Universal power tool battery pack coupled to a portable internal combustion engine

• US 8,759,991 B2
• Filed: 07/29/2011
• Issued: 06/24/2014
• Est. Priority Date: 06/06/2002
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Grant, Jeffrey P., Forster, Michael K.
• Primary Examiner(s): GONZALEZ, JULIO CESAR
• Application Number:
  US13/193,818
• Publication Number:
  US 20110285358A1
• Time in Patent Office: 1,061 Days
• Field of Search: 290/1.A, 290/34, 290/38.R, 322/10, 322/16, 322/29, 439/504, 439/500, 320/112, 320/114, 320/137
• US Class Current: 290/1.A
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02B 63/047 Movable engine-generator combinations on wheels
• CPC Class Codes: F02N 11/0862 characterised by the electrical power supply means, e.g. battery
• CPC Class Codes: F02N 11/14 Starting of engines by means of electric starters with external current supply F02N11/12 takes precedence
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle

Abstract

A portable internal combustion engine and a charging device that generates AC power are supported on a manually movable frame. A coupling mechanism which can include a starter circuit and starting device, or a charging circuit and charging device, or both device couples a battery receptacle terminal block to the internal combustion engine. The battery receptacle can include various features to permit and retain electrical coupling between a battery pack for a cordless power tool. For example, key protrusions and corresponding recesses can be associating with latching projections. Additionally or alternatively, cooperating rails and recesses may be associated with the battery pack and receptacle, respectively. Spring loaded movable clips or resilient flexing clips can be included to act on the battery pack. An electrical cord may also be used to couple receptacle terminals to the coupling mechanism.

Claims

1. An electro-mechanical device comprising:

an internal combustion engine supported on a manually movable frame;

a battery receptacle associated with the manually movable frame, the battery receptacle comprising a receptacle terminal block coupled to the internal combustion engine via a coupling mechanism, the receptacle terminal block being associated with a distal end of a tower receptacle and comprising a positive receptacle contact and a negative receptacle contact;

a battery pack for a cordless power tool having a battery terminal block associated with a distal end of a battery tower, the battery terminal block comprising a positive battery contact located and configured to make electrical contact with the positive receptacle contact, and a negative battery contact located and configured to make contact with the negative receptacle contact when the battery pack is inserted into the battery receptacle;

the battery receptacle further comprising a retention clip biased toward a retention position in which the retention clip continuously exerts a biasing force on the battery pack to urge the battery tower into the tower receptacle to retain the positive and negative battery contacts in electrical communication with the corresponding positive and negative receptacle contacts, and the retention clip being manually movable into an open position in which the battery tower may be removed or inserted into the tower receptacle; and

wherein the coupling mechanism is one of;

a starting circuit electrically coupling the positive and negative contacts to a starting device during a starting operation, the starting device being coupled to the internal combustion engine and being configured to start the internal combustion engine using electrical power provided by the cordless power tool battery pack during the starting operation;

a charging circuit electrically coupling the positive and negative contacts to a charging device during a charging operation, the charging device being coupled to the internal combustion engine and being configured to charge the cordless power tool battery pack during the charging operation;

or both.

2. The electro-mechanical device of claim 1, wherein the biasing force is exerted on the battery pack via contact between an outer side of the battery pack opposing the distal end of the tower receptacle and the retention clip, when the retention clip is in the retention position.

3. The electro-mechanical device of claim 2, wherein the retention clip is configured to resist at least part of a weight of the battery pack via contact between a bottom side of battery pack and the retention clip, when the retention clip is in the retention position.

4. The electro-mechanical device of claim 1, wherein a spring member provides the biasing force.

5. The electro-mechanical device of claim 2, wherein the battery receptacle has two opposite lateral sides, and wherein the positive receptacle contact is associated with a first side of the tower receptacle corresponding to one of the two opposite lateral sides and the negative receptacle contact is associated with a second side of the tower receptacle corresponding to the other of the two opposite lateral sides.

6. The electro-mechanical device of claim 5, wherein the battery receptacle further comprises a temperature receptacle contact associated with a front wall of the tower receptacle located between the first and second sides, wherein the battery pack further comprises a temperature battery contact located and configured to make electrical contact with the temperature receptacle contact;

and wherein the temperature receptacle contact is electrically coupled to the charging circuit.

7. The electro-mechanical device of claim 2, wherein the battery receptacle has two opposite lateral sides, a front side, and a back side and wherein the receptacle terminal block comprises a positive receptacle contact extending from an end wall of the tower receptacle and located adjacent a back side of the tower receptacle corresponding to the back side of the battery receptacle, and a negative receptacle contact extending from an end wall of the tower receptacle and located adjacent a front side of the tower receptacle corresponding to the front side of the battery receptacle.

8. The electro-mechanical device of claim 5, wherein the receptacle terminal block further comprises a first intermediate pair of chemistry sensor receptacle contacts extending from an end wall of the tower receptacle in side-by-side relation and located between the positive and negative receptacle contacts and adjacent the positive receptacle contact, and a second intermediate pair of chemistry sensor receptacle contacts extending from the end wall of the tower receptacle in side-by-side relation and located between the positive and negative receptacle contacts and adjacent the negative receptacle contact, and wherein the battery pack further comprises a cooperating first intermediate pair of chemistry sensor battery contacts located and configured to make electrical contact with the first intermediate pair of chemistry sensor receptacle contacts, and a second intermediate pair of chemistry sensor battery contacts located and configured to make electrical contact with the second intermediate pair of chemistry sensor receptacle contacts;

and wherein the first and second pair of chemistry sensor receptacle contacts are electrically coupled to the charging circuit.

9. An electro-mechanical device comprising:

an internal combustion engine supported on a manually movable frame;

a battery receptacle associated with the manually movable frame, the battery receptacle having two opposite lateral sides and a receptacle terminal block coupled to the internal combustion engine via a coupling mechanism, the receptacle terminal block comprising a terminal end defined by two opposite lateral side walls and a terminal face extending generally perpendicular to and between the two opposite lateral side walls, a positive receptacle contact associated with the terminal face and adjacent one of the two opposite lateral side walls, a negative receptacle contact associated with the terminal face and adjacent the other of the two opposite lateral side walls, and a recess in an offset intermediate position of the terminal face between the positive and negative receptacle contacts;

the battery receptacle further comprising an outwardly directed rail recess extending along each of the two opposite lateral sides;

a battery pack for a cordless power tool having a battery terminal block associated with an end of a recessed area of an upper side of the battery pack, the battery terminal block comprising a positive battery contact located and configured to make electrical contact with the positive receptacle contact, and a negative battery contact located and configured to make electrical contact with the negative receptacle contact when the battery pack is inserted into the battery receptacle, and an divider wall in an offset intermediate position between the positive and negative battery contacts and configured to extend into the recess when the battery pack is inserted into the battery receptacle;

the battery pack further comprising an inwardly directed coupling rail associated with each opposite lateral side of the recessed area and each rail being configured to cooperate with one of the rail recesses to retain the battery pack to the battery receptacle when the battery pack is coupled to the battery receptacle,

wherein the coupling mechanism is one of;

a starting circuit electrically coupling the positive and negative contacts to a starting device during a starting operation, the starting device being coupled to the internal combustion engine and being configured to start the internal combustion engine using electrical power provided by the cordless power tool battery pack during the starting operation;

a charging circuit electrically coupling the positive and negative contacts to a charging device during a charging operation, the charging device being coupled to the internal combustion engine and being configured to charge the cordless power tool battery pack during the charging operation;

or both.

10. The electro-mechanical device of claim 9, wherein the battery receptacle further comprises a key in the form of a projection, and the battery pack further comprises a key recess configured to cooperate with the projection to permit coupling of a corresponding battery pack with the battery receptacle.

11. The electro-mechanical device of claim 9, wherein the battery receptacle further comprises a latch recess associated with each of the two opposite lateral sides, and the battery pack further comprises a latch projection on each opposite lateral side of the recessed area that is associated with a manually actuatable push button, the latch projection being configured to cooperate with the latch recess to retain the battery pack and receptacle together, and being movable into an unlatched position upon actuation of the push-button to permit removal of the battery pack from the battery receptacle.

12. The electro-mechanical device of claim 9, wherein the receptacle terminal block further comprises a temperature receptacle contact associated with the terminal face and located between one of the first and second walls and the recess;

and wherein the battery pack further comprises a temperature battery contact located between one of the positive and negative battery contacts and the divider wall, the temperature battery contact being configured to make electrical contact with the temperature receptacle contact; and

wherein the temperature receptacle contact is electrically coupled to the charging circuit.

13. An electro-mechanical device comprising:

an internal combustion engine supported on a manually movable frame;

a battery receptacle associated with the manually movable frame, the battery receptacle having two opposite lateral sides and a receptacle terminal block coupled to the internal combustion engine via a coupling mechanism, the receptacle terminal block comprising a terminal end defined by two opposite lateral side walls and a terminal face extending generally perpendicular to and between the two opposite lateral side walls, a positive receptacle contact associated with the terminal face and adjacent one of the two opposite lateral side walls, a negative receptacle contact associated with the terminal face and adjacent the other of the two opposite lateral side walls;

the battery receptacle further comprising an inwardly directed rail recess extending along each of the two opposite lateral sides;

a battery pack for a cordless power tool having a battery terminal block associated with an end of a recessed area of an upper side of the battery pack, the battery terminal block comprising a positive battery contact located and configured to make electrical contact with the positive receptacle contact, and a negative battery contact located and configured to make electrical contact with the negative receptacle contact when the battery pack is inserted into the battery receptacle;

the battery pack further comprising an outwardly directed coupling rail associated with each opposite lateral side of the recessed area and each rail being configured to cooperate with one of the rail recesses to retain the battery pack to the battery receptacle;

the inwardly directed rail recess of the battery receptacle comprising a sloping surface and the outwardly directed coupling rail comprises a cooperating surface, wherein the sloping surface and the cooperating sloping surface are configured to cause a friction fit between the battery pack and the battery receptacle, thereby resisting removal of the battery pack from the battery receptacle,

wherein the coupling mechanism is one of;

a starting circuit electrically coupling the positive and negative contacts to a starting device during a starting operation, the starting device being coupled to the internal combustion engine and being configured to start the internal combustion engine using electrical power provided by the cordless power tool battery pack during the starting operation;

a charging circuit electrically coupling the positive and negative contacts to a charging device during a charging operation, the charging device being coupled to the internal combustion engine and being configured to charge the cordless power tool battery pack during the charging operation;

or both.

14. The electro-mechanical device of claim 13, wherein the receptacle terminal block further comprises a protrusion centrally located on the terminal face, and the battery pack further comprises an arm associated with a manually actuatable push button, and wherein the arm pushes on the protrusion to facilitate release of the battery pack from the battery receptacle, upon manual actuation of the push button.

15. An electro-mechanical device comprising:

an internal combustion engine supported on a manually movable frame;

a battery receptacle associated with the manually movable frame, the battery receptacle having two opposite lateral sides and a receptacle terminal block coupled to the internal combustion engine via a coupling mechanism, the receptacle terminal block comprising a terminal end defined by two opposite lateral side walls and a terminal face extending generally perpendicular to and between the two opposite lateral side walls, a positive receptacle contact associated with the terminal face and adjacent one of the two opposite lateral side walls, a negative receptacle contact associated with the terminal face and adjacent the other of the two opposite lateral side walls;

the battery receptacle further comprising an inwardly directed rail recess extending along each of the two opposite lateral sides;

a battery pack for a cordless power tool having a battery terminal block associated with an end of a recessed area of an upper side of the battery pack, the battery terminal block comprising a positive battery contact located and configured to make electrical contact with the positive receptacle contact, and a negative battery contact located and configured to make electrical contact with the negative receptacle contact when the battery pack is inserted into the battery receptacle;

the battery pack further comprising an outwardly directed coupling rail associated with each opposite lateral side of the recessed area and each rail being configured to cooperate with one of the rail recesses to retain the battery pack to the battery receptacle;

the receptacle terminal block further comprises a first receptacle temperature contact associated with the terminal face and adjacent the positive receptacle contact, and a second receptacle temperature contact associated with the terminal face and adjacent the positive receptacle contact; and

wherein the battery pack further comprises a first battery temperature contact configured to electrically couple with the first receptacle temperature contact and a second battery temperature contact configured to electrically couple with the second receptacle temperature contact, when the battery pack is received in the battery receptacle;

wherein the coupling mechanism is one of;

a starting circuit electrically coupling the positive and negative contacts to a starting device during a starting operation, the starting device being coupled to the internal combustion engine and being configured to start the internal combustion engine using electrical power provided by the cordless power tool battery pack during the starting operation;

a charging circuit electrically coupling the positive and negative contacts to a charging device during a charging operation, the charging device being coupled to the internal combustion engine and being configured to charge the cordless power tool battery pack during the charging operation;

or both.

16. The electro-mechanical device of claim 15, wherein the battery receptacle further comprises a latch recess, and the battery pack further comprises a latch member associated with a manually actuatable push button, and wherein the latch member cooperates with the latch recess to couple the battery pack to the battery receptacle in a latched position;

and the latch member moves to an unlatched position permitting uncoupling of the battery pack from the battery receptacle, upon manual actuation of the push button.

17. An electro-mechanical device comprising:

an internal combustion engine supported on a manually movable frame;

a battery receptacle associated with the manually movable frame, the battery receptacle having two opposite lateral sides and a receptacle terminal block coupled to the internal combustion engine via a coupling mechanism, the receptacle terminal block comprising a terminal end defined by two opposite lateral side walls and a terminal face extending generally perpendicular to and between the two opposite lateral side walls, a positive receptacle contact associated with the terminal face and adjacent one of the two opposite lateral side walls, a negative receptacle contact associated with the terminal face and adjacent the other of the two opposite lateral side walls;

the battery receptacle further comprising an inwardly directed rail recess extending along each of the two opposite lateral sides;

a battery pack for a cordless power tool having a battery terminal block associated with an end of a recessed area of an upper side of the battery pack, the battery terminal block comprising a positive battery contact located and configured to make electrical contact with the positive receptacle contact, and a negative battery contact located and configured to make electrical contact with the negative receptacle contact when the battery pack is inserted into the battery receptacle;

the battery pack further comprising an outwardly directed coupling rail associated with each opposite lateral side of the recessed area and each rail being configured to cooperate with one of the rail recesses to retain the battery pack to the battery receptacle;

the battery receptacle further comprises a key recess adjacent the inwardly directed rail recess, and the battery pack further comprises a key projection adjacent an end of the outwardly directed coupling rail configured to cooperate with the key recess to allow coupling of the battery pack with the battery receptacle;

wherein the coupling mechanism is one of;

a starting circuit electrically coupling the positive and negative contacts to a starting device during a starting operation, the starting device being coupled to the internal combustion engine and being configured to start the internal combustion engine using electrical power provided by the cordless power tool battery pack during the starting operation;

a charging circuit electrically coupling the positive and negative contacts to a charging device during a charging operation, the charging device being coupled to the internal combustion engine and being configured to charge the cordless power tool battery pack during the charging operation;

or both.