Reconfigurable Battery Pack for Runtime and Fast Recharge

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Solution Overview

Problem

Cordless electrical devices have limited run-time and charge-time due to battery packs that are not optimized for specific applications, often requiring frequent replacements during operation.

Innovation Solution

A battery pack system with a controller that adjusts operation modes between high-power and high-capacity modes, utilizing advanced cell configurations, active cooling, and smart charging protocols to optimize run-time and charge-time for specific applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If the battery pack capacity is increased to extend runtime, then the runtime is improved, but the charge time increases

Engineering Contradiction:
ImproveruntimeVSAvoidcharge time
Core Design Contradiction:
Duration of action of moving objectVSLoss of time

Solution Approach 1:

The battery pack employs dynamic switching between series and parallel cell configurations. The controller monitors application requirements and switches between high-voltage mode (series connection for extended runtime in low-power applications) and high-current mode (parallel connection for fast charging in high-power applications), allowing the system to adapt its electrical characteristics in real-time based on operational demands

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system changes electrical parameters by reconfiguring the battery cell connections. By switching between series and parallel configurations, the voltage and current parameters are dynamically adjusted to match application requirements, enabling both extended runtime and fast charging capabilities within the same battery pack

Inventive Principle:
Principle #35Parameter changes

2Power

If the battery pack is optimized for high-power applications, then the power output is improved, but the runtime decreases

Engineering Contradiction:
Improvepower outputVSAvoidruntime
Core Design Contradiction:
PowerVSDuration of action of moving object

Solution Approach 1:

The switching control circuit dynamically reconfigures the battery cell connections based on the detected application type. For high-power applications, cells are connected in parallel to provide high current output. For runtime-critical applications, cells are reconfigured in series to extend operational duration, allowing the same battery pack to serve multiple application requirements

Inventive Principle:
Principle #15Dynamics

3Duration of action of moving object

If multiple battery packs are used to ensure sufficient runtime, then the runtime is improved, but the device complexity increases

Engineering Contradiction:
ImproveruntimeVSAvoidbattery pack configuration
Core Design Contradiction:
Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The battery pack is designed as a universal multi-functional unit that can serve both high-power and runtime-extended applications through internal reconfiguration. The switching control circuit and controller enable a single battery pack to replace multiple specialized packs, simplifying the overall system by eliminating the need for users to manage multiple different battery configurations

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentEP4583204A1Battery pack
Publication Date: 2025.07.09 MILWAUKEE ELECTRIC TOOL CORP
  • EP4583204A1 patent drawingFigure 1
  • EP4583204A1 patent drawingFigure 2
  • EP4583204A1 patent drawingFigure 3

AI summary

A battery pack comprising: a housing (14) including an interface couplable to an external device (20) configured to perform a group of applications, and a plurality of battery cells disposed within the housing and electrically connected to the interface, the battery cells including a cathode, an anode, and a separator; wherein the plurality of battery cells is configured to provide power to the external device for a runtime, wherein the plurality of battery cells is configured to fully recharge within a charge time, and wherein the charge time is less than a sum of the runtime plus a rest time corresponding to the time taken to prepare a new application group.