Movable Inductive Heater Assembly for Cold Battery Pack Charging
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Solution Overview
Problem
Lithium-based battery packs face challenges in maintaining capacity and performance when charged in cold weather, as charging below a certain temperature threshold can damage the cells and reduce their effectiveness.
Innovation Solution
An inductive heater assembly is integrated into the battery pack system, which includes a coil winding that generates an electromagnetic field to heat the battery pack before or during charging, ensuring it operates within an optimal temperature range by connecting between the charger and the battery pack, and is movable to accommodate different positions for efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery packs are charged in cold weather below the temperature threshold, then charging speed and productivity are improved, but the reliability and safety of the battery cells deteriorate due to damage to internal chemistry
Solution Approach 1:
The inductive heater assembly is activated before charging begins to preheat the battery pack to the required temperature threshold. This preliminary heating action ensures the battery is at the correct temperature before the charging process starts, allowing fast charging to proceed safely without damaging the battery chemistry.
Solution Approach 2:
The inductive heater assembly acts as an intermediary device between the charger and the battery pack. It mediates the temperature condition by providing controlled heating through electromagnetic induction, enabling the charging process to occur at safe temperatures even in cold environmental conditions.
2Temperature
If the battery pack is heated using traditional resistance heating, then the temperature is raised to the charging threshold, but energy loss and heating efficiency deteriorate due to excessive power consumption and uneven heat distribution
Solution Approach 1:
The patent replaces traditional resistance heating (mechanical/thermal system) with inductive heating using electromagnetic fields. The coil winding generates an alternating magnetic field that induces eddy currents in the battery pack's conductive housing, which then generates heat internally through resistive losses in the housing material. This method is more efficient because it heats the battery from the outside through electromagnetic coupling without requiring direct electrical contact or high-power resistance elements inside the battery.
Solution Approach 2:
The inductive heater assembly includes a movable coil housing that can adjust its position relative to the battery pack. This dynamic positioning allows the coil to optimize its coupling with the battery pack's conductive housing, ensuring efficient energy transfer and uniform heat distribution across the battery surface, thereby reducing energy loss.
3Adaptability or versatility
If the coil winding is fixed in position, then the device complexity is reduced, but the adaptability and heating efficiency deteriorate because the coil cannot accommodate different battery pack positions or optimize heating coverage
Solution Approach 1:
The coil housing is designed to be movable relative to the battery pack, allowing the coil winding to adjust its position dynamically. This enables the heater assembly to adapt to different battery pack orientations and positions while optimizing the electromagnetic coupling for efficient heating. The movability is achieved through a simple mechanical linkage that does not significantly increase device complexity.
Solution Approach 2:
The inductive heater assembly is designed with universal adaptability to work with different battery pack configurations. The movable coil housing and adjustable positioning mechanism allow the same heater assembly to effectively heat various battery pack sizes and orientations, making it a versatile solution that does not require multiple specialized heating devices.
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 inductive heater assembly effectively raises the battery pack temperature to the charging threshold, allowing for efficient charging and maintaining performance in cold conditions without damaging the internal chemistry of the battery cells.
Implementation Method 1
a coil winding operable to receive power from the circuit and generate an inductive field to heat the battery pack
Implementation Method 2
an inductive heater assembly connectable between the charger and the battery pack and operable to inductively heat the battery pack
Data Source
AI summary
A battery pack charger configured to heat a power tool battery pack, the battery pack charger comprising a housing, an adapter portion integrated with the housing of the battery pack charger, the adapter portion configured to mechanically and electrically connect to the power tool battery pack, and an inductive heater including a coil portion, the coil portion including a coil housing and one or more inductive coil windings, the inductive heater configured to generate an electromagnetic field to heat the power tool battery pack.