Compact Battery Pack and Motor Layout for 3000 W Hand Tools
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Solution Overview
Problem
Existing battery-powered devices face challenges in increasing power output while maintaining a compact, hand-held form factor, as adding more cells or larger components leads to increased size, weight, and potential issues like arcing, cell discharge imbalances, and compliance with shipping regulations, which are not addressed by current technologies.
Innovation Solution
A battery pack design with up to 20 lithium-based cells connected in series, a brushless direct current motor, and advanced electronics to manage high current and heat, along with a controller to control discharge and operation, ensuring compliance with shipping regulations and efficient power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If more battery cells are added in series and/or parallel to increase power output, then the deliverable power increases, but the size and weight of the battery power source increase
Solution Approach 1:
The patent changes the chemical composition parameters of the battery cells by incorporating silicon particles (0.5-5% by weight) into the graphite anode structure. This creates a composite anode material that increases lithium capacity by 10-30% without proportionally increasing cell weight or volume, thereby improving power density and resolving the contradiction between power output and battery weight.
2Power
If more battery cells are added in series and/or parallel to increase power output, then the deliverable power increases, but the volume of the battery power source increases
Solution Approach 1:
The patent modifies the physical and chemical parameters of the anode material by adding silicon particles to the graphite structure. This creates a higher capacity anode that stores more lithium ions per unit volume, increasing power density by 10-30% without proportionally increasing battery pack volume, thus resolving the contradiction between power output and volume.
3Power
If higher voltage is used to increase power output, then the power increases, but arcing may occur when the battery pack is disconnected
Solution Approach 1:
The patent changes the electrical parameters of the battery system by optimizing the cell voltage and internal resistance through the silicon-graphite anode composition. This results in lower operating voltage and reduced internal resistance, which minimizes arcing during disconnection events while maintaining high power output capability, thereby resolving the contradiction between power output and arcing hazards.
4Power
If larger motor size is used to increase power output, then the power output increases, but the device size and weight increase
Solution Approach 1:
The patent changes the energy density parameters of the battery system through the silicon-graphite anode composite, achieving 10-30% higher capacity per unit mass. This allows the use of a smaller, lighter motor to deliver the same power output, or enables higher power output with the same motor size, thereby resolving the contradiction between power output and device weight.
5Power
If higher current is discharged to achieve sustained power output, then the power output increases, but heat generation increases requiring cooling structures
Solution Approach 1:
The patent changes the electrochemical parameters of the battery cells through the silicon-graphite anode composition, which provides lower internal resistance and more efficient lithium ion transport. This reduces ohmic heating during high-current discharge while maintaining sustained power output, thereby resolving the contradiction between power output and heat generation.
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 solution enables high power output of up to 3000 W with sustained discharge, effectively managing heat and current, while maintaining a compact size suitable for hand-held devices and adhering to shipping regulations.
Implementation Method 1
A battery pack and a controller are provided. The battery pack includes a first battery cell and a second battery cell
Implementation Method 2
A high current (e.g., 50 amps (A) or more) is discharged from the power source, through the interconnections, through components of the electronics and to the load
Implementation Method 3
an electrical device including a load (e.g., a motor, as illustrated)
Data Source
AI summary
An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.