Battery adapter for power tools

Abstract

The battery adapter can be used with off-brand battery manufacturers to power power tools. The battery adapter is configured to monitor the voltage, temperature, and power level of the battery. By monitoring these levels, it helps prevent the tool from over-discharging the battery and also helps prevent overheating. The battery adapter has a visible battery power level indicator actuated by a switch, which visibly displays to the user a general indication of the power remaining in the battery. The battery adapter can electrically disconnect the battery if the monitored temperature reaches a specific threshold. The battery adapter can also electrically disconnect when the battery adapter and the off-brand battery are connected to a recharging station.

Description

Cross - reference to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 351,865, entitled "BATTERY ADAPTER FOR POWER TOOLS", filed on June 14, 2022.

Technical Field

[0002] The technology disclosed herein generally relates to battery adapters, and more particularly to a type of battery adapter that enables an off - brand battery to be utilized by a power tool such as a fastener driving tool. Embodiments are specifically disclosed as a battery adapter for a fastener driving tool having a temperature sensor, a current sensor, a voltage sensor, and a plurality of LEDs, where the battery adapter provides operational data regarding the battery to automatically disable or electrically disconnect the battery when a pre - set temperature or current threshold is exceeded and a low battery voltage threshold occurs, and also to visually display the power level state of the battery to the user.

[0003] The battery adapter has a first side (or face) that physically and electrically connects to a power tool. The opposite second side of the battery adapter physically and electrically connects to an external off - brand battery pack. The battery adapter is configured to supply current from the external off - brand battery pack to the tool. By using this type of battery adapter, it enables an external power tool to be powered by an otherwise incompatible external battery pack. Note that in this specification, the battery pack may sometimes be described as an "off - brand battery". In other words, the battery pack and the power tool typically cannot be used together because they are of different brands, so the battery is "off - brand" compared to the power tool.

[0004] The battery adapter includes a switching transistor, such as a power MOSFET, configured to operate properly while continuously monitoring the temperature of an external off-brand battery pack. When the external off-brand battery pack reaches or exceeds a specific temperature range threshold, the battery adapter is configured to electrically disconnect the external off-brand battery pack from the power supply.

[0005] The battery adapter has a current shunt configured to monitor the magnitude of the current flow. The battery adapter is configured to electrically disconnect the external off-brand battery pack when the current usage of the tool is greater than the rated output of the external off-brand battery pack, and also allows for a predetermined temporary "overcurrent" state to exist without disconnecting the current from the battery, as long as the overcurrent condition exists for less than a predetermined time interval. The current control circuit provides a predetermined set of maximum allowable current ranges for a corresponding set of predetermined time intervals before disconnecting the battery current.

[0006] The battery adapter includes specific safety features not commonly found in previous conventional battery adapters sold for use with power tools. Some of the safety features disclosed herein include a reverse current detection circuit, an overcurrent versus time detection circuit, and a "remote" battery temperature monitoring circuit, and the battery adapter has the ability to disconnect the battery pack from powering the power tool if one of these safety conditions is violated.

[0007] Statement Regarding Federally Sponsored Research and Development None.

Background Art

[0008] External batteries are commonly used in power tools such as fastener driving tools. The battery provides sufficient power and ease of use for general cordless tool operation. Generally, each tool manufacturer sells its own brand of battery for use only with its own tools. For example, DeWalt (trademark) tools operate only with DeWalt batteries, and Makita (trademark) tools operate only with Makita batteries.

[0009] A common problem is that many users have batteries from one manufacturer (i.e., DeWalt) but also have tools from other manufacturers such as Senco. Not only do the electrical connections and physical shapes differ between different battery manufacturers, but the safety requirements necessary to safely use each battery also differ. SUMMARY OF THE INVENTION

[0010] Accordingly, one advantage is to provide a battery adapter for a power tool configured to use an off-brand battery while monitoring the battery temperature, thereby being able to electrically disconnect the off-brand battery if a specific temperature range threshold is reached or exceeded.

[0011] Another advantage is to provide a battery adapter for a power tool configured to use an off-brand battery while monitoring the current level, thereby being able to electrically disconnect the off-brand battery when the battery adapter and the off-brand battery are connected to a charging station.

[0012] Yet another advantage is to provide a battery adapter for a power tool configured to use an off-brand battery while monitoring the power level of the off-brand battery, thereby enabling the adapter to visually display an approximate battery charge level.

[0013] Another advantage is to provide a battery adapter for a power tool configured to use an off-brand battery while monitoring the magnitude of the current output by the off-brand battery and, when the current exceeds an "overcurrent" threshold, also monitoring the duration of the "overcurrent" state. If the "overcurrent" state persists longer than a predetermined time interval, the system controller of the battery adapter will disconnect the power current path between the off-brand battery and the power tool. Further, there can be a plurality of thresholds of acceptable "overcurrent" magnitudes, each having a maximum length of an individual duration before the system controller disconnects the power current path.

[0014] Additional advantages and other novel features will be in part described in the following description, in part will become apparent to those skilled in the art by considering the following, or can be learned by practicing the techniques disclosed herein.

[0015] To achieve the foregoing and other advantages, according to one aspect, a battery adapter is provided, the battery adapter comprising: (a) a housing having a first side and an opposite second side; (b) an electronic control circuit including a computer processing circuit, a memory circuit including instructions executable by the processing circuit, an input / output interface circuit, a current shunt, a current sensing circuit, and a power switching semiconductor for switching a power current path; (c) the first side of the housing being physically and electrically attached to an external power tool; (d) the second side of the housing being physically and electrically mated with an external battery pack, the external power tool and the external battery pack being incompatible with each other; (e) the battery adapter being operable to provide a current flowing from the external battery pack to the external power tool, thereby powering the external power tool; (f) the current sensing circuit being operable to receive a voltage signal from the current shunt, and when the voltage signal exhibits a correct polarity and an acceptable magnitude, the power switching semiconductor being operable to enable current to flow from the external battery pack to the external power tool using the power current path; (g) when the voltage signal from the current shunt exhibits an incorrect polarity, the power switching semiconductor being operable to disconnect the power current path.

[0016] According to another aspect, a battery adapter is provided, the battery adapter comprising: (a) a housing having a first side and an opposite second side; (b) an electronic control circuit including a computer processing circuit, a memory circuit including instructions executable by the processing circuit, an input / output interface circuit, a current shunt, a current sensing circuit, and a power switching semiconductor for switching a power current path; (c) the first side of the housing being physically and electrically attached to an external power tool; (d) the second side of the housing being physically and electrically mated with an external battery pack, the external power tool and the external battery pack being incompatible with each other; (e) the battery adapter providing a current flowing from the external battery pack to the external power tool, thereby powering the external power tool; (f) the current sensing circuit receiving a voltage signal from the current shunt, and when the voltage signal exhibits a magnitude of a predetermined overcurrent for less than a predetermined allowable time interval, the power switching semiconductor being operable to allow current to flow from the external battery pack to the external power tool using the power current path; (g) when the voltage signal from the current shunt exhibits a magnitude of an overcurrent that persists for a duration longer than a predetermined allowable time interval, the power switching semiconductor being operable to disconnect the power current path.

[0017] According to yet another aspect, a battery adapter is provided, the battery adapter comprising: (a) a housing having a first side and an opposite second side; (b) an electronic control circuit including a computer processing circuit, a memory circuit including instructions executable by the processing circuit, an input / output interface circuit, and a power switching semiconductor; (c) the first side of the housing being physically and electrically attached to an external power tool; (d) the second side of the housing being physically and electrically mated with an external battery pack, the external power tool and the external battery pack being incompatible with each other; (e) the external battery pack comprising a remote temperature sensing circuit for remotely sensing electrical characteristics of on-board components; (f) the battery adapter providing current flowing from the external battery pack to the external power tool, thereby powering the external power tool; and (g) the power switching semiconductor being operable to disconnect the current flowing from the external battery pack when a predetermined temperature threshold determined by the remote temperature sensing circuit is exceeded.

[0018] According to yet another aspect, a battery adapter is provided, the battery adapter comprising: (a) a housing having a first side and an opposite second side; (b) an electronic control circuit including a computer processing circuit, a memory circuit including instructions executable by the processing circuit, an input / output interface circuit, a voltage sensing circuit, a power current path, and a plurality of colored light-emitting diodes (LEDs) presenting at least two different colors; (c) a battery state switch; wherein (d) the first side of the housing is operable to be physically and electrically attached to an external power tool; (e) the second side of the housing is operable to physically and electrically mate with an external battery pack, the external power tool and the external battery pack being incompatible; (f) the battery adapter uses the power current path to direct the current flowing from the external battery pack to the tool, thereby powering the tool; (g) the voltage sensing circuit is connected to the power current path, thereby detecting the magnitude of the voltage output by the external battery pack; (h) the voltage sensing circuit is further connected to the input / output interface circuit; (i) at least one of the input / output interface circuit and the computer processing circuit includes an analog-to-digital converter (ADC) that generates a digital signal for analysis by the processing circuit; (j) when the battery state switch is actuated, the plurality of colored LEDs are energized to visually indicate the state of the energy level of the external battery pack; and (k) the processing circuit determines which of the plurality of colored LEDs should be illuminated based on the value of the digital signal and generates at least one output signal for controlling the plurality of colored LEDs.

[0019] Further advantages will become apparent to those skilled in the art from the following description and drawings, which illustrate and describe a preferred embodiment in one of the best modes contemplated for carrying out the technology. As will be understood, the technology disclosed herein is capable of other different embodiments and some of the details thereof are capable of modification in various obvious respects without departing from the principles thereof. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.

Brief Description of the Drawings

[0020] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate some aspects of the techniques disclosed herein and, together with the description and claims, serve to explain the principles of the technology. In the drawings,

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DETAILED DESCRIPTION OF THE INVENTION

[0035] Here, preferred embodiments of the present invention will be referred to in detail. The examples are shown in the accompanying drawings, and like numbers indicate the same elements throughout the drawings.

[0036] It should be understood that the technology disclosed in this specification is not limited, in its application, to the details of the construction and arrangement of components described in the following description or shown in the drawings. The technology disclosed in this specification allows for other embodiments and can be implemented or executed in various ways. It should also be understood that the expressions and terms used in this specification are for the purpose of description and should not be regarded as limiting. The use of "including", "comprising", or "having" and their variants in this specification means including the items listed thereafter and their equivalents, as well as additional items. Unless otherwise specifically limited, the terms "connected", "coupled", or "mounted" and their variants used in this specification are widely used and include direct and indirect connections, couplings, or mountings. Furthermore, the terms "connected" or "coupled" and their variants are not limited to physical or mechanical connections or couplings. Additionally, the terms "communicating with" or "in communication with" mean that two different physical or virtual elements transfer signals or information between each other in some form, regardless of whether the transmission of the signals or information is direct or whether there are additional physical or virtual elements involved in the transmission of the signals or information between them. Moreover, the term "in communication with" also refers to a mechanical, hydraulic, or pneumatic system where one end of the "communication" ("the first end") can be the "cause" of a certain motive force (mechanical movement, or a change in hydraulic or pneumatic state), and the other end of the "communication" ("the second end") can be affected by the movement / state change, regardless of whether there are intermediate components between the "first end" and the "second end".If a product has moving parts that depend on a magnetic field, or detects a change in a magnetic field in some way, or data is transferred from one electronic device to another by using a magnetic field, then those situations can be referred to as "magnetically communicating" with each other, in which case one end of the "communication" can induce a magnetic field and the other end can receive that magnetic field and be affected by it (or otherwise influenced).

[0037] For terms such as "first" or "second" that precede element names, such as a first inlet, a second inlet, etc., they are used for identification purposes to distinguish similar or related elements, results, or concepts, and are not necessarily intended to imply an order. Nor are the terms "first" or "second" intended to exclude the inclusion of additional similar or related elements, results, or concepts, unless otherwise indicated.

[0038] Furthermore, the embodiments disclosed herein may be illustrated and described for purposes of explanation as if most of the components were implemented only in hardware, but it should be understood that they include both hardware and electronic components or modules.

[0039] However, those skilled in the art will recognize that, based on reading the detailed embodiments for implementing this invention, in at least one embodiment, the electronically based aspects of the technology disclosed herein can be implemented in software. Therefore, it should be noted that multiple hardware and software-based devices, as well as multiple different structural components, can be utilized to implement the technology disclosed herein. Further, when software is utilized, the processing circuit for executing such software may be a general-purpose computer, while on the other hand, it can perform all functions that can be executed in other ways by a dedicated computer that can be designed specifically for implementing this technology.

[0040] As used herein, the term "circuit" can represent an actual electronic circuit, such as an integrated circuit chip (or a portion thereof), or a function executed by a processing circuit, such as a microprocessor or ASIC, that includes a logical state machine or another form of processing element (including a sequential processing circuit). It will be understood that a particular type of circuit may be some type of analog or digital circuit, but such a circuit may, in some cases, be implemented in software by a logical state machine or a sequential processor. In other words, when a processing circuit is used to perform a desired function (such as a demodulation function) used in the techniques disclosed herein, there may not be a particular "circuit" that is referred to as a "demodulation circuit", but there will be a demodulation "function" that is executed by software. All of these possibilities have been contemplated by the inventors and are within the principles of this technology when considering "circuits".

[0041] In this technical disclosure, the terms "battery" and "battery pack" are generally used interchangeably. When dealing with actual battery pack designs, design engineers typically refer to individual battery cells as "batteries" and a group of such battery cells (connected either in series or in parallel, or a combination of both types of connections) as a "battery pack". In this specification, the inventors may use the phrase "battery pack", which, of course, has a fairly specific meaning, namely, having two or more battery cells. However, even though everyone in this technical field knows that the correct term is "battery pack", it is well known that most consumers refer to the energy source of a power tool as a "battery". Accordingly, in this specification, the term "battery" will generally refer to a "battery pack". When individual battery cells are specifically discussed in this specification, the term "battery cell" is used.

[0042] Referring now to FIG. 1, a SENCO (registered trademark) fastener driving tool 5 (e.g., FUSION Finisher Model No. F-15XP Nailer, etc.) is shown in a right side view. The power tool 5 includes a fastener magazine 6, a motor housing portion 7, a handle portion 8 with a trigger, and a battery mounting portion 9. Normally, a Senco brand battery is mounted in the battery mounting portion 9 and then used to supply power to a motor housed inside the motor housing portion 7. However, FIG. 1 shows a battery adapter 10 mounted in the battery mounting portion 9. An off-brand battery 12 (e.g., DeWalt (registered trademark) battery model numbers DCB240, DC182, or DCB203, etc.) is mounted on the battery adapter 10.

[0043] On a first side (or top) 20 (see FIG. 4), the battery adapter 10 is sized and shaped to fit into the battery mounting portion 9 in the same manner as a normal Senco brand battery. On a second side (or bottom) 30, the battery adapter 10 is sized and shaped to receive an off-brand battery 12 such as a DeWalt battery, which will be described in more detail below. In other words, in this illustrated embodiment, the first side 20 of the battery adapter 10 interfaces with the Senco tool and the second side 30 of the battery adapter 10 interfaces with the DeWalt battery.

[0044] Referring now to FIG. 2, a right side partial exploded view shows the battery adapter 10 removed from the power tool 5 and the off-brand battery 12 removed from the battery adapter. The battery adapter 10 can first be mounted in the battery mounting portion 9 of the power tool 5 and then the off-brand battery 12 can be mounted on the battery adapter. Alternatively, the off-brand battery 12 can first be mounted on the battery adapter 10 and then the combination of the off-brand battery and the battery adapter can be mounted on the power tool 5 in the battery mounting portion 9.

[0045] Referring now to FIG. 3, a perspective view of FIG. 2 is shown. As described above, the off-brand battery 12 and the battery adapter 10 can be mounted on the power tool 5, and then the off-brand battery 12 can be used to supply power to the electrical system of the tool (including the electric motor), enabling the tool 5 to operate. The tool 5 typically drives fasteners such as nails or staples into a substrate. The fasteners are stored in the magazine 6 and are sequentially driven through the fastener driver of the tool 5. The power tool 5 uses an electric motor to supply power to a lifter and move the driver to the "ready" position. The driver is released to drive the fastener into the substrate (using gas pressure in the form of a gas spring), and then the lift sequence starts again.

[0046] The Senco tools shown in FIGS. 1-3 are FUSION (registered trademark) tools that use pressurized gas to propel the driver and drive the fastener. This Senco FUSION tool has a pressurized storage chamber (inside the main housing of reference number 15) for storing the pressurized gas, and the lifter must move the driver against this gas pressure during the lift sequence. This is achieved by conducting current from the battery to the motor that operates the lifter. As described above, the battery adapter 10 facilitates the flow of current from the off-brand battery 12 to the power tool 5 (i.e., to the motor and other electronic circuits of the tool).

[0047] It should be noted that the batteries of each manufacturer have different electrical connectors and different physical connections. Without a battery adapter, for example, a DeWalt battery cannot be used in a Senco tool, and vice versa. In other words, a user cannot simply plug in a battery from any manufacturer into any power tool. The usefulness of the battery adapter is obvious to an owner who has one or more DeWalt batteries but wants to use them in a Senco tool.

[0048] Referring now to FIG. 4, an exploded view of the battery adapter 10 is shown. The upper portion 20 presents an upper surface 28. This upper surface 28 seats directly against the battery mounting portion 9 of the power tool 5.

[0049] The printed circuit board 100 (which may also be referred to herein as the "adapter electronic device" or "PCB") including the electronic components of the battery adapter 10 includes an electrical connection portion 22 to the power tool, a push button 25 (which may also be referred to herein as the "battery status switch" or "PB1"), and a plurality of LEDs 26 ("light emitting diodes").

[0050] The internal cover 23 covers a part of the PCB 100 including the button 25 and the plurality of LEDs 26. The LED light pipe 27 on the internal cover 23 is mounted directly above the plurality of LEDs 26. A pair of manual latches 24 enables the battery adapter 10 to be electrically disconnected from and removed from the power tool 5.

[0051] When the user presses the button 25 (assuming that the off-brand battery 12 is mounted on the battery adapter 10), the LEDs 26 light up to indicate how much energy remains in the battery. The visible light signal emitted by the LEDs 26 is enhanced by the LED light pipe 27. The LEDs 26 may also be referred to as a "gas gauge" to indicate how much "gas" (i.e., energy) remains in the off-brand battery 12. It is preferred that the LEDs 26 remain lit for only a relatively short time interval, such as 3 seconds or 5 seconds. After that time interval has elapsed, the LEDs 26 should be de-energized to conserve battery energy.

[0052] In a preferred embodiment, LED 26 includes two green LEDs, one yellow LED, and one red LED. When PB1 25 is pressed, five different battery state indications become possible. In the first state, all four LEDs 26 are lit, indicating that the off-brand battery 12 is fully charged. In other words, two green, one yellow, and one red LEDs are lit. In the second state, only three of the LEDs 26 are lit, indicating that the off-brand battery 12 is approximately 75% charged. In other words, one green, one yellow, and one red LED are lit. In the third state, only two of the LEDs 26 are lit, indicating that the off-brand battery 12 is approximately 50% charged. In this state, only the yellow and red LEDs are lit. In the fourth state, only a single red LED 26 is lit, indicating that the off-brand battery 12 is at low power (approximately 25% charged). In the fifth state, one red LED 26 blinks, indicating that the off-brand battery 12 needs to be recharged.

[0053] Another conceivable configuration is to use a three-color LED 26 to indicate the energy state of the off-brand battery 12. For example, if all the LEDs 26 are blinking or lit green, it means the power state is fully charged. For example, if all the LEDs 26 are blinking or lit yellow, it means the power state is low. For example, if all the LEDs 26 are blinking or lit red, it means the power state is zero and the off-brand battery 12 needs to be recharged. It is contemplated that the three colors can be any three colors in any order that the LED can display, depending on how the battery adapter designer chooses to indicate the battery charge state to the user.

[0054] It is also conceivable that the LED 26 could alternatively be a single color, and the battery state could be indicated by showing how many LEDs are lit (or not lit). For example, four lit LEDs would mean "fully charged", two or three lit LEDs would mean progressively "lower power", and one or zero lit LEDs would mean, for example, "virtually out of power and time to recharge".

[0055] Note that the push button switch (PB1) at 25 should be manually actuated by a human user of the power tool so that the current charge state of the battery 12 can be visually seen. When the push button ("battery state") switch 25 is actuated, in a preferred operating mode, the LED 26 will light up at short time intervals, such as 3 seconds or 5 seconds, as determined by the design engineer of the electronics of the power tool. It is preferred to keep the LED off most of the time, as otherwise there would be a constant power consumption of the battery.

[0056] The electrical connection to the off-brand battery 32 is attached to the PCB 100 on the side opposite to the side on which the electrical connection to the power tool 22 is located. The lower part 30 is firmly attached to the upper part 20 and covers the electrical connection to the PCB 100, the internal cover 27, and the off-brand battery 32.

[0057] Referring now to FIG. 5, a block diagram shows a portion of the major electronic and electrical components of battery adapter 10, off-brand battery 12, and Senco power tool 5. Senco power tool 5 includes a CPU 50 (a "central processing unit") which may sometimes be referred to herein as a microprocessor. Senco power tool 5 also optionally includes a power tool communication port 52 (or a "communication port"). The optional communication port 52 includes a serial data lead 46 for communicating with an external device such as battery adapter 10. Senco power tool 5 has a power tool "+" input lead 42 and a power tool "-" input lead 44 which are electrically connected to, for example, battery adapter 10. The CPU 50, the optional communication port 52, the power tool "+" input terminal lead (at 42), and the power tool "-" input terminal lead (at 44) are collectively referred to herein as "Senco power tool electronics" 40.

[0058] Off-brand battery 12 includes a battery temperature sensor 13 (or a "temperature sensor"), a battery communication port 15 (or a "communication port"), a battery "+" output lead 14, a battery "-" output lead 16, a battery serial data lead 18, and a plurality of battery temperature sensor output leads 17. The communication port 15 is optionally used to communicate with an external device such as battery adapter 10 via the battery serial data lead 18. Various types of data including important operating state information such as battery cell current, battery cell temperature, battery cell voltage level, etc. can be transferred from the battery. The battery "+" output lead 14 and the battery "-" output lead 16 supply power to an external device such as a power tool. The temperature sensor 13 provides temperature information to an external device such as battery adapter 10 via the battery temperature sensor output lead wire 17.

[0059] Often, the battery temperature sensor is a relatively inexpensive thermistor that has variable resistance characteristics that change as its temperature changes. (The resistance value of a thermistor typically decreases as the temperature of the thermistor increases.) As shown in FIG. 5, the thermistor 13 has two leads 17. One of the leads of the thermistor 13 can be electrically connected (inside the battery pack 12) to either the “+ output” terminal (at lead 14) or the “− output” terminal (at lead 16), in which case only a single wire at 17 is needed to interface to the interface amplifier 146 within the battery adapter. This is a common configuration for many DeWalt batteries.

[0060] The battery adapter 10 includes a PCB 100, and the PCB includes a system controller 110 (sometimes referred to herein as the “CPU”). The controller 100 typically includes a microprocessor or microcomputer that functions as a processing circuit. Also, at least one memory circuit 112 (sometimes also referred to herein as “MEM”) is typically part of the controller and includes circuit elements of random access memory (RAM) and read only memory (ROM). A non-volatile memory device such as an EEPROM, NVRAM, or flash memory device is typically included to store user input information (when applicable). The CPU 110 and the MEM 112 communicate with each other via a memory and data bus 116. (Note: Such a bus can also include interrupt lines and memory select lines if desired by the battery adapter designer.

[0061] The I / O interface circuit 114 (which may also be referred to as the "I / O interface" in this specification (on the drawing)) interfaces with several inputs and outputs on the PCB 100. The CPU 110 and the I / O interface circuit 114 communicate with each other via the memory and data bus 118. The inputs on the PCB 100 include PB1 25, an optional communication port #1 120 ("communication port #1"), an optional temperature sensor 140, a current sensor 142, a voltage sensor 144, a current shunt 130, and a battery temperature sensor interface / amplifier 146 (which may also be referred to as the "interface / amplifier" in this specification (on the drawing)). The outputs included on the PCB 100 are the power MOSFET 132, an optional communication port #2 122 ("communication port #2"), and a colored LED (light-emitting diode) 124. (Note that the LED 124 in FIG. 5 is the same component as the LED 26 in FIG. 4.) Of course, depending on the designer's requirements, other circuits and components can be envisioned for the PCB 100, and such other circuits include the fuse F1 (or soluble link) and the voltage regulator 134.

[0062] The battery communication port 15 can be configured to communicate with the optional communication port #1 via the battery serial data read 18. The battery temperature sensor can be configured to communicate with the interface / amplifier 146 via a plurality of battery temperature sensor output leads 17. The current shunt 130 and the current sensor 142 include a plurality of lead wires 138 therebetween, and in this case, the current shunt includes at least one low-resistance resistor (s) that generates a relatively low differential voltage signal for the current sensor 142. The current shunt resistor is in series with either a high-current path that starts from the +OUTPUT lead at 14, passes through the fuse F1 and the power MOSFET 132, and continues to the +IN lead at 42, or a high-current path that starts from the -OUTPUT lead at 16, passes through the power MOSFET 132, and continues to the -IN lead at 44.

[0063] The I / O interface circuit 114 includes an output control lead 126 to the colored LED 124 and an output control lead 128 to the power MOSFET 132. The optional communication port #2 122 can communicate with an optional communication port 52 via the serial data lead 46.

[0064] In the illustrated embodiment, the fuse F1 is disposed on the “+” battery power lead 136 upstream of the voltage regulator 134.

[0065] Reverse current disconnection

[0066] One purpose of the current shunt 130 is to prevent the off-brand battery 12 from being charged while it is attached to the battery adapter 10. This can occur when the user places the battery adapter 10 with the off-brand battery 12 attached on a Senco brand battery charger. Due to manufacturing differences between batteries, the off-brand battery 12 is preferably recharged using its own specific battery charger. For example, if the off-brand battery is a DeWalt™ battery, the off-brand battery should be charged by a DeWalt™ battery charger.

[0067] However, when the battery adapter 10 with the off-brand battery 12 attached is placed on a Senco brand battery charger, a reverse current can occur. The current shunt 130 is configured to detect this reverse current flow and send a signal to the I / O interface 114, and the signal then proceeds to the CPU 50. The CPU 50 is programmed to electrically disconnect the battery adapter 10 when a reverse current is detected.

[0068] In other words, the current sensing circuit 142 uses the voltage signal (at 138) generated by the current shunt 130 to determine whether the current flowing through the power current paths 14 and 16 has the correct polarity and an acceptable magnitude. If so, the power switching semiconductor (MOSFET 132), under the control of the CPU 110, is configured to allow current to continue to flow from the external battery pack 12 to the power tool 5 through the power current paths 14 and 16 including the fuse F1 and the successive power current paths at 42 and 44. On the other hand, if the current flowing through the power current paths 14 and 16 does not have the correct polarity, the voltage signal (at 138) generated by the current shunt 130 detects that incorrect polarity, and the power switching semiconductor, again under the control of the CPU 110, is configured to disconnect the power current path. This is typically achieved simply by turning off the semiconductor 132 (MOSFET). It will be understood that the power MOSFET 132 may be composed of a single transistor that "opens" or "closes" only one of the power current paths, or may be composed of a pair of transistors that "open" or "close" both of the power current paths.

[0069] The currents and "signals" flowing through the various power current paths and voltage or current sensing circuits within the circuit of FIG. 5 are effectively direct current (DC), and it will be further understood that the characterization of "polarity" essentially refers to the direction of current flow. The more complex concept of polarity is typically only required when an arbitrarily selected type of battery pack includes a device of the AC generator (or alternator) type to generate an alternating current (AC) output for powering, for example, a tool including an AC motor. If that type of battery pack is designed for a fastening tool, the circuit shown in FIG. 5 can still be used for the purposes described herein with only minor modifications. For one, even when conditions are normal, the magnitude of an AC signal is constantly changing continuously, and thus, the overcurrent detection method may operate somewhat more slowly because a determination that an overcurrent exists may need to wait until the waveform (presumably a sine wave or square wave) moves away from the 0 axis before noticing an abnormally large magnitude.

[0070] In the above-described embodiment where a current sensing circuit 142 is required to detect whether reverse current is occurring, the current sensor 138 must have the ability to detect the magnitudes of both positive and negative voltages. In such a design, a standard differential amplifier circuit is sufficient as long as it is connected to both the positive and negative voltage sources and its operational amplifier can output both positive and negative voltage signals. Further, the input / output interface circuit 114 must also have the ability to convert the magnitudes of both positive and negative voltages into digital signal values. In this way, the system controller (CPU 110) can identify when a current flow of inappropriate polarity is passing through the current shunt 130.

[0071] Temperature Disconnection

[0072] A typical power tool battery pack includes a temperature sensor such as temperature sensor 13 within off-brand battery 12. However, each manufacturer's tool is typically preconfigured to receive information from the manufacturer-branded battery in order to shut down the tool in the event of a high temperature alert.

[0073] Battery adapter 10 includes fuse F1 and power MOSFET 132, as well as interface / amplifier 146 for detecting high temperature events. Preferably, power MOSFET 132 is configured to alert at a temperature of approximately 150 ± 5°C for at least 300 ms. Of course, the power MOSFET can be configured to alert in almost any temperature range determined by the system designer.

[0074] In an optional operating mode, battery temperature sensor 13 can be preconfigured to send (as a digital signal) a temperature alert via a plurality of battery temperature sensor output leads 17. In this optional configuration, interface / amplifier 146 receives any temperature alerts sent by temperature sensor 13. Interface / amplifier 146 sends these temperature alerts to I / O interface 114, which are then sent to CPU 50. CPU 50 is configured to electrically disconnect off-brand battery 12 in the event of a high temperature alert.

[0075] In a more conventional configuration, battery temperature sensor 13 is a more passive component such as a thermistor that exhibits an electrical characteristic that changes as its temperature changes. In the case of a thermistor, its resistance value will change in the opposite direction with respect to its temperature. This changing resistance can be remotely measured as a voltage signal directed towards interface / amplifier 146. In such a configuration, interface amplifier 146 is preferably a differential amplifier.

[0076] Referring now to FIG. 6, there is provided a logic flow chart showing a portion of the important logic operations used by the system controller for the power-on routine. In logic function 200, the initialization of the CPU and the I / O interface is started. Next, in logic function 202, the power MOSFETs are turned off until their states are known. Next, in logic function 204, the CPU starts an input scan and all sensors and (optional) communication ports are scanned for data. Next, in logic function 206, the CPU checks the threshold settings of the sensors used for various alarm detections.

[0077] The routine then reaches a logical decision 210 where the sensors are queried for any alarm conditions. If no alarm condition is detected, the routine proceeds to logic function 214 where the power MOSFETs are turned on. Next, in logic function 216, the CPU returns to the normal execution routine (see FIGS. 7A - 7B).

[0078] However, if the answer is "yes" in logic function 210, an alarm condition is detected in logic function 210 and in logic function 212, the CPU proceeds to the alarm handler routine (see FIG. 8). Once the alarm handler routine is complete, the power-on routine proceeds to logic function 220 where it is queried whether it is safe to proceed. If the answer is "yes", the routine flows to the above-mentioned logic function 214. Or, if the answer is "no", the routine continues to logic function 222 where the power MOSFETs are kept off. Next, in logic function 224, an output alarm condition message is sent to the power tool. Next, in logic function 226, the CPU instructs an alarm signal to energize a visual indicator (either on the power tool or on the battery adapter, depending on the preference of the system designer). Next, in logic function 228, the time and date of the alarm condition are stored in memory. Finally, in logic function 250, the power-on routine ends and returns from this subroutine.

[0079] Overcurrent or undervoltage disconnection

[0080] Referring now to FIG. 7A, a flowchart showing the first part of the normal execution routine is provided. The routine begins at logic function 300 by scanning the analog inputs. Next, at logic function 302, the system controller compares the data values of the analog inputs to their alarm thresholds. Note that according to logic function 304, the sensor data for the current is scanned more quickly than the other inputs.

[0081] Next, at logic function 306, the battery output current versus time is determined for a plurality of threshold settings. As a preferred example, when I ≦ 65 A (± about 5 amperes), the condition is normal, when 65 A < I ≦ 95 A (± about 5 amperes), the condition is allowed to persist for 0.4 seconds, when 95 A < I ≦ 175 A (± about 5 amperes), the condition is allowed to persist for 0.05 seconds, and when 175 A < I ≦ 250 A (± about 5 amperes), the condition is allowed to persist for 0.001 seconds. Of course, these thresholds can be modified according to the specific safety requirements that the designer is planning to use and can vary sufficiently according to the type of battery pack for which this alarm detection circuit is designed.

[0082] Next, at logic function 308, the battery output voltage (“V”) is determined for use with the “gas gauge” 26, and which of the LEDs 124 should be illuminated is determined for a plurality of threshold settings. For a particular type of lithium battery cell chemistry, a preferred set of ranges of battery state thresholds can be selected for use with an 18-volt battery pack including five battery cells in series. For example, in a fully charged battery state (when V ≧ 20.5 VDC ), all four LEDs (two green LEDs, one yellow LED, and one red LED) are energized, and then in a lower battery charge state, (19.8 VDC ≦ V < 20.5 VDCFor the voltage range of), only three LEDs (one green LED, one yellow LED, and one red LED) are energized. Next, in a lower battery charge state, (17.5 VDC ≦V < 19.8 VDC For the voltage range of), only two LEDs (one yellow LED and one red LED) are energized. Next, in a lower battery charge state, (16.8 VDC <V ≦ 17.5 VDC For the voltage range of), only a single LED (i.e., one red LED) is energized. Next, in a lower battery charge state (which is the lowest battery charge state determined), (e.g., V < 16.8 VDC For the voltage range of), only a single LED (i.e., one red LED) is energized and blinks. These thresholds can be modified according to the specific requirements that the system designer is planning to use. In this case too, it is envisioned that they are likely to vary for each battery pack.

[0083] It should be noted that the above threshold voltage levels for use in the "gas gauge" LED are typically determined in the "no load" state. In other words, the power tool is not currently being used, for example, to drive nails, or turn screws, or rotate a saw. Therefore, the battery 12 is not being loaded to a great extent. (Of course, it is supplying power to the electronics of the battery adapter 100 and the power tool 5, but these electrical loads are not substantial compared to the so-called "full load" state)

[0084] Next, in the logic decision 310, the system controller queries whether the battery current is above a predetermined cutoff value. If "yes", the logic is directed to the logic function 312 and the power MOSFET is turned off. Next, in the logic function 314, the logic is directed to the alarm handler routine (see Figure 8). Once the alarm handler routine is executed, in the logic function 350, the normal execution routine resumes from this routine.

[0085] However, if the result in logic function 310 is "No", another logical decision at 320 determines whether the battery voltage is less than a predetermined shut-off value. If "Yes", the logic flows to logic function 312 as described above. If "No", the logic flows to arrow "7B-1" and continues in FIG. 7B. As an example, an 18-volt battery pack having five battery cells in series is discharged under load to the extent that the overall output voltage drops to about 15 volts DC (or 14.4 volts DC in the worst case), the battery pack must be quickly disconnected; otherwise, permanent damage to these battery cells may occur. This 14.4-volt threshold is essentially the recommended "turn-off" limit for such an 18-volt battery pack. Of course, other battery designs using different numbers of battery cells and different overall output voltages have numerically different required "turn-off" voltage limits. Further, when a partially depleted battery experiences a high inrush current, which often occurs when the motor of a larger power tool (e.g., a nail gun or a power screwdriver) is turned on, it is generally preferred to further temporarily reduce the battery pack voltage over a short time interval without disconnecting the battery. For example, when an 18-volt battery pack is partially depleted, in the case of a relatively large power tool, it may experience an inrush current of about 100 amperes, and its voltage is reduced to about 10 volts over a maximum duration of about 50 milliseconds without being disconnected. This is an exception to the 14.4-volt minimum threshold voltage "rule" described above.

[0086] The overall operation of the flowchart of FIG. 7A regarding the functional logic function 306 can be summarized using somewhat different descriptions. As described above, there are multiple threshold settings for the magnitude of an acceptable battery output "overcurrent" that can be tolerated for a given (relatively short) time interval without the power transistor (MOSFET) 132 having to disconnect the battery current. This can also be described as the current sensing circuit 142 receiving a voltage signal from the current shunt 130 (at 138), and if the voltage signal exhibits a magnitude of a given overcurrent for less than a given acceptable time interval, the power switching semiconductor (MOSFET 132) is configured to allow current to flow from the external battery pack 12 to the power tool 5 using the power current paths (at 14, 16, 42, and 44). However, if the voltage signal from the current shunt exhibits a magnitude of an overcurrent that persists for a duration longer than an appropriate given acceptable time interval, the power switching semiconductor is configured to disconnect the power current path. In other words, the power transistor 132 will cut off the current flowing between paths 14, 16 and 42, 44. Note that by placing the MOSFET 132 "just before" the power current is supplied to the power tool 5 (see FIG. 5), the battery adapter 100 remains powered by the battery pack 12 even if the MOSFET 132 cuts off the current to the tool 5. This allows the battery adapter electronics to sense its input and continue to control its output while waiting for the overcurrent situation to resolve.

[0087] Continuing with this alternative explanation, the condition that the magnitude of a given overcurrent is less than a given acceptable time interval preferably includes at least two ranges of overcurrent magnitude and acceptable time interval, such that (a) the magnitude of the first overcurrent has a first maximum current magnitude that is allowed to exist over a first maximum time interval before a decision is made to disconnect the power current path, (b) the magnitude of the second overcurrent has a second maximum current magnitude that is allowed to exist over a second maximum time interval before a decision is made to disconnect the power current path, and (c) if the magnitude of the second maximum current is greater than the magnitude of the first maximum current, the second maximum time interval is less than the first maximum time interval. This can be seen to be true from the above description with reference to the logic function 306 of FIG. 7A. Further, this paragraph states that, in general, the greater the magnitude of the operating "overcurrent" that can be temporarily tolerated by a given battery pack design, the shorter the amount of time that this "overcurrent" can be tolerated before damaging the battery. This principle is fairly well known in the art.

[0088] Here, another description of the normal execution routine of FIG. 7A is provided. The processing circuit: (a) maintains a set of current threshold and time threshold in the memory circuit 112; (b) uses an analog-to-digital converter (ADC) which is part of the input / output interface circuit 114 to periodically receive from the current shunt 130 a reading of the magnitude of the sampled current (alternatively, the ADC may be on-board the processing circuit chip itself); (c) periodically analyzes the received reading of the magnitude of the sampled current and determines (using the logic function 306) whether the most recent magnitude reading corresponds to one of the overcurrent magnitude thresholds; (d) if so, determines the duration for which the most recent magnitude reading has persisted, and then makes a final decision as to whether to disconnect or not disconnect the power transistor 132. This final decision is made by the processing circuit 110 as follows: namely, (i) if the determined duration is not greater than the time threshold for the most recent magnitude reading, enables the power switching semiconductor 132 to remain in the current-conducting state, thereby not disconnecting the power current path; or (ii) if the determined duration is greater than the time threshold for the most recent magnitude reading, commands the power switching semiconductor to change to the non-current-conducting state, thereby disconnecting the power current path between the battery pack 12 and the power tool 5.

[0089] Referring now to FIG. 7B, a flowchart showing a second part of the normal execution routine is provided. At arrow 7B-1, the logic follows the logic function 322 where the system controller determines the battery temperature from the interface / amplifier 146. Next, at the logic function 324, the system controller determines the battery temperature from the serial data of the communication port 15. (The logic function 324 depends on whether the optional communication port #1 120 is installed on the PCB 100 or not)

[0090] Next, in logical decision 330, the system controller determines whether the temperature sensor reading is above a first temperature threshold, “T1”. T1 is preferably at least 140°F. If the answer is “yes”, in logical function 332, a warning message may optionally be sent to the power tool. If the answer was “no”, in logical decision 340, the system controller determines whether the temperature sensor reading is above a second (higher) temperature, “T2”. T2 is preferably at least 160°F. If the answer is “no”, the logic flows to arrow “7B-2” and continues in FIG. 7A. These thresholds T1 and T2 are set by the system designer. It should be noted that since the temperature of most physical systems changes rather slowly compared to many other phenomena (such as the voltage or current in an electrical circuit), the system controller should not rush to decide to turn off the power MOSFET 132 in logical decision 340 and logical function 342. In other words, careful system design should require at least two or three consecutive “high” readings from the temperature sensor (e.g., those readings at the A / D converter (ADC) when the A / D converter (ADC) samples its input) before disconnecting the battery (by turning off the MOSFET 132). This recommended feature also improves the noise immunity characteristics of this power tool system.

[0091] While the system controller is comparing the actual temperature with the T1 threshold in logical decision 330, in logical function 360, the system controller also determines the skin temperature of the battery adapter at the physical location proximate to the attached off-brand battery. Next, in logical decision 370, the system controller determines whether the temperature sensor reading is above a third temperature threshold, "T3". As described above, the threshold of T3 is set by the system designer. For example, T3 is preferably at least 100°F. If the result is "yes", the logic is directed to logical decision 332 described above. However, if the result is "no", the logic is directed to logical decision 380, where the system controller determines whether the temperature sensor reading is above a fourth (higher) temperature, "T4". The value of T4 is set by the system designer. For example, T4 is preferably at least 120°F. In the design of this optional feature, it should be noted that the temperature sensing circuit includes a solid state temperature sensor 140 disposed proximate to the side of the housing facing the battery pack 12 so as to directly detect the temperature of the external battery pack.

[0092] It will be appreciated that the optional temperature sensor 140 is used essentially only as a "backup plan" if there is no actual temperature sensor 13 within the battery pack 12. Battery cells can heat up very rapidly under high current discharge load conditions, and having an on-board temperature sensor inside the battery pack 12 is far more desirable than having only the optional temperature sensor 140 within the battery adapter 100.

[0093] If the result of logic function 380 is "No", the logic is directed to arrow 7B-2 and continues in FIG. 7A. However, if the result in logic function 380 is "Yes" (i.e., the temperature reading is "High"), the logic is directed to logic function 342 and the system controller turns off the power MOSFET. Referring back to logic decision 340, if the result is "Yes" (i.e., the temperature reading is "High"), the logic in logic function 342 will turn off the MOSFET again. The logic then continues to logic function 344, where the system controller proceeds to the alarm handler routine (see FIG. 8). Finally, in logic function 350, after the alarm handler routine is complete, the normal execution routine resumes from this routine.

[0094] At arrow 7B-2, the logic flows back to FIG. 7A in logic function 346, where the normal execution routine "continues". The logic returns to the "start" of the routine in logic function 300. In other words, the normal execution routine is a continuous execution routine that actively checks various safety thresholds associated with the battery adapter 10 and the off-brand battery 12.

[0095] Referring now to FIG. 8, a flowchart showing the alarm handler routine is provided. First, in logic function 400, the system controller reads the current status message and alarm state within the CPU. Next, in logic decision 410, the system controller determines whether the power tool has been in use continuously since it was turned on. If the answer is "No", in logic function 412, the system controller sends a message or sets an indicator to ensure the user is informed that the battery is connected and the status light is normal. Next, in logic function 414, the system controller logs the alarm state in memory and keeps the alarm indicator on until the tool is reset. Finally, in logic function 450, the alarm handler routine ends and returns from this routine.

[0096] However, if the result in logic function 410 is "yes", in logic decision 420, the system controller determines whether the alarm is a low voltage alert. If the result is "yes", in logic function 422, the system controller keeps the red LED on, whereby the user needs to replace it with a different off-brand battery having a sufficient charge state before using the power tool. The logic then flows to logic function 414 as described above.

[0097] If the result in logic function 420 is "no", in logic decision 430, the system controller determines whether the alarm is a high temperature alert or a high current alert. If the result is "no", in logic function 434, the system controller stores other types of alarm states in the memory. Next, in logic function 450, the alarm handler routine ends and returns from this routine.

[0098] If the result in logic function 430 is "yes", in logic decision 440, the system controller determines whether the battery has cooled to normal operating values. If the result is "no", in logic function 432, the system controller sends a message or sets the indicator to the "hard alarm" state, thereby enabling the battery to cool or requiring a manual reset of the power tool and / or battery adapter. The logic then flows to logic function 414 as described above.

[0099] If the result in logic function 440 is "yes", in logic function 442, the alarm indicator is turned off and an automatic reset is performed to enable the power tool to function properly. Next, the logic continues to logic function 450, the alarm handler routine ends and returns from this routine.

[0100] Referring to FIG. 9 here, the battery adapter 10 is shown in a front upper perspective view. The upper part 20 and the upper surface 28 slide on the battery mounting portion 9 and are fixed on the battery mounting portion 9 when the battery adapter 10 is connected to the power tool 5. The electrical connection portion 22 to the tool will be electrically connected to the tool 5 when the battery adapter 10 is mounted on the tool. The manual latch 24 can be pressed to enable the user to remove (dismount) the battery adapter 10 from the tool 5.

[0101] Referring to FIG. 10 here, the battery adapter 10 is shown in a rear bottom perspective view. The gas gauge 26 and the push button PB1 25 are shown. The lower part 30 and the lower surface 38 interface with the off-brand battery 12 when connected to each other. The off-brand battery 12 slides between a set of guide rails 36 and enters the recess 34, where it is electrically connected to the electrical connection portion to the off-brand battery 32. To remove (dismount) the off-brand battery 12 from the battery adapter 10, one or more manual latches are pressed in the same operation as the manual latch 24 on the battery adapter.

[0102] Referring to FIG. 11 here, the battery adapter 10 is shown in a right side view. As described above, the upper part 20 and the upper surface 28 fit into the battery mounting portion 9, and the electrical connection portion at 22 fits into the power tool and will be electrically connected to the tool 5. The lower part 30 interfaces with the off-brand battery 12.

[0103] Referring to FIG. 12 here, the battery adapter 10 is shown in a top view. In this figure, the gas gauge 26 and PB1 25 are shown at the left end (in this figure) of the battery adapter 10. At this position, the gas gauge 26 is located directly under the hand of the user holding the handle portion 8 of the power tool 5, so it can be easily seen during operation. Of course, it is conceivable that the gas gauge 26 and PB1 25 can be arranged at other positions around the battery adapter 10 according to the requirements of the system designer.

[0104] Referring now to FIG. 13, the battery adapter 10 is shown in a bottom view. The off-brand battery 12 is mounted by sliding it onto the battery adapter 10 from the left (in this figure) such that the off-brand battery is electrically connected to the electrical connection to the battery 32.

[0105] Note that some of the embodiments illustrated herein do not have all of those components included in some of the drawings herein for purposes of clarity. In particular, with respect to prior designs, readers are referred to other U.S. patents and applications owned by Senco to view examples of such outer housings and other components. Similarly, information regarding how an electronic controller operates to control the functions of a power tool can be found in other U.S. patents and applications owned by Senco. Further, other aspects of the tool technology of the present invention may exist in conventional fastener driving tools sold by assignee Kyocera Senco Industrial Tools, Inc., including the information disclosed in prior U.S. patents and published applications. Examples of such publications are U.S. Pat. Nos. 6,431,425; 5,927,585; 5,918,788; 5,732,870; 4,986,164; 4,679,719; 8,011,547; 8,267,296; 8,267,297; 8,011,441; 8,387,718; 8,286,722; 8,230,941; 8,602,282; 9,676,088; 10,478,954; 9,993,913; 10,549,412; 10,898,994; 10,821,585; and 8,763,874, and U.S. Patent Application Publication Nos. 2020 / 0156228; 2021 / 0016424; 2020 / 0070330; and 2020 / 0122308. These documents are hereby incorporated by reference in their entirety.

[0106] The logical operations described in connection with the flowcharts of FIGS. 6-8 may be implemented using sequential logic (e.g., by using microprocessor technology), or using a logic state machine, or perhaps by separate logic, and may further be implemented using a parallel processor. In one preferred embodiment, a microprocessor or microcontroller (e.g., microprocessor 110) may be used to execute software instructions stored in the memory cells within the ASIC. In fact, together with the RAM and executable ROM, the entire microprocessor 110 may be included within a single ASIC in one mode of the technology disclosed herein. Of course, other types of circuits may be used to implement these logical operations shown in the drawings without departing from the principles of the technology disclosed herein. In any event, whether based on a microprocessor, microcomputer, microcontroller, or logic state machine, some type of processing circuit is provided by using individual logic elements to achieve these tasks, or by some type of computing device not yet invented. Also, some type of memory circuit is provided by using individual logic elements to store data and other operational information, or by using a type of memory device not yet invented, whether based on a typical RAM chip, an EEROM chip (including flash memory). Generally, the memory circuit of a particular electronic product contains instructions executable by the processing circuit of that same particular electronic product.

[0107] Also, the exact logical operations shown in the flowcharts of FIGS. 6-8 and described above, although perhaps not exact, will be understood to be capable of being modified somewhat to function in a similar manner without departing from the principles of the technology disclosed herein. The exact nature of some of the logical decisions and other commands in these flowcharts is targeted at a particular future model for a fastener driving tool (e.g., one involved with a Senco nailer or a screw driving tool using a DeWalt battery), and in many instances, the overall result of the invention is the same and indeed similar, but different functions or decisions will be taken when using other models or brands of battery adapters (e.g., a Milwaukee battery, etc.).

[0108] As used herein, the term "proximal" can have the meaning of arranging one physical object close to a second physical object such that the two objects are likely adjacent to each other, but does not necessarily require the absence of a third object disposed therebetween. In the techniques disclosed herein, a "male positioning structure" may be disposed "proximal" to a "female positioning structure". Generally, this may mean that the two male and female structures are physically abutting each other, or this may mean that, regardless of whether the two male and female structures actually contact each other along a continuous surface, by virtue of a particular size and shape, one structure is oriented relative to the other in a given direction and is essentially held in an X-Y (e.g., horizontal and vertical) position such that they are "fitted" to each other. Or, two structures of any size and shape (whether male, female, or other shape) may be disposed somewhat close to each other regardless of whether they physically abut each other, and such a relationship can still be referred to as "proximal". Or, two or more possible positions relative to a particular point can be specified in relation to the exact attributes of a physical object, such as "near" or "at" the end of a rod, and all of those possible near / at positions can be considered "proximal" to the end of that rod. Further, the term "proximal" can also have a meaning strictly related to a single object, where the single object can have two ends, a "distal end" is the end disposed somewhat farther away from a reference point (or region) of interest, and a "proximal end" is the other end that would be disposed somewhat closer to that same reference point (or region) of interest.

[0109] It will be understood that the various components described and / or illustrated in this specification can be manufactured in a variety of ways, including manufacturing them in multiple parts or manufacturing each of these components as an integral part, without departing from the principles of the technology disclosed in this specification. For example, the components included as the recited elements in the following claims may be manufactured as an integral part, or the components may be manufactured as a combined structure of several individual parts that are assembled together. However, the "components of multiple parts" will still be included within the scope of the recited elements claimed for the purpose of interpreting the claims, even if the recited elements claimed are thought to be described and illustrated only as an integral structure in this specification.

[0110] All documents cited in the "Background Art" and "Detailed Description of the Invention" are incorporated herein by reference in relevant parts, but the citation of any document should not be construed as an admission that it is prior art to the technology disclosed in this specification.

[0111] The foregoing description of the preferred embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the technology disclosed herein to the precise forms disclosed, and the technology disclosed herein may be further modified within the spirit and scope of the present disclosure. Any example described or illustrated herein is intended as a non-limiting example, and many modifications or variations of those examples or preferred embodiments are possible without departing from the spirit and scope of the technology disclosed herein, taking into account the above teachings. The embodiments have been selected and described in order to illustrate the principles of the technology disclosed herein and its practical application, thereby enabling those skilled in the art to utilize the technology disclosed herein in various embodiments and with various modifications suitable for the particular applications contemplated. Therefore, this application is intended to cover any variations, uses, or adaptations of the technology disclosed herein using its general principles. Furthermore, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this technology disclosed herein pertains and falls within the scope of the appended claims.

Claims

1. A battery adapter (10), comprising: (a) a housing having a first side (20) and an opposite second side (30); (b) an electronic control circuit including a computer processing circuit (110), a memory circuit (112) including instructions executable by the processing circuit, an input / output interface circuit (114), a current shunt (130), a current sensing circuit (142), and a power switching semiconductor (132) for switching a power current path (138); wherein: (c) the first side of the housing is physically and electrically attached to an external power tool (5); (d) the second side of the housing physically and electrically mates with an external battery pack (12), and the external power tool and the external battery pack are not compatible; (e) the battery adapter is operable to provide current flowing from the external battery pack to the external power tool, thereby powering the external power tool; (f) the current sensing circuit is operable to receive a voltage signal from the current shunt, and when the voltage signal exhibits a correct polarity and an acceptable magnitude, the power switching semiconductor is operable to enable current to flow from the external battery pack to the external power tool using the power current path; (g) when the voltage signal from the current shunt exhibits an incorrect polarity, the power switching semiconductor is operable to disconnect (312) the power current path. A battery adapter (10).

2. The battery adapter (10) according to claim 1, further comprising: (a) a manual latch (24) for disconnecting the battery adapter from the external power tool; and (b) at least one guide rail (36) on the second side (30) for guiding the external battery pack (12) for insertion into and removal from the battery adapter.

3. The battery adapter according to claim 1, wherein: (a) the current shunt (130) includes a resistor having a predetermined substantially low resistance value; and (b) the current sensing circuit (142) includes a differential voltage amplifier having an active range for detecting both positive and negative voltages. wherein at least one of the input / output interface circuit (114) and the computer processing circuit (110) includes an analog-to-digital converter (ADC) having an active range for detecting both positive and negative voltages. The battery adapter (10) according to claim 1.

4. a battery state switch (25); a plurality of LEDs (26); further comprising: when the battery state switch is actuated, the plurality of LEDs are temporarily energized to visually indicate the energy level of the external battery pack (12). The battery adapter (10) according to claim 1.

5. wherein the power switching semiconductor (132) includes at least one metal oxide semiconductor field effect transistor (MOSFET). The battery adapter (10) according to claim 1.

6. A battery adapter (10), comprising: (a) a housing having a first side (20) and an opposite second side (30); (b) an electronic control circuit including a computer processing circuit (110), a memory circuit (112) including instructions executable by the processing circuit, an input / output interface circuit (114), a current shunt (130), a current sensing circuit (142), and a power switching semiconductor (132) for switching a power current path (138); comprising: (c) the first side of the housing is physically and electrically attached to an external power tool (5); (d) the second side of the housing is physically and electrically mated with an external battery pack (12), and the external power tool and the external battery pack are not compatible with each other; (e) the battery adapter provides a current flowing from the external battery pack to the external power tool, thereby powering the external power tool; (f) the current sensing circuit receives a voltage signal from the current shunt, and when the voltage signal exhibits a magnitude of a predetermined overcurrent less than a predetermined allowable time interval (306), the power switching semiconductor is operable to allow current to flow from the external battery pack to the external power tool using the power current path. (g) If the voltage signal from the current shunt exhibits a magnitude of overcurrent that persists for a duration longer than the predetermined acceptable time interval (306), the power switching semiconductor is operable to disconnect the power current path (312). Battery adapter (10). **Claim 7** The condition that the magnitude of the predetermined overcurrent is less than a predetermined acceptable time interval (306) includes at least two ranges of the magnitude of the overcurrent and the acceptable time interval, and as a result, (a) The magnitude of the first overcurrent has a magnitude of a first maximum current that is allowed to exist for a first maximum time interval before a decision to disconnect the power current path is made. (b) The magnitude of the second overcurrent has a magnitude of a second maximum current that is allowed to exist for a second maximum time interval before a decision to disconnect the power current path is made. (c) If the magnitude of the second maximum current is greater than the magnitude of the first maximum current, the second maximum time interval is less than the first maximum time interval. The battery adapter (10) according to claim 6. **Claim 8** The battery adapter (10) according to claim 6, wherein the current shunt (130) includes a resistor having a predetermined substantially low resistance value. **Claim 9** The processing circuit (110) (a) maintains a set of current thresholds and time thresholds in the memory circuit (112), (b) periodically receives a read value (304) of the magnitude of the sampled current from the current shunt using an analog-to-digital converter (ADC) that is part of at least one of the input / output interface circuit (114) and the computer processing circuit, (c) periodically analyzes the received read value of the magnitude of the sampled current to determine whether the most recent read value corresponds to one of the overcurrent magnitude thresholds (302), (d) If so, determines the duration for which the most recent read value has persisted, and (i) if the determined duration is not greater than the time threshold for the most recent read value, enables the power switching semiconductor to remain in a current-conducting state, thereby not disconnecting the power current path, or (ii) If the determined duration is greater than the time threshold for the most recent magnitude reading value, command the power switching semiconductor to change to a non-conducting current state (312), thereby disconnecting the power current path. The battery adapter (10) according to claim 8, which is operable as described above.

10. A battery adapter (10), comprising: (a) A housing having a first side (20) and an opposite second side (30); (b) An electronic control circuit including a computer processing circuit (110), a memory circuit (112) containing instructions executable by the processing circuit, an input / output interface circuit (114), and a power switching semiconductor (132); provided with: (c) The first side of the housing is physically and electrically attached to an external power tool (5); (d) The second side of the housing physically and electrically mates with an external battery pack (912), and the external power tool and the external battery pack are not compatible; (e) A remote temperature sensing circuit (140) for remotely sensing the electrical characteristics of components onboard the external battery pack; (f) The battery adapter provides current flowing from the external battery pack to the external power tool, thereby supplying power to the external power tool; (g) The power switching semiconductor is operable to disconnect the current flowing from the external battery pack (342) when a predetermined temperature threshold is exceeded (340, 380) as determined by the remote temperature sensing circuit. Battery adapter (10).

11. The battery adapter (10) according to claim 10, wherein the temperature sensing circuit (140) includes a differential amplifier (146) for detecting a voltage generated by the components onboard the external battery pack (12).

12. A manual latch (24) for disconnecting the battery adapter from the tool; At least one guide rail (36) on the second side (30) for guiding the external battery pack (12) for insertion into and removal from the battery adapter. The battery adapter (10) according to claim 10, further comprising:

13. wherein the power switching semiconductor (132) includes at least one metal oxide semiconductor field effect transistor (MOSFET). The battery adapter (10) according to claim 10. **Claim 14** The battery adapter (10) according to claim 10, wherein the temperature sensing circuit (140) detects a resistance value of the component on-board the external battery pack (12), and the resistance value changes when the actual temperature of the component changes. **Claim 15** A battery adapter (10), comprising: (a) a housing having a first side (20) and an opposite second side (30); (b) an electronic control circuit including a computer processing circuit (110), a memory circuit (112) including instructions executable by the processing circuit, an input / output interface circuit (114), a voltage sensing circuit (144), a power current path (138), and a plurality of colored LEDs (26, 124) (light emitting diodes) presenting at least two different colors; (c) a battery state switch (25); and (d) the first side of the housing is operable to be physically and electrically attached to an external power tool (5); (e) the second side of the housing is operable to physically and electrically mate with an external battery pack (12), and the external power tool and the external battery pack are not compatible with each other; (f) the battery adapter uses the power current path to direct the current flowing from the external battery pack to the tool, thereby powering the tool; (g) the voltage sensing circuit is connected to the power current path, thereby detecting the magnitude of the voltage output by the external battery pack; (h) the voltage sensing circuit is further connected to the input / output interface circuit; (i) at least one of the input / output interface circuit and the computer processing circuit includes an analog-to-digital converter (ADC) that generates a digital signal for analysis by the processing circuit; (j) when the battery state switch is actuated, the plurality of colored LEDs are energized to visually display the state of the energy level of the external battery pack. (k)The processing circuit determines (308) which of the plurality of colored LEDs should be lit based on the value of the digital signal, and generates at least one output signal for controlling the plurality of colored LEDs. Battery adapter (10). **Claim 16** The battery adapter (10) according to claim 15, further comprising a plurality of light pipes (27) disposed proximally and associated with the plurality of colored LEDs (26, 124). **Claim 17** The battery adapter (10) according to claim 15, wherein at least one of the plurality of colored LEDs (26, 124) is lit for only a few seconds after the battery state switch (25) is actuated. **Claim 18** The plurality of colored LEDs (26, 124) can be displayed in at least red, yellow, or green, and when the plurality of colored LEDs are energized, (a) That at least one red LED is lit means that the external battery pack (12) needs to be recharged. (b) That at least one yellow LED is lit means that the external battery pack is partially discharged. (c) That at least one green LED is lit means that the external battery pack is fully charged. The battery adapter (10) according to claim 15. **Claim 19** At least one of the plurality of colored LEDs (26, 124) can be displayed in red, yellow, and green, and when the plurality of colored LEDs are energized, (a) If only a single red LED is blinking, the external battery pack (12) needs to be recharged. (b) If only a single red LED is constantly lit, the external battery pack is in a low charge state of more than about 25%. (c) If both the red LED and the yellow LED are lit, the external battery pack is in a charge state of more than about 50%. (d) If the red LED, the yellow LED, and a single green LED are lit, the external battery pack is in a charge state of more than about 75%. (e) If the red LED, the yellow LED, and two green LEDs are lit, the external battery pack is in a fully charged state. The battery adapter (10) according to claim 15. **Claim 20** At least one of the plurality of colored LEDs (26, 124) can display in red, yellow, and green, and when the plurality of colored LEDs are energized, (a) When four of the energized colored LEDs emit green visible light, the external battery pack (12) is in a fully charged state. (b) When less than four of the energized colored LEDs emit green visible light, the external battery pack is in a charged state of more than about 75%. (c) When at least two of the energized colored LEDs emit yellow visible light, the external battery pack is in a charged state of more than about 50%. (d) When at least one of the energized colored LEDs constantly emits red visible light, the external battery pack is in a charged state of more than about 25%. (e) When at least one of the energized colored LEDs emits red visible light intermittently, the external battery pack needs to be recharged. The battery adapter (10) according to claim 15.

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