Battery Pack Heat Spreader for Power Tool Thermal Management

The patent applies composite materials by integrating a heat spreader element made of thermally conductive material (such as metal or thermally conductive plastic) into the plastic housing structure. This creates a composite construction where the heat spreader layer is embedded within or attached to the housing wall, combining the mechanical advantages of plastic with the thermal conductivity of metal or specialized polymers, thereby resolving the contradiction between ease of manufacture and heat dissipation capability

The patent implements local quality by concentrating thermal conductivity enhancement specifically in the regions where heat dissipation is most needed. The heat spreader element is positioned adjacent to battery cells and thermal inserts, creating localized zones of high thermal conductivity within the otherwise insulating plastic housing. This allows the housing to maintain its overall mechanical properties while providing targeted heat dissipation pathways

The patent introduces thermal inserts and heat spreader elements as intermediary components between the battery cells and the housing. These intermediaries serve as thermal bridges that capture heat generated by high-power battery cells and redirect it through dedicated pathways to external heat dissipation surfaces, thereby enabling high power conversion while managing the associated heat generation through intermediate thermal management stages

The patent segments the thermal management function by separating heat dissipation into distinct stages: thermal inserts in contact with individual battery cells, heat spreader elements that distribute heat laterally, and housing walls that conduct heat to the environment. This segmentation allows each component to be optimized for its specific thermal task, enabling support for high-power battery cells through a distributed thermal management architecture

The patent applies local quality by creating differentiated zones within the housing: tightly sealed regions for moisture protection and localized thermally conductive pathways for heat dissipation. The heat spreader elements and thermal inserts provide dedicated thermal channels that operate independently of the overall sealing structure, allowing the housing to maintain both moisture tightness and heat dissipation capability through spatially differentiated functional zones

The patent uses thermal inserts and heat spreader elements as intermediary thermal pathways that bridge the gap between the sealed battery cell environment and the external environment. These intermediaries provide controlled thermal transmission routes that do not compromise the overall sealing integrity, allowing heat to escape through designated thermal pathways while maintaining moisture protection through the sealed housing structure