Power tool battery charger

Abstract

The present invention relates to power tool battery chargers. The battery charging unit includes a battery interface. The battery interface includes a cover that surrounds at least a portion of the battery interface to prevent external elements from damaging the electrical functionality of the battery interface.

Description

Technical Field

[0001] This disclosure generally relates to battery chargers. Specifically, this disclosure relates to battery charging units for power tools. Background Technology

[0002] A battery charger for power tools includes one or more battery interfaces. Each battery interface includes an external interface extending from it and electrical components such as wiring. The external interface is coupled to a battery being recharged, and the wiring electrically couples a power input to the external interface. In various embodiments, the battery charging unit includes coupling elements for coupling the battery charging unit within a modular storage system. Summary of the Invention

[0003] One embodiment of the present invention relates to a battery charging unit comprising: a housing; a power input configured to receive power; and a battery interface electrically coupled to the power input. The battery interface is configured to recharge a rechargeable power tool battery using the power received from the power input. The battery interface includes: an external interface configured to be coupled to the rechargeable power tool battery; a circuit system electrically coupling the power input to the external interface via an electrical connection; and a water-blocking shell coupled to the housing, the water-blocking shell surrounding the electrical connection between the circuit system and the external interface such that a watertight seal is formed around the electrical connection.

[0004] Another embodiment of the invention relates to a battery charging unit including a housing, a power source, and a battery interface. The battery interface is electrically coupled to the power source. The battery interface is configured to recharge a rechargeable power tool battery using power received from the power source. The battery interface includes: an external interface configured to be coupled to the rechargeable power tool battery; a circuit system that electrically couples the power source to the external interface via an electrical connection; a sleeve circumferentially surrounding the circuit system; and a seal coupled to the housing and the sleeve. The seal surrounds the electrical connection between the circuit system and the external interface, thereby forming a watertight seal around the electrical connection.

[0005] Another embodiment of the invention relates to a battery charging unit including a housing, a power input configured to receive power, and a battery interface. The battery interface is electrically coupled to the power input. The battery interface is configured to recharge a rechargeable power tool battery using the power received from the power input. The battery interface includes: an external interface configured to be coupled to the rechargeable power tool battery; a circuit system electrically coupled to the external interface via an electrical connection; and a seal coupled to the housing. The seal surrounds the electrical connection between the circuit system and the external interface, thereby forming a watertight seal around the electrical connection.

[0006] Another embodiment of the invention relates to a battery charging unit comprising: a housing; a coupling element configured to couple the housing to a modular system; a power input configured to receive power; and a battery interface. The battery interface is electrically coupled to the power input. The battery interface is configured to recharge a rechargeable power tool battery using the power received from the power input. The battery interface includes: an external interface configured to couple to the rechargeable power tool battery; a circuit system electrically coupling the power input to the external interface via an electrical connection; and a seal coupled to the housing. The seal surrounds the electrical connection between the circuit system and the external interface, thereby forming a watertight seal around the electrical connection.

[0007] Additional features and advantages will be set forth in the following detailed description, which will be apparent to those skilled in the art in some respects based on this specification, or will be recognized by practice of the embodiments as described in the written description and drawings. It should be understood that the foregoing general description and the following detailed description are exemplary.

[0008] This invention includes accompanying drawings to provide a further understanding, and the drawings are incorporated in and constitute a part of this application. The drawings illustrate one or more embodiments and, together with the description, serve to explain the principles and operation of the various embodiments. Attached Figure Description

[0009] This application will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, wherein the same reference numerals refer to the same elements, wherein:

[0010] Figure 1 This is a front perspective view taken from above the battery charging unit according to an exemplary embodiment.

[0011] Figure 2 It is based on an exemplary implementation method. Figure 1 Rear perspective view taken from above the battery charging unit.

[0012] Figure 3 It is based on an exemplary implementation method. Figure 1 A perspective view taken from below the battery charging unit.

[0013] Figure 4 It includes, according to exemplary embodiments Figure 1 A modular system for battery charging units.

[0014] Figure 5 According to an exemplary implementation Figure 1 A side view of the battery charging unit, including the battery interface portion.

[0015] Figure 6 According to an exemplary implementation Figure 1 The battery charging unit along Figure 5 The cross-sectional view of the portion cut by line 6-6 in the diagram.

[0016] Figure 7 According to an exemplary implementation Figure 6 A perspective view of the battery interface. Detailed Implementation

[0017] Referring generally to the accompanying drawings, an embodiment of a battery charging unit for power tool batteries is shown. Some power tools use batteries that can be removed from the power tool. The battery charging unit is used to recharge the rechargeable power tool battery. In some workplaces, the battery charging unit is exposed to weather conditions such as rain. If water, such as rainwater, is allowed into the housing of the battery charging unit, it can damage the electrical system, especially at non-water-resistant electrical connections. An innovative structure is provided herein to protect one or more electrical connections of the battery charging unit from the damaging effects of water or other contaminants entering the housing. In the specific embodiments discussed herein, a single-molded polymer shell is formed, which is coupled to the battery terminals and encapsulates the electrical connection points between the power input and the terminals. The applicant believes that, at least in some embodiments, such an arrangement provides robust water resistance while also benefiting from the efficiency of the molding technique. This contrasts with at least some water-resistant techniques such as waterproof housings or encapsulating electrical connections separately in a polymer material.

[0018] refer to Figures 1 to 3 The illustration shows a unit and / or device, shown as battery charging unit 10, according to an exemplary embodiment. A power supply and / or device configured to receive power—shown as power input 20—extends from battery charging unit 10. In a particular embodiment, power input 20 is a plug configured to interface with a wall socket.

[0019] The battery charging unit 10 includes one or more means for charging a rechargeable power tool battery, shown as a battery interface 40. The battery interface 40 is physically coupled to the housing 12 and electrically coupled to a power input 20. In a particular embodiment, the battery interface 40 is configured to be physically coupled to the rechargeable power tool battery and then recharged using power received from the power input 20. In various embodiments, a first side 24 of the housing 12 includes a plurality of battery interfaces 40, and a second side 26 of the housing 12 opposite to the first side 24 includes a plurality of battery interfaces 40. In a particular embodiment, the first side 24 of the housing 12 includes three battery interfaces 40, and the second side 26 of the housing 12 opposite to the first side 24 includes three battery interfaces 40.

[0020] A structure for coupling a battery charging unit 10 to a container, unit, and / or device is shown, illustrated as a coupling element 14. The coupling element 14 includes a protrusion 16 that is linearly actuated along axis 22.

[0021] Reference Figure 4 The modular system, illustrated as a modular storage system 80, includes a battery charging unit 10, and a modular storage unit 82 is shown according to an exemplary embodiment. In a particular embodiment, a coupling element 14 is configured to engage with a hole 84 and / or the bottom surface 18 of the battery charging unit 10 is configured to engage with a coupling mechanism 86 of the modular storage unit 82. In a particular embodiment, the coupling element 14 is configured to couple a housing 12 to the modular storage system 80. In a particular embodiment, the coupling element 14 and / or the bottom surface 18 of the battery charging unit 10 are compatible with the coupling mechanism described in International Patent Application PCT / US2018 / 044629, which is incorporated herein by reference, and thus the battery charging unit 10 is configured to be coupled to the modular storage system 80.

[0022] Reference Figures 5 to 7 The battery interface 40 includes one or more battery contacts for recharging the power tool battery, shown as an external interface 44. The external interface 44 is configured to be coupled to the rechargeable power tool battery. The external interface 44 is coupled to and extends from the body 42 of the battery interface 40. When the rechargeable power tool battery is coupled to the battery interface 40, the external interface 44 is electrically coupled to the rechargeable power tool battery.

[0023] The diagram shows the body 42 of the wiring 50, to which electrical components and / or circuitry are coupled to the battery interface 40. Wiring 50 couples the power input 20 to an external interface 44 via an electrical connection 52. Wiring 50 receives power from the power input 20 and provides the received power to the external interface 44. In a particular embodiment, a sleeve 54 circumferentially surrounds wiring 50.

[0024] Wiring 50 is electrically coupled to an external interface 44 via electrical connection 52. A seal and / or liquid-resistant housing, such as a water-resistant housing—shown as a cover 48—is coupled to housing 12. In a particular embodiment, cover 48 is coupled to housing 12 and sleeve 54. Cover 48 surrounds at least a portion of electrical connection 52. In a particular embodiment, cover 48 and body 42 are formed together as a single component, such as a single, integral, continuous polymer material piece. In another embodiment, cover 48 and body 42 are formed separately and adhered to each other to form a watertight seal.

[0025] Typically, the cover 48 surrounds the electrical connection 52 between the wiring 50 and the external interface 44, thereby forming a watertight seal around the electrical connection 52. In this way, the battery terminal 40 uses the cover 48 to prevent water from causing a short circuit at the electrical connection 52.

[0026] In a particular embodiment, the cover 48 includes a polymer material surrounding the electrical connection 52. In a particular embodiment, the cover 48 includes a single, integral, continuous polymer material piece molded around the electrical connection 52. In a particular embodiment, the single, integral, continuous polymer material piece is coupled to an external interface 44 and, for example, to the housing 12 via the external interface 44 extending downward through the body 42 of the battery interface 40 and the cover 48 being coupled to the lower portion of the external interface 44.

[0027] In certain embodiments, a cover 48 is formed around the electrical connection 52, such as by molding and / or embedding into an embedded-molded terminal block. In alternative embodiments, the cover 48 is formed of two or more structures, such as two or more polymer structures coupled together.

[0028] In one embodiment, the battery charging unit 10 includes a plurality of electrical connections 52 between the power input 20 and the external interface 44 of the battery interface 40. In another embodiment, a single, integral, continuous polymer material piece is molded around each of the plurality of electrical connections 52, thereby forming a watertight seal around all the plurality of electrical connections 52.

[0029] Battery interface 40 includes sliding pin interface 60, which is in direction 62 ( Figure 7 The cover 48 interfaces with one or more components, such as sliding pins. In a particular embodiment, the sliding pin interface 60 is used to facilitate the formation (e.g., molding) of the cover 48 around the electrical connection 52. In a particular embodiment, from Figures 6 to 7 From this angle, cavity 64 is located at the lower part of battery interface 40, and core 66 is located at the upper part of battery interface 40.

[0030] In an exemplary method of manufacturing a battery charging unit, a wiring 50 having a sleeve 54 is inserted into a body 42. A polymer material, such as a cap 48, is then molded onto the sleeve 54 to form a watertight and / or water-resistant seal.

[0031] It should be understood that the accompanying drawings illustrate exemplary embodiments in detail, and that this application is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology is for descriptive purposes only and should not be considered limiting.

[0032] Given this description, further modifications and alternative embodiments of various aspects of this disclosure will be apparent to those skilled in the art. Therefore, this description should be interpreted as illustrative only. The constructions and arrangements shown in the various exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, many modifications are possible (e.g., variations in the size, shape, and proportion of various elements, parameter values, mounting arrangements, use of materials, color, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integral may be composed of multiple parts or elements, the positions of elements may be reversed or otherwise changed, and the nature or number or position of discrete elements may be changed or altered. According to alternative embodiments, the order or sequence of any process, logical algorithm, or method steps may be changed or reordered. Other substitutions, modifications, alterations, and omissions may also be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of this disclosure.

[0033] Unless otherwise expressly stated, there is no intention to interpret any method described herein as requiring its steps to be performed in a particular order. Therefore, no particular order is intended to be inferred unless the method claims actually enumerate the order in which the steps should be followed, or unless the claims or description specifically state that the steps should be limited to a particular order. Furthermore, as used herein, the article “a” is intended to include one or more parts or elements and is not intended to be construed as meaning only one. As used herein, “rigid coupling” refers to two parts coupled in such a way that they move together in a fixed positional relationship when subjected to force.

[0034] Various embodiments of this disclosure relate to any combination of any features, and any such combination of features may be claimed in this application or a future application. Any feature, element, or component of any exemplary embodiment discussed above may be used alone or in combination with any feature, element, or component of any other embodiment discussed above.

[0035] For the purposes of this disclosure, the term "coupled" refers to the direct or indirect engagement of two components with each other. Such engagement may be fixed or removable in nature. Such engagement can be formed by integrating two components and any additional intermediate components into a single unit or by attaching two components or two components and any additional components to each other. Such engagement may be permanent, or removable or releaseable in nature.

[0036] Although this application refers to specific combinations of features in the appended claims, various embodiments of the invention relate to any combination of any features described herein, whether or not such combinations are currently claimed, and any such combination of features may be claimed in this application or a future application. Any feature, element, or component of any exemplary embodiment discussed above may be used alone or in combination with any feature, element, or component of any other embodiment discussed above.

Claims

1. A battery charging unit, comprising: case; power supply; as well as A battery interface electrically coupled to the power source, the battery interface being configured to recharge a rechargeable power tool battery using power received from the power source, the battery interface comprising: An external interface configured to be coupled to the rechargeable power tool battery; A circuit system that electrically couples the power supply to the external interface via multiple electrical connections; A sleeve that circumferentially surrounds the circuit system; and A sealing element, coupled to the housing and the sleeve, surrounds the plurality of electrical connections between the circuit system and the external interface, thereby forming a watertight seal around the plurality of electrical connections. The seal comprises a single, integral, continuous polymer material piece molded around each of the plurality of electrical connections to form a watertight seal around all of the plurality of electrical connections.

2. The battery charging unit according to claim 1, wherein, The power source includes a power input configured to interface with a wall socket.

3. The battery charging unit of claim 1, further comprising a coupling element configured to couple the housing to a modular system.

4. The battery charging unit according to claim 3, wherein, The coupling element causes the protrusion to be linearly actuated along the axis.

5. The battery charging unit of claim 1, comprising a plurality of battery interfaces, each of the plurality of battery interfaces being electrically coupled to the power source, the battery interfaces being configured to recharge a rechargeable power tool battery using power received from the power source.

6. A battery charging unit, comprising: case; Power input, which is configured to receive power; as well as A battery interface electrically coupled to the power input, the battery interface being configured to recharge a rechargeable power tool battery using power received from the power input, the battery interface comprising: An external interface configured to be coupled to the rechargeable power tool battery; A circuit system that electrically couples the power input to the external interface via a plurality of electrical connections; and A sealing element, coupled to the housing, surrounds the plurality of electrical connections between the circuit system and the external interface, thereby forming a watertight seal around the plurality of electrical connections. In this embodiment, a single, integral, continuous polymer material component is molded around each of the plurality of electrical connections to form a watertight seal around all of the plurality of electrical connections and to be coupled to the external interface and the housing.

7. The battery charging unit according to claim 6, wherein the seal comprises a polymer material surrounding the plurality of electrical connections.

8. The battery charging unit of claim 6, wherein the seal comprises the single, integral, continuous polymer material piece molded around the plurality of electrical connections.

9. The battery charging unit of claim 6, further comprising a coupling element that linearly actuates the protrusion along an axis, the coupling element being configured to couple the housing to a modular system.

10. A battery charging unit, comprising: case; A coupling element configured to couple the housing to a modular system; Power input, which is configured to receive power; as well as A battery interface electrically coupled to the power input, the battery interface being configured to recharge a rechargeable power tool battery using power received from the power input, the battery interface comprising: An external interface configured to be coupled to the rechargeable power tool battery; A circuit system that electrically couples the power input to the external interface via a plurality of electrical connections; and A sealing element, coupled to the housing, surrounds the plurality of electrical connections between the circuit system and the external interface, thereby forming a watertight seal around the plurality of electrical connections. The seal comprises a single, integral, continuous polymer material piece molded around each of the plurality of electrical connections to form a watertight seal around all of the plurality of electrical connections.

11. The battery charging unit of claim 10, comprising a sleeve circumferentially surrounding the circuit system, wherein, The seal is coupled to the sleeve.

12. The battery charging unit of claim 10, wherein the seal comprises a single, integral, continuous polymer material piece molded around the plurality of electrical connections.

13. The battery charging unit according to claim 10, wherein, The coupling element causes the protrusion to be linearly actuated along the axis.

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