Rechargeable battery pack for a hand-held power tool and method for manufacturing a rechargeable battery pack for a hand-held power tool

Abstract

A rechargeable battery pack for a hand-held power tool, including a housing having at least first and second housing components, the pack including at least one cell holder, accommodating at least two battery cells in a parallel/series circuit, the battery cells each including two end faces extending perpendicularly to a longitudinal axis; and a pack electronics system including contact elements for establishing electrical connection between the pack and a power tool. The cell holder includes sleeve-like insulating walls, corresponding to the battery cells at least in some areas, to prevent electrical contact between the battery cells. A method for manufacturing a pack for a hand-held power tool, the cell holder including sleeve-like insulating walls, having cylindrical cell openings for accommodating the battery cells, the battery cells being pressed into the cell openings so that a form-locked and force-fit connection is established between the cell holder and the battery cells.

1 - 22 . (canceled) 
     
     
         23 . A rechargeable battery pack for a hand-held power tool, comprising:
 a rechargeable battery pack housing having at least one first housing component and a second housing component;   at least one cell holder to accommodate at least two battery cells which are interconnected in a parallel circuit and/or a series circuit, each of the battery cells including two end faces extending perpendicularly to a longitudinal axis;   a rechargeable battery pack electronics system having contact elements for providing an electrical connection between the rechargeable battery pack and the hand-held power tool;   wherein the cell holder includes sleeve-like insulating walls corresponding to the battery cells at least in some areas, the insulating walls being configured to prevent electrical contact between the battery cells.   
     
     
         24 . The rechargeable battery pack of  claim 23 , wherein, for each of the battery cells, the cell holder has a cell opening, which is intended for accommodating a battery cell, the insulating walls being situated between the cell openings. 
     
     
         25 . The rechargeable battery pack of  claim 24 , wherein a diameter of the cell openings before the battery cells are inserted into the cell openings is between 97% and 99% of a diameter of the corresponding battery cells. 
     
     
         26 . The rechargeable battery pack of  claim 24 , wherein a diameter of the cell openings before the battery cells are inserted into the cell openings is between 0.05 mm and 0.20 mm less than a diameter of the corresponding battery cells. 
     
     
         27 . The rechargeable battery pack of  claim 24 , wherein a circumference of the cell openings before the battery cells are inserted into the cell openings is between 97% to 99.5% of a circumference of the cell casing 
     
     
         28 . The rechargeable battery pack of  claim 23 , wherein a cell holding force acts between the cell holder and the accommodated battery cells, the cell holding force being between 20 N and 400 N. 
     
     
         29 . The rechargeable battery pack of  claim 23 , wherein the cell holder has free areas in the area of the end faces of the battery cells, in which the electrical connection of the battery cells to each other takes place via cell connectors. 
     
     
         30 . The rechargeable battery pack of  claim 24 , wherein the cell holder includes, in the area of the cell openings, stops which correspond to the battery cells and ensure a desired position of the battery cells in the cell holder. 
     
     
         31 . The rechargeable battery pack of  claim 23 , wherein the cell holder forms an outer side of the rechargeable battery pack housing, at least in some areas. 
     
     
         32 . The rechargeable battery pack of  claim 23 , wherein the cell holder forms the second housing component. 
     
     
         33 . The rechargeable battery pack of  claim 23 , wherein the cell batteries do not include an insulating sheathing, at least in some areas. 
     
     
         34 . A hand-held power tool, comprising:
 an electric motor; and   a rechargeable battery pack, which is detachably connectable to the hand-held power tool, the rechargeable battery pack, including:
 a rechargeable battery pack housing having at least one first housing component and a second housing component; 
 at least one cell holder to accommodate at least two battery cells which are interconnected in a parallel circuit and/or a series circuit, each of the battery cells including two end faces extending perpendicularly to a longitudinal axis; 
 a rechargeable battery pack electronics system having contact elements for providing an electrical connection between the rechargeable battery pack and the hand-held power tool; 
 wherein the cell holder includes sleeve-like insulating walls corresponding to the battery cells at least in some areas, the insulating walls being configured to prevent electrical contact between the battery cells. 
   
     
     
         35 . A method for manufacturing a rechargeable battery pack for a hand-held power tool, the method comprising:
 providing a cell holder and at least two battery cells, which are electrically connected to each other with corresponding cell connectors in a parallel circuit and/or a series circuit, wherein the cell holder includes sleeve-like insulating walls, between which cylindrical cell openings for accommodating the battery cells are located; and   pressing the battery cells into the cell openings so as to provide a form-locked and force-fit connection between the cell holder and the battery cells.   
     
     
         36 . The method of  claim 35 , wherein, after the battery cells have been pressed in, the cell holder rests on the battery cells in the area of the cell openings in an essentially gap-free manner. 
     
     
         37 . The method of  claim 35 , wherein a diameter of the cell openings before the press-fit of the battery cells into the cell openings is between 97% and 99% of a diameter of the corresponding battery cells. 
     
     
         38 . The method of  claim 35 , wherein a circumference of the cell openings before the battery cells are inserted into the cell openings is between 97% to 99.5% of a circumference of the cell casing. 
     
     
         39 . The method of  claim 35 , wherein a diameter of the cell openings before the press-fit of the battery cells into the cell openings is between 0.10 mm and 0.15 mm less than a diameter of the corresponding battery cells. 
     
     
         40 . The method of  claim 35 , wherein the cell holder is made up of a plastic material, a thermosetting plastic, or an elastomer. 
     
     
         41 . The method of  claim 40 , wherein the elastomer includes a polyethylene having a density between 0.90 g/cm 3  and 1.0 g/cm 3 . 
     
     
         42 . The method of  claim 35 , wherein the cell holder is preheated before the press-fit process to a temperature between 60° C. and 110° C. 
     
     
         43 . The method of  claim 35 , wherein a material expansion occurs in the cell holder after the battery cells have been pressed in, the material expansion being between 0.2% and 5%. 
     
     
         44 . The method of  claim 35 , wherein a cell holding force acts between the cell holder and the pressed-in battery cells, the cell holding force being between 20 N and 400 N. 
     
     
         45 . The method of  claim 35 , wherein a diameter of the cell openings before the press-fit of the battery cells into the cell openings is between 97.5% and 98.5% of a diameter of the corresponding battery cells. 
     
     
         46 . The method of  claim 35 , wherein a circumference of the cell openings before the battery cells are inserted into the cell openings is between 98% to 99% of a circumference of the cell casing. 
     
     
         47 . The method of  claim 35 , wherein a diameter of the cell openings before the press-fit of the battery cells into the cell openings is between 0.10 mm and 0.15 mm less than a diameter of the corresponding battery cells. 
     
     
         48 . The method of  claim 35 , wherein the cell holder is made up of a plastic material, including a thermoplastic polymer, a thermosetting plastic, or an elastomer, including a polyethylene. 
     
     
         49 . The method of  claim 48 , wherein the polyethylene has a density between 0.95 g/cm 3  and 0.99 g/cm 3 . 
     
     
         50 . The method of  claim 48 , wherein the polyethylene has a density between 0.96 g/cm 3  and 0.98 g/cm 3 . 
     
     
         51 . The method of  claim 35 , wherein the cell holder is preheated before the press-fit process, to a temperature between 70° C. and 80° C. 
     
     
         51 . The method of  claim 35 , wherein a material expansion occurs in the cell holder after the battery cells have been pressed in, the material expansion being between 0.5% and 3%. 
     
     
         52 . The method of  claim 35 , wherein a material expansion occurs in the cell holder after the battery cells have been pressed in, the material expansion being between 1% and 2%. 
     
     
         53 . The method of  claim 35 , wherein a cell holding force acts between the cell holder and the pressed-in battery cells, the cell holding force being between 100 N and 300 N. 
     
     
         54 . The method of  claim 35 , wherein a cell holding force acts between the cell holder and the pressed-in battery cells, the cell holding force being between 150 N and 250 N. 
     
     
         55 . The rechargeable battery pack of  claim 24 , wherein a diameter of the cell openings before the battery cells are inserted into the cell openings is between 97.5% and 98.5% of a diameter of the corresponding battery cells. 
     
     
         56 . The rechargeable battery pack of  claim 24 , wherein a diameter of the cell openings before the battery cells are inserted into the cell openings is between 0.10 mm and 0.15 mm less than a diameter of the corresponding battery cells. 
     
     
         57 . The rechargeable battery pack of  claim 24 , wherein a circumference of the cell openings before the battery cells are inserted into the cell openings is between 98% to 99% of a circumference of the cell casing. 
     
     
         58 . The rechargeable battery pack of  claim 23 , wherein a cell holding force acts between the cell holder and the accommodated battery cells, the cell holding force being between 100 N and 300 N. 
     
     
         59 . The rechargeable battery pack of  claim 23 , wherein a cell holding force acts between the cell holder and the accommodated battery cells, the cell holding force being between 150 N and 250 N.