Terminal protection system for portable power tools

• US 6,237,698 B1
• Filed: 03/09/2000
• Issued: 05/29/2001
• Est. Priority Date: 12/10/1999
• Status: Expired due to Term

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Carrier, David, Yahnker, Chris, Woods, Samuel G., Privett, Zollie W.
• Primary Examiner(s): Smith, Scott A.
• Application Number:
  US09/521,560
• Time in Patent Office: 446 Days
• Field of Search: 173/216, 173/2, 173/11, 173/217, 173/117, 173/171, 310/47, 310/50, 337/405, 337/406, 337/198, 337/166, 307/64, 307/66, 307/80
• US Class Current: 173/2
• CPC Class Codes: B25F 5/008 Cooling means
• CPC Class Codes: B25F 5/02 Construction of casings, bodies or handles B25F5/006, B25F5/008 take precedence
• CPC Class Codes: H02H 7/0852 directly responsive to abnormal temperature by using a temperature sensor in a control circuit H02H7/0833
• CPC Class Codes: H02J 7/0044 specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: H02M 3/1555 for the generation of a regulated current to a load whose impedance is substantially inductive
• CPC Class Codes: H02P 7/288 using variable impedance

Abstract

A thermal control circuit (49) for inexpensively protecting the power interface of cordless and dual-mode powered devices (12), such as hand-held power tools and appliances. The powered device includes a motor (11) that is operable in a preselected voltage range. A switch assembly (110) controls the flow of electrical energy to the motor (11). A power module (14, 16) is configured to supply electric power and to mate with the low-voltage DC power tool (12). The power module (14, 16) is adapted to provide a DC voltage in the preselected voltage range suitable for powering the low-voltage DC power tool (12). A case (91) for the power tool (12) has a pre-defined envelope for electrically and mechanically mating with the power module (14, 16). A power interface that includes at least two terminals, electrically couples the power module (14, 16) to the motor (11). The thermal control circuit (49) protects the power interface from damage caused by an overtemperature level. The thermal control circuit (49), in response to detecting an operating temperature that exceeds the overtemperature level, permanently interrupts the flow of electricity from the power module (14, 16) to the motor (11).

Claims

1. A low-voltage DC power tool comprising:

a motor operable in a preselected voltage range for converting electrical energy to mechanical energy;

a switch assembly to control the flow of electrical energy to the motor;

a power module configured to supply electric power and to mate with the low-voltage DC power tool, said power module being adapted to provide a DC voltage in the preselected voltage range suitable for powering the low-voltage DC power tool;

a case having a pre-defined envelope for electrically and mechanically mating with the power module;

a power interface having at least two terminals to electrically couple the power module to the motor, a terminal having an operating temperature; and

a thermal control circuit to protect the terminal from damage caused by an overtemperature level such that the thermal control circuit, in response to detecting that the terminal operating temperature exceeds the overtemperature level, permanently interrupts the flow of electricity from the power module to the motor.

2. The power tool of claim 1 wherein the power module is a corded converter module electrically and mechanically configured to connect to a source of relatively high voltage electric power and to mate with the low-voltage DC power tool, said converter module being adapted to convert said relatively high voltage electric power from the source of electric power to a DC voltage in the preselected voltage range suitable for powering the low-voltage DC power tool.

3. The power tool of claim 2 wherein the corded converter module further includes a control circuit to regulate the conversion of the relatively high voltage electric power to the DC voltage.

4. The power tool of claim 1 wherein the power module is a cordless battery module mechanically and electrically configured to mate with the low-voltage DC power tool and to contain a battery assembly having a DC voltage in the preselected voltage range suitable for powering the low-voltage DC power tool, said battery module to provide power from the battery assembly to the DC power tool;

wherein the power tool is configured to receive power from either the corded converter module or the cordless battery module.

5. The power tool of claim 1 wherein the power interface further comprises a physical envelope configuration to accept either of said corded converter module and said cordless battery module.

6. The power tool of claim 5 wherein the power interface further comprises an electrical connector operative to electrically connect to an electrical connector attached to either of said corded converter module and said cordless battery module.

7. The power tool of claim 6 wherein the corded converter module electrical connector is a terminal block and the battery module electrical connector is a terminal block.

8. The power tool of claim 3 wherein the thermal control circuit is coupled to the converter module control circuit.

9. The power tool of claim 1 wherein the thermal control circuit is coupled to the switch assembly.

10. The power tool of claim 1 wherein the thermal control circuit includes a first temperature sensing device having a first state and a second state, being thermally coupled to a terminal of the power interface, wherein the terminal overtemperature condition causes the first temperature sensor to change state.

11. The power tool of claim 10 wherein the thermal control circuit further includes a heat pipe coupled between the terminal and the first temperature sensing device.

12. The power tool of claim 11 wherein the heat pipe is an electrical insulator.

13. The power tool of claim 10 wherein the thermal control circuit further includes an electrically insulating heat pipe coupled between at least two terminals of the power interface and the first temperature sensing device.

14. The power tool of claim 11 wherein the thermal control circuit further includes a second temperature sensor thermally coupled to the terminal for limiting the current flowing through the terminal in response to a sensed terminal temperature.

15. The power tool of claim 10 wherein the first temperature sensing device is located near the terminal of the power interface.

16. A low-voltage DC power tool comprising:

a motor operable in a preselected voltage range for converting electrical energy to mechanical energy;

a switch assembly to control the flow of electrical energy to the motor;

a corded converter module electrically and mechanically configured to connect to a source of relatively high voltage electric power and to mate with the low-voltage DC power tool, the converter module including a control circuit being adapted to regulate the conversion of relatively high voltage electric power from the source of electric power to a DC voltage in the preselected voltage range suitable for powering the low-voltage DC power tool;

a case having a pre-defined envelope for electrically and mechanically mating with the power module;

a power interface having at least two terminals to electrically couple the power supply module to the motor; and

a thermal control circuit, in response to sensing a terminal overtemperature condition, to permanently interrupt the flow of electricity from the converter module to the motor.

17. The power tool of claim 16 wherein the thermal control circuit is coupled to the converter module control circuit.

18. The power tool of claim 16 wherein the thermal control circuit is coupled to the switch assembly.

19. The power tool of claim 16 wherein the power interface comprises a first terminal block mounted to the converter module and a second terminal block mounted to the power tool.

20. The power tool of claim 16 wherein the thermal control circuit further includes a heat pipe coupled between the terminal and a first temperature sensing device.

21. The power tool of claim 20 wherein the heat pipe is an electrical insulator.

22. The power tool of claim 20 wherein the heat pipe is coupled between at least two terminals of the power interface and the first temperature sensing device.

23. The power tool of claim 16 wherein the thermal control circuit further includes a second temperature sensor thermally coupled to the terminal for limiting the current flowing through the terminal in response to a sensed terminal temperature.