Integrated Battery Pack Charger for Simpler Charging and Pack Heating
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Solution Overview
Problem
Conventional rechargeable battery packs require separate chargers, leading to potential operator errors and inefficiencies in charging operations, especially in outdoor power equipment applications.
Innovation Solution
Integration of a battery charger within the battery pack, allowing for simplified charging operations and the ability to selectively heat the battery pack under predefined conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate charger is used for battery packs, then charging operations require additional equipment and operator intervention, but this leads to operator errors and reduced charging efficiency
Solution Approach 1:
The charger is integrated within the battery pack housing, combining the charging function with the battery storage unit. This eliminates the need for separate charger equipment and reduces operator intervention requirements, directly resolving the contradiction between operational simplicity and device complexity
Solution Approach 2:
The battery pack serves multiple functions: energy storage and integrated charging. The single unit performs both battery storage and charging operations, eliminating the need for dedicated charging equipment and reducing the overall system complexity while improving ease of operation
2Productivity
If the battery charger is integrated within the battery pack, then charging efficiency is enhanced and operator error is eliminated, but the internal cavity space must accommodate additional charging components
Solution Approach 1:
The charger components are nested within the battery pack's internal cavity, with the charger positioned to utilize available space efficiently. The charger is arranged to fit within the existing structural constraints while maintaining charging functionality, resolving the space constraint issue
3Temperature
If the battery charger dissipates energy into the housing for heating, then thermal management capability is provided, but energy is consumed from the battery system
Solution Approach 1:
The charger's waste heat, which would normally be dissipated to the environment, is instead directed into the battery pack to provide thermal management and heating when needed. This converts a harmful waste product into a beneficial thermal resource, addressing both temperature control and energy utilization
Solution Approach 2:
The system monitors battery temperature and controls the charger's heat dissipation accordingly. When heating is needed, the charger dissipates energy into the housing; when cooling is needed, the dissipation is reduced or redirected. This feedback mechanism balances thermal management needs with energy conservation
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
Eliminates the need for operator error in charger selection and enhances charging efficiency by integrating the charger, while providing thermal management capabilities.
Implementation Method 1
The battery charger is configured dissipate energy into the housing, when a temperature measurement of the temperature sensor is below a threshold value
Data Source
AI summary
A battery pack includes a battery housing defining an internal cavity, a first positive terminal extending through the housing, a first negative terminal extending through the housing, a plurality of battery cells within the internal cavity, and a battery charger within the internal cavity. The plurality of battery cells are electrically coupled to the first positive terminal and the first negative terminal. The battery charger is configured to charge the plurality of battery cells and includes a second positive terminal electrically coupled to the first positive terminal within the housing, and a second negative terminal electrically coupled to the first negative terminal within the housing.