Cordless power system

• US 20060087286A1
• Filed: 10/14/2005
• Published: 04/27/2006
• Est. Priority Date: 10/18/2004
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Francis, Jeffrey J., Carrier, David A., Brotto, Daniele C., Phillips, Steven J., Seman, Andrew E. Jr., White, Daniel J., Yahnker, Christopher R., Watson, James B., Trinh, Danh T.
• Granted Patent: US 7,688,028 B2
• 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: B25F 5/02 Construction of casings, bodies or handles B25F5/006, B25F5/008 take precedence
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/247 specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 6/42 Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02J 7/0063 with circuits adapted for supplying loads from the battery
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process
• CPC Class Codes: H02J 7/00714 in response to battery charging or discharging current
• CPC Class Codes: H02J 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/007194 : of the battery
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

A cordless system has cordless system components that include a cordless device, such as a cordless power tool, a battery pack and a charger. The battery pack is mated with either the cordless device to provide power to operate the cordless device or to the charger to charge the battery cells in the battery pack. In an aspect, the cordless system has an identification and communication system by which the battery pack identifies and communicates information about the battery pack to the cordless device or to the charger to which the battery pack is mated. In an, the battery pack of the cordless system is capable of multiple modes, such as controlling the cordless device and controlling the charger. In an aspect, the battery pack validates the cordless device or charger to which it is mated in an aspect of the invention, the cordless system uses any of a wired interface, radio frequency interface, an optical interface or a magnetic interface to communicate information between the battery pack and the cordless device or charger to which the battery pack is mated. In an aspect, female terminals are used in a terminal block of the battery pack to protect against foreign objects contacting the terminals. In aspect, the terminals in the terminal block of the battery pack are staggered or scattered to reduce the likelihood of a short circuit. In an aspect of the invention, the battery pack has a trap door that closes when the battery pack is not mated to a cordless device or charger to protect the terminal block of the battery pack. In an aspect of the invention, multi-spring, split contact terminals are used in the terminal block of at least one of the cordless system components. In an aspect of the invention, the battery cells are Lithium Ion battery cells.

Claims

1. A multi-mode battery pack for a cordless power tool, comprising:

a housing in which a plurality of battery cells are disposed; and

a controller that in a first mode controls a power tool when the battery pack is coupled to the power tool and in a second mode controls a charger when the battery pack is coupled to the charger.

2. The apparatus of claim 1 wherein the plurality of battery cells include a plurality of Lithium Ion battery cells.

3. The apparatus of claim 1 wherein the controller of the battery pack controls a discharge profile of the cordless power tool when in the first mode and controls a charge profile of the charger when in the second mode.

4. The apparatus of claim 1 wherein the battery pack controller validates the power tool when the battery pack is coupled to the power tool and enables the battery pack to operate with the power tool only when it determines that the power tool is a valid power tool.

5. The apparatus of claim 4 wherein the battery pack controller validates the charger when the battery pack is coupled to the charger and enables the battery pack to operate with the charger only when it determines that the charger is a valid charger.

6. A multi-mode battery pack for a cordless power tool, comprising:

a housing in which a plurality of battery cells are disposed; and

a controller that in a first mode determines whether to control a power tool when the battery pack is coupled to the power tool and in a second mode determines whether to control a charger when the battery pack is coupled to the charger.

7. The apparatus of claim 6 wherein when the battery pack is coupled to the power tool, the battery pack controller determines whether the power tool is a smart power tool or a dumb power tool.

8. The apparatus of claim 7 wherein upon determining that the battery pack is coupled to a smart power tool, the battery pack controller is set to a slave to a controller in the power tool and exchanges data with the power tool controller for use by the power tool controller in controlling the power tool, and upon determining that the battery pack is coupled to a dumb power tool, the battery pack controller controlling the dumb power tool.

9. The apparatus of claim 8 wherein the battery pack controller validates the power tool when the battery pack is coupled to the smart power tool and enables the battery pack to operate with the smart power tool only when it determines that the smart power tool is a valid power tool.

10. The apparatus of claim 9 wherein the power tool controller reads a trigger potentiometer of the power tool and sets a speed and discharge profile based on the data exchanged between the battery pack controller and the power tool controller and the trigger potentiometer reading by which the power tool controller controls a motor of the power tool.

11. The apparatus of claim 7 wherein the battery pack controller in controlling the dumb power tool, initializes discharge parameters, reads a trigger potentiometer of the dumb power tool and sets a speed and discharge profile to control a motor of the dumb power tool based on the discharge parameters and trigger potentiometer reading.

12. The apparatus of claim 6 wherein when the battery pack is coupled to the charger, the battery pack controller determines whether the charger is a smart charger and upon determining that the charger is a smart charger, exchanges data with a controller of the charger for use by the charger controller in controlling the charger.

13. The apparatus of claim 12 wherein when the battery pack controller determines that the charger is a smart charger, the battery pack controller is set to a master and a charger controller is set to a slave.

14. The apparatus of claim 13 wherein the battery pack controller validates the charger when the battery pack is coupled to the charger and enables the battery pack to operate with the charger only when it determines that the charger is a valid charger.

15. A multi-mode battery pack for a cordless power tool, comprising:

a housing in which a plurality of battery cells are disposed;

a controller that determines whether the battery pack is coupled to a power tool or to a charger;

the controller in a first mode upon determining that the battery pack is coupled to the power-tool and determining whether the power tool is a smart power tool or a dumb power tool, the controller upon determining that the battery pack is coupled to a smart power tool, validates the smart power tool and enables the battery pack to operate with the smart power tool only when it determines that the smart power tool is a valid power tool, and upon determining that the smart power tool is a valid power tool, the battery pack controller set to a slave and exchanging information with a power tool controller for use by the power tool controller in controlling the smart power tool, and upon determining that the battery pack is coupled to a dumb power tool, the battery pack controller controlling the dumb power tool; and

the controller in a second mode upon determining that the battery pack is coupled to a charger, when in the second mode, the battery pack controller determining whether the charger is a smart charger and upon determining that the charger is a smart charger, validating the smart charger and enabling the battery pack to operate with the smart charger only when the battery pack controller determines that the smart charger is a valid charger, the battery pack controller upon determining that the smart charger is a valid charger, exchanging data with a controller of the charger for use by the charger controller in controlling the charger.

16. The apparatus of claim 15 wherein the battery cells include Lithium Ion battery cells.

17. A battery pack for a cordless power tool system that includes a plurality of system components, the battery pack comprising a housing in which a plurality of battery cells are disposed and a controller that validates the system component to which the battery pack is coupled and enabling the battery pack to operate with that system component only upon determining that the system component is valid system component.

18. The apparatus of claim 17 wherein the plurality of system components include a cordless power tool and a charger.

19. The apparatus of claim 17 wherein the plurality of battery cells include a plurality of Lithium Ion battery cells.

20. A battery pack for a cordless power tool system that includes a plurality of system components, the battery pack comprising a housing in which a plurality of battery cells are disposed and a controller that determines, when the battery pack is coupled to a system component, whether the system component is a smart system component having a controller or a dumb system component that does not have a controller.

21. The apparatus of claim 20 wherein the plurality of system components include a cordless power tool and a charger.

22. The apparatus of claim 20 wherein the plurality of system components include a cordless power tool and upon determining that the power tool is a smart system component, the battery pack controller is set to a slave to the power tool controller and exchanges data with the power tool controller for use by the power tool controller in controlling the power tool, and upon determining that the power tool is a dumb system component, the battery pack controller controlling the dumb power tool.

23. The apparatus of claim 22 wherein the power tool controller when the power tool is a smart system component reads a trigger potentiometer of the power tool and sets a speed and discharge profile based on data exchanged between the battery pack controller and the power tool controller and the trigger potentiometer reading by which the power tool controller controls a motor of the power tool.

24. The apparatus of claim 22 wherein the battery pack controller in controlling the dumb power tool initializes discharge parameters, reads a trigger potentiometer of the dumb power tool and sets a speed and discharge profile to control a motor of the dumb power tool based on the discharge parameters and trigger potentiometer reading.

25. The apparatus of claim 20 wherein the plurality of system components include a charger and upon determining that the charger is a smart system component, the battery pack controller exchanges data with the charger controller for use by the charger controller in controlling the charger.

26. The apparatus of claim 25 wherein when the battery pack controller determines that the charger is a smart system component, the battery pack controller is set to a master and the charger controller is set to a slave.

27. The apparatus of claim 20 wherein the plurality of battery cells include a plurality of Lithium Ion battery cells.

28. A cordless power tool system, comprising a plurality of system components including a battery pack, a cordless power tool, and a charger, the battery pack including a housing in which a plurality of battery cells are disposed, the battery pack having a controller that in a first mode controls the power tool when the battery pack is coupled to the power tool and in a second mode controls a charger when the battery pack is coupled to the charger.

29. The apparatus of claim 28 wherein the plurality of battery cells include Lithium Ion battery cells.

30. The apparatus of claim 29 wherein the controller of the battery pack controls a discharge profile of the cordless power tool when in the first mode and controls a charge profile of the charger when in the second mode.

31. The apparatus of claim 28 wherein the battery pack controller validates the power tool when the battery pack is coupled to the power tool and enables the battery pack to operate with the power tool only when it determines that the power tool is a valid power tool.

32. The apparatus of claim 31 wherein the battery pack controller validates the charger when the battery pack is coupled to the charger and enables the battery pack to operate with the charger only when it determines that the charger is a valid charger.

33. A cordless power tool system, comprising a plurality of system components including a battery pack, a cordless power tool, and a charger, the battery pack including a housing in which a plurality of battery cells are disposed;

and a controller that in a first mode determines whether to control the power tool when the battery pack is coupled to the power tool and in a second mode determines whether to control the charger when the battery pack is coupled to the charger.

34. The apparatus of claim 33 wherein when the battery pack is coupled to the power tool, the battery pack controller determines whether the power tool is a smart power tool or a dumb power tool.

35. The apparatus of claim 34 wherein upon determining that the battery pack is coupled to a smart power tool, the battery pack controller is set to a slave to a controller in the power tool and exchanges data with the power tool controller that the power tool controller uses in controlling the power tool, and upon determining that the battery pack is coupled to a dumb power tool, the battery pack controller controlling the dumb power tool.

36. The apparatus of claim 35 wherein the battery pack controller validates the power tool when the battery pack is coupled to the smart power tool and enables the battery pack to operate with the smart power tool only when it determines that the smart power tool is a valid power tool.

37. The apparatus of claim 36 wherein the power tool controller reads a trigger potentiometer of the power tool and sets a speed and discharge profile based on the data exchanged between the battery pack controller and the power tool controller and the trigger potentiometer reading by which the power tool controller controls a motor of the power tool.

38. The apparatus of claim 34 wherein the battery pack controller in controlling the dumb power tool, initializes discharge parameters, reads a trigger potentiometer of the dumb power tool and sets a speed and discharge profile to control a motor of the dumb power tool based on the discharge parameters and trigger potentiometer reading.

39. The apparatus of claim 33 wherein when the battery pack is coupled to the charger, the battery pack controller determines whether the charger is a smart charger and upon determining that the charger is a smart charger, exchanges data with a controller of the charger for use by the charger controller in controlling the charger.

40. The apparatus of claim 39 wherein when the battery pack controller determines that the charger is a smart charger, the battery pack controller is set to a master and a charger controller is set to a slave.

41. The apparatus of claim 40 wherein the battery pack controller validates the charger when the battery pack is coupled to the charger and enables the battery pack to operate with the charger only when it determines that the charger is a valid charger.

42. A cordless power tool system, comprising a plurality of system components including a battery pack and a cordless power tool, the battery pack including a housing in which a plurality of battery cells are disposed and a controller that validates the system component to which the battery pack is coupled and enabling the battery pack to operate with that system component only upon determining that the system component is valid system component.

43. The apparatus of claim 42 wherein the plurality of battery cells include a plurality of Lithium Ion battery cells.

44. The apparatus of claim 42 wherein the plurality of system components include a charger.

45. A cordless power tool system, comprising a plurality of system components including a battery pack and a cordless power tool, the battery pack comprising a housing in which a plurality of battery cells are disposed and a controller that determines, when the battery pack is coupled to a system component, whether the system component is a smart system component having a controller or a dumb system component that does not have a controller.

46. The apparatus of claim 45 wherein the plurality of battery cells include a plurality of Lithium Ion battery cells.

47. The apparatus of claim 45 wherein the system component to which the battery pack is coupled is the power tool and upon the battery pack controller determining that the power tool is a smart system component, the battery pack controller is set to a slave to the power tool controller and exchanges data with the power tool controller that the power tool controller uses in controlling the power tool, and upon determining that the power tool is a dumb system component, the battery pack controller controlling the dumb power tool.

48. The apparatus of claim 47 wherein the power tool controller when the power tool is a smart system component reads a trigger potentiometer of the power tool and sets a speed and discharge profile based on data exchanged between the battery pack controller and the power tool controller and the trigger potentiometer reading by which the power tool controller controls a motor of the power tool.

49. The apparatus of claim 47 wherein the battery pack controller in controlling the dumb power tool initializes discharge parameters, reads a trigger potentiometer of the dumb power tool and sets a speed and discharge profile to control a motor of the dumb power tool based on the discharge parameters and trigger potentiometer reading.

50. The apparatus of claim 45 wherein the plurality of system components include a charger, and, when the battery pack is coupled to the charger, the battery pack controller upon determining that the charger is a smart system component exchanges data with the charger controller that the charger controller uses in controlling the charger.

51. The apparatus of claim 50 wherein when the battery pack controller determines that the charger is a smart system component, the battery pack controller is set to a master and the charger controller is set to a slave.

52. In a cordless power tool system having a plurality of system components including a battery pack, a cordless power tool and a charger, a method of controlling the cordless power tool and the charger comprising controlling the power tool with a controller of the battery pack when the battery pack is coupled to the power tool and controlling the charger with the battery pack controller when the battery pack is coupled to the charger.

53. The method of claim 52 including validating the system component to which the battery pack is coupled and enabling the battery pack to operate with the system component to which it is coupled only upon determining that the system component is a valid system component.

54. In a cordless power tool system having a plurality of system components including a battery pack, a cordless power tool and a charger, a method of controlling the cordless power tool and the charger comprising when the battery pack is coupled to the power tool determining whether to control the power tool with a controller of the battery pack and determining whether to control the charger with the battery pack controller when the battery pack is coupled to the charger.

55. The method of claim 54 including determining whether when the battery pack is coupled to the power tool whether the power tool is a smart power tool having a controller and upon determining that the power tool is a smart power tool, setting the battery pack control to a slave of the power tool controller, exchanging data between the battery pack controller and the power tool controller and controlling the power tool with the power tool controller using the data exchanged, and controlling the power tool with the battery pack controller upon determining that the power tool is a dumb power tool.

56. The method of claim 55 including validating the smart power tool when the battery pack is coupled to the smart power tool and enabling battery pack to operate with the smart power tool only upon determining that the smart power tool is a valid power tool.

57. The method of claim 54 wherein when the battery pack is coupled to the charger, determining whether the charger is a smart charger and upon determining that the charger is a smart charger, exchanging data between a controller of the pack and a controller of the charger and controlling the charger with the charger controller using the exchanged data.

58. The method of claim 57 including setting the battery pack controller to a master and the charger controller to a slave upon determining that the charger is a smart charger.

59. The method of claim 58 including when the battery pack is coupled to the smart charger, validating the smart charger and enabling the battery pack to operate with the smart charger only upon determining that the smart charger is a valid charger.

60. In a cordless power tool system including a plurality of system components including a battery pack and a power tool, a method of controlling the system components comprising validating the system component to which the battery pack is coupled and enabling the battery pack to operate with the system component only upon determining that the system component is a valid system component.

61. The method of claim 60 wherein the plurality of system components include a charger.

62. In a cordless power tool system including a plurality of system components including a battery pack and a power tool, a method of controlling the system components comprising determining whether the system component is a smart system component having a controller or a dumb system component without a controller.

63. The method of claim 62 including determining when the battery pack is coupled to the power tool whether the power tool is a smart system component having a controller and upon determining that the power tool is a smart system component, setting the battery pack controller to a slave of the power tool controller, exchanging data between the battery pack controller and the power tool controller, and controlling the power tool with the power tool controller using the exchanged data, and upon determining that the power tool is not a dumb system component, controlling the power tool with the battery pack controller.

64. The method of claim 62 wherein the plurality of system components include a charger, determining when the battery pack is coupled to the charger whether the charger is a smart system component and upon determining that the charger is a smart system component, exchanging data between a battery pack controller and the charger controller and controlling the charger with the charger controller using the exchanged data.

65. The method of claim 64 including setting the battery pack controller to a master and the charger controller to a slave upon determining that the charger is a smart system component.