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EP-4111527-B1 - BATTERY PACK

EP4111527B1EP 4111527 B1EP4111527 B1EP 4111527B1EP-4111527-B1

Inventors

  • PEÑA, Matthew J.
  • SCHULZ, CAMERON R.

Dates

Publication Date
20260506
Application Date
20210224

Claims (19)

  1. A battery pack (10) configured to be coupled to a power tool, the battery pack (10) comprising: a battery cell carrier (30) including first and second carriages (65a, 65b), the first and second carriages (65a, 65b) configured to be spaced a first distance relative to each other to support a plurality of first battery cells (60a) therebetween, the first and second carriages (65a, 65b) configured to be spaced a second distance relative to each other to support a plurality of second battery cells (60b) therebetween; a housing (15) including a cavity (55), the cavity (55) configured to receive the battery cell carrier (30) when the first and second carriages (65a, 65b) are spaced at the first distance, the cavity (55) configured to receive the battery cell carrier (30) when the first and second carriages (65a, 65b) are spaced at the second distance; a plurality of mounting posts (100) coupled to one of the housing (15) and the battery cell carrier (30); and a plurality of mounting apertures (115) formed in the other one of the housing (15) and the battery cell carrier (30), wherein the plurality of mounting apertures (115) is configured to enable the first and second carriages (65a, 65b) to be secured to the housing (15) when the first and second carriages (65a, 65b) are spaced at the first distance, wherein the plurality of mounting apertures (115) is configured to enable the first and second carriages (65a, 65b) to be secured to the housing (15) when the first and second carriages (65a, 65b) are spaced at the second distance.
  2. The battery pack (10) of claim 1, wherein the plurality of mounting apertures (115) is formed in the housing (15), and wherein a first mounting aperture of the plurality of mounting apertures (115) is shaped differently than a second mounting aperture of the plurality of mounting apertures (115).
  3. The battery pack (10) of claim 2, wherein the first mounting aperture is circular and the second mounting aperture is noncircular.
  4. The battery pack (10) of claim 3, wherein the housing (15) includes a plurality of protrusions (135) spaced around the first mounting aperture, and wherein the plurality of protrusions (135) engage a first mounting post of the plurality of mounting posts (100) to position the plurality of mounting posts (100) relative to the plurality of mounting apertures (115).
  5. The battery pack (10) of claim 1, wherein the first and second carriages (65a, 65b) are configured to support the plurality of first battery cells (60a) with each battery cell of the plurality of first battery cells (60a) including a first length, and wherein the first and second carriages (65a, 65b) are configured to support the plurality of second battery cells (60b) with each battery cell of the plurality of second battery cells (60b) including a second length shorter than the first length.
  6. The battery pack (10) of claim 1, further comprising a plurality of fasteners (170) securing the battery cell carrier (30) to the housing (15) via the plurality of mounting posts (100) and the plurality of mounting apertures (115).
  7. The battery pack (10) of claim 6, wherein the plurality of fasteners (170) are screws.
  8. The battery pack (10) according to claim 1, wherein the battery cell carrier is configurable in different configurations based on a size of the plurality of battery cells (60a, 60b) supported between the first and second carriages (65a, 65b).
  9. The battery pack (10) of claim 8, wherein a first mounting aperture of the plurality of mounting apertures (115) is shaped differently than a second mounting aperture of the plurality of mounting apertures (115).
  10. The battery pack (10) of claim 9, wherein the first mounting aperture is circular and the second mounting aperture is noncircular.
  11. The battery pack (10) of claim 9, further comprising a plurality of protrusions (135) spaced around at least one of the plurality of mounting apertures (115), and wherein the plurality of protrusions (135) engage a first mounting post of the plurality of mounting posts (100) to position the plurality of mounting posts (100) relative to the plurality of mounting apertures (115).
  12. The battery pack (10) of claim 11, wherein the plurality of mounting posts (100) is coupled to the battery cell carrier (30), wherein the plurality of mounting apertures (115) is formed in the housing (15), and wherein the plurality of protrusions (135) is coupled to the housing.
  13. The battery pack of claim 8, wherein the battery cell carrier (30) is configurable in the different configurations based on a length of the plurality of battery cells (60a, 60b) supported between the first and second carriages (65a, 65b).
  14. The battery pack of claim 8, further comprising a plurality of fasteners (170) securing the battery cell carrier (30) to the housing (15) via the plurality of mounting posts (110) and the plurality of mounting apertures (115).
  15. The battery pack (10) of claim 14, wherein the plurality of fasteners (170) are screws.
  16. A method of manufacturing a battery pack (10), the battery pack (10) configured to be coupled to a power tool, the method comprising: providing (145) a housing (15) including a cavity (55); providing (150) a first battery cell carrier (30) including a plurality of first battery cells (60a), each battery cell of the plurality of first battery cells (60a) including a first length, the first battery cell carrier (30) configured to be coupled to the housing (15); providing (155) a second battery cell carrier (30) including a plurality of second battery cells (60b), each battery cell of the plurality of second battery cells (60b) including a second length different than the first length, the second battery cell carrier (30) configured to be coupled to the housing (15); selecting (160) the first battery cell carrier (30) or the second battery cell carrier (30) to be coupled to the housing; and securing (165) the selected battery cell carrier (30) to the housing (15).
  17. The method of claim 16, further comprising aligning a plurality of mounting features (100, 115) between the selected battery cell carrier (30) and the housing (15), wherein the plurality of mounting features (100, 115) include a plurality of mounting posts (100) and a plurality of mounting apertures (115), wherein the plurality of mounting posts (100) is coupled to one of the selected battery cell carrier (30) and the housing (15), and wherein the plurality of mounting apertures (115) is formed in the other one of the selected battery cell carrier (30) and the housing (15).
  18. The method of claim 17, wherein securing the selected battery cell carrier (30) to the housing (15) includes coupling a plurality of fasteners (170) between the plurality of mounting apertures (115) and the plurality of mounting posts (100).
  19. The method of claim 18, wherein the plurality of mounting apertures (115) is formed in the housing (15), and wherein the plurality of mounting posts (100) is coupled to the selected battery cell carrier (30).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent No. 62/981,175 filed on February 25, 2020. FIELD OF THE DISCLOSURE The present disclosure relates to a battery pack, and more particularly to a battery cell carrier coupled to a housing of the battery pack. CN 207 233 816 discloses a battery pack including a battery box, battery module and a plurality of fixing plates. US 2013/136956 A1 discloses a battery pack detachably mounted in a device for supplying power to the device to operate the device. SUMMARY The invention is defined by the appended claims. In one aspect of the present disclosure, a battery pack is configured to be coupled to a power tool. The battery pack includes a battery cell carrier having first and second carriages. The first and second carriages are configured to be spaced a first distance relative to each other to support a plurality of first battery cells therebetween. The first and second carriages are configured to be spaced a second distance relative to each other to support a plurality of second battery cells therebetween. The battery pack includes a housing having a cavity. The cavity is configured to receive the battery cell carrier when the first and second carriages are spaced at the first distance. The cavity is configured to receive the battery cell carrier when the first and second carriages are spaced at the second distance. The battery pack includes a plurality of mounting posts coupled to one of the housing and the battery cell carrier, and a plurality of mounting apertures formed in the other one of the housing and the battery cell carrier. The plurality of mounting apertures is configured to enable the first and second carriages to be secured to the housing when the first and second carriages are spaced at the first distance. The plurality of mounting apertures is configured to enable the first and second carriages to be secured to the housing when the first and second carriages are spaced at the second distance. In another aspect of the present disclosure, a battery pack is configured to be coupled to a power tool. The battery pack includes a housing having a cavity. The battery pack includes a battery cell carrier having first and second carriages. The first and second carriages support a plurality of battery cells therebetween. The battery cell carrier is configurable in different configurations based on a size of the plurality of battery cells supported between the first and second carriages. The battery pack includes a plurality of mounting features between the housing and the battery cell carrier. The plurality of mounting features is configured to alternatively secure the different configurations of the battery cell carrier to the housing. In yet another aspect of the present disclosure, a method of manufacturing a battery pack. The battery pack is configured to be coupled to a power tool. The method includes providing a housing including a cavity and providing a first battery cell carrier including a plurality of first battery cells. Each battery cell of the plurality of first battery cells includes a first length. The first battery cell carrier is configured to be coupled to the housing. The method includes providing a second battery cell carrier including a plurality of second battery cells. Each battery cell of the plurality of second battery cells includes a second length different than the first length. The second battery cell carrier is configured to be coupled to the housing. The method includes selecting the first battery cell carrier or the second battery cell carrier to be coupled to the housing and securing the selected battery cell carrier to the housing. Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top perspective view of a battery pack.FIG. 2 is a partial exploded view of the battery pack of FIG. 1 illustrating a battery cell carrier received within a lower housing portion of the battery pack.FIG. 3 is a bottom perspective view of the battery cell carrier of FIG. 2 in a first configuration.FIG. 4 is a bottom perspective view of the battery cell carrier of FIG. 2 in a second configuration.FIG. 5 is a bottom perspective view of the battery pack of FIG. 1.FIG. 6 is a bottom view of the battery pack of FIG. 1 illustrating mounting apertures of the lower housing portion providing access to the battery cell carrier for fasteners to couple the battery cell carrier to the lower housing portion.FIG. 7 is a detailed view of two mounting apertures of FIG. 6.FIG. 8 is a flowchart illustrating a method of manufacturing the battery pack of FIG. 1 including either the battery cell carrier of FIG. 3 in the first configuration or the battery cell carrier of FIG. 4 in the second configuration. DETAILED DESCRIPTION Before any embodiments of the disclosure are explained in detail, it is to be