BATTERY PACK AND INTERNAL COMPONENT ARRANGEMENT WITHIN THE BATTERY PACK FOR CORDLESS POWER TOOL SYSTEM
First Claim
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1. A battery pack for a cordless power tool, comprising:
- a top housing supporting an electronic module and a battery terminal block connected to the electronics module, anda bottom housing containing a plurality of battery cells constrained between a pair of end caps, wherein each end cap includes a plurality of sense wires extending across an outer surface thereof and electrically connected between a corresponding cell and the electronics module.
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Abstract
An internal component arrangement within a battery pack housing having multiple cells and adapted for cordless power tools may provide desired mechanical support to constrain the cells. The housing with internal component arrangement is configured to route sensing wires from the cells to an electronics module of the pack.
70 Citations
31 Claims
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1. A battery pack for a cordless power tool, comprising:
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a top housing supporting an electronic module and a battery terminal block connected to the electronics module, and a bottom housing containing a plurality of battery cells constrained between a pair of end caps, wherein each end cap includes a plurality of sense wires extending across an outer surface thereof and electrically connected between a corresponding cell and the electronics module. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. An internal component arrangement within a battery pack of a cordless power tool, the pack having a top housing and a bottom housing, comprising:
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a plurality of battery cells disposed in the bottom housing, a pair of end caps constraining the cells between inner surfaces of the end caps, and a plurality of sense wires extending across an outer surface of each end cap, each sense line having a first end electrically connected to an electronics module in the top housing and a second end electrically connected to a corresponding cell between the end caps. - View Dependent Claims (25, 26, 27, 28, 29, 30)
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31. A method or arranging a plurality of internal components with a battery pack housing, comprising:
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providing a pair of end caps, each end cap having a plurality of spaced apart recesses formed on an inner surface thereof which are shaped to receive a plurality of cell straps and a pair of power terminal leads, each end cap having a plurality of spaced apart access holes which extend through a given recess, placing the cell straps and leads within the spaced apart recesses so that a portion of the cell strap or power lead is exposed through a corresponding access hole, disposing a plurality of cylindrical battery cells between the end caps so that ends of corresponding cells contact a given cell strap or lead at a junction that is exposed through a corresponding access hole, wherein sides of the end caps have a scalloped shape that conforms to the rounded shape of the cylindrical cells to constrain the cells there between, welding the cell straps and power leads to the cells through the access holes to form a core pack comprised of the cells connected to the straps and leads between the end caps, attaching a plurality of sense wires within outer surfaces of the end caps in the core pack, wherein one end of each sense line is a spring end which is retained within a corresponding access hole of the core pack to contact a junction of a cell strap/battery cell, and the other end of each sense line is attached to a integrated connector formed in each end cap of the core pack, and inserting the core pack into the housing.
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Specification