Battery Pack Lead-Out Layout for High-Current Heat Control
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Solution Overview
Problem
Existing battery packs for power tools face safety and reliability issues due to increased heat generation during high current usage, which shortens their lifespan and requires frequent replacements, increasing operational costs.
Innovation Solution
The battery pack design incorporates longer lead-out pieces for improved heat dissipation, a protective element to disconnect the discharge path when excessive current is detected, and a cell elastic piece for shock resistance and thermal management, along with a deformation sensor to monitor and prevent cell deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple cylindrical lithium batteries are connected in series and parallel to increase discharge and charge current, then the electric energy output and operating efficiency are improved, but the heat generation of components increases sharply causing safety and reliability problems
Solution Approach 1:
The patent changes the physical parameters of the lead-out pieces by increasing their length and adjusting their cross-sectional dimensions. This parameter modification reduces electrical resistance and improves heat dissipation capacity, allowing the battery pack to handle high currents safely without excessive heat generation, thus resolving the contradiction between power output and safety reliability
Solution Approach 2:
The patent introduces a protective element as an intermediary component in the current path. This protective element acts as a mediator that can disconnect the discharge path when excessive current is detected, preventing heat-related safety issues while allowing normal high-power operation, thus resolving the contradiction between power output and safety reliability
2Productivity
If multiple cylindrical lithium batteries are connected in series and parallel to increase discharge and charge current, then the operating efficiency is improved, but the heat generation increases causing shortened battery pack life
Solution Approach 1:
The patent modifies the physical parameters of thermal management components, specifically increasing the length of lead-out pieces and optimizing their cross-sectional area. These parameter changes enhance heat dissipation efficiency, allowing the battery pack to maintain high operating efficiency without excessive temperature rise that would shorten its service life
Solution Approach 2:
The patent implements a feedback mechanism through the deformation sensor that monitors the state of battery cells. When the sensor detects deformation or abnormal conditions indicating excessive heat or stress, it triggers the protective element to disconnect the circuit, preventing damage and extending battery pack life while maintaining high productivity during normal operation
3Temperature
If longer lead-out pieces are used to improve heat dissipation, then the heat generation is reduced, but the device complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the dimensions of existing components rather than introducing entirely new systems. By carefully selecting the length and cross-sectional area of lead-out pieces, the patent achieves improved heat dissipation through simple dimensional modifications, avoiding significant increases in device complexity
4Reliability
If a protective element is added to disconnect the discharge path when excessive current is detected, then the safety and reliability are improved, but the device complexity increases
Solution Approach 1:
The protective element serves as a simple intermediary component that passively responds to electrical conditions. It automatically disconnects the discharge path when excessive current is detected without requiring complex control systems, thereby improving safety and reliability with minimal increase in device complexity
Solution Approach 2:
The protective element operates on a self-service principle by automatically detecting and responding to excessive current conditions without external intervention. This self-activating mechanism provides safety protection while maintaining simplicity, as the component monitors and protects itself without requiring additional complex control circuitry
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 reduces heat generation, enhances safety and reliability, and extends the battery pack's service life by effectively managing thermal and mechanical stresses.
Implementation Method 1
the heat generation of components of the battery pack through which the currents flow increases gradually
Implementation Method 2
longer lead-out pieces for improved heat dissipation
Implementation Method 3
a cell elastic piece for shock resistance and thermal management
Implementation Method 4
a protective element to disconnect the discharge path when excessive current is detected
Data Source
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AI summary
Provided is a battery pack. The battery pack includes a cell assembly. The cell assembly includes a cell assembly positive terminal, a cell assembly negative terminal, a positive lead-out piece, a negative lead-out piece, a discharge path, and a protective element. The positive lead-out piece connects the cell assembly positive terminal to a battery pack positive terminal. The negative lead-out piece connects the cell assembly negative terminal to a battery pack negative terminal. The discharge path is configured to supply power to a power tool and consists of the cell assembly positive terminal, the positive lead-out piece, the battery pack positive terminal, the cell assembly negative terminal, the negative lead-out piece, and the battery pack negative terminal. The protective element is disposed on the discharge path. In response to the discharge current of the discharge path being greater than or equal to a preset current, the protective element turns off to disconnect the discharge path. The length of one of the positive lead-out piece or the negative lead-out piece close to the protective element is greater than the length of the other one of the positive lead-out piece or the negative lead-out piece away from the protective element. The preceding technical solutions can reduce the heat generation of the battery pack, thus improving the safety and reliability of the battery pack and extending the service life of the battery pack.