Soft-Pack Battery Module Layout for Lightweight Power Tools

The patent replaces rigid metal housings with flexible pouch cell structures that have thin film encapsulation. The pouch cells use aluminum plastic film or similar thin film materials to encapsulate the electrolyte and electrodes, eliminating the need for heavy metal casings while maintaining structural integrity through the flexibility and tensile strength of the thin film materials.

The patent employs composite material structures in the pouch cell construction, combining aluminum foil current collectors with plastic film encapsulation layers. This composite approach provides both mechanical strength and flexibility, achieving structural requirements without the weight penalty of solid metal housings.

The patent merges multiple pouch cell units into an integrated cell module structure. Instead of connecting separate cylindrical cells with spacing and connection hardware, the pouch cells are arranged and connected in series and parallel configurations within a unified module, reducing overall volume while achieving the required power output through direct electrical connections between cell tabs.

The patent implements a nested structure where multiple pouch cell units are arranged within a compact cell module housing. The cells are positioned in space-efficient configurations, with connection terminals and circuit board assemblies integrated into the same volume space, effectively nesting functional components within the battery pack structure to maximize power density.