Press-Fit Cell Holder for Power Tool Battery Pack Cooling
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Solution Overview
Problem
Rechargeable battery packs for hand-held power tools face issues with waste heat dissipation and mechanical robustness due to indirect cell connections and air gaps, leading to potential damage and reduced service life.
Innovation Solution
A rechargeable battery pack design featuring a cell holder with sleeve-like insulating walls and a pressing-fit mechanism to securely accommodate battery cells, ensuring electrical insulation and efficient heat dissipation, along with a thermally conductive and electrically insulating material for improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If battery cells are fixed directly within the rechargeable battery housing or positioned without being fixed, then the device complexity is reduced, but the mechanical robustness and service life are worsened due to vibrations transmitted during operation
Solution Approach 1:
The battery housing is segmented into a cell holder component that specifically accommodates and secures battery cells, separating the cell securing function from the main housing structure. This allows for a focused, simple yet effective fixing mechanism that addresses vibration issues without overly complicating the overall device.
Solution Approach 2:
The cell holder is designed with pre-formed recesses and positioning features that preliminarily secure battery cells in the correct positions before final assembly. This preliminary action ensures proper alignment and prevents movement during operation, extending service life without requiring complex additional fixing mechanisms.
2Reliability
If mechanical installation principles combine elastic inserts with force-fit connecting elements to build up high contact pressure, then the electrical connection reliability is improved, but the device complexity and manufacturing effort are worsened
Solution Approach 1:
The cell holder integrates both mechanical securing and electrical contact functions into a single component. The holding elements simultaneously secure battery cells mechanically and establish electrical connections, eliminating the need for separate elastic inserts and force-fit connecting elements while maintaining high contact pressure and connection reliability.
Solution Approach 2:
The cell holder serves multiple functions: it secures battery cells mechanically, provides electrical insulation between cells, establishes electrical contacts, and dissipates heat. This multi-functionality reduces device complexity while maintaining or improving electrical connection reliability compared to specialized separate components.
3Manufacturing precision
If air gaps are present in the cell holder, then the manufacturing precision requirements are reduced, but the heat dissipation efficiency and electrical insulation are worsened
Solution Approach 1:
The cell holder is made from a composite material or a material with combined properties that provides both electrical insulation and thermal conduction. This allows the material to naturally manage heat transfer and electrical isolation without requiring precision gaps or additional insulating components, resolving the contradiction between manufacturing precision and heat dissipation efficiency.
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 solution provides reliable waste heat dissipation, enhanced mechanical robustness, and extended service life by preventing short circuits and air gaps, while simplifying the installation process and reducing material costs.
Implementation Method 1
a thermally conductive and electrically insulating material for improved thermal management
Implementation Method 2
sleeve-like insulating walls corresponding to the battery cells at least in some areas, the insulating walls being configured in such a way that an electrical contacting between the battery cells is prevented
Data Source
AI summary
A rechargeable battery pack for a hand-held power tool, including a housing having at least first and second housing components, the pack including at least one cell holder, accommodating at least two battery cells in a parallel/series circuit, the battery cells each including two end faces extending perpendicularly to a longitudinal axis; and a pack electronics system including contact elements for establishing electrical connection between the pack and a power tool. The cell holder includes sleeve-like insulating walls, corresponding to the battery cells at least in some areas, to prevent electrical contact between the battery cells. A method for manufacturing a pack for a hand-held power tool, the cell holder including sleeve-like insulating walls, having cylindrical cell openings for accommodating the battery cells, the battery cells being pressed into the cell openings so that a form-locked and force-fit connection is established between the cell holder and the battery cells.