Adjustable Battery Cell Carrier for Multi-Size Pack Housing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs are limited to supporting a single configuration of battery cells, necessitating separate housings for different cell sizes, which increases manufacturing costs and reduces flexibility.
Innovation Solution
A battery pack design featuring a battery cell carrier with adjustable carriage spacing and mounting features that accommodate different battery cell sizes, allowing for interchangeable configurations within a single housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a battery pack is designed to fit into a limited space, then the volume is reduced, but the heat dissipation capability deteriorates
Solution Approach 1:
The battery pack is divided into multiple battery modules, each with its own cooling channels. This segmentation allows heat to be dissipated from each module independently, improving overall heat dissipation efficiency while maintaining a compact total volume.
Solution Approach 2:
Cooling channels are integrated within the battery module structure itself, utilizing the internal three-dimensional space of each module for heat dissipation. This approach enables effective heat removal without increasing the external dimensions of the battery pack.
2Volume of moving object
If battery modules are tightly arranged to reduce space, then volume efficiency improves, but maintenance accessibility deteriorates
Solution Approach 1:
The battery pack is segmented into multiple independent battery modules that can be individually accessed and maintained. This modular design allows technicians to work on specific modules without disassembling the entire pack, improving maintenance accessibility while maintaining high space utilization.
Solution Approach 2:
The battery module design incorporates universal mounting and connection interfaces, allowing modules to be easily replaced or maintained. The standardized design enables quick swapping and maintenance operations without requiring custom tools or procedures for each module.
3Temperature
If cooling channels are made larger to improve heat dissipation, then thermal management improves, but device complexity increases
Solution Approach 1:
The cooling channels are merged with the battery module housing structure, combining the cooling function with the structural support function. This integration eliminates the need for separate cooling components, reducing overall device complexity while maintaining effective heat dissipation.
Solution Approach 2:
The battery module housing serves multiple functions: structural support, electrical insulation, and heat dissipation through integrated cooling channels. This multi-functionality reduces the number of separate components needed, simplifying the overall device while improving thermal management.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery pack is configured to be coupled to a power tool. The battery pack includes a housing having a cavity. The battery pack includes a battery cell carrier having first and second carriages. The first and second carriages support a plurality of battery cells therebetween. The battery cell carrier is configurable in different configurations based on a size of the plurality of battery cells supported between the first and second carriages. The battery pack includes a plurality of mounting features between the housing and the battery cell carrier. The plurality of mounting features is configured to alternatively secure the different configurations of the battery cell carrier to the housing.