Cordless power tool system

• US 10,177,701 B2
• Filed: 05/03/2018
• Issued: 01/08/2019
• Est. Priority Date: 05/18/2014
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: White, Daniel J., Velderman, Matthew J., Seman, Jr., Andrew E
• Primary Examiner(s): Ro, Bentsu
• Application Number:
  US15/970,382
• Publication Number:
  US 20180262151A1
• Time in Patent Office: 250 Days
• CPC Class Codes: B25F 5/00 Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for
• CPC Class Codes: B25F 5/02 Construction of casings, bodies or handles B25F5/006, B25F5/008 take precedence
• CPC Class Codes: H01M 10/0445 Multimode batteries, e.g. containing auxiliary cells or electrodes switchable in parallel or series connections
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: H01M 50/247 specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 50/588 outside the batteries, e.g. incorrect connections of terminals or busbars
• CPC Class Codes: H01M 50/597 Protection against reversal of polarity
• CPC Class Codes: H02J 5/00 Circuit arrangements for transfer of electric power between ac networks and dc networks H02J3/36 takes precedence
• CPC Class Codes: H02J 7/00045 Authentication, i.e. circuits for checking compatibility between one component, e.g. a battery or a battery charger, and another component, e.g. a power source
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0024 Parallel/serial switching of connection of batteries to charge or load circuit
• CPC Class Codes: H02J 7/0029 with safety or protection devices or circuits
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/007 : Regulation of charging or discharging current or voltage
• CPC Class Codes: H02J 7/00714 : in response to battery charging or discharging current
• CPC Class Codes: H02J 7/02 : for charging batteries from ac mains by converters
• CPC Class Codes: H02J 7/36 : Arrangements using end-cell switching
• CPC Class Codes: H02P 25/14 : Universal motors H02P25/12 takes precedence
• CPC Class Codes: H02P 27/08 : with pulse width modulation
• CPC Class Codes: H02P 29/00 : Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors arrangements for starting electric motors H02P1/00; arrangements for stopping or slowing electric motors H02P3/00; control of motors that can be connected to two or more different electric power supplies H02P4/00; regulating or controlling the speed or torque of two or more electric motors H02P5/00; vector control H02P21/00
• CPC Class Codes: H02P 29/024 : Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
• CPC Class Codes: H02P 29/0241 : the fault being an overvoltage
• CPC Class Codes: H02P 29/032 : Preventing damage to the motor, e.g. setting individual current limits for different drive conditions
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

A power tool system including a multi-voltage battery pack for use with a first power tool, wherein the first power tool comprises a first battery pack interface and is configured to operate at a first operating voltage and a second power tool configured for use with the multi-voltage battery pack such that the system includes both the multi-voltage battery pack and the second power tool, wherein the second power tool comprises a second battery pack interface and is configured to operate at a second operating voltage, wherein the second operating voltage is higher than the first operating voltage.

Claims

1. A power tool system comprising:

a multi-voltage battery pack for use with a first power tool, wherein the first power tool comprises a first battery pack interface and is configured to operate at a first operating voltage; and

a second power tool configured for use with the multi-voltage battery pack such that the system includes both the multi-voltage battery pack and the second power tool, wherein the second power tool comprises a second battery pack interface and is configured to operate at a second operating voltage, wherein the second operating voltage is higher than the first operating voltage,

wherein the multi-voltage battery pack comprises

a housing,

a first string of battery cells arranged in electrical series and disposed inside the housing, the first string having a first positive voltage terminal and a first negative voltage terminal,

a second string of battery cells arranged in electrical series and disposed inside the housing, the second string having a second positive voltage terminal and a second negative voltage terminal, and

a power tool interface,

wherein the power tool interface and second battery pack interface are both shaped and configured to mechanically and electrically couple with each other,

wherein, when the power tool interface is coupled with the second battery pack interface, the first positive voltage terminal is electrically connected to the second negative voltage terminal such that the first and second strings are electrically connected to each other in a series configuration so as to provide the second operating voltage to the second power tool,

wherein the power tool interface is further configured such that the first battery pack interface to which the power tool interface can be coupled is shaped and configured to mate with a second power tool interface of a single voltage battery pack, the single voltage battery pack being configured to provide the first operating voltage, but not the second operating voltage,

wherein the power tool interface is shaped and configured to mechanically and electrically couple with the first battery pack interface,

wherein, when the power tool interface is coupled with the first battery pack interface, the first and second positive voltage terminals are electrically connected to each other and the first and second negative voltage terminals are electrically connected to each other such that the first and second strings are electrically connected to each other in a parallel configuration so as to provide the first operating voltage to the first power tool,

wherein the power tool interface and the second power tool interface are interchangeably coupleable to the first battery pack interface so that the first power tool is operable with either of the multi-voltage battery pack or the single voltage battery pack.

2. The power tool system of claim 1, wherein:

the second power tool interface of the single voltage battery pack is not mechanically coupleable with the second battery pack interface of the second power tool;

the second power tool interface of the single voltage battery pack is not electrically coupleable with the second battery pack interface of the second power tool;

the power tool interface comprises a slot in the housing; and

the second battery pack interface of the second power tool comprises a downwardly extending projection that is shaped and configured to mate with the slot in the housing of the multi-voltage battery pack when power tool interface couples with the second battery pack interface of the second power tool;

the second battery pack interface comprises a plurality of rails and grooves;

the power tool interface of the multi-voltage battery pack comprises a plurality of rails and grooves that are shaped and configured to selectively mechanically couple with (1) a complimentarily shaped plurality of rails and grooves on the first battery pack interface, and (2) the plurality of rails and grooves on the second battery pack interface of the second power tool;

the power tool interface of the multi-voltage battery pack comprises a latch that is shaped and configured to maintain a mechanical and electrical connection between the power tool interface and the first or second battery pack interfaces;

the second power tool interface of the single voltage battery pack comprises a plurality of rails and grooves that are shaped and configured to couple with the complementarily shaped plurality of rails and grooves on the first battery pack interface;

the battery cells of the first string comprises five battery cells that are arranged in a first row within the housing;

the battery cells of the second string comprise five battery cells that are arranged in a second row within the housing;

the second row is positioned on top of the first row;

the battery cells of the first and second strings together are arranged in a 2×

5 matrix within the housing;

the battery cells of the first string and battery cells of the second string each define respective longitudinal axes that are parallel to each other;

the multi-voltage battery pack has first and second opposing lateral sides;

each of the battery cells of the first and second strings has positive and negative voltage terminals;

the positive voltage terminals of three of the five battery cells of the first string are disposed on the first lateral side of the battery pack;

the positive voltage terminals of three of the five battery cells of the second string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of two of the five battery cells of the first string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of two of the five battery cells of the second string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of the cells within the first string on the first lateral side are vertically aligned with respective ones of the negative voltage terminals of the cells within the second string on the first lateral side;

the positive voltage terminals of the cells within the first string on the first lateral side are vertically aligned with respective ones of the positive voltage terminals of the cells within the second string on the first lateral side;

the second power tool comprises an electrically conductive jumper having first and second electrically interconnected contacts;

the second battery pack interface of the second power tool includes the first and second electrically interconnected contacts such that coupling the power tool interface to the second battery pack interface causes the first and second contacts of the jumper to electrically contact the first positive voltage terminal and the second negative voltage terminal, respectively, so that first and second strings electrically connect to each other in series by way of the electrically conductive jumper of the second power tool;

the first operating voltage is between approximately 17 to 20 volts and the second operating voltage is between approximately 34 to 40 volts;

the second power tool comprises a power tool housing;

the second battery pack interface is disposed on the power tool housing;

the multi-voltage battery pack has an open circuit configuration in which the first and second strings are not electrically connected to each other in parallel or series;

the power tool interface comprises a first row of electrical terminals that are shaped and configured to physically and electrically contact corresponding electrical contacts of the second power tool when the power tool interface is mechanically and electrically coupled with the second battery pack interface;

the power tool interface comprises a second row of electrical terminals that are shaped and configured to physically and electrically contact corresponding electrical contacts of the second power tool when the power tool interface is mechanically and electrically coupled with the second battery pack interface;

the first row is vertically offset from the second row;

a plurality of the electrical terminals of the first row of electrical terminals comprise signal terminals;

the electrical terminals of the second row of electrical terminals comprise first and second terminals;

the first terminal of the second row is electrically connected to the first positive voltage terminal of the first string of battery cells;

the second terminal of the second row is electrically connected to the second negative voltage terminal of the second string of battery cells;

the electrical terminals of the first row are spaced apart in a horizontal direction; and

the electrical terminals of the second row are spaced apart in the horizontal direction.

3. The power tool system of claim 1, wherein the second power tool interface of the single voltage battery pack is not mechanically coupleable with the second battery pack interface of the second power tool.

4. The power tool system of claim 3, wherein the second power tool interface of the single voltage battery pack is not electrically coupleable with the second battery pack interface of the second power tool.

5. The power tool system of claim 4, wherein:

the power tool interface comprises a slot in the housing; and

the second battery pack interface of the second power tool comprises a downwardly extending projection that is shaped and configured to mate with the slot in the housing of the multi-voltage battery pack when power tool interface couples with the second battery pack interface of the second power tool.

6. The power tool system of claim 5, wherein the first battery pack interface of the first power tool lacks a projection that would mate with the slot in the housing when the power tool interface mechanically and electrically couples with the first battery pack interface of the first power tool.

7. The power tool system of claim 5, wherein the second power tool interface has a physical structure that occupies a space on the second power tool interface that corresponds to a location of the slot of the power tool interface.

8. The power tool system of claim 1, wherein:

the second battery pack interface comprises a plurality of rails and grooves;

the power tool interface of the multi-voltage battery pack comprises a plurality of rails and grooves that are shaped and configured to selectively mechanically couple with (1) a shaped plurality of rails and grooves on the first battery pack interface, and (2) the plurality of rails and grooves on the second battery pack interface; and

the power tool interface of the multi-voltage battery pack comprises a latch that is shaped and configured to maintain a mechanical and electrical connection between the power tool interface and the first or second battery pack interfaces.

9. The power tool system of claim 8, wherein the second power tool interface of the single voltage battery pack comprises a plurality of rails and grooves that are shaped and configured to couple with the complementarily shaped plurality of rails and grooves on the first battery pack interface.

10. The power tool system of claim 1, wherein:

the battery cells of the first string comprise n battery cells that are arranged in a first row within the housing;

the battery cells of the second string comprise n battery cells that are arranged in a second row within the housing;

the second row is positioned on top of the first row; and

n is a whole number greater than or equal to 3.

11. The power tool system of claim 10, wherein the battery cells of the first and second strings together are arranged in a 2×

n matrix within the housing.

12. The power tool system of claim 1, wherein:

the battery cells of the first string comprise five battery cells; and

the battery cells of the second string comprise five battery cells.

13. The power tool system of claim 12, wherein:

the battery cells of the first string and battery cells of the second string each define respective longitudinal axes that are parallel to each other;

the multi-voltage battery pack has first and second opposing lateral sides;

each of the battery cells of the first and second strings has positive and negative voltage terminals;

the positive voltage terminals of three of the five battery cells of the first string are disposed on the first lateral side of the battery pack;

the positive voltage terminals of three of the five battery cells of the second string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of two of the five battery cells of the first string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of two of the five battery cells of the second string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of the cells within the first string on the first lateral side are vertically aligned with respective ones of the negative voltage terminals of the cells within the second string on the first lateral side; and

the positive voltage terminals of the cells within the first string on the first lateral side are vertically aligned with respective ones of the positive voltage terminals of the cells within the second string on the first lateral side.

14. The power tool system of claim 1, wherein:

the second power tool comprises an electrically conductive jumper having first and second electrically interconnected contacts;

the second battery pack interface of the second power tool includes the first and second electrically interconnected contacts such that coupling the power tool interface to the second battery pack interface causes the first and second contacts of the jumper to electrically contact the first positive voltage terminal and the second negative voltage terminal, respectively, so that first and second strings electrically connect to each other in series by way of the electrically conductive jumper of the second power tool.

15. The power tool system of claim 1, wherein the first operating voltage is between approximately 17 to 20 volts and the second operating voltage is between approximately 34 to 40 volts.

16. The power tool system of claim 1, wherein the second power tool comprises a power tool housing, and wherein the second battery pack interface is disposed on the power tool housing.

17. The power tool system of claim 1, wherein the multi-voltage battery pack has an open circuit configuration in which the first and second strings are not electrically connected to each other in parallel or series.

18. The power tool system of claim 17, wherein the power tool interface and second battery pack interface are shaped and configured such that decoupling the power tool interface from the second battery pack interface causes the multi-voltage battery pack to change from the series configuration to the open circuit configuration.

19. The power tool system of claim 18, wherein the power tool interface is shaped and configured such that decoupling the power tool interface from the second battery pack interface causes the multi-voltage battery pack to sequentially change from:

(1) the series configuration, to (2) the open configuration, to (3) the parallel configuration.

20. The power tool system of claim 1, wherein:

the power tool interface comprises a first row of electrical terminals that are shaped and configured to physically and electrically contact corresponding electrical contacts of the second power tool when the power tool interface is mechanically and electrically coupled with the second battery pack interface;

the power tool interface comprises a second row of electrical terminals that are shaped and configured to physically and electrically contact corresponding electrical contacts of the second power tool when the power tool interface is mechanically and electrically coupled with the second battery pack interface; and

a top of the first row is vertically offset from a top of the second row.

21. The power tool system of claim 20, wherein:

a plurality of the electrical terminals of the first row of electrical terminals comprise signal terminals;

the electrical terminals of the second row of electrical terminals comprise first and second terminals;

the first terminal of the second row is electrically connected to the first positive voltage terminal of the first string of battery cells; and

the second terminal of the second row is electrically connected to the second negative voltage terminal of the second string of battery cells.

22. The power tool system of claim 20, wherein:

the housing comprises a first row of slots;

the electrical terminals of the first row of electrical terminals are disposed in respective ones of the first row of slots;

the housing comprises a second row of slots;

the electrical terminals of the second row of electrical terminals are disposed in respective ones of the second row of slots; and

a top of the first row of slots is vertically offset from a top of the second row of slots.

23. The power tool system of claim 1, wherein:

the power tool interface comprises a first row of electrical contacts that are shaped and configured to physically and electrically contact corresponding electrical contacts of the second power tool when the power tool interface is mechanically and electrically coupled with the second battery pack interface;

the power tool interface comprises a second row of electrical contacts that are shaped and configured to physically and electrically contact corresponding electrical contacts of the second power tool when the power tool interface is mechanically and electrically coupled with the second battery pack interface; and

the first row is vertically offset from the second row.

24. A power tool system comprising:

a multi-voltage battery pack; and

a second power tool having a plurality of grooves, a plurality of rails, and a plurality of electrical terminals,

wherein the multi-voltage battery pack comprises

a housing having a bottom wall, a pair of side walls, a pair of end walls, and a top wall that together define a receptacle;

an electromechanical interface coupled to the top wall, the interface having a terminal block with a plurality of slots containing a plurality of electrical terminals, a pair of longitudinal rails extending along the terminal block and defining a pair of longitudinal grooves between the rails and the top wall, and a latch,

wherein the electromechanical interface is configured to be coupled to a first power tool operating at a first voltage by sliding the pair of longitudinal rails and grooves of the electromechanical interface into corresponding grooves and rails of the first power tool so that electrical terminals on the first power tool are received in the slots of the electromechanical interface to engage the battery pack electrical terminals and the latch engages the first power tool to maintain coupling between the electromechanical interface and the first power tool, and

wherein the electromechanical interface is configured to be coupled to the second power tool operating at a second, different voltage by sliding the pair of longitudinal rails and grooves of the electromechanical interface into the grooves and rails of the second power tool so that the electrical terminals of the second power tool are received in the slots to engage the battery pack electrical terminals and the latch engages the second power tool to maintain coupling between the electromechanical interface and the second power tool; and

a plurality of battery cells disposed in the receptacle, the cells configured (1) to be connectable to each other in parallel to provide power at the first operating voltage to the electrical terminals upon coupling the electromechanical interface to the first power tool, and (2) to be connectable to each other in series to provide power at the first operating voltage to the electrical terminals upon coupling the electromechanical interface to the second power tool,

wherein the terminal block, the slots, the battery pack terminals, the longitudinal rails, the longitudinal grooves, and the latch of the electromechanical interface have substantially the same configuration as a terminal block, slots, battery pack terminals, longitudinal rails, longitudinal grooves, and a latch of an electromechanical interface of a single-voltage battery pack that is operable at only the first voltage and can be coupled to the first power tool to provide power at the first voltage to the first power tool.

25. The power tool system of claim 24, wherein:

the electromechanical interface of the single-voltage battery pack is not mechanically or electrically coupleable with the second power tool;

the electromechanical interface of the multi-voltage battery pack comprises a slot in the housing; and

the second power tool comprises a downwardly extending projection that is shaped and configured to mate with the slot in the housing of the multi-voltage battery pack when the electromechanical interface of the multi-voltage battery pack couples with second power tool.

26. The power tool system of claim 24, wherein:

the plurality of battery cells of the multi-voltage battery pack comprises

a first string of five battery cells that are arranged in series with each other, and

a second string of five battery cells that are arranged in series with each other;

the battery cells of the first string are arranged in a first row within the housing;

the battery cells of the second string are arranged in a second row within the housing;

the second row is positioned on top of the first row;

the battery cells of the first and second strings together are arranged in a 2×

5 matrix within the housing;

the battery cells of the first string and battery cells of the second string each define respective longitudinal axes that are parallel to each other;

the multi-voltage battery pack has first and second opposing lateral sides;

each of the battery cells of the first and second strings has positive and negative voltage terminals;

the positive voltage terminals of three of the five battery cells of the first string are disposed on the first lateral side of the battery pack;

the positive voltage terminals of three of the five battery cells of the second string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of two of the five battery cells of the first string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of two of the five battery cells of the second string are disposed on the first lateral side of the battery pack;

the negative voltage terminals of the cells within the first string on the first lateral side are vertically aligned with respective ones of the negative voltage terminals of the cells within the second string on the first lateral side; and

the positive voltage terminals of the cells within the first string on the first lateral side are vertically aligned with respective ones of the positive voltage terminals of the cells within the second string on the first lateral side.

27. The power tool system of claim 24, wherein:

the plurality of battery cells of the multi-voltage battery pack comprises

a first string of battery cells that are arranged in series with each other, and

a second string of battery cells that are arranged in series with each other;

the plurality of electrical terminals of the electromechanical interface of the multi-voltage battery pack comprise a first electrical contact and a second electrical contact;

the first electrical contact is electrically connected to the first positive voltage terminal of the first string;

the second electrical contact is electrically connected to the second negative voltage terminal of the second string; and

the first and second electrical contacts are shaped and configured such that coupling the electromechanical interface of the multi-voltage battery pack to the second power tool causes the first and second electrical contacts to electrically connect to each other by way of an electrical jumper of the second power tool so as to cause the first and second strings to electrically connect to each other in series by way of the jumper when the electromechanical interface of the multi-voltage battery pack couples with the second power tool.

28. The power tool system of claim 24, wherein:

the plurality of battery cells of the multi-voltage battery pack comprises

a first string of battery cells that are arranged in series with each other, and

a second string of battery cells that are arranged in series with each other;

the multi-voltage battery pack has an open circuit configuration in which the first and second strings are not electrically connected to each other in parallel or series.

29. The power tool system of claim 24, wherein:

the plurality of battery cells of the multi-voltage battery pack comprises

a first string of battery cells that are arranged in series with each other such that the first string has a first positive voltage terminal and a first negative voltage terminal, and

a second string of battery cells that are arranged in series with each other such that the second string has a second positive voltage terminal and a second negative voltage terminal;

the plurality of electrical terminals of the multi-voltage battery pack comprise a first row of electrical terminals and a second row of electrical terminals;

the first row is vertically offset from the second row;

a plurality of the electrical terminals of the first row of electrical terminals comprise signal terminals;

the electrical terminals of the second row of electrical terminals comprise first and second terminals;

the first terminal of the second row is electrically connected to the first positive voltage terminal of the first string of battery cells;

the second terminal of the second row is electrically connected to the second negative voltage terminal of the second string of battery cells;

the electrical terminals of the first row are spaced apart in a horizontal direction; and

the electrical terminals of the second row are spaced apart in the horizontal direction.