Integrated Battery Pack Cell Detection for Vibration-Proof Wiring
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Solution Overview
Problem
Conventional tool battery packs face issues with increased wiring harnesses leading to reduced energy density, complex routing, insulation damage from vibrations, and degraded waterproofing due to relative displacement at plug-in terminals.
Innovation Solution
A tool battery pack design that integrates multiple unit battery cell detectors onto a single connecting member, replacing discrete wiring harnesses and plug-in terminals with a bonding pad matrix, enhancing space utilization, dynamic reliability, and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete wiring harnesses are used for each battery cell, then electrical connection and monitoring are achieved, but space utilization deteriorates and energy density is reduced
Solution Approach 1:
The patent merges multiple discrete wiring harnesses into a single integrated circuit board that provides both electrical connections and monitoring functions for all battery cells. The circuit board integrates power distribution traces and signal detection traces into unified pathways, eliminating the need for separate wiring harnesses for each cell while maintaining reliable electrical connections and monitoring capabilities.
Solution Approach 2:
The circuit board serves multiple functions simultaneously: it distributes power to all battery cells through power traces, monitors cell voltages through detection traces, and provides structural support. This multi-functional integration replaces the single-function discrete wiring harnesses, achieving both space savings and functional completeness.
2Measurement precision
If multiple independent wiring harnesses are used for monitoring, then detection precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple voltage detection functions into a single circuit board with integrated detection traces. Each battery cell is monitored through dedicated detection trace pathways on the circuit board, maintaining individual measurement precision while eliminating the complexity of multiple independent wiring harnesses. The circuit board provides a unified, organized structure for all detection functions.
3Ease of manufacture
If conventional plug-in terminals with silicone seals are used, then ease of assembly is improved, but waterproofing reliability deteriorates under vibration
Solution Approach 1:
The patent replaces the mechanical plug-in terminal system with silicone seals and compression springs with a direct welding connection system. The circuit board is welded directly to the battery cell tabs, creating permanent, vibration-resistant electrical connections that eliminate the mechanical interfaces prone to displacement and waterproofing failure under vibration conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated design improves space utilization, reduces short-circuit risks, and maintains IPX7 waterproofing under high-vibration and high-humidity conditions, ensuring stable electrical connections and efficient heat dissipation.
Implementation Method 1
the second connecting end is connected to the control board through a welding process
Data Source
AI summary
Embodiments of the present application relate to the technical field of energy. A tool battery pack is provided. The tool battery pack includes: multiple unit battery cells and a control device, where the control device includes a control board and a connecting member, where the connecting member includes multiple connecting tabs and a plate- or sheet-shaped unit battery cell detector having a first connecting end and a second connecting end, each of the multiple connecting tabs has one end connected to a corresponding one of the multiple unit battery cells and another end directly connected to the first connecting end; the multiple connecting tabs are integrated at the first connecting end, and the second connecting end is connected to the control board through a welding process.