Convertible battery pack

Patent metadata

Field	Value
Publication number	US-12424696-B2
Application number	US-202217849495-A
Country	US
Kind code	B2
Filing date	Jun 24, 2022
Priority date	Jun 25, 2021
Publication date	Sep 23, 2025
Grant date	Sep 23, 2025

Abstract

A battery pack including a first battery cell and a second battery cell. The first battery cell is received at least partially within a primary cell casing and extends along a first axis. The second battery cell is received at least partially within an auxiliary cell casing extending along a second axis, the second battery cell being movable relative to the first battery cell.

First claim

What is claimed is:

1. A battery pack comprising:
a first battery cell received at least partially within a primary cell casing and extending along a first axis,
a second battery cell received at least partially within an auxiliary cell casing extending along a second axis, the second battery cell movable relative to the first battery cell, and
an outer housing including a primary portion, a connector, and an auxiliary portion, and
wherein
the primary portion is fixed to the primary cell casing,
the connector includes a first connector end and an opposite second connector end, the first connector end coupled to the primary portion, the second connector end coupled to the auxiliary portion, and
the auxiliary portion includes a first auxiliary end and an opposite tip end, the first auxiliary end coupled to the second connector end.

2. The battery pack of claim 1 , wherein the auxiliary cell casing is hingedly coupled to the primary cell casing.

3. The battery pack of claim 2 , further comprising a piano hinge hingedly coupled to the primary cell casing and the auxiliary cell casing.

4. The battery pack of claim 1 , wherein
the battery pack extends in a longitudinal direction extending perpendicular to the first axis,
the second battery cell is movable relative to the first battery cell such that the battery pack is convertible between a first configuration and a second configuration, and
the first axis and the second axis are offset along the longitudinal direction by a greater distance in the first configuration than in the second configuration.

5. The battery pack of claim 4 , wherein
a lateral direction extends perpendicular to the first axis and perpendicular to the longitudinal direction, and
the first axis and the second axis are offset along the lateral direction by a lesser distance in the first configuration than in the second configuration.

6. The battery pack of claim 1 , further comprising a plurality of second battery cells including the second battery cell, each of the plurality of second battery cells received at least partially within a respective auxiliary cell casing.

7. The battery pack of claim 6 , wherein
each auxiliary cell casing has a corresponding auxiliary portion of the outer housing, each auxiliary portion includes a tip end,
in a first configuration, the respective tip ends are located adjacent each other, and
in a second configuration, the respective tip ends are spaced apart from each other.

8. The battery pack of claim 1 , wherein
the battery pack extends in a longitudinal direction extending perpendicular to the first axis, and
in a first configuration of the battery pack, a length of the battery pack measured parallel to the longitudinal direction is between 50% and 75% less than in the second configuration.

9. A battery pack comprising:
a first battery cell received at least partially within a primary cell casing and extending along a first axis,
at least one second battery cell received at least partially within at least one auxiliary cell casing extending along a second axis parallel to the first axis,
a hinge rotatably coupling the primary cell casing to the auxiliary cell casing, such that the battery pack is convertible between a first configuration and a second configuration,
a flexible circuit electrically coupling the first battery cell to the second battery cell, the flexible circuit including a first portion and a second portion, the first portion of the flexible circuit coupled to the first battery cell, the second portion of the flexible circuit coupled to the second battery cell,
a printed circuit board,
a separator mounted within the primary cell casing between the printed circuit board and the first battery cell, and
wherein the flexible circuit electrically connects the printed circuit board to the first battery cell and the at least one second battery cell.

10. The battery pack of claim 9 , wherein the first portion of the flexible circuit and the second portion of the flexible circuit are closer to each other in the first configuration than in the second configuration.

11. The battery pack of claim 9 , further comprising a protective layer surrounding the flexible circuit.

12. The battery pack of claim 9 , wherein the flexible circuit includes between 2 ounces and 4 ounces of conductive tracks having a width of between 3 millimeters and 5 millimeters.

13. The battery pack of claim 9 , further comprising a thermistor electrically coupled to the flexible circuit.

14. The battery pack of claim 9 , further comprising a voltage tap electrically coupled to the flexible circuit, the voltage tap comprising a plurality of resistors.

15. A battery pack comprising:
a first battery cell received at least partially within a primary cell casing and extending along a first axis,
at least one second battery cell received at least partially within at least one auxiliary cell casing extending along a second axis parallel to the first axis,
a hinge rotatably coupling the primary cell casing to the auxiliary cell casing, such that the battery pack is convertible between a first configuration and a second configuration, and
an outer housing surrounding at least a portion of the primary cell casing and at least a portion of the auxiliary cell casing, the outer housing including a sliding cam assembly to move the outer housing between the first configuration and the second configuration.

16. The battery pack of claim 15 , wherein the sliding cam assembly further comprises
an interface plate including at least one arcuate recess defined therein and
at least one latch slidably disposed within the at least one arcuate recess.

17. The battery pack of claim 16 , wherein
the sliding cam assembly further comprises a connector including a first connector end and a second connector end, the first connector end coupled to the latch
the auxiliary cell casing rotatably coupled to the second connector end, and
further comprising a pin rotatably coupling the auxiliary cell casing to the interface plate.

Assignees

• Milwaukee Electric Tool Corp

Inventors

• Fassbender Kyle C
• Jipp Ryan B

Classifications

• H01M50/213 Primary

  adapted for cells having curved cross-section, e.g. round or elliptic (H01M50/209, H01M50/216 take precedence) · CPC title

• H01M50/284

  with incorporated circuit boards, e.g. printed circuit boards [PCB] · CPC title

• H01M50/269 Primary

  Mechanical means for varying the arrangement of batteries or cells for different uses, e.g. for changing the number of batteries or for switching between series and parallel wiring (methods or arrangements for servicing or maintenance H01M6/50, H01M10/42) · CPC title

• H01M50/247

  specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers · CPC title

• H01M2220/30

  Batteries in portable systems, e.g. mobile phone, laptop · CPC title