Convertible Battery Pack Circuit Layout for Multi-Voltage Power Tools
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Solution Overview
Problem
Existing power tools are limited by their power and runtime capabilities, with corded tools requiring an AC power supply and cordless tools being inadequate for heavy-duty applications due to weight and voltage constraints, leading to ergonomic disadvantages and limited acceptance in industries like construction.
Innovation Solution
A power tool system featuring a convertible battery pack that can operate in multiple configurations to match the voltage requirements of different power tools, allowing a single battery pack to power tools with varying rated voltages, including AC/DC compatibility and automatic configuration based on tool type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher voltage and capacity batteries are used in cordless tools to increase power and runtime, then the battery weight increases, creating ergonomic disadvantages
Solution Approach 1:
The battery pack uses a reconfigurable electrical connection system with switching elements that dynamically change the series/parallel configuration of battery cells based on the power tool's voltage requirements. This dynamic reconfiguration allows the same battery pack to adapt between different voltage outputs without physical changes or additional weight.
Solution Approach 2:
A single battery pack design serves multiple functions by providing compatibility with both 18V and 36V power tools through electrical reconfiguration. The battery pack includes terminals and control circuits that enable it to function as either a lower voltage or higher voltage power source, eliminating the need for separate battery packs for different tool types.
2Adaptability or versatility
If multiple battery pack types are used to match different power tool voltage requirements, then voltage compatibility is achieved, but device complexity and user burden increase
Solution Approach 1:
The battery pack incorporates a universal design with reconfigurable electrical connections that enable it to interface with power tools of different voltage ratings. The control circuit automatically or manually configures the battery cell connections to match the required voltage, allowing one battery pack type to replace multiple specialized packs.
Solution Approach 2:
The battery pack is divided into multiple individual battery cells that can be electrically reconfigured through switching elements. This segmentation allows flexible arrangement of cells in series or parallel configurations, enabling the same physical battery pack to output different voltages by changing the electrical connection topology between cell groups.
Data Source
AI summary
A method of manufacturing a battery pack including the creation of a support board for enabling conversion of the battery pack from providing a first voltage to providing a second voltage. The support board is created by injection molding about a precut set of power traces for coupling a converting element to a plurality of battery cells. The power traces couple the plurality of battery cells to a set of battery pack terminals. The support board may be mechanically coupled to a battery cell holder.