Cordless power tool system

• US 10,361,651 B2
• Filed: 05/03/2018
• Issued: 07/23/2019
• 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): Dhakal, Bicky
• Application Number:
  US15/970,421
• Publication Number:
  US 20180262152A1
• Time in Patent Office: 446 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 system comprising a multi-voltage battery pack for use with tools of different operating voltages, including a housing and a power tool interface shaped and configured to interchangeably (1) mechanically and electrically couple with a first battery pack interface of a first power tool that is configured to operate at a first operating voltage and that was on sale prior to May 18, 2014 and, and (2) mechanically and electrically couple with a second battery pack interface of a second power tool that is configured to operate at a second operating voltage and that was not on sale prior to May 18, 2014.

Claims

1. A system comprising a multi-voltage battery pack for use with tools of different operating voltages, the multi-voltage battery pack comprising:

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 shaped and configured to interchangeably (1) mechanically and electrically couple with a first battery pack interface of a first power tool that is configured to operate at a first operating voltage and that was on sale prior to May 18, 2014 and, and (2) mechanically and electrically couple with a second battery pack interface of a second power tool that is configured to operate at a second operating voltage and that was not on sale prior to May 18, 2014,

wherein the second operating voltage is higher than the first operating voltage,

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, 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 is coupleable, is shaped and configured to mate with a second power tool interface of a single voltage battery pack that was on sale prior to May 18, 2014, the single voltage battery pack being configured to provide the first operating voltage, but not the second operating voltage, and

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 system of claim 1, further comprising the second power tool such that the system includes both the multi-voltage battery pack and the second power tool, wherein the second power tool comprises a power tool housing, and wherein the second battery pack interface is disposed on the power tool housing.

3. The system of claim 2, wherein:

the multi-voltage battery pack is compatible with a set of power tools that were not on sale prior to May 18, 2014;

the set of power tools are configured to operate at the second operating voltage;

and

the set of power tools includes the second power tool.

4. The system of claim 1, further comprising the first power tool such that the system includes both the multi-voltage battery pack and the first power tool, wherein the first power tool comprises a power tool housing, and wherein the first battery pack interface is disposed on the power tool housing.

5. The system of claim 4, wherein:

the multi-voltage battery pack is backwards compatible with a pre-existing set of power tools that were on sale prior to May 18, 2014 and were configured to operate at the first operating voltage; and

the pre-existing set of power tools includes the first power tool.

6. The system of claim 5, further comprising the single voltage battery pack such that the system includes the multi-voltage battery pack, the first power tool, and the single voltage battery pack.

7. The 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;

the slot is shaped and configured to mate with a downwardly extending projection of the second battery pack interface of the second power tool when power tool interface couples with the second battery pack interface of the second power tool;

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 complementarily shaped plurality of rails and grooves on the first battery pack interface, and (2) a complimentarily shaped plurality of rails and grooves on 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 power tool interface comprises a first electrical contact that is electrically connected to the first positive voltage terminal of the first string;

the power tool interface comprises a second electrical contact that is electrically connected to the second negative voltage terminal of the second string;

the first and second electrical contacts are shaped and configured such that coupling the power tool interface to the second battery pack interface 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 power tool interface couples with the second battery pack interface;

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

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.

8. The 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.

9. The system of claim 8, further comprising the second power tool such that the system includes both the multi-voltage battery pack and the second power tool, 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 the power tool interface couples with the second battery pack interface of the second power tool.

10. The system of claim 1, wherein:

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 complementarily shaped plurality of rails and grooves on the first battery pack interface, and (2) a complimentarily shaped 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.

11. The system of claim 10, further comprising the single voltage battery pack such that the system includes both the multi-voltage battery pack and the single voltage battery pack, 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.

12. The 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.

13. The system of claim 12, wherein the battery cells of the first and second strings together are arranged in a 2×

n matrix within the housing.

14. The system of claim 12, wherein n equals five.

15. The system of claim 14, wherein:

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.

16. The system of claim 1, further comprising the second power tool such that the system includes both the multi-voltage battery pack and the second power tool, wherein:

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

the second battery pack interface 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 jumper of the second power tool.

17. The system of claim 1, wherein:

the power tool interface comprises a first electrical contact that is electrically connected to the first positive voltage terminal of the first string;

the power tool interface comprises a second electrical contact that is electrically connected to the second negative voltage terminal of the second string;

the first and second electrical contacts are shaped and configured such that coupling the power tool interface to the second battery pack interface 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 power tool interface couples with the second battery pack interface.

18. The system of claim 1, further comprising a battery pack charger such that the system includes both the multi-voltage battery pack and the battery pack charger, wherein the battery pack charger is configured to charge the multi-voltage battery pack, and wherein the battery pack charger is configured to charge the single voltage battery pack.

19. The system of claim 18, wherein the battery pack charger was on sale prior to May 18, 2014.

20. The system of claim 18, wherein:

the battery charger comprises a third battery pack interface that is shaped and configured to mechanically and electrically couple with the power tool interface;

the multi-voltage battery pack and charger are shaped and configured such that when the power tool interface is coupled with the third 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 parallel for simultaneous charging by the battery charger while in parallel; and

the third battery pack interface is shaped and configured to mechanically and electrically couple with the second power tool interface of the single voltage battery pack for charging the single voltage battery pack.

21. The system of claim 1, wherein the multi-voltage battery pack is backwards compatible with a battery pack charger that was on sale prior to May 18, 2014.

22. The 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.

23. The system of claim 1, wherein the multi-voltage battery pack has an open circuit configuration in which the first string is electrically disconnected from the second string such that the first and second strings are not electrically connected to each other in parallel or series.

24. The 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.

25. The system of claim 24, 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.

26. The system of claim 24, 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.

27. The 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.

28. A system comprising a multi-voltage battery pack for use with tools of different operating voltages, the multi-voltage battery pack comprising:

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 into corresponding grooves and rails on the first power tool so that electrical terminal on the first power tool are received in the slots 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 a second power tool operating at a second, different voltage by sliding the pair of longitudinal rails and grooves into corresponding grooves and rails on the second power tool so that electrical terminal on 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 is coupleable to the first power tool to provide power at the first voltage to the first power tool,

wherein the first power tool was on sale prior to May 18, 2014,

wherein the single voltage battery pack was on sale prior to May 18, 2014, and

wherein the second power tool was not on sale prior to May 18, 2014.

29. The system of claim 28, further comprising the second power tool such that the system includes both the multi-voltage battery pack and the second power tool.

30. The system of claim 28, further comprising the single voltage battery pack such that the system includes both the multi-voltage battery pack and the single voltage battery pack.