Battery Pack Structure for Handheld High-Power Output
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Solution Overview
Problem
Existing battery-powered devices face challenges in delivering high power output within the size and weight constraints of hand-held devices, including increased impedance, heat management, and component damage due to high current and heat, while existing solutions conflict with the limitations of being hand-held.
Innovation Solution
The solution involves a battery pack with up to 15 cells connected in series and parallel, a brushless direct current motor with reduced impedance, and advanced electronics to control current discharge and manage heat, along with improved interconnections and electronics to handle high currents and heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of battery cells is increased to deliver higher power, then the power output increases, but the size and weight of the battery power source increase
Solution Approach 1:
The patent changes the electrical parameters of the battery system by configuring 15 battery cells in a specific series-parallel arrangement to achieve 18-20V nominal voltage and 100A peak current capability, delivering 1800-2400W peak power without proportionally increasing battery pack size or weight
2Power
If the number of battery cells is increased to deliver higher power, then the power output increases, but the volume of the battery power source increases
Solution Approach 1:
The patent achieves high power output through optimized electrical parameter configuration (15 cells in series-parallel, 18-20V, 100A peak current) rather than simply increasing cell quantity, thereby avoiding proportional volume increase
3Power
If the current is increased to achieve higher power output, then the power output increases, but heat generation increases requiring cooling structures
Solution Approach 1:
The patent converts the harmful heat generated by high current (100A peak) into a manageable parameter through optimized battery cell configuration and electrical system design, where the heat is dissipated through controlled thermal paths without requiring additional active cooling structures
Solution Approach 2:
The patent manages heat by changing electrical parameters (voltage 18-20V, current 100A peak) and configuring the battery system to operate efficiently at these parameters, reducing unnecessary heat generation through optimized resistance and current distribution
4Device complexity
If existing interconnections are used with increased current, then the device complexity remains low, but component damage occurs due to high current and heat
Solution Approach 1:
The patent changes the current handling parameters by configuring 15 battery cells in series-parallel to achieve 100A peak current capability, with interconnections and electronics specifically designed and rated for these high current parameters, preventing component damage while maintaining operational reliability
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 solution achieves a peak power output of 1800-2400 watts with a nominal voltage of 18-20 volts, exceeding existing limits, while maintaining a compact and lightweight design suitable for hand-held devices.
Implementation Method 1
a battery pack including a plurality of battery cells (100) connected in a 5S3P configuration
Implementation Method 2
a brushless direct current motor with reduced impedance
Implementation Method 3
improved interconnections and electronics to handle high currents and heat
Data Source
AI summary
A battery pack may include a housing including a support portion connectable to and supportable by an electrical device, the support portion defining a channel operable to receive a projection on the electrical device, the support portion including a plastic material molded to define the channel, and a metal material molded in the plastic material, the metal material defining a C-shaped portion around the channel. A battery pack may include a plurality of battery cells supported by the housing. A battery pack may include a battery terminal electrically connected to the plurality of battery cells and connectable to a terminal of the electrical device.