Power Tool Battery Cell Replacement Kit and Methods Thereof

• US 20110133695A1
• Filed: 12/09/2009
• Published: 06/09/2011
• Est. Priority Date: 12/09/2009
• Status: Abandoned Application

• Current Assignee: Richard Cadway
• Original Assignee: Richard Cadway
• Inventors: Cadway, Richard
• Application Number:
  US12/634,668
• Publication Number:
  US 20110133695A1
• Time in Patent Office: Days
• US Class Current: 320/114
• 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: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/34 Gastight accumulators
• CPC Class Codes: H01M 50/20 Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders structural combination of accumulators with charging apparatus H01M10/46
• 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 50/247 specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/509 characterised by the type of connection, e.g. mixed connections
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/512 Connection only in parallel
• CPC Class Codes: H01M 50/516 by welding, soldering or brazing
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

The present invention relates generally to a kit which allows replacement of a removable battery cell cluster from a power tool which is no longer viable or operational and replacing it with a new battery cell cluster so to operate the power tool normally. The invention further relates to methods of replacing the expired battery cluster and assembling the new battery cluster so that it is attachable to the power tool and so that it is easily transported by the user while working with the power tool.

Claims

1. An external battery cluster kit for an electrically powered tool comprising, a fabric bandolier belt which is worn by a user wherein, the bandolier belt using elastic material holds a plurality of rechargeable battery cells, said battery cells being electrically connected to one another with a plurality of electrical contacts and electrical connectors which are attached to the battery cells to produce an electric current to power the tool, wherein the battery cluster is electrically connected to the tool by means of primary and secondary cables, wherein a first end of said primary electrical cable is connected to the battery cluster by a secondary electrical cable and a second opposite end of said primary electrical cable is connected to another secondary electrical cable, said secondary electrical cable being connected to a battery pack appropriate for the tool, allowing the user to recharge the battery cluster using the recharger provided with the power tool, wherein said electric current provides sufficient voltage to power the tool for normal operation, wherein said voltage may be modulated by the user with an electrical switch in series on the battery cluster to provide electrical power to a variety of tools which require different operating voltages and wherein said bandolier belt is attached to a tool holster appropriate for holding said electrically powered tool.

2. The battery cluster of claim 1, wherein Velcro sections which secure the fabric bandolier belt and holster, break away and separate from one another, when accidentally snagged in a work environment, providing a measure of safety to the user.

3. The battery cluster of claim 1, wherein the fabric bandolier belt contains elastic battery cell pockets that stretch to accommodate holding a variety of battery cell sizes and types.

4. The battery cluster of claim 1, wherein the electrical contacts comprise the contacts essentially as shown in FIG. 10, 11, 12A, 12B, 14, 15, 16, 17, 18 or 19.

5. The electrical contacts of claim 4, further comprising contacts composed of brass, nickel or alloys of nickel, phosphor bronze or beryllium copper.

6. The electrical contacts of claim 5, wherein a male portion of said contacts rotate 360°

relative to a female portion of the contact to provide the battery kit with flexibility during use.

7. The battery cluster of claim 1, wherein the tool holster is attached to the bandolier belt with a Velcro attachment.

8. The battery cluster of claim 1, further comprising rechargeable battery cells composed of nickel metahydride (NiMH), nickel cadmium (NiCD) or Lithium ion.

9. The battery cluster of claim 1, wherein the rechargeable battery cells are electrically connected serially, in parallel or a combination of both.

10. The battery cluster of claim 1, further comprising a fabric handle that attaches to the belt which allows the user the ability to hand-carry the battery cluster during use.

11. The battery cluster of claim 1, further comprising battery cell caps that cover the electrical contacts of the battery cluster and house the secondary electrical cable, providing protection to the cells and electrical connections.

12. A method of assembling an external battery cluster worn by a user to power an electrically powered tool comprising the steps of connecting a plurality of rechargeable battery cells to one another with electrical contacts and connectors which are attached to the battery cells to produce a battery cell cluster, said battery cluster producing an electric current to power the tool, wherein said contacts and connectors are fixed or rotatable and allow flexibility of the battery cluster while in use and wherein the battery cell cluster is electrically connected to the power tool by means of primary and secondary cables, wherein a first end of the primary electrical cable is connected to the battery cell cluster by a secondary electrical cable and a second opposite end of the primary electrical cable is attached to another secondary electrical cable that is electrically connected to a battery housing, wherein the battery housing fits the tool thus allowing the battery to be recharged using the power tool battery recharger and wherein said electrical current provides sufficient voltage to power the tool for normal operation, wherein said voltage may be modulated by the user with an electrical switch connected in series on the battery cluster to provide electrical power to a variety of tools which require different operating voltages, wherein said bandolier belt is attached to a tool holster appropriate for holding said electrically powered tool and wherein the belt and holster act as a safety device in which the Velcro sections separate from one another when the belt or holster are accidentally snagged in a work environment, providing the user a measure of safety.

13. The method of claim 12, wherein the fabric bandolier contains elastic battery cell pockets that stretch to accommodate holding a variety of battery cell sizes and types.

14. The method of claim 12, wherein the electrical contacts comprise the contacts essentially as shown in FIG. 10, 11, 12A, 12B, 14, 15, 16, 17, 18 or 19.

15. The method of claim 14, wherein said contacts are comprised of brass, nickel or alloys of nickel, phosphor bronze or beryllium copper.

16. The method of claim 12, wherein a male portion of said contacts rotate 360°

relative to a female portion of the contact to provide the battery kit with flexibility during use.

17. The method of claim 12, wherein the tool holster is attached to the bandolier belt with a Velcro attachment.

18. The method of claim 12 further comprising rechargeable battery cells that are nickel metahydride (NiMH), nickel cadmium (NiCD) or Lithium ion.

19. The method of claim 12, wherein the rechargeable battery cells are electrically connected serially, in parallel or in a combination of both.

20. A method of constructing an internal battery cluster to power an electrically powered tool comprising the steps of connecting a plurality of rechargeable battery cells to one another with electrical contacts and connectors, wherein said contacts and connectors are fixed or rotatable and allow flexibility of the battery while being assembled and wherein the battery cells are housed within a battery pack supplied by the manufacturer of the power tool which has had the factory-supplied battery cell cluster removed, allowing the internal battery cluster to be recharged using the power tool battery recharger.