ABSTRACT
Abstract
An electrical combination including a power tool and a battery pack. The power tool includes power tool terminals. The battery pack is configured to be interfaced with the power tool. The battery pack includes a battery pack housing, at least three terminals, and a plurality of battery cells. The battery pack terminals include a positive terminal, a negative terminal, and a sense terminal. The at least three terminals are configured to be interfaced with the power tool terminals. The plurality of battery cells are arranged within and supported by the battery pack housing. Each of the battery cells has a lithium-based chemistry and a respective state of charge, and power is transferable between the battery cells and the power tool. A circuit is configured to monitor the battery cells, detect a charge imbalance among the battery cells, and prevent the battery pack from operating when the charge imbalance is detected.
Description
RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 16/588,686, filed Sep. 30, 2019, which is a continuation of U.S. patent application Ser. No. 16/200,171, filed Nov. 26, 2018, now U.S. Pat. No. 10,431,857, which is a continuation of U.S. patent application Ser. No. 15/785,396, filed Oct. 16, 2017, now U.S. Pat. No. 10,141,614, which is a continuation of U.S. patent application Ser. No. 15/181,108, filed Jun. 13, 2016, now U.S. Pat. No. 9,793,583, which is a continuation of U.S. patent application Ser. No. 14/726,140, filed May 29, 2015, now U.S. Pat. No. 9,368,842, which is a continuation of U.S. patent application Ser. No. 13/943,237, filed Jul. 16, 2013, now U.S. Pat. No. 9,048,515, which is a continuation of U.S. patent application Ser. No. 13/443,694, filed Apr. 10, 2012, now U.S. Pat. No. 8,487,585, which is a continuation of U.S. patent application Ser. No. 12/766,965, filed on Apr. 26, 2010, now U.S. Pat. No. 8,154,249, which is a continuation of U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. Provisional Patent Application No. 60/582,138, filed on Jun. 22, 2004; Application No. 60/582,728, filed on Jun. 24, 2004; Application No. 60/582,730, filed on Jun. 24, 2004; Application No. 60/612,352, filed on Sep. 22, 2004; Application No. 60/626,013, filed on Nov. 5, 2004; Application No. 60/626,230, filed on Nov. 9, 2004 and Application No. 60/643,396, filed on Jan. 12, 2005, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 10/720,027, filed on Nov. 20, 2003, now U.S. Pat. No. 7,157,882, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 10/719,680, filed on Nov. 20, 2003, now U.S. Pat. No. 7,176,654, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 10/721,800, filed on Nov. 24, 2003, now U.S. Pat. No. 7,253,585, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,356, filed on Nov. 22, 2002; Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,712, filed on Nov. 19, 2003; and Application No. 60/523,716, filed on Nov. 19, 2003, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 11/138,070, filed on May 24, 2005, now U.S. Pat. No. 7,589,500, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/574,278, filed on May 24, 2004; Application No. 60/574,616, filed on May 25, 2004; Application No. 60/582,138, filed on Jun. 22, 2004; Application No. 60/582,728, filed on Jun. 24, 2004; Application No. 60/582,730, filed on Jun. 24, 2004; Application No. 60/612,352, filed on Sep. 22, 2004; Application No. 60/626,013, filed on Nov. 5, 2004; Application No. 60/626,230, filed on Nov. 9, 2004 and Application No. 60/643,396, filed on Jan. 12, 2005, and prior filed U.S. patent application Ser. No. 10/720,027, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); application Ser. No. 10/719,680, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); and application Ser. No. 10/721,800, filed on Nov. 24, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,356, filed on Nov. 22, 2002; Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,712, filed on Nov. 19, 2003; and Application No. 60/523,716, filed on Nov. 19, 2003), the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 11/139,020, filed on May 24, 2005, now U.S. Pat. No. 7,425,816, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/574,278, filed on May 24, 2004; Application No. 60/574,616, filed on May 25, 2004; Application No. 60/582,138, filed on Jun. 22, 2004; Application No. 60/582,728, filed on Jun. 24, 2004; Application No. 60/582,730, filed on Jun. 24, 2004; Application No. 60/612,352, filed on Sep. 22, 2004; Application No. 60/626,013, filed on Nov. 5, 2004; Application No. 60/626,230, filed on Nov. 9, 2004 and Application No. 60/643,396, filed on Jan. 12, 2005, and prior filed U.S. patent application Ser. No. 10/720,027, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); application Ser. No. 10/719,680, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); and application Ser. No. 10/721,800, filed on Nov. 24, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,356, filed on Nov. 22, 2002; Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,712, filed on Nov. 19, 2003; and Application No. 60/523,716, filed on Nov. 19, 2003), the entire contents of all of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention generally relates to battery packs and, more particularly, to power tool battery packs.
BACKGROUND OF THE INVENTION
Typically, electrical equipment, such as, for example, a cordless power tool, is powered by a rechargeable battery. The battery may be periodically charged in a compatible battery charger.
SUMMARY OF THE INVENTION
FIGS. 36 - 38 illustrate an existing battery pack 230 . The existing battery pack 230 includes a housing 242 and at least one rechargeable battery cell 246 (shown in FIGS. 39 - 40 ) supported by the housing 242 . In the illustrated construction, the existing battery pack 230 is an 18V battery pack including (see FIGS. 39 - 40 ) fifteen approximately 1.2 V battery cells 246 connected in series. The battery cells 246 are a rechargeable battery cell chemistry type, such as, for example, NiCd or NiMH.
As shown in FIGS. 39 - 40 , in the existing battery pack 230 , each battery cell 246 is generally cylindrical and extends along a cell axis 250 parallel to the cylindrical outer cell wall. In the existing battery pack 230 , the cell axes 250 are parallel to one another. Also, in the existing battery pack 230 , each battery cell 246 has a cell length 252 which is about two times the cell diameter 254 . In the illustrated construction, each battery cell 246 has a length of about forty-six millimeters (46 mm) and a diameter of about twenty-three millimeters (23 mm).
The existing battery pack 230 is connectable to (see FIG. 12 ) a battery charger 38 , and the battery charger 38 is operable to charge the existing battery pack 230 . The existing battery pack 230 is connectable to electrical equipment, such as, for example, a power tool 34 (shown in FIG. 11 A ), to power the power tool 34 . As shown in FIGS. 36 - 38 , the housing 242 provides a support portion 250 for supporting the existing battery pack 230 on an electrical device. In the illustrated construction, the support portion 250 provides (see FIG. 36 ) a C-shaped cross section which is connectable to a complementary T-shaped cross section support portion on the electrical device (the support portion on the power tool 34 (shown in FIG. 11 B ) and/or the battery support portion on the battery charger 38 (shown in FIG. 12 ).
The existing battery pack 230 includes (see FIGS. 36 - 37 and 39 - 40 ) a terminal assembly 286 operable to electrically connect battery cells 246 to a circuit in the electrical device. The terminal assembly 286 includes a positive battery terminal 298 , a ground terminal 302 , and a sense terminal 306 . As illustrated in <figref idrefs="DRAWING
RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 16/588,686, filed Sep. 30, 2019, which is a continuation of U.S. patent application Ser. No. 16/200,171, filed Nov. 26, 2018, now U.S. Pat. No. 10,431,857, which is a continuation of U.S. patent application Ser. No. 15/785,396, filed Oct. 16, 2017, now U.S. Pat. No. 10,141,614, which is a continuation of U.S. patent application Ser. No. 15/181,108, filed Jun. 13, 2016, now U.S. Pat. No. 9,793,583, which is a continuation of U.S. patent application Ser. No. 14/726,140, filed May 29, 2015, now U.S. Pat. No. 9,368,842, which is a continuation of U.S. patent application Ser. No. 13/943,237, filed Jul. 16, 2013, now U.S. Pat. No. 9,048,515, which is a continuation of U.S. patent application Ser. No. 13/443,694, filed Apr. 10, 2012, now U.S. Pat. No. 8,487,585, which is a continuation of U.S. patent application Ser. No. 12/766,965, filed on Apr. 26, 2010, now U.S. Pat. No. 8,154,249, which is a continuation of U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. Provisional Patent Application No. 60/582,138, filed on Jun. 22, 2004; Application No. 60/582,728, filed on Jun. 24, 2004; Application No. 60/582,730, filed on Jun. 24, 2004; Application No. 60/612,352, filed on Sep. 22, 2004; Application No. 60/626,013, filed on Nov. 5, 2004; Application No. 60/626,230, filed on Nov. 9, 2004 and Application No. 60/643,396, filed on Jan. 12, 2005, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 10/720,027, filed on Nov. 20, 2003, now U.S. Pat. No. 7,157,882, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 10/719,680, filed on Nov. 20, 2003, now U.S. Pat. No. 7,176,654, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 10/721,800, filed on Nov. 24, 2003, now U.S. Pat. No. 7,253,585, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,356, filed on Nov. 22, 2002; Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,712, filed on Nov. 19, 2003; and Application No. 60/523,716, filed on Nov. 19, 2003, the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 11/138,070, filed on May 24, 2005, now U.S. Pat. No. 7,589,500, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/574,278, filed on May 24, 2004; Application No. 60/574,616, filed on May 25, 2004; Application No. 60/582,138, filed on Jun. 22, 2004; Application No. 60/582,728, filed on Jun. 24, 2004; Application No. 60/582,730, filed on Jun. 24, 2004; Application No. 60/612,352, filed on Sep. 22, 2004; Application No. 60/626,013, filed on Nov. 5, 2004; Application No. 60/626,230, filed on Nov. 9, 2004 and Application No. 60/643,396, filed on Jan. 12, 2005, and prior filed U.S. patent application Ser. No. 10/720,027, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); application Ser. No. 10/719,680, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); and application Ser. No. 10/721,800, filed on Nov. 24, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,356, filed on Nov. 22, 2002; Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,712, filed on Nov. 19, 2003; and Application No. 60/523,716, filed on Nov. 19, 2003), the entire contents of all of which are hereby incorporated by reference.
This application also claims the benefits, through U.S. patent application Ser. No. 11/165,615, filed on Jun. 22, 2005, now U.S. Pat. No. 7,714,538, of prior filed U.S. patent application Ser. No. 11/139,020, filed on May 24, 2005, now U.S. Pat. No. 7,425,816, which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/574,278, filed on May 24, 2004; Application No. 60/574,616, filed on May 25, 2004; Application No. 60/582,138, filed on Jun. 22, 2004; Application No. 60/582,728, filed on Jun. 24, 2004; Application No. 60/582,730, filed on Jun. 24, 2004; Application No. 60/612,352, filed on Sep. 22, 2004; Application No. 60/626,013, filed on Nov. 5, 2004; Application No. 60/626,230, filed on Nov. 9, 2004 and Application No. 60/643,396, filed on Jan. 12, 2005, and prior filed U.S. patent application Ser. No. 10/720,027, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); application Ser. No. 10/719,680, filed on Nov. 20, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,716, filed on Nov. 19, 2003; and Application No. 60/523,712, filed on Nov. 19, 2003); and application Ser. No. 10/721,800, filed on Nov. 24, 2003 (which claims the benefits of prior filed U.S. Provisional Patent Application No. 60/428,356, filed on Nov. 22, 2002; Application No. 60/428,358, filed on Nov. 22, 2002; Application No. 60/428,450, filed on Nov. 22, 2002; Application No. 60/428,452, filed on Nov. 22, 2002; Application No. 60/440,692, filed on Jan. 17, 2003; Application No. 60/440,693, filed on Jan. 17, 2003; Application No. 60/523,712, filed on Nov. 19, 2003; and Application No. 60/523,716, filed on Nov. 19, 2003), the entire contents of all of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention generally relates to battery packs and, more particularly, to power tool battery packs.
BACKGROUND OF THE INVENTION
Typically, electrical equipment, such as, for example, a cordless power tool, is powered by a rechargeable battery. The battery may be periodically charged in a compatible battery charger.
SUMMARY OF THE INVENTION
FIGS. 36 - 38 illustrate an existing battery pack 230 . The existing battery pack 230 includes a housing 242 and at least one rechargeable battery cell 246 (shown in FIGS. 39 - 40 ) supported by the housing 242 . In the illustrated construction, the existing battery pack 230 is an 18V battery pack including (see FIGS. 39 - 40 ) fifteen approximately 1.2 V battery cells 246 connected in series. The battery cells 246 are a rechargeable battery cell chemistry type, such as, for example, NiCd or NiMH.
As shown in FIGS. 39 - 40 , in the existing battery pack 230 , each battery cell 246 is generally cylindrical and extends along a cell axis 250 parallel to the cylindrical outer cell wall. In the existing battery pack 230 , the cell axes 250 are parallel to one another. Also, in the existing battery pack 230 , each battery cell 246 has a cell length 252 which is about two times the cell diameter 254 . In the illustrated construction, each battery cell 246 has a length of about forty-six millimeters (46 mm) and a diameter of about twenty-three millimeters (23 mm).
The existing battery pack 230 is connectable to (see FIG. 12 ) a battery charger 38 , and the battery charger 38 is operable to charge the existing battery pack 230 . The existing battery pack 230 is connectable to electrical equipment, such as, for example, a power tool 34 (shown in FIG. 11 A ), to power the power tool 34 . As shown in FIGS. 36 - 38 , the housing 242 provides a support portion 250 for supporting the existing battery pack 230 on an electrical device. In the illustrated construction, the support portion 250 provides (see FIG. 36 ) a C-shaped cross section which is connectable to a complementary T-shaped cross section support portion on the electrical device (the support portion on the power tool 34 (shown in FIG. 11 B ) and/or the battery support portion on the battery charger 38 (shown in FIG. 12 ).
The existing battery pack 230 includes (see FIGS. 36 - 37 and 39 - 40 ) a terminal assembly 286 operable to electrically connect battery cells 246 to a circuit in the electrical device. The terminal assembly 286 includes a positive battery terminal 298 , a ground terminal 302 , and a sense terminal 306 . As illustrated in FIGS. 39 - 40 , the terminals
298 and 302 are connected to the opposite ends of the cell or series of cells 246 . The sense terminal 306 is connected to (see FIG. 40 ) an electrical component 314 which is connected in the circuit of the existing battery pack 230 . In the illustrated construction, the electrical component 314 is a temperature-sensing device or thermistor to communicate the temperature of the existing battery pack 230 and/or of the battery cells 246 .
The present invention provides a battery pack which substantially alleviates one or more independent problems with the above-described and other existing battery packs. In some aspects and in some constructions, the present invention provides a battery pack including two cells which are positioned in non-parallel relation to each other. In some aspects, the two cells are positioned in normal relation to each other.
More particularly, in some aspects and in some constructions, the present invention provides a battery pack including a housing, a first cell extending along a first cell axis, and a second cell extending along a second cell axis, the first cell and the second cell being supported by the housing in an orientation in which the first cell axis is non-parallel to the second cell axis. In some aspects and in some constructions, the first cell axis is normal to the second cell axis.
Also, in some aspects and in some constructions, the present invention provides a method of assembling a battery pack, the method including the acts of providing a battery pack housing, supporting a first cell with the housing, and supporting a second cell with the housing in non-parallel relation to the first cell. In some aspects, the act of supporting the second cell includes supporting the second cell in normal relation to the first cell.
In addition, in some aspects and in some constructions, the present invention provides a battery pack including a plurality of cells, a sensor for sensing the voltage of a first group of the plurality of cells, a sensor for sensing the voltage of a second group of the plurality of cells, and a controller for comparing the voltage of the first group to the voltage of the second group to determine if one of the plurality of cells is at or below a voltage.
Further, in some aspects and in some constructions, the present invention provides a method of determining a voltage of a cell of a battery pack, the battery pack including a plurality of cells, the method including the acts of sensing the voltage of a first group of the plurality of cells, sensing the voltage of a second group of the plurality of cells, and comparing the voltage of the first group to the voltage of the second group to determine if one of the plurality of cells is at or below a voltage.
Also, in some aspects and in some constructions, the present invention provides a battery pack including a housing, a cell supported by the housing, a FET connected to the cell, and a heat sink in heat-transfer relationship with the FET.
In addition, in some aspects and in some constructions, the present invention provides a method of assembling a battery pack, the method including the acts of providing a housing, supporting a cell with the housing, supporting a FET with the housing, connecting the FET to the cell, and supporting a heat sink in heat-transfer relationship with the FET.
Further, in some aspects and in some constructions, the present invention provides a battery including a housing supportable by an electrical device, a cell supported by the housing and connectable to the electrical device and a locking assembly for locking the battery to the electrical device. The locking assembly includes a locking member supported by the housing for movement between a locked position, in which the battery is locked to the electrical device, and an unlocked position, an actuator supported by the housing and operable to move the locking member between the locked position and the unlocked position and a biasing member operable to bias the locking member to the locked position, the biasing member being fixed between the actuator and the housing and retaining the actuator in a position relative to the housing.
Independent features and independent advantages of the invention will become apparent to those skilled in the art upon review of the detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a battery.
FIG. 2 is a top rear perspective view of the battery pack shown in FIG. 1 .
FIG. 3 is a bottom rear perspective view of the battery pack shown in FIG. 1 .
FIG. 4 is a top view of the battery pack shown in FIG. 1 .
FIG. 5 is a bottom view of the battery pack shown in FIG. 1 .
FIG. 6 is a front view of the battery pack shown in FIG. 1 .
FIG. 7 is a rear view of the battery pack shown in FIG. 1 .
FIG. 8 is a right side view of the battery pack shown in FIG. 1 .
FIG. 9 is a left side view of the battery pack shown in FIG. 1 .
FIG. 10 is a bottom view of an alternate construction of a battery pack embodying aspects of the present invention.
FIG. 11 A is a perspective view of an electrical device, such as a power tool, for use with the battery pack shown in FIG. 1 .
FIG. 11 B is a perspective view of the support portion of the power tool shown in FIG. 11 A .
FIG. 12 is a perspective view of an electrical device, such as a battery charger, for use with the battery pack shown in FIG. 1 .
FIG. 13 is a perspective view of a portion of the battery pack shown in FIG. 1 and illustrating the battery cells and the battery terminal assembly.
FIG. 14 is a top view of the battery cells and the battery terminal assembly shown in FIG. 13 .
FIG. 15 is a bottom view of the battery cells and the battery terminal assembly shown in FIG. 13 .
FIG. 16 is a front view of the battery cells and the battery terminal assembly shown in FIG. 13 .
FIG. 17 is a rear view of the battery cells and the battery terminal assembly shown in FIG. 13 .
FIG. 18 is a right side view of the battery cells and the battery terminal assembly shown in FIG. 13 .
FIG. 19 is a left side view of the battery cells and the battery terminal assembly shown in FIG. 13 .
FIG. 20 is a schematic diagram of components of a battery pack, such as the battery pack shown in FIG. 1 .
FIG. 21 is another schematic diagram of components of a battery pack.
FIG. 22 is yet another schematic diagram of components of a battery pack.
FIG. 23 is still another schematic diagram of components of a battery pack.
FIG. 24 is a perspective view of a portion of the battery pack shown in FIG. 1 with portions removed.
FIG. 25 is a perspective view of a portion of the battery pack shown in FIG. 1 with portions removed.
FIG. 26 is a perspective view of a portion of the battery pack shown in FIG. 1 with portions removed.
FIG. 27 is a top view of the portion of the battery pack shown in FIG. 26 .
FIGS. 28 A- 28 E include views of portions of the battery pack shown in FIG. 26 .
FIG. 29 is an exploded perspective view of a portion of the battery pack shown in FIG. 1 with portions removed.
FIG. 30 is a rear perspective view of a portion of the battery pack shown in FIG. 1 with portions removed.
FIG. 31 is another rear perspective view of the portion of the battery pack shown in FIG. 30 .
FIG. 32 is an exploded perspective view of a portion of the battery pack shown in FIG. 1 with portions removed.
FIG. 33 is a perspective view of the portion of the battery pack shown in FIG. 32 .
FIG. 34 is an enlarged perspective view of a portion of the battery pack shown in FIG. 33 .
FIGS. 35 A- 35 C include views of portions of the battery pack shown in FIG. 1 with portions removed.
FIG. 36 is a rear perspective view of an existing battery pack.
FIG. 37 is a front perspective view of the battery pack shown in FIG. 36 .
FIG. 38 is a left side view of the battery pack shown in FIG. 36 .
FIG. 39 is a perspective view of a portion of the battery pack shown in FIG. 36 and illustrating the battery cells and the battery terminal assembly.
FIG. 40 is a right side view of the battery cells and the battery terminal assembly shown in FIG. 39 .
FIG. 41 is a front perspective view of another battery pack.
FIG. 42 is a right side view of the battery pack shown in FIG. 41 .
FIG. 43 is a left side view of the battery pack shown in FIG. 41 .
FIG. 44 is a top view of the battery pack shown in FIG. 41 .
FIG. 45 is a bottom rear perspective view of the battery pack shown in FIG. 41 .
FIG. 46 is a front view of the battery pack shown in FIG. 41 .
FIG. 47 is a rear view of the battery pack shown in FIG. 41 .
FIG. 48 is a front perspective view of a further battery pack.
FIG. 49 is a right side view of the battery pack shown in FIG. 48 .
FIG. 50 is a left side view of the battery pack shown in FIG. 48 .
FIG. 51 is a top view of the battery pack shown in FIG. 48 .
FIG. 52 is a bottom rear perspective view of the battery pack shown in FIG. 48 .
FIG. 53 is a front view of the battery pack shown in FIG. 48 .
FIG. 54 is a rear view of the battery pack shown in FIG. 48 .
FIG. 55 is a perspective view of a battery pack in use with a first electrical device, such as a power tool.
FIG. 56 is a perspective view of a battery pack in use with a second electrical device, such as a power tool.
FIG. 57 is a perspective view of a portion of a battery pack and illustrating the battery cells.
FIG. 58 is a perspective view of a portion of a battery pack and illustrating the battery cells, terminals, end caps and circuitry.
FIG. 59 is a rear perspective view of the portion of the battery pack shown in FIG. 58 .
FIG. 60 is a right side view of the portion of the battery pack shown in FIG. 58 .
FIG. 61 is a left side view of the portion of the battery pack shown in FIG. 58 .
FIG. 62 is a front view of the portion of the battery pack shown in FIG. 58 .
FIG. 63 is a rear view of the portion of the battery pack shown in FIG. 58 .
FIG. 64 is a top view of the portion of the battery pack shown in FIG. 58 .
FIG. 65 is a perspective view of a portion of a battery pack and illustrating the end caps.
FIG. 66 is a partial side perspective view of a portion of the housing of a battery pack.
FIG. 67 is a partial front perspective view of the portion of the housing shown in FIG. 66 .
FIGS. 68 - 69 are still further schematic diagrams of components of a battery pack.
FIG. 70 is a partial cross-section of a battery cell.
FIG. 71 is a graph illustrating charging thresholds of Li-based battery packs.
FIG. 72 is a graph illustrating the performance of two battery packs during discharge.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of âincluding,â âcomprising,â or âhavingâ and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
DETAILED DESCRIPTION
A battery pack 30 embodying aspects of the invention is illustrated in FIGS. 1 - 9 . The battery pack 30 can be connectable to electrical equipment, such as, for example, a cordless power tool 34 (shown in FIG. 11 A ) to selectively power the power tool 34 . The battery pack 30 can be removable from the power tool 34 and can be rechargeable by a battery charger 38 (shown in FIG. 8 ).
As shown in FIGS. 1 - 9 , the battery pack 30 includes a housing 42 and at least one rechargeable battery cell 46 (shown in FIGS. 13 - 19 ) supported by the housing 42 . In the illustrated construction, the battery pack 30 can be a 21V battery pack including five approximately 4.2
V battery cells
46 a , 46 b , 46 c , 46 d and 46 e connected in series. In another construction, the battery pack 30 can be a 28V battery pack including seven approximately 4.2 V battery cells 46 . In other constructions, the battery pack 30 includes at least six battery cells 46 to have a nominal voltage of approximately 28V. In further constructions (not shown), the battery pack 30 may have another nominal battery voltage, such as, for example, 9.6V, 12V, 14.4V, 24V, 28V, 40V, etc., to power the electrical equipment and be charged by the battery charger 38 .
In some constructions, the battery pack 30 may include five to ten battery cells 46 . In other constructions, the battery pack 30 may include six to eight battery cells 46 . In further constructions, the battery pack 20 may include two to ten battery cells 46 . In some constructions, the battery cells 46 can have a nominal voltage of approximately 3.6V. In other embodiments, the battery cells 46 can have a nominal voltage of approximately 4.2V. In further constructions, the battery cells 46 can have another nominal voltage, such as, for example, approximately 3.6V, approximately 4.0 V, and approximately 4.3 V. It should be understood that, in other constructions (not shown), the battery cells 46 may have a different nominal cell voltage and/or may be connected in another configuration, such as, for example, in parallel or in a parallel/series combination.
The battery cells 46 may be any rechargeable battery cell chemistry type, such as, for example, nickel cadmium (NiCd), nickel-metal hydride (NiMH), Lithium (Li), Lithium-ion (Li-ion), other Lithium-based chemistry, other rechargeable battery cell chemistry, etc. In the illustrated construction, the battery cells 46 can be lithium-ion (Li-ion) battery cells. For example, the battery cells 46 can have a chemistry of Lithium-Cobalt (LiâCo), Lithium-Manganese (LiâMn) Spinel, LiâMn Nickel, another lithium metal chemistry, or the like.
In some constructions and in some aspects, such as the construction shown in FIG. 70 , the battery cells 46 can have a Li-ion based chemistry, such as, for example, LiâMn Spinel or LiâCo. As shown in FIG. 70 , the battery cell 46 includes cathode material 705 and anode material 710 . The cathode material 705 and anode material 710 are separated by a separator 715 . In one construction, the cathode material 705 includes LiâMn Spinel, the anode material 710 includes lithium graphite and the separator 715 includes polyethylene polypropylene laminate. In this construction, the LiâMn Spinel battery cell 46 is typically more stable than a LiâCo battery cell, which can allow for a larger cell size. A battery cell 46 of this construction can operate at high current discharge rates and does not build large internal resistance during cycle life.
In some constructions, such as the illustrated construction of FIG. 70 , the cell 46 includes one or more safety mechanisms. For example, in one construction, the separator 715 can include a plastic porous separator material that melts between approximately 120° C. and approximately 150° C. When the separator 715 begins to melt, the pores close. This causes the cell 46 to be disabled.
Also, the cell 46 can include a disconnect device 720 , in some constructions. In these constructions, the disconnect device 720 is pressure activated. If the cell 46 is overcharged, a voltage triggered polymer (not shown) within the cell 46 creates gas and pressure. With enough pressure, the disconnect device 720 will permanently open the electrical connection to the outside, which disables the cell 46 .
Also in some constructions, the cell 46 can include a rupture vent 730 . In the instance of large internal pressure buildup (under thermal or mechanical abuse situations), the vent 730 can safely release the gas pressure, such that the cell 46 does not explode.
In one construction of the Li- ion battery cell 46 , the working temperature range for the Li- ion battery cells 46 is approximately â20° C. to +75° C. As compared to battery cells of other chemistries, the Li- ion battery cells 46 have a wider working temperature range. For example, battery cells of NiCd construction do not deliver power as well as Li- ion cells 46 at higher temperatures, and battery cells of NiMH construction do not deliver power as well as Li- ion cells 46 at lower temperatures. Also, Li- ion battery cells 46 can be lightweight and compact without sacrificing performance due to high energy densities. Gravimetric energy density for Li- ion battery cells 46 is approximately 150 Wh/kg, which can be compared to existing NiCd battery cells. In some constructions, the gravimetric energy density for Li- ion battery cells 46 is approximately 2.5 times as high as existing NiCd battery cells. Volumetric energy density for Li- ion battery cells 46 is approximately 390 Wh/L, which can also be compared to existing NiCd battery cells. In some constructions, the volumet
CLAIMS
Claims ( 18 )
What is claimed is:
1. An electrical combination comprising:
a power tool including power tool terminals;
a battery pack configured to be interfaced with the power tool, the battery pack including
a battery pack housing,
at least three terminals including a positive terminal, a negative terminal, and a sense terminal, the at least three terminals configured to be interfaced with corresponding terminals of the power tool, and
a plurality of rechargeable battery cells arranged within and supported by the housing, each of the battery cells having a respective state of charge, power being transferable between the battery cells and the power tool;
a balancing circuit configured to detect a charge imbalance among the battery cells based on a plurality of voltages of the plurality of rechargeable battery cells detected at substantially the same time; and
a control circuit configured to initiate a controlled discharging process to discharge at least one of the battery cells whose present state of charge is high relative to a present state of charge of another of the battery cells, the control circuit including a microprocessor.
2. The electrical combination of claim 1 , wherein the microprocessor is configured to detect voltages of the battery cells throughout the controlled discharging process.
3. The electrical combination of claim 1 , wherein the microprocessor is configured to end the controlled discharging process when a present state of charge of the at least one of the battery cells is approximately equal to a present state of charge of the other of the battery cells.
4. The electrical combination of claim 1 , wherein the balancing circuit includes a plurality of resistors or a plurality of transistors.
5. The electrical combination of claim 1 , wherein the control circuit is further configured to identify a battery cell among the plurality of battery cells that is imbalanced.
6. The electrical combination of claim 5 , wherein the identified battery cell is a low voltage cell.
7. The electrical combination of claim 1 , wherein the battery pack is configured to balance the battery cells when the battery pack is in a discharging operation.
8. The electrical combination of claim 1 , wherein the microprocessor is configured to disable the battery pack via a switch when a balanced ratio between the battery cells falls outside a predetermined range.
9. The electrical combination of claim 8 , wherein the microprocessor is configured to interrupt operation of the battery pack when the balanced ratio between the battery cells falls outside the predetermined range.
10. A method of operating a battery pack configured to be interfaced with a power tool including power tool terminals, the battery pack including a battery pack housing, at least three terminals including a positive terminal, a negative terminal, and a sense terminal, the at least three terminals configured to be interfaced with corresponding terminals of the power tool, and a plurality of rechargeable battery cells arranged within and supported by the housing, each of the battery cells having a respective state of charge, power being transferable between the battery cells and the power tool, the method comprising:
detecting, with a balancing circuit, a charge imbalance among the battery cells based on a plurality of voltages of the plurality of rechargeable battery cells detected at substantially the same time; and
initiating, with a control circuit, a controlled discharging process to discharge at least one of the battery cells whose present state of charge is high relative to a present state of charge of another of the battery cells, the control circuit including a microprocessor.
11. The method of claim 10 , further comprising detecting, with the microprocessor, voltages of the battery cells throughout the controlled discharging process.
12. The method of claim 10 , further comprising ending, with the microcontroller, the controlled discharging process when a present state of charge of the at least one of the battery cells is approximately equal to a present state of charge of the other of the battery cells.
13. The method of claim 10 , wherein the balancing circuit includes a plurality of resistors or a plurality of transistors.
14. The method of claim 10 , further comprising identifying, with the control circuit, a battery cell among the plurality of battery cells that is imbalanced.
15. The method of claim 14 , wherein the identified battery cell is a low voltage cell.
16. The method of claim 10 , further comprising balancing the battery cells when the battery pack is in a discharging operation.
17. The method of claim 10 , further comprising disabling, with the microprocessor, the battery pack via a switch when a balanced ratio between the battery cells falls outside a predetermined range.
18. The method of claim 17 , further comprising interrupting, with the microprocessor, operation of the battery pack when the balanced ratio between the battery cells falls outside the predetermined range.
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