Abstract:
A battery pack of an electric power tool comprises ten lithium-ion cells. The ten lithium-ion cells are connected in series. Each lithium-ion cell has a diameter equal to or less than 18 millimeters, a length equal to or less than 65 millimeters, and an internal resistance equal to or less than 30 milliohms. Because the battery pack has a high voltage in operation and is therefore able to supply large current, the battery pack is preferably configured incapable of being used in a conventional electric power tool that cannot operate under such a large current.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to Japanese Patent Application No. 2010-192239 filed on Aug. 30, 2010 and U.S. Provisional Application No. 61/379,984 filed on Sep. 3, 2010, the contents of which are hereby incorporated by reference into the present application. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to a battery pack of an electric power tool, and more particularly to a battery pack having lithium-ion cells. 
       DESCRIPTION OF RELATED ART 
       [0003]    JP 2008-518798 A discloses an electric power tool powered by a battery pack. The battery pack of this electric power tool has a plurality of lithium-ion cells. The lithium-ion cell makes it possible to obtain a high output voltage and merits a high energy density. With the technique described in JP 2008-518798 A, since the lithium-ion cells are used in the battery pack, an output-to-weight ratio of the electric power tool (including the battery pack; same hereinbelow) is increased. 
       SUMMARY OF THE INVENTION 
       [0004]    It is preferable that an electric tool has a high output-to-weight ratio or output-to-volume ratio. For this reason, it is necessary not only to use lithium-ion cells in a battery pack, but also to increase the output-to-weight or output-to-volume ratio of the electric power tool. 
         [0005]    To meet the above-mentioned demand, it is necessary to increase the output voltage of the battery pack, without changing the size or number of the lithium-ion cells used therein. Thus, in accordance with the present invention, lithium-ion cells with a small internal resistance are used in the battery pack of the electric power tool. Where the internal resistance of a lithium-ion cell is small, the internal voltage drop in the lithium-ion cell decreases. Since a comparatively high current flows in electric power tools, the internal voltage drop caused by the lithium-ion cells also becomes comparatively large. In particular, in a battery pack in which a plurality of lithium-ion cells is connected in series, the internal voltage drop caused by the lithium-ion cells can surpass the output voltage of one lithium-ion cell or the plurality of lithium-ion cells. By suppressing such an internal voltage drop, it is possible to increase the working voltage of the battery pack (output voltage during conduction), without changing the size or number of the lithium-ion cells used therein. Thus, the output-to-weight or output-to-volume ratio of the electric power tool can be increased. 
         [0006]    The inventors have verified that lithium-ion cells having an internal resistance equal to or higher than 30.3 milliohm have been used in the battery packs of conventional electric power tools. Therefore, by using lithium-ion cells having an internal resistance equal to or less than 30 milliohm, it is possible to increase the output-to-weight and output-to-volume ratio over those of the conventional products. The abovementioned value of 30.3 milliohm is obtained by measuring the internal resistance of the conventional lithium-ion cell having a diameter of 18 millimeters and a length of 65 millimeters. Therefore, in accordance with the present invention, a lithium-ion cell that has a diameter equal to or less than 18 millimeters and a length equal to or less than 65 millimeters and also has an internal resistance equal to or less than 30 milliohm is preferred. 
         [0007]    On the basis of the above-described findings, it is preferred that the battery pack for an electric power tool disclosed in the present description have at least one lithium-ion cell, wherein the lithium-ion cell has an internal resistance equal to or less than 30 milliohms. In this case, it is preferred that the lithium-ion cell have a diameter equal to or less than 18 millimeters and a length equal to or less than 65 millimeters. With such a configuration, the output of the battery pack can be increased, without changing the size or number of lithium-ion cells with respect to that of the conventional product. As a result, the output-to-weight and output-to-volume ratio of the electric power tool can be increased. 
         [0008]    In the above-described electric power tool, lithium-ion cells of a small size can be used. Usually, the decrease in size of lithium-ion cells results in the increased internal resistance thereof. Where the diameter of the above-mentioned conventional lithium-ion cell (diameter 18 millimeters, length 65 millimeters, internal resistance 30.3 milliohms) is reduced to 14 millimeters, the internal resistance thereof becomes 49.2 milliohms. Alternatively, where the length of the conventional lithium-ion cell is assumed to decrease to 45 millimeters, the internal resistance thereof becomes 43.6 milliohms. Therefore, where a lithium-ion cell with a diameter equal to or less than 14 millimeters and a length equal to or less than 65 millimeter is used, it is preferred that this lithium-ion cell have an internal resistance equal to or less than 49 milliohms. Further, where a lithium-ion cell with a diameter equal to or less than 18 millimeters and a length equal to or less than 45 millimeter is used, it is preferred that this lithium-ion cell have an internal resistance equal to or less than 40 milliohms. As a result, the output-to-weight and output-to-volume ratio of the electric power tool can be increased with respect to those of the conventional product. 
         [0009]    It is preferable that each of the abovementioned battery packs has a plurality of lithium-ion cells connected in series. Where the plurality of lithium-ion cells is connected in series, the working voltage of the battery pack can be increased. Even when the plurality of lithium-ion cells is connected in series, since the internal resistance of each lithium-ion cell is comparatively small, so the internal resistance of the battery pack can be suppressed to a comparatively low value. 
         [0010]    For example, a battery pack having ten lithium-ion cells connected in series can be used. In this case, the nominal voltage of the battery pack can be 36 V and the nominal capacity of the battery pack can be equal to or higher than 1 Ampere-hour. 
         [0011]    As described hereinabove, where lithium-ion cells with a low internal resistance are used, the working voltage of the battery pack rises and the output of the electric power tool can be increased. However, where the battery pack using the lithium-ion cells with a small internal resistance is used as a power supply of the conventional electric power tool, a high current supplied by the battery pack can damage the constituent components of the conventional electric power tool. For this reason, the battery pack in accordance with the present invention should be used only with specially designed electric power tools, and it is preferred that the use for the conventional electric power tool be prohibited. Meanwhile, the electric power tool that can use the battery pack in accordance with the present invention can also use, without any problem, the battery packs of the conventional electric power tools. 
         [0012]    Based on the above-described findings, the present invention provides the below-described electric power tool system. This electric power tool system includes a first electric power tool powered by a first battery pack and a second electric power tool powered by a second battery pack. The first and second battery packs include the same number of lithium-ion cells. The first battery pack accommodates lithium-ion cells with an internal resistance lower than that of the lithium-ion cells of the second battery pack. Thus, the first battery pack corresponds to the above-described battery pack in accordance with the present invention, and the second battery pack corresponds to the battery pack of the conventional electric power tool. In this case, it is preferred that the first battery pack be configured capable of being detachably attached to the main body of the first electric power tool. It is also preferred that the second battery pack be configured capable of being detachably attached to the main body of the second electric power tool and also capable of being detachably attached to the main body of the first electric power tool. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a side view of an electric power tool according to an embodiment. 
           [0014]      FIG. 2  shows a battery receiving portion of the electric power tool according to the embodiment, as viewed from the front surface (from the left side in  FIG. 1 ). 
           [0015]      FIG. 3  is a perspective view of a battery pack of the electric power tool according to the embodiment. 
           [0016]      FIG. 4  is a front view of the battery pack of the electric power tool according to the embodiment. 
           [0017]      FIG. 5  illustrates schematically the compatibility of the battery pack with the electric power tool according to the embodiment and the conventional electric power tool. 
           [0018]      FIG. 6  is a graph illustrating the results obtained in measuring the internal resistance of a lithium-ion cell. 
           [0019]      FIG. 7  illustrates measurement conditions for the internal resistance of the lithium-ion cell. 
           [0020]      FIG. 8  illustrates outer dimensions and effective dimensions of the lithium-ion cell.  FIG. 8(A)  shows schematically a vertical section of the lithium-ion cell.  FIG. 8(B)  is a cross-sectional view taken along the B-B line in  FIG. 8(A)  that shows schematically the transverse section of the lithium-ion cell. 
           [0021]      FIG. 9  shows a battery receiving portion of the conventional electric power tool, as viewed from the front surface. 
           [0022]      FIG. 10  is a perspective view of a battery pack of the conventional electric power tool. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    Representative, non-limiting examples of the present invention will now be described in further detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed below may be utilized separately or in conjunction with other features and teachings to provide improved battery packs for electric power tools, as well as methods for using and manufacturing the same. 
         [0024]    Moreover, combinations of features and steps disclosed in the following detail description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described and below-described representative examples, as well as the various independent and dependent claims, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings. 
         [0025]    All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter. 
         [0026]    An electric power tool  10  according to an embodiment will be explained below with reference to the drawings. As shown in  FIGS. 1 and 2 , the electric power tool  10  is provided with a main body  12  and a battery pack  50  that supplies power to the main body  12  of the electric power tool  10 . A tool holder  14  that can be detachably attached to the tool, a main switch  16  operated by the user, and a grip  18  held by the user are provided at the main body  12 . A battery receiving portion  20  that can detachably receive the battery pack  50  is provided at the lower end of the grip  18 . A motor or a circuit substrate (not shown in the figure) for driving the tool holder  14  is accommodated inside the main body  12 . The electric power tool  10  of the present embodiment is, by way of example, an electric power driver, and a driver bit (not shown in the figure) is mounted on the tool holder  14 . 
         [0027]    The battery pack  50  has a housing  52  and ten lithium-ion cells  70  housed in the housing  52 . The ten lithium-ion cells  70  are electrically connected in series. The nominal voltage of each lithium-ion cell  70  is 3.6 V. Therefore, the nominal voltage of the entire battery pack  50  is 36 V. The rated voltage of the electric power tool  10  is also 36 V. A connector portion  60  is provided at the upper surface of the housing  52 . The connector portion  60  is detachably engaged with the battery receiving portion  20  of the main body  12 . 
         [0028]    As shown in  FIG. 2 , a pair of rails  22  is formed at the battery receiving portion  20  of the main body  12 . Further, as shown in  FIGS. 3 and 4 , a pair of rails  62  is also formed in the connector portion  60  of the battery pack  50 . The pair of rails  62  of the battery pack  50  is slidably engaged with the pair of rails  22  of the main body  12 . As a result, the battery pack  50  is physically connected to the main body  12 . 
         [0029]    As shown in  FIG. 2 , the battery receiving portion  20  of the main body  12  is provided with a positive terminal  26  and a negative terminal  28 . The positive terminal  26  and the negative terminal  28  are electrically connected to the circuit board and motor located inside the main body  12 . As shown in  FIGS. 3 and 4 , the connector portion  60  of the battery pack  50  is provided with a positive terminal  66  and a negative terminal  68 . The positive terminal  66  and the negative terminal  68  are electrically connected to the ten lithium-ion cells  70  that are connected in series. Where the battery pack  50  is attached to the battery receiving portion  20  of the main body  12 , the positive terminal  66  and the negative terminal  68  of the battery pack  50  are electrically connected to the positive terminal  26  and the negative terminal  28 , respectively, of the main body  12 . As a result, the battery pack  50  is electrically connected to the main body  12 , and the discharge power of the ten lithium-ion cells  70  is supplied to the circuit board and motor located inside the main body  12 . 
         [0030]    The attachment structure of the battery pack in the electric power tool  10  according to the above-described embodiment is essentially similar to the attachment structure of a battery pack  150  in a conventional electric power tool  110  shown in  FIGS. 9 and 10 . Thus, in the conventional electric power tool  110 , a battery receiving portion  120  of a main body  112  is also provided with a pair of rails  122 , a positive terminal  126 , and a negative terminal  128 , and a housing  152  of the battery pack  150  is provided with a pair of rails  162 , a positive terminal  166 , and a negative terminal  168 . In this case, similarly to the battery pack  50  of the present embodiment, the conventional battery pack  150  shown in  FIG. 10  has ten lithium-ion cells connected in series, and the nominal voltage thereof is 36 V. Thus, the rated voltage of the conventional electric power tool  110  is also 36 V. 
         [0031]    As shown in  FIGS. 2 ,  3 , and  4 , in the electric power tool  10  of the present embodiment, a rib  64  is formed at the connector portion  60  of the battery pack  50 , and a groove  24  for receiving the rib  64  is formed at the battery receiving portion  20  of the main body  12 . By contrast, as shown in  FIGS. 9 and 10 , in the conventional electric power tool  110 , no portion corresponding to the abovementioned rib  64  is present at the connector portion  160  of the battery pack  150 , and no site corresponding to the abovementioned groove  24  is present at the battery receiving portion  120  of the main body  112 . Therefore, as shown schematically in  FIG. 5 , the battery pack  50  of the present embodiment is configured attachable only to the main body  12  of the present embodiment and cannot be attached to the main body  112  of the conventional electric power tool  110 . By contrast, the main body  12  of the present embodiment is configured suitable for use not only with the battery pack  50  of the present embodiment, but also with the battery pack  150  of the conventional electric power tool  110 . 
         [0032]    As compared with the conventional electric power tool  110 , the electric power tool  10  of the present embodiment uses new lithium-ion cells  70  with a low internal resistance. The internal resistance of the new lithium-ion cell  70  is improved to 26.8 milliohms. The new lithium-ion cell  70  is a cylindrical lithium-ion cell and has a diameter of 18 millimeters and a length of 65 millimeters. By using the lithium-ion cells  70  with a low internal resistance, it is possible to inhibit the decrease in internal voltage of the battery pack  50  during conduction. As a result, the working voltage of the battery pack  50  is increased and the output performance of the electric power tool  10  is improved. More specifically, since a high current is supplied from the battery pack  50  to the main body  12 , the maximum torque that can be outputted by the electric power tool  10  is increased. Furthermore, since the power loss in the battery pack  50  is reduced, the interval in which the electric power tool  10  can be used is extended. 
         [0033]    The nominal voltage of the battery pack  50  of the present embodiment is equal to the nominal voltage of the conventional battery pack  150 , but the actual output voltage during conduction of the battery pack  50  of the present embodiment is higher than that of the conventional battery pack  150 . Therefore, where the battery pack  50  of the present embodiment is used in the conventional electric power tool  110 , the electric current supplied by the battery pack  50  can exceed the level allowed for the main body  112  of the conventional electric power tool  110  and constituent components thereof can be damaged. For this reason, as mentioned hereinabove, the battery pack  50  of the present embodiment is configured such that the attachment thereof to the main body  112  of the conventional electric power tool  110  is impossible and the use thereof on the conventional electric power tool  110  is prohibited (see  FIG. 5 ). 
         [0034]    The inventors have measured the internal resistance for three products A, B, C of the conventional lithium-ion cells that have been developed for electric power tools. The conventional three products A, B, C are all cylindrical lithium-ion cells and have a diameter of 18 millimeters and a length of 65 millimeters. According to the measurement results obtained by the inventors, the internal resistance of the conventional product A is 30.3 milliohms, the internal resistance of the conventional product B is 40.0 milliohms, and the internal resistance of the conventional product C is 50.9 milliohms. These measurement results confirmed that among the conventional cylindrical lithium-ion cells that have been used in electric power tools, there is no cell having a diameter equal to or less than 18 millimeters, a length equal to or less than 65 millimeters, and an internal resistance equal to or less than 30 milliohms. The internal resistance of lithium-ion cells slightly varies depending on the measurement method used. A method for measuring the internal resistance according to the present description will be explained below in greater detail. 
         [0035]    In the electric power tool  10  of the abovementioned embodiment, the size (diameter:  18  millimeters and length: 65 millimeters) of the new lithium-ion cells  70  can be reduced. Typically, where the size of lithium-ion cells is reduced, the internal resistance thereof increases.  FIG. 6  shows the relationship between the diameter of a lithium-ion cell (abscissa) and the internal resistance thereof (ordinate). In  FIG. 6 , a graph X shows the internal resistance of the new lithium-ion cell  70 , a graph A shows the internal resistance of the conventional product A, a graph B shows the internal resistance of the conventional product B, and a graph C shows the internal resistance of the conventional product C. Among the internal resistance values shown in  FIG. 6 , the internal resistance value at a diameter of 18 millimeters is a measured value, and the values at other diameters are estimated values determined by calculations from the measured value. The method for calculating the estimated values will be described below in greater detail. 
         [0036]    As shown in  FIG. 6 , the internal resistance increases as the diameter of the lithium-ion cell decreases. However, in the case of the new lithium-ion cell  70  used in the present embodiment, although the cell diameter is reduced to 14 millimeters, the internal resistance thereof is restricted to a value equal to or less than 43.1 milliohms. This value is on par with the internal resistance of the conventional products A, B, C having the diameter of 18 millimeters. Therefore, with the new lithium-ion cells  70  used in the present embodiment, it is possible to reduce the size and weight of the electric power tool  10  including the battery pack  50 , while maintaining the output performance identical to that of the conventional electric power tool  110 . In the case of the conventional lithium-ion cells A, B, C, where the diameter is reduced to 14 millimeters, the internal resistance increases to become equal to or greater than 49.2 milliohms. 
         [0037]    When the size and weight of the electric power tool  10  are to be reduced, not only the diameter of the lithium-ion cells  70 , but also the length of the lithium-ion cells  70  may be decreased. In the case of the lithium-ion cells  70  used in the present embodiment, even when the length is reduced to 45 millimeters, the internal resistance is restricted to a value equal to or less than 38.3 milliohms. This value is on par with the internal resistance of the conventional products A, B, C with the length of 65 millimeters. Therefore, with the new lithium-ion cells  70  used in the present embodiment, the size and weight of the electric power tool  10  including the battery pack  50  can be reduced, while maintaining the output performance identical to that of the conventional electric power tool  110 . In the case of the conventional lithium-ion cells, A, B, C, where the length is reduced to 45 millimeters, the internal resistance thereof is increased to at least 43.6 milliohms. These values are also estimated values calculated by the below-described calculation method. 
         [0038]    As described hereinabove, with the electric power tool  10  of the present embodiment, where the new lithium-ion cells  70  with a low internal resistance are used, the output performance of the electric power tool  10  is improved without increasing the size or weight of the electric power tool  10 . Alternatively, by decreasing the new lithium-ion cells  70  in size, it is possible to decrease the size or weight of the electric power tool  10 , while maintaining the output performance identical to that of the conventional electric power tool  110 . Further, since the power loss in the battery pack  50  is reduced, the interval in which the electric power tool  10  can be used is extended. Further, even when the battery pack  50  is charged, the power loss is small and the increase in temperature of the new lithium-ion cells  70  is suppressed. 
       (Method for Measuring the Internal Resistance)  
       [0039]    A method for measuring the internal resistance in the present embodiment will be explained below. With this measurement method, first, a discharge depth (charge level) of a lithium-ion cell is set to 50%. More specifically, after the lithium-ion cell is appropriately charged, the quantity of electricity corresponding to a half of the nominal capacitance is discharged. The terminal voltage of the lithium-ion cell is then measured, while discharging the lithium-ion cell. In this case, the ambient temperature is maintained at 25±−1° C., and the temperature of the lithium-ion cell is also 25±1° C. As shown in  FIG. 7 , when the lithium-ion cell is discharged, the discharge current changes with time. More specifically, in the first 1 sec, the discharge current is adjusted to 10 A, and in the subsequent 5 sec, the discharge current is adjusted to 20 A. The specific feature of this measurement method is that the lithium-ion cell is discharged at a high current, with consideration for the use in an electric power tool. While the lithium-ion cell is thus discharged, the current C 1  and voltage V 1  are measured after 1 sec has elapsed, and the current C 2  and voltage V 2  are measured after 6 sec have elapsed. The internal resistance of the lithium-ion cell is determined from the slope of the current-voltage line between the two points in which measurements have been conducted. Thus, the internal resistance R is represented by the following formula. 
         [0000]        R= ( V 1− V 2)/( C 2− C 1)×1000 [mΩ]
 
       (Method for Calculating the Estimated Value of Internal Resistance)  
       [0040]    A method for calculating the estimated value of internal resistance in the present embodiment will be explained below. As shown in  FIG. 8 , an electrode assembly  72  having a positive electrode sheet and a negative electrode sheet wound with a separator being interposed therebetween is accommodated in the lithium-ion cell  70 , and the internal resistance of the lithium-ion cell  70  is inversely proportional to the surface area of the electrode assembly  72  spread on a plane. In this case, the surface area of the electrode assembly  72  spread on a plane is proportional to the height h 1  of the electrode assembly  72  accommodated in the lithium-ion cell  70  and also proportional to the transverse cross-sectional area S of the electrode assembly  72  accommodated in the lithium-ion cell  70 . In this case, the difference h 2  between the height H of the lithium-ion cell  70  and the height h 1  of the electrode assembly  72  is 7 millimeters. The diameter d 1  of the cavity formed in the center of the electrode assembly  72  is 5 millimeters. The share of structural resistance fraction created by the collector or the like in the internal resistance of the lithium-ion cell  70  is 5 milliohms. 
         [0041]    Therefore, it can be calculated that when the new lithium-ion cell  70  having the diameter of 18 millimeters, the length of 65 millimeters, and the internal resistance of 26.8 milliohms, is reduced in diameter to 14 millimeters, the internal resistance thereof will become 43.1 milliohms. Alternatively, it can be calculated that when the new lithium-ion cell  70  is reduced in length to 45 millimeters, the internal resistance thereof will become 38.3 milliohms. Likewise, it can be calculated that when the lithium-ion cell that is the conventional product A having the diameter of 18 millimeters, the length of 65 millimeters, and the internal resistance of 30.3 milliohms, is reduced in diameter to 14 millimeters, the internal resistance thereof will become 49.2 milliohms. Alternatively, it can be calculated that when the lithium-ion cell that is the conventional product A is reduced in length to 45 millimeters, the internal resistance thereof will become 43.6 milliohms. 
         [0042]    The embodiments of the present invention are described above in detail, but these embodiments are merely exemplary and place no limitation on the patent claims. Thus, the technical scope of the claims includes various modifications and changes of the above-described specific examples. In particular, the actual diameter and length of the battery cells do not necessarily strictly match the dimensions (diameter: 18 millimeters and length: 65 millimeters) explained in the present detailed description of the invention, and a certain difference in dimensions (several millimeters) may be present.