Battery Pack Housing with Segmented Cell Holder for Flexible Configuration
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Solution Overview
Problem
Existing battery packs for portable power tools are inflexible in accommodating different numbers of battery cells, limiting their ability to adjust voltage and power ranges without modifying the housing structure.
Innovation Solution
The battery pack housing is designed with an open end face and a cell holder system that allows for secure positioning of battery cells using inner positional securing elements, enabling easy configuration of various cell numbers and arrangements without altering the housing structure, allowing for different voltage and power ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery cells are inserted directly into the battery pack housing without a cell holder, then the housing structure remains simple, but the battery pack cannot accommodate different numbers of cells or configurations without modifying the housing
Solution Approach 1:
The battery pack is divided into modular components: a fixed housing and removable cell holders. The cell holders can be independently inserted or removed from the housing, allowing flexible configuration of battery cell numbers without modifying the housing structure itself.
Solution Approach 2:
The housing is designed with universal receptacles that can accommodate different types and numbers of cell holders. The same housing structure can support various battery configurations (different cell counts and arrangements) by simply changing the cell holders, making the housing multi-functional.
2Adaptability or versatility
If the housing structure is modified to accommodate different battery cell configurations, then adaptability improves, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of modifying the housing for different configurations, the system segments the battery assembly into standardized housing and interchangeable cell holders. This allows mass production of standardized housings while accommodating various configurations through different cell holder combinations.
Solution Approach 2:
The system changes the number and arrangement of cell holders rather than modifying the housing structure itself. By varying parameters such as the quantity of cell holders (1, 2, or more) and their positions within the same housing, different voltage and power ranges are achieved without retooling the housing manufacturing process.
3Reliability
If positional securing elements are added to the housing to secure cell holders, then cell holder positioning stability improves, but the housing structure becomes more complex
Solution Approach 1:
The positional securing elements are strategically positioned at asymmetric locations within the housing (e.g., specific walls or corners). This asymmetric arrangement provides stable positioning for cell holders while minimizing the number of securing elements needed, as each element is placed where it provides maximum structural leverage.
Solution Approach 2:
The cell holders are designed with features that enable them to self-secure into the housing using the positional securing elements. The insertion process itself activates the securing mechanism (e.g., through elastic deformation or mechanical interlocking), eliminating the need for additional active securing components or complex assembly steps.
Data Source
AI summary
An exchangeable battery pack for an electric device has a housing with a first end face and a second end face opposite the first end face, wherein the first end is open. A housing cover closes off the first end face. Battery cells are disposed in the housing. Cell connectors electrically connect the cells with one another. An external electrical connector is disposed on the second end face. All of the battery cells are connected to the external electrical connector. The battery cells are charged and discharged through the external electrical connector. A cell holder secures several of the battery cells. An inner positional securing element is provided on an inner side of a sidewall of the housing and the cell holder interacts with the positional securing element.