Battery Pack Switch for Shipping-Compliant Cell Reconfiguration
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Solution Overview
Problem
Battery packs with lithium-ion cells face shipping regulations that limit voltage and power capacity, necessitating a solution to safely and efficiently configure and disconnect battery cells to meet these constraints.
Innovation Solution
A battery pack design incorporating a switch with a conductive and non-conductive portion that allows for electrical connection and disconnection of battery cells, enabling configuration in series or parallel types to achieve desired voltage and power capacity while complying with shipping regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are connected in series to increase voltage output, then the voltage capacity is improved, but the battery pack may exceed shipping regulation limits
Solution Approach 1:
The battery pack incorporates a switchable configuration system that allows dynamic reconfiguration of battery cell connections between series and parallel arrangements. This enables the voltage output to be adjusted based on operational needs while ensuring compliance with shipping regulations by switching to parallel configuration when voltage limits are approached.
Solution Approach 2:
The system changes the electrical configuration parameters of the battery pack by switching between series and parallel connections. This alters the effective voltage and current characteristics of the battery pack, allowing it to meet different operational requirements and regulatory constraints by modifying the connection topology rather than changing the physical battery cells.
2Adaptability or versatility
If a switchable configuration system is added to reconfigure battery cells, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated switch mechanism that simultaneously handles both the series and parallel reconfiguration of battery cells. This unified approach reduces the overall complexity compared to having separate switching mechanisms for each configuration change.
Solution Approach 2:
The battery pack is segmented into modular battery cell groups that can be independently switched and reconfigured. This modular segmentation allows for simpler switching mechanisms that only need to manage discrete groups of cells rather than individual cells, reducing overall system complexity.
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 allows for flexible configuration of battery packs to output specific voltages (e.g., 72V or 120V) and power capacities (e.g., up to 300 watt-hours), ensuring compliance with shipping regulations while providing reliable power for devices like power tools.
Implementation Method 1
The conductive portion is configured to electrically connect the first terminal to the second terminal when the switch is in the first position
Implementation Method 2
The non-conductive portion is configured to galvanically isolate the first terminal from the second terminal when the switch is in the second position
Data Source
AI summary
A battery pack including a housing defining an aperture, a first battery cell within the housing, a second battery cell within the housing, and a switch. The first battery cell is electrically connected to a first terminal. The second battery cell is electrically connected to a second terminal. The switch is configured to be in a first position and a second position. The switch includes a user-interface, that may extend through the aperture, and a plate, located within the housing. The plate includes a conductive portion and a non-conductive portion. The conductive portion is configured to electrically connect the first terminal to the second terminal when the switch is in the first position. The non-conductive portion is configured to galvanically isolate the first terminal from the second terminal when the switch is in the second position.