Battery Pack Contact Arrangement for Handheld Power Tool
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Solution Overview
Problem
The assembly process of battery packs for handheld power tools is costly, error-prone, and labor-intensive due to the complex series connection of battery cells and extensive cabling, which complicates the electrical and mechanical connections.
Innovation Solution
A battery pack design featuring a cell holder with a cladding surface and end faces for electrical poles, along with a flexible circuit board that allows for direct contact arrangements to connect battery cells to the battery pack electronics, eliminating the need for additional current conductors and enabling tolerance compensation and thermal expansion management through welded or soldered connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor plates and cables are soldered onto battery cell poles for series connection, then electrical connection between battery cells is achieved, but assembly process becomes costly and labor-intensive
Solution Approach 1:
The patent merges the electrical connection function into the battery cell structure itself by making the cladding surface electrically conductive. This eliminates the need for separate conductor plates and cables, as the cladding surface directly serves as the electrical contact surface. The contact arrangement on the circuit board contacts the cladding surface directly, achieving series connection without additional components.
Solution Approach 2:
The patent extracts the electrical connection function from the traditional conductor plate and cable assembly and integrates it into the battery cell's cladding surface. By making the cladding surface electrically conductive, the patent removes the need for separate connection components, simplifying the overall structure and assembly process.
2Adaptability or versatility
If extensive cabling is used for battery cell connections, then electrical connectivity is achieved, but assembly becomes error-prone and time-consuming
Solution Approach 1:
The patent combines the electrical connection function with the mechanical cladding surface of the battery cell. The cladding surface serves dual purposes: structural protection and electrical conduction. This eliminates the need for separate cabling, reducing assembly steps and time while maintaining electrical connectivity.
Solution Approach 2:
The battery cell's cladding surface serves its own electrical connection needs by being made electrically conductive. The contact arrangement on the circuit board directly contacts the cladding surface, allowing the battery cell structure to provide its own electrical connection function without requiring external cabling systems.
3Reliability
If conductor plates and cables are used for battery cell connections, then electrical connection is achieved, but device complexity increases
Solution Approach 1:
The patent merges the electrical connection function into the battery cell's cladding surface by making it electrically conductive. This eliminates the need for separate conductor plates and cables, significantly reducing device complexity while maintaining reliable electrical connection between battery cells.
Solution Approach 2:
The patent extracts the electrical connection function from the complex cabling system and integrates it into the battery cell structure itself. The cladding surface directly provides electrical conduction, removing the need for separate connection components and simplifying the overall device architecture.
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
This design simplifies the assembly process, reduces costs, enhances electrical and mechanical security, and allows for flexible adaptation to the battery pack housing, resulting in a more robust and longer-lasting battery pack with improved ergonomics and ease of use.
Implementation Method 1
the contact arrangement being connected to the battery pack electronics via a welded or soldered connection
Implementation Method 2
the contact arrangement being connected to the battery pack electronics via a welded or soldered connection
Implementation Method 3
through a correspondingly realized welded connection, a tolerance compensation and compensation of thermal expansion can also be achieved
Data Source
AI summary
A battery pack for a handheld power tool, having a cell holder that accommodates at least one battery cell, the battery cell having a cladding surface that runs parallel to a longitudinal axis, the cladding surface being limited by two end faces that run perpendicular to the longitudinal axis, and the cladding surface and the end faces forming an outer shell of the battery cell, and a battery pack electronics. The battery pack electronics includes at least one circuit board having contact elements for producing an electrical connection between the battery pack and the handheld power tool, in addition at least one contact arrangement corresponding to the battery cell is provided, the contact arrangement electrically contacting the corresponding battery cell at the cladding surface.