Battery Pack with Non-Parallel Cell Orientation for Heat Management
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Solution Overview
Problem
Existing battery packs face inefficiencies in heat management and cell arrangement, leading to reduced performance and lifespan due to parallel cell configurations, which can result in inadequate heat transfer and uneven voltage distribution among cells.
Innovation Solution
A battery pack design featuring non-parallel cell orientations, with a housing that supports cells in a normal relation to each other, along with a sensor system for voltage comparison and a controller to balance cell voltages, and a heat sink for efficient heat management, along with a locking assembly for secure attachment to devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cells are arranged in parallel configuration, then battery pack capacity is increased, but heat transfer becomes inadequate and voltage distribution becomes uneven
Solution Approach 1:
The patent transitions from a two-dimensional parallel cell arrangement to a three-dimensional configuration where cells are stacked vertically with alternating orientations. This dimensional change increases surface area exposure for heat dissipation and improves thermal management while maintaining high cell density for battery capacity.
Solution Approach 2:
The patent employs asymmetric cell orientations where adjacent cells are positioned at different angles (e.g., 0 degrees and 90 degrees). This asymmetric arrangement prevents uniform heat distribution patterns, enhances convective heat transfer, and improves voltage balance by creating varied current paths through the cell connections.
2Quantity of substance
If cells are arranged in parallel configuration, then battery pack capacity is increased, but voltage distribution among cells becomes uneven
Solution Approach 1:
The patent employs asymmetric cell orientations where adjacent cells are positioned at different angles (e.g., 0 degrees and 90 degrees). This asymmetric arrangement prevents uniform heat distribution patterns, enhances convective heat transfer, and improves voltage balance by creating varied current paths through the cell connections.
Solution Approach 2:
The patent transitions from a two-dimensional parallel cell arrangement to a three-dimensional configuration where cells are stacked vertically with alternating orientations. This dimensional change increases surface area exposure for heat dissipation and improves thermal management while maintaining high cell density for battery capacity.
3Temperature
If non-parallel cell orientations are used, then heat transfer is enhanced and voltage balance is improved, but device complexity increases
Solution Approach 1:
The patent divides the battery pack into modular cell groups that can be independently assembled. Each group follows the alternating orientation pattern, allowing for standardized manufacturing processes and simplified assembly procedures despite the complex overall configuration. This segmentation reduces device complexity by creating repeatable modular units.
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 enhances heat transfer, maintains optimal operating temperatures, balances cell voltages, and provides secure attachment, resulting in improved battery pack performance, efficiency, and extended lifespan.
Implementation Method 1
a heat sink for efficient heat management
Data Source
AI summary
An electrical combination including a driver drill capable of producing an average current draw of approximately 20-amps, a circular saw capable of producing an average current draw of approximately 20-amps, and a power tool battery pack operable to supply power to the driver drill and to the circular saw, the battery pack including a plurality of battery cells, the plurality of battery cells each having a lithium-based chemistry.