Modular Battery Pack Interface for Hot-Swappable Equipment Power
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Solution Overview
Problem
Existing battery-powered indoor and outdoor power equipment face challenges in terms of battery compatibility, charging efficiency, and versatility across different equipment types.
Innovation Solution
A modular battery assembly system that includes a battery pack with multiple cells, a handle with a movable member for easy disconnection, and a mating feature for connecting to both power equipment and charging stations, allowing for hot-swappable battery replacement and efficient charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed battery design is used in power equipment, then the equipment structure is simple, but the battery cannot be reused across different equipment types
Solution Approach 1:
The battery system is divided into a standardized battery pack module and equipment-specific receptacle module. The battery pack contains standardized electrical contacts and mechanical engagement features that can interface with multiple equipment types, while the equipment contains corresponding receptacles. This segmentation allows the battery pack to be a separate, reusable component across different power equipment.
Solution Approach 2:
The battery pack is designed with universal electrical and mechanical interfaces that can connect to multiple types of power equipment through standardized receptacles. The mating feature includes standardized ports and engagement mechanisms that work across different equipment types, enabling one battery pack to serve multiple functions and equipment platforms.
2Productivity
If batteries are designed for specific equipment types, then the equipment design is simplified, but charging efficiency and versatility are reduced
Solution Approach 1:
The receptacle is designed with universal electrical contacts and mechanical features that can accept multiple battery pack types. The standardized interface allows a single receptacle design to charge different battery chemistries and form factors, improving charging station versatility while maintaining efficient electrical connection through standardized port geometry.
Solution Approach 2:
The system accommodates different battery parameters (chemistry, voltage, capacity) through standardized mechanical and electrical interfaces. The receptacle and battery pack designs allow for parameter variations in battery technology while maintaining consistent connection geometry, enabling efficient charging across different battery types without requiring equipment redesign.
3Reliability
If batteries are permanently attached to equipment, then connection reliability is high, but battery replacement and charging time is increased
Solution Approach 1:
The mating feature incorporates a movable member that transitions between locked and unlocked positions. When locked, the connection is secure and reliable for operation. When unlocked, the battery pack can be quickly removed and replaced. This dynamic locking mechanism maintains connection reliability during use while enabling rapid battery exchange when needed.
Solution Approach 2:
The movable member acts as an intermediary locking mechanism between the battery pack and receptacle. It provides a simple user interface for securing or releasing the battery connection, enabling reliable attachment during operation and quick detachment for replacement or charging without complex tools or procedures.
4Adaptability or versatility
If a standardized mating feature is used across equipment, then battery interchangeability is improved, but manufacturing complexity increases
Solution Approach 1:
The standardized mating feature is segmented into modular components: electrical contacts, mechanical engagement features, and housing elements. This segmentation allows each component to be manufactured independently using optimized processes, then assembled into the complete battery pack or receptacle. The modular approach reduces overall manufacturing complexity while maintaining standardized interfaces.
Data Source
AI summary
A battery pack includes a housing defining an upper portion and a lower portion, a first protector portion coupled to a first corner of the housing, a second protector portion coupled to a second corner of the housing, a plurality of battery cells disposed within the housing, and a mating feature including a plurality of ports electrically connected to the plurality of battery cells and structured to supply power from the plurality of battery cells through the ports.