Inductive charging holster for power tool

• US 10,381,856 B2
• Filed: 10/02/2015
• Issued: 08/13/2019
• Est. Priority Date: 10/03/2014
• Status: Active Grant

• Current Assignee: Robert Bosch GmbH, Robert Bosch Tool Corporation (Robert Bosch GmbH)
• Original Assignee: Robert Bosch Tool Corporation (Robert Bosch GmbH)
• Inventors: Zhang, Yizhuo, Laubach, Marco, Cole, Steve
• Primary Examiner(s): Grant, Robert J
• Assistant Examiner(s): Trischler, John T
• Application Number:
  US14/873,766
• Publication Number:
  US 20160099606A1
• Time in Patent Office: 1,411 Days
• Field of Search: 320108, 320107
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• CPC Class Codes: H02J 7/0044 specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage

Abstract

A wireless charging system for a power tool includes a charging module, docking frame, and tool holder. The charging module has a charging surface and an inductive charging device for charging a power tool resting on the charging surface, and is mounted in the docking frame, which is mounted in a mounting interface of the tool holder such that the charging surface is at an angle. The tool holder further includes a holding portion extending from a downward portion of the mounting interface such that the holding portion transversely supports the power tool. A soft insert structure received in the holding portion forms an interference fit with the power tool and applies a load to the power tool toward the charging surface that urges the power tool to an optimal location for charging, relative to the inductive charging device.

Claims

1. A wireless charging system, comprising:

a tool holder that includes;

a mounting interface; and

a holding portion that extends from an end region of the mounting interface, and that includes a removable insert structure that has a material that is soft relative to the tool holder, and that has a bladder that defines a cavity; and

a charging module that defines a charging surface, that is removably mountable in the mounting interface of the tool holder, and that includes an inductive charging device configured to wireless charge a wirelessly rechargeable battery of a device resting on the charging surface;

the holding portion having a shape configured to at least partially engage a geometry of a body of the device such that the holding portion acts as a transverse support for the device relative to the mounting interface,

the bladder configured to form an interference fit between the cavity and at least a portion of the body of the device as the bladder is expanded therebetween,

the holding portion configured to apply a load to the body of the device resting on the charging surface such that the device is (i) at least partially compressed between the holding portion and the charging surface when resting on the charging surface and (ii) urged toward a location within a wireless charging tolerance zone of the charging module, and

the removable insert structure of the holding portion configured to apply at least a portion of the load to the body of the device.

2. The system of claim 1, wherein the expansion of the bladder is adjustable.

3. The system of claim 1, wherein the bladder includes a foaming agent disposed therein that forms foam to expand the bladder upon activation.

4. A wireless charging system, comprising:

a tool holder that includes;

a mounting interface; and

a holding portion that extends from an end region of the mounting interface, and that includes a removable insert structure that includes;

a rigid shell that is removably mountable within the holding portion of the tool holder; and

a receiving area that has a material that is soft relative to the tool holder; and

a charging module that defines a charging surface, that is removably mountable in the mounting interface of the tool holder, and that includes an inductive charging device configured to wireless charge a wirelessly rechargeable battery of a device resting on the charging surface;

the holding portion having a shape configured to at least partially engage a geometry of a body of the device such that the holding portion acts as a transverse support for the device relative to the mounting interface,

the receiving area of the removable insert structure configured to receive at least a portion of the body of the device, and defining a cavity sized for an interference fit with at least a portion of the body of the device,

the holding portion configured to apply a load to the body of the device resting on the charging surface such that the device is (i) at least partially compressed between the holding portion and the charging surface when resting on the charging surface and (ii) urged toward a location within a wireless charging tolerance zone of the charging module, and

the removable insert structure of the holding portion configured to apply at least a portion of the load to the body of the device.

5. The system of claim 4, wherein the tool holder further includes at least one stop member that has a shape configured to engage at least a portion of the geometry of the body of the device, and that delimits an installation region for the device such that the battery of the device is located within the tolerance zone of the charging module.

6. The system of claim 4, further comprising a strap that is configured to restrain the device within the tool holder.

7. The system of claim 4, wherein walls of the tool holder have double-walled structures that are each formed by a first wall and a second wall and a gap defined therebetween.

8. The system of claim 7, wherein a damping material is disposed within the gap.

9. The system of claim 4, wherein the mounting interface includes a docking frame separate from the charging module that is removably mounted within the tool holder, and that includes a receiving interface for mounting the charging module.

10. The system of claim 9, wherein the docking frame includes a pushing device that applies a load directly to the charging module that urges the charging module toward the power tool in opposition to the load applied by the holding portion.

11. The system of claim 10, wherein at least one of the pushing device and removable insert structure is adjustable in order to adjust a compression of the power tool in the tool holder.

12. The system of claim 4, further comprising a pushing device that is disposed in the mounting interface of the tool holder, and that directly applies a load to the charging module that loads the charging module toward the holding portion such that the charging module is configured to apply a load to the device in opposition to the load applied by the holding portion.

13. The system of claim 12, wherein the pushing device includes at least one spring mounted on the mounting interface of the tool holder that is configured to bias the pushing device toward the holding portion.

14. The system of claim 12, wherein the pushing device includes an adjustment member that is operable to adjust the load applied by the pushing device.

15. A wireless charging system, comprising:

a tool holder that includes;

a first mounting interface; and

a holding portion that extends from an end region of the first mounting interface, and that includes a soft insert structure;

a docking frame removably mountable in the first mounting interface, the docking frame including;

a second base surface; and

a second mounting interface; and

a charging module that defines a charging surface, that is removably mountable in the second mounting interface, and that includes an inductive charging device that defines a wireless charging tolerance zone;

a power tool that includes a wirelessly rechargeable battery, and that is disposable on the charging surface of the charging module such that the holding portion at least partially transversely supports the power tool relative to the first mounting interface,

the soft insert structure defining a cavity sized for an interference fit with at least a portion of the power tool, and applying a load to the power tool in a direction toward the charging surface such that the power tool is at least partially compressed between the holding portion and the charging surface and urged toward a location such that the battery is within the wireless charging tolerance zone, and

the induction charging device configured to wirelessly charge the battery;

a further power tool having a geometry that is different from the geometry of the power tool; and

a further soft insert structure that defines a further cavity sized for an interference fit with the further power tool, and that is configured to replace the soft insert structure to enable the tool holder to receive the further power tool with an interference fit.

16. The system of claim 15, further comprising at least one of:

a strap configured to restrain the power tool within the tool holder; and

a clamping device that includes at least one clamping arm, and that is actuatable between

a first position whereat the at least one clamping arm engages the power tool to hold the power tool captive within the tool holder, and

a second position whereat the at least one clamping arm is released from the power tool.

17. The system of claim 15, wherein at least one of the tool holder and docking frame further includes at least one stop member that delimits an installation location of the power tool so that the battery is within the wireless charging tolerance zone.