Battery powered circular saw

• US 7,343,683 B2
• Filed: 01/09/2006
• Issued: 03/18/2008
• Est. Priority Date: 08/13/1998
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Bascom, James P, Moore, Keith, Buck, John E
• Primary Examiner(s): Ashley; Boyer D.
• Assistant Examiner(s): FLORES SANCHEZ, OMAR
• Application Number:
  US11/328,519
• Publication Number:
  US 20060107536A1
• Time in Patent Office: 799 Days
• Field of Search: 30D/IG.1, 303/75, 303/77, 303/88, 303/91, 303/90, 310/50, 310/47, 310/389, 310/391, 307/147, 307/150
• US Class Current: 30/388
• CPC Class Codes: B25F 5/02 Construction of casings, bodies or handles B25F5/006, B25F5/008 take precedence
• CPC Class Codes: B27B 9/02 Arrangements for adjusting the cutting depth or the amount of tilting
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• 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 50/543 Terminals
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10S 30/01 Rechargeable battery operated

Abstract

A battery powered circular saw includes a rechargeable battery removably attached to the housing and an adjustable shoe pivotally attached to the housing for controlling a depth of cut. A locking mechanism for preventing relative movement between the adjustable shoe and the housing includes a clamp that is located so as to permit the battery pack to be inserted to and removed from a rear end of the housing in a direction that is generally parallel to a plane in which the circular saw blade is disposed.

Claims

1. A circular saw comprising:

a housing;

a guard coupled to the housing;

a circular saw blade associated with the housing and laterally positioned within the guard, the circular saw blade being rotatable about a rotational axis;

a handle with a generally V-shaped portion coupled to the housing, the generally V-shaped portion being disposed generally transverse to the rotational axis and having a first end, a second end that is positioned rearward of the first end, an apex, which is disposed above the housing between the first and second ends;

a battery pack fixedly but releasably engaged to the housing;

a pair of grooves formed on one of the battery pack and the housing;

a pair of rails formed on the other one of the battery pack and the housing, the rails being configured to cooperate with the grooves to align the battery pack to the housing;

a shoe; and

an adjustment mechanism having a first bracket, a depth-of-cut member and a clamp, the first bracket being fixedly coupled to the shoe, the depth-of-cut member being pivotally coupled to the first bracket, the clamp including a first threaded member and a second threaded member, the first threaded member being movably coupled to the depth-of-cut member and extending through the housing, the second threaded member being threadably engaged to the first threaded member and being configured to translate the first threaded member to selectively secure the depth-of-cut member to the housing, the first threaded member being disposed between the rotational axis and an aft end of the battery pack when the battery rack is fixedly but releasably engaged to the housing, the second threaded member being disposed on a side of the housing opposite the circular saw blade;

wherein the battery pack includes a plurality of pack terminals and a battery, the pack terminals being disposed between the rails or grooves formed on the battery pack, wherein the pack terminals are associated with a top side of the battery pack and wherein at least a majority of the battery being disposed beneath the pack terminals and the rails or grooves formed on the battery pack;

wherein a center of gravity of the circular saw including the battery pack is located in-line with a center of the generally V-shaped portion;

wherein a trigger is mounted in an apex of the generally V-shaped portion; and

wherein the center of gravity is disposed in-line with the trigger in a direction that is perpendicular to both the rotational axis and a direction in which the battery pack is releasably engaged to the housing.

2. The circular saw of claim 1, wherein the first threaded member is disposed between the rotational axis and a forward end of the battery pack.

3. The circular saw of claim 2, wherein the first threaded member is disposed above a bottom surface of the battery pack when the battery pack is releasably engaged to the housing.

4. The circular saw of claim 1, wherein the first threaded member is disposed above a bottom surface of the battery pack when the battery pack is releasably engaged to the housing.

5. The circular saw of claim 1, wherein the shoe is positionable into at least one position in which at least a portion of the battery pack is disposed rearwardly of a rear side of the shoe.

6. The circular saw of claim 1, wherein the shoe is positionable in a position in which the line along which the battery pack is insertable into and removable from the battery connection portion is generally parallel to a bottom surface of the shoe.

7. The circular saw of claim 1, wherein the clamp includes a clamp lever that is rotatably mounted to the housing, the clamp lever being disposed on a side of the battery pack opposite the circular saw blade.

8. The circular saw of claim 1, wherein the battery pack is laterally centered to the handle when the battery pack is positioned in the fully inserted position.

9. The circular saw of claim 1, wherein a recess is formed in one of the battery pack and the housing and a latch is carried by the other one of the battery pack and the housing, the latch cooperating with the recess to retain the battery pack to the housing when the battery pack is positioned in the fully inserted position.

10. The circular saw of claim 9, wherein the latch includes a latch release and a latch member, the latch member being received into the latch recess when the battery pack is positioned in the fully inserted position, the latch release being operable for selectively retracting the latch member to permit the battery pack to be removed from the housing.

11. The circular saw of claim 9, wherein the recess is formed in a top surface of the battery pack.

12. The circular saw of claim 1, wherein the tool terminal block includes a plurality of tool terminals and the battery terminal block includes a plurality of pack terminals, at least a portion of the pack terminals engaging the tool terminals when the battery pack is positioned in the fully inserted position.

13. The circular saw of claim 12, wherein one of the tool terminals and the pack terminals is a male spade terminal and the other one of the tool terminals and the pack terminals is a female terminal into which an associated one of the male spade terminals is slidingly received.

14. The circular saw of claim 12, wherein the battery pack includes a first keying feature and the housing includes a second keying feature, the first and second keying features cooperating to align the pack terminals and the tool terminals when the battery pack is moved to the fully inserted position.

15. The circular saw of claim 14, wherein the first keying feature is disposed between two of the pack terminals.

16. The circular saw of claim 14, wherein one of the first and second keying features is a tab.

17. The circular saw of claim 16, wherein the other one of the first and second keying features is an opening.

21. The circular saw of claim 14, wherein the second keying feature is disposed between two of the tool terminals.

18. A circular saw comprising:

a housing;

a circular saw blade associated with the housing and rotatable about a rotational axis;

a handle with a generally V-shaped portion coupled to the housing, the generally V-shaped portion being disposed generally transverse to the rotational axis and having a first end, a second end that is positioned rearward of the first end, an apex, which is disposed above the housing between the first and second ends;

a battery pack fixedly but releasably engaged to the housing;

a pair of grooves formed on one of the battery pack and the housing;

a pair of rails formed on the other one of the battery pack and the housing, the rails being configured to cooperate with the grooves to align the battery pack to the housing such that a center of the battery pack is laterally aligned to a center of the generally V-shaped portion;

a shoe; and

an adjustment mechanism having a first bracket, a depth-of-cut member and a clamp, the first bracket being fixedly coupled to the shoe, the depth-of-cut member being pivotally coupled to the first bracket and having an arcuate groove formed therein, the clamp including a first threaded member and a second threaded member, the first threaded member having a non-circular portion that is disposed in the arcuate groove of the depth-of-cut member, the first threaded member extending through the housing, the second threaded member being threadably engaged to the first threaded member and being configured to translate the first threaded member relative to the housing to selectively secure the depth-of-cut member to the housing, the first threaded member being disposed between the rotational axis and an aft end of the battery pack when the battery pack is fixedly but releasably engaged to the housing, the second threaded member being disposed on a side of the housing opposite the circular saw blade;

wherein a center of gravity of the circular saw including the battery pack is located in-line with a center of the generally V-shaped portion, wherein a trigger is mounted in an apex of the generally V-shaped portion and wherein the center of gravity is disposed in-line with the trigger in a direction that is perpendicular to both the rotational axis and a direction in which the battery pack is releasably engaged to the housing.

19. A circular saw comprising:

a housing;

a guard coupled to the housing;

a circular saw blade associated with the housing and laterally positioned within the guard, the circular saw blade being rotatable about a rotational axis;

a handle with a generally V-shaped portion coupled to the housing, the generally V-shaped portion being disposed generally transverse to the rotational axis and having a first end, a second end that is positioned rearward of the first end, an apex, which is disposed above the housing between the first and second ends;

a battery pack fixedly but releasably engaged to the housing;

a pair of grooves formed on one of the battery pack and the housing;

a pair of rails formed on the other one of the battery pack and the housing, the rails being configured to cooperate with the grooves to align the battery pack to the housing;

a shoe; and

an adjustment mechanism having a first bracket, a depth-of-cut member and a clamp, the first bracket being fixedly coupled to the shoe, the depth-of-cut member being pivotally coupled to the first bracket, the clamp including a first threaded member and a second threaded member, the first threaded member being movably coupled to the depth-of-cut member and extending through the housing, the second threaded member being threadably engaged to the first threaded member and being configured to translate the first threaded member to selectively secure the depth-of-cut member to the housing, the first threaded member being disposed between the rotational axis and an aft end of the battery pack when the battery pack is fixedly but releasably engaged to the housing, the second threaded member being disposed on a side of the housing opposite the circular saw blade;

wherein the battery pack includes a plurality of pack terminals and a battery, the pack terminals being disposed between the rails or grooves formed on the battery pack, wherein the pack terminals are associated with a top side of the battery pack and wherein at least a majority of the battery being disposed beneath the pack terminals and the rails or grooves formed on the battery pack;

wherein a center of gravity of the circular saw including the battery pack is located in-line with a center of the generally V-shaped portion;

wherein a trigger is mounted in an apex of the generally V-shaped portion; and

wherein the center of gravity is disposed in-line with the trigger in a direction that is perpendicular to both the rotational axis and a direction in which the battery pack is releasably engaged to the housing;

wherein the first threaded member is disposed between the rotational axis and a forward end of the battery pack;

wherein the first threaded member is disposed above a bottom surface of the battery pack when the battery pack is releasably engaged to the housing; and

wherein the first threaded member is disposed above a bottom surface of the battery pack when the battery pack is releasably engaged to the housing.

20. A circular saw comprising:

a housing;

a guard coupled to the housing;

a circular saw blade associated with the housing and laterally positioned within the guard, the circular saw blade being rotatable about a rotational axis;

a handle with a generally V-shaped portion coupled to the housing, the generally V-shaped portion being disposed generally transverse to the rotational axis and having a first end, a second end that is positioned rearward of the first end, an apex, which is disposed above the housing between the first and second ends;

a battery pack fixedly but releasably engaged to the housing;

a pair of grooves formed on one of the battery pack and the housing;

a pair of rails formed on the other one of the battery pack and the housing, the rails being configured to cooperate with the grooves to align the battery pack to the housing;

a shoe; and

an adjustment mechanism having a first bracket, a depth-of-cut member and a clamp, the first bracket being fixedly coupled to the shoe, the depth-of-cut member being pivotally coupled to the first bracket, the clamp including a first threaded member and a second threaded member, the first threaded member being movably coupled to the depth-of-cut member and extending through the housing, the second threaded member being threadably engaged to the first threaded member and being configured to translate the first threaded member to selectively secure the depth-of-cut member to the housing, the first threaded member being disposed between the rotational axis and an aft end of the battery pack when the battery pack is fixedly but releasably engaged to the housing, the second threaded member being disposed on a side of the housing opposite the circular saw blade;

wherein a center of gravity of the circular saw including the battery pack is located in-line with a center of the generally V-shaped portion;

wherein a trigger is mounted in an apex of the generally V-shaped portion; and

wherein the center of gravity is disposed in-line with the trigger in a direction that is perpendicular to both the rotational axis and a direction in which the battery pack is releasably engaged to the housing.