Pouch Cell Battery Pack Housing With Curved Corner Clearance
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Solution Overview
Problem
Existing battery packs for cordless power tools face challenges in efficiently housing and protecting pouch cells, leading to stress concentration and limited clearance, which can affect performance and durability.
Innovation Solution
The battery pack design incorporates a core housing with partial-cylindrical corners and a tongue-and-groove assembly, along with printed circuit board alignment features, to minimize stress concentration and provide clearance for pouch cells, ensuring secure and efficient assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional housing designs with sharp corners are used, then manufacturing is simpler, but stress concentration occurs and clearance for pouch cells is limited
Solution Approach 1:
The housing incorporates partial-cylindrical corners with a defined radius of curvature instead of sharp 90-degree angles. This curvature distributes stress more evenly across the housing structure and provides adequate clearance space for pouch cell corners, preventing stress concentration while maintaining structural integrity.
2Reliability
If secure assembly is prioritized with complex retention mechanisms, then reliability improves, but device complexity increases
Solution Approach 1:
The tongue-and-groove retention mechanism utilizes curved surfaces that naturally guide and secure the pouch cells through geometric interlocking rather than complex fastening systems. The curved geometry provides inherent retention while simplifying the overall assembly structure.
3Manufacturing precision
If alignment features are added to prevent misalignment, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
Alignment features incorporate curved geometries that guide the PCBA into proper positioning during assembly. The curved surfaces provide self-aligning characteristics that ensure precise placement without requiring complex alignment mechanisms or multiple adjustment steps.
Data Source
AI summary
A battery pack is disclosed and includes a battery housing, a core housing disposed within the battery housing, and at least one pouch cell disposed within the core housing, the pouch cells including at least one corner, wherein the core housing includes a baseplate, at least one sidewall extending from the baseplate, and a rear wall extending from the baseplate to the sidewall, wherein the rear wall meets the sidewall at a partial-cylindrical corner and wherein the partial-cylindrical corner provides clearance for the corner of the pouch cell.