Patent Publication Number: US-2022216707-A1

Title: Battery pack including a high- and low-current discharge terminals

Description:
RELATED APPLICATIONS 
     The present application is a continuation of, and claims priority to, U.S. patent application Ser. No. 16/536,422, filed Aug. 9, 2019, published as U.S. Patent Publication No. 2021/0044122, the entire contents of which are hereby incorporated by reference. 
    
    
     FIELD 
     Embodiments described herein relate to a battery pack for powering a device. 
     SUMMARY 
     Embodiments described herein provide a battery pack that includes a housing and a plurality of battery cells. The housing includes a support portion that is configured to removably connect to a device, such as a cordless, hand-held power tool. The battery pack is configured to electrically and/or communicatively connect to the device through at least one terminal. The at least one terminal can include a high-current discharge terminal and a common ground terminal. The high-current discharge terminal is configured to output a current having a first value (e.g., at least 20 Amps). The battery pack is also configured to electrically and/or communicatively connect to device through a low-current discharge terminal and the common ground terminal. The low-current discharge terminal is configured to output a current having a second value (e.g., less than 10 Amps). A current limiting circuit is connected between the plurality of battery cells and the low-current discharge terminal to limit the discharge current from the low-current discharge terminal. 
     Embodiments described herein provide a battery pack that includes a housing, a plurality of battery cells located within the housing, a current limiting circuit, a first battery pack terminal, a second battery pack terminal, and a third battery pack terminal. The housing includes a battery pack support portion configured to removably mechanically connect the battery pack to a device. The battery pack support portion includes a first rail, a second rail, and a coupling mechanism for securing the battery pack to the device. The plurality of battery cells include a highest-potential battery cell and a lowest-potential battery cell. The current limiting circuit is connected to a positive terminal of the highest-potential battery cell. The first battery pack terminal is configured to electrically connect the battery pack to the device. The first battery pack terminal is connected to the positive terminal of the highest-potential battery cell. The second battery pack terminal is configured to electrically connect the battery pack to the device. The second battery pack terminal is connected to the current limiting circuit. The third battery pack terminal is configured to electrically connect the battery pack to the device. The third battery pack terminal is connected to a negative terminal of the lowest-potential battery cell. The current limiting circuit limits an electrical current that can be discharged from the second battery pack terminal to a value that is lower than an electrical current that can be discharged from the first battery pack terminal. 
     In some embodiments, the electrical current that can be discharged from the first battery pack terminal is an average discharge current of at least 20 Amps. In some embodiments, the electrical current that can be discharged from the second battery pack terminal is limited by the current limiting circuit to less than 10 Amps. In some embodiments, the current limiting circuit includes a switch. In some embodiments, the switch includes a field-effect transistor. In some embodiments, the battery pack is configured to electrically connect to a drain terminal of the field-effect transistor; and the second battery pack terminal is configured to electrically connect to a source terminal of the field-effect transistor. In some embodiments, an output voltage at the first battery pack terminal is approximately equal to an output voltage at the second battery pack terminal. 
     Embodiments described herein provide a battery pack that includes a housing, a plurality of battery cells located within the housing, a current limiting circuit, a first battery pack terminal, and a second battery pack terminal. The housing includes a battery pack support portion configured to removably mechanically connect the battery pack to a device. The battery pack support portion includes a first rail, a second rail, and a coupling mechanism for securing the battery pack to the device. The current limiting circuit is connected to the plurality of battery cells. The first battery pack terminal is configured to electrically connect the battery pack to the device. The first battery pack terminal is connected to the plurality of battery cells. The second battery pack terminal is configured to electrically connect the battery pack to the device. The second battery pack terminal is connected to the current limiting circuit. The current limiting circuit limits an electrical current that can be discharged from the second battery pack terminal to a value that is lower than an electrical current that can be discharged from the first battery pack terminal. 
     In some embodiments, the first battery pack terminal is connected to a positive terminal of a highest-potential battery cell in the plurality of battery cells, the current limiting circuit is connected to the positive terminal of the highest-potential battery cell, and the second battery pack terminal is connected to the current limiting circuit. In some embodiments, the electrical current that can be discharged from the first battery pack terminal is an average discharge current of at least 20 Amps. In some embodiments, the electrical current that can be discharged from the second battery pack terminal is limited by the current limiting circuit to less than 10 Amps. In some embodiments, the current limiting circuit includes a switch. In some embodiments, the switch includes a field-effect transistor. In some embodiments, an output voltage at the first battery pack terminal is approximately equal to an output voltage at the second battery pack terminal. 
     Embodiments described herein provide a battery pack that includes a housing, a plurality of battery cells located within the housing, a current limiting circuit, a first battery pack terminal, and a second battery pack terminal. The housing including a battery pack support portion is configured to removably mechanically connect the battery pack to a device. The current limiting circuit is connected to the plurality of battery cells. The first battery pack terminal is configured to electrically connect the battery pack to the device. The first battery pack terminal is connected to the plurality of battery cells. The second battery pack terminal is configured to electrically connect the battery pack to the device. The second battery pack terminal is connected to the current limiting circuit. The current limiting circuit limits an electrical current that can be discharged from the second battery pack terminal to a value that is lower than an electrical current that can be discharged from the first battery pack terminal. 
     In some embodiments, the first battery pack terminal is connected to a positive terminal of a highest-potential battery cell in the plurality of battery cells, the current limiting circuit is connected to the positive terminal of the highest-potential battery cell, and the second battery pack terminal is connected to the current limiting circuit. In some embodiments, the electrical current that can be discharged from the first battery pack terminal is an average discharge current of at least 20 Amps. In some embodiments, the electrical current that can be discharged from the second battery pack terminal is limited by the current limiting circuit to less than 10 Amps. In some embodiments, the current limiting circuit includes a switch. In some embodiments, the switch includes a field-effect transistor. In some embodiments, an output voltage at the first battery pack terminal is approximately equal to an output voltage at the second battery pack terminal. 
     Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in its application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. 
     In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers” and “computing devices” described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components. 
     Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a battery pack, according to embodiments described herein. 
         FIG. 2  is a front view of the battery pack of  FIG. 1 . 
         FIG. 3  is a rear view of the battery pack of  FIG. 1 . 
         FIG. 4  is a top view of the battery pack of  FIG. 1 . 
         FIG. 5  is a bottom view of the battery pack of  FIG. 1 . 
         FIG. 6  is a right-side view of the battery pack of  FIG. 1 . 
         FIG. 7  is a rear-perspective view of the battery pack of  FIG. 1 . 
         FIG. 8  is a perspective view of the battery pack of  FIG. 1  with a top housing portion of the battery pack removed. 
         FIG. 9  is a top view of the battery pack of  FIG. 8  with the top housing portion of the battery pack removed. 
         FIG. 10  is a front-perspective view of the battery pack of  FIG. 8  with the top housing portion of the battery pack removed. 
         FIGS. 11 and 12  illustrate battery cells included in the battery pack of  FIG. 1 . 
         FIG. 13  is an electrical schematic diagram for the battery pack of  FIG. 1 , according to embodiments described herein. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments described herein provide a battery pack for powering any one of a variety of different devices. The battery pack powers the devices by electrically connecting to the devices using at least one terminal. For example, the battery pack electrically connects to a first device using a high-current discharge terminal and a common ground terminal. The battery pack electrically connects to a second device using a low-current discharge terminal and the common ground terminal. Both the high- and low-current discharge terminals are connected to the highest potential battery cell of a plurality of battery cells in the battery pack. As a result, the output voltages of both the high- and low-current discharge terminals are substantially the same. However, a current limiting circuit (e.g., including a switch) is connected between the plurality of battery cells and the low-current discharge terminal for limiting the output current from the low-current discharge terminal. 
       FIG. 1  illustrates a battery pack  100  that is connectable to and supportable by a cordless, hand-held power tool or another battery pack powered device. For example, the battery pack  100  is configured to be connectable to either high-current draw devices or low-current draw devices. The devices to which the battery pack  100  is configured to connect include a screwdriver, a drill driver, an impact driver, an impact wrench, a hammer drill, a jigsaw, a bolt cutter, an offset shear, a planar, a table saw, a miter saw, a grinder, a circular saw, a reciprocating saw, a rotary cutter, a scroll saw, a fan, a caulk gun, a drain auger, a hot glue gun, a transfer pump, a blower, a vacuum cleaner, a propane heater, a cement mixer, a sander, a router, a buffer, a nailer, a staple gun, a light, a speaker, a compressor, an inflator, etc. 
     As shown in  FIGS. 1-7 , the battery pack  100  includes a housing  105 . The housing  105  includes a top housing portion  110  and a bottom housing portion  115 . Although the battery pack  100  is illustrated in  FIGS. 1-7  including the top housing portion  110  and the bottom housing portion  115 , in some embodiments, the battery pack  100  includes a left housing portion and a right housing portion. The battery pack  100  also includes a support portion  120  for supporting the battery pack  100  on, and coupling the battery pack  100  to, a device such as a hand-held power tool. The support portion  120  includes a first rail  125  and a second rail  130  for slidably attaching the battery pack  100  to the device. The support portion  120  is connectable to a complementary support portion on the device (e.g., a battery pack receiving portion of a power tool). The battery pack  100  also includes a button  135  and a latch or coupling mechanism  140  for selectively coupling the battery pack  100  to, or releasing the battery pack  100  from, the device. In some embodiments, the button  135  and coupling mechanism  140  are considered to be included in the battery pack support portion  120 . 
     The battery pack  100  includes a plurality of terminals within the support portion  120  that are operable to electrically connect one or more battery cells within the battery pack  100  to the device. As illustrated in  FIG. 3 , the plurality of terminals include a first terminal  145 , a second terminal  150 , a third terminal  155 , a fourth terminal  160 , and a fifth terminal  165 . In some embodiments, the first terminal  145  is a battery negative terminal, the second terminal  150  is a temperature terminal, the third terminal  155  is a communication terminal, the fourth terminal  160  is a low power or charging terminal, and the fifth terminal  165  is a battery positive terminal. In some embodiments, the second terminal  150  is the communication terminal and the third terminal  155  is a bypass terminal for bypassing a current sensing circuit. 
     The battery pack  100  is removably and interchangeably connected to a device, such as a hand-held power tool, to provide operational power to the device. The terminals  145 ,  150 ,  155 ,  160 , and  165  are configured to mate with corresponding terminals extending from the device. The battery pack  100  substantially encloses and covers the terminals on the device when the pack  100  is positioned within a battery pack receiving portion of the device (i.e., the battery pack  100  functions as a cover for the opening and terminals of the device). Once the battery pack  100  is disconnected from the device, the terminals on the device are generally exposed to the surrounding environment. In this illustrated embodiment, the battery pack  100  is designed to substantially follow the contours of a hand-held power tool to match the general shape of an outer casing of a handle of the power tool, and the battery pack  100  generally increases (i.e., extends) the length of the grip of the power tool (e.g., a portion of the power tool below a motor). 
     As illustrated in  FIG. 5 , the bottom housing portion  115  of the housing  105  includes four fasteners  170  for fastening the bottom housing portion  115  to the top housing portion  110 . For example, in some embodiments, the fasteners  170  are screws that extend vertically through apertures in the bottom housing portion  115  to engage a threaded aperture in the top housing portion  110 . In other embodiments, the top housing portion  110  and the bottom housing portion  115  are fastened together in a different manner, such as using an adhesive or a fastener other than a screw. 
       FIG. 8  illustrates the battery pack  100  with the top housing portion  110  removed. With the top housing portion  110  removed from the battery pack  100 , the terminals  145 ,  150 ,  155 ,  160 , and  165  and a printed circuit board (“PCB”)  175  are exposed. In the illustrated embodiment, the first terminal  145  and fifth terminal  165  include first and second pairs of female blade terminals for receiving a male blade terminal from a device connected to the battery pack  100 . The second terminal  150 , the third terminal  155 , and the fourth terminal  160  include a single pair of female blade terminals for receiving a male blade terminal from a device connected to the battery pack  100 . In some embodiments, the first terminal  145  is used by low power devices and, when a device is connected to the first terminal  145 , the battery pack  100  is configured to monitor a discharge current to the device. In such embodiments, the third terminal  155  can be sa bypass terminal that bypasses a discharge current monitoring circuit (e.g., when the battery pack  100  is connected to a high power device). Although five terminals  145 ,  150 ,  155 ,  160 , and  165  are illustrated, a device connected to the battery pack  100  is not required to electrically connect to each of the terminals  145 ,  150 ,  155 ,  160 , and  165 . For example, in some embodiments, a low- or lower-powered device electrically connects to the first terminal  145  and the fourth terminal  160 . In some embodiments, a charger for the battery pack  100  electrically connects to the first terminal  145 , the third terminal  155 , and the fourth terminal  160 . In some embodiments, a high- or higher-powered device (e.g., a power tool) electrically connects to the first terminal  145 , the third terminal  155 , and the fifth terminal. 
     The battery pack  100  is configured to include a plurality of battery cells that are arranged and spaced apart from one another by a first battery cell holder  180  and a second battery cell holder  185 , as illustrated in  FIGS. 9 and 10 . The first battery cell holder  180  receives a first end of the battery cells, and the second battery cell holder  185  receives a second end of the battery cells. As a result, the first battery cell holder  180  and the second battery cell holder  185  are configured to sandwich the battery cells and hold the battery cells within the battery pack housing  105 . In some embodiments, the first battery cell holder  180  and the second battery cell holder  185  are configured as an upper cell holder and a lower cell holder such that the battery cells are sandwiched between the upper cell holder and the lower cell holder. In other embodiments, a single cell holder is used in place of the first cell holder  180  and the second cell holder  185 . 
     In some embodiments, the battery pack  100  includes five battery cells  190 . In other embodiments, the battery pack  100  includes more or fewer battery cells  190 . The battery cells  190  can be arranged in series, parallel, or a series-parallel combination. For example, the battery pack  100  can include a total of five battery cells  190  configured in a series arrangement. In some embodiments, a series-parallel combination of battery cells  190  allows for an increased voltage and an increased capacity of the battery pack  100 . In other embodiments, the battery pack  100  includes a different number of battery cells (e.g., between three and twelve battery cells) connected in series, parallel, or a series-parallel combination in order to produce a battery pack having a desired combination of nominal battery pack voltage and capacity. 
     The battery cells  190  are, for example, cylindrical  18650  battery cells (18 mm diameter and 65 mm length). Each battery cell includes a cell axis  195 , a cell length, L C , and a cell diameter, Dc, as illustrated in  FIGS. 11 and 12 . In other embodiments, the battery cells  190  are, for example, cylindrical  14500  battery cells (14 mm diameter and 50 mm length),  14650  battery cells (14 mm diameter and 65 mm length),  17500  battery cells (17 mm diameter and 50 mm length),  17670  battery cells (17 mm diameter and 67 mm length),  18500  battery cells (18 mm diameter and 50 mm length),  21650  battery cells (21 mm diameter and 65 mm length),  21700  battery cells (21 mm diameter and 70 mm length), etc. Each battery cell  190  can be generally cylindrical and can extend along the cell axis  195  parallel to the cylindrical outer cell wall. Also, in the battery pack  100 , each battery cell  190  can have a cell length, L C , which is greater than or equal to two times the cell diameter, D C . 
     The battery cells  190  are lithium-based battery cells having a chemistry of, for example, lithium-cobalt (“Li—Co”), lithium-manganese (“Li—Mn”), or Li—Mn spinel. In some embodiments, the battery cells  190  have other suitable lithium or lithium-based chemistries, such as a lithium-based chemistry that includes manganese, etc. The battery cells within the battery pack  100  provide operational power (e.g., voltage and current) to a device. In some embodiments, each battery cell  190  has a nominal voltage of approximately 3.6V, such that the battery pack  100  has a nominal voltage of approximately 18V. In other embodiments, the battery cells  190  have different nominal voltages, such as, for example, between 3.6V and 4.2V, and the battery pack has a different nominal voltage, such as, for example, 10.8V, 12V, 14.4V, 24V, 28V, 36V, 50V, between 10.8V and 100V, etc. The battery cells  190  also have a capacity of, for example, approximately between 1.0 Ah and 10.0 Ah. In exemplary embodiments, the battery cells have capacities of approximately, 1.5 Ah, 2.4 Ah, 3.0 Ah, 4.0 Ah, between 1.0 Ah and 10.0 Ah, etc. 
     The battery cells  190  are arranged and spaced apart from one another by the first battery cell holder  180  and the second battery cell holder  185  to reduce the cell-to-cell heat transfer between the battery cells  190  and to improve the collection and removal of heat from the battery cells  190 . In this manner, the battery cells  190  may be able to be maintained in an appropriate temperature operating range (e.g., below 60° C.) for longer durations of use. The battery cells  190  are also arranged to provide an efficient use of space and to maintain a relatively small pack size. 
       FIG. 13  is an electrical schematic diagram of a circuit  200  for the battery pack  100 . In the embodiment illustrated in  FIG. 13 , the circuit  200  includes a plurality of battery cells  205 A- 205 E, a control unit  210  (e.g., a processing unit, a processor, a microcontroller, etc.), a communication unit  215 , a current limiting circuit  220 , a switch  225  (e.g., a field-effect transistor [“FET”]), and a plurality of terminals. The plurality of terminals include, for example, a battery pack positive power terminal (“B+”), a charge terminal (“CHG”), a communication terminal (“COMM”), and a battery pack negative power terminal (“B−”). In the embodiment illustrated in  FIG. 13 , the battery pack negative terminal, B−, is a common ground terminal for the battery pack  100 . The battery pack negative terminal, B−, can be used in conjunction with either the battery pack positive terminal, B+, or the charge terminal, CHG. In the embodiment illustrated in  FIG. 13 , the battery pack positive terminal, B+, is configured as a high-current discharge terminal, HC-DSG, and the charge terminal, CHG, is additionally configured as a low-current discharge terminal, LC-DSG. As a result, the battery pack  100  is capable of outputting different levels of discharge current to different battery pack terminals. 
     For example, when the battery pack  100  is connected to a device that requires a high current output from the battery pack  100 , the device can be configured to connect to the battery pack positive terminal, B+, and the battery pack negative terminal, B−. When the battery pack  100  is connected to a device that requires a lower current output from the battery pack  100 , the lower power device can be configured to connect to the low-current discharge terminal, LC-DSG, and the battery pack negative terminal, B−. In some embodiments, the high-current discharge terminal, HC-DSG, is capable of providing discharge currents of at least 20 Amps (e.g., as an average discharge current over the rated capacity of the battery pack  100 ). As a result, the battery pack  100  is capable of providing discharge currents that are sufficient for powering high power devices, such as power tools. In some embodiments, the low-current discharge terminal, LC-DSG, is capable of providing discharge currents of up to 5 Amps or up to 10 Amps. As a result, the battery pack  100  is also capable of providing a lower discharge current to a device that requires less current to operate than, for example, a power tool. Both the high-current discharge terminal, HC-DSG, and the low-current discharge terminal, LC-DSG, have output voltages of approximately the same value (e.g., 18V+/−0.5V). 
     As shown in the embodiment of  FIG. 13 , the high-current discharge terminal, HC-DSG, is directly connected to the positive end of the highest potential battery cell  205 E of the plurality of battery cells  205 A- 205 E. The low-current discharge terminal, LC-DSG, is connected to the highest potential battery cell  205 E of the plurality of battery cells  205 A- 205 E through the current limiting circuit  220  and the switch  225 . In some embodiments, the switch  225  is included in the current limiting circuit  220 . The current limiting circuit  220  and/or the switch  225  are configured to limit a discharge current from the battery cells  205 A- 205 E that is output through the low-current discharge terminal, LC-DSG. The current limiting circuit  220  includes active and or passive components (e.g., resistors, capacitors, diodes, transistors, etc.) that are operable to reduce and/or limit the current output of the low-current discharge terminal, LC-DSG. In some embodiments, the switch  225  is used to reduce or limit the current output of the low-current discharge terminal, LC-DSG. For example, the control unit  210  is configured to control a switching state of the switch  225  to regulate a duty cycle of the signal output from the low-current discharge terminal, LC-DSG. By controlling the switch  225 , the control unit  210  is able to reduce the output current output from the low-current discharge terminal, LC-DSG. 
     In some embodiments, the switch  225  includes a FET for limiting the current output of the low-current discharge terminal, LC-DSG. As is generally known in the art, a FET has a source terminal, a drain terminal, and a gate terminal. The battery pack  100  is configured to electrically connect to the drain terminal of the FET. The low-current discharge terminal, LC-DSG, is configured to electrically connect to the source of the FET. With the increase of the current output of the low-current discharge terminal, LC-DSG, the operation of the field-effect transistor switches from a variable resistance region to a saturation region. In the variable resistance region, as the drain-source resistance is small, the current output of the low-current discharge terminal, LC-DSG is not affected. In the saturation region, the drain-source voltage increases significantly with the current output of the low-current discharge terminal, LC-DSG. Hence the drain-source resistance works like a variable resistance having a large resistance value, which provides a function of limiting the output of the low-current discharge terminal, LC-DSG. 
     Although the current from the low-current discharge terminal, LC-DSG, is reduced, the voltage at the low-current discharge terminal, LC-DSG, is substantially the same as the voltage at the high-current discharge terminal, HC-DSG (e.g., 18V). In other embodiments, the switch  225  is used in conjunction with the current limiting circuit to reduce or limit the current output of the low-current discharge terminal, LC-DSG. 
     In some embodiments, the battery pack  100  is configured to connect to a device using each of the high-current discharge terminal, HC-DSG, and the low-current discharge terminal, LC-DSG. For example, the battery pack can be configured to output a higher discharge current to a device for a primary operation (e.g., powering a motor) using the high-current discharge terminal, HC-DSG. The battery pack can also be configured to output a lower discharge current to the device for a secondary operation (e.g., powering a control or processing unit) using the low-current discharge terminal, LC-DSG. As such, in some embodiments, the battery pack  100  is not prevented from outputting discharge currents to both the high-current discharge terminal, HC-DSG and the low-current discharge terminal, LC-DSG. In other embodiments, the battery pack  100  is prevented from outputting discharge currents to both the high-current discharge terminal, HC-DSG and the low-current discharge terminal, LC-DSG. 
     Thus, embodiments described herein provide, among other things, a battery pack that includes a high-current discharge terminal and a low-current discharge terminal. Various features and advantages are set forth in the following claims.