Battery Pack Air Cooling via Flexible Membrane and Segmented Housing
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Solution Overview
Problem
Air-cooled battery packs face issues with metallic dust and water ingress through ventilation openings, leading to short circuits and corrosion, while sealed packs overheat due to lack of air cooling, and existing connections are costly and prone to defects.
Innovation Solution
A battery pack design featuring a housing with detachable components, using connecting screws for conductor plates and a cell carrier that maintains pole separation, along with an air-guiding structure and elastic sealing elements to prevent contamination and allow air cooling, and an integrated fuse area for cost-effectiveness and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ventilation openings are provided for air cooling, then cooling performance is improved, but dust and water ingress occurs leading to short circuits and corrosion
Solution Approach 1:
A flexible membrane is integrated into the ventilation opening to allow air passage while blocking metallic dust and water particles. The membrane selectively permits gas molecules to pass while filtering out larger particulate contaminants, resolving the contradiction between cooling needs and contamination prevention.
2Reliability
If battery cells are arranged at a distance from one another, then short circuit risk is reduced, but housing volume increases
Solution Approach 1:
The housing interior is segmented into isolated compartments using partition walls and insulating structures. Each battery cell or cell block is placed in its own compartment, preventing direct contact between cells while maintaining compact overall dimensions. This segmentation approach reduces short circuit risk without requiring excessive spacing.
3Reliability
If conductor plates are used for series connection, then electrical connection is achieved, but connection cost and defect risk increase
Solution Approach 1:
The conductor plate is integrated directly into the housing structure as a built-in component rather than being a separate attached element. The housing and conductor plate form a unified structure that is manufactured as one piece or pre-assembled unit, eliminating separate connection steps and reducing assembly costs while maintaining reliable electrical connection.
4Object-affected harmful factors
If housing is sealed off from outside, then protection from dust and water is improved, but air cooling capability is lost
Solution Approach 1:
A flexible membrane is installed in the ventilation opening to create a selective barrier. The membrane allows air molecules to pass through for cooling purposes while blocking larger particulate matter such as metallic dust and water droplets, thus maintaining both protection and cooling functions simultaneously.
5Ease of repair
If detachable housing components are used, then assembly and maintenance is simplified, but structural complexity increases
Solution Approach 1:
The housing is divided into modular segments (first housing part, second housing part, cell carrier) that can be independently assembled and disassembled. Each segment serves a specific function and can be accessed separately for maintenance or replacement, simplifying repair operations while the modular design keeps the overall structure manageable.
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 design enhances air cooling, prevents short circuits and corrosion, simplifies assembly, and extends battery life while reducing costs by using a non-destructive connection method and integrated components.
Implementation Method 1
a flow of cooling air that can flow around the battery cells accommodated in the interior of the housing, at least in the region of their lateral surface
Implementation Method 2
an elastic sealing element that is able to seal the housing in the area of the charge level indicator from the environment
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
The invention relates to a battery pack (10), in particular for an electric hand tool, comprising: at least two battery cells (20) and/or battery cell blocks connected in series or parallel, a housing for receiving the battery cells (20) and/or battery cell blocks, and a circuit board (24) comprising electronic components, wherein the battery cells (20) are connected to each other via at least one first conductor sheet (22) and to the circuit board (24) via at least two second conductor sheets, and wherein the first and second conductor sheets (22) are connected to the circuit board (24) via first and second connecting screws (90, 92, 94, 98 and 62, 96).