Segmented Battery Pack Layout for High-Discharge Power Tools
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Solution Overview
Problem
Existing battery packs for power tools do not meet the requirements for higher output characteristics, such as longer battery life, higher energy density, and continuous discharge power, which are necessary for various types of power tools, including garden tools and handheld tools.
Innovation Solution
The battery pack includes a housing with a cell module containing multiple full-tab batteries, which provide continuous discharge power greater than or equal to 300 W, instantaneous discharge power greater than or equal to 550 W, and power density greater than or equal to 1500 W/kg, along with heat dissipation structures and a magnetic current sensor to manage current effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional battery packs are used, then the structure is simple and easy to manufacture, but the continuous discharge power and energy density are insufficient
Solution Approach 1:
The battery pack is divided into multiple cell units (first cell unit, second cell unit, third cell unit, fourth cell unit) with different discharge power characteristics. Each cell unit is independently configured with specific discharge power ranges, allowing the system to achieve high continuous discharge power (≥300W) by combining multiple units rather than relying on a single complex high-power cell.
Solution Approach 2:
The patent specifies precise parameter ranges for each cell unit (continuous discharge power: 75-150W for first unit, 75-150W for second unit, 50-100W for third unit, 50-100W for fourth unit; instantaneous discharge power: 100-200W for first and second units, 80-150W for third and fourth units). By controlling these parameters within defined ranges, the battery pack achieves ≥300W continuous discharge power while maintaining manageable structural complexity.
2Duration of action of moving object
If battery capacity is increased to extend battery life, then the battery life is longer, but the energy density and discharge power may be compromised
Solution Approach 1:
The battery pack uses four separate cell units instead of one large capacity cell. This segmentation allows each unit to be optimized for both capacity (to extend battery life) and discharge power capability. The parallel configuration of multiple units provides both extended operational duration and sufficient power output (≥300W continuous, ≥550W instantaneous).
Solution Approach 2:
Each cell unit is designed to serve multiple functions: providing both energy storage (for extended battery life) and power delivery (for high discharge requirements). The first and second cell units with higher instantaneous discharge power (100-200W) handle peak power demands, while all four units collectively provide extended operational duration, making each unit multi-functional.
3Power
If high power density is achieved, then the energy density increases, but the heat generation and thermal management become more challenging
Solution Approach 1:
The battery pack is divided into four separate cell units with defined power ranges, which physically distributes the heat generation sources throughout the battery pack structure. This segmentation prevents concentration of thermal load in a single location, making thermal management more effective while maintaining high power density (≥1500W/kg).
Solution Approach 2:
Different cell units are assigned different power characteristics tailored to local requirements: the first and second cell units (with higher instantaneous discharge power of 100-200W) are positioned to handle peak power demands, while the third and fourth cell units (with 80-150W instantaneous discharge power) provide supplementary power. This local optimization of power distribution helps manage thermal loads more effectively across different regions of the battery pack.
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 battery pack achieves enhanced output performance, supporting power tools with continuous discharge power, high energy density, and efficient heat management, suitable for a wide range of power tools including handheld and riding vehicles.
Implementation Method 1
a cell module accommodated in the housing and electrically connected to the terminal assembly, where the cell module includes at least multiple cell units
Implementation Method 2
a magnetic current sensor to manage current effectively
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Provided are a power tool and a battery pack. The battery pack includes: a housing; a power tool interface configured to be connected to the power tool, where the power tool interface includes a terminal assembly; and a cell module accommodated in the housing and electrically connected to the terminal assembly, where the cell module includes at least multiple cell units. The continuous discharge power of the cell unit is greater than or equal to 300 W.