Onboard Circuit Battery Communication for Charging Systems
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Solution Overview
Problem
Cordless power tool batteries and charging systems lack advanced features for efficient communication, universal compatibility, and battery health management, limiting their performance and usability across different tools and environments.
Innovation Solution
Integration of an onboard circuit in batteries for communication with charging systems, which includes identifying indicia, charging protocols, and data storage, along with a versatile charging system that accepts multiple voltages, charges different chemistries, and recommends battery renewal based on capacity analysis, featuring flexible contacts and a heat sink with a fan for efficient charging and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an onboard circuit is integrated into the battery for communication and data storage, then battery management and charging efficiency are improved, but device complexity increases
Solution Approach 1:
The patent integrates an onboard circuit directly into the battery pack, merging communication, data storage, and battery management functions into a single unit. This allows the battery to autonomously communicate with the charging system, enabling efficient charging protocols and real-time monitoring without requiring separate external management systems.
Solution Approach 2:
The onboard circuit enables the battery to self-manage its charging process by storing battery-specific parameters and communication protocols internally. The battery can independently provide identifying indicia and charging information to the charging system, reducing the need for complex external control systems.
2Adaptability or versatility
If the charging system is designed to accept multiple input voltages and charge different battery chemistries, then versatility and adaptability are improved, but device complexity increases
Solution Approach 1:
The charging system is designed with universal capabilities to accept multiple input voltages and charge different battery chemistries (NiCd, NiMH, Li-ion). The system uses a single integrated design that can adapt to various battery types through the onboard circuit communication, eliminating the need for multiple dedicated charging systems for different battery types.
Solution Approach 2:
The charging system dynamically adjusts charging parameters based on communication with the onboard circuit, which provides battery-specific information. This allows the same physical charging system to accommodate different voltages and chemistries by changing operational parameters rather than requiring hardware modifications.
3Measurement precision
If the battery includes an onboard circuit with identifying indicia and charging protocols, then charging precision and battery health management are improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical or visual identification methods with an electronic onboard circuit that stores and communicates battery information. This substitution enables precise automatic identification and charging protocol selection through electronic communication rather than manual configuration or physical markers.
Solution Approach 2:
The onboard circuit contains copied information about the battery's chemistry, voltage, and capacity that can be read by the charging system. This allows the charging system to access complete battery specifications without physically analyzing the battery, simplifying the charging decision-making process.
4Reliability
If the charging system includes flexible contacts and heat sink with fan, then charging reliability and thermal management are improved, but device complexity increases
Solution Approach 1:
The charging system employs flexible battery contacts that can adapt to slight variations in battery positioning and contact geometry. This flexibility ensures reliable electrical connection without requiring precision mechanical tolerances, improving charging reliability while simplifying the mechanical design.
Solution Approach 2:
The heat sink with integrated fan provides active thermal management to dissipate heat generated during charging. The heat sink structure accommodates thermal expansion and convection currents, maintaining reliable operation across varying thermal conditions without requiring complex temperature control mechanisms.
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 efficient charging of various battery types, ensures proper polarity alignment, and recommends battery renewal, enhancing mobility and portability of cordless power tools while maintaining battery health and safety.
Implementation Method 1
a fan mounted on a heat sink and wherein the heat sink may further include through passages aligned with the fan
Data Source
AI summary
A cordless power tool battery pack including an onboard circuit configured to electronically communicate with an associated battery charging system. The onboard circuit communicates information relating to the batter pack to a microprocessor or the like within the battery charging system and charging of the battery pack is controlled based on such communication.