Patent Publication Number: US-2022223964-A1

Title: Drop protection system for rechargeable batteries

Description:
This is a continuation of U.S. patent application Ser. No. 17/343,413, filed on Jun. 6, 2021, now published as U.S. Patent Publication 2021/0384579 A1, which is a continuation of International Patent Application PCT/EP2020/057056, filed on Mar. 16, 2020 which claims priority to European Patent Application EP 19164821.1, filed Mar. 25, 2019. All of the above applications are hereby incorporated by reference herein. 
     The present invention relates to a shock absorbing device for a rechargeable battery, in particular for supplying a machine tool with electrical energy, wherein the rechargeable battery comprises a housing for accommodating at least one energy storage cell. 
    
    
     BACKGROUND 
     Rechargeable batteries available on the market usually contain a multiplicity of energy storage cells, also called rechargeable battery cells, which are used for storing and releasing electrical energy. The housing of the rechargeable battery usually consists of a relatively hard plastic shell. For example, the hard plastic may be polyamide. 
     Conventional energy storage cells or rechargeable battery cells are relatively sensitive and should be protected from a suddenly occurring effect of a force, from shocks and the like. Such an effect of a force on the energy storage cells can occur as a consequence of a fall or drop of the rechargeable battery when the housing of the rechargeable battery strikes a hard inelastic surface (e.g. a concrete floor) from a certain falling height. During this process, the shock energy can be transmitted via the rechargeable battery housing to the energy storage cells and can produce damage to the energy storage cells. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to solve the abovementioned problem and, in particular, to better protect energy storage cells in the interior of a rechargeable battery housing in the case of a fall. 
     The present invention provides a shock absorbing device for a rechargeable battery, in particular for supplying a machine tool with electrical energy, wherein the rechargeable battery comprises a housing for accommodating at least one energy storage cell. 
     The shock absorbing device comprises at least one shock absorbing element for absorbing shock energy exerted on the housing of the rechargeable battery. 
     According to an advantageous embodiment of the present invention, it is possible for the at least one shock absorbing element to extend from a first side face of the housing of the rechargeable battery to a second side face of the housing of the rechargeable battery. It is thereby possible in an effective manner to protect a lateral edge between a first and a second side face of the housing of the rechargeable battery via the shock absorbing element. In the case of a fall or a drop of the rechargeable battery onto a hard surface, the sudden action of shock energy, particularly at the lateral edges between the side faces, can lead to damage to the housing of the rechargeable battery and to the energy storage cells. 
     It should be noted here that two mutually adjoining side faces are in each case arranged substantially at a right angle (i.e. 90°) to one another. However, it is also possible for two mutually adjoining side faces not to be arranged at a right angle to one another (i.e. greater or less than 90°) in each case. 
     In this case, the housing of the rechargeable battery can comprise six side faces. 
     According to an advantageous embodiment of the present invention, it may be possible for the at least one shock absorbing element to be configured in the form of a yoke. 
     The choice of material and the particular shaping of the shock absorbing element enable said element to be plastically or elastically deformable. 
     According to an advantageous embodiment of the present invention, it is possible for the shock absorbing element configured as a yoke to comprise a first end and a second end, wherein the first end is positioned on a first side face of the housing, and the second end is positioned on a second side face of the housing. It is thereby possible to produce a cavity or recess between the side faces and the shock absorbing element which, in the case of shock energy acting suddenly on the rechargeable battery housing, can be used as a crumple zone or as a region into which the shock absorbing element can be deformed. By means of the deformation of the shock absorbing element, energy, in particular shock energy, can be absorbed. Here, the deformation of the shock absorbing element can take place elastically or plastically. 
     According to an advantageous embodiment of the present invention, it may be possible for a substantially constant distance to be provided between the surface of the shock absorbing element and an outer surface of the housing of the rechargeable battery. 
     According to another advantageous embodiment of the present invention, however, it is also possible for the distance between the surface of the shock absorbing element and an outer surface of the housing of the rechargeable battery to be non-constant or variable. 
     According to an advantageous embodiment of the present invention, it is possible for the shock absorbing element configured as a yoke to be positioned on the housing in such a way that an arcuate section of the shock absorbing element configured as a yoke extends around a lateral edge of two mutually adjoining side faces of the housing. 
     According to an advantageous embodiment of the present invention, it may be possible for the shock absorbing element configured as a yoke to comprise at least two component pieces, in particular five component pieces, wherein two mutually adjoining component pieces are in each case arranged at an obtuse angle to one another. The obtuse angle can have a value between 110° and 150°. The component piece can also be referred to as a yoke section. 
     According to an advantageous embodiment of the present invention, it is possible for the shock absorbing element configured as a yoke to be configured in the form of a circular arc. 
     According to an advantageous embodiment of the present invention, it may be possible for the shock absorbing element of the shock absorbing device to be fixed to the housing of the rechargeable battery or to be an integral part of the housing of the rechargeable battery. Via the fixed (i.e. permanent) connection of the shock absorbing device to the housing of the rechargeable battery, a high strength or robustness of the shock absorbing device can be produced. The fixed connection can be by way of common encapsulation or a casting process for the production of the rechargeable battery housing and of the shock absorbing device. This is possible, in particular, if the rechargeable battery housing and the shock absorbing device are produced from the same material (e.g. polycarbonate or polyamide). 
     As an alternative and according to another advantageous embodiment of the present invention, it may be possible for the at least one shock absorbing element of the shock absorbing device not to be fixed to the housing of the rechargeable battery but to be detachable therefrom. A connection which is not fixed and is detachable can be achieved via a screwed joint, for example. 
     The present invention also provides a device for supplying a machine tool with electrical energy, the device comprising: a rechargeable battery including a housing for accommodating at least one energy storage cell, the housing having a first side face and a second side face angled with respect to the first side face and connected at a corner; and a shock absorbing device including at least one shock absorber, the shock absorber extending around the corner and spaced apart from the housing at the corner by an empty space. 
     The present invention also provides a device for supplying a machine tool with electrical energy, the device comprising: a rechargeable battery including a housing for accommodating at least one energy storage cell, the housing having a first side face and a second side face angled with respect to the first side face and connected via a curved surface; and a shock absorbing device including at least one shock absorber, the shock absorber having a first inner surface spaced apart and parallel to the first side face, a second inner surface spaced apart and facing the curved surface, and a third inner surface is parallel to the second side face, the shock absorbing device being configured so that the second inner surface is movable with respect to the curved surface to enable contact between the second inner surface and the curved surface. 
     The present invention also provides a device for supplying a machine tool with electrical energy, the device comprising:
         a rechargeable battery including a housing for accommodating at least one energy storage cell, the housing having a first side face and a second side face angled with respect to the first side face and connected at a corner; and a shock absorbing device including at least one shock absorber, the shock absorber extending around the corner and spaced apart from the housing at the corner, the shock absorber having a thickness t at the corner and being spaced apart from the corner by a distance b, wherein t meets the following: 0.5×b≤t≤2×b.       

     Further advantages will become apparent from the following description of the figures. Various exemplary embodiments of the present invention are illustrated in the figures. The figures, the description and the claims contain numerous features in combination. A person skilled in the art will expediently also consider the features individually and combine them to produce useful further combinations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the figures, identical and similar components are denoted by identical reference signs. 
       In the figures: 
         FIG. 1  shows a perspective view of a rechargeable battery having a housing, of a shock absorbing device according to the invention and shock absorbing elements; 
         FIG. 2  shows a side view of the rechargeable battery having the housing, of the shock absorbing device according to the invention and of the shock absorbing elements; 
         FIG. 3  shows a lateral sectional view through the housing of the rechargeable battery having a first and a second row of energy storage cells; 
         FIG. 4  shows a lateral sectional view through the housing of the rechargeable battery having a first, a second and a third row of energy storage cells; 
         FIG. 5  shows a lateral sectional view through a corner region of the housings of the rechargeable battery and of the shock absorbing element; 
         FIG. 6 a    shows a lateral sectional view through a corner region of the housings of the rechargeable battery and of the shock absorbing element according to a first embodiment in a no-load state; 
         FIG. 6 b    shows a sectional view of section plane A-A in  FIG. 6   a;    
         FIG. 7 a    shows a lateral sectional view through a corner region of the housings of the rechargeable battery and of the shock absorbing element according to a first embodiment in a partially loaded state; 
         FIG. 7 b    shows a sectional view of section plane A-A in  FIG. 7   a;    
         FIG. 8 a    shows a lateral sectional view through a corner region of the housings of the rechargeable battery and of the shock absorbing element according to a first embodiment in a fully loaded state; 
         FIG. 8 b    shows a sectional view of section plane A-A in  FIG. 8   a;    
         FIG. 9 a    shows a lateral sectional view through a corner region of the housings of the rechargeable battery and of the shock absorbing element according to a second embodiment in a no-load state; 
         FIG. 9 b    shows a sectional view of section plane A-A in  FIG. 9   a;    
         FIG. 10 a    shows a lateral sectional view through a corner region of the housings of the rechargeable battery and of the shock absorbing element according to a second embodiment in a partially loaded state; 
         FIG. 10 b    shows a sectional view of section plane A-A in  FIG. 10   a;    
         FIG. 11 a    shows a lateral sectional view through a corner region of the housings of the rechargeable battery and of the shock absorbing element according to a second embodiment in a fully loaded state; and 
         FIG. 11 b    shows a sectional view of section plane A-A in  FIG. 11   a.    
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 and 2  show a rechargeable battery  1  having a housing  2 . The housing  2  of the rechargeable battery  1  can also be referred to as a rechargeable battery housing and comprises six side faces or six sides, namely a front side face  2   a , a left-hand wall side face  2   b , a right-hand wall side face  2   c  and a rear side face  2   d , a bottom side face  2   e  and a top side face  2   f.    
     In  FIG. 1 , the left-hand wall side face  2   b , rear side face  2   d  and bottom side face  2   e  are merely indicated. 
     An interface  3  for outputting electrical energy (electric current) to a consuming unit (e.g. a machine tool) or for receiving electrical energy via a charging device is provided on a top side face  2   f . With the aid of the interface  3 , the rechargeable battery  1  can be connected detachably to a machine tool or a charging device. 
     The rechargeable battery  1  illustrated in  FIG. 1  is used, in particular, to supply a machine tool with electrical energy. 
     As illustrated in  FIGS. 3 and 4 , a multiplicity of energy storage cells  4  is contained in the interior of the housing  2  of the rechargeable battery  1 . The energy storage cells  4  can also be referred to as rechargeable battery cells and are used to store electrical energy. As is apparent, the rechargeable battery cells  4  can be arranged side-by-side and one above the other in two or three layers. The number of rechargeable battery cells  4  side-by-side and one above the other is variable. However, it is also possible for just a single energy storage cell  4  to be provided in the interior of the housing  2  of the rechargeable battery  1 . 
     As is likewise illustrated in  FIGS. 3 and 4 , the energy storage cells  4  are of cylindrical configuration and are positioned in a cell holding device  5  (also referred to as a cell holder). The “cell holder”  5  is positioned in the interior of the rechargeable battery housing  2 . For this purpose, the cell holding device  5  is configured substantially as a block with a number of bores  6 . The individual rechargeable battery cells  4  are inserted into these bores  6 , thus ensuring that the rechargeable battery cells  4  are held by the cell holding device  5 . The bores  6  can also be referred to as recesses or holes. 
     According to an alternative embodiment, it is also possible for the energy storage cells  4  to be configured in the form of “pouch cells” (also referred to as pouch-bag cells or coffee bag cells). 
     There is furthermore a shock absorbing device  7  on the housing  2  of the rechargeable battery  1 . According to the exemplary embodiment which is shown in  FIGS. 1 and 2 , the shock absorbing device  7  comprises a first, second, third and fourth shock absorbing element  8   a ,  8   b ,  8   c ,  8   d . The fourth shock absorbing element  8   d  is merely indicated in the figures. The configuration of the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  is substantially identical and adapted to the respective position thereof on the housing  2  of the rechargeable battery  1 . 
     The first shock absorbing element  8   a  is positioned at a first corner of the rechargeable battery housing  2  and is configured as a yoke with a first and a second end  9   a ,  9   b . As illustrated in  FIG. 2 , the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  configured as a yoke comprises a first component piece  81 , a second component piece  82 , a third component piece  83 , a fourth component piece  84  and a fifth component piece  85 . The first component piece  81  is connected to the second component piece  82  at an obtuse angle α. The second component piece  82  is furthermore connected to the third component piece  83  at an obtuse angle β. The third component piece  83  is, in turn, connected to the fourth component piece  84  at an obtuse angle γ. Finally, the fourth component piece  84  is connected to the fifth component piece  85  at an obtuse angle θ. The obtuse angle α, β, γ, δ can have a value between 110° and 150°. However, a larger or smaller angle α, β, γ, δ is also possible, depending on the design. The angles α, β, γ, δ do not have to have the same value, and therefore the angles α, β, γ, δ may have different values. It is also possible for more or fewer than five component pieces to be used. 
     In this arrangement, the first end  9   a  of the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  configured as a yoke is arranged on the front side face  2   a , and the second end  9   b  of the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  configured as a yoke is arranged on the bottom side face  2   e . The shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  configured as a yoke thus extends over the lateral edge  10  between the front side face  2   a  and the bottom side face  2   e  of the rechargeable battery housing  2  (cf.  FIGS. 1 and 2 ). 
     As illustrated in the figures and especially in  FIG. 5 , the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  configured as a yoke is positioned on the rechargeable battery housing  2  in such a way that a constant distance b (can also be referred to as travel distance b) is provided between the inner surface  11  of the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  and the outer surface  12  of the rechargeable battery housing  2 . As shown especially in  FIGS. 5 to 11   b , the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  configured as a yoke has a wall thickness t (also referred to as thickness). 
     Moreover, the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  configured as a yoke is positioned on the rechargeable battery housing  2  in such a way that a distance a from a surface  13  of a rechargeable battery cell  4  to the outer surface  12  of the rechargeable battery housing  2  is provided (cf.  FIG. 5 ). 
     The shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  as well as the rechargeable battery housing  2  are configured in such a way that the distance a, the distance b and the wall thickness t have a certain value and are formed in a certain relation to one another. Depending on the type of rechargeable battery  1  used (rechargeable battery type), i.e. on the number of rows or layers of rechargeable battery cells  4  (1p=one layer of rechargeable battery cells; 2p=two layers of rechargeable battery cells and 3p=3 layers of rechargeable battery cells), the distance a, the distance b and the wall thickness t have the numerical values in table 01. 
     
       
         
           
               
               
               
               
               
             
               
                   
                 TABLE 01 
               
               
                   
                   
               
               
                   
                 Rechargeable battery type 
                 a (mm) 
                 b (mm) 
                 t (mm) 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
            
               
                   
                 1p 
                 3.5 
                 2 
                 2.5 
               
               
                   
                 2p 
                 3.5 
                 2 
                 2.5 
               
               
                   
                 1p 
                 4.5 
                 3 
                 2.5 
               
               
                   
                 2p 
                 4.5 
                 3 
                 3 
               
               
                   
                 3p 
                 4.5 
                 3 
                 3.5 
               
               
                   
                   
               
            
           
         
       
     
     The ratio of the numerical values for the distance b and the wall thickness t can furthermore be set in relation by means of the formula 01. 
       0.5× b≤t≤ 2× b    Formula 01
 
     As already mentioned above, the shock absorbing device  7  and, in particular, the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  serve to convert shock energy acting suddenly on the rechargeable battery housing  2  in the case of a fall or drop of the rechargeable battery into deformation energy by virtue of its specific physical properties and thereby to protect the rechargeable battery cells  4  arranged in the rechargeable battery housing  2  from possible damage. 
     The actual deformation of the shock absorbing element  8   a ,  8   b ,  8   c ,  8   d  is illustrated for the respective embodiment of the shock absorbing device  7  in  FIGS. 6 a    to  11   b.    
       FIGS. 6 a  and 6 b    show a shock absorbing device  7  according to a first embodiment, in which the shock absorbing element  8   a  has a symmetrical rectangular cross-sectional area  20 . Here,  FIG. 6 a    shows a lateral sectional view through a corner region of the rechargeable battery housing  2  and of the shock absorbing element  8   a  according to the first embodiment in a no-load state. The shock absorbing element  8   a  is at a distance b from the rechargeable battery housing  2 .  FIG. 6 b    shows a sectional view of section plane A-A in  FIG. 6 a   , likewise in a no-load state. A no-load state means that there is no external force acting on the shock absorbing element  8   a . As is also apparent in  FIG. 6 b   , the rechargeable battery housing  2  projects with an overlap s beyond the bottom edge of the cell holder  5  in arrow direction N. 
     In  FIG. 7 a   , the shock absorbing device  7  according to the first embodiment is shown when a first force F is exerted on the shock absorbing element  8   a . The first force F results from a fall of the rechargeable battery  1  and the impact of the rechargeable battery housing  2  on a hard inelastic underlying surface (e.g. concrete). In  FIG. 7 a   , it is apparent in comparison with  FIG. 6 a    that the shock absorbing element  8   a  is being deformed and moved toward the outer surface  12  of the rechargeable battery housing  2 . As illustrated in  FIG. 7 b   , the inner surface  11  of the shock absorbing element  8   a  is resting against the outer surface  12  of the rechargeable battery housing  2 , with the result that the shock energy or the force flow FF is diverted from the shock absorbing element  8   a , via the front side face  2   a , into the top side face  2   f  of the rechargeable battery housing  2  and partially into the cell holder  5  and is guided around the rechargeable battery cells  4 . As is likewise apparent from  FIG. 7 b   , the front side face  2   a  of the rechargeable battery housing  2  is not compressed, and therefore the overlap s of the rechargeable battery housing  2  still exists. 
     In  FIGS. 8 a  and 8 b   , the shock absorbing device according to the first embodiment is shown when a second force F′, which is greater than the first force F, is being exerted on the shock absorbing element  8   a . The second force F′ exerted on the shock absorbing element  8   a  has the effect that the shock absorbing element  8   a  is pressed more strongly against the front side face  2   a  of the rechargeable battery housing  2 . Owing to the higher second force F′, the front side face  2   a  of the rechargeable battery housing  2  is compressed, with the result that the overlap s of the rechargeable battery housing  2  is pressed in. By the pressing in of the overlap s, additional shock energy or impact energy is absorbed by the rechargeable battery housing  2 , and the rechargeable battery cells  4  are additionally protected. 
       FIGS. 9 a  and 9 b    show a shock absorbing device  7  according to a second embodiment, in which the shock absorbing element  8   a  has an asymmetrical or trapezoidal (also referred to as wedge-shaped) cross-sectional area  30 . Here, the cross-sectional area  30  is configured in such a way that the shorter side face of the cross-sectional area configured as a trapezoid is in arrow direction M. In other words: the shorter side face of the trapezoid (or of the cross-sectional area  30  configured as a trapezoid) faces the front side face  2   a  of the rechargeable battery housing  2 . 
       FIG. 9 a    shows a lateral sectional view through a corner region of the rechargeable battery housing  2  and of the shock absorbing element according to the second embodiment in a no-load state. The shock absorbing element  8   a  is at a distance b from the rechargeable battery housing.  FIG. 9 b    shows a sectional view of section plane A-A in  FIG. 9 a   , likewise in a no-load state. A no-load state means that there is no external force acting on the shock absorbing element  8   a . As is also apparent in  FIG. 9 b   , the rechargeable battery housing  2  projects with an overlap s beyond the bottom edge of the cell holder  5  in arrow direction N. 
     In  FIG. 10 a   , the shock absorbing device  7  according to the second embodiment is shown when a first force F is exerted on the shock absorbing element  8   a . The first force F results from a fall of the rechargeable battery  1  and the impact of the rechargeable battery housing  2  on a hard inelastic underlying surface UG (e.g. concrete). In  FIG. 10 a   , it is apparent in comparison with  FIG. 9 a    that the shock absorbing element is being deformed and moved toward the surface of the rechargeable battery housing. As illustrated in  FIG. 10 b   , the inner surface  11  of the shock absorbing element  8   a  is resting against the outer surface  12  of the rechargeable battery housing  2 , with the result that the shock energy or the force flow FF is diverted from the shock absorbing element  8   a , via the front side face  2   a , into the top side face  2   f  of the rechargeable battery housing  2  and partially into the cell holder  5  and is guided around the rechargeable battery cells  4 . As is likewise apparent from  FIG. 10 b   , the front side face  2   a  of the rechargeable battery housing  2  is not compressed, and therefore the overlap s of the rechargeable battery housing  2  still exists. 
     In  FIGS. 11 a  and 11 b   , the shock absorbing device  7  according to the second embodiment is shown when a second force F′, which is greater than the first force F, is being exerted on the shock absorbing element  8   a . The second force F′ exerted on the shock absorbing element  8   a  has the effect that the shock absorbing element  8   a  is pressed more strongly against the front side face  2   a  of the rechargeable battery housing  2 . Owing to the higher second force F′, the front side face  2   a  of the rechargeable battery housing  2  is compressed, with the result that the overlap s of the rechargeable battery housing  2  is pressed in. By the pressing in of the overlap s, additional shock energy or impact energy is absorbed by the rechargeable battery housing  2 , and the rechargeable battery cells  4  are additionally protected. 
     LIST OF REFERENCE SIGNS 
     
         
         
           
               1 : rechargeable battery 
               2 : housing for the rechargeable battery 
               2   a : front side face 
               2   b : left-hand wall side face 
               2   c : right-hand wall side face 
               2   d : rear side face 
               2   e : bottom side face 
               2   f : top side face 
               3 : interface 
               4 : energy storage cell 
               5 : cell holding device 
               6 : bores 
               7 : shock absorbing device 
               8   a ,  8   b ,  8   c ,  8   d : shock absorbing element 
               9   a : first end of the shock absorbing element configured as a yoke 
               9   b : second end of the shock absorbing element configured as a yoke 
               10 : lateral edge between the front side face and the bottom side face of the rechargeable battery housing 
               11 : inner surface of the shock absorbing element 
               12 : outer surface of the rechargeable battery housing 
               13 : surface of an energy storage cell 
               20 : symmetrical rectangular cross-sectional area of the shock absorbing element 
               30 : trapezoidal cross-sectional area 
               81 : first component piece of the shock absorbing element configured as a yoke 
               82 : second component piece of the shock absorbing element configured as a yoke 
               83 : third component piece of the shock absorbing element configured as a yoke 
               84 : fourth component piece of the shock absorbing element configured as a yoke 
               85 : fifth component piece of the shock absorbing element configured as a yoke 
             α, β, γ, δ: obtuse angles between component pieces of the shock absorbing element configured as a yoke 
             UG: underlying surface 
             FF: force flow 
             F: first force 
             F′: second force