Battery pack with electrical connector for use with power tool

Abstract

A battery pack having an electrical connector for use with a power tool. The battery pack includes: a case including one or more battery cells; a first terminal in electrical communication with the battery cell, the first terminal including a pair of spaced apart terminal walls forming a gap therebetween and a turn spring positioned at least partially within the gap. Wherein, when the electrical connector is at least partially positioned within the gap, the wire turn spring is configured to selectively engage and form an electrical connection with the electrical connector of the power tool.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application No. 63 / 441,077 filed on January 25, 2023, U.S. Patent Application No. 63 / 486,075 filed on February 21, 2023, and U.S. Patent Application No. 63 / 488,659 filed on March 6, 2023. The entire contents of each application are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to battery terminal connectors. Background Art

[0004] The power tool can accommodate a battery pack that is also compatible with many other power tools and electrical devices. The battery pack includes a tool engagement portion and a circuit board. The tool engagement portion mechanically secures the battery pack to the power tool. The circuit board uses a plurality of terminals to electrically connect the battery pack to the power tool. Utility Model Content

[0005] In one aspect, the present disclosure provides a battery pack for use with a power tool, the battery pack comprising: a housing containing one or more battery cells; a circuit board disposed in the housing; a first terminal; and a second terminal. The circuit board is electrically connected to the one or more battery cells. The first terminal is electrically connected to the circuit board. The second terminal is also electrically connected to the circuit board and has a different configuration than the first terminal. The second terminal includes a pair of spaced-apart terminal walls and a wire turn spring disposed between the pair of spaced-apart walls. The wire turn spring is configured to engage and electrically couple with a portion of the power tool.

[0006] In another aspect, the present disclosure provides a battery pack for use with a power tool, the battery pack comprising: a housing containing one or more battery cells; a circuit board disposed in the housing; and a terminal. The circuit board is electrically connected to the one or more battery cells. The terminal is electrically connected to the circuit board and is configured to accommodate a portion of the power tool and electrically connected thereto. The terminal assembly includes a pair of external forks and a pair of internal forks nested within the external forks. Each of the internal forks has a different shape from the external forks.

[0007] In another aspect, the present disclosure provides a battery pack for use with a power tool, the battery pack comprising: a housing containing one or more battery cells; a plurality of terminals; and a plurality of lateral terminals. The housing includes a tool engagement portion having a pair of spaced-apart housing walls configured to mechanically engage and retain a portion of the power tool. The terminals are disposed between the pair of housing walls. The lateral terminals are configured to conduct electricity through openings in corresponding housing walls of the pair of spaced-apart housing walls.

[0008] In another aspect, the present disclosure provides a battery pack having an electrical connector for use with a power tool. The battery pack includes: a housing containing one or more battery cells; a first terminal electrically connected to the battery cell, the first terminal including a pair of spaced-apart terminal walls and a wire turn spring, the pair of spaced-apart terminal walls forming a gap therebetween, the wire turn spring being at least partially positioned within the gap. Wherein, when the electrical connector is at least partially positioned within the gap, the wire turn spring is configured to selectively engage the electrical connector of the power tool and form an electrical connection therewith.

[0009] Alternatively or additionally, in any combination, wherein the wire turn spring is inclined.

[0010] Alternatively or additionally, in any combination, wherein the first terminal is introduced into the gap in a first insertion direction, and wherein the wire turn spring is inclined such that the wire turn spring produces a compression direction perpendicular to the insertion direction.

[0011] Alternatively or additionally, in any combination, the battery pack further includes a circuit board disposed in the housing, the circuit board being in electrical communication with the one or more battery cells and the first terminal.

[0012] Alternatively or additionally, in any combination, wherein the first terminal comprises a pair of legs mounted to the circuit board.

[0013] Alternatively or additionally, in any combination, wherein at least one of the terminal walls defines a recess therein, and wherein the spring is at least partially positioned within the recess.

[0014] Alternatively or additionally, in any combination, wherein both terminal walls define a groove therein, and wherein the spring is at least partially positioned in both grooves.

[0015] Alternatively or additionally, in any combination, wherein the first terminal defines a mid-plane located equidistant from the two terminal walls, and wherein the wire turn spring is located on both sides of the mid-plane.

[0016] Alternatively or additionally, in any combination, wherein the wire turn springs are arranged in a U-shape.

[0017] In another aspect, the present disclosure provides a battery pack having an electrical connector for use with an electric power tool, the battery pack comprising: a housing containing one or more battery cells; a terminal electrically connected to the battery cell, the terminal being configured to receive the electrical connector of the electric power tool and form an electrical connection therewith, the terminal comprising a pair of external forks, and a pair of internal forks nested between the pair of external forks.

[0018] Alternatively or additionally, in any combination, wherein the pair of outer forks has a different shape than the pair of inner forks.

[0019] Alternatively or additionally, in any combination, wherein both the pair of outer forks and the pair of inner forks are formed from a single unitary piece of material.

[0020] Alternatively or additionally, in any combination, wherein the pair of outer prongs and the pair of inner prongs are electrically isolated from each other.

[0021] Alternatively or additionally, in any combination, wherein the pair of outer forks has a first insertion depth, wherein the pair of inner forks has a second insertion depth, and wherein the first insertion depth is less than the second insertion depth.

[0022] Alternatively or additionally, in any combination, wherein a pair of external forks define a first insertion axis parallel to the insertion direction, wherein a pair of internal forks define a second insertion axis parallel to the insertion direction, and wherein the first insertion axis is coaxial with the second insertion axis.

[0023] Alternatively or additionally, in any combination, wherein both the pair of outer forks and the pair of inner forks are coupled to a circuit board, wherein the first insertion axis is spaced a first distance from the circuit board, and wherein the second insertion axis is spaced a second distance from the circuit board greater than the first distance.

[0024] Alternatively or additionally, in any combination, wherein the pair of outer forks has a different insertion depth than the pair of inner forks.

[0025] Alternatively or additionally, in any combination, wherein the terminal is a first terminal, and further comprising a second terminal in electrical communication with the battery cell, and wherein the second terminal is different from the first terminal.

[0026] Alternatively or additionally, in any combination, wherein a pair of inner forks are interdigitated.

[0027] In another aspect, the present disclosure provides a battery pack having an electrical connector for use with a power tool, the battery pack comprising: a housing containing one or more battery cells therein, the housing having a tool engagement portion configured to releasably engage the power tool and define an insertion direction; a lateral terminal configured to form an electrical connection with the electrical connector of the power tool, wherein the lateral terminal is accessible through a window through the housing, and wherein the window is oriented parallel to the insertion direction.

[0028] Alternatively or additionally, in any combination, wherein the housing further defines a pair of grooves configured to mechanically engage and retain a portion of the power tool therein, wherein the grooves extend parallel to the insertion direction.

[0029] Alternatively or additionally, in any combination, wherein the window is positioned in one of a pair of grooves.

[0030] Alternatively or additionally, in any combination, further comprising a plurality of terminals positioned between the pair of grooves.

[0031] Alternatively or additionally, in any combination, further comprising one or more terminals accessible via an opening in the housing, and wherein the opening in the housing is at least partially oriented orthogonal to the insertion direction.

[0032] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 A perspective view of the battery pack is shown.

[0034] Figure 1A Shown Figure 1 End cross-sectional view of a battery pack.

[0035] Figure 2 A detailed perspective view of multiple connectors of a power tool is shown with a portion of the power tool housing cut away.

[0036] Figure 3 A perspective view of a circuit board including a terminal separator is shown.

[0037] Figure 4 A perspective view showing a circuit board without the terminal dividers.

[0038] Figure 5 A perspective view of a circuit board engaging multiple connectors of a power tool housing is shown.

[0039] Fig. 6A A perspective view of the second terminal is shown.

[0040] Figure 6B Shown Fig. 6A Front view of the second terminal.

[0041] Fig. 7A A perspective view of an alternative embodiment of the second terminal is shown.

[0042] Figure 7B Shown Fig. 7A Front view of the second terminal.

[0043] Fig. 8A A perspective view of an alternative embodiment of the second terminal is shown.

[0044] Figure 8B Shown Fig. 8A Front view of the second terminal.

[0045] Fig.9A A perspective view of an alternative embodiment of the second terminal is shown.

[0046] Fig. 9B Shown Fig.9A A front view of a second terminal that receives a connector of a power tool housing.

[0047] Fig. 9C Shown Fig.9A A stereoscopic view of the internal terminal of the second terminal.

[0048] Fig. 10A A perspective view of an alternative embodiment of the second terminal is shown.

[0049] Fig. 10B Shown Fig. 10A A front view of a second terminal that receives a connector of a power tool housing.

[0050] Fig. 10C Shown Fig. 10A A stereoscopic view of the internal terminal of the second terminal.

[0051] Fig.11 A perspective view of an alternative embodiment of the second terminal is shown.

[0052] Fig.12 A connector for receiving a power tool housing is shown. Fig.11 A perspective view of the second terminal.

[0053] Fig.13 A perspective view of an alternative embodiment of a circuit board is shown, the circuit board including an alternative embodiment of the second terminal.

[0054] Fig.14 Shown Fig.13A top view of the circuit board and the second terminal.

[0055] Fig.15 A perspective view showing an alternative embodiment of multiple connectors for a power tool housing.

[0056] Fig.16A Shown Fig.15 An internal view of a first connector of a power tool housing, the first connector being connected to Fig.13 The second terminal is engaged.

[0057] Fig. 16B Shown Fig.15 An internal view of a second connector of a power tool housing, the second connector being connected to Fig.13 The second terminal is engaged.

[0058] Fig.17 A perspective view of an alternative embodiment of the second terminal is shown.

[0059] Fig.18 Shown Fig.17 A stereoscopic view of the internal terminal of the second terminal.

[0060] Fig.19A A second connector for receiving a power tool housing is shown. Fig.17 A cross-sectional view of a second terminal.

[0061] Fig.19B A vertical connector is shown engaging a power tool housing. Fig.17 A cross-sectional view of a second terminal.

[0062] Fig. 20 A perspective view of an alternative embodiment of a circuit board is shown, the circuit board including an alternative embodiment of the second terminal.

[0063] Fig.21 A perspective view of an alternative embodiment of a plurality of second connectors and a plurality of discrete connectors of a power tool housing is shown.

[0064] Fig.22A Demonstrated bonding Fig.21 Discrete connectors for power tool housings Fig. 20 Internal view of the second terminal.

[0065] Fig. 22B Demonstrated bonding Fig.21 The second connector of the power tool housing Fig. 20 Internal view of the second terminal.

[0066] Fig.23A A perspective view of an alternative embodiment showing the top side of a circuit board.

[0067] Fig. 23B Shown Fig.23A A perspective view of the bottom side of a circuit board.

[0068] Fig.24A A perspective view of an alternative embodiment showing the top side of a circuit board.

[0069] Fig. 24B Shown Fig.24A A perspective view of the bottom side of a circuit board.

[0070] Fig.25A Shown Fig.24A A bottom view of the bottom of a circuit board including a bottom PCB cover.

[0071] Fig.25B Shown Fig.24A A top view of the bottom of a circuit board with the bottom PCB cover omitted.

[0072] Fig.26A A perspective view of an alternative embodiment of a battery pack is shown.

[0073] Fig.26B Shown Fig.26A Another perspective view of the battery pack.

[0074] Fig.27A A bottom view of an alternative embodiment of a circuit board is shown.

[0075] Fig.27B Shown Fig.27A A perspective view of the circuit board and lateral terminals.

[0076] Fig.27C Shown Fig.27A Another perspective view of the circuit board and lateral terminals.

[0077] Fig.28 A detailed perspective view of an alternative embodiment of a connector for a power tool is shown with a portion of the power tool housing cut away.

[0078] Fig.29 A cutaway view showing a battery pack engaged with a power tool.

[0079] Fig.30 A number of alternative embodiments of the terminals are shown.

[0080] Fig.31 and Fig.32 A tilted wire turn spring is shown.

[0081] Fig.33 It shows Fig.31 A graphical representation of the deflection of a wire-turn spring relative to the force applied to it.

[0082] FIG. 34A to FIG. 34C Alternative embodiments of terminals are shown.

[0083] FIG. 35A to FIG. 35C Additional alternative embodiments of terminals are shown.

[0084] Before explaining any embodiment of the utility model in detail, it should be understood that the application of the utility model is not limited to the details of the component construction and arrangement set forth in the following description or shown in the following drawings. The utility model can have other embodiments and can be practiced or executed in a variety of different ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered as limiting. DETAILED DESCRIPTION

[0085] Figure 1 and Figure 1A A battery pack 10 is shown that is configured to be releasably coupled to a power tool 12 or other electrical device (see Figure 2 ) and form a temporary electrical connection with the electrical mounting point 15. More specifically, the battery pack 10 can provide power to various components of the power tool 12, including but not limited to one or more motors, sensors, LEDs, controllers, pumps, etc.

[0086] The battery pack 10 includes a housing 14, a tool engagement portion 16, a circuit board 18, one or more battery cells 19, and an electrical interface 17 in electrical communication with both the circuit board 18 and the battery cells 19. The housing 14 further at least partially defines an interior cavity 21 that supports the battery cells 19 and the circuit board 18 therein.

[0087] The tool engagement portion 16 of the battery pack 10 is configured to selectively engage the mounting point 15 of the power tool 12. In the illustrated embodiment, the tool engagement portion 16 includes: a pair of outer housing walls or ribs 20 extending parallel to the insertion direction A; a groove 22 at least partially formed by the ribs 20 and also extending parallel to the insertion direction A; a pair of inner housing walls 24 at least partially forming a terminal interface 26, and a pair of actuators or latches 28. The grooves 22 and actuators 28 are configured to mechanically engage and retain corresponding rails 30 of the mounting point 15 of the power tool 12. In other embodiments, the grooves 22 can be formed on the power tool 12, and the rails 30 can be formed on the battery pack 10.

[0088] The terminal interface 26 includes a plurality of slots 32 in the housing 14, each slot generally corresponding to one or more terminals (discussed below) of the electrical interface 17. Each slot 3 is in turn sized and shaped to receive one or more connectors 36 of the power tool 12 therein. Figure 2As shown in FIG. 1 , a plurality of first connectors 36 of the power tool 12 are arranged on the mounting point 15 and extend generally parallel to the insertion direction A. In the illustrated embodiment, each connector 36 is generally formed as a flat plate having an inclined front edge.

[0089] like Figures 3 to 6B As shown in FIG. 1 , the electrical interface 17 includes one or more first terminals 38, one or more second terminals 40, and a terminal separator 58 that physically and electrically isolates each terminal 38, 40 from each other. When assembled, each terminal 38, 40 is configured to align with and be accessible through a corresponding slot 32 of the terminal interface 26 (see FIG. 1 ). Figure 1 ).

[0090] The terminals 38, 40 of the battery pack 10 are each physically sized and shaped to receive a corresponding one of the first connectors 36 of the power tool housing 12 therein to form a separate electrical connection therewith. Figure 5 As shown in FIG. 8 , the first connector 36 , together with the electrical connections formed between their corresponding terminals 36 , 40 , electrically connects the power tool 12 to the circuit board 18 and the battery 19 .

[0091] like FIG. 6A to FIG. 6B , the second terminal 40 is constructed differently from the first terminal 38. More specifically, the second terminal 40 includes a pair of spaced apart terminal walls 42, the pair of spaced apart terminal walls forming a terminal gap or opening 50 therebetween, and one or more wire turn springs 44, the pair of spaced apart terminal walls forming a terminal gap or opening 50 therebetween, the one or more wire turn springs at least partially positioned in or leading to the terminal gap 50. When assembled, each wire turn spring 44 is in electrical communication with the terminal wall 42, which in turn is in electrical communication with the circuit board 18 via a pair of legs 48.

[0092] In the illustrated embodiment, the terminal walls 42 are generally planar and spaced apart a distance such that the terminal gaps 50 are sized to at least partially accommodate the corresponding first connectors 36 therein. The walls 42 also each define one or more spring receiving recesses 46 formed in an inner surface 47 of the wall, the one or more spring receiving recesses being sized and shaped to accommodate at least a portion of a corresponding wire turn spring 44 therein. When assembled, the terminal walls 42 and wire turn springs 44 are configured such that the wire turn springs 44 extend inwardly beyond the inner surface 47 of the wall 42 and into the gaps 50 such that the wire turn distance 49 between opposing springs 44 is less than the distance between the walls 42 at the same location.

[0093] In some embodiments, one or more of the turn springs 44 of the second terminal 40 can be configured so that they deflect more easily and consistently when engaged with the first connector 36. More specifically, the turn springs 44 can be "angled" so that they apply a nearly constant force toward and against the first connector 36 (e.g., in an inward direction toward the center of the gap 50) because the individual turns of the springs 44 deflect outward to accommodate the presence of the connector 36 within the gap 50.

[0094] In some embodiments, the wire turn springs 44 are inclined in the sense that their size and shape are designed to accommodate compression in a predetermined compression direction B. More specifically, the geometry of the wire turn springs 44 is configured such that, when a force is applied to the springs 44 in the compression direction B, the wire turn springs 44 exert a nearly constant reaction force as they deflect over the operating deflection range (see Fig.33 ). In the illustrated embodiment, the operating deflection range is between 10% and 35% of the resting spring height 61 in the compression direction B. In other embodiments, the operating deflection range is between about 10% and about 35% deflection of the resting spring height 61 in the compression direction B (e.g., ±1%, ±2%, ±5%, or ±10%). In still other embodiments, the force applied by the wire turn spring 44 in the compression direction B varies between 50% and 58% when deflected over the operating deflection range between 10% and 35% deflection of the resting spring height 61 in the compression direction B. In still other embodiments, the force applied by the wire turn spring 44 in the compression direction B varies between 50% and 55% when deflected over the operating deflection range between 10% and 35% deflection of the resting spring height 61 in the compression direction B. In yet other embodiments, when deflected over an operating deflection range between 10% and 35% deflection of the rest spring height 61 in the compression direction B, the force applied by the wire turn spring 44 in the compression direction B varies between 52% and 58%.

[0095] In yet other embodiments, the wire turn spring 44 can be tilted by modifying various characteristics of the spring geometry, such as the diameter of the wire 163, the turn height 165 relative to the turn width 167, the turn spacing 169, and the turn angle 171 (see Fig.31 and 32 More specifically, the illustrated turn spring 44 is configured such that the turn height 165 (eg, the turn dimension in the compression direction B) is smaller than the turn width 167 (eg, the turn dimension perpendicular to the compression direction B; see Fig.32 ). Furthermore, the illustrated turn springs 44 are configured such that they have a turn angle 171 that is reduced relative to an axis 173 of the spring 44 .

[0096] Compared to the first terminal 38, the second terminal 40 includes more individual contact points with the first connector 36 (e.g., one contact point for each wire turn of the contact connector 36) due to the wire turn spring 44. More specifically, the second terminal 40 has more than four contact points with a particular connector 36. In other embodiments, the inner diameter of the wire turn spring 44 can be larger to be able to receive or transmit higher currents. The terminal separator 58 is configured to electrically separate the first terminal 38 and the second terminal 40 to reduce the risk of short circuits.

[0097] In the illustrated embodiment, the shape of the wire turn spring 44 is designed so that it forms a generally "U" shape within the gap 50 (see Figure 6B More specifically, the spring 44 is positioned so that there is a first leg 175A extending parallel to the first wall 42A, a second leg 175B extending parallel to the second wall 42B, and an interconnecting leg 175C extending between the first leg 175A and the second leg 175B (e.g., extending between the two walls 42A, 42B) and near the bottom of the gap 50 (see Figure 6B By doing so, the resilient nature of the wire turn spring 44 (eg, remaining straight) provides an outward pressure against the two walls 42A, 42B, thereby helping to hold the spring 44 in place within the terminal 40. Fig. 6A As shown in FIG, the first leg 175A and the second leg 175B are respectively positioned in the corresponding receiving grooves 46 of the walls 42A, 42B, so that the grooves 46 provide lateral support to the spring 44. Specifically, when the connector 36 is inserted therein, the grooves 46 help limit any movement of the spring 44 along the insertion direction A.

[0098] Although the illustrated spring 44 is U-shaped, such that both the first leg 175A and the second leg 175B are formed as a single piece. It should be understood that in other embodiments, the first leg 175A and the second leg 175B may be formed separately, such that there is no interconnecting leg 175C. In such embodiments, each leg 175A, 175B may be mechanically (e.g., by the shape of the groove 46, the use of a tab, etc.) or by an adhesive, etc., retained within the corresponding receiving groove 46. In still other embodiments, the spring 44 itself may form a continuous loop, such that a single spring 44 forms the first leg 175A, the second leg 175B, the interconnecting leg 175C near the bottom of the gap 50, and a second interconnecting leg (not shown) near the top of the gap 50.

[0099] Once installed in the illustrated U-shaped configuration, the wire turn spring 44 may be further oriented such that when tilted, the compression direction B of the wire turn spring 44 is perpendicular to the insertion direction A of the first and second legs 175A, 175B of the spring 44 .

[0100] FIG. 7A to FIG. 7B Another embodiment of the second terminal 1040 is shown. The second terminal 1040 is substantially similar to the second terminal 40, so only the differences are discussed in detail herein. The second terminal 1040 includes a pair of terminal walls 1042 having one or more curved portions 1052. The curved portions 1052 further define a plurality of spring receiving grooves 1046, which retain the wire turn springs 44, as discussed above. More specifically, the curved nature of the wall 1042 allows the presence of the receiving grooves 1046 while maintaining a constant wall thickness. Thus, the wall 1042 shown can be formed by a single piece of material that is pressed or otherwise formed. In fact, the entire terminal 1040 is configured so that it can be formed by a single piece of formed material.

[0101] FIG. 8A to FIG. 8B Another embodiment of the second terminal 2040 is shown. The second terminal 2040 is substantially similar to the second terminal 40, so only the differences are discussed in detail herein. The second terminal 2040 includes a pair of receiving grooves 2046, each of which forms a curved path along the inner surface 2047 of their respective walls 2042A, 2042B. More specifically, each receiving groove 2046 includes a first portion 2071 oriented generally perpendicular to the insertion direction A (e.g., ±1%, ±2%, ±5%, or ±10%) and a second portion 2073 oriented generally parallel to the insertion direction A (e.g., ±1%, ±2%, ±5%, or ±10%). As such, the wire turn spring 44 positioned within the groove 2046 also includes portions oriented generally perpendicular to and generally parallel to the insertion direction A (e.g., ±1%, ±2%, ±5%, or ±10%).

[0102] In the illustrated embodiment, the wire turn spring 44 forms a complete ring, such that the spring 44 includes a first leg 2075A extending along the receiving recess 2046 in the first wall 2042A, a second leg 2075B extending along the receiving recess 2046 in the second wall 2042B, and a pair of interconnecting legs 2075C, 2075D extending between the walls 2042A, 2042B and interconnecting the first leg 2075A and the second leg 2075B. By doing so, the natural elastic properties of the wire turns 44 (e.g., assuming its resting circular shape) help retain the spring 44 within the recess 2046 of the terminal 2040. In other embodiments, a separate wire turn spring 44 may be used to extend along all or a portion of each receiving recess 2046 and be retained therein, such that no interconnecting portion is required or present.

[0103] 9A to 9CAnother embodiment of the terminal 3000 is shown. The terminal 3000 can be used to replace one or more of the second terminals 40 or one of the first terminals 38 of the electrical interface 17. The terminal 3000 includes an external terminal 3060 and an internal terminal 3062 nested within the external terminal 3060, so that the two terminals 3060, 3062 form a single electrical connection. The external terminal 3060 includes a pair of first legs 3064 and a pair of external forks 3066. The pair of first legs 3064 are inserted into the circuit board 18 and can be welded to electrically connect the terminal 3000 to the circuit board 18. The external fork 3066 is configured to electrically connect and engage the corresponding first connector 36 of the power tool housing 12 to the circuit board 18. As shown in FIG. Fig.9A and Fig. 9B As shown in , as the external fork 3066 extends from the base 3063 of the terminal 3000, the fork 3066 first gathers together to form the clamping point 3065, and then they form a shape that opens forward at the clamping point so that the ends of the fork extend forward and expand away from each other when these ends extend away from the corresponding clamping point 3065. In the embodiment shown, the external terminal 60 is formed by a conductive material with a thickness between 0.15mm and 0.35mm. In some embodiments, the thickness is between 0.2mm and 0.3mm. In some embodiments, the thickness is 0.25mm.

[0104] like Fig. 9C As shown in FIG. 1 , the internal terminal 3062 is nested in the external terminal 3060 and includes a pair of second legs 3068 and a pair of internal forks 3070. The pair of second legs 3068 are also inserted into the circuit board 18 and can be welded to electrically connect the internal terminal 3062 to the circuit board 18. The pair of internal forks 3070 have a different shape from the external forks 3066. More specifically, the internal forks 3070 are bent into a V-shape and are configured to provide additional contact area for the first connector 36 when fully installed. Fig.9A and Fig. 9B As shown in FIG. 3 , as the internal forks 3070 extend from the base 3063 of the terminal 3000, the forks 3070 first converge together to form a distal end 3067, and the forks then extend back toward the base 3063, where they continue to converge until they form a pinch point 3069. In other words, the pinch point 3069 is located closer to the base 3063 than the distal end 3065.

[0105] In some embodiments, the internal fork 3070 is configured to limit the insertion depth of the first connector 36. In other embodiments, the internal fork 3070 is configured to capture or otherwise clamp onto the connector 36. In such alternative embodiments, the clamping force of the internal fork 3070 can be different from the clamping force applied by the external fork 3066. By doing so, the user will receive tactile feedback to determine how far the connector 36 is inserted. More specifically, the clamping force applied by the internal fork 3070 can be greater than the clamping force applied by the external fork 3066.

[0106] FIG. 10A to FIG. 10C Another embodiment of terminal 4000 is shown.Terminal 4000 is substantially similar to terminal 3000, so only the difference is described in detail herein.Terminal 4000 comprises internal terminal 4062, and this internal terminal has a pair of internal fork-shaped pieces 4070 that are bent to cross each other.In other words, the shape of fork-shaped pieces 4070 is designed so that they cross the center line 4071 of terminal 4000, so that the fork-shaped pieces 4070 on one side of center line 4071 will terminate at the opposite side of center line 4071.Internal fork-shaped pieces 4070 also accommodate first connector 36 and increase the contact area between second terminal 4000 and first connector 36.In certain embodiments, internal fork-shaped pieces 4070 also limit the insertion depth of first connector 36.

[0107] Figure 11 to Figure 12 Another embodiment of the terminal 5000 is shown. The terminal 5000 can replace any one of the second terminal 40 or the first terminal 38 of the electrical interface 17. The terminal 5000 is formed of a single piece of material (e.g., metal) and forms a pair of external forks 5066, a pair of internal forks 5070 nested in the external forks 5066, and a mounting portion 5097. The external forks 5066 are configured to receive the first connector 36 and electrically connect it to the circuit board 18, such as Fig.12 5097 is a schematic diagram showing a schematic diagram of a second embodiment of the present invention. In some embodiments, the internal fork 5070 is configured to limit the insertion depth of the first connector 36 into the second terminal 5000. In other embodiments, the internal fork 5070 is used as the second clamping point to increase the electrical connection surface area and the accommodation strength of the terminal 5000. Because the internal fork 5070 is nested in the external fork 5066, the second terminal 5000 allows to increase the contact area without increasing the length of the external fork 5066 (for example, in a direction parallel to the insertion direction A) or damaging the area of ​​each contact area. The mounting portion 5097 is electrically connected to the second terminal 5000 and supported on the circuit board 18.

[0108] like Fig.11 and Fig.12As shown in , the terminal 5000 is configured such that the external fork 5066, the internal fork 5070, and the mounting portion 5097 can all be formed from a single piece of material by bending and forming the single piece. More specifically, the external fork 5066 has a first or distal end 5081 that forms a first clamping point or clamp 5083 and a second end 5085 opposite the first end 5081. The internal fork 5070 starts at the second end 5085 of the external fork 5066, whereby the 180-degree fold allows the internal fork 5070 to extend in the same direction as the external fork 5066 while being nested within the external fork 5066. In other words, the internal fork 5070 also includes a distal end 5087 that forms a second clamping point or clamp 5089 and a second end 5091 opposite the first end 5087. As shown in FIG. Fig.12 As shown in the figure, the second end 5091 of the inner fork 5070 and the second end 5085 of the outer fork 5066 are connected together so that the inner fork 5070 and the outer fork 5066 can be formed by a single piece of material. In some embodiments, the connection of the two second ends 5085, 5091 is formed by a 180 degree bend in the whole piece of material.

[0109] Terminal 5000 also includes a crossover or bridge portion 5093 extending between two external forks 5066 and continuous with the two. The crossover is positioned so that it does not interfere with the gap 5050 into which connector 38 is to be inserted. In the illustrated embodiment, bridge 5093 is positioned and its shape is designed to (e.g., near the second end 5085 of external fork 5066) so that two independent external forks 2066 are connected together and therefore can be formed by a single piece of whole material. More specifically, bridge 5093 can include two folding portions of approximately 90 degrees on both sides thereof, to allow external forks 5066 to be generally placed parallel to each other and spaced a certain distance from each other.

[0110] Figure 13 to Figure 14 An alternative embodiment of an electrical interface 6017 is shown. The electrical interface 6017 is substantially similar to the electrical interface 17 described above, so only the differences are described in detail herein. The electrical interface 6017 can replace the electrical interface 17 in the battery pack 10. The circuit board 6018 includes a plurality of first terminals 6038, a plurality of second terminals 6040, and a terminal separator 6058.

[0111] In the illustrated embodiment, the first terminal 6038 and the second terminal 6040 are configured so that they can each accommodate a differently configured connector 36 and form a different type of electrical connection therewith. More specifically, the first terminal 6038 can accommodate the first connector 6036 of the power tool 12, while the second terminal 6040 can accommodate the first connector 6036 or the second connector 6037 (discussed below) of the power tool housing 6012.

[0112] In addition, each first terminal 6038 can form only a single electrical connection point (e.g., the first terminal 6038 can form a single circuit), while each second terminal 6074 forms one or more electrical connection points (e.g., the second terminal 6074 can form two or more independent circuits). When docked to the mounting point 6015, the first terminal 6038 can form a single electrical connection with both the first connector 6036 and the second connector 6037, while the second terminal 6040 can form a single electrical connection with the first connector 6036 and two electrical connections with the second connector 6040.

[0113] The terminal 6040 includes an outer terminal 6060 and an inner terminal 6062, which are nested in and electrically isolated from the outer terminal 6060. The outer terminal 6060 includes a pair of first legs 6064 soldered to the circuit board 18, and a pair of outer forks 6066 having a first connection depth 6071. The outer terminal 6060 is configured to receive the first connector 6036 or the second connector 6037 and electrically connect it to the circuit board 18.

[0114] The inner terminal 6062 includes a pair of second legs 6068 soldered to a different position on the circuit board 18 than the pair of first legs 6064, and a pair of inner forks 6070 having a second connection depth 6073 different from the first connection depth 6071. More specifically, the second connection depth 6073 is greater than the first connection depth 6071. The inner terminal 6062 is configured to receive and electrically connect to only the second connector 6037.

[0115] like Fig.16A As shown in , the second connector 6037 is installed in the second terminal 6040, and both the external terminal 6060 and the internal terminal 6062 are engaged with the second connector and form an electrical connection therewith (see, for example, the connection point C between the connector 6037 and the external terminal 6060, and the connection point D between the connector 6037 and the internal terminal 6062). In contrast, Fig. 16BThe first connector 6036 is shown installed in the second terminal 6040 and only forms an electrical connection with the external terminal 6060 (see the connection point E between the external terminal 6060 and the connector 6036). More specifically, since the insertion length 6039 of the first connector 6036 is shorter than the insertion length 6041 of the second connector 6037, the first connector 6036 is only engaged with the external terminal 6060 of the second terminal 6040.

[0116] like Fig.14 As shown in, the second terminal 6040 includes a pad or insulator 6072 positioned between the internal terminal 6062 and the external terminal 6060 so that the two terminals remain electrically isolated from each other. In the embodiment shown, the pad 72 is made of mica. In other embodiments, the pad 72 can be made of any electrical insulating material.

[0117] Fig.15 Another embodiment of a mounting point 6015 for a power tool 12 is shown. The mounting point 6015 further includes one or more first connectors 6036 having a first insertion length 6039 (e.g., the length of the connector 6036 measured in the insertion direction A), and includes one or more second connectors 6037 having a second insertion length 6041 that is different from the first insertion length 6039. More specifically, the second insertion length 6041 is greater than the first insertion length 6039. During use, the first connector 6036 has sufficient insertion length 6039 to form an electrical connection with the external terminal 6060 of the second terminal 6040 and the first terminal 6038, but does not form an electrical connection with the internal terminal 6062 of the second terminal 6040. In contrast, the second connector 6037 has sufficient insertion length 6041 to form an electrical connection with the internal terminal 6062 and the external terminal 6060 of the second terminal 6040 and the first terminal 6038.

[0118] Figures 17 to 19B Another embodiment of an electrical interface 7017 is shown. Electrical interface 7017 is substantially similar to electrical interface 6017, so only the differences are described in detail herein. Electrical interface 7017 can replace electrical interface 17 in battery pack 10. Electrical interface 7017 includes a second terminal 7040, which includes an external terminal 7060 and an internal terminal 7062. External terminal 7060 includes a pair of first legs 7064 soldered to circuit board 18, and a pair of external forks 7066. Fig.18 As shown in FIG. 19 , the internal terminal 7062 includes a pair of second legs 7068 soldered to the circuit board 18 , and a pair of internal forks 7070 .

[0119] Compared to the external terminal 7060, the internal terminal 7062 includes a pair of second legs 7068 that are alternately placed to reduce the overall footprint of the second terminal 7040 on the circuit board 18. More specifically, the illustrated external terminal 7060 defines a length envelope 7061 extending in the insertion direction A (see Fig.19A ). The internal terminal 7062 is configured such that the pair of second legs 7068 are completely positioned within the length envelope 7061 of the external terminal 7060. In yet other embodiments, the overall length 7063 of the external terminal 7060 (measured parallel to the insertion direction A) is greater than the overall length 7065 of the internal terminal 7062 (measured parallel to the insertion direction A). In yet other embodiments, both the clamping point 7067 of the internal terminal 7062 and the pair of second legs 7068 fall within the length envelope 7061 of the external terminal 7060.

[0120] like Fig.19A As shown in , the second terminal 7040 is configured to receive a second connector 6037 that is electrically connected to both the outer fork 7066 and the inner fork 7070.

[0121] Although the illustrated internal fork 7070 is shown as being substantially horizontal, the fork 7070 and the base or joint 7069 between the fork 7070 are horizontally offset from each other (e.g., in a direction parallel to the insertion direction A) and the joint 7069 itself is oriented perpendicular to the insertion direction (see Fig.18 ), but it should be understood that in other embodiments, the fork 7070 can be vertically configured. In such an embodiment, the link 7069 and the fork 7070 are vertically offset (e.g., perpendicular to the insertion direction A), and the link itself 7069 is positioned near the circuit board 18 and extends parallel to the insertion direction A along the circuit board (see Fig.18 ). This layout allows for shorter leads extending to the legs 7068. The vertical layout also allows the internal fork 7070 to match the shape of the connector and maximize the contact area for a given terminal length.

[0122] Fig. 20 and FIG. 22A to FIG. 22B Another embodiment of an electrical interface 11017 is shown. The electrical interface 11017 is substantially similar to the electrical interface 7017 described above, so only the differences are discussed in detail herein. The electrical interface 11017 can replace the electrical interface 17 in the battery pack 10. The electrical interface 11017 includes one or more first terminals 11038 and one or more second or stacked terminals 11074.

[0123] In addition, each first terminal 11038 includes a single electrical connection point (e.g., the first terminal 11038 can form a single circuit), while each second terminal 11074 includes multiple electrical connection points (e.g., the second terminal 11074 can form two or more independent circuits). More specifically, the second terminal 11074 includes multiple electrical connection points 11039A, 11039B, wherein each electrical connection point 11039A, 11039B can be individually accessed through a corresponding slot 32 in the battery housing 14 without being electrically connected to other connection points 11039A, 11039B. More specifically, each connection point 11039A, 11039B defines an insertion axis 11041A, 11041B (extending parallel to the insertion direction A), which is offset from the insertion axes 11041A, 11041B of all other electrical connection points 11039A, 11039B and is unique. In the illustrated embodiment, the terminal 11074 includes two connection points 11039A, 11039B having two insertion axes 11041A, 11041B that are offset by different distances from the underlying circuit board 18. In other words, the first insertion axis 11041A is spaced a first distance from the circuit board 18, while the second insertion axis 11041B is spaced a second distance greater than the first distance from the circuit board 18. Furthermore, in the illustrated embodiment, the two insertion axes 11041A, 11041B lie on a common plane oriented perpendicular to the circuit board 18.

[0124] The second terminal 11074 includes an upper terminal 11082 forming a first electrical connection point 11039A, and a lower terminal 11084 forming a second electrical connection point 11039B electrically isolated from the first electrical connection point 11039A. Fig. 20 As shown in , the upper terminal 11082 defines a first insertion axis 11041A spaced a first distance from the circuit board 18, and the lower terminal 11084 defines a second insertion axis 11041B spaced a second distance less than the first distance from the circuit board 18. In addition, the upper terminal 11082 also has an insertion distance greater than that of the lower terminal 11084.

[0125] During use, if the stacked terminals 11074 accommodate discrete connectors 11042, such as Fig.22A As shown in (described below), the upper terminal 11082 is configured to receive the upper connector 11078 (see connection G), and the lower terminal 11084 is configured to receive the lower connector 11080 (see connection H). If the stacked terminal 11074 receives the first connector 11036, as shown in FIG. Fig. 22BAs shown in (described below), the lower terminals 11084 receive and electrically connect the first connector 11036, and the upper terminals 11082 are left empty and unconnected (see connection J).

[0126] Fig.21 Another embodiment of a mounting point 11015 for a power tool 12 is shown. The mounting point 11015 is substantially similar to the mounting point 15 described above, so only the differences are described in detail herein. The mounting point 11015 includes one or more discrete connectors 11042 and one or more first connectors 11036. Each discrete connector 11042 includes a plurality of separate and electrically isolated connecting elements 11078, 11080, each of which extends generally parallel to the insertion direction A but is offset from one another. More specifically, the separate connecting elements 11078, 11080 are positioned so that when the battery 10 is connected to the mounting point 11015 of the power tool 12 in the insertion direction A, each connecting element 11078, 11080 will correspond to and be coaxial with the corresponding insertion axis 11041A, 11041B. Each connecting element 11078, 11080 also has an insertion length corresponding to the insertion depth of the corresponding terminal 11082, 11084.

[0127] Each first connector 11036 forms a single electrical connection point. During use, the first terminal 11038 is configured to accommodate the first connector 11036 therein. In some embodiments, the connector 11036 has a connector height (e.g., perpendicular to the insertion direction A) that is large enough to cover both the upper terminal 11082 and the lower terminal 11084 of the discrete terminal 11074. In this way, the first connector 11036 can be configured to be electrically connected to one or both of the terminals 11082 and 11084 of the discrete terminal 11074, depending on the insertion distance of the connector. In such embodiments, when the insertion distance of any one of the connectors 11036 exceeds the insertion length of both the terminals 11082 and 11084, the connector can be electrically connected to both the terminals 11082 and 11084 at the same time, but in other embodiments, when the insertion distance is greater than the insertion depth of one terminal but less than the insertion depth of the other terminal, the first connector 11036 can be electrically connected only to the shallower of the two terminals.

[0128] FIG. 23A to FIG. 23BAnother embodiment of a circuit board 8018 is shown. The circuit board 8018 is substantially similar to the circuit board 18 described above, so only the differences are described in detail herein. The circuit board 8018 can replace the circuit board 18 in the battery pack 10. The circuit board 8018 includes an electrical interface 8017, which includes one or more first terminals 8038, one or more second terminals 8040, and a terminal separator 8058. The circuit board 8018 also includes an upper PCB cover 8098 and a lower PCB cover 8099. The rear of the second terminal 8040 is surrounded by the upper PCB cover 8098. The upper PCB cover 8098 is made of a material that is heat-conductive but not electrically conductive. The upper PCB cover 8098 is configured to dissipate the heat generated on the rear end of the second terminal 8040. The lower PCB cover 8099 is also made of the same material as the upper PCB cover 8098 and is configured to dissipate the heat from a pair of legs 8064 of the second terminal 8040. Furthermore, the upper PCB cover 8098 and the lower PCB cover 8099 are manufactured using low pressure molding.

[0129] FIG. 24A to FIG. 24B Another embodiment of a circuit board 9018 is shown. Circuit board 9018 includes similar components to circuit board 8018, so only the differences are described in detail herein. Upper PCB cover 9098 and lower PCB cover 9098 are thicker than upper PCB cover 8098 and lower PCB cover 8099. The additional material on upper PCB cover 9098 and lower PCB cover 9099 increases thermal mass and has greater heat dissipation potential than upper PCB cover 9098 and lower PCB cover 9099. Fig.25A The lower PCB cover 9099 is shown, while Fig.25B Circuit board 9018 is shown with lower PCB cover 9099 removed.

[0130] FIG. 26A to FIG. 29 Another embodiment of a battery pack 10010 is shown. The battery pack 10010 is substantially similar to the battery pack 10 described above, and therefore only the differences are described in detail herein. Fig.26A and Fig.26BAs shown in , the battery pack 10010 includes a housing 10014, a tool engagement portion 10016, a circuit board 10018, one or more battery cells (not shown), and an electrical interface 10017 electrically connected to both the circuit board 10018 and the one or more battery cells. The tool engagement portion 10016 includes a first spaced-apart housing wall or rib 10020 extending parallel to the insertion direction A and a second spaced-apart housing wall or rib 10021 also extending parallel to the insertion direction A. The first rib 10020 and the second rib 10021 each define a groove 10022 also extending parallel to the insertion direction A. The grooves 10022 in turn each include at least one window 10086 leading to the internal cavity of the housing 10014 of the battery pack 10010. During use, when the battery pack 10010 is coupled to the power tool 10012, the groove 10022 is configured to accommodate the guide rail 10030 of the power tool 10012 therein. In other embodiments, the groove 10022 can be formed in the power tool 12 and the rail 10030 can be positioned on the battery pack 10010.

[0131] like Fig.27A and Fig.27C As shown in , the circuit board 10018 of the battery pack 10010 includes a plurality of first terminals 10038 and a plurality of lateral terminals 10088 angled relative to the first terminals 10038. More specifically, each of the first terminals 10038 can be accessed via a slot 10032 formed in the housing 10014 of the battery pack 10010, which is at least partially orthogonal to the insertion direction A orientation (e.g., parallel to the insertion direction A introduction connector). On the contrary, the lateral terminals 10088 can be accessed via a window 10086 that is not orthogonal to the insertion direction A orientation. In the embodiment shown, the window 10086 that provides access to the lateral terminals 10088 is oriented parallel to the insertion direction A and is completely positioned in one of the two grooves 10022.

[0132] During use, each of the first terminals 10038 is configured to receive a connector 10036 of the power tool 10012. More specifically, each first connector 10036 is configured to be inserted into the terminal 10038 along the insertion direction A. In contrast, the lateral terminal 10088 is arranged in the window 10086 of the groove 10022 and is configured to receive a plurality of lateral connectors 10089 of the power tool 10012. During use, the lateral connector 10089 is configured to be in sliding contact with the lateral terminal 10088 (e.g., slide along a surface of the terminal 10088 oriented parallel to the insertion direction A), whereby a biasing force acting perpendicular to the insertion direction A presses or otherwise forces the connector 10089 to come into contact with the terminal 10088. In the illustrated embodiment, connector 10089 is configured to apply a contact force (e.g., inwardly toward terminals 10088) to produce the desired contact, but in other embodiments, terminals 10088 may be biased outwardly to engage connector 10089. In still other embodiments, both connector 10089 and terminals 10088 may be biased to engage one another.

[0133] like Fig.26A and Fig.27B As shown in , the positive lateral terminal 10090 of the plurality of lateral terminals 10088 is positioned on the first spaced-apart wall 10020 and is welded to different areas of the circuit board 10018. In this configuration, the positive lateral terminal 10090 can be operated separately from any one of the first terminals 10038. Fig.26B and Fig.27C As shown in , the negative lateral terminal 10092 of the plurality of lateral terminals 10088 is positioned on the second spaced-apart wall 10021 and welded to the first leg 10048 of one of the pair of first terminals 10038. In this configuration, the lateral terminal 10088 is connected in parallel with at least one of the first terminals 10038.

[0134] Fig.28 and Fig.29 The lateral connector 10089 is shown disposed in the rail 10030 of the mounting point 10015 and configured to engage the lateral terminal 10088 when the battery pack 10010 is fully mounted on the power tool 10012 .

[0135] like Fig.27B As shown in , the positive lateral terminal 10090 includes a shield 10094 to physically and electrically isolate the lateral terminal 10088 from the first terminal 10038. The shield 10094 prevents a short circuit between the lateral terminal 10088 and the first terminal 10038 and seals the internal cavity of the battery pack 10010 to prevent dust and debris from entering through the window 10086.

[0136] Fig.30 Many alternative embodiments 40K to 40U of the terminal are shown. The second terminal 40K to 40U can replace any of the previously described terminals. The terminal 40K includes a pair of spaced terminal walls 42K, a pair of legs 64K, a rear wall 65K, and a pair of forked pieces 66K. The thickness of the spaced terminal walls 42K is greater than the thickness of the pair of forked pieces 66K. The terminal 40L includes components similar to the second terminal 40K, but a pair of forked pieces 66L and a pair of spaced walls 65L, 42L have equal thickness. The terminal 40M includes components similar to the second terminal 40K, 40L, but the transition between a pair of spaced terminal walls 42M and the rear wall 65M has a greater radius of curvature than the terminals 40K, 40L. In addition, the thickness of the forked pieces 66M decreases as they extend farther from the spaced terminal walls 42M. Terminal 40N includes components similar to terminals 40K to 40M, but includes a pair of bridged terminal walls 43N instead of spaced apart terminal walls 42K to 42M. Bridging wall 43N also includes through hole 45N on the top surface and does not include a rear wall. Terminal 40O includes components similar to second terminal 40N, but through hole 45O is bored. Terminal 40P includes components similar to terminals 40N and 40O, but the thickness of a pair of bridged terminal walls 43P is greater than the thickness of the corresponding fork 66P. Terminal 40Q includes components similar to terminals 40N to 40P, but through hole 45Q includes a curved countersunk hole. Terminal 40R includes components similar to terminals 40N to 40Q, but through hole 45R includes a countersunk hole. Terminal 40S includes components similar to second terminals 40N to 40R, but does not include through hole 43S in the bridged wall. However, terminal 40S includes a rear wall 65S. Terminal 40T includes similar components as terminal 40S, but includes a rear wall 65T having multiple layers of sheet metal.

[0137] FIG. 34A to FIG. 34C An alternative embodiment 40U of a terminal is shown. More specifically, the terminal 40U is generally formed of a solid block of a metallic material (e.g., copper, aluminum, etc.) and is assembled and / or machined to define a recess 41U therein that is sized to accommodate a corresponding blade or connector 43U. By being formed of a solid material rather than a sheet material (e.g., metal), the terminal 40U shown is able to accommodate relatively large current rates. As shown, the resulting recess 41U can be supplemented with a spring 45U (e.g., an inclined spring) positioned therein to help retain the blade 43U therein (see Fig.34C In yet other embodiments, the material forming the terminal 40U may be coated with, for example, gold, etc., to reduce current resistance and corrosion.

[0138] FIG. 35A to FIG. 35CAlternative embodiments of terminals 40V, 40W are shown which are generally cylindrical in configuration. The first terminal 40V includes a series of pivotable conductors 41V which are removably attached to the terminal 40V for accommodating any changes in size or position between the male connector 43V and the female terminal 40V. Although the illustrated Fig.35A The configuration of illustrative embodiments shows that both the connector 43V and the terminal 40V have the conductor 41V included therein, but it should be understood that in other embodiments, only one of them may include such a conductor 41V.

[0139] Fig.35B And 35C shows another embodiment in which a wire turn spring 47W (e.g., a canted spring) is incorporated into one of the terminal 40W or the connector 51W. The wire turn spring 47W operates as discussed above and is configured to both help retain the connector 51W within the terminal 40W and improve conductivity between the two elements.

[0140] Various features and advantages of the invention are set forth in the following claims.

Claims

1. A battery pack having an electrical connector for use with an electric tool, the battery pack comprising: a housing containing one or more battery cells; A first terminal electrically connected to the battery cell, the first terminal comprising a pair of spaced-apart terminal walls and a wire turn spring, the pair of spaced-apart terminal walls forming a gap therebetween, the wire turn spring being at least partially positioned within the gap, wherein when the electrical connector is at least partially positioned within the gap, the wire turn spring is configured to selectively engage with the electrical connector of the power tool and form an electrical connection.

2. The battery pack according to claim 1, wherein: The wire turn spring is inclined.

3. The battery pack according to claim 1, wherein: The first terminal is introduced into the gap in a first insertion direction, and wherein the wire turn spring is inclined such that the wire turn spring generates a compression direction perpendicular to the insertion direction.

4. The battery pack according to claim 1, wherein: The battery pack further includes a circuit board disposed in the housing, the circuit board being in electrical communication with the one or more battery cells and the first terminal.

5. The battery pack according to claim 4, wherein: The first terminal includes a pair of legs mounted to the circuit board.

6. The battery pack according to claim 1, wherein: At least one terminal wall defines a recess therein, and wherein the spring is at least partially positioned within the recess.

7. The battery pack according to claim 6, wherein: Both terminal walls define a groove therein, and wherein the spring is at least partially positioned in both grooves.

8. The battery pack according to claim 1, wherein: The first terminal defines a mid-plane located equidistant from the two terminal walls, and wherein the wire turn spring is located on both sides of the mid-plane.

9. The battery pack according to claim 1, wherein: The wire turn spring is arranged in a U-shape.

10. A battery pack having an electrical connector for use with a power tool, the battery pack comprising: a housing containing one or more battery cells therein; a terminal in electrical communication with the battery cell, the terminal being configured to receive an electrical connector of the power tool and form an electrical connection therewith, the terminal comprising: a pair of external forks, and A pair of inner prongs are nested between the pair of outer prongs.

11. The battery pack according to claim 10, wherein: The pair of outer forks has a different shape than the pair of inner forks.

12. The battery pack according to claim 10, wherein: Both the pair of outer tines and the pair of inner tines are formed from a single unitary piece of material.

13. The battery pack according to claim 10, wherein: The pair of outer tines and the pair of inner tines are electrically isolated from each other.

14. The battery pack according to claim 10, wherein: The pair of outer forks has a first insertion depth, wherein the pair of inner forks has a second insertion depth, and wherein the first insertion depth is less than the second insertion depth.

15. The battery pack according to claim 10, wherein: The pair of outer forks defines a first insertion axis parallel to the insertion direction, wherein the pair of inner forks defines a second insertion axis parallel to the insertion direction, and wherein the first insertion axis is not coaxial with the second insertion axis.

16. The battery pack according to claim 15, wherein: The pair of outer forks and the pair of inner forks are both coupled to a circuit board, wherein the first insertion axis is spaced a first distance from the circuit board, and wherein the second insertion axis is spaced a second distance from the circuit board that is greater than the first distance.

17. The battery pack according to claim 15, wherein: The pair of outer forks has a different insertion depth than the pair of inner forks.

18. The battery pack according to claim 10, wherein: The terminal is a first terminal, and further includes a second terminal in electrical communication with the battery cell, and wherein the second terminal is different from the first terminal.

19. The battery pack according to claim 10, wherein: The pair of inner forks are interdigitated.

20. A battery pack having an electrical connector for use with a power tool, the battery pack comprising: a housing containing one or more battery cells therein, the housing having a tool engagement portion configured to releasably engage the power tool and define an insertion direction; and A lateral terminal is configured to form an electrical connection with an electrical connector of the power tool, wherein the lateral terminal is accessible through the housing via a window, and wherein the window is oriented parallel to the insertion direction.

21. The battery pack according to claim 20, wherein: The housing further defines a pair of grooves configured to mechanically engage and retain a portion of the power tool therein, wherein the grooves extend parallel to the insertion direction.

22. The battery pack according to claim 21, wherein: The window is positioned in one of the pair of grooves.

23. The battery pack of claim 21, further comprising a plurality of terminals positioned between the pair of grooves.

24. The battery pack of claim 20, further comprising one or more terminals accessible via the opening in the housing, and wherein: The opening in the housing is at least partially oriented orthogonal to the insertion direction.

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