A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.

A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least approximately 1750 watts at a torque of approximately 1.5 to 2 Newton-meters.

A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least approximately 1750 watts at a torque of approximately 1.5 to 2 Newton-meters.

An electrical system can include a power supply configured to provide electrical power to components at a time at which the electrical system experiences an electrical fault. The electrical system can include a first battery electrically coupled in parallel to a second battery via an electrical bus, whereby the first and second batteries can provide electrical power to a first electrical load and a second electrical load. Upon experiencing a fault, a first circuit element can electrically decouple the first battery and the second battery by opening a circuit provided by the electrical bus, thereby isolating the first battery from the second battery. Next, the battery experiencing the fault can include a second circuit element that can electrically decouple the battery experiencing the fault from a respective electrical load, while the battery isolated from the fault can continue to provide electrical power to components.

An electrical system can include a power supply configured to provide electrical power to components at a time at which the electrical system experiences an electrical fault. The electrical system can include a first battery electrically coupled in parallel to a second battery via an electrical bus, whereby the first and second batteries can provide electrical power to a first electrical load and a second electrical load. Upon experiencing a fault, a first circuit element can electrically decouple the first battery and the second battery by opening a circuit provided by the electrical bus, thereby isolating the first battery from the second battery. Next, the battery experiencing the fault can include a second circuit element that can electrically decouple the battery experiencing the fault from a respective electrical load, while the battery isolated from the fault can continue to provide electrical power to components.

A battery cell includes a housing having an opening, a cover plate configured to close the opening, and an electrode assembly disposed in the housing and including a main body and a tab extending from an end of the main body along a first direction. The cover plate is located on a side of the main body along a second direction perpendicular to the first direction. The battery cell further includes a first insulation piece disposed between the electrode assembly and the cover plate to dielectrically insulate the electrode assembly from the cover plate, and a second insulation piece disposed between the main body and an inner surface of the housing to dielectrically insulate the tab from the housing. The second insulation piece and the first insulation piece are discretely disposed and connected to each other.

The present document describes techniques associated with a blind battery connector. The blind battery connector described herein enables a user to blindly engage, safely and securely, a battery connector with a system-side connector. In aspects, the blind battery connector includes polarity-oriented magnets at both the battery connector and the system-side connector to automatically align and engage the battery connector with the system-side connector with correct orientation. The magnets may be embedded or removably assembled to the battery connector and the system-side connector. The blind battery connector controls initial alignment of the battery connector for coupling with the system-side connector and provides additional mechanical strength to the coupling against drop, vibration, and shock. The techniques described herein may decrease battery connection time at factory assembly, increase units per hour, and lower operating costs, while decreasing the likelihood of battery connector damage and/or reverse polarity engagement.

The present document describes techniques associated with a blind battery connector. The blind battery connector described herein enables a user to blindly engage, safely and securely, a battery connector with a system-side connector. In aspects, the blind battery connector includes polarity-oriented magnets at both the battery connector and the system-side connector to automatically align and engage the battery connector with the system-side connector with correct orientation. The magnets may be embedded or removably assembled to the battery connector and the system-side connector. The blind battery connector controls initial alignment of the battery connector for coupling with the system-side connector and provides additional mechanical strength to the coupling against drop, vibration, and shock. The techniques described herein may decrease battery connection time at factory assembly, increase units per hour, and lower operating costs, while decreasing the likelihood of battery connector damage and/or reverse polarity engagement.

A battery pack and charger system includes a first battery pack having a first set of battery cells and configured to provide only a first operating voltage and a second battery pack having a second set of battery cells and configured to provide the first operating voltage and a second operating voltage that is different from the first operating voltage and a battery pack charger configured to be able to charge the first battery pack and the second battery pack.

In a loaded condition, the controller increases at least one of the conduction band or the advance angle from a baseline value up to a maximum value within a first torque range below a torque threshold to as to maintain the output speed of the motor at a linear speed-torque profile. After the at least one of the conduction band or the advance angle reaches the maximum value, the controller maintains the at least one of the conduction band or the advance angle at the maximum value within a second torque range greater than or equal to the torque threshold so as to maintain the output speed of the motor at a naturally-curved speed-torque profile.