Rechargeable battery pack with improved energy density

Abstract

To provide a rechargeable battery pack with improved energy density.SOLUTION: A battery pack includes a housing at least partially defining an interior volume therein, a docking interface, and a cell pack assembly at least partially positioned within the interior volume. The cell pack assembly includes a plurality of battery cells, where each battery cell includes a body, an anode extending from the body, and a cathode extending from the body, where the cell pack assembly defines cell packing volume in the shape of a rectangular prism that completely encompasses each body portion of the plurality of cells, and where the cell pack assembly is packaged such that the combined volume of the body portions of each battery cell of the plurality of battery cells occupies 80% or more of the cell packing volume.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to earlier filed and co-pending U.S. Provisional Patent Application No. 63 / 369,200, filed July 22, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to rechargeable battery packs, and more particularly to rechargeable battery packs having improved energy density. [Background technology]

[0003] Rechargeable battery packs typically store power in a number of individual cylindrical battery cells contained within the battery pack housing. Summary of the Invention [Means for solving the problem]

[0004] In one aspect, a battery pack includes a housing at least partially defining an internal volume therein, a docking interface, and a cell pack assembly at least partially disposed within the internal volume, the cell pack assembly including a plurality of battery cells, each battery cell including a body, an anode extending from the body, and a cathode extending from the body, the cell pack assembly defining a rectangular parallelepiped-shaped cell packing volume that completely contains each body portion of the plurality of cells, and the cell pack assembly being packaged such that a combined volume of the body portions of each battery cell of the plurality of battery cells occupies 80% or more of the cell packing volume.

[0005] Alternatively or additionally, in any combination, the cell pack assembly is packaged such that the total volume of the body portion of each battery cell of the plurality of battery cells occupies 85% or more of the cell packing volume.

[0006] Alternatively or additionally, in any combination, the cell pack assembly is packaged such that the total volume of the body portion of each battery cell of the plurality of battery cells occupies 87.5% or more of the cell packing volume.

[0007] Alternatively or additionally, in any combination, each battery cell of the plurality of battery cells has the same outer dimensions.

[0008] Alternatively or additionally, in any combination, each battery cell of the plurality of battery cells is of the same battery construction.

[0009] Alternatively or additionally, in any combination, the cell pack assembly includes at least five individual battery cells contained therein.

[0010] Alternatively or additionally, in any combination, the body portion of each battery cell forms a rectangular parallelepiped shape.

[0011] In another aspect, a battery pack includes a housing at least partially defining an interior volume therein, a docking interface, and a cell pack assembly at least partially disposed within the interior volume, the cell pack assembly including a plurality of battery cells, each battery cell including a body portion, an anode extending from the body portion, and a cathode extending from the body portion, the cell pack assembly defining a rectangular parallelepiped-shaped cell packing volume that completely contains each body portion of the plurality of battery cells, and the cell pack assembly is packaged such that the cell packing volume stores 150 Ah / L or more of energy when fully charged.

[0012] Alternatively or additionally, in any combination, the cell pack assembly is packaged to store between 150 Ah / L and 200 Ah / L of energy when fully charged.

[0013] Alternatively or additionally, in any combination, the cell pack assembly is packaged such that when fully charged, the cell pack volume stores approximately 166.7 Ah / L of energy.

[0014] Alternatively or additionally, in any combination, each battery cell of the plurality of battery cells is of the same construction.

[0015] Alternatively or additionally, in any combination, the body portion of each battery cell includes a body height, a body width, and a body length, and the body height is at least 3 mm.

[0016] Alternatively or additionally, in any combination, the body height is 7 mm.

[0017] In another aspect, a battery pack includes a housing at least partially defining an interior volume therein, a docking interface, and a cell pack assembly at least partially disposed within the interior volume, the cell pack assembly including a plurality of battery cells arranged in a stack along a stack axis, each battery cell defining a battery cell height parallel to the stack axis, and a plurality of intermediate members disposed between adjacent battery cells, each intermediate member defining a intermediate member height parallel to the stack axis, wherein a ratio of the battery cell heights to the intermediate member heights is at least 3:1.

[0018] Alternatively or additionally, in any combination, the ratio of the battery cell height to the intermediate member height is at least 7:1.

[0019] Alternatively or additionally, in any combination, each battery cell of the plurality of battery cells has the same battery cell height.

[0020] Alternatively or additionally, in any combination, each intermediate member of the plurality of intermediate members has the same intermediate member height.

[0021] Alternatively or additionally, in any combination, each battery cell of the plurality of battery cells includes a body portion, an anode extending from the body portion, and a cathode extending from the body portion, the body portion forming a rectangular parallelepiped shape.

[0022] Alternatively or additionally, in any combination, at least one of the intermediate members forms a rectangular parallelepiped shape. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a perspective view of a rechargeable battery pack having improved energy density. [Figure 2] FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. [Figure 3] FIG. 2 is a perspective view of a cell pack assembly of the rechargeable battery pack of FIG. 1. [Figure 4] FIG. 4 is a side view of the cell pack assembly of FIG. 3. [Figure 5] FIG. 4 is a perspective view of a battery cell from the cell pack assembly of FIG. 3. [Figure 6-7] 1 illustrates another embodiment of a cell pack assembly. [Figure 8-9] 1 illustrates another embodiment of a cell pack assembly. [Figure 10-11] 1 illustrates another embodiment of a cell pack assembly. [Figure 12-15] 1 illustrates various embodiments of a cell pack assembly. [Figure 16] 1 illustrates a prior art embodiment of a cell pack assembly. [Figure 17-18] Compare 2P and 3P style battery packs with a similarly sized 1P style battery pack. DETAILED DESCRIPTION OF THE INVENTION

[0024] Before describing any embodiments of the present disclosure in detail, it is to be understood that the disclosure 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 disclosure is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0025] 1-2 generally illustrate a rechargeable battery pack 10 having improved energy density for use in selectively powering an electrically powered device, such as a power tool or the like (not shown). Battery pack 10 includes a housing 14 at least partially defining an interior volume 18 therein, a docking interface 22 formed at least in part by housing 14, a cell-pack assembly 26 disposed within interior volume 18, and a battery management system 30 in electrical communication with both cell-pack assembly 26 and docking interface 22 and configured to selectively direct the flow of electrical energy therebetween.

[0026] 1, the housing 14 of the battery pack 10 is a clamshell structure that includes a first or upper housing portion 14a and a second or lower housing portion 14b. When assembled, the upper housing portion 14a is fixedly coupled (e.g., by snaps, fasteners, etc.) to the lower housing portion 14b to at least partially enclose an interior volume 18 therebetween. As shown in FIG. 1, the housing 14 also includes a pair of rubber-coated bumpers 34 coupled to the housing 14, which are configured to help cushion the transmission of external impact forces to the housing 14 during operation.

[0027] 1 , the docking interface 22 of the battery pack 10 serves as a mounting location where the battery pack 10 can be physically and electrically connected to another device (e.g., a power tool, a battery charger, etc.). In the illustrated embodiment, the docking interface 22 is integrally formed with the upper housing portion 14a and includes a pair of rails 38, a pair of user-actuable latches 42, and one or more electrical contacts 46, each configured to form a temporary electrical connection with an external device for transferring power to and from the external device. While the illustrated docking interface 22 is shown in the form of a “slide and lock” system, it should be understood that different configurations and connection styles may be used in other embodiments.

[0028] 2 , the cell pack assembly 26 of the rechargeable battery pack 10 includes a plurality of individual rechargeable battery cells 50 that are physically positioned and packaged in close proximity to one another in a manner configured to minimize unused space and maximize overall energy storage density. More specifically, the individual cells 50 are coupled or otherwise secured to one another to form a signal stack, which may then be fitted into the interior volume 18 of the housing 14. In the illustrated embodiment, each of the individual rechargeable battery cells 50 are wired together (e.g., combining series and / or parallel groups) so that the resulting cell pack assembly 26 is configured to provide a single combined electrical output at a desired power level to the docking interface 22 via the battery management system 30. While the illustrated embodiment of the battery pack 10 includes a single cell pack assembly 26 that is disposed entirely within the interior volume 18, it should be understood that additional cell pack assemblies 26 may be present in other embodiments of the battery pack 10.

[0029] 5, each individual battery cell 50 of the cell pack assembly 26 is a pouch-style cell having a pouch or body portion 54, a positive tab 58 (e.g., positive terminal) extending outwardly from the body portion 54, and a negative tab 62 (e.g., negative terminal) extending outwardly from the body portion 54. In the illustrated embodiment, both the negative tab 62 and the positive tab 58 exit the body portion 54 along a single edge of the body portion 54 (see FIG. 3), although in other embodiments, the negative tab 62 and the positive tab 58 can exit the body portion 54 anywhere as needed to minimize the distance involved in the resulting electrical connection.

[0030] The body portion 54 of each rechargeable cell 50 includes an outer semi-flexible pouch that encloses a sealed inner battery volume (not shown). This sealed battery volume, in turn, contains multiple layered anode and cathode materials with a separator sandwiched therebetween to form a rechargeable lithium-polymer cell. The specific layout of the cells is critical to the desired performance of the completed battery pack 10.

[0031] The illustrated rechargeable cell 50 is generally based on lithium-ion technology, although it should be understood that in other embodiments, different types of rechargeable battery chemistries or layouts may be used. In the illustrated embodiment, the configuration of the internal battery volume is such that the body portion 54 of the cell 50 can store 650 Wh / L when fully charged.

[0032] In the illustrated embodiment, the body portion 54 of each cell 50 forms a substantially rectangular parallelepiped shape that defines a cell height 66, a cell width 70, and a cell length 74. As shown in FIG. 3 , the overall shape of the body portion 54 is generally flat and plate-like, with the cell length 74 and cell width 70 being relatively much larger than the cell height 66. The illustrated shape also produces planar top and bottom surfaces 78, 82 suitable for stacking. While the illustrated body portion 54 is generally rectangular in cross-sectional shape along a cutting plane set parallel to the top and bottom surfaces 78, 82, it should be understood that in other embodiments, different cross-sectional sizes and shapes may be used while still maintaining a generally “flat” profile. For example, the exterior profile of the body portion 54 of each cell 50 may be varied to correspond to the size and shape of the available interior volume.

[0033] 3, each individual battery cell 50 of the cell pack assembly 26 is organized in a generally "stack-like" configuration, whereby the top surface 78 of one cell 50 is disposed adjacent to the bottom surface 82 of an adjacent cell 50, and so on. The cells 50 are also oriented such that the peripheries of each body portion 54 are generally aligned to create an overall rectangular parallelepiped shape.

[0034] In some embodiments, the cell pack assembly 26 may further include one or more interlayers 86 disposed between adjacent cells 50. The interlayers 86 may include, but are not limited to, insulating layers, cooling layers, adhesive layers, shielding layers, etc. In yet other embodiments, two or more interlayers 86 may be present between pairs of adjacent cells 50. In the illustrated embodiment, the size (e.g., thickness) of the interlayers is minimized because space is occupied by items that are not battery cells. Thus, the ratio of the cell height 66 to the interlayer height 88 is 3:1. In other embodiments, the ratio of the cell height 66 to the interlayer height 88 is 1.5:1, 2:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, and 10:1. In yet other embodiments, the ratio of the cell height 66 to the interlayer height 88 is 3:1 to 10:1, 3:1 to 7:1, 5:1 to 10:1, and 7:1 to 10:1.

[0035] The resulting assembly of cells 50 and intermediate layer 86 also defines a stack axis 90 that passes through the geometric center of the top and bottom surfaces 78, 82 of each cell 50 and is oriented generally perpendicular to those surfaces. The stack axis 90 is configured to represent the alignment of the individual cells 50 in the stack. As shown in FIG. 4 , the stack axis 90 is parallel to the height dimension 66 of each stacked cell 50.

[0036] The body portions 54 of the battery cells 50 of the cell pack assembly 26 also together define a cell packing volume or CPV 100 (see FIGS. 3 and 4). For purposes of this application, the CPV 100 of an article is defined as the smallest possible rectangular reference box within which the article can be completely enclosed. More specifically, the CPV 100 of the present cell pack assembly 26 generally comprises the smallest possible rectangular reference box within which the body portions 54 of all stacked cells 50 can be enclosed, disregarding negative tabs 62, positive tabs 58, or outwardly extending flash (see FIG. 4).

[0037] In the illustrated configuration, the body portions 54 of the cell-pack assembly 26 are stacked and packaged such that the combined volume of the body portions 54 of each of the stacked cells 50 occupies 80% or more of the overall volume of the CPV 100. In other embodiments, the combined volume of the body portions 54 of each of the battery cells 50 may occupy 81%, 82%, 83%, 84%, 85%, 86%, 87%, or 87.5% or more of the overall volume of the CPV 100. In still other embodiments, the combined volume of the body portions 54 of each of the battery cells 50 may occupy 80%-90%, 80%-87.5%, 85%-87.5%, or 85%-90% of the overall volume of the CPV 100.

[0038] The cells 50 of the cell pack assembly 26 may also be packaged so that, when fully charged, the corresponding CPV 100 can store 464 Wh / L or more of energy. In other embodiments, the battery pack assembly 26 may be packaged so that, when fully charged, the corresponding CPV 100 can store 475 Wh / L, 500 Wh / L, 525 Wh / L, 550 Wh / L, 575 Wh / L, 600 Wh / L, 625 Wh / L, and 650 Wh / L or more of energy. In still other embodiments, the battery pack assembly 26 may be packaged so that, when fully charged, the corresponding CPV 100 can store 464 Wh / L to 600 Wh / L, 464 Wh / L to 650 Wh / L, 500 Wh / L to 600 Wh / L, and 525 Wh / L to 600 Wh / L of energy.

[0039] Additionally, the cells 50 of the cell-pack assembly 26 are packaged such that the corresponding CPV 100 can store 129 Ah / L or more when fully charged. In other embodiments, the CPV 100 can store 140 Ah / L, 150 Ah / L, 160 Ah / L, or 166.7 Ah / L or more when fully charged. In still other embodiments, the cells 50 of the cell-pack assembly 26 are packaged such that the corresponding CPV 100 can store 129 Ah / L to 166.7 Ah / L, 129 Ah / L to 170 Ah / L, or 140 Ah / L to 166.7 Ah / L when fully charged.

[0040] Once assembled, the cell pack assembly 26 may be placed within the interior volume 18 of the battery housing 14 and wired in place. In the illustrated embodiment, each cell 50 of the cell pack assembly 26 is identical in structure, and therefore each body portion 54 has similar outer dimensions. In other embodiments, different cell structures and / or cell types forming different sizes and shapes may be combined to produce the cell pack assembly 26.

[0041] In addition to minimizing unused volume and maximizing energy density within the interior volume 18 of the battery pack 10, the cell pack assembly 26 is also configured to utilize and package the individual battery cells 50 to minimize the number of electrical connections required to electrically integrate the cell pack assembly 26 into a battery for operation and to minimize losses incurred at any given connection. More specifically, each cell 50 generally requires the creation of two electrical junctions (e.g., one to connect the anode and one to connect the cathode) in order to electrically incorporate the corresponding cell 50 into the battery pack 10 for use. Each electrical junction, in turn, adds resistance to the circuit.

[0042] In the illustrated embodiment, each cell 50 has a weld area of ​​3.13 mm 2 In another embodiment, each cell is joined to the battery pack 10 using a weld-type connection that is greater than 6.65 mm 2 , 16.27mm 2 , 27.03mm 2 or 36.65 mm 2 The joints are made using a weld-type connection that is larger than the

[0043] In other embodiments, cell-pack assembly 26 may minimize losses incurred due to electrical connections by reducing the number of connections required. More specifically, cell-pack assembly 26 may be configured to replace 2P or 3P style batteries with 1P systems, thereby reducing the number of connections by two or three orders of magnitude, respectively. In such systems, the 1P cells are configured to maintain the original power output requirements within the same or smaller housing (see FIGS. 17 and 18).

[0044] 6 and 7 illustrate a first alternative embodiment of a cell-pack assembly 1026. The cell-pack assembly 1026 includes a plurality (e.g., five) of rechargeable battery cells 1050, each having a first alternative structure and wired for a 5S1P layout. The cells 1050 are then stacked vertically on one another with 1 mm thick intermediate layers 1086 sandwiched between them. The body portion 1054 of each cell 1050 is rectangular shaped and has a body width 1070 of 65 mm, a body length 1074 of 90 mm, and a body height 1066 of 7 mm. The resulting combination of the five body portions 1054 and five intermediate layers 1086 together defines a CPV 1100 that is 65 mm wide, 90 mm long, and 40 mm high (see FIG. 7). As a result, the body portion 1054 of the battery cells 1050 contained within the cell pack assembly 1026 occupies 87.5% of the volume of the overall CPV 1100. The ratio of the body height 1066 to the intermediate layer height 88 is 7:1.

[0045] Furthermore, the alternating structure of battery cells 1050 and intermediate layers 1086 results in a cell pack assembly 1026 in which 87.5% or more of the vertical height 1500 (e.g., parallel to the stack axis 1090) of the CPV 1100 is occupied by the height of the battery cells 1050. In other words, only 12.5% ​​of the vertical height of the CPV 1100 is occupied by the intermediate layers 1086.

[0046] 8 and 9 show a second alternative embodiment of a cell pack assembly 2026. The cell pack assembly 2026 includes a plurality (e.g., ten) of rechargeable battery cells 2050, each having a second alternative structure and wired in a 5S2P configuration. The cells 2050 are then stacked vertically on top of each other with 1 mm thick intermediate layers 2086 sandwiched between them. The body portion 2054 of each cell 2050 is rectangular shaped and has a body width 2070 of 65 mm, a body length 2074 of 90 mm, and a body height 1066 of 3 mm. The resulting combination of the ten body portions 2054 and ten intermediate layers 2086 together defines a CPV 2100 that is 65 mm wide, 90 mm long, and 40 mm high (see FIG. 9 ). As a result, the body portion 2054 of the battery cell 2050 contained within the cell pack assembly 2026 occupies 75% of the volume of the overall CPV 2100. The ratio of the body height 1066 to the intermediate layer height 88 is 3:1.

[0047] Furthermore, the alternating structure of battery cells 2050 and intermediate layers 2086 results in a cell pack assembly 2026 in which 75% or more of the vertical height 2500 (e.g., parallel to the stack axis 2090) of the CPV 2100 is occupied by the total height of the battery cells 2050. In other words, 25% of the vertical height of the CPV 2100 is occupied by the intermediate layers 2086.

[0048] 10 and 11 illustrate a third alternative embodiment of a cell pack assembly 3026. The cell pack assembly 3026 includes a plurality (e.g., 15) of rechargeable battery cells 3050, each having a third alternative structure and wired in a 5S3P configuration. Furthermore, the cells 3050 are stacked vertically on top of each other with 1 mm thick intermediate layers 3086 sandwiched between them. The body portion 3054 of each cell 3050 is rectangular shaped and has a body width 3070 of 65 mm, a body length 3074 of 90 mm, and a body height 3066 of 1.67 mm. The resulting combination of the 15 body portions 3054 and the 15 intermediate layers 3086 together defines a CPV 3100 that is 65 mm wide, 90 mm long, and 40 mm high (see FIG. 11 ). As a result, the body portion 3054 of the battery cell 3050 contained within the cell pack assembly 3026 occupies 62.5% of the volume of the overall CPV 3100. The ratio of the body height 3066 to the intermediate layer height 88 is 1.67:1.

[0049] Furthermore, the alternating structure of battery cells 3050 and intermediate layers 3086 results in a cell pack assembly 3026 in which 62.5% or more of the vertical height 3500 (e.g., parallel to the stack axis 3090) of the CPV 3100 is occupied by the height of the battery cells 3050. In other words, 37.5% of the vertical height 3500 of the CPV 3100 is occupied by the intermediate layers 3086.

[0050] FIG. 12 illustrates a fourth alternative embodiment of a cell pack assembly 4026. The cell pack assembly 4026 includes a plurality of rechargeable battery cells 4050, each having the same fourth alternative battery cell structure. In the illustrated structure, the cell pack assembly 4026 includes three individual cells 4050 stacked vertically on top of each other without any intermediate layers between them. The body portion 4054 of each cell 4050 forms a rectangular parallelepiped shape with the entire body portion 4054 having a volume of 24 cc. The cell 4050 is also capable of storing 4 Ah of charge such that the body portion 4054 has an energy density of 650 Wh / L. Three body portions 4054 of the cell 4050 are packaged together to produce a 72 cc CPV 4100. The resulting CPV 4100 therefore has an energy density of 650 Wh / L and a capacity of 175 Ah / L.

[0051] FIG. 13 illustrates a fifth alternative embodiment of a cell pack assembly 5026. The cell pack assembly 5026 includes a plurality of rechargeable battery cells 5050, each having the same fifth alternative battery cell structure. In the illustrated structure, the cell pack assembly 5026 includes three individual cells 5050 stacked vertically on top of each other without any intermediate layers. The body portion 5054 of each cell 5050 forms a rectangular parallelepiped shape, with each individual body portion 5054 having a volume of 30 cc. The cell 5050 can store 5 Ah of charge such that the body portion 5054 has an energy density of 600 Wh / L. Three body portions 5054 of the cell 5050 are packaged together to produce a 90 cc CPV 5100. The resulting CPV 5100 therefore has an energy density of 650 Wh / L and a capacity of 175 Ah / L.

[0052] FIG. 14 illustrates a sixth alternative embodiment of a cell pack assembly 6026. The cell pack assembly 6026 includes a plurality of rechargeable battery cells 6050, each having the same sixth alternative battery cell structure. In the illustrated structure, the cell pack assembly 6026 includes two individual cells 6050 stacked vertically on top of each other without an intermediate layer between them. The body portion 6054 of each cell 6050 forms a rectangular parallelepiped shape with the entire body portion 6054 having a volume of 36 cc. The cell 6050 can store 6 Ah of charge such that the body portion 6054 has an energy density of 600 Wh / L. Two body portions 6054 of the cell 6050 are packaged together to produce a 72 cc CPV 6100. The resulting CPV 6100 therefore has an energy density of 650 Wh / L and a capacity of 175 Ah / L.

[0053] FIG. 15 illustrates a seventh alternative embodiment of a cell pack assembly 7026. The cell pack assembly 7026 includes a plurality of rechargeable battery cells 7050, each having the same seventh alternative battery cell structure. In the illustrated structure, the cell pack assembly 7026 includes two individual cells 7050 stacked vertically on top of each other without an intermediate layer between them. The body portion 7054 of each cell 7050 forms a rectangular parallelepiped shape with the entire body portion 7054 having a volume of 45 cc. The cells 7050 can store 7.5 Ah of charge each, such that the body portion 7054 has an energy density of 600 Wh / L. Two body portions 7054 of the cells 7050 are packaged together to produce a 90 cc CPV7100. The resulting CPV7100 therefore has an energy density of 650 Wh / L and a capacity of 175 Ah / L.

[0054] FIG. 16 shows a prior art battery pack 8000 for use in a battery-powered device, such as a power tool (not shown). The cell pack assembly 8012 includes multiple rechargeable battery cells 8016, each having the same cylindrical battery cell structure. In the illustrated structure, the cell pack assembly 8012 includes three individual cells 8016, each oriented parallel to one another and stacked horizontally next to one another (see FIG. 16 ). The body portion 8020 of each cell 8016 is cylindrical in shape, with an individual cell volume of 24 cc. The cells 8016 can store 4 Ah of charge, such that each body portion 8020 has an energy density of 650 Wh / L. Three body portions 8020 are packaged together to produce a 93 cc CPV 8100. The resulting CPV 8100 therefore has an energy density of 464.5 Wh / L and a capacity of 129 Ah / L. Furthermore, the three cells 8016 are packaged such that the combined volume of the three body portions 8020 occupies 79% of the total volume of the CPV 8100.

[0055] 17 compares a first battery housing 9000a with a first exterior shape including a plurality of cylindrical cells 9004a with a second battery housing 9000b with the same first exterior shape but including a plurality of pouch-style cells 9004b. Additionally, cell 9004b has planar top and bottom surfaces 9008b and 9012b, as described above, but also includes a non-rectangular cross-sectional shape parallel to the top and bottom surfaces 9008b and 9012b. Cell 9004a has one of a 2P or 3P layout, while cell 9004b has a 1P layout.

[0056] 18 compares a first battery housing 10000a with a first exterior shape including a plurality of cylindrical cells 10004a with a second battery housing 10000b with the same first exterior shape but including a plurality of pouch-style cells 10004b. Additionally, the cells 10004b have planar top and bottom surfaces 10008b and 10012b, as described above, but are oriented such that the axial stack height (e.g., along axis 10016b) of the stack of cells 10000b is greater than both the length and width of an individual cell 10000b perpendicular to axis 10016b. Cell 10004a is in one of a 2P or 3P layout, while cell 10004b is in a 1P layout. [Explanation of symbols]

[0057] 10 Rechargeable Battery Pack 14 Housing 14a Upper housing part 14b Lower housing part 18 Internal Volume 22 Docking Interface 26 Cell Pack Assembly 30 Battery Management System 34 Rubber-coated bumper 38 Rail 42 Latch 46 Electrical Contacts 50 rechargeable battery cells 54 Main body part 55 cell height 58 Positive Tab 62 negative tab 66 cell height 70 cells wide 74 cell length 78 Top 82 bottom 86 Middle Class 88 Mid-level height 90 stack axis 1026 Cell Pack Assembly 1050 rechargeable battery cell 1054 Main body part 1066 Body height 1070 Body width 1074 Body length 1086 Middle Class 1090 stack axis 1500 vertical height 2026 Cell Pack Assembly 2050 rechargeable battery cell 2054 Main body part 2070 Body width 2074 Body length 2086 Middle Class 2090 stack axis 2500 vertical height 3026 Cell Pack Assembly 3050 Rechargeable Battery Cell 3054 Main body part 3066 Body height 3070 Body width 3074 Body length 3086 Middle Class 3090 stack axis 3500 vertical height 4026 Cell Pack Assembly 4050 rechargeable battery cell 4054 Main body part 5026 Cell Pack Assembly 5050 Rechargeable Battery Cell 5054 Main body part 6026 Cell Pack Assembly 6050 rechargeable battery cell 6054 Main body part 7026 Cell Pack Assembly 7050 Rechargeable Battery Cell 7054 Main body part 8000 Conventional battery pack 8012 Cell Pack Assembly 8016 Rechargeable Battery Cell 8020 Main body part 9000a 1st Battery Housing 9000b Second Battery Housing 9004a Cylindrical Cell 9004b Pouch format cell 9008b Top side 9012b bottom 10000a 1st battery housing 10000b Second Battery Housing 10004a Cylindrical Cell 10004b Pouch-type cell 10008b Top surface 10012b bottom 10016b axis

Claims

[Claim 1] A battery pack, a housing at least partially defining an interior volume therein; a docking interface; a cell pack assembly at least partially disposed within the interior volume; and the cell pack assembly includes a plurality of battery cells, each battery cell including a body, an anode extending from the body, and a cathode extending from the body; the cell pack assembly defines a cell packing volume in the shape of a rectangular parallelepiped that completely contains each body portion of the plurality of cells; The cell pack assembly is packaged such that a total volume of the body portion of each battery cell of the plurality of battery cells occupies 80% or more of the cell packing volume. Battery pack.

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