Battery pack

Abstract

To solve problems with the prior art.SOLUTION: A battery pack assembly includes a housing, a battery cell assembly, and a fan. The housing has a plurality of sides and defines an internal cavity. The battery cell assembly is disposed in the internal cavity. The battery cell assembly includes a plurality of battery cells and a frame supporting the battery cells. The frame includes a first support member, a second support member, and a plurality of leg members connecting the first support member and the second support member. The first support member and the second support member each have a body extending between a first edge and a second edge opposite the first edge. The body defines a plurality of openings configured to align with one of the battery cells. The fan is configured to circulate air within the housing and through the battery cell assembly.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (See related application). This application claims priority to co-pending U.S. Provisional Patent Application No. 63 / 194,614, filed May 28, 2021, and claims foreign priority to co-pending Chinese Patent Application No. 202110252873.1, filed March 8, 2021, and co-pending Chinese Patent Application No. 202011411151.8, filed December 4, 2020, the entire contents of all of which are incorporated herein by reference.

[0002] (Technical field) The present invention relates to sealed battery packs, and more particularly to the internal structure of the battery pack configured to facilitate thermal cooling within the sealed housing. [Background technology]

[0003] Generally, electrical equipment such as power tools may be powered by a rechargeable battery pack, which may be charged in a corresponding battery charger. Summary of the Invention [Means for solving the problem]

[0004] In one aspect disclosed herein, a battery pack assembly is provided, comprising a housing, a battery cell assembly, and a fan. The housing has multiple sides and defines an internal cavity. The battery cell assembly is disposed in the internal cavity. The battery cell assembly comprises multiple battery cells and a frame supporting the battery cells. The frame comprises a first support member, a second support member, and multiple leg members connecting the first support member and the second support member. The first support member and the second support member each have a body extending between a first edge and a second edge opposite the first edge. The body defines multiple openings configured to align with one of the battery cells. The fan is configured to circulate air within the housing and through the battery cell assembly.

[0005] In some embodiments, the battery pack assembly further comprises a heat sink integrated with the housing.

[0006] In some embodiments, the battery pack assembly further comprises a plurality of baffles disposed within the interior cavity.

[0007] In some embodiments, each of the baffles is positioned to direct airflow toward the battery cell assemblies.

[0008] In some embodiments, the battery pack assembly is configured as a high-power battery pack that is connectable to and operable to power a variety of motorized power tools.

[0009] In some embodiments, the battery cell assembly is positioned within the interior cavity such that each of the battery cells is oriented relative to the longitudinal axis of the housing.

[0010] In some embodiments, each of the battery cells is connected by a wire to a connector located adjacent to the corresponding battery cell.

[0011] In some embodiments, the connector is a conductive plate and is directly coupled to at least two of the battery cells.

[0012] In some embodiments, the connector is disposed on a side of the second support member.

[0013] In some embodiments, the battery pack assembly further comprises a battery terminal contact.

[0014] In some embodiments, the battery cell assemblies are electrically connected to battery terminal contacts within the battery pack assembly.

[0015] In some embodiments, the first support member and the second support member are configured to maintain the position of the battery cell within the interior cavity.

[0016] In some embodiments, a first support member is disposed adjacent to the interior surface of the housing.

[0017] In some embodiments, the first support member is coupled to the interior surface of the housing.

[0018] In some embodiments, the battery pack assembly further comprises battery electronics.

[0019] In some embodiments, the space within the interior cavity not occupied by the battery cell assemblies or battery electronics is divided into one or more airflow channels arranged to surround the battery cell assemblies.

[0020] In some embodiments, the battery pack assembly further comprises an airflow tunnel disposed on the top surface of the housing.

[0021] In some embodiments, the air flow tunnel is in fluid communication with the interior cavity of the housing.

[0022] In some embodiments, the air flow tunnel has a curved shape to receive the air flow and guide the air flow back towards the battery cells.

[0023] In some embodiments, the air flow tunnel comprises a deflector configured to direct a portion of the air circulated by the fan around the battery cell assembly and into gaps between adjacent battery cells disposed within the battery cell assembly.

[0024] In some embodiments, the deflector has an end portion and two guide members.

[0025] In some embodiments, the battery cells are thermally coupled to the air flow tunnels, deflectors, or end portions by a thermally conductive gap filler, adhesive, potting, or sealant to enclose the housing or portions of the housing.

[0026] In some embodiments, a fan is positioned adjacent to the battery cell assembly.

[0027] In some embodiments, the battery cells are disposed in a metal or plastic sleeve.

[0028] In some embodiments, the housing or the portion of the housing surrounding the battery cells is not sealed to allow a fan to exchange air from outside the battery pack assembly.

[0029] In some embodiments, each of the battery cells is equally spaced apart.

[0030] In some embodiments, adjacent columns of battery cells are aligned lengthwise, vertically, and laterally.

[0031] In some embodiments, adjacent columns of battery cells are staggered and offset relative to one another.

[0032] In another aspect disclosed herein, a battery pack assembly is provided that includes a housing, a battery cell assembly, a fan, and an air flow tunnel. The housing defines an interior cavity. The battery cell assembly is disposed in the interior cavity. The battery cell assembly includes a plurality of battery cells and a frame that supports the battery cells. The fan is configured to circulate air within the housing and through the battery cell assembly. The air flow tunnel is disposed on an upper surface of the housing and in fluid communication with the interior cavity of the housing. The air flow tunnel includes a deflector configured to direct a portion of the air circulated by the fan around the battery cell assembly and into gaps between adjacent battery cells disposed within the battery cell assembly.

[0033] In some embodiments, the housing is sealed so that no air is present in the interior cavity.

[0034] In some embodiments, the battery pack assembly further comprises a heat sink integrated with the housing.

[0035] In some embodiments, the battery pack assembly further comprises a plurality of baffles disposed within the interior cavity.

[0036] In some embodiments, each of the baffles is positioned to direct airflow toward the battery cell assemblies.

[0037] In some embodiments, the battery pack assembly is configured as a high-power battery pack that is connectable to and operable to power a variety of motorized power tools.

[0038] In some embodiments, the battery cell assembly is positioned within the interior cavity such that each of the battery cells is oriented relative to the longitudinal axis of the housing.

[0039] In some embodiments, the frame comprises a first support member, a second support member, and a plurality of leg members connecting the first support member and the second support member.

[0040] In some embodiments, the first support member and the second support member each have a body extending between a first edge and a second edge opposite the first edge.

[0041] In some embodiments, the body defines a plurality of openings configured to align with one of the battery cells.

[0042] In some embodiments, the first support member and the second support member are configured to maintain the position of the battery cell within the interior cavity.

[0043] In some embodiments, a first support member is disposed adjacent to the interior surface of the housing.

[0044] In some embodiments, the first support member is coupled to the interior surface of the housing.

[0045] In some embodiments, each of the battery cells is connected by a wire to a connector located adjacent to the corresponding battery cell.

[0046] In some embodiments, the connector is a conductive plate and is directly coupled to at least two of the battery cells.

[0047] In some embodiments, the connector is disposed on a side of the second support member.

[0048] In some embodiments, the battery pack assembly further comprises a battery terminal contact.

[0049] In some embodiments, the battery cell assemblies are electrically connected to battery terminal contacts within the battery pack assembly.

[0050] In some embodiments, the battery pack assembly further comprises battery electronics.

[0051] In some embodiments, the space within the interior cavity not occupied by the battery cell assemblies or battery electronics is divided into one or more airflow channels arranged to surround the battery cell assemblies.

[0052] In some embodiments, the air flow tunnel has a curved shape to receive the air flow and guide the air flow back towards the battery cells.

[0053] In some embodiments, the deflector has an end portion and two guide members.

[0054] In some embodiments, the battery cells are thermally coupled to the air flow tunnels, deflectors, or end portions by a thermally conductive gap filler, adhesive, potting, or sealant to enclose the housing or portions of the housing.

[0055] In some embodiments, a fan is positioned adjacent to the battery cell assembly.

[0056] In some embodiments, the battery cells are disposed in a metal or plastic sleeve.

[0057] In some embodiments, the housing or the portion of the housing surrounding the battery cells is not sealed to allow a fan to exchange air from outside the battery pack assembly.

[0058] In some embodiments, each of the battery cells is equally spaced apart.

[0059] In some embodiments, adjacent columns of battery cells are aligned lengthwise, vertically, and laterally.

[0060] In some embodiments, adjacent columns of battery cells are staggered and offset relative to one another.

[0061] In yet another aspect disclosed herein, a battery pack assembly is provided that includes a housing and one or more battery cell assemblies received in the housing. Each of the one or more battery cell assemblies includes a frame at least partially defining an internal cavity therein, a plurality of battery cells disposed in the internal cavity, and a heat sink. The heat sink includes a body having a first surface and a second surface opposite the first surface. The heat sink further includes a plurality of fins extending from the first surface and a plurality of protrusions extending from the second surface. The fins are external to the internal cavity, and the plurality of protrusions are disposed within the internal cavity. The protrusions are disposed between the battery cells such that the battery cells and the protrusions are disposed sequentially in at least one direction within the internal cavity.

[0062] In some embodiments, one or more of the protrusions include a channel extending partially therethrough, and each of the one or more battery cell assemblies further includes a heating rod received in each of the channels.

[0063] In some embodiments, the body of the heat sink comprises a plurality of openings, each opening connected to one of the channels, and a heating rod inserted into the channel through a corresponding opening.

[0064] In some embodiments, each of the openings is disposed between some of the plurality of fins on the first surface of the body of the heat sink.

[0065] In some embodiments, the end of each heating rod is positioned outside of the corresponding aligned channel and opening.

[0066] In some embodiments, each of the one or more battery cell assemblies includes an adhesive material disposed in the interior cavity, the adhesive material contacting the protrusions and the battery cells, and the adhesive material being thermally conductive to facilitate heat transfer between the battery cells and the protrusions.

[0067] In some embodiments, each of the plurality of protrusions extends from the second surface of the body to an end, each of the plurality of protrusions extends parallel to each of the battery cells, and an end of each of the protrusions is positioned adjacent to an end of one of the battery cells.

[0068] In some embodiments, the frame includes a plurality of support members, each of which may be disposed between a battery cell and an adjacent one of the plurality of protrusions, and each of which may be configured to position one of the battery cells and one of the protrusions in the internal cavity.

[0069] In some embodiments, the battery pack assembly includes a fan assembly disposed within the housing proximate to the one or more battery cell assemblies, the fan assembly operable to direct airflow past fins of the one or more battery cell assemblies.

[0070] In some embodiments, the battery pack assembly further comprises a cover coupled to the frame, the frame, the cover, and the second surface of the body of the heat sink may cooperate to define an interior cavity.

[0071] In some embodiments, the battery pack assembly further comprises a plurality of connectors supported by the frame, each of the connectors being connected to two or more of the battery cells.

[0072] In yet another aspect disclosed herein, a battery pack assembly is provided that includes a housing and one or more battery cell assemblies received in the housing. Each of the one or more battery cell assemblies includes a frame at least partially defining an internal cavity therein, a plurality of battery cells disposed in the internal cavity, and a heat sink. The heat sink includes a body having a first surface and a second surface opposite the first surface. The heat sink further includes a plurality of protrusions extending from the second surface. The first surface is external to the internal cavity, and the plurality of protrusions are disposed within the internal cavity. One or more of the protrusions include channels extending partially into the interior. One or more of the battery cell assemblies further includes a plurality of heating rods. Each heating rod is received in one of the channels. The protrusions are disposed between the battery cells such that the battery cells and the protrusions are disposed in sequence within the internal cavity.

[0073] In some embodiments, one or more of the protrusions include a channel extending partially therethrough, and each of the one or more battery cell assemblies further includes a heating rod received in each of the channels.

[0074] In some embodiments, the body of the heat sink comprises a plurality of openings, each opening connected to one of the channels, and a heating rod inserted into the channel through a corresponding opening.

[0075] In some embodiments, each of the one or more battery cell assemblies comprises an adhesive material disposed in the internal cavity, the adhesive material contacting the protrusions and the battery cells, and the adhesive material being thermally conductive to promote heat transfer between the battery cells and the protrusions.

[0076] In some embodiments, each of the plurality of protrusions extends from the second surface of the body to an end, each of the plurality of protrusions extends parallel to each of the battery cells, and an end of each of the protrusions is positioned adjacent to an end of one of the battery cells.

[0077] In some embodiments, the battery pack assembly further comprises a cover coupled to the frame, the frame, the cover, and the second surface of the body of the heat sink may cooperate to define an interior cavity.

[0078] In another aspect disclosed herein, there is provided a battery cell assembly for a battery pack, the battery cell assembly including: a frame at least partially defining an internal cavity therein; a plurality of battery cells disposed in the internal cavity; and a heat sink. The heat sink includes a body having a first surface and a second surface opposite the first surface. The heat sink further includes a plurality of fins extending from the first surface and a plurality of protrusions extending from the second surface. The fins are external to the internal cavity, and the plurality of protrusions are disposed within the internal cavity. One or more of the protrusions include a channel extending partially into the interior. The protrusions are disposed between the battery cells such that the battery cells and the protrusions are disposed in sequence within the internal cavity.

[0079] In some embodiments, the battery cell assembly further comprises one or more heating rods, each of the one or more heating rods received in one of the channels.

[0080] In some embodiments, the battery cell assembly further comprises an adhesive material disposed in the internal cavity, the adhesive material contacting the protrusions and the battery cells, the adhesive material being thermally conductive to facilitate heat transfer between the battery cells and the protrusions.

[0081] In yet another aspect disclosed herein, a battery pack assembly is provided. The battery pack assembly includes a housing having multiple sides and defining an internal cavity, a plurality of battery cells received in the internal cavity, and battery electronics received in the internal cavity. A battery pack interface is supported by the housing and connectable to a device. An injection port is supported by the housing. The injection port includes one or more channels disposed on one or more of the sides of the housing. Each channel connects the internal cavity to an exterior of the battery pack. The injection port is configured to direct a fluid, including an adhesive material, from the exterior of the battery pack into the internal cavity. The fluid is configured to cover at least one of portions of the battery cells and portions of the battery electronics.

[0082] In some embodiments, the housing comprises a top housing portion and a bottom housing portion, the top housing portion comprising the injection port.

[0083] In some embodiments, the bottom housing portion includes a battery cell holder configured to hold a plurality of battery cells within the internal cavity, the battery cell holder including a surface in opposing relationship with the top housing portion, the surface configured to support the battery electronics, and a fluid configured to cover a portion of the surface.

[0084] In some embodiments, the battery electronics include a printed circuit board and battery contacts extending from the printed circuit board, the battery pack interface includes a terminal block surrounding the battery contacts, and the fluid is configured to cover a surface of the printed circuit board.

[0085] In some embodiments, the housing has a longitudinal axis extending therein, and each of the one or more channels of the injection port extends along the injection axis, the injection axis extending at an angle relative to the longitudinal axis.

[0086] In some embodiments, the battery electronics comprises a printed circuit board, with the ends of the one or more channels of the injection port located adjacent to a surface of the printed circuit board.

[0087] In some embodiments, the fluid comprises a thermally conductive silicone sealant.

[0088] In yet another aspect disclosed herein, a method for manufacturing a battery pack assembly is provided, the method including assembling at least a portion of a housing of the battery pack assembly, disposing a plurality of battery cells and battery electronics within an interior cavity of the housing, and injecting a fluid including an adhesive material into the interior cavity through an injection port of the housing such that the fluid covers at least one of portions of the battery cells and portions of the battery electronics.

[0089] In some embodiments, assembling at least a portion of the housing includes providing a battery cell holder, and disposing the plurality of battery cells and battery electronics within the internal cavity includes receiving the plurality of battery cells with the battery cell holder and securing a printed circuit board of the battery electronics to the battery cell holder.

[0090] In some embodiments, injecting the fluid includes covering a surface of the printed circuit board.

[0091] In some embodiments, assembling at least a portion of the housing includes joining a bottom housing portion to an upper housing portion to form an internal cavity, and injecting the fluid includes injecting the fluid through the upper housing portion using an injection port.

[0092] In some embodiments, assembling at least a portion of the housing includes assembling a bottom housing portion, and the method further includes injecting a fluid into the bottom housing portion before joining the top housing portion to the bottom housing portion.

[0093] In some embodiments, the fluid comprises a thermally conductive silicone sealant.

[0094] In yet another aspect disclosed herein, a battery pack assembly is provided. The battery pack assembly includes a housing having multiple sides and defining an internal cavity, a plurality of battery cells received in the internal cavity, and battery electronics received in the internal cavity. A battery pack interface is supported by the housing and connectable to a device. A layer including an adhesive material is disposed within the internal cavity between portions of the battery cells and the battery electronics and multiple inner surfaces of the housing. The layer has a continuous surface covering the portions of the battery cells and the battery electronics. The layer is injectable into the internal cavity as a fluid configured to harden to form the layer.

[0095] In some embodiments, the battery pack assembly further comprises an inlet port configured to direct fluid from the exterior of the battery pack to the interior cavity.

[0096] In some embodiments, the housing comprises a top housing portion and a bottom housing portion, the top housing portion comprising the injection port.

[0097] In some embodiments, the bottom housing portion includes a battery cell holder configured to hold a plurality of battery cells within the internal cavity, the battery cell holder including a surface in opposing relationship with the top housing portion, the surface configured to support the battery electronics, and the layer configured to cover a portion of the surface.

[0098] In some embodiments, the battery electronics comprises a printed circuit board and battery contacts extending from the printed circuit board, the battery pack interface comprises a terminal block surrounding the battery contacts, and the layer is configured to cover a surface of the printed circuit board.

[0099] In some embodiments, the battery electronics comprises a printed circuit board, and the fluid is received in the internal cavity by an inlet port, an end of the inlet port being disposed proximate a surface of the printed circuit board.

[0100] In some embodiments, the layer comprises a thermally conductive silicone encapsulant.

[0101] Other independent aspects of the invention will become apparent upon review of the detailed description and accompanying drawings. Where appropriate and applicable, any feature described herein in connection with one aspect or embodiment may be combined with any other feature described herein in connection with any other aspect or embodiment. [Brief explanation of the drawings]

[0102] [Figure 1] FIG. 2 is a perspective view of a battery pack assembly. [Figure 2] FIG. 2 is a cross-sectional view of the battery pack assembly of FIG. 1. [Figure 3] 2 is another cross-sectional view of the battery pack assembly of FIG. 1 showing multiple battery cell assemblies within a housing of the battery pack assembly. [Figure 4] 4 is a cross-sectional side view of the battery pack assembly of FIG. 1 showing a plurality of battery cell assemblies of FIG. 3 within a housing. [Figure 4A] FIG. 4 is a perspective view of one of the battery cell assemblies of FIG. 3. [Figure 5A] FIG. 10 is a schematic cross-sectional view of another battery pack assembly. [Figure 5B] FIG. 10 is a schematic cross-sectional view of yet another battery pack assembly. [Figure 6] FIG. 10 is a cross-sectional view of yet another battery pack assembly. [Figure 7] FIG. 7 is another cross-sectional view of the battery pack assembly of FIG. 6 showing the location of the printed circuit board. [Figure 8] FIG. 5 is a perspective view of some of the plurality of battery cells of one of the battery cell assemblies of FIG. 4, further including a plurality of deflectors according to a first configuration, one of the deflectors being positioned between two adjacent rows of the plurality of battery cells. [Figure 9] 9 is a schematic diagram of some of the battery cells and fans of FIG. 8. [Figure 10] 5 is a perspective view of some of the battery cells of one of the battery cell assemblies of FIG. 4, further including a plurality of deflectors according to a second configuration. [Figure 11] FIG. 11 is a schematic diagram of some of the battery cells and fans of FIG. 10. [Figure 12A] 12 is another schematic diagram of some of the battery cells and fans of FIG. 11 showing a first direction of airflow through the deflectors. [Figure 12B] 12 is yet another schematic diagram of some of the battery cells and fans of FIG. 11 showing a second direction of airflow through the deflectors. [Figure 12C] 12 is yet another schematic diagram of some of the battery cells and fans of FIG. 11 showing the reciprocating direction of airflow through the deflectors. [Figure 13] 5 is a perspective view of some of the battery cells of one of the battery cell assemblies of FIG. 4, further including a plurality of deflectors according to a third configuration. [Figure 14] FIG. 10 is a perspective view of a portion of another battery pack assembly including multiple battery cell assemblies and multiple fans. [Figure 15] FIG. 15 is a side view of a portion of the battery pack assembly of FIG. 14 excluding the fans. [Figure 16] FIG. 16 is a partial cross-sectional view of the battery pack assembly of FIG. 15. [Figure 17] FIG. 10 is a perspective view of a portion of yet another battery pack assembly including multiple battery cell assemblies and a thermally conductive material disposed in one of the battery cell assemblies. [Figure 18] 18 is a cross-sectional view of a portion of the battery pack assembly of FIG. 17 showing a thermally conductive material disposed in one of the battery cell assemblies of FIG. 17. [Figure 19] FIG. 10 is a perspective view of a multiple battery cell assembly according to another configuration, showing a first position of the printed circuit board. [Figure 20] FIG. 20 is a perspective view of the multiple battery cell assembly of FIG. 19 showing the printed circuit board in a second position. [Figure 21] FIG. 20 is an exploded view of one of the battery cell assemblies of FIG. 19. [Figure 22] 10 is a cross-sectional view of a portion of one of the plurality of battery cell assemblies showing a thermally conductive material disposed in one of the plurality of battery cell assemblies. [Figure 23] 2 is a cross-sectional view of the battery pack assembly of FIG. 1 showing the airflow path within the housing. [Figure 24] FIG. 4 is a schematic diagram of a portion of one of the battery cell assemblies of FIG. 3. [Figure 25] 4 is a schematic diagram of an alternative configuration of one portion of the battery cell assembly of FIG. 3. [Figure 26] FIG. 10 is a perspective view of another battery pack assembly including multiple battery cell assemblies and multiple fans. [Figure 27] FIG. 27 is a cross-sectional view of the battery pack assembly of FIG. 26. [Figure 28] FIG. 27 is another cross-sectional view of the battery pack assembly of FIG. 26. [Figure 29] FIG. 27 is a perspective view of another example of the battery pack assembly of FIG. 26. [Figure 30]FIG. 30 is a perspective cross-sectional view of the battery pack assembly of FIG. 29. [Figure 31] FIG. 27 is a cross-sectional view of yet another example of the battery pack assembly of FIG. 26. [Figure 32] 30 is another cross-sectional view of the battery pack assembly of FIG. 29 illustrating the kinetic energy of the airflow along the airflow path within the housing. [Figure 33] FIG. 10 is a perspective view of yet another battery pack assembly. [Figure 34] FIG. 34 is a perspective cross-sectional view of the battery pack assembly of FIG. 33. [Figure 35] FIG. 34 is a cross-sectional view of the battery pack assembly of FIG. 33. [Figure 36] FIG. 34 is another cross-sectional view of the battery pack assembly of FIG. 33 illustrating the magnitude of the airflow velocity of the airflow along the airflow path within the housing. [Figure 37] FIG. 10 is a perspective view of another battery pack assembly. [Figure 38] 38 illustrates a plurality of battery cell assemblies that can be placed in the housing of the battery pack assembly of FIG. 37. [Figure 39] FIG. 38 is a cross-sectional view of the battery pack assembly of FIG. 37. [Figure 40] FIG. 27 is a cross-sectional view of yet another example of the battery pack assembly of FIG. 26. [Figure 41] FIG. 1 is a perspective view of a system configured to receive one of the battery pack assemblies. [Figure 42] FIG. 2 is a perspective view of a portion of a battery pack assembly showing a plurality of battery cell assemblies of the battery pack assembly. [Figure 43] FIG. 43 is a perspective view of two of the battery cell assemblies and the fan assembly of FIG. 42. [Figure 44] FIG. 44 is a front perspective view of one of the battery cell assemblies of FIG. 43, showing the frame, cover, connectors, and heat sink. [Figure 45] FIG. 45 is a rear perspective view of the battery cell assembly of FIG. 44. [Figure 46] FIG. 45 is an enlarged view of a portion of the battery cell assembly of FIG. 44. [Figure 47] FIG. 46 is a rear view of the battery cell assembly of FIG. 45. [Figure 48] FIG. 45 is a perspective view of the battery cell assembly of FIG. 44 with a portion of the heat sink removed. [Figure 49] FIG. 45 is another perspective view of the battery cell assembly of FIG. 44 with the heat sink portion, cover, and connector removed. [Figure 49A] FIG. 45 is an exploded view of the battery cell assembly of FIG. 44. [Figure 49B] FIG. 49B is an exploded view of a portion of the battery cell assembly of FIG. 49A. [Figure 49C] FIG. 49B is an exploded view of another portion of the battery cell assembly of FIG. 49A. [Figure 49D] FIG. 45 is a perspective view of a frame of the battery cell assembly of FIG. 44. [Figure 49E] FIG. 49E is a perspective view of a portion of the frame of FIG. 49D. [Figure 50] FIG. 45 is a rear perspective view of the battery cell assembly of FIG. 44 with the cover, heat sink, and connector removed, including the frame. [Figure 51] FIG. 45 is an enlarged rear view of a portion of the battery cell assembly of FIG. 44 with the frame and heat sink removed. [Figure 52] FIG. 45 is a perspective view of the battery cell assembly of FIG. 44 with the cover and connector removed. [Figure 53] FIG. 53 is an enlarged view of a portion of the battery cell assembly of FIG. 52. [Figure 54] FIG. 53 is an enlarged front view of a portion of the battery cell assembly of FIG. 52. [Figure 55] FIG. 53 is a cross-sectional view of the battery cell assembly of FIG. 52 showing the heating rod. [Figure 56] FIG. 45 is a front perspective view of a heat sink of the battery cell assembly of FIG. [Figure 57]FIG. 57 is a rear perspective view of the heat sink of FIG. 56. [Figure 58] FIG. 57 is another front perspective view of the portion of the heat sink of FIG. 56. [Figure 59] FIG. 57 is a rear perspective view of the heat sink and the plurality of battery cells of FIG. 56. [Figure 60] FIG. 56 is a perspective view of the heating rod of FIG. 55. [Figure 61] FIG. 53 is an enlarged front view of a portion of the battery cell assembly of FIG. 52, further including an adhesive material disposed within the battery cell assembly. [Figure 62] 45 is another example of the battery cell assembly of FIG. 44. [Figure 63] 43 is another example of a battery pack of the battery pack assembly of FIG. 42. [Figure 64] 43 is yet another example of a battery pack of the battery pack assembly of FIG. 42. [Figure 65] FIG. 2 is a perspective view of a battery pack assembly. [Figure 66] FIG. 66 is a top view of the battery pack assembly of FIG. 65. [Figure 67] FIG. 66 is a side view of the battery pack assembly of FIG. [Figure 68] FIG. 66 is an exploded view of the battery pack assembly of FIG. [Figure 69] FIG. 66 is a bottom perspective view of the upper housing portion of the battery pack assembly of FIG. 65. [Figure 70] FIG. 66 is a cross-sectional view of the battery pack assembly of FIG. 65. [Figure 71] FIG. 66 is another cross-sectional view of the battery pack assembly of FIG. 65. [Figure 72] FIG. 2 is a top perspective view of the lower housing portion of the battery pack assembly. [Figure 73A] 66A-66C are a series of diagrams illustrating a manufacturing process for the battery pack assembly of FIG. 65. [Figure 73B] 66A-66C are a series of diagrams illustrating a manufacturing process for the battery pack assembly of FIG. 65. [Figure 73C]66A-66C are a series of diagrams illustrating a manufacturing process for the battery pack assembly of FIG. 65. [Figure 73D] 66A-66C are a series of diagrams illustrating a manufacturing process for the battery pack assembly of FIG. 65. [Figure 73E] 66A-66C are a series of diagrams illustrating a manufacturing process for the battery pack assembly of FIG. 65. [Figure 73F] 66A-66C are a series of diagrams illustrating a manufacturing process for the battery pack assembly of FIG. 65. [Figure 73G] In another example of a manufacturing process for the battery pack assembly of FIG. 65, adhesive material is shown disposed within the battery pack. [Figure 73H] In another example of a manufacturing process for the battery pack assembly of FIG. 65, adhesive material is shown disposed within the battery pack. [Figure 74] FIG. 66 is another example of a battery pack of the battery pack assembly of FIG. 65. DETAILED DESCRIPTION OF THE INVENTION

[0103] Before describing the independent embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other independent embodiments and of being practiced or carried out in various ways.

[0104] As used herein, the use of "including" and "comprising" and variations thereof means including the subsequently listed items and equivalents thereof as well as additional items. As used herein, the use of "consisting of" and variations thereof means including only the subsequently listed items and equivalents thereof.

[0105] Those skilled in the art will understand that relative terms used in connection with a quantity or condition, such as "about," "approximately," "substantially," etc., are inclusive of the stated value and have the meaning dictated by the context (e.g., the term includes at least the degree of error or tolerance associated with the measurement (e.g., manufacture, assembly, use, etc.)). Such terms should also be considered to indicate a range defined by the absolute values of the two endpoints. For example, the phrase "from about 2 to about 4" indicates a range of "from 2 to 4." Relative terms can refer to a percentage increase or decrease (e.g., 1%, 5%, 10% or more) of the stated value.

[0106] Additionally, functionality described herein as being performed by one component may be performed in a distributed manner by multiple components. Similarly, functionality performed by multiple components may be integrated and performed by a single component. Similarly, an element described as performing a particular function may also perform additional functions not described herein. For example, a device or structure "configured" in a particular way is configured in at least that way, but may also be configured in ways not described.

[0107] Additionally, some embodiments described herein may include one or more electronic processors configured to perform the functions described herein by executing instructions stored on a non-transitory computer-readable medium. Similarly, embodiments described herein may be implemented as a non-transitory computer-readable medium having stored thereon instructions executable by one or more electronic processors to perform the functions described herein. As used herein, "non-transitory computer-readable medium" includes any computer-readable medium, but does not consist of a transitory propagating signal. Thus, a non-transitory computer-readable medium may include, for example, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a read-only memory (ROM), a random access memory (RAM), a register memory, a processor cache, or any combination thereof.

[0108] Many of the modules and logical structures described herein can be implemented in software executed by a microprocessor or similar device, or in hardware using various components including, for example, application-specific integrated circuits (ASICs). Terms such as "controller" and "module" can include or refer to both hardware and / or software. Capitalized terms conform to common practice and help associate the description with code examples, mathematical formulas, and / or figures. However, no particular meaning is implied or should be inferred simply because of the use of capital letters. Therefore, the claims should not be limited to specific examples or terms, or to specific hardware or software implementations or combinations of software or hardware.

[0109] 1-4A show a battery pack assembly 10 including a housing 14 and a plurality of battery cell assemblies 18 received within the housing 14. In the illustrated embodiment, the battery pack assembly 10 includes two battery cell assemblies 18. In other embodiments, the battery pack assembly 10 may include one or more battery cell assemblies 18 (e.g., three, four, etc.). The battery pack assembly 10 is configured to be a high-power battery pack (e.g., a battery pack having a nominal voltage of at least about 80 volts (V)) that is connectable to and operable to power a variety of motorized power tools (e.g., cut-off saws, miter saws, table saws, core drills, augers, chippers, demolition hammers, compactors, vibrators, compactors, drain cleaners, welders, cable tuggers, pumps, etc.), outdoor tools (e.g., chainsaws, string trimmers, hedge trimmers, blowers, lawn mowers, etc.), other motorized devices (e.g., vehicles, utility carts, material handling carts, etc.), and non-motorized electrical devices (e.g., power sources, lighting, AC / DC adapters, generators, personal electronic devices, etc.) (hereinafter, any of these will be referred to as a "device").

[0110] The housing 14 includes a top surface 22, a bottom surface 26, a first side surface 30, a second side surface 34 opposite the first side surface 30, a first end surface 38, and a second end surface 42 opposite the first end surface 38. Additionally, the housing 14 includes a longitudinal axis 46 extending through the first end surface 38 and the second end surface 42. A transverse axis 50 of the housing 14 extends through the first side surface 30 and the second side surface 34. The transverse axis 50 is perpendicular to the longitudinal axis 46.

[0111] 2-4 , the housing 14 further includes an internal cavity 58 defined therein. Each battery cell assembly 18 is disposed within the internal cavity 58. Additionally, the housing 14 is sealed so that the internal cavity 58 is not in fluid communication with the outside of the battery pack assembly 10.

[0112] 3-4A, each battery cell assembly 18 includes a plurality of battery cells 62, a plurality of connectors 66, and a housing or frame 70 that supports the plurality of battery cells 62 within the interior cavity 58. Each battery cell 62 has a body 74 that extends between a first end 78 and a second end 82. Additionally, each body 74 extends along a battery cell axis 86 (FIG. 4) that extends through corresponding first and second sides 30 and 34 of the body 74, respectively.

[0113] Each battery cell assembly 18 is positioned within the interior cavity 58 such that each of the battery cells 62 is oriented relative to the longitudinal axis 46 of the housing 14. In the illustrated embodiment, the battery cell axis 86 of each corresponding battery cell 62 extends orthogonal to the longitudinal axis 46 (i.e., parallel to the transverse axis 50) within the interior cavity 58. In other embodiments, the battery cell axes 86 may be oriented parallel to the longitudinal axis 46, and / or some of the battery cell axes 86 may be oriented in the same or different directions. Additionally, each illustrated battery cell assembly 18 includes 70 battery cells 62. In other embodiments, the battery cell assembly 18 may include two or more battery cells 62. The housing 14 is shaped and sized to receive a predetermined number of battery cell assemblies 18, with each battery cell assembly 18 having portions of the predetermined number of battery cells 62.

[0114] Each battery cell 62 may have a nominal voltage of about 3 V to about 5 V and a nominal capacity of about 2 Ah to about 6 Ah (in some cases, about 3 Ah to about 5 Ah). Battery cells 62 may be any type of rechargeable battery cell chemistry type, such as lithium (Li), lithium ion (Li-ion), other lithium-based chemistries, nickel-cadmium (NiCd), nickel-metal hydride (NiMH), etc.

[0115] 4A , the battery cells 62 can be connected in series, parallel, or a combination of series and parallel to provide desired electrical characteristics (e.g., nominal voltage, current output, current capacity, power capacity, etc.) of the battery pack assembly 10. The battery cells 62 are connected together by connectors 66 (e.g., bus bars). Each battery cell 62 is connected to one of the connectors 66 by one or more wires 90. In the illustrated embodiment, each battery cell 62 is connected by one wire 90 to the connector 66 adjacent to the corresponding battery cell 62. The wire 90 is coupled to the second end 82 of the battery cell 62 (e.g., by a wire bonding process such as welding). Each connector 66 is directly coupled to at least two or more battery cells 62. In the illustrated embodiment, each connector 66 is directly coupled to ten battery cells 62.

[0116] Each of the illustrated connectors 66 is a conductive plate. Furthermore, the connectors 66 are configured to electrically connect to other battery cell assemblies 18 within the battery pack assembly 10 and / or to battery terminal contacts (not shown) of the battery pack assembly 10. As shown in FIG. 5 , the two battery cell assemblies 18 are electrically coupled by crimp bonding the ends of each battery cell assembly 18 adjacent the bottom surface 26 of the housing 14. The battery terminal contacts of the battery pack assembly 10 are configured to electrically and mechanically engage with device contacts of a device to facilitate the transfer of power between the device and the battery pack assembly 10. Thus, each of the battery cell assemblies 18 can be electrically connected to a battery terminal contact within the battery pack assembly 10. The battery pack assembly 10 is configured to be modularized so that each battery pack assembly 10 includes one or more battery cell assemblies 18, and each battery cell assembly 18 can include two or more battery cells 62. The battery pack assembly 10 may further include battery pack electronics disposed within the housing 14. The battery pack electronics may include, among other things, a printed circuit board (PCB 94 in FIG. 5A), one or more electrical components (eg, a CPU, a transformer, a FET, etc.), and battery terminal contacts.

[0117] FIGS. 5A and 5B each schematically illustrate another example of a battery pack assembly 10′, 10″. Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in FIGS. 1-4A are designated with similar reference numerals, each with the addition of a prime (“′”) or double prime (“′”). Therefore, what was discussed above with respect to battery pack assembly 10 equally applies to battery pack assemblies 10′, 10″ and will not be repeated. In particular, FIGS. 5A and 5B illustrate the location of a PCB 94 of the battery pack electronics. The PCB 94 can be positioned relative to the battery cell assemblies 18′, 18″. In one example, as shown in FIG. 5A, the PCB 94 is positioned between the top edge of each of the battery cell assemblies 18′ and the top surface 22′ of the housing 14′. In another example, shown in FIG. 5B, the PCB 94 is positioned between opposing sides of the battery cell assembly 18″.

[0118] 2-4A, the frame 70 of each battery cell assembly 18 includes a plurality of support members 102, 104 and a plurality of leg members 106 connecting the support members 102, 104. Each support member 102, 104 has a body 110 extending between a first edge 114 and a second edge 118 opposite the first edge 114 (FIG. 4A). Additionally, the body 110 defines a plurality of openings 122. Each opening 122 is configured to align with one of the battery cells 62 within the internal cavity 58. Thus, each support member 102, 104 has the same number of openings 122 as the number of battery cells 62. Each end 78, 82 of a corresponding battery cell 62 is received in one of the openings 122. The illustrated openings 122 are arranged in rows, some of which are spaced apart from one another, as described further below, to form gaps 126 ( FIG. 4 ) between some of the rows of battery cells 62. Thus, the support members 102, 104 may be configured to determine and maintain the position of the battery cells 62 within the interior cavity 58. The remaining space in the battery cell assembly 18 that does not form the gaps 126 may be sealed.

[0119] In the illustrated embodiment, each battery cell assembly 18 includes two support members 102, 104 disposed at opposite ends 78, 82 of the battery cell. The first support member 102 is disposed adjacent to the inner surface of the housing 14. The first support member 102 of each battery cell assembly 18 is coupled to the inner surface of the housing 14. As such, the frame 70 is configured to at least partially support the battery cells 62 within the interior cavity 58 of the housing 14.

[0120] A second support member 104 is disposed opposite the first support member 102. Each second support member 104 of the two battery cell assemblies 18 includes a side surface 130 ( FIG. 4A ). The side surfaces 130 of the second support members 104 are disposed in opposing relationship within the interior cavity 58. The connectors 66 of each battery cell assembly 18 are disposed on the corresponding side surface 130 of the second support member 104.

[0121] 4A , the leg members 106 of the frame 70 extend between the first support member 102 and the second support member 104, respectively. Each of the leg members 106 is disposed on the first edge 114 or the second edge 118 of the support members 102, 104, respectively. Each leg member 106 extends parallel to the battery cell axis 86 of the corresponding battery cell 62. The leg members 106 may be formed by one or more sections 134, 136, 138. For example, in the illustrated embodiment, each leg member 106 is formed by three sections 134, 136, 138, with the first section 134 coupled to the first support member 102, the second section 136 coupled to the second support member 104, and the intermediate third section 138 extending between the first section 134 and the second section 136. Additionally, the leg member 106 and / or portions thereof may be integral with one or more of the support members 102, 104. Alternatively, the leg member 106 may be formed separately and secured to the support members 102, 104.

[0122] 2-4 , the space within the interior cavity 58 not occupied by the battery cell assemblies 18 or battery electronics is divided into one or more air flow channels 142. The air flow channels 142 are positioned within the sealed housing 14 to surround each battery cell assembly 18. In the illustrated embodiment, the battery pack assembly 10 further includes a plurality of air flow tunnels 150 disposed on the top surface 22 of the housing 14. The air flow tunnels 150 are in fluid communication with the interior cavity 58 of the housing 14. The illustrated housing 14 includes four holes 154 and two air flow tunnels 150. Each air flow tunnel 150 is positioned to cover one of the holes 154. The remaining two holes 154 are covered by a plate member 158 ( FIG. 3 ). In other embodiments, the illustrated battery pack assembly 10 may include fewer than four air flow tunnels 150.

[0123] Referring to FIG. 2 , the battery pack assembly 10 may further include a plurality of fans 162. Each fan 162 is disposed adjacent to one or more of the plurality of battery cell assemblies 18. In the illustrated embodiment, the battery pack assembly 10 includes two fans 162, with each fan 162 disposed within one of the air flow tunnels 150. Thus, one, some, or all of the air flow tunnels 150 include a fan 162. In other embodiments, one, some, or all of the fans 162 can be disposed within the housing 14 of the battery pack assembly 10. For example, as shown in FIGS. 5A-5B , the battery pack assembly 10 includes two fans 162 disposed within the internal cavity 58 of the housing 14. More specifically, the fans 162 are disposed on either side of the PCB 94 and adjacent to the top surface 22 of the housing 14.

[0124] The plurality of fans 162 are operable to circulate airflow within the sealed housing 14 of the battery pack assembly 10. More specifically, air is circulated within the interior cavity 58 of the sealed battery pack assembly 10, but does not escape (or at least a negligible amount of air escapes) the interior cavity 58 of the battery pack assembly 10. In the illustrated embodiment, the airflow is directed between the top surface 22 and the bottom surface 26 of the housing 14. In other embodiments, the battery pack assembly 10 may include one or more fans 162 (three, four, etc.) for circulating airflow in the same or different directions within the sealed housing 14. FIG. 23 illustrates an example of airflow circulated within the housing 14.

[0125] 6-7 illustrate yet another example of a battery pack assembly 10'". Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in FIGS. 1-4A are designated with similar reference numerals plus a triple prime ("'") symbol. Therefore, what was discussed above with respect to battery pack assembly 10 equally applies to battery pack assembly 10'" and will not be repeated. In particular, FIGS. 6-7 illustrate alternative locations for multiple fans 162'". The multiple fans 162'" can be positioned relative to the battery cell assemblies 18'" within the interior cavity 58'". Additionally, each fan 162 is positioned proximate each of the first and second ends 38'" and 42'" of the housing 14'". Furthermore, each fan 162'" is positioned between the corresponding end 38'", 42'" of the housing 14'" and the battery cell assembly 18'". One or more air flow tunnels 150''', similar to the air flow tunnels 150''' shown in FIGS. 1-4A, may be provided for each fan 162''' proximate the first end 38''' and the second end 42''' of the housing 14''' of the battery pack assembly 10''' (rather than the top surface 22 shown in FIGS. 1-4A) to direct air flow within the housing 14'''. In the illustrated embodiment, the air flow is directed between the first side 30''' and the second side 34''' of the housing 14'''. More specifically, the air flow may be directed in a direction of increasing voltage through the plurality of battery cells 62'''.

[0126] 8-13, in other embodiments, one or more of the air flow tunnels 150 and / or the housing 14 may have multiple deflectors 170A, 170B, 170C therein so that some of the air can be directed around the battery cell assembly 18 by one or more fans 162 and some of the air can be directed through the gaps 126 between adjacent rows of battery cells of the battery cell assembly 18.

[0127] Deflectors 170A, 170B, 170C may be coupled to housing 14 of battery pack assembly 10, to frame 70 of one or more of battery cell assemblies 18, or a combination thereof. Deflectors 170A, 170B, 170C may be integral with or separately formed from housing 14 / frame 70. One or more of deflectors 170A, 170B, 170C may be in fluid communication with one another.

[0128] 8-9 show an example in which two deflectors 170A are positioned adjacent to one another. Each deflector 170A is positioned at one end of a row of battery cells 62 and extends through a corresponding gap 126 between two of the rows of battery cells 62. Each deflector 170A includes an end portion 174 and a plurality of guide members 178 fluidly connected to the end portion 174. The illustrated deflector 170A includes two guide members 178, each extending through one of the gaps 126. Furthermore, the end portion 174 can be positioned adjacent to one of the fans 162 ( FIG. 9 ) for directing airflow through the corresponding deflector 170A. In some embodiments, the end portion 174 can be configured to at least partially receive one of the fans 162 or to be positioned adjacent to one of the fans 162.

[0129] In another example, referring to FIGS. 10-11 , a deflector 170B may be disposed at one end of a row of battery cells 62 and extend past one of the first end 78 and the second end 82 of the battery cells 62. Similar to the above, the deflector 170B includes an end portion 174 and a plurality of guide members 178 fluidly connected to the end portion 174. Rather than extending through the gap 126 between adjacent battery rows as shown in FIGS. 8-9 , each guide member 178 extends past one of the first end 78 and the second end 82 of the battery cells 62. The end portion 174 may be disposed adjacent to one of the fans 162 ( FIG. 11 ) for directing airflow through the corresponding deflector 170B. Furthermore, in the illustrated example, one of the guide members 178 of the first deflector 170B is in fluid communication with an adjacent guide member 178 of the second deflector 170B. Thus, multiple fans 162 may be configured to direct the combined airflow through two or more deflectors 170B.

[0130] 12A-12C show several examples of directing airflow through deflectors 170B. FIG. 12A shows an example with a single fan 162, which directs airflow in a first direction through a first deflector 170B and then directs the airflow in a second direction opposite the first direction through a second deflector 170B. FIG. 12B shows another example with two fans 162, each of which directs airflow through a corresponding deflector 170B. FIG. 12C shows yet another example, also with two fans 162, in which airflow can be directed in a reciprocating fashion through the connected deflectors 170B.

[0131] 13 illustrates yet another example including four deflectors 170C positioned adjacent to one another, each deflector 170C having an end portion 174 and two guide members 178. As in the examples discussed above, the guide members 178 extend past one of the first end 78 and the second end 82 of the battery cell 62. In some embodiments, a fan 162 may be positionable adjacent each end portion 174 of a corresponding deflector 170C. In other embodiments, only some of the end portions 174 are adjacent to a corresponding fan 162, with the remaining deflectors 170C in fluid communication with the deflector 170C that receives the airflow from the fan 162. In yet other embodiments, some of the guide members 178 may be positioned to extend past one of the first ends 78 and second ends 82 of the battery cells 62, and the remaining guide members 178 may extend through the gaps 126 between adjacent rows of battery cells 62.

[0132] In other embodiments, in the configuration of the air flow tunnel 150 and deflectors 170A, 170B, 170C, the battery cells 62 may be thermally coupled to the air flow tunnel 150, deflectors 170A, 170B, 170C, and / or end portions 174 by a thermally conductive gap filler, adhesive, potting, or encapsulant to seal the housing 14 or portion thereof. The PCB 94, power wiring, and battery cells 62 are disposed in the sealed portion of the housing 14. In the sealed housing 14 or portion thereof, the air flow tunnel 150, deflectors 170A-C, and / or end portions 174 are thermally coupled to the battery cells 62 via a thermally conductive gap filler, adhesive, potting, or encapsulant. Thus, the fan 162 is configured to direct air from outside the sealed battery pack assembly 10 or portion thereof through the air flow tunnel 150.

[0133] FIGS. 14-16 illustrate yet another example of a portion of a battery pack assembly 210. Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in FIGS. 1-4A are labeled with similar reference numerals, plus the addition of "200." Accordingly, the discussion previously described with respect to battery pack assembly 10 applies equally to battery pack assembly 210 and will not be repeated. In particular, FIGS. 14-16 illustrate an alternative configuration of air flow tunnels 350 and multiple fans 362 for battery pack assembly 210. Air flow tunnel 350 is positioned on one side of battery cell assembly 218, and fans 362 are positioned on the other, opposite side. Each of air flow tunnels 350 has a curved shape for receiving airflow and directing the airflow back toward battery cells 262 of battery pack assembly 210. Fans 362 are oriented to direct airflow through battery cell assembly 218 and toward air flow tunnel 350. A cross-flow airflow is formed within the housing 214 of the battery pack assembly 210. In other words, each fan 362 is configured to direct air in a first direction through a corresponding battery cell assembly 218. The airflow is then redirected by a corresponding airflow tunnel 350 through the corresponding battery cell assembly 218 in a second direction opposite the first direction.

[0134] 16 , each row of battery cells is spaced equidistant from one another (rather than gaps 126 between some of the adjacent rows as in FIG. 4 ). Each of the battery cells 262 is disposed in a sleeve member 382. Ribs 386 extend between and connect the sleeve members 382. More specifically, each row of battery cells is connected by the ribs 386. In other embodiments, all of the battery cells 362 in the battery cell assembly 218 are connected by the ribs 386. The sleeve member 382 and the ribs 386 are formed of a material. In the illustrated embodiment, the material is plastic.

[0135] The battery cells 262 are disposed in metal or plastic sleeves 382 to seal the battery cells 262 from the external environment. In this configuration, the housing 14 or portions of the housing 14 surrounding the battery cells 262 do not need to be sealed so that the fan 362 can ventilate using air from outside the battery pack assembly 310. Additionally, the air flow tunnels 350 and power wiring (e.g., bus bars, cell headers, etc.) can also be sealed but thermally coupled to the air flow tunnels of the frame 270. This can reduce or prevent damage to the battery cells 262 due to air entering from the external environment.

[0136] In another embodiment, the battery cells 262 are not in metal or plastic sleeves but are disposed in a sealed housing 14 as disclosed in Figures 1-4A, and a cross-flow fan 362 is configured to circulate air within the sealed housing 14 of Figures 1-4A.

[0137] 17-18 illustrate yet another example of a portion of a battery pack assembly 410. Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in FIGS. 1-4A are labeled with similar reference numerals, plus "400." Accordingly, the discussion above regarding battery pack assembly 10 equally applies to battery pack assembly 410 and will not be repeated. In particular, FIGS. 17-18 illustrate an alternative configuration of an air flow tunnel 550 coupled with the inner surface 416 of housing 414 (FIG. 18). The illustrated air flow tunnel 550 is a baffle integrated with the top surface 422 of housing 414 that at least partially defines one or more of the air flow channels 542. The air flow tunnel 550 has a curved surface. The air flow tunnel 550 is disposed within an interior cavity 458. Battery pack assembly 410 may further include additional air flow tunnels (not shown) similar to air flow tunnel 150 of FIGS. 1-4A disposed on an opposite side (e.g., bottom surface 426) of housing 414 from air flow tunnel 550. Additionally, one or more fans (e.g., fan 162 of FIGS. 1-4A) may be disposed in interior cavity 458 and / or one or more of the additional air flow tunnels.

[0138] 19-22 illustrate another example of a battery pack assembly 610 including a plurality of battery cell assemblies 618. Components and features similar to those in the embodiment of battery pack assembly 10 shown in FIGS. 1-4A are designated with similar reference numerals, with the addition of "600." Therefore, what was discussed above with respect to battery pack assembly 10 applies equally to battery pack assembly 610 and will not be repeated. In particular, differences in the housing and frame will be discussed herein.

[0139] Each battery cell assembly 618 includes a plurality of battery cells 662, a plurality of connectors 666, and a housing or frame 670 that supports the plurality of battery cells 662. The frame 670 includes a base portion 672 and a cover portion 676 coupled to the base portion 672. The base portion 672 and the cover portion 676 cooperatively define a portion of an interior cavity 658 of the battery pack assembly 610. The portion of the interior cavity 658 is divided into a plurality of sections 680.

[0140] In the illustrated embodiment, the base portion 672 comprises a plurality of outer walls 684, 685, 687 and a plurality of inner walls 688 ( FIG. 21 ). The plurality of outer walls 684, 685, 687 includes first and second outer walls 684 that define first and second edges 714, 718, respectively, of the battery cell assembly 618. The plurality of outer walls 684, 685, 687 further includes a side wall 685 and first and second end walls 687. The plurality of inner walls 688 extend between the first and second outer walls 684. The inner walls 688 also extend from the side walls 685 toward the cover portion 676. The inner walls 688 divide the interior cavity 658 into a plurality of sections 680.

[0141] The base portion 672 further includes a plurality of protrusions 692 extending from the side wall 685 toward the cover portion 676. A protrusion 692 can be positioned in each of the plurality of sections 680. Additionally, a protrusion 692 can be positioned between the plurality of battery cells 662 within the internal cavity 658. Each of the illustrated protrusions 692 has a generally diamond-shaped cross-sectional shape. In other embodiments, the protrusions 692 can have other cross-sectional shapes, such as rectangular or circular, and some or all of the protrusions 692 can have the same shape or different shapes. Each of the protrusions 692 extends parallel to a respective one of the battery cells 662.

[0142] The cover portion 676 includes a body 696 and a plurality of openings 722 defined by the body 696. Each opening 722 is configured to align with one of the battery cells 662 within the interior cavity 658. Thus, the cover portion 676 has the same number of openings 722 as the number of battery cells 662. The first end 678 of each of the battery cells 662 is received in a corresponding one of the openings 722. Additionally, the body 696 has a surface 698, and the connector 666 is supported by the surface 698.

[0143] 19 and 20 , the battery pack assembly 10 includes two battery cell assemblies 618. The battery cell assemblies 618 are positioned such that the cover portions 676 are in opposing relationship to one another. The battery cell assemblies 618 may be positioned such that the cover portions 676 are spaced apart by a predetermined distance A. The predetermined distance A is selected to form a space 699 between the battery cell assemblies 618.

[0144] Each battery cell assembly 618 forms a portion of the housing 614 of the battery pack assembly 610 (rather than being disposed in the housing as disclosed in the battery pack assembly 10 of FIGS. 1-4A). More specifically, a base portion 672 of each battery cell assembly 618 defines one or more sides of the housing 614. In the illustrated embodiment, each battery cell assembly 618 forms one half of the battery pack assembly 610. Additionally, spaces 699 are sealed to form sealed regions between the battery cell assemblies 618. The spaces 699 are configured to receive electronics (e.g., PCB 694, connectors 666 connecting battery cells 662, etc.). Thus, the battery cell assemblies 618 and the sealed gaps 699 therebetween form a sealed enclosure.

[0145] The PCB 694 can be positioned relative to the battery cell assemblies 618. In one example, as shown in FIG. 20 , the PCB 694 is positioned in the space 699 adjacent to a first edge 714 of each of the battery cell assemblies 618. In this embodiment, the PCB 694 extends laterally relative to the battery cell assemblies 618. In another example, as shown in FIG. 19 , the PCB 694 is positioned between the cover portions 676 of the battery cell assemblies 618 in the space 699 and extends parallel to the surface of the cover portions 676.

[0146] 24 and 25 schematically illustrate alternative configurations of battery cells 62 for the battery cell assembly 18. Each of the battery cells 62 is equally spaced apart. As shown in FIG. 24, each of adjacent rows is aligned such that the battery cells 62 are aligned in one or more of the following directions: longitudinally (parallel to the longitudinal axis 46), vertically, and laterally (parallel to the horizontal axis 50). In contrast, as shown in FIG. 25, each of adjacent rows is staggered such that the battery cells 62 are offset from one another. This can affect the direction of airflow through the housing 14.

[0147] FIGS. 26-28 illustrate another example of a battery pack assembly 810. Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in FIGS. 1-4A are labeled with similar reference numerals, with the addition of "800." Accordingly, the discussion previously described with respect to battery pack assembly 10 applies equally to battery pack assembly 810 and will not be repeated. In particular, FIGS. 26-28 illustrate a staggered arrangement of rows of battery cells 862, as illustrated in FIG. 25. Additionally, FIGS. 26-28 illustrate an alternative location for a fan 962 within the housing 814, proximate one end (second end 842) and the top surface 822. Furthermore, FIGS. 26-28 illustrate alternative configurations of air flow tunnels 950 (i.e., baffles), each having a curved shape for directing airflow along a flow path through the housing 814. Additionally, air flow tunnels 950 are positioned within the housing 814 proximate each end 838, 842. The fan 962 is oriented to direct airflow toward an airflow tunnel 950 proximate one end 842 to direct the airflow through the battery cell assembly 818. The airflow tunnel 950 may be coupled to or otherwise integrated with the housing 814. The airflow tunnel 950 is disposed within the interior cavity 858.

[0148] 28 , the housing 814 may include screw bosses 928 located on the outer periphery of the battery cells 862. The PCB 894 is located between the top edge of each of the battery cell assemblies 818 and the top surface 822 of the housing 814. The fan 962 is located between the edge of the PCB 894 and the end 842 of the housing 814.

[0149] 29-32 illustrate another example of a battery pack assembly 1010. Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in FIGS. 1-4A are designated with similar reference numerals, plus the addition of "1000." Therefore, the discussion previously described with respect to battery pack assembly 10 equally applies to battery pack assembly 10 and will not be repeated. Similar to the embodiment of FIGS. 26-28, the embodiment of FIGS. 29-32 also illustrates a staggered arrangement of rows of battery cells 1062, as illustrated in FIG. 25, an alternative placement of a fan 1162 within the housing 1014 adjacent one end (second end 1042) and the top surface 1022, and an air flow tunnel 1150 (i.e., baffle). The fan 1162 is oriented to direct airflow toward the air flow tunnel 1150 adjacent one end 1042 to direct airflow through the battery cell assembly 1018. The air flow tunnels 1150 may be coupled to or otherwise integrated with the housing 1014. The air flow tunnels 1150 are disposed within the interior cavity 1058. Additionally, a PCB 1194 ( FIG. 31 ) is disposed between the top edge of each of the battery cell assemblies 1018 and the top surface 1022 of the housing 1014. Fans 1162 (only one of which is shown) are disposed between the edge of the PCB 1094 and the end 1042 of the housing 1014.

[0150] The battery pack assembly 1010 further comprises a plurality of ports 1152, 1156. In the illustrated embodiment, the battery pack assembly 1010 comprises a first plurality of ports 1152 and a second plurality of ports 1156. Each of the ports 1152, 1156 is defined by the housing 1014. The first plurality of ports 1152 are static ports, and the second plurality of ports 1156 are dynamic ports. A fan 1162 is positioned within the housing 1014 at a distance from the second plurality of ports 1156. Each of the ports 1152, 1156 is adjustable to selectively place the exterior of the battery pack assembly 1010 in fluid communication with the interior cavity 1058.

[0151] FIG. 32 shows the spatial intensity of the turbulent energy of the air through a steady state air flow.

[0152] Figures 33-36 illustrate another example of a battery pack assembly 1210. Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in Figures 1-4A are designated with similar reference numerals, with the addition of "1200." Therefore, what was discussed above with respect to battery pack assembly 10 applies equally to battery pack assembly 1210 and will not be repeated. Similar to the embodiments of Figures 26-28 and 29-32, the embodiment of Figures 33-36 also illustrates a staggered arrangement of rows of battery cells 1262 as shown in Figure 25, an alternative placement of a fan 1362 within the housing 1214 adjacent one end (second end 1242) and the top surface 1222, and air flow tunnels 1350 (i.e., baffles). The battery pack assembly 1210 may include additional airflow guide members 1353 within the housing 1214 and may be positioned between the ends of the battery cell assemblies 1218 and the corresponding ends 1238, 1242 of the housing 1214. A baffle 1350 may be disposed on the guide members 1353. Additionally, similar to the embodiments of FIGS. 26-28 and 29-32, the embodiment of FIGS. 33-36 further illustrates that a PCB 1394 (FIG. 34) is positioned between the top edge of each of the battery cell assemblies 1218 and the top surface 1222 of the housing 1214. A fan 1362 (only one of which is shown) is positioned between the edge of the PCB 1294 and the end 1242 of the housing 1214.

[0153] The battery pack assembly 1210 further includes a plurality of heat sinks 1360 ( FIGS. 35-36 ) coupled to or otherwise integrated into the interior of the housing 1214. In the illustrated embodiment, an interior surface 1364 of one or more of the walls of the housing 1214 includes the heat sink 1360. Each of the illustrated heat sinks 1360 includes a plate member 1366 having a plurality of fins 1368 extending therefrom. Additionally, each of the illustrated heat sinks 1360 is fabricated by an insert-molded aluminum stamping. Each of the heat sinks 1360 is configured to thermally conduct heat from the interior cavity 1258 to the housing 1214.

[0154] 37-39 illustrate another example of a battery pack assembly 1410. Components and features similar to those of the embodiment of battery pack assembly 10 illustrated in FIGS. 1-4A are designated by similar reference numerals, with the addition of "1400." Accordingly, the discussion above regarding battery pack assembly 10 equally applies to battery pack assembly 1410 and will not be repeated. The embodiment of FIGS. 37-39 illustrates each of the battery cell assemblies 1418 disposed within housing 1414 such that the battery cell axis 1486 of each corresponding battery cell 1462 extends within interior cavity 1458 perpendicular to longitudinal axis 1446 and perpendicular to horizontal axis 1450. In other words, the battery cells 1462 extend vertically within housing 1414.

[0155] FIG. 40 illustrates an alternative embodiment of the battery pack assembly 810 of FIGS. 26-28. Components and features similar to those in the embodiment of the battery pack assembly 810 illustrated in FIGS. 26-28 are designated with similar reference numerals, with the addition of an "A." Therefore, the discussion previously provided with respect to the battery pack assembly 810 applies equally to the battery pack assembly 810 and will not be repeated. The embodiment of FIG. 40 illustrates an alternative location for the fan 962A, which is intermediate or central to the battery cells 862A. Additionally, a baffle 950 is positioned centrally between the battery cells 862A to split the airflow from the fan 962A in opposite directions toward two separate battery cell assemblies 818A positioned on either side of the housing 814.

[0156] Each of the battery pack assemblies 10, 210, 410, 610, 810, 1010, 1210, 1410 is a sealed enclosure and is configured such that heat generated by the battery cells 62, 262, 462, 662, 862, 1062, 1262, 1462 is transferred from within the internal cavity 58, 258, 458, 658, 858, 1058, 1258, 1458 of the battery pack assembly 10, 210, 410, 610, 810, 1010, 1210, 1410 to the housing 14, 214, 414, 614, 814, 1014, 1214, 1414. In some embodiments, the housing 14, 214, 414, 614, 814, 1014, 1214, 1414 is made of plastic and the heat is transferred to the plastic housing 14, 214, 414, 614, 814, 1014, 1214, 1414.

[0157] 41, the sealed battery pack assemblies 10, 210, 410, 610, 810, 1010, 1210, 1410 may be disposed in a system 192. The system 192 may be sealed or unsealed. The fan 196 of the system 192 may be positioned outside the sealed battery pack assembly 10, 210, 410, 610, 810, 1010, 1210, 1410 to direct airflow across the sealed battery pack assembly 10, 210, 410, 610, 810, 1010, 1210, 1410 (e.g., sides and top) to transfer heat from the housing 14, 214, 414, 614, 814, 1014, 1214, 1414 to the outside of the housing 14, 214, 414, 614, 814, 1014, 1214, 1414.

[0158] 9, 16, 18, and 22, the battery pack assembly 10, 10′, 10″, 10′″, 210, 410, 610 is configured to receive a fluid 190, such as during assembly of the battery cell assembly 18. The fluid 190 includes a thermally conductive material with adhesive properties, such as a gap filler, potting material, or sealant, or an adhesive material (e.g., an adhesive) that is thermally conductive. In the illustrated embodiment, the fluid 190 is a thermally conductive silicone. Referring to FIGS. 9 and 18, each battery cell column of the battery cell assembly 18, 418 is configured to receive the fluid 190 (only one column is shown receiving the fluid 190). The fluid 190 is configured to fill spaces defined by the battery cell columns of the battery cell assembly 18, 418 that are not occupied by the corresponding battery cells 62, 462. The columns are separated by gaps 126, 526 provided within the battery cell assembly 18, 418. 16 , fluid 190 is configured to be received in each sleeve member 382 of a corresponding battery cell 262. As such, fluid 190 is disposed between the battery cell 262 and the inner surface of the corresponding sleeve member 382. With reference to FIG. 22 , fluid 190 is configured to be received in one or more of the sections 680 of the internal cavity 658. More specifically, fluid 190 is configured to be disposed between adjacent interior walls 688 of the base portion 672 of the frame 670.

[0159] The fluid 190 is positioned in contact with each of the battery cells 62, 262, 462, 662 in the battery cell string. After curing, the adhesive material is configured to promote heat transfer away from the battery cells 62, 262, 462, 662. In particular, in some of the illustrated embodiments, the adhesive material is positioned to direct heat generated by the battery cells 62, 262, 462, 662 toward the gaps 126, 526 and / or the first and second ends 78, 82 of the battery cells 62, 262, 462, 662. As such, the primary heat dissipation is axially along the battery cell axis 86 of the corresponding battery cell 62, 262, 462, 662.

[0160] During operation, the airflow generated by the plurality of fans 162, 362, 962, 1162, 1362 and / or the adhesive material 190 are configured to facilitate the transfer of heat away from the battery cells 62, 262, 462, 662, 862, 1062, 1262, 1462. More specifically, when the battery pack assembly 10 is being discharged, heat generated by the battery cells 62, 262, 462, 662, 862, 1062, 1262, 1462 is directed (for some embodiments) through the adhesive material 190 toward the airflow channels 142 and, in some embodiments, the gaps 126, 526 between some of the adjacent rows in the interior cavity 58, 58′, 58″, 58′″, 258, 458, 658, 858, 1058, 1258 of the housing 14 that are in fluid communication with the airflow channels 142. Thus, the adhesive material 190 facilitates thermal conduction of heat within the battery cell assemblies 18, 18', 18'', 18''', 218, 418, 618. The battery cell assemblies 18, 18', 18'', 18''', 218, 418, 618 are disposed in the housing 14, 14', 14'', 14''', 214, 414 to facilitate heat transfer from the adhesive material 190 through the airflow channels 142 and / or gaps 126, 526 and to the airflow generated by the plurality of fans 162. Additionally, the air flow tunnels / baffles 150, 350, 550, 950, 1150, 1350 within or otherwise integrated into the housing 14, 214, 414, 614, 814, 1014, 1214, 1414 are further configured to direct air flow through the battery cell assemblies 18, 218, 418, 618, 818, 1018, 1218, 1418.

[0161] 42 shows a portion of a battery pack assembly 2010 including a portion of a housing 2014 and a plurality of battery cell assemblies 2018 received within the portion of the housing 2014. In the illustrated embodiment, the battery pack assembly 2010 includes four battery cell assemblies 2018. In other embodiments, the battery pack assembly 2010 may include one or more battery cell assemblies 2018 (e.g., two, three, etc.). The battery pack assembly 2010 is configured to be a high-power battery pack (e.g., a battery pack having a nominal voltage of at least about 2080 volts (V)) that is connectable to and operable to power a variety of motorized power tools (e.g., cut-off saws, miter saws, table saws, core drills, augers, chippers, demolition hammers, compactors, vibrators, compactors, drain cleaners, welders, cable tuggers, pumps, etc.), outdoor tools (e.g., chainsaws, string trimmers, hedge trimmers, blowers, lawn mowers, etc.), other motorized devices (e.g., vehicles, utility carts, material handling carts, etc.), and non-motorized electrical devices (e.g., power sources, lighting, AC / DC adapters, generators, etc.) (hereinafter any of these will be referred to as "devices" in this specification).

[0162] 44-47 , each battery cell assembly 2018 includes a plurality of battery cells 2022, a housing or frame 2026, a cover 2030 coupled to the frame 2026, a plurality of connectors 2034, 2038, 2042, and a heat sink 2050. The battery cell assembly 2018 includes a front surface 2054, a rear surface 2058, a first side surface 2062, a second side surface 2066 opposite the first side surface 2062, a first end surface 2070, and a second end surface 2074 opposite the first end surface 2070. In the illustrated embodiment, the plurality of connectors 2034, 2038, 2042 are disposed on the front surface 2054, and the heat sink 2050 is disposed on the rear surface 2058. Additionally, the battery cell assembly 2018 includes a longitudinal axis 2078 extending through the first end 2070 and the second end 2074 .

[0163] 49 , the frame 2026 and the cover 2030 cooperatively define an interior cavity 2082 of the battery cell assembly 2018 in which one or more of the battery cells 2022 are received. Each battery cell 2022 extends perpendicular to the longitudinal axis 2078 within the interior cavity 2082. In the illustrated embodiment, the battery cell assembly 2018 includes 84 battery cells 2022. In other embodiments, the battery cell assembly 2018 may include more than one battery cell 2022. For example, as shown in FIG. 62 , the battery cell assembly 2018′ includes 30 battery cells 2022. The frame 2026 and the cover 2030 are shaped and sized to receive a predetermined number of battery cells 2022. The cover 2030 is positioned adjacent a first end 2086 of each of the battery cells 2022. The frame 2026 and the cover 2030 are configured to support the battery cells 2022.

[0164] 49B and 49D-50, the frame 2026 of the battery cell assembly 2018 includes a plurality of support members 2087. Each support member 2087 is coupled to and extends from a bottom surface 2088 of the frame 2026 (FIG. 49E). In the illustrated embodiment, the support members 2087 are integral with the frame 2026. Alternatively, the support members 2087 may be formed separately and secured to the frame 2026. Each support member 2087 is disposed within the internal cavity 2082. Additionally, each support member 2087 is configured to be disposed within the internal cavity 2082 between two adjacent battery cells 2022 of the plurality of battery cells 2022. Furthermore, two of the opposing support members 2087 cooperate to define a space 2089 within the internal cavity 2082 for receiving a portion of the heat sink 2050, as will be described in more detail below. As such, each support member 2087 forms one of a pair of support member assemblies 2091. As shown in FIG.

[0165] 49C , the cover 2030 includes a body 2092 and a plurality of openings 2093 defined by the body 2092. Each opening 2093 is configured to align with one of the battery cells 2022 within the internal cavity 2082. As such, the cover 2030 has the same number of openings 2093 as the number of battery cells 2022. The first end 2086 of each of the battery cells 2022 is received in a corresponding one of the openings 2093. Additionally, the body 2092 has a surface 2096, and the connectors 2034, 2038, 2042 are supported by the surface 2096. As such, the cover 2030 can be configured to determine and maintain the positions of the battery cells 2022 within the internal cavity 2082.

[0166] The frame and cover are each formed of a material, which may be a plastic (e.g., nylon, polycarbonate, ABS, etc.), or in some embodiments, a thermally conductive material such as a metal (e.g., aluminum).

[0167] Each battery cell 2022 may have a nominal voltage of about 3 V to about 5 V and a nominal capacity of about 2 Ah to about 6 Ah (in some cases, about 3 Ah to about 5 Ah). The battery cells 2022 may be any type of rechargeable battery cell chemistry type, such as lithium (Li), lithium ion (Li-ion), other lithium-based chemistry, nickel-cadmium (NiCd), nickel-metal hydride (NiMH), etc.

[0168] 46 , the battery cells 2022 can be connected in series, parallel, or a combination of series and parallel to provide desired electrical characteristics (e.g., nominal voltage, current output, current capacity, power capacity, etc.) of the battery pack assembly 2010. The battery cells 2022 are connected together by connectors 2034, 2038, 2042 (e.g., bus bars). The connectors 2034, 2038, 2042 include a first connector 2034, a second connector 2038, and one or more intermediate connectors 2042. Each battery cell 2022 is connected to two of the connectors 2034, 2038, 2042 by one or more wires 2090. In the illustrated embodiment, each battery cell 2022 is connected by three wires 2090 to each connector 2034, 2038, 2042 adjacent to the corresponding battery cell 2022. The wires 2090 are coupled (e.g., by a wire bonding process such as welding) to the first ends 2086 of the battery cells 2022. Each connector 2034, 2038, 2042 is directly coupled to at least two or more battery cells 2022. In the illustrated embodiment, each connector 2034, 2038, 2042 is directly coupled to twelve battery cells 2022.

[0169] 44 and 49C , the connectors 2034, 2038, 2042 are disposed on the front surface 2054 of the battery cell assembly 2018. Additionally, the illustrated connectors 2034, 2038, 2042 are coupled to the cover 2030. The first connector 2034 is disposed at a first end 2070 of the battery cell assembly 2018. The second connector 2038 is disposed at a second end 2074 of the battery cell assembly 2018. Each of the intermediate connectors 2042 is disposed between the first connector 2034 and the second connector 2038 with respect to the longitudinal axis 2078. Each of the illustrated connectors 2034, 2038, 2042 is a conductive plate. Furthermore, each of the first connector 2034 and the second connector 2038 is configured as an electrical contact configured to electrically connect to other battery cell assemblies 2018 within the battery pack assembly 2010 and / or battery terminal contacts (not shown) of the battery pack assembly 2010. The first connector 2034 is configured as a positive electrical contact, and the second connector 2038 is configured as a negative electrical contact.

[0170] The battery terminal contacts of the battery pack assembly 2010 are configured to electrically and mechanically engage with device contacts of the device to facilitate the transfer of power between the device and the battery pack assembly 2010. Thus, each of the battery cell assemblies 2018 can be electrically connected to a battery terminal contact within the battery pack assembly 2010. The battery pack assembly 2010 is configured to be modularized such that each battery pack assembly 2010 includes one or more battery cell assemblies 2018, and each battery cell assembly 2018 can include two or more battery cells 2022. The battery pack assembly 2010 may further include battery pack electronics (not shown) disposed within the housing 2014. The battery pack electronics may include, among other things, a printed circuit board (PCB), one or more electrical components (e.g., a CPU, a transformer, an FET, etc.), and battery terminal contacts.

[0171] 54-59, the heat sink 2050 of each battery cell assembly 2018 includes a body 2094, a plurality of fins 2098, and a plurality of protrusions 2102 opposite the fins 2098. The body 2094 is disposed adjacent to the rear surface 2058 of the battery cell assembly 2018. The body 2094 includes a first surface 2106 and a second surface 2110 opposite the first surface 2106 (FIGS. 46 and 57). The first surface 2106 includes a plurality of fins 2098 extending outward therefrom. Thus, the fins 2098 are disposed outside the internal cavity 2082 of the battery cell assembly 2018. The body is formed of a thermally conductive material. The material may be a metal such as aluminum or copper.

[0172] The second surface 2110 of the body 2094 partially defines the internal cavity 2082. More specifically, the body 2094 covers the rear surface 2058 of the battery cell assembly 2018. The second surface 2110 includes a plurality of protrusions 2102 extending therefrom. When the heat sink 2050 is coupled to the frame 2026, the protrusions 2102 extend from the body 2094 into the internal cavity 2082. The protrusions 2102 are positionable between the plurality of battery cells 2022 within the internal cavity 2082. In particular, as shown in FIG. 54 , a portion of each protrusion 2102 is positioned between two adjacent battery cells 2022 of the plurality of battery cells 2022. Thus, each protrusion 2102 is positioned adjacent to four of the battery cells 2022.

[0173] Each of the protrusions 2102 shown has a generally diamond-shaped cross-sectional shape. In other embodiments, the protrusions 2102 may have other cross-sectional shapes, such as rectangular, circular, etc., and some or all of the protrusions 2102 may have the same shape or different shapes. Each of the protrusions 2102 extends parallel to each of the battery cells 2022. Furthermore, each of the protrusions 2102 is received in a space 2089 defined by one of the support member assemblies 2091. Therefore, the battery cell assembly 2018 includes the same number of protrusions 2102 as the number of support member assemblies 2091.

[0174] The support member assemblies 2091 are sized and shaped to be disposed between one or more of the battery cells 2022 and the corresponding protrusions 2102 ( FIG. 44 ). In the illustrated embodiment, each support member 2087 of one of the support member assemblies 2091 is disposed between two of the battery cells 2022 and on one side of the protrusions 2102. In other embodiments, one, some, or all of the support members 2087 are configured to be disposed between one or more of the battery cells 2022 and one of the protrusions 2102. The support members 2087 are configured to facilitate positioning of the battery cells 2022 and the protrusions 2102, respectively, within the internal cavity 2082, such as during assembly. Additionally, the support members 2087 are configured to separate the protrusions 2102 of the heat sink 2050 from the battery cells 2022. The support members 2087 may insulate the battery cells 2022 from the protrusions 2102 of the heat sink 2050.

[0175] 44 and 45 , the battery cells 2022 and the support member assemblies 2091 / protrusions 2102 are sequentially disposed within the internal cavity 2082. In particular, the battery cells 2022 and the support member assemblies 2091 / protrusions 2102 are sequentially disposed (i.e., one after the other) in one or more directions (e.g., upward from the frame of reference of FIG. 54 , rightward from the frame of reference of FIG. 52 from the first end 2070 to the second end 2074), although in other embodiments they may be sequentially disposed in all directions. As such, the battery cells 2022 and the support member assemblies 2091 / protrusions 2102 may be sequentially disposed. Respective portions of the support member assembly 2091 separate each of the battery cells 2022 from one another.

[0176] As shown in FIG. 55, the body 2094 of the heat sink 2050 defines a plurality of openings 2118 ( FIG. 55 ) that extend through the first surface 2106 to the second surface 2110. Each opening 2118 is aligned with one of the protrusions 2102. More specifically, each protrusion 2102 defines a channel 2122 extending partially therein. Each opening 2118 is connected to a corresponding channel 2122. Each channel 2122 extends from the second surface 2110 of the body 2094 proximate to an end 2126 of the corresponding protrusion 2102. The end 2126 of each protrusion 2102 is positioned adjacent to the first end 2086 of each battery cell 2022 ( FIG. 53 ). Furthermore, the openings 2118 are positioned between the fins 2098 of the first surface 2106 of the heat sink 2050. In other embodiments, only some of the protrusions 2102 may include channels 2122. Additionally, each opening 2118 is aligned with a corresponding one of the holes 2089A in the frame 2026.

[0177] 55 and 58-60, the battery cell assembly 2018 further includes a plurality of heating rods 2130. Each rod 2130 is selectively received in one of the channels 2122 of the projection 2102. More specifically, each rod 2130 is inserted into the channel 2122 through an opening 2118 in the body 2094. A first end 2134 of the rod 2130 is disposed adjacent to the end 2126 of the projection 2102 (and the first end 2086 of each of the battery cells 2022). A second end 2138 of the rod 2130, opposite the first end 2134, is disposed proximate the opening 2118. In the illustrated embodiment, the rod 2130 is sized such that the second end 2138 extends through the opening 2118 and is disposed outside the opening 2118 and the channels 2122.

[0178] The heating rods 2130 may be disposed on some or all of the protrusions 2102. For example, in the illustrated embodiment, the heating rods 2130 are alternately received in the channels 2122 of the protrusions 2102 ( FIGS. 55 and 58 ). Thus, a heating rod 2130 is disposed on every other protrusion 2102. In other embodiments, a heating rod 2130 may be disposed on all of the protrusions 2102. Additionally, wires 2142 connect each of the heating rods 2130 to the electronics (e.g., PCB) of the battery pack assembly. The wires 2142 extend from the second ends 2138 of the corresponding heating rods 2130. Additionally, the wires 2142 extend between the fins 2098 of the first surface 2106 of the heat sink 2050.

[0179] The heating rod 2130 is formed from a conductive metallic material such as copper. In another embodiment, the heating rod 2130 is made from copper and configured as a liquid or gas filled heat pipe.

[0180] Each of the rods 2130 is configured to generate (e.g., electrically) or otherwise transfer heat from a separate source to selectively heat the battery cells 2022, as discussed further below. The source may be bidirectional, a charger for the battery pack assembly 2010, or the battery cells 2022. In some embodiments, one or more of the heating rods 2130 are positioned to heat four of the battery cells 2022.

[0181] 49A, 49C, and 51 , the internal cavity 2082 of each battery cell assembly 2018 is configured to receive a fluid, such as during assembly of the battery cell assembly 2018. The fluid includes an adhesive material 2150 (e.g., an adhesive). In the illustrated embodiment, the fluid is a thermally conductive silicone. When the fluid is received in the internal cavity 2082, the fluid is configured to fill any remaining space between the protrusions 2102 and the battery cells 2022. In particular, the fluid is configured to fill any gaps between the protrusions 2102 and the battery cells 2022. After curing, the adhesive material 2150 is configured to facilitate heat transfer between the battery cells 2022 and the heat sink 2050.

[0182] During operation, the heat sink 2050 and the adhesive material 2150 are configured to facilitate the transfer of heat to and away from the battery cells 2022. More specifically, the heating rods 2130 can be activated to generate heat. Each of the protrusions 2102 of the heat sink 2050 is positioned to direct heat from the heating rods 2130 through the adhesive material 2150 toward the battery cells 2022. In some embodiments, one, some, or all of the heating rods 2130 can be activated when the battery pack assembly electronics determine that the battery pack assembly 2010 and / or one of the corresponding battery cell assemblies 2018 is at or above a predetermined temperature limit. Additionally, in some embodiments, the heating rods 2130 can be activated when the battery pack assembly 2010 is discharging or not discharging.

[0183] The battery cell assembly 2018 is further configured to conduct heat away from the battery cells 2022. More specifically, when the battery pack assembly 2010 is discharging, heat generated by the battery cells 2022 is conducted through the adhesive material, to the protrusions 2102, then to the body 2094 of the heat sink 2050, and finally to the fins 2098. Thus, the heat sink 2050 and adhesive material 2150 facilitate thermal conduction of heat within the battery cell assembly 2018. Additionally, the heat sink 2050 is shaped to facilitate even distribution of heat to and away from the battery cells 2022 within the battery cell assembly 2018.

[0184] 43 , the battery pack assembly 2010 may further include a fan assembly 2154 having one or more fans. The fan assembly 2154 is disposed adjacent to one or more of the plurality of battery cell assemblies 2018. In the illustrated embodiment, the fan assembly 2154 is disposed adjacent to two of the battery cell assemblies 2018. The fan assembly 2154 can be disposed within the housing 2014 of the battery pack assembly 2010. The battery pack assembly 2010 is configured to be sealed, and the fan assembly 2154 is operable to circulate air within the sealed housing 2014 of the battery pack assembly 2010.

[0185] The fan assembly 2154 is positioned proximate to one or more fins 2098 of the battery cell assemblies 2018. Additionally, while the illustrated fan assembly 2154 is positioned adjacent the first end 2070 of each battery cell assembly 2018, it may alternatively be positioned adjacent any face or end of the battery cell assembly 2018 (e.g., the first side 2062, the second side 2066, the second end 2074, etc.). The fan assembly 2154 is operable to generate an airflow to direct air over and / or past the fins 2098 of the heat sink 2050. The battery pack assembly 2010 may also include one or more guide members positioned within the housing 2014 of the battery pack assembly 2010 to direct air toward and / or away from the fins 2098 of the battery cell assemblies 2018. Accordingly, the battery pack assembly 2010 may have improved thermal performance, which may improve the cycle life and cycle run time of the battery pack.

[0186] Each of Figures 63 and 64 illustrates another example of a battery pack assembly 2010', 2010" that may include one or more of the same components and features as the embodiment of battery pack assembly 10 shown in Figures 42-62 above. Therefore, what was discussed above with respect to battery pack assembly 2010 applies equally to battery pack assemblies 2010', 2010" and will not be repeated.

[0187] 65-69 illustrate a battery pack assembly 3010 including a battery pack 3014 and an inlet port 3018. In the illustrated embodiment, the battery pack assembly 3010 includes a high-power battery pack 3014 (e.g., a battery pack having a nominal voltage of at least about 80 volts (V)) that is connectable to and operable to power a variety of motorized power tools (e.g., cut-off saws, miter saws, table saws, core drills, augers, chippers, demolition hammers, compactors, vibrators, compactors, drain cleaners, welders, cable tuggers, pumps, etc.), outdoor tools (e.g., chainsaws, string trimmers, hedge trimmers, blowers, lawn mowers, etc.), other motorized devices (e.g., vehicles, utility carts, material handling carts, etc.), and non-motorized electrical devices (e.g., power sources, lights, AC / DC adapters, generators, etc.) (any of which will be referred to hereinafter as a "device").

[0188] The battery pack 3014 includes a battery pack housing 3030. The illustrated housing includes a body portion 3034, a cover portion 3038, and a first side portion 3042 and a second side portion 3046 coupled to a first side and a second side portion, respectively, of the body portion 3034. The cover portion 3038 of the housing 3030 may be referred to herein as the "top housing portion 3050," and the body portion 3034 and the first side portion 3042 and second side portion 3046 may be collectively referred to herein as the "bottom housing portion 3054." In other embodiments, the housing 3030 may include one or more portions forming the housing 3030. Additionally, the housing 3030 includes a longitudinal axis 3058 extending therein.

[0189] The housing 3030 comprises a front surface 3062, a rear surface 3066, a first side 3070, a second side 3074 opposite the first side 3070, a top surface 3078, and a bottom surface 3082 opposite the top surface 3078. In the illustrated embodiment, the body portion 3034 forms the front surface 3062, the rear surface 3066, and the bottom surface 3082. The first surface portion 3042 and the second surface portion 3046 form the first side 3070 and the second side 3074, respectively, and the cover portion 3038 forms the top surface 3078 of the housing 3030.

[0190] 69 , the housing 3030 defines an interior cavity 3086 in which one or more battery cells 3090 are supported. More specifically, the body portion 3034 is disposed within the interior cavity 3086 and configured to receive the battery cells 3090. As such, the body portion 3034 is configured as a battery cell holder that restrains the battery cells 3090 within the interior cavity 3086.

[0191] Each battery cell 3090 may have a nominal voltage of about 3 V to about 5 V and a nominal capacity of about 2 Ah to about 6 Ah (in some cases, about 3 Ah to about 5 Ah). The battery cells 3090 may be any type of rechargeable battery cell chemistry type, such as lithium (Li), lithium ion (Li-ion), other lithium-based chemistries, nickel-cadmium (NiCd), nickel-metal hydride (NiMH), etc.

[0192] The battery cells 3090 may be connected in series, parallel, or a combination of series and parallel to provide desired electrical characteristics (e.g., nominal voltage, current output, current capacity, power capacity, etc.) of the battery pack 14. The battery cells 3090 are connected together by battery straps 3094 ( FIG. 73B ). In addition, the battery cells 3090 are electrically coupled to battery contacts 3098 ( FIG. 69 ) supported within the housing 3030 and configured to electrically and mechanically engage device contacts of the device to facilitate the transfer of power between the device and the battery pack 3014.

[0193] 65-69, the upper housing portion 3050 includes a wall 3102 and a battery pack interface 3106 extending from the wall 3102. The battery pack interface 3106 includes a terminal block 3110 having an opening 3114 extending therein. The opening 3114 allows access to battery contacts 3098 (FIG. 69) disposed within the housing 3030. The terminal block 3110 surrounds the battery contacts 3098. The battery pack interface 3106 further includes rails 3118, 3122 and grooves 3126, 3130 disposed on either side of the terminal block 3110. In particular, the grooves 3126, 3130 are defined between the corresponding rails 3118, 3122 and the wall 3102. The battery pack interface 3106 is configured to selectively mate with a device interface having structure (eg, device contacts and grooves / rails) that corresponds to the structure of the battery pack interface 3106.

[0194] 69 and 71 , the battery pack 3014 includes battery pack electronics 3134 disposed within the housing 3030. The battery pack electronics 3134 may include, among other things, a printed circuit board (PCB) 3138, one or more electrical components 3142 (e.g., a CPU, a transformer, FETs, etc.), and battery contacts 3098. The PCB 3138 is securely coupled (e.g., by welding) to and supported by the body portion 3034. The upper housing portion 3050 includes an inner surface 3146 opposite the wall 3102 of the upper housing portion 3050. The PCB 3138 includes a surface 3150 in opposing relationship with and spaced apart from the inner surface 3146 of the upper housing portion 3050 ( FIG. 71 ).

[0195] The battery contacts 3098 are securely coupled (e.g., by welding) to the PCB 3138 and extend from the PCB 3138 toward the inner surface 3146 at one end of the PCB 3138. The ends of the battery contacts 3098 are positioned adjacent to the openings 3114 in the terminal block 3110. Additionally, the battery contacts 3098 are electrically connected to the PCB 3138.

[0196] 65 and 70-72, the housing 3030 includes an injection port 3018. The injection port 3018 includes one or more channels 3158 disposed on one or more of the sides of the housing 3030 (e.g., top surface 3078, bottom surface 3082, front surface 3062, rear surface 3066, first side surface 3070, second side surface 3074). In the illustrated embodiment, the injection port 3018 includes a single channel 3158 defined by the upper housing portion 3050 such that the channel 3158 is disposed on the top surface 3078 of the housing 3030. The channel 3158 extends from a first end 3162 disposed on the wall 3102, through the upper housing portion 3050 (e.g., cover portion 3038), and to an opposite second end 3166 disposed on the inner surface 3146 of the upper housing portion 3050. In other embodiments, the housing 3030 may include multiple channels extending through the same or different sides of the housing 3030 (e.g., two channels on the top surface 3078, or one channel on the top surface 3078 and another channel on the rear surface 3066, etc.). The fill port 3018 connects the interior cavity 3086 of the battery pack 3014 to the exterior of the housing 3030.

[0197] 71 and 72, the channels 3158 extend along an injection axis 3170. The injection axis 3170 extends relative to the longitudinal axis 3058. In the illustrated embodiment, the injection axis 3170 extends at an angle A (e.g., 90 degrees) relative to the longitudinal axis 3058. In other embodiments, one or more channels 3158 may be positioned such that the corresponding injection axis 3170 extends parallel to the longitudinal axis 3058. Additionally, while the illustrated injection axis 3170 extends through the longitudinal axis 3058 (FIG. 72), it may alternatively be spaced apart from the longitudinal axis 3058. When multiple channels 3158 are provided, the injection axes 3170 of each of the channels 3158 may extend at the same or different angles A relative to the longitudinal axis 3058, and / or the injection axes 3170 of one, some, or all of the channels 3158 may extend through or at a distance from the longitudinal axis 3058.

[0198] 71 and 72 , the channel 3158 can be located near some of the sides 3062, 3066, 3070, 3074, 3078, 3082 of the housing 3030 (rather than the corresponding opposite side 3062, 3066, 3070, 3074, 3078, 3082). For example, the illustrated channel 3158 is located closer to the front side 3062 of the housing 3030 than to the rear side 3066 of the housing 3030, as viewed from the frame of reference of FIG. 71 . The channel 3158 is located equidistant between the first side 3070 and the second side 3074, as viewed from the frame of reference of FIG. 72 . Thus, the injection port 3018 can be selectively positioned at predetermined locations on the housing 3030.

[0199] The channel 3158 is disposed proximate the terminal block 3110. Additionally, a second end 3166 of the channel 3158 is disposed proximate the surface 3150 of the PCB 3138. The channel 3158 is shaped and sized to allow fluid to pass through the injection port 3018 from the exterior of the housing 3030 to the interior cavity 3086. The illustrated channel 3158 has a circular cross-sectional shape and a predetermined size B (e.g., diameter).

[0200] 70-72, the battery pack assembly 3010 further includes a plurality of guide members 3174. Each guide member 3174 is configured as a wall extending from the inner surface 3146 of the upper housing portion 3050 (FIG. 70). An end of each guide member 3174 is spaced apart from the PCB 3138 (FIGS. 71-72). The guide members 3174 define a chamber 3178 within the internal cavity 3086 into which the fill port 3018 extends. The chamber 3178 is positioned adjacent to the PCB 3138 (e.g., upward from the perspective of the frame of reference of FIG. 72). Additionally, with particular reference to FIG. 71, the chamber 3178 axially separates the terminal block 3110 from the remaining space above the surface 3150 of the PCB 3138 within the internal cavity 3086, relative to the longitudinal axis 3058. The plurality of guide members 3174 are configured to direct fluid from the injection port 3018 to other portions of the internal cavity 3086 .

[0201] The battery pack internal cavity 3086 is configured to receive a fluid, such as during assembly of the battery pack 3014. In particular, the internal cavity 3086 has a volume, and each of the battery pack 3014 components (e.g., battery cells 3090, PCB 3138, etc.) and the fluid occupy a predetermined percentage of the volume. For example, in some embodiments, the battery pack components occupy at least 75% of the volume, and the fluid occupies 15% or less of the volume. Thus, the fluid is configured to fill gaps between the battery pack components and the interior surface of the housing 3030. Still further, in some embodiments, the fluid may not fill some of the gaps, such that a portion (e.g., 10% or less) of the volume of the internal cavity 3086 is not occupied by the battery pack components or the fluid. Hereinafter, this portion of the volume may be referred to as the “unoccupied space” of the internal cavity 3086. In the illustrated embodiment, the unoccupied space is located within a portion of the interior cavity 3086 defined by the upper housing portion 3050 (e.g., adjacent the inner surface 3146 of the upper housing portion 3050 and adjacent the battery contacts 3098).

[0202] In some embodiments, the battery pack components occupy 80%-85% of the volume, the liquid occupies 5-15% of the volume, and the remaining volume is unoccupied space. In further embodiments, the battery pack components occupy 85%-90% of the volume, the liquid occupies 5-15% of the volume, and the remaining volume is unoccupied space. In still further embodiments, the battery pack components occupy 90%-95% of the volume, the liquid occupies 2-5% of the volume, and the remaining volume is unoccupied space.

[0203] The fluid includes an adhesive material (e.g., glue). In the illustrated embodiment, the fluid is a two-part, addition-cure, thermally conductive silicone encapsulant 905. The adhesive material is configured to be poured into the battery pack 3014 (e.g., via the fill port 3018) until it occupies a predetermined volume of the internal cavity 3086 and is then cured to become a cured coating or layer 3188 ( FIG. 73H ) within the battery pack 3014. In particular, the fluid is configured to cover one, some, or all of the ends of the battery cells 3090, the top surface 3182 ( FIG. 79 ) of the body portion 3034, and / or the surface 3150 of the PCB 3138 (i.e., including the electrical components 3142 of the PCB 3138 as shown in FIG. 73G ). The fluid is distributed within the internal cavity 3086 (e.g., by the guide members 3174, gravity, etc.) such that at least an end portion of each of the battery contacts 3098 is not covered by the adhesive material. After curing, the adhesive material is configured to form a surface within the interior cavity 3086.

[0204] As shown in Table 1 below, the 905 two-component addition-cure thermally conductive silicone encapsulant adhesive has a thermal conductivity (W / m K), density (g / cm 3 Some adhesive properties can be varied, such as the volume resistivity (Ω·cm), the mixing viscosity (mPa·sec), and the like. For example, TDS-905 (G11) has a thermal conductivity of 0.7 or greater, and TDS-9225 (G91) has a thermal conductivity of 3.0 or greater. In addition, TDS-905 (G11) has a volume resistivity of 1.0*10 13 and TDS-9225 (G91) has a volume resistivity of 1.0*1012 Greater than.

[0205] [Table 1]

[0206] 73A-73F illustrate an example of a manufacturing process for the battery pack assembly 3010 of FIG. 65. In step 1, referring to FIG. 73A, battery cells 3090 and a battery cell holder (i.e., body portion 3034) are provided. Each of the battery cells 3090 is received (e.g., pressed into) the battery cell holder 3034. In step 2, referring to FIG. 73B, a battery strap 3094 is secured (e.g., by welding) to each end of the battery cell 3090. In step 3, referring to FIG. 73C, a PCB 3138 is secured (e.g., by welding) to the top surface 3182 of the body portion 3034. In step 4, referring to FIG. 73D, the top housing portion 3050 (having the fill port 3018) is positioned on the body portion 3034 of the bottom housing portion 3054. In step 5, referring to FIG. 73E, the first face portion 3042 and the second face portion 3046 are placed on the first and second faces of the body portion 3034. Fasteners (e.g., screws 3186 in FIG. 69) extending through the first face portion 3042 and the second face portion 3046 secure the entire assembly together. In the illustrated embodiment, four fasteners 3186 are used on each side 3070, 3074 of the housing 3030. In step 6, referring to FIG. 73F, fluid is injected into the internal cavity 3086 of the housing 3030 using the injection port 3018. In the illustrated embodiment, the tube 3190 is aligned with the injection axis 3170 of the channel 3158, and the fluid is directed through the tube 3180 and into the channel 3158. Thus, the fluid is received in the internal cavity 3086 with a single injection of fluid.

[0207] In another embodiment, as shown in FIGS. 73G-73H, the bottom housing portion 3054 is assembled first (e.g., the body portion 3034 and the first and second side portions 3042, 3046 are coupled together), and a portion of the fluid is received (e.g., injected) into the bottom housing portion 3054 before the top housing portion 3050 is coupled to the bottom housing portion 3054 ( FIG. 73G ). The remaining fluid is then received into the internal cavity 3086 of the completed assembly using the injection port 3018 of the top housing portion 3050. FIG. 73H shows the fluid disposed within the internal cavity 3086 after the remaining fluid has been received within the internal cavity 3086 and the top housing portion 3050 has been separated from the bottom housing portion 3054. Thus, the fluid is received into the internal cavity 3086 by at least two injections of fluid.

[0208] In yet another embodiment, the battery pack 3014 is fully assembled (i.e., by steps 1-5 of Figures 73A-73E), and then placed in a vacuum before beginning step 6 of injecting fluid into the internal cavity 3086 of the battery pack 3014 (Figure 73F).

[0209] The adhesive material is configured to be thermally conductive. For example, as shown in Table 2 below, thermal tests were performed on multiple battery packs at three different discharge rates of 40 A, 50 A, and 60 A. Temperature sensors T1 through T6 were placed at six different locations within the backpack. That is, T1 was located on the top surface 3182 of the body portion 3034 near one end of the PCB 3138, T2 was located on the top surface 3182 of the body portion 3034 near the opposite end of the PCB 3138 having the battery contacts 3098, T3 through T5 were located at the end of the corresponding battery cell 3090, and T6 was located on the bottom surface 3082 of the housing 3030. Each temperature sensor measured the temperature at the corresponding location. The battery packs 3014 with the adhesive material (e.g., battery packs 3# and 4#) had an overall lower temperature at each of the six locations during discharge of the corresponding battery pack 3014 compared to the battery packs without the adhesive material. As such, the battery pack 3014 having the adhesive material facilitates thermal conduction of heat away from the battery cells 3090 and the battery cell holder 3034 as the battery cells 3090 discharge. Thus, the adhesive material can improve the thermal performance of the battery pack 3014, which may improve the cycle life and cycle run time of the battery pack.

[0210] [Table 2]

[0211] The adhesive material is configured to prevent the ingress of water and / or moisture and / or to increase the strength of the battery pack housing 3030. More specifically, the adhesive material is configured to form a barrier between the battery pack components (e.g., battery cells 3090, PCB 3138, etc.) and the exterior of the housing 3030. As such, water and / or moisture is prevented from reaching the interior cavity 3086 of the battery pack housing 3030. The adhesive material is also configured to eliminate space between the various structures / components included in the battery pack 3014 and bond the battery pack components to the interior surface of the housing 3030 and to each other. As such, the strength of the housing 3030 is increased (e.g., if the battery pack 3014 is dropped). Additionally, the adhesive material is configured to withstand temperatures ranging from -50°C to 200°C, is not configured to shrink during curing, and / or is configured to be non-corrosive.

[0212] 74 illustrates another example of a battery pack 3014′ of the battery pack assembly 3010, which may include similar components and features as the embodiment of the battery pack 3014 illustrated in FIGS. 65-73F above. Accordingly, what was discussed above with respect to the battery pack assembly 3010 equally applies to the battery pack 3014 and will not be repeated. In particular, the battery pack 3014′ may include an inlet port 3018 having one or more channels 3158 configured to direct fluid into the interior cavity of the battery pack 3014.

[0213] Further details of the present disclosure are provided in the appendix.

[0214] Although the invention 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 invention described.

[0215] Various features of the invention are set forth in the following claims.

Claims

1. Housing and One or more battery cell assemblies received in the housing, wherein each of the one or more battery cell assemblies is A frame that defines, at least partially, the internal cavity, Multiple battery cells arranged in the aforementioned internal cavity, A heat sink comprising a body having a first surface, a second surface opposite to the first surface, a plurality of fins extending from the first surface, and a plurality of protrusions extending from the second surface, wherein the fins are located outside the internal cavity and the plurality of protrusions are arranged inside the internal cavity. Equipped with, The projection is positioned between the battery cells such that the battery cells and the projection are arranged sequentially in at least one direction within the internal cavity, in one or more battery cell assemblies. A battery pack assembly comprising the above features.

2. The battery pack assembly according to claim 1, wherein one or more of the projections comprises a channel that extends partially inward, and each of the one or more battery cell assemblies further comprises a heating rod received in each of the channels.

3. The battery pack assembly according to claim 2, wherein the body of the heat sink has a plurality of openings, each opening is connected to one of the channels, and the heating rod is inserted into the channel through the corresponding opening.

4. The battery pack assembly according to claim 3, wherein each of the openings is positioned between some of the plurality of fins on the first surface of the body of the heatsink.

5. The battery pack assembly according to claim 3, wherein the ends of each heating rod are positioned outside the corresponding aligned channels and openings.

6. The battery pack assembly according to claim 1, wherein each of the one or more battery cell assemblies comprises an adhesive material disposed in the internal cavity, the adhesive material in contact with the protrusions and the battery cells, and the adhesive material is thermally conductive to facilitate heat transfer between the battery cells and the protrusions.

7. The battery pack assembly according to claim 1, wherein each of the plurality of protrusions extends from the second surface of the main body to its end, each of the plurality of protrusions extends parallel to each of the battery cells, and the end of each of the protrusions is positioned adjacent to one end of the battery cell.

8. The battery pack assembly according to claim 1, wherein the frame comprises a plurality of support members, each support member positioned between a battery cell and one adjacent projection among the plurality of projections, and each support member is configured to position one of the battery cells and one of the projections in the internal cavity.

9. The battery pack assembly according to claim 1, further comprising a fan assembly disposed within the housing in close proximity to one of the one or more battery cell assemblies, wherein the fan assembly is operable to direct airflow through the fins of the one or more battery cell assemblies.

10. The battery pack assembly according to claim 1, further comprising a cover coupled to the frame, wherein the frame, the cover, and the second surface of the body of the heatsink cooperate to define the internal cavity.

11. The battery pack assembly according to claim 1, further comprising a plurality of connectors supported by the frame, each of which is connected to two or more of the battery cells.

12. Housing and One or more battery cell assemblies received in the housing, wherein each of the one or more battery cell assemblies is A frame that defines, at least partially, the internal cavity, Multiple battery cells arranged in the aforementioned internal cavity, A heat sink comprising a body having a first surface, a second surface opposite to the first surface, and a plurality of protrusions extending from the second surface, wherein the first surface is outside the internal cavity, the plurality of protrusions are arranged within the internal cavity, and one or more of the protrusions have channels that partially extend inward, A plurality of heating rods, each heating rod being received into one of the channels, and the projections being positioned between the battery cells such that the battery cells and the projections are arranged sequentially within the internal cavity, and A battery cell assembly comprising one or more battery cell assemblies A battery pack assembly comprising the above features.

13. The battery pack assembly according to claim 12, wherein one or more of the projections comprises a channel that extends partially inward, and each of the one or more battery cell assemblies further comprises a heating rod received in each of the channels.

14. The battery pack assembly according to claim 13, wherein the body of the heat sink has a plurality of openings, each opening is connected to one of the channels, and the heating rod is inserted into the channel through the corresponding opening.

15. The battery pack assembly according to claim 12, wherein each of the one or more battery cell assemblies comprises an adhesive material disposed in the internal cavity, the adhesive material in contact with the protrusions and the battery cells, and the adhesive material is thermally conductive to facilitate heat transfer between the battery cells and the protrusions.

16. The battery pack assembly according to claim 12, wherein each of the plurality of protrusions extends from the second surface of the main body to its end, each of the plurality of protrusions extends parallel to each of the battery cells, and the end of each of the protrusions is positioned adjacent to one end of the battery cell.

17. The battery pack assembly according to claim 12, further comprising a cover coupled to the frame, wherein the frame, the cover, and the second surface of the body of the heatsink cooperate to define the internal cavity.

18. A battery cell assembly for a battery pack, wherein the battery cell assembly is A frame that defines, at least partially, the internal cavity, Multiple battery cells arranged in the aforementioned internal cavity, A heat sink comprising a body having a first surface, a second surface opposite to the first surface, a plurality of fins extending from the first surface, and a plurality of protrusions extending from the second surface, wherein the fins are located outside the internal cavity, the plurality of protrusions are arranged inside the internal cavity, and one or more of the protrusions have channels that partially extend inward. Equipped with, A battery cell assembly in which the protrusions are positioned between the battery cells such that the battery cells and the protrusions are arranged sequentially within the internal cavity.

19. The battery cell assembly according to claim 18, further comprising one or more heating rods, each of which is received in one of the channels.

20. The battery cell assembly according to claim 18, further comprising an adhesive material disposed in the internal cavity, wherein the adhesive material is in contact with the protrusion and the battery cell, and the adhesive material is thermally conductive to facilitate heat transfer between the battery cell and the protrusion.