Cordless Tool Battery Pack with Phase-Change Heat Absorbing Plate
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Solution Overview
Problem
Battery-powered cordless tools face limitations in continuous operation due to limited battery capacity and increased charging time, especially in high-temperature environments, requiring multiple battery packs and chargers, which is costly and inefficient.
Innovation Solution
A cordless system with at least two lithium battery packs that alternate in discharging and charging, using a charger to maintain continuous operation, along with a heat absorption device and intelligent temperature monitoring to extend discharging time and shorten charging time, ensuring uninterrupted power supply at a lower cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the battery capacity is increased to extend discharging time, then the working time is improved, but the battery pack size and weight increase
Solution Approach 1:
The system divides the power supply function into multiple battery packs that can be used alternately. Instead of using one large-capacity battery, the invention segments the total capacity requirement across multiple smaller battery packs, allowing continuous operation through sequential charging and discharging while keeping each individual battery pack lightweight.
2Duration of action of moving object
If multiple battery packs are prepared to ensure continuous operation, then the discharging time is extended, but the system cost increases
Solution Approach 1:
The invention merges multiple battery packs into a unified system with a single charger that can charge multiple packs simultaneously or sequentially. This integration allows resource sharing and coordinated management of multiple battery packs, reducing the total number needed compared to having separate charger-battery pairs.
Solution Approach 2:
The system ensures continuous useful action by implementing an alternating charging-discharging cycle among multiple battery packs. While one battery is discharging to power the tool, another is charging, ensuring uninterrupted operation without requiring a battery for every possible time slot.
3Power
If the battery pack operates in high-temperature environment, then the power output is maintained, but the charging time increases due to heat dissipation requirements
Solution Approach 1:
The invention introduces a heat-absorbing plate as an intermediary component between the battery and the environment. This plate acts as a thermal buffer that absorbs excess heat generated during charging in high-temperature environments, allowing the battery to charge at optimal rates without thermal damage, thereby reducing charging time compared to passive cooling methods.
4Loss of time
If the battery pack is charged quickly to reduce charging time, then the charging speed is improved, but the temperature increases causing safety issues
Solution Approach 1:
The heat-absorbing plate utilizes phase transition materials that change phase (e.g., from solid to liquid or between crystalline structures) at specific temperature thresholds. During quick charging, these materials absorb excessive heat through endothermic phase transitions, maintaining battery temperature within safe limits while allowing high charging currents to be applied without thermal runaway risks.
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 system allows for continuous and circular operation of high-power cordless tools by maintaining a safe and efficient electrical supply, extending the working time of battery packs to be equal to or greater than the charging time, while minimizing heat-related issues and reducing the need for multiple battery packs.
Implementation Method 1
a heat absorbing plate is disposed in the battery pack to absorb heat from the battery pack, thereby allowing for a faster charging speed
Data Source
AI summary
A tool discharges one battery pack and a charger simultaneously charges another battery pack to provide for continuous and circular operation of the tool. Tool system includes a tool and a lithium based battery pack having a nominal voltage of at least 56 volts for supplying power to the tool. A heat absorbing device is associated with the battery pack and includes a phase-change material.