Pouch Cell Battery Pack Stacking for Tool Fit and Energy Density
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Solution Overview
Problem
Existing battery packs for power tools lack versatility and efficiency in terms of energy density and compatibility with different power tools, as they often have standardized dimensions and capacities that do not adapt well to varying tool requirements.
Innovation Solution
The development of battery packs with pouch cells arranged in stacks of uniformly prismatic structures, allowing for customizable dimensions and capacities, and the use of cylindrical cells with crimped can designs to optimize energy density and compatibility with various power tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standardized battery pack dimensions and capacities are used, then manufacturing and compatibility are simplified, but energy density and adaptability to different power tool requirements deteriorate
Solution Approach 1:
The battery pack is divided into multiple modular pouch cells that can be independently arranged in different configurations. Each pouch cell is a separate unit that can be combined with others to create various pack sizes and capacities, allowing customization for different power tool applications while maintaining standardized cell manufacturing processes
Solution Approach 2:
The battery pack design allows for dynamic reconfiguration of pouch cells into different stack arrangements (series, parallel, or combination configurations). This enables the same basic cell design to be adapted for various voltage and capacity requirements across different power tool platforms, providing versatility without requiring entirely different manufacturing processes
2Quantity of substance
If pouch cells with noncircular and nonrectangular two-dimensional projections are used, then space utilization and energy density are improved, but manufacturing complexity increases
Solution Approach 1:
The pouch cells utilize asymmetric three-dimensional configurations with noncircular and nonrectangular two-dimensional projections. This asymmetric design allows the cells to fit together more efficiently in stacked arrangements, maximizing space utilization within the battery pack housing and increasing the quantity of active material that can be packed into a given volume
Solution Approach 2:
Multiple pouch cells are arranged in nested stack configurations where cells are positioned within defined spatial boundaries. The stacks are organized with specific longitudinal axes arranged perpendicular to each other, creating a compact nested structure that optimizes space utilization while maintaining manageable manufacturing and assembly processes
3Adaptability or versatility
If multiple stacks with perpendicular longitudinal axes are used, then adaptability and space utilization are improved, but structural complexity increases
Solution Approach 1:
The battery pack employs three-dimensional stack arrangements with longitudinal axes oriented in different spatial dimensions. Specifically, stacks are configured with first, second, and third longitudinal axes where the second and third axes are parallel and the first axis is perpendicular to both, creating a three-dimensional configuration that maximizes adaptability and space utilization while providing clear geometric organization for manufacturing
Data Source
AI summary
A battery pack includes an outer housing and a plurality of pouch cells arranged within the outer housing. Each of the plurality of pouch cells has a first cell end, a second cell end, and a cell side surface provided between the first cell end and the second cell end. The cell side surface includes a first face, a second face, and a third face. Each of the plurality of pouch cells has a thickness in a first direction extending between the first cell end and the second cell end and has a two-dimensional projection in a plane that is orthogonal to the first direction.