusion, and The lobe is the top lobe of the core shell.

17. The battery pack according to claim 16, wherein: The outer shell further includes a bottom cover, The bottom cover includes a bottom inwardly facing protrusion including a bottom aperture defined therein, and The core housing further includes a bottom lobe protruding outwardly away from the interior cavity, the bottom lobe including a bottom hole defined therein.

18. The battery pack according to claim 17, wherein: The bottom cover extends across most of the height of the core housing.

19. The battery pack according to claim 18, wherein: The fastener extends transversely to the height of the core housing.

20. A battery pack comprising: an outer shell defining a base having an outer surface and an inner surface, the outer shell comprising a first material; a band molded into the outer surface of the base, the band including a plurality of protrusions formed on the inner surface; as well as a rod formed to an inner surface of the base, the rod being integrally formed with the band; Wherein, the belt and the rod comprise a second material, the second material being different from the first material.

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