Battery technology allows power tools and other portable devices such as lighting equipment, cooling devices, yard tools, and sound systems to be used in a cordless manner. Different batteries can implement different form factors such as a cylindrical form factor or a pouch form factor, each having different advantages in size, shape, packing density, power density, ease of manufacture, and/or cost of manufacture.
The present disclosure relates to a power tool system. The power tool system includes a first power tool having a mechanical connector and an electrical connector and a second power tool having a mechanical connector and an electrical connector. At least one of the mechanical or the electrical connector of the second power tool is dissimilar from the mechanical or the electrical connector of the first power tool. The power tool system further includes a battery housing defining a cavity therein, the battery housing at least partially defined by an upper housing portion, a battery cell positioned within the cavity of the battery housing, a mechanical connector physically coupled to the upper housing portion and configured to mechanically couple with the mechanical connector of the first power tool, an electrical connector electrically coupled to the battery cell and configured to electrically couple with the electrical connector of the first power tool, and an adaptor configured to removably engage the mechanical connector of the battery and/or the electrical connector of the battery such that the battery is configured to mechanically and electrically couple to the second power tool when the adaptor is coupled to the battery and is configured to mechanically and electrically couple to the first power tool when the adaptor is removed from the battery.
The present disclosure further relates to a power tool system. The power tool system includes a power tool having a mechanical connector and an electrical connector, a battery housing defining a cavity therein, the battery housing at least partially defined by an upper housing portion, a battery cell positioned within the cavity of the battery housing, a mechanical connector physically coupled to the upper housing portion and configured to mechanically couple with the mechanical connector of the power tool, and an electrical connector electrically coupled to the battery cell and configured to electrically couple with the electrical connector of the power tool. Each of the electrical connector of the battery cell and the electrical connector of the power tool is a magnetic connector such that the electrical connector of the battery cell and the electrical connector of the power tool form a magnetic connection.
The present disclosure further relates to a power tool system. The power tool system includes a first power tool having an electrical connector formed as a magnetic connector, a second power tool having an electrical connector formed as a terminal block, a battery housing defining a cavity therein, the battery housing at least partially defined by an upper housing portion, a battery cell positioned within the cavity of the battery housing, a first electrical connector physically coupled to the upper housing portion and formed as a magnetic connector configured to electrically couple the first power tool with the battery cell, and a second electrical connector physically coupled to the upper housing portion and formed as a terminal block configured to electrically couple the second power tool with the battery cell.
Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include hydraulic or electrical connections or couplings, whether direct or indirect.
Battery-operated devices such as power tools often utilize rechargeable batteries that are removable, rechargeable, and replaceable. This arrangement allows a first battery (i.e., power storage device, battery pack) to electrically and mechanically couple to the power tool for use while a second battery charges via a separate battery charger such that when the first battery is depleted, the second battery may be electrically and mechanically coupled for use while the first battery is charged via the battery charger. The batteries have electrical connectors that electrically couple to mating connectors of the power tool (and the battery charger) such that the power tool is powered by the coupled battery. Mechanical connectors are implemented on the battery in addition to the electrical connectors to mechanically fasten the battery to mating mechanical fasteners of the power tool (and the battery charger) to hold the battery thereto. By mechanically and electrically coupling the battery to the power tool, the battery is both functional to provide power to the power tool and to remain fixed to the power tool.
Different power tools have different arrangements for electrically and mechanically coupling to batteries that can prohibit certain batteries from coupling to certain power tools. These differences may include, for example, electrical contacts of different lengths, widths, or heights, electrical contacts in different arrangements or locations along the body of the battery, and batteries having different numbers of electrical contacts. Similarly, batteries can include different mechanical interfaces for engaging certain power tools. These mechanical interfaces can also prohibit attachment to other power tools. As such, certain power tools are usable with only certain batteries and certain batteries are usable with only certain power tools based on mechanical and electrical components associated with the battery that are only configured to electrically or mechanically couple to certain power tools.
As shown in the figures, systems are provided for electrically and mechanically coupling a battery to a power tool that has dissimilar electrical and/or mechanical interfaces. In this way, a battery that is typically unable to couple (either mechanically, electrically, or both) to a particular power tool is able to do so via the coupling means described below.
In a first embodiment shown in
With continued reference to
The separable terminal block 130A, 130B may be coupled directly or indirectly (i.e., via an intermediate component positioned between the terminal block 130A, 130B and the housing 114 or via connection to the mechanical connector 138) to the upper housing portion 118 of the housing 114. The terminal blocks 130A, 130B are each separately couplable to the housing 114 via a mechanical retention mechanism. In some embodiments, the terminal block 130A, 130B is removably coupled to the housing 114 via fasteners (e.g., screws) that require tools for removal. In other embodiments, a quick-release latch or other tool-free retention mechanism (e.g., slot and mating protrusion) may couple the terminal block 130A, 130B to the housing 114. In the embodiment shown in
Further, electrical communication between the separable terminal blocks 130A, 130B and the batteries within the housing 114 is accomplished via an electrical interface 140 of the housing 114. The electrical interface 140 provides an electrical connection between the batteries and the electrical contacts 134A, 134B when the respective terminal block 130A, 130B is mechanically coupled to the housing 114.
In operation, coupling the battery 110 when equipped with the first terminal block 130A includes electrically coupling the battery 110 to electrical terminals of the first power tool and mechanically engaging the mechanical connector 138 with a mating mechanical interface of the first power tool. When the battery 110 is mechanically and electrically uncoupled from the first power tool, a user can remove the terminal block 130A from the remainder of the battery 110 and replace it with a different, dissimilar terminal block 130B having a different arrangement, size, and/or number of contacts. After connecting the dissimilar terminal block 130B, the battery 110 can be coupled to a second power tool via the same mechanical connector 138 and via the new electrical connection of the second terminal block 130B. As such, the battery 110 is capable of providing power to different power tools having different electrical connectors.
In a second embodiment, as shown in
In operation, a battery is configured to electrically and mechanically couple with a first power tool by coupling a mechanical connector 214A, 214B, 214C, 214D of the battery with a mechanical connector of the power tool (e.g., sliding the battery into engagement with a slot/protrusion of the power tool). When the battery is mechanically coupled, the contacts of the power tool engage contacts 214A, 214B, 214C, 214D of the battery such that the battery is electrically coupled to the power tool and provides power to the power tool. In switching to a second tool that is not capable of simply engaging the contacts 214A, 214B, 214C, 214D of the battery, the user removes the battery from the first power tool and installs an electrical adaptor 230 onto either the contacts 214A, 214B, 214C, 214D of the battery or the contacts of the power tool, effectively extending the length of the contacts 214A, 214B, 214C, 214D. Then, the user couples the mechanical connectors together which indirectly but electrically engages the contacts of the power tool to the contacts of the battery through the adaptor. The battery provides power to the power tool via the electrical adaptor.
In a third embodiment as shown in
In an embodiment where the adaptor 310 mounts to the power tool, the adaptor 310 includes engagement features 322 for permanently or temporarily mechanically engaging the housing of the power tool. The adaptor 310 additionally includes mechanical connectors 326 that selectively engage and disengage the battery 314. An intermediary electrical connector or passthrough 334 (e.g., an opening, a cutout, a relief) is provided in the adaptor 310 as described above to provide electrical contact between the power tool and the battery 314.
The adaptor 310 according to the third embodiment provides a greater number of power tools that are engageable with the battery 314 as described. A first plurality of power tools may be engageable with the battery 314 without the adaptor 310 while a second plurality of power tools are not capable of electrically or mechanically connecting to the battery 314 without the adaptor 310. By providing the adaptor 310, the user is able to connect to any power tool from the first and second pluralities of power tools by either using or removing the adaptor 310.
In a fourth embodiment, the adaptor 410 positioned (mechanically and/or electrically) between the battery 420 and the power tool 430 incorporates the battery management system (BMS) 414 therein. The battery management system 414 monitors the status (state of balance, voltage, temperature, current, etc.) of the battery 420 and is often incorporated into the housing of the battery 420. By instead incorporating the battery management system 414 into the adaptor 410, the overall size of the battery housing can be reduced, and the manufacturing cost of each battery 420 can be reduced. The battery 420 itself would still retain a central processing unit 424 and/or arrangement of resistors for purposes of battery identification.
With a separated BMS 414, the battery 420 communicates electrically with the adaptor 410 to relay battery status information. The electrical connection between the battery 420 and the adaptor 410 can likewise be used to transmit power from the battery 420, through the adaptor 410, and to the power tool 430. Alternatively, the adaptor 410 can incorporate an alternative electrical connector to function as an intermediary between the contacts of the battery 420 and the contacts of the power tool 430. As a still further alternative, the electrical connection for providing power from the battery 429 to the power tool 430 can be independent of the adaptor 410, bypassing the adaptor 410 entirely.
In a fifth embodiment, as shown in
While the battery housing 510 shown in
The battery 500 shown in
In a sixth embodiment, as shown in
The rail adaptor 610 is a plastic rail adaptor and may be made from a similar material as the remainder of the upper housing portion 618 of the battery 600. As shown, the rail adaptor 610 slides over the metal insert 626 of the terminal block 630. In some embodiments, a retention feature (e.g., detent) holds the rail adaptor 610 in place. A release mechanism may disengage the retention feature to permit removal. Alternatively, a user may physically overcome the retention feature to remove the rail adaptor 610 from the terminal block 630. By introducing the rail adaptor 610 as a separate part (i.e., separate from the remainder of the battery), differently sized rail adaptors 610 may be incorporated to mechanically couple the battery 600 to different power tools having different mechanical connectors. Additionally, the rail adaptor 610 can be replaced if it becomes worn down without replacing the entirety of the upper housing portion 618 of the battery housing 622.
In some embodiments, the battery housing 622 is provided with a rail (e.g., formed with the remainder of the terminal block) and the rail adaptor 610 is sized to fit over the existing, integral rail, thereby increasing the size of the rail. In this way, the rail engages the mechanical connectors of some power tools while the rail adaptor 610 engages the differently sized mechanical connectors of other power tools.
In a seventh embodiment as shown in
The first battery may utilize a dedicated terminal 714 for identifying the battery (e.g., identifying the form factor of the battery) that is not utilized by the second battery. The power tool may be limited (e.g., power draw, speed, power output) based on the form factor of the battery attached thereto and this information can be communicated between the battery and the power tool via one or more terminals 714 otherwise unused by the different battery.
In an eighth embodiment as shown in
In still other embodiments as shown in
Except where contradictory, any of the embodiments described above and shown in the figures can be used in combination with one another to create a mechanical and/or electrical connection between a battery pack and a plurality of different power tools having different mechanical and/or electrical connections such that the battery pack is configured to separately mechanically engage each power tool while simultaneously providing power to the respective power tool.
Number | Date | Country | |
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63356854 | Jun 2022 | US |