Convertible Battery Pack Switching Circuit
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Solution Overview
Problem
Conventional power tool battery packs are limited in their ability to provide versatile power solutions, as they cannot efficiently switch between series and parallel connections, leading to limitations in power tools' usage, weight, and frequent recharging, making them unsuitable for heavy-duty applications and inconvenient to manage on construction sites.
Innovation Solution
A convertible battery pack with an improved switching circuit that includes mechanical and electrical elements, such as sliding housing and spring-loaded contacts, allowing for reliable switching between series and parallel configurations, and a manufacturing process that enhances electrical contact performance and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional battery packs use fixed series or parallel connections, then the battery pack structure is simple, but the adaptability to different power requirements is limited
Solution Approach 1:
The battery pack employs a dynamic switching mechanism that allows the connection configuration between battery cells to change from fixed to variable. The switching circuit enables transitions between series and parallel connections based on power requirements, making the battery pack adaptable to different applications while maintaining manageable complexity through modular design.
Solution Approach 2:
The battery pack is designed with multi-functionality to serve both cordless power tools and corded electrical devices. By incorporating a switching circuit that can reconfigure battery cell connections, a single battery pack design can provide multiple output configurations (series for higher voltage, parallel for higher current), eliminating the need for separate battery packs for different applications.
2Power
If cordless power tools use higher capacity batteries to increase power and runtime, then the power and runtime are improved, but the battery weight increases creating ergonomic disadvantages
Solution Approach 1:
Instead of increasing battery capacity (which increases weight), the invention changes the electrical configuration parameters by switching between series and parallel connections. This allows the same battery cells to provide different voltage and current outputs, achieving higher power for heavy-duty applications without adding weight, as the physical battery pack remains the same.
3Duration of action of moving object
If cordless power tools use higher capacity batteries to extend runtime, then the runtime is improved, but the battery weight increases creating ergonomic disadvantages
Solution Approach 1:
The invention extends runtime by changing operational parameters through switching between series and parallel configurations rather than increasing battery capacity. The same battery cells can be reconfigured to provide extended runtime at lower power draws, or higher power for shorter durations, without any weight increase since the physical battery pack remains unchanged.
4Ease of manufacture
If conventional battery packs are designed for specific voltage outputs, then the manufacturing process is simple, but the versatility for different applications is limited
Solution Approach 1:
The battery pack is segmented into modular components with a switching circuit that can independently configure connections between battery cells. This segmentation allows the same manufactured battery pack to be adapted for different applications by changing the switching configuration, maintaining ease of manufacture while achieving versatility through software or mechanical switching control.
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 battery pack provides multiple output voltages, enhances ergonomic usability by reducing weight, and improves reliability and efficiency, enabling the use of cordless power tools for heavier applications and reducing the need for frequent recharging.
Implementation Method 1
at least one spring held in the housing positioned between the housing and the at least one contact forcing the at least one contact towards the planar surface and the plurality of contact pads
Data Source
AI summary
The present disclosure is directed to a convertible battery pack having an improved switching circuit. The switching circuit includes a converter element having a plurality of contacts positioned in the converter element such that as the converter element slides within the battery pack the contacts move from a first position to engage a first set of contact pads to a second position to engage a second set of contact pads. The converter element includes a pair of springs for each of the plurality of contacts that force the contacts into engagement with the contact pads but also allow the contacts to adjust for imperfections in the contact pad surface or the manufacturing tolerances of the contact pads or a support board that holds the contact pads.