Modular Energy Storage Pack for Electric Power Tools
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Solution Overview
Problem
Existing battery packs, particularly lithium-ion batteries, are inefficient for high-energy-demand electric power tools like large angle grinders or chainsaws due to limitations in power peaks and running time, and face transportation safety and handling challenges when capacity exceeds certain limits, affecting profitability.
Innovation Solution
An energy storage pack design featuring a housing with multiple cell blocks and electrical pole terminals that can be connected in series or parallel, allowing for the combination of lower-power cell blocks to achieve higher energy content, using tulip contacts for easy connection and compatibility with existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If Li-ion battery capacity is increased to provide higher energy content for high-power tools, then running time and power level are improved, but transportation safety and handling become problematic
Solution Approach 1:
The battery pack is divided into multiple separate cell blocks (first cell block, second cell block, etc.) that can be independently connected to the same pole terminals. This segmentation allows the total capacity to be distributed across multiple smaller units rather than one large battery, improving safety while maintaining total energy content.
2Duration of action of moving object
If multiple cell blocks are connected in parallel to increase capacity, then running time is extended, but the physical size and complexity of the battery pack increases
Solution Approach 1:
Multiple cell blocks are electrically merged by connecting them to common pole terminals through the connection device. This allows the cell blocks to function as a single unified energy source with increased capacity, while the mechanical structure remains relatively simple with shared terminals and housing.
3Ease of operation
If cell blocks are electrically separated to improve safety and modularity, then handling becomes easier, but the energy content is reduced compared to a single large battery
Solution Approach 1:
The pole terminals and connection devices are designed to serve multiple functions: they connect individual cell blocks during assembly, maintain electrical connections during operation, and enable parallel configuration of multiple cell blocks. This universal design allows the same components to support both modular handling and aggregated energy storage.
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
Enables extended running time and higher power levels for electric power tools, reducing self-heating and increasing service life by allowing parallel discharge and providing a higher energy content than individual cell blocks, while maintaining compatibility with existing chargers and tools.
Implementation Method 1
cell blocks (52, 54, 56, 58) having electrochemical storage cells
Data Source
AI summary
An energy storage pack for an electric power tool comprising a housing for reception of a plurality of cell blocks having electrochemical storage cells, as well as electrical pole terminals to which poles of the cell blocks are electrically connectable. At least one pole terminal is embodied as a subassembly that encompasses two electrically separated contacts.