Battery pack with heat dissipation component

Abstract

A battery pack can include a housing made of a first material having a first thermal conductivity, defining a cavity, and an interface configured to couple to a power tool. The battery pack can include a cell pod frame supported within the cavity of the housing, the cell pod frame including a cell pod core including a plurality of apertures for securing a plurality of battery cells, a first cell pod end frame disposed adjacent the cell pod core, the first cell pod end frame surrounding a first portion of the battery cells, and a second cell pod end frame disposed adjacent the cell pod core, opposite the first cell pod end frame, the second cell pod end frame surrounding a second portion of the battery cells, wherein the first cell pod end frame and the second cell pod end frame are made of a second material having a second thermal conductivity greater than the first thermal conductivity.

Description

TECHNICAL FIELD

[0001] The present utility model relates to a battery pack, which includes a battery pack for a power tool. BACKGROUND

[0002] Battery packs typically generate heat during use and during charging. As the demand for battery packs continues to increase (to provide greater power and performance, or faster charging times), there is a need for battery packs with improved heat dissipation capabilities. SUMMARY

[0003] In some aspects, the technology described in the present utility model relates to a battery pack, comprising: a housing made of a first material having a first thermal conductivity, the housing defining a cavity and an interface configured to couple to a power tool; and a cell bay frame supported within the cavity of the housing, the cell bay frame including a cell bay core comprising a plurality of apertures for securing a plurality of battery cells, a first cell bay end frame disposed adjacent the cell bay core, the first cell bay end frame surrounding a first portion of the battery cells, and a second cell bay end frame disposed adjacent the cell bay core opposite the first cell bay end frame, the second cell bay end frame surrounding a second portion of the battery cells; wherein the first and second cell bay end frames are made of a second material having a second thermal conductivity greater than the first thermal conductivity.

[0004] In some aspects, the technology described in the present utility model relates to a battery pack, wherein the first cell bay end frame surrounds a first end portion of the battery cells, and the second cell bay end frame surrounds a second end portion of the battery cells.

[0005] In some aspects, the technology described in the present utility model relates to a battery pack, wherein the first and second cell bay end frames surround a majority of a surface area of each of the plurality of battery cells.

[0006] In some aspects, the technology described in the present utility model relates to a battery pack, further comprising a plurality of conductive straps coupled to the battery cells.

[0007] In some aspects, the technology described in the present utility model relates to a battery pack, wherein the first and second cell bay end frames each include an end plate having a through hole to expose the conductive straps.

[0008] In some aspects, the technology described in the present utility model relates to a battery pack, wherein the conductive straps are molded in the first or second cell bay end frame, or the conductive straps are positioned between the battery cells and the end plate.

[0009] In some aspects, the technology described in this document relates to a battery pack, wherein the second thermal conductivity is equal to or greater than 2.0 Watts per meter Kelvin.

[0010] In some aspects, the technology described in this document relates to a battery pack, wherein the first monomer bin end frame and the second monomer bin end frame each have a Shore A hardness that is greater than or equal to 40 and less than or equal to 70.

[0011] In some aspects, the technology described in this document relates to a battery pack, wherein the first monomer bin end frame and the second monomer bin end frame each have a hardness that is greater than a hardness of a monomer bin core to which the interface is secured.

[0012] In some aspects, the technology described in this document relates to a battery pack, wherein the first monomer bin end frame includes a first plurality of fins spanning a perimeter of the first monomer bin end frame, and wherein the second monomer bin end frame includes a second plurality of fins spanning a perimeter of the second monomer bin end frame.

[0013] In some aspects, the technology described in this document relates to a battery pack, wherein the housing includes a plurality of vents disposed adjacent to the first plurality of fins and the second plurality of fins.

[0014] In some aspects, the technology described in this document relates to a battery pack, wherein the second thermal conductivity is at least twice the first thermal conductivity.

[0015] In some aspects, the technology described in this document relates to a battery pack, wherein the housing further includes an upper portion defining the interface, a lower portion opposite the upper portion, a first side portion disposed between the upper portion and the lower portion, and a second side portion disposed between the upper portion and the lower portion, the second side portion positioned opposite the first side portion, wherein the upper portion, the lower portion, the first side portion, and the second side portion cooperate with one another to form the cavity.

[0016] In some aspects, the technology described in this document relates to a battery pack, wherein the upper portion is coupled to the first side portion by a first fastener, and the first side portion is coupled to the lower portion by a second fastener.

[0017] In some aspects, the technology described in this document relates to a battery pack, wherein each of the upper portion, the lower portion, the first side portion, and the second side portion includes at least one aperture for receiving a fastener in a direction parallel to a longitudinal axis of the battery monomer.

[0018] In some aspects, the technology described in this document relates to a battery pack, wherein the housing includes a top housing and a bottom housing, the bottom housing forming the cavity.

[0019] In some aspects, the technology recited in the present utility model relates to a battery pack, comprising: a housing and a cell pod frame, the housing comprising an upper portion defining an interface configured to couple to a power tool, a lower portion opposite the upper portion, a first side portion disposed between the upper portion and the lower portion, and a second side portion disposed between the upper portion and the lower portion, the second side portion positioned opposite the first side portion; the cell pod frame supported within a cavity of the housing, the cell pod frame comprising a cell pod core, a first cell pod end frame, and a second cell pod end frame, the cell pod core comprising a plurality of apertures for securing a plurality of battery cells, the first cell pod end frame disposed adjacent the cell pod core, the first cell pod end frame surrounding a first portion of the battery cells, the second cell pod end frame disposed adjacent the cell pod core opposite the first cell pod end frame, the second cell pod end frame surrounding a second portion of the battery cells.

[0020] In some aspects, the technology recited in the present utility model relates to a battery pack, comprising: a housing and a cell pod frame, the housing defining a plurality of vents, the cell pod frame supported within the housing, the cell pod frame comprising a cell pod core, a cell pod end frame, the cell pod core comprising a plurality of apertures to secure a plurality of battery cells, the cell pod end frame disposed adjacent the cell pod core, the first cell pod end frame surrounding a first portion of the battery cells and defining a first plurality of fins spanning a perimeter of the first cell pod end frame.

[0021] In some aspects, the technology recited in the present utility model relates to a battery pack, wherein the plurality of vents are disposed adjacent the first plurality of fins, which causes heat to dissipate from the fins through the vents.

[0022] In some aspects, the technology recited in the present utility model relates to a battery pack, further comprising a plurality of conductive straps coupled to the battery cells, wherein the conductive straps are disposed between the battery cells and the cell pod end frame.

[0023] In some aspects, the technology recited in the present utility model relates to a battery pack, wherein the cell pod end frame defines a plurality of openings disposed adjacent the plurality of battery cells.

[0024] In some aspects, the technology recited in the present utility model relates to a battery pack, wherein the cell pod end frame is made of a material having a thermal conductivity equal to or greater than 2.0 Watts per meter Kelvin.

[0025] Other aspects will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 is a perspective view of a battery pack according to some configurations.

[0027] Figure 2It is based on some structure Figure 1 An exploded view of the battery pack.

[0028] Figure 3 It is based on some structural lines Figure 1 The side view section is taken from line 3-3 in the figure.

[0029] Figure 4 It is based on some structure Figure 1 A 3D view of the cell frame of the battery pack.

[0030] Figure 5 It is based on some structure Figure 4 An exploded view of the single-unit warehouse frame.

[0031] Figure 6 It is based on some structure Figure 4 A three-dimensional view of the end frame of the single-unit compartment. Detailed Implementation

[0032] Before explaining any independent construction of this invention in detail, it should be understood that the invention, in its application, is not limited to the details of the construction and arrangement of the components described in the following description or shown in the drawings. This invention can have other independent constructions and can be practiced or implemented in various ways.

[0033] Figure 1 and Figure 2 A battery pack 100 including a housing 104 is shown, the housing 104 being configured to protect electrical components stored within the battery pack from liquid ingress and physical damage. The housing 104 may be made of plastic. In some configurations, the housing 104 may have a thermal conductivity of approximately 1.1 w / mK (e.g., 0.9, 1.0, 1.1, 1.25, etc.). The housing 104 includes an upper portion 106, a lower portion 108, and opposing sides 110, 112. In the illustrated configuration, the upper portion 106 and the lower portion 108 are coupled to the two sides 110, 112 using fasteners (not shown). Figure 2As best shown, each of the upper portion 106, lower portion 108, and side portions 110, 112 can include at least one hole 114 for receiving a fastener. The respective holes 114 can be aligned such that a fastener extends through the respective holes 114 of the side portions 110, 112 and into the holes 114 of the upper portion 106 and lower portion 108, respectively. For example, during assembly, the upper portion 106 and side portion 112 can be aligned such that the axis Al is aligned with the axis A2. A fastener can then be passed through the respective holes 114 of the side portion 112 and upper portion 106, thereby coupling the upper portion 106 and side portion 112. Similarly, the lower portion 108 and side portion 112 can be aligned such that the axis Bl is aligned with the axis B2. A fastener can then be passed through the respective holes 114 of the side portion 112 and lower portion 108, thereby coupling the lower portion 108 and side portion 112.

[0034] In the illustrated embodiment, the axes Al, Bl are perpendicular to a longitudinal axis of the battery pack 100 and extend from one side portion 112 toward the other side portion 110. In other words, the fasteners are received by the housing 104 in a direction parallel to the longitudinal axis of the battery cells. In other configurations, the axes Al, Bl extend from one of the upper portions 106 to the lower portion 108 or from the lower portion 108 to the upper portion 108. In some configurations, the upper portions 106 and lower portion 108 can additionally or alternatively be snap-fit to one another. Each of the upper portions 106, lower portion 108, and side portions 110, 112 mate with one another to form a cavity 116 within the outer housing 104.

[0035] The upper portion 106 of the battery pack 100 additionally includes a tool interface 120 that is mechanically and electrically couplable to a power tool or another electrical device. The tool interface 120 is shaped and dimensioned to fit within an opening or receptacle in a corresponding electrical device and includes a plurality of terminals 124 and latches 128. The terminals 124 are in mechanical contact and electrically coupled with corresponding terminals of the electrical device. The latches 128 are coupled to corresponding buttons 132 to operably couple the tool interface 120 to the corresponding electrical device. More specifically, the latches 128 engage corresponding recesses formed in the electrical device to secure the battery pack 100 in place. Due to the resiliency of the material of the latches 128, the latches 128 are normally biased in an outward position (i.e., away from the tool interface 120). Engagement (e.g., depression) of the buttons 132 moves the latches 128 inward toward the tool interface 120 and partially into the tool interface 120 and out of engagement with the recesses, which allows the battery pack 100 to be pulled out of the receptacle and away from the electrical device. In some configurations, a single latch 128 and / or button 132 is included in the battery pack 100. In the illustrated implementation, two latches and buttons (only one pair is shown) are provided on opposite sides of the battery pack 100.

[0036] Referring toFigures 3-5 The battery pack 100 further includes a cell pod frame 136 and a printed circuit board 140 (“PCB”) supported within the cavity 116 of the outer housing 104. The PCB 140 is electrically coupled to the terminals 124 of the tool interface 120 and regulates power transmitted to and from the battery pack 100. The cell pod frame 136 defines a cell pod core 144 and a plurality of cell pod end frames 148 disposed on opposite ends of the cell pod core 144. As best shown in Figure 5 The cell pod core 144 includes a plurality of holes 152 for receiving and supporting a corresponding plurality of battery cells 150. In other words, the battery cells 150 are secured within the holes 152 of the cell pod core 144. In some constructions, the battery cells 150 are cylindrical and define a cell pod housing and opposite cell pod end caps. In other constructions, other types of batteries can be implemented (e.g., pouch cells, square cells, etc.). In some constructions, the cell pod core 144 can be formed of a rubber or plastic material. In some constructions, an adhesive or gasket material can be incorporated within the holes 152 to prevent the battery cells 150 from moving within the holes 152 and to reduce vibrations transmitted between the cell pod frame 136 and the battery cells 150.

[0037] The battery cells 150 provide run power (e.g., DC power) to the hand-held power tool through the terminals 124. The battery cells 150 can be arranged in series, in parallel, or in a series-parallel combination. In the illustrated construction, the cell pod core 144 supports ten battery cells 150. In some constructions, the battery pack 100 can include a different number of battery cells 150 that can be connected in series, in parallel, or in a series-parallel combination to produce a desired combination of nominal battery pack voltage and battery capacity. The illustrated battery cells 150 are cylindrical battery cells. The battery cells 150 can have different sizes or shapes depending on their power capacity. For example, the battery cells can be 14500 battery cells (14 mm diameter and 50 mm length), 17500 battery cells (17 mm diameter and 50 mm length), 18500 battery cells (18 mm diameter and 50 mm length), 26700 battery cells (26 mm diameter and 70 mm length), or other battery cells. The battery cells 150 are lithium-based battery cells having a chemistry of, for example, lithium cobalt (“Li-Co”), lithium manganese (“Li-Mn”), or Li-Mn spinel. The battery cells 150 have other suitable lithium or lithium-based chemistries, such as lithium-based chemistries including manganese.

[0038] Continuing to refer to Figure 4 and Figure 5The battery pack 100 further includes a plurality of conductive straps 156 coupled (e.g., welded, soldered, etc.) to the battery cells 150 and the plurality of busbars 160. The conductive straps 156 are electrically and communicatively connected to the PCB 140, which enables the battery cells 150 to provide power to the terminals 124. The busbars 160 are disposed adjacent to the cell pod core 144 and interconnect the battery cells to each other and couple the battery cells 150 to the PCB 140 and the terminals 124 through the conductive straps 156. The busbars can be made of metal. The busbars 160 can connect the battery cells in series, in parallel, or a combination thereof. The PCB 140 can control the power transmitted between the battery cells and the terminals 124 of the tool interface 120. In the illustrated configuration, each busbar 160 is integrally formed as a single piece. In other configurations, the busbars can be formed using a plurality of components coupled together. In other configurations, the busbars are incorporated within the cell pod end frame 148.

[0039] Referring to Figures 5-6 The cell pod end frame 148 is configured to contact and partially surround portions of the battery cells 150. The cell pod end frame 148 absorbs heat from the battery cells 150. In some configurations, the cell pod end frame 148 surrounds at least half (i.e., a majority) of the surface area of the battery cells 150. In the illustrated configuration, two cell pod end frames 148 are placed on top of the conductive straps 156 on opposite ends of the battery cells 150. Thus, the cell pod end frame 148 can also contact and partially surround portions of the conductive straps 156. In some implementations, the conductive straps 156 can be insert molded with the cell pod end frame 148. In such implementations, the conductive straps 156 can first be insert molded to the cell pod end frame 148 and then subsequently coupled to the battery cells 150 (e.g., by welding, by wire or strap bonding, or any other suitable manner). The cell pod end frame 148 is formed of a material having a high thermal conductivity and such that the cell pod end frame 148 can act as a heat sink for the battery cells 150. For example, the cell pod end frame 148 can have a thermal conductivity equal to or greater than 2.0 Watts per meter Kelvin (w / mK), including 2.5 w / mK and / or 3.0 w / mK. In some configurations, the material of the cell pod end frame 148 can have a thermal conductivity that is more than twice that of the material of the outer housing 104. The cell pod end frame can have a Shore A hardness greater than or equal to 40 (e.g., 50, 60, 70, between 40-70, 80, etc.). The cell pod end frame 148 can be made of metal, plastic or polymer, graphene, or another material that is sufficiently thermally conductive.

[0040] The monobloc end frame 148 can include a cap portion 164 for contacting the monobloc end cap and the conductive strap 156, and a plurality of fins 168 spanning the perimeter of each monobloc end frame 148 Figure 6 . The fins 168 dissipate heat from the battery monoblocs by increasing the available surface area for transferring heat between the monobloc end frame 148 and the environment. Additionally, in some configurations, the outer housing 104 can include a plurality of vents 172 Figure 1 adjacent the fins 168 for heat to escape from the cavity 116. The monobloc end frame 148 can partially protect the battery monoblocs 150 from liquids or particulates received through the vents 172. The monobloc end frame 148 can also include an opening 176 disposed adjacent the monobloc end cap of the battery monoblocs 150. In other words, the monobloc end cap can be exposed to the outer housing 104 through the opening 176. In some configurations, the opening 176 provides an exit for the conductive strap 156 to displace and disconnect from the battery monoblocs 150. The opening 176 can also provide a flow path for hot gases or monobloc ejecta during a thermal runaway event. It will be appreciated that the opening can correspondingly protect the battery monoblocs 150 during a thermal runaway event by cutting off current from a failing battery and by providing an exit for hot materials to flow out of the battery monoblocs.

[0041] In some configurations, the cap portion 164 can be formed by a separately formed monobloc end plate (not shown) coupled to the end of each monobloc end frame 148. The monobloc end plate can be coupled to the monobloc end frame 148 using fasteners, snaps, adhesive, or another coupling method. The monobloc end plate can further include a through hole adjacent the opening 176, which allows the conductive strap 156 to be exposed. In some configurations, the monobloc end plate can additionally include fins extending adjacent the fins 168. Additionally or alternatively, the monobloc end plate can include fins extending away from the battery monoblocs 150 along the monobloc end plate 180 in a direction parallel to the longitudinal axis of the battery monoblocs 150.

[0042] While the application has been described with reference to certain preferred aspects, modifications and alterations to the one or more independent aspects of the application described herein are still possible. Various features and advantages of the application are set forth in the claims that follow.

Claims

1. A battery pack, characterized in that, include: A housing made of a first material having a first thermal conductivity, the housing defining a cavity and an interface configured to be coupled to a power-consuming device; and A single-unit compartment frame, which is supported within the cavity of the housing, the single-unit compartment frame comprising... The core of a single-cell compartment includes a plurality of holes to support a plurality of battery cells. A first single-cell end frame, disposed adjacent to the single-cell core, surrounds a first portion of the battery cell, and... The second single-cell end frame is arranged adjacent to the single-cell core and opposite to the first single-cell end frame, and surrounds the second part of the battery cell; The first and second single-unit end frames are made of a second material having a second thermal conductivity greater than the first thermal conductivity.

2. The battery pack according to claim 1, characterized in that, The first cell end frame surrounds the first end of the battery cell, and the second cell end frame surrounds the second end of the battery cell.

3. The battery pack according to claim 2, characterized in that, The first and second cell end frames surround a large portion of the surface area of ​​each of the plurality of cell units.

4. The battery pack according to claim 1, characterized in that, It further includes a plurality of conductive strips coupled to the battery cell.

5. The battery pack according to claim 4, characterized in that, The first and second individual compartment end frames each include an end plate having through holes to expose the conductive strip.

6. The battery pack according to claim 5, characterized in that, The conductive strip is molded in the end frame of the first or second cell compartment, or the conductive strip is positioned between the cell and the end plate.

7. The battery pack according to claim 1, characterized in that, The second thermal conductivity is equal to or greater than 2.0 watts / meter Kelvin.

8. The battery pack according to claim 1, characterized in that, The first and second single-unit end frames each have a Shore A hardness of 40 or greater and 70 or less.

9. The battery pack according to claim 1, characterized in that, The first and second single-unit end frames each have a hardness greater than that of the single-unit core, and the interface is fixed to the single-unit core.

10. The battery pack according to claim 1, characterized in that, The first single-unit end frame includes a first plurality of fins spanning the periphery of the first single-unit end frame, and wherein the second single-unit end frame includes a second plurality of fins spanning the periphery of the second single-unit end frame.

11. The battery pack according to claim 10, characterized in that, The housing includes a plurality of vents disposed adjacent to the first plurality of fins and the second plurality of fins.

12. The battery pack according to claim 1, characterized in that, The second thermal conductivity is at least twice that of the first thermal conductivity.

13. The battery pack according to claim 1, characterized in that, The housing further includes: The upper part, which defines the interface, The lower part is opposite to the upper part. A first side portion, the first side portion being disposed between the upper portion and the lower portion, and A second side portion, disposed between the upper portion and the lower portion, is positioned opposite to the first side portion. The upper part, the lower part, the first side part, and the second side part cooperate with each other to form the cavity.

14. The battery pack according to claim 13, characterized in that, The upper part is coupled to the first side part by a first fastener, and the first side part is coupled to the lower part by a second fastener.

15. The battery pack according to claim 13, characterized in that, Each of the upper portion, the lower portion, the first side portion, and the second side portion includes at least one hole for receiving a fastener along a direction parallel to the longitudinal axis of the battery cell.

16. The battery pack according to claim 1, characterized in that, The housing includes a top housing and a bottom housing, with the bottom housing forming the cavity.

17. A battery pack, characterized in that, include: A housing defining a plurality of ventilation openings; and A single-unit compartment frame, supported within the housing, the single-unit compartment frame comprising... The single-cell core includes a plurality of holes for fixing a plurality of battery cells. A single-cell end frame is disposed adjacent to the single-cell core, the single-cell end frame surrounds a first portion of the battery cell and defines a first plurality of fins spanning the periphery of the single-cell end frame.

18. The battery pack according to claim 17, characterized in that, The plurality of vents are arranged adjacent to the first plurality of fins, which allows heat to dissipate from the fins through the vents.

19. The battery pack according to claim 17, characterized in that, It further includes a plurality of conductive strips coupled to the battery cell, wherein the conductive strips are disposed between the battery cell and the cell end frame.

20. The battery pack according to claim 19, characterized in that, The end frame of the individual cell defines a plurality of openings disposed adjacent to the plurality of individual cells.

21. The battery pack according to claim 17, characterized in that, The end frame of the single-unit compartment is made of a material with a thermal conductivity equal to or greater than 2.0 watts / meter Kelvin.

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