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

• US 7,989,969 B2
• Filed: 04/23/2008
• Issued: 08/02/2011
• 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: Forster, Michael K., Grant, Jeffrey P.
• Primary Examiner(s): GONZALEZ, JULIO CESAR
• Application Number:
  US12/107,807
• Publication Number:
  US 20080231144A1
• Time in Patent Office: 1,196 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: 290/1.00A
• 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 examples, 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 having two opposite lateral sides and comprising a receptacle terminal block coupled to the internal combustion engine via a coupling mechanism, the receptacle terminal block being located adjacent a distal end of a tower receptacle and comprising a positive receptacle contact associated with a first side of the tower receptacle corresponding to one of the two opposite lateral sides and a negative receptacle contact associated with a second side of the tower receptacle corresponding to the other of the two opposite lateral sides;

the battery receptacle further comprising a receptacle latch projection associated with each of the two opposite lateral sides of the battery receptacle;

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 pack further comprising a battery latch projection associated with a manually actuatable latch and the battery latch projection being located and configured to cooperate with the receptacle latch projection to latch the battery pack to the battery receptacle when the battery pack is inserted into the battery receptacle;

a latch key in the form of at least one projection extending from and generally perpendicular to the battery latch projection, and the receptacle latch projection being configured to accept the at least one projection;

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;

the receptacle terminal block further comprises a temperature receptacle contact associated with a front side of the tower receptacle located between the first and second sides, and 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; and

the battery pack further comprises a raised platform connected to a lower platform of the battery pack by an intermediate wall, and a pair of chemistry sensor battery contacts associated with a front side of the intermediate wall, and wherein the battery receptacle further comprises a cooperating chemistry sensor receptacle contact located and configured to make electrical contact with the each of the pair of chemistry sensor battery contacts, and wherein each chemistry sensor receptacle contact is electrically coupled to the charging circuit.

2. The electro-mechanical device of claim 1, wherein a front side of the battery tower comprises a tower key in the form of a projection, and the front side of the tower receptacle includes a key recess adapted to cooperate with the tower key to permit insertion of the battery pack into the battery receptacle.

3. 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 a two opposite lateral sides, a front side, and a back side and 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 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;

the battery receptacle further comprising a receptacle latch projection associated with each of the two opposite lateral sides of the battery receptacle;

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 pack further comprising a battery latch projection associated with a manually actuatable latch and the battery latch projection being located and configured to cooperate with the receptacle latch projection to latch the battery pack to the battery receptacle when the battery pack is inserted into the battery receptacle,

a latch key in the form of at least one projection extending from and generally perpendicular to the battery latch projection, and the receptacle latch projection being configured to accept the at least one projection;

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; and

the receptacle terminal block further comprises a 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 the battery pack further comprises a pair of chemistry sensor battery contacts located and configured to make electrical contact with the pair of chemistry sensor receptacle contacts; and

wherein the pair of chemistry sensor receptacle contacts is electrically coupled to the charging circuit.

4. The electro-mechanical device of claim 3, wherein the receptacle terminal block further comprises an additional 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 negative receptacle contact, and the battery pack further comprises an additional pair of chemistry sensor battery contacts located and configured to make electrical contact with the pair of chemistry sensor receptacle contacts;

and wherein each pair of chemistry sensor receptacle contacts is electrically coupled to the charging circuit.

5. 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 an upwardly facing recess formed by two opposite lateral side walls and two end walls extending upwardly and having a drain opening configured to permit fluid to drain out of the upwardly facing recess, and a receptacle terminal block supported by one of the end walls and 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 being associated with the terminal face and adjacent one of the two opposite lateral side walls, a negative receptacle contact being associated with the terminal face and adjacent the other of the two opposite lateral side walls;

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;

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.

6. The electro-mechanical device of claim 5, wherein the two opposite lateral side walls and the two end walls are substantially continuous.

7. 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 an upwardly facing recess formed by two opposite lateral side walls and two end walls extending upwardly, and a receptacle terminal block supported by one of the end walls and 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 being associated with the terminal face and adjacent one of the two opposite lateral side walls, a negative receptacle contact being associated with the terminal face and adjacent the other of the two opposite lateral side walls;

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;

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; and

wherein the receptacle terminal block comprises a recess in an offset intermediate position of the terminal face between the positive and negative receptacle contacts; and

wherein the battery terminal block further comprises a 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.

8. The electro-mechanical device of claim 7, 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.

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 comprising an upwardly facing recess formed by two opposite lateral side walls and two end walls extending upwardly, and a receptacle terminal block supported by one of the end walls and 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 being associated with the terminal face and adjacent one of the two opposite lateral side walls, a negative receptacle contact being associated with the terminal face and adjacent the other of the two opposite lateral side walls;

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;

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; and

wherein 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.

10. The electro-mechanical device of claim 9, wherein the receptacle terminal block further comprises a protrusion centrally located on the terminal face between the first and second receptacle temperature contacts;

and wherein 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.