Patent Description:
The present invention relates to rechargeable battery pack and systems for safety transporting the battery pack.

Conventional rechargeable battery packs include a plurality of lithium-ion battery cells. Due to the nature of the chemistry of these battery packs, a lot of combustion and explosion accidents are caused by improperly packaging and transportation of the battery packs, therefore many countries and international bodies have implemented special rules directed to the shipping of Lithium-ion batteries. If a battery or battery pack exceeds these limits, there are additional fees and shipping costs for shipping the battery pack. As such, there is an interest in keeping the watt-hour levels below the 100WH limits. Today, it is common for Lithium-ion batteries already exceed these limits. As battery power and capacity increases, it will become more common for batteries to exceed these limits. As such, there is a great desire to keep the battery packs below these limits. A prior art transport system for a battery pack is disclosed in <CIT>, disclosing a battery pack and transport coupler for enabling the battery pack to reduce the pack power capacity. The battery pack includes a plurality of strings of battery cells and a switching network for coupling and decoupling the strings of battery cells from each other.

Typically, shipping regulations pose limitations how much energy is disposed in a battery pack. For example, some regulations require that each battery cell has an energy equal to or less than <NUM>-watt hours, and each battery pack has an energy limit equal to or less than <NUM>-watt hours. However, as the demand for large-capacity, high-power battery packs is increasing, most lithium-ion battery packs have exceeded the limits of these transport regulations, and a transport cost of these products are increased. Furthermore, as the battery pack power and capacity increase, it becomes more and more common for battery pack to exceed these limitations.

Therefore, there is a requirement to provide an improved battery pack transport system for protecting the battery pack from damaging during shipping.

The present invention provides a battery pack transport system according to claim <NUM> for safely shipping battery pack and reducing cost.

In an aspect, a battery pack transport system comprising: a battery pack including a first cover; a second cover mounted to the first cover; a battery module received in a receiving space formed between the first and second covers and a female connector connected to the battery module, the battery module having two battery cell groups, each battery cell group configured with a plurality of cells and having a positive electrode and a negative electrode; a female connector having a plurality of conductive terminals respectively and electrically connected to positive and negative electrodes of two battery cell groups, two conductive terminals with same polarity may be connected with each other in parallel to connect two battery cell groups with each other in parallel; and the battery pack transport system further comprises a protective member adapted to be mechanically coupled to the battery pack to change the electrical connection of two conductive terminals with same polarity from parallel connected state to isolated state, the protective member comprises a plurality of inserting portions corresponding to the conductive terminals of the battery pack, and wherein the inserting portions each is connected to a corresponding conductive terminal when the protective member is coupled to the battery pack.

In one embodiment, two battery cell groups are isolated from each other when the protective member is coupled to the battery pack.

According to the present invention the female connector comprises a converter slidably received therein, and the converter includes a plurality of inner contacts corresponding to the conductive terminals, and each inner contact is simultaneously connected to two conductive terminals with same polarity when the protective member is separated from the battery pack.

In one embodiment, the converter includes a protruding portion forwardly extending therefrom, and the protective member defines a protrusion corresponding to the protruding portion, and the protrusion abuts against the protruding portion to drive the converter to move away from the conductive terminals when the protective member is coupled to the battery pack.

In one embodiment, the female connector defines a guiding rail for receiving the protruding portion of the converter, and the protruding portion slides along the guiding rail when abutted by the protrusion of the protective member.

In one embodiment, the female connector further comprises a pair of ribs located at two opposite sides of the guiding rail.

In one embodiment, the converter comprises a plurality of posts opposite to the protruding portion and a plurality of elastic members respectively assembled to the corresponding post, and the elastic members are sandwiched between the sidewall of the female connector and the converter.

In one embodiment, the female connector comprises at least one positioning column corresponding to at least one of the plurality of posts, wherein at least one of the plurality of elastic members is sandwiched between the positioning column and the post.

In one embodiment, the elastic members are compressed when the converter moves away from the conductive terminals under the pushing of the protective member, and the elastic members recover from deformation to drive the converter to move towards the conductive terminals when the protective member is separated from the battery pack.

In one embodiment, the battery pack comprises a depressible locking portion protruding above the top of the second cover, and the protective member comprises a groove upwardly recessed from the bottom thereof for receiving the locking portion of the battery pack.

In order to clarify the objects, characteristics and advantages of the present invention, embodiments of the present invention will be described in detail in conjunction with the drawings.

<FIG> illustrate a battery pack transport system <NUM> in accordance with one embodiment of the present invention. <FIG> illustrate a battery pack transport system <NUM>' in accordance with another embodiment of the present invention. The system <NUM>, <NUM>' in two different embodiments have the same battery pack <NUM> but different protective member <NUM>, <NUM>.

As shown in <FIG> and <FIG>, the battery pack transport system <NUM> according to the first embodiment of the present invention includes a battery pack <NUM> and a protective member <NUM> coupled to the battery pack <NUM> for protecting the battery pack <NUM> from damaging during shipping. The battery pack <NUM> for supplying power to corresponding power tool (not shown) connected thereto includes a first or lower cover <NUM>, and a second or upper cover <NUM> mounted on the lower cover <NUM>, a battery module <NUM> received in a receiving space formed between the lower and upper covers <NUM>, <NUM>, a printed circuit board (PCB) <NUM> mounted on the battery module <NUM>, a female connector <NUM> assembled to the battery module <NUM> through the PCB <NUM> and a locking assembly <NUM> assembled on the upper cover <NUM> for locking the battery pack <NUM> to the power tool (not shown) or releasing the battery pack <NUM> from the power tool (not shown).

Referring to <FIG> and <FIG>, the battery module <NUM> includes a plurality of cells <NUM>, a cell holder <NUM> for housing the cells <NUM> and a plurality of nickel strips <NUM> for electrically connecting the cells <NUM>. The cell holder <NUM> has a diameter larger than that of each cell <NUM>. Each cell holder <NUM> has four guiding portions <NUM> for guiding the cell <NUM> therein. Each guiding portion <NUM> has a chamfer <NUM> located at the end thereof for easily inserting the cell <NUM> into the cell holder <NUM>. The cell holder <NUM> also has a positioning portion <NUM> extending upwardly from the top thereof. The positioning portion <NUM> is configured with a hollow cylinder shape.

The cells <NUM> electrically connected by the strips <NUM> are divided into two battery cell groups. The cells <NUM> in each battery cell group are connected with each other in series. Each battery cell group has a positive electrode and a negative electrode respectively connected to the strips <NUM>. Each strip <NUM> defines a convex tab <NUM> extending upwardly therefrom. The PCB <NUM> has a plurality of holes <NUM> corresponding to the convex tabs <NUM>. Each convex tab <NUM> of the strips <NUM> passes through the corresponding hole <NUM> of the PCB <NUM> and is soldered to the PCB <NUM> to achieve the electrical connection between the battery module <NUM> and the PCB <NUM>.

Two battery cell groups are electrically connected to the female connector <NUM> through electrically connecting the convex tabs <NUM> of the strips <NUM> to the female connector <NUM> by the PCB <NUM>, so that the electrical connection between the female connector <NUM> and the battery module <NUM> is achieved. Each battery cell group has a "n" voltage. The battery module <NUM> can output a "n" voltage when two battery cell groups are connected with each other in parallel and a "2n" voltage when two battery cell groups are connected with each other in series.

Referring to <FIG>, the female connector <NUM> supplying power from the battery module <NUM> to corresponding power tool includes a housing <NUM> mounted upon the battery module <NUM> through the PCB <NUM>, a plurality of terminals <NUM> received in the housing <NUM>, and a converter <NUM> retained in the housing <NUM> for switching the electrical connection of two battery cell groups in two states. One state of two battery cell groups is parallel connected state, and the other state of two battery cell groups is isolated state.

Referring to <FIG>, the housing <NUM> configured with a rectangular shape has an accommodating space <NUM> surrounded by three sidewalls thereof and a plurality of terminal receiving slots <NUM> opposite to the accommodating space <NUM>. The upper cover <NUM> defines a plurality of through slots <NUM> corresponding to the terminal receiving slots <NUM> for guiding corresponding portion of protective member <NUM>. The accommodating space <NUM> is recessed from the top of the housing <NUM> for receiving the converter <NUM>. The terminal receiving slots <NUM> horizontally extend along a length direction of the housing <NUM> for respectively receiving the terminals <NUM>. The receiving slots <NUM> are configured with two different structures. One is the first receiving slots <NUM> and communicated with the accommodating space <NUM>. The other is the second receiving slot <NUM> and separated with the accommodating space <NUM>. A pairs of positioning columns <NUM> horizontally extend towards the accommodating space <NUM> from the sidewall <NUM> of the housing <NUM>. The housing <NUM> defines a guiding rail <NUM> for guiding the converter <NUM> move along a front-to-rear direction in the accommodating space <NUM>. The guiding rail <NUM> extends along the length direction of the housing <NUM>. The guiding rail <NUM> passes through the accommodating space <NUM> and located in the middle of the receiving slots <NUM>. A pair of ribs <NUM> are disposed at two opposite sides of the guiding rail <NUM> for preventing the converter <NUM> from separating with the housing <NUM>.

Referring to <FIG>, the terminals <NUM> received in the housing <NUM> for achieving the electrical connection between the power tool (not shown) and the battery module <NUM> includes two pair of conductive terminals <NUM> and one communication terminal <NUM> and one charging terminal <NUM> disposed in the same row. The conductive terminals <NUM> are received in the first receiving slots <NUM> of the housing <NUM>. The communication and charging terminals <NUM>, <NUM> received in the second receiving slot <NUM> of the housing <NUM> are adjacently disposed in the middle of the terminals <NUM>. The communication terminal <NUM> disposed in the middle of four conductive terminals <NUM> are electrically connected to the PCB <NUM> for achieving the communication between the battery pack <NUM> and the power tool. The charging terminal <NUM> is used for charging the battery pack <NUM> when the battery pack <NUM> is connected to an external charging device (not shown). And two pair of conductive terminals <NUM> are respectively located at two opposite sides of the communication and charging terminals <NUM>, <NUM>. The conductive terminals <NUM> located at the same side of the communication and charging terminals <NUM>, <NUM> has same polarity. The conductive terminals <NUM> disposed at two opposite sides of the communication and charging terminals <NUM>, <NUM> have different polarities. Four conductive terminals <NUM> are configured with same structure. The communication and charging terminals <NUM>, <NUM> are configured with same structure but different with that of the conductive terminals <NUM>. Four conductive terminals <NUM> are respectively and electrically connected to positive or negative electrodes of corresponding battery cell groups through the PCB <NUM> electrically connecting the conductive terminals <NUM> to corresponding convex tabs <NUM> of the battery module <NUM>.

Each conductive terminal <NUM> has a U-shaped main portion <NUM>, a pair of contacting arms <NUM> extending backwardly from the main portion <NUM>, a pair of clamping arms <NUM> extending forwardly from the main portion <NUM>, and a plurality of soldering pins <NUM> extending downwardly from the main portion <NUM>. Two contacting arms <NUM> are disposed at two opposite ends of the main portion <NUM> and located at the same side of the main portion <NUM>. Each contacting arm <NUM> extends horizontally from corresponding side of the main portion <NUM> and defines a pair of contacting ends <NUM> branched at the end thereof. Two clamping arms <NUM> are disposed at another two opposite ends of the main portion <NUM> and located at the other same side of the main portion <NUM>. Each clamping arm <NUM> extends horizontally form corresponding side of the main portion <NUM> and defines a pair of clamping ends <NUM> branched at the end thereof. Two clamping arms <NUM> and two contacting arms <NUM> are disposed at two opposite sides of the main portion <NUM>. The soldering pins <NUM> are soldered to the PCB <NUM> to achieve the electrical connection between the female connector <NUM> and the battery module <NUM> when inserted into the PCB <NUM>. The contacting arms <NUM> can be connected to the converter <NUM> to achieve the parallel connection of two battery cell groups. The clamping arms <NUM> can be connected to corresponding terminals of the power tool to achieve the electrical connection between the battery pack <NUM> and the corresponding power tool. Two battery cell groups can be switched between parallel connected state and isolated state through the contacting arms <NUM> of the terminals <NUM> connected or disconnected to the converter <NUM>.

The communication terminal <NUM> has a U-shaped base portion <NUM>, a pair of connecting arms <NUM> extending forwardly from the base portion <NUM> and a plurality of contacting pins extending downwardly from the bottom of the base portion <NUM>. The connecting arms <NUM> horizontally extends from two opposite ends of the base portion <NUM> and are disposed at the same side of the base portion <NUM>. The connecting arms <NUM> can achieve the communication function between the battery pack <NUM> and the corresponding power tools when the battery pack <NUM> is coupled to the power tool. The contacting pins are soldered to the PCB <NUM> to achieve the electrical connection between the communication terminal <NUM> and the battery module <NUM>. The connecting arms <NUM> of the communication terminal <NUM> are located at the same side with the clamping arms <NUM> of the conductive terminals <NUM>.

Referring to <FIG> and <FIG>, the converter <NUM> slidably assembled in the housing <NUM> can slide along the guiding rail <NUM> of the housing <NUM> in the inserting direction of the battery pack <NUM>. The converter <NUM> has a main body <NUM>, a pair of inner contacts <NUM> horizontally received in the main body <NUM>, and a pair of elastic members <NUM> sandwiched between the main body <NUM> and the sidewall <NUM> of the housing <NUM>. The main body <NUM> sliding along the length direction of the housing <NUM> has a base <NUM> for housing the inner contacts <NUM>, a protruding portion <NUM> and a pair of posts <NUM> respectively extending from two opposite sides of the base <NUM>. The base <NUM> extends along a width direction of the battery pack <NUM>. The protruding position <NUM> and the posts <NUM> are respectively located at two opposite sides of the base <NUM>. The protruding portion <NUM> and two posts <NUM> extend away from each other. The protruding portion <NUM> forwardly extends from the bottom middle of the base <NUM>. The protruding portion <NUM> can slide in the guiding rail <NUM> of the housing <NUM> along a front-to-back direction and can be prevented from separating from the housing <NUM> by two ribs <NUM> of the housing <NUM>. Two posts <NUM> are horizontally located at two opposite ends of the base <NUM> and configured with a hollow cylindrical shape for receiving the elastic members <NUM>. The protruding portion <NUM> can be pushed to drive the converter <NUM> slide along the length direction of the housing <NUM> to connect or disconnect the inner contacts <NUM> to the conductive terminals <NUM>, so as to achieve the function of connecting the conductive terminals <NUM> with same polarity in parallel or isolating two conductive terminals <NUM> with same polarity.

Each elastic member <NUM> is sandwiched between the inner wall of corresponding post <NUM> and the sidewall <NUM> of the housing <NUM>. The converter <NUM> can slide along the length direction of the housing <NUM> under the driving of the protruding portion <NUM> when external force is applied to the protruding portion <NUM>, so as to disconnect the inner contacts <NUM> to the conductive terminals <NUM>. Therefore, two battery cell groups are in isolated state when the inner contacts <NUM> are not clamped by the contacting ends <NUM> of the conductive terminals <NUM>. When the external force is applied to the protruding portion <NUM>, the main body <NUM> moves backwardly and away from the terminals <NUM>, the elastic members <NUM> are compressed by the main body <NUM> and has elastic deformation. When the external force is not applied to the protruding portion <NUM>, the main body <NUM> moves forwardly along the guiding rail <NUM> of the housing <NUM> under the elastic force caused by the elastic member <NUM> recovering from elastic deformation and the inner contacts <NUM> can be clamped by two contacting arms <NUM> of the terminals <NUM>, so as to connect two pair of conductive terminals <NUM> in parallel, therefore, two battery cell groups are connected with each other in parallel.

Preferably, the main body <NUM> has an anti-flip portion <NUM> adjacently disposed at two opposite sides of the protruding portion <NUM>. The anti-flip portion <NUM> inclinedly protrudes from the base <NUM> and has a right-triangle side-surface <NUM> for abutting corresponding sidewall of the receiving slot <NUM>. A groove <NUM> formed on the bottom of the main body <NUM> is adjacent to the protruding position <NUM>. The main body <NUM> also defines a pair of U-shaped receiving passages <NUM> for receiving corresponding inner contacts <NUM>. Each inner contact <NUM> configured with a U-shape defines a pair of connecting arms <NUM> horizontally extending towards the corresponding terminals <NUM>. Each connecting arm <NUM> of the inner contact <NUM> is the provided with a rounded corner, so as to easily and quickly engage with or separate from corresponding connecting ends <NUM> of the contacting arms <NUM> of the conductive terminals <NUM>, so that corresponding conductive terminals <NUM> with same polarity can be connected with each other in parallel or isolated to each other. Therefore, two battery cell groups can be switched between parallel connected state and isolated state through the connecting arms <NUM> of the inner contacts <NUM> clamped or not clamped by the contacting ends <NUM> of the conductive terminals <NUM>. In initial state, the connecting arms <NUM> are clamped by the contacting ends <NUM> of conductive terminals <NUM> and two battery cell group are in parallel connected state, and the battery pack <NUM> can output a "n" voltage, referring to <FIG>.

Referring to <FIG>, the locking assembly <NUM> sandwiched between the upper cover <NUM> and the battery module <NUM> for locking or releasing the battery pack <NUM> includes a pressing portion <NUM>, a locking portion <NUM> integrated with the pressing portion <NUM>, a fixing column <NUM> located below the locking portion <NUM> and a spring <NUM> surrounded the fixing column <NUM>. The locking portion <NUM> protrudes from the top of the upper cover <NUM> and can matches with corresponding portion of power tool to lock the battery pack <NUM> to the power tool or release the battery pack <NUM> from the power tool. The locking portion <NUM> can move downwardly to release the battery pack <NUM> when the pressing portion <NUM> is downwardly pressed.

One end of the spring <NUM> is surrounded around the fixing column <NUM>, the other end of the spring <NUM> is surrounded around the positioning portion <NUM> of the cell holder <NUM>. Therefore, the spring <NUM> is sandwiched between the locking assembly <NUM> and the battery module <NUM>. When the pressing portion <NUM> is downwardly pressed under the external force applied thereto, the locking portion <NUM> move downwardly together with the pressing portion <NUM> and the spring <NUM> is compressed and has elastic deformation. When external force is not applied on the pressing portion <NUM>, the spring <NUM> recovers from elastic deformation and pushes the pressing and locking portions <NUM>, <NUM> to move upwardly. So that the locking assembly <NUM> can move upwardly under the elastic force caused by the spring <NUM> recovering from elastic deformation. The locking assembly <NUM> can move downwardly and upwardly relative to the upper cover <NUM>, so as to achieve the function of locking or releasing battery pack <NUM>.

Referring to <FIG>, the protective member <NUM> according to the first embodiment of the present invention is assembled to the battery pack <NUM> to prevent the battery pack <NUM> from damaging during shipping. The protective member <NUM> coupled to the battery pack <NUM> through matching with the female connector <NUM> includes a body <NUM> extending along a width direction of the battery pack <NUM> and a plurality of inserting portions <NUM> receiving in the body <NUM>. The body <NUM> covering the conductive terminals <NUM> of the female connector <NUM> defines a protrusion <NUM> corresponding to the protruding portion <NUM> of the converter <NUM>. The protrusion <NUM> forwardly extends from the bottom middle of the body <NUM>. The inserting portions <NUM> each is located at the bottom of the body <NUM> corresponding to the terminals <NUM>. When external force is applied to the protrusion <NUM>, the protrusion <NUM> abuts against the protruding portion <NUM> and pushes the protruding portion <NUM> moving backwardly along the guiding rail <NUM> to separate the inner contacts <NUM> from the conductive terminals <NUM>, and meanwhile the inserting portions <NUM> each is clamped by corresponding terminal <NUM> after passing through the corresponding through slot <NUM> of the upper cover <NUM>, so that two conductive terminals <NUM> with same polarity are isolated with each other, and two battery cell groups are isolated with each other. Therefore, the battery pack <NUM> can be safely transported. The inserting portion <NUM> can be integrated with the body <NUM>. Specifically, the body <NUM> is made of insulating material. The inserting portion <NUM> can be made of metallic material or insulating material. In other embodiment, the body <NUM> is made of metallic material, but the inserting portion <NUM> is made of insulating material.

Claim 1:
A battery pack transport system (<NUM>; <NUM>') comprising:
a battery pack (<NUM>) including a first cover (<NUM>); a second cover (<NUM>) mounted to the first cover (<NUM>); a battery module (<NUM>) received in a receiving space formed between the first and second covers (<NUM>, <NUM>) and a female connector (<NUM>) connected to the battery module (<NUM>), the battery module (<NUM>) having two battery cell groups, each battery cell group configured with a plurality of cells (<NUM>) and having a positive electrode and a negative electrode; a female connector (<NUM>) having a plurality of conductive terminals (<NUM>) respectively and electrically connected to positive and negative electrodes of two battery cell groups,
two conductive terminals (<NUM>) with same polarity may be connected with each other in parallel to connect two battery cell groups with each other in parallel; and the battery pack transport system (<NUM>; <NUM>') further comprises a protective member (<NUM>; <NUM>) adapted to be mechanically coupled to the battery pack (<NUM>) to change the electrical connection of two conductive terminals (<NUM>) with same polarity from parallel connected state to isolated state,
the protective member (<NUM>; <NUM>) comprises a plurality of inserting portions (<NUM>; <NUM>) corresponding to the conductive terminals (<NUM>) of the battery pack (<NUM>), and wherein the inserting portions (<NUM>; <NUM>) each is connected to a corresponding conductive terminal (<NUM>) when the protective member (<NUM>; <NUM>) is coupled to the battery pack (<NUM>),
characterized in that the female connector (<NUM>) comprises a converter (<NUM>) slidably received therein, and wherein the converter (<NUM>) includes a plurality of inner contacts (<NUM>) corresponding to the conductive terminals (<NUM>), and each inner contact (<NUM>) is simultaneously connected to two conductive terminals (<NUM>) with same polarity when the protective member (<NUM>; <NUM>) is separated from the battery pack (<NUM>).