Battery pack terminal

Abstract

To provide a battery pack for use with a power tool having an electric connector.SOLUTION: The battery pack includes: a housing containing one or more battery cells; and a first terminal in electrical communication with the battery cells, the first terminal including a pair of spaced terminal walls forming a gap therebetween and a coil spring positioned at least partially within the gap. The coil spring is configured to selectively engage and form an electrical connection with the electric connector of the power tool when the electric connector is positioned at least partially within the gap.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 63 / 441,077, filed January 25, 2023, U.S. Patent Application No. 63 / 486,075, filed February 21, 2023, and U.S. Patent Application No. 63 / 488,659, filed March 6, 2023, the entire contents of each of which are incorporated herein by reference.

[0002] The present disclosure relates to battery pack terminal connections. [Background technology]

[0003] The power tool can receive a battery pack that is also compatible with several other power tools and electrical devices. The battery pack includes a tool-engaging portion and a circuit board. The tool-engaging portion mechanically secures the battery pack to the power tool. The circuit board electrically connects the battery pack to the power tool using a plurality of terminals. Summary of the Invention [Means for solving the problem]

[0004] In one aspect, the present disclosure provides a battery pack for use with a power tool, the battery pack including: a housing that houses one or more battery cells; a circuit board disposed in the housing; a first terminal; and a second terminal. The circuit board is in electrical communication with the one or more battery cells. The first terminal is in electrical communication with the circuit board. The second terminal is also in electrical communication with the circuit board and is constructed differently from the first terminal. The second terminal includes a pair of spaced-apart terminal walls and a coil spring disposed between the pair of spaced-apart terminal walls. The coil spring is configured to engage and electrically couple with a portion of the power tool.

[0005] In another aspect, the present disclosure provides a battery pack for use with a power tool, the battery pack including: a housing that houses one or more battery cells; a circuit board disposed in the housing; and terminals. The circuit board is in electrical communication with the one or more battery cells. The terminals are in electrical communication with the circuit board and are configured to receive and electrically couple to a portion of the power tool. The terminals include a pair of outer protrusions and a pair of inner protrusions nested within the outer protrusions. Each of the inner protrusions has a different shape from the outer protrusions.

[0006] In another aspect, the present disclosure provides a battery pack for use with a power tool, the battery pack including a housing containing one or more battery cells, a plurality of terminals, and a plurality of side terminals. The housing includes a tool engaging 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 side terminals are configured to conduct electricity through openings in corresponding ones of the pair of spaced-apart housing walls.

[0007] In another aspect, the present disclosure provides a battery pack for use with a power tool having an electrical connector. The battery pack includes: a housing that contains one or more battery cells; and a first terminal in electrical communication with the battery cell, the first terminal including a pair of spaced-apart terminal walls that form a gap therebetween and a coil spring that is at least partially disposed within the gap. The coil spring is configured to selectively engage with the electrical connector of the power tool to form an electrical connection when the electrical connector is at least partially disposed within the gap.

[0008] Alternatively or additionally, the coil springs are canted in any combination.

[0009] Alternatively or additionally, in any combination, the electrical connector is introduced into the gap in a first insertion direction and the coil spring is angled to provide compression in a direction perpendicular to the insertion direction.

[0010] Alternatively or additionally, in any combination, the battery pack further comprises a circuit board disposed in the housing and in electrical communication with the one or more battery cells and the first terminal.

[0011] Alternatively or additionally, in any combination, the first terminal comprises a pair of legs attached to the circuit board.

[0012] Alternatively or additionally, in any combination, at least one terminal wall defines a groove therein, with the spring being at least partially disposed within the groove.

[0013] Alternatively or additionally, in any combination, both terminal walls define a groove therein, and the spring is at least partially disposed within both grooves.

[0014] Alternatively or additionally, in any combination, the first terminal defines a mid-plane disposed equidistant from both terminal walls, with the coil springs disposed on either side of the mid-plane.

[0015] Alternatively or additionally, the coil springs are arranged in a U-shape in any combination.

[0016] In another aspect, the present disclosure provides a battery pack for use with a power tool having an electrical connector, the battery pack comprising: a housing that houses one or more battery cells therein; and terminals in electrical communication with the battery cells, the terminals configured to receive and form an electrical connection with the electrical connector of the power tool, the terminals comprising a pair of outer protrusions and a pair of inner protrusions nested between the pair of outer protrusions.

[0017] Alternatively or additionally, in any combination, the pair of outer protrusions has a different shape than the pair of inner protrusions.

[0018] Alternatively or additionally, in any combination, the pair of outer protrusions and the pair of inner protrusions are both formed from a single piece of monolithic material.

[0019] Alternatively or additionally, in any combination, the pair of outer protrusions and the pair of inner protrusions are electrically insulated from each other.

[0020] Alternatively or additionally, in any combination, the pair of outer protrusions has a first insertion depth and the pair of inner protrusions has a second insertion depth, the first insertion depth being less than the second insertion depth.

[0021] Alternatively or additionally, in any combination, the pair of outer protrusions define a first insertion axis parallel to the insertion direction, and the pair of inner protrusions define a second insertion axis parallel to the insertion direction, the first insertion axis not being coaxial with the second insertion axis.

[0022] Alternatively or additionally, in any combination, the pair of outer protrusions and the pair of inner protrusions are both coupled to the circuit board, the first insertion axis is spaced a first distance from the circuit board, and the second insertion axis is spaced a second distance from the circuit board that is greater than the first distance.

[0023] Alternatively or additionally, in any combination, the pair of outer protrusions has a different insertion depth than the pair of inner protrusions.

[0024] Alternatively or additionally, in any combination, further comprising a second terminal in electrical communication with the battery cell, the second terminal being different from the first terminal.

[0025] Alternatively or additionally, in any combination, a pair of inner protrusions interdigitate with each other.

[0026] In another aspect, the present disclosure provides a battery pack for use with a power tool having an electrical connector, the battery pack comprising: a housing that houses 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 side terminal configured to form an electrical connection with the electrical connector of the power tool, the side terminal being accessible through a window through the housing, the window being oriented parallel to the insertion direction.

[0027] Alternatively or additionally, in any combination, the housing further defines a pair of grooves configured to mechanically engage with and retain a portion of the power tool therein, the grooves extending parallel to the insertion direction.

[0028] Alternatively or additionally, in any combination, a window is disposed in one of the pair of grooves.

[0029] Alternatively or additionally, the connector may further comprise one or more terminals disposed between the pair of grooves in any combination.

[0030] Alternatively or additionally, in any combination, the connector may further comprise one or more terminals accessible through an opening in the housing, the opening in the housing being oriented at least partially perpendicular to the insertion axis.

[0031] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. [Brief explanation of the drawings]

[0032] [Figure 1] FIG. 2 shows a perspective view of the battery pack.

[0033] [Figure 1A] 2 shows a cross-sectional view of the end of the battery pack of FIG. 1.

[0034] [Figure 2] 1 shows a detailed perspective view of several connectors of a power tool with a portion of the power tool housing cut away.

[0035] [Figure 3] 1 shows a perspective view of a circuit board with a terminal separator.

[0036] [Figure 4] FIG. 1 is a perspective view of a circuit board omitting a terminal separator.

[0037] [Figure 5] 1 shows a perspective view of a circuit board mating with multiple connectors from a power tool housing.

[0038] [Figure 6A] FIG. 2 shows a perspective view of a second terminal.

[0039] [Figure 6B] 6B shows a front view of the second terminal of FIG. 6A.

[0040] [Figure 7A] 10 shows a perspective view of another embodiment of the second terminal.

[0041] [Figure 7B] 7B shows a front view of the second terminal of FIG. 7A.

[0042] [Figure 8A] 10 shows a perspective view of another embodiment of the second terminal.

[0043] [Figure 8B] 8B shows a front view of the second terminal of FIG. 8A.

[0044] [Figure 9A] 10 shows a perspective view of another embodiment of the second terminal.

[0045] [Figure 9B]9B shows a front view of the second terminal of FIG. 9A receiving a connector from a power tool housing.

[0046] [Figure 9C] 9B shows a perspective view of the inner terminal of the second terminal of FIG. 9A.

[0047] [Figure 10A] 10 shows a perspective view of another embodiment of the second terminal.

[0048] [Figure 10B] 10B shows a front view of the second terminal of FIG. 10A receiving a connector from a power tool housing.

[0049] [Figure 10C] 10B shows a perspective view of the inner terminal of the second terminal of FIG. 10A.

[0050] [Figure 11] 10 shows a perspective view of another embodiment of the second terminal.

[0051] [Figure 12] 12 shows a perspective view of the second terminal of FIG. 11 receiving a connector of the power tool housing.

[0052] [Figure 13] 10 shows a perspective view of another embodiment of a circuit board including another embodiment of a second terminal.

[0053] [Figure 14] 14 shows a top view of the circuit board and second terminal of FIG. 13.

[0054] [Figure 15] 10 shows a perspective view of another embodiment of multiple connectors on a power tool housing. FIG.

[0055] [Figure 16A] 16 illustrates an internal view of the first connector of the power tool housing of FIG. 15 engaged with the second terminal of FIG. 13.

[0056] [Figure 16B] 16 illustrates an internal view of the second connector of the power tool housing of FIG. 15 engaged with the second terminal of FIG. 13.

[0057] [Figure 17] 10 shows a perspective view of another embodiment of the second terminal.

[0058] [Figure 18] 18 shows a perspective view of the inner terminal of the second terminal of FIG. 17;

[0059] [Figure 19A] 18 shows a cross-sectional view of the second terminal of FIG. 17 receiving the second connector of the power tool housing.

[0060] [Figure 19B] 18 illustrates a cross-sectional view of the second terminal of FIG. 17 engaging with a vertical connector of a power tool housing.

[0061] [Figure 20] 10 shows a perspective view of another embodiment of a circuit board including another embodiment of a second terminal.

[0062] [Figure 21] 10 shows a perspective view of another embodiment of a plurality of second connectors and a plurality of split connectors of a power tool housing. FIG.

[0063] [Figure 22A] 22 shows an internal view of the second terminal of FIG. 20 mating with the split connector of the power tool housing of FIG. 21;

[0064] [Figure 22B] 22 shows an internal view of the second terminal of FIG. 20 mating with the second connector of the power tool housing of FIG. 21.

[0065] [Figure 23A] 10 shows a perspective view of another embodiment of the top side of a circuit board.

[0066] [Figure 23B] 23B shows a perspective view of the bottom side of the circuit board of FIG. 23A.

[0067] [Figure 24A] 10 shows a perspective view of another embodiment of the top side of a circuit board.

[0068] [Figure 24B] 24B shows a perspective view of the bottom side of the circuit board of FIG. 24A.

[0069] [Figure 25A] 24B shows a top view of the bottom side of the circuit board of FIG. 24A with the bottom PCB cover.

[0070] [Figure 25B] 24B shows a top view of the bottom side of the circuit board of FIG. 24A without the bottom PCB cover.

[0071] [Figure 26A] FIG. 10 shows a perspective view of another embodiment of a battery pack.

[0072] [Figure 26B] 26B shows another perspective view of the battery pack of FIG. 26A.

[0073] [Figure 27A] 10 shows a bottom view of another embodiment of a circuit board.

[0074] [Figure 27B] 27B shows a perspective view of the circuit board and side terminals of FIG. 27A.

[0075] [Figure 27C] 27B shows another perspective view of the circuit board and side terminals of FIG. 27A.

[0076] [Figure 28] 10 shows a detailed perspective view of another embodiment of a connector for a power tool with a portion of the power tool housing cut away.

[0077] [Figure 29] 1 shows a cutaway view of a battery pack engaged with a power tool.

[0078] [Figure 30] 10 illustrates a number of alternative embodiments of the terminal.

[0079] [Figure 31-32] 1 shows a canted coil spring.

[0080] [Figure 33] 32 is a graph showing the deflection of the coil spring of FIG. 31 versus force applied to the coil spring.

[0081] [Figures 34A-34C] 10 shows an alternative embodiment of a terminal.

[0082] [Figures 35A-35C] 10 shows a further alternative embodiment of a terminal. DETAILED DESCRIPTION OF THE INVENTION

[0083] Before describing embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0084] 1 and 1A show a battery pack 10 configured to releasably couple to an electrical attachment point 15 of a power tool 12 or other electrical device (see FIG. 2) to form a temporary electrical connection. More specifically, the battery pack 10 may provide power to various elements of the power tool 12, including, but not limited to, one or more motors, sensors, LEDs, controllers, pumps, etc.

[0085] Battery pack 10 includes a housing 14, a tool-engaging portion 16, a circuit board 18, one or more battery cells 19, and an electrical interface 17 in electrical communication with both circuit board 18 and battery cells 19. Housing 14 at least partially defines an interior cavity 21 that supports battery cells 19 and circuit board 18 therein.

[0086] The tool engagement portion 16 of the battery pack 10 is configured to selectively engage the attachment 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 on the attachment point 15 of the power tool 12. In other embodiments, the grooves 22 may be formed on the power tool 12 while the rails 30 are formed on the battery pack 10.

[0087] Terminal interface 26 includes a plurality of slots 32 in housing 14, each slot generally corresponding to one or more terminals (described below) of electrical interface 17. Each slot 32 is sized and shaped to receive one or more connectors 36 from power tool 12 therein. As shown in FIG. 2 , the plurality of first connectors 36 of power tool 12 are disposed on attachment point 15 and extend generally parallel to insertion direction A. In the illustrated embodiment, each connector 36 is generally formed as a flat plate having a chamfered leading edge.

[0088] 3-6B, electrical interface 17 includes one or more first terminals 38, one or more second terminals 40, and a terminal separator 58 for physically isolating and electrically insulating each of terminals 38, 40. When assembled, each of terminals 38, 40 is configured to be accessed through a corresponding slot 32 in terminal interface 26 (see FIG. 1).

[0089] Each of the terminals 38, 40 of the battery pack 10 is physically sized and shaped to receive therein and form a respective electrical connection with a corresponding one of the first connectors 36 from the power tool housing 12. Together, the electrical connections formed between the first connectors 36 and their corresponding terminals 36, 40 electrically connect the power tool 12 to the circuit board 18 and the battery 19, as shown in FIG.

[0090] 6A-6B, the second terminal 40 is constructed differently than the first terminal 38. More specifically, the second terminal 40 includes a pair of spaced apart terminal walls 42 that form a terminal gap or opening 50 therebetween, and one or more coil springs 44 that are at least partially disposed within or open to the terminal gap 50. When assembled, each coil spring 44 is in electrical communication with a terminal wall 42, which in turn is in electrical communication with the circuit board 18 via a pair of legs 48.

[0091] In the illustrated embodiment, the terminal walls 42 are generally planar and spaced apart a distance such that the terminal gap 50 is sized sufficiently to at least partially receive a corresponding first connector 36 therein. Each wall 42 also defines one or more spring retention grooves 46 formed in an inner surface 47 thereof and sized and shaped to receive at least a portion of a corresponding coil spring 44 therein. When assembled, the terminal walls 42 and coil springs 44 are configured such that the coil springs 44 extend inwardly into the gap 50 beyond the inner surfaces 47 of the walls 42 such that the coil distance 49 between opposing springs 44 is less than the distance between the walls 42 at the same location.

[0092] In some embodiments, one or more of the coil springs 44 of the second terminal 40 may be configured to flex more easily and consistently when engaged by the first connector 36. More specifically, the coil springs 44 may be "tilted" so as to apply a generally constant force into and against the first connector 36 (e.g., in an inward direction toward the center of the gap 50) as the individual coils of the spring 44 flex outward to accommodate the presence of the connector 36 within the gap 50.

[0093] In some embodiments, the coil spring 44 is canted, in the sense that it is sized and shaped to correspond to compression in a predetermined compression direction B. More specifically, the geometry of the coil spring 44 is configured so that when a force is applied to the spring 44 in the compression direction B, the coil spring 44 applies a substantially constant reaction force as the spring 44 deflects through its deflection operating range (see FIG. 33 ). In the illustrated embodiment, the deflection operating range is 10% to 35% of the resting spring height 61 in the compression direction B. In other embodiments, the deflection operating range is a deflection of about 10% to about 35% (e.g., ±1%, ±2%, ±5%, or ±10%) of the resting spring height 61 in the compression direction B. In yet other embodiments, the force applied by the coil spring 44 in the compression direction B changes by 50% to 58% as the spring 44 deflects through its deflection operating range of 10% to 35% of the resting spring height 61 in the compression direction B. In yet another embodiment, the force applied by coil spring 44 in compression direction B varies by 50% to 55% when deflected in compression direction B over a deflection operating range of 10% to 35% of rest spring height 61. In yet another embodiment, the force applied by coil spring 44 in compression direction B varies by 52% to 58% when deflected in compression direction B over a deflection operating range of 10% to 35% of rest spring height 61.

[0094] In yet other embodiments, the coil spring 44 may be tilted by modifying various characteristics of the spring geometry, such as the wire diameter 163, the coil height 165 relative to the coil width 167, the coil spacing 169, and the coil angle 171 (see FIGS. 31 and 32). More specifically, the illustrated coil spring 44 is configured such that the coil height 165 (e.g., the coil dimension in the compression direction B) is less than the coil width 167 (e.g., the coil dimension perpendicular to the compression direction B; see FIG. 32). Additionally, the illustrated coil spring 44 is configured to have a reduced coil angle 171 relative to the axis 173 of the spring 44.

[0095] Compared to the first terminal 38, the second terminal 40 includes more individual contact points with the first connector 36 due to the coil spring 44 (e.g., one contact point for each coil that contacts the connector 36). More specifically, the second terminal 40 has five or more contact points with a particular connector 36. In other embodiments, the inner diameter of the coil spring 44 can be larger so that it can receive or transmit a larger current. The terminal separator 58 is configured to electrically insulate the first terminal 38 and the second terminal 40 to reduce the risk of a short circuit.

[0096] In the illustrated embodiment, the coil spring 44 is shaped to form a substantial "U" shape within the gap 50 (see FIG. 6B). More specifically, the spring 44 is arranged such 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 adjacent the bottom of the gap 50 (e.g., extending between the two walls 42A, 42B (see FIG. 6B)). In doing so, the elastic properties of the coil spring 44 (e.g., its ability to maintain a straight state) exert outward pressure against the two walls 42A, 42B, helping to maintain the spring 44 in place within the terminal 40. 6A, first leg 175A and second leg 175B are respectively disposed within corresponding retention grooves 46 in walls 42A, 42B such that grooves 46 laterally support spring 44. Specifically, grooves 46 help limit movement of spring 44 along insertion direction A when connector 36 is inserted therein.

[0097] The illustrated spring 44 is U-shaped such that both the first leg 175A and the second leg 175B are formed as a single unit. It should be understood that in other embodiments, the first leg 175A and the second leg 175B may be formed separately, and the interconnecting leg 175C may not be present. In such embodiments, each leg 175A, 175B may be retained within the corresponding retention groove 46 mechanically (e.g., via the shape of the groove 46, the use of tabs, etc.), or via adhesive or the like. In still other embodiments, the spring 44 itself may form a continuous loop such that the single spring 44 forms the first leg 175A, the second leg 175B, the interconnecting leg 175C proximate the bottom of the gap 50, and a second interconnecting leg (not shown) proximate the top of the gap 50.

[0098] When installed in the illustrated U-shaped configuration, the coil spring 44 can be further oriented such that when tilted, the compression direction B of the coil spring 44 is perpendicular to the insertion direction A of the first leg 175A and second leg 175B of the spring 44.

[0099] 7A-7B illustrate another embodiment of a second terminal 1040. The second terminal 1040 is substantially similar to the second terminal 40, and therefore only the differences will be 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, in turn, define a plurality of spring retention grooves 1046 that retain the coil springs 44, as discussed above. More specifically, the curvature of the walls 1042 allows for the retention grooves 1046 to exist while maintaining a consistent wall thickness. As such, the illustrated walls 1042 may be formed from a single sheet of pressed or otherwise formed material. In fact, the entire terminal 1040 is configured to be formed from a single formed sheet of material.

[0100] 8A-8B illustrate another embodiment of a second terminal 2040. The second terminal 2040 is substantially similar to the second terminal 40 described above, and therefore only the differences will be discussed in detail herein. The second terminal 2040 includes a pair of retention grooves 2046, each forming a curved path along the inner surface 2047 of its corresponding wall 2042A, 2042B. More specifically, each retention groove 2046 includes a first portion 2071 oriented substantially perpendicular (e.g., ±1%, ±2%, ±5%, or ±10%) to the insertion direction A and a second portion 2073 oriented substantially parallel (e.g., ±1%, ±2%, ±5%, or ±10%) to the insertion direction A. As such, the coil spring 44 disposed within the groove 2046 also includes a portion oriented substantially perpendicular or parallel (e.g., ±1%, ±2%, ±5%, or ±10%) to the insertion direction A.

[0101] In the illustrated embodiment, the coil spring 44 forms a complete loop such that the spring 44 has a first leg 2075A extending along the retention groove 2046 in the first wall 2042A, a second leg 2075B extending along the retention groove 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. In doing so, the inherent elastic properties of the coil 44 (e.g., its ability to assume a resting circular shape) help retain the spring 44 within the groove 2046 of the terminal 2040. In other embodiments, a separate coil spring 44 may be used, extending along all or part of each retention groove 2046 and retained therein such that no interconnecting portions are needed or present.

[0102] 9A-9C illustrate another embodiment of a terminal 3000. The terminal 3000 may be used in place of 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 outer terminal 3060 and an inner terminal 3062 nested within the outer terminal 3060 such that the two terminals 3060, 3062 form a single electrical connection. The outer terminal 3060 includes a first pair of legs 3064 and a pair of outer protrusions 3066. The first pair of legs 3064 may be inserted into the circuit board 18 and soldered to electrically connect the terminal 3000 to the circuit board 18. The outer protrusions 3066 are configured to electrically connect and engage a corresponding first connector 36 from the power tool housing 12 to the circuit board 18. 9A and 9B, as the outer protrusions 3066 extend from the base 3063 of the terminal 3000, the protrusions 3066 first meet to form a pinch point 3065, at which the ends of the protrusions extend forward, forming an open-ended shape that flares away from each other as they move away from the corresponding pinch point 3065. In the illustrated embodiment, the outer terminal 3060 is formed from a conductive material having a thickness between 0.15 mm and 0.35 mm. In some embodiments, the thickness is between 0.2 mm and 0.3 mm. In some embodiments, the thickness is 0.25 mm.

[0103] The inner terminal 3062 shown in FIG. 9C is nested inside the outer terminal 3060 and includes a second pair of legs 3068 and a pair of inner protrusions 3070. The second pair of legs 3068 can also be inserted into the circuit board 18 and soldered to electrically connect the inner terminal 3062 to the circuit board 18. The pair of inner protrusions 3070 have a different shape than the outer protrusions 3066. More specifically, the inner protrusions 3070 are bent in a V-shape and configured to increase the contact area with the first connector 36 when fully attached to the first connector 36. As shown in FIGS. 9A and 9B , as the inner protrusions 3070 extend from the base 3063 of the terminal 3000, the protrusions 3070 first converge together to form a distal end 3067, then extend back toward the base 3063 and continue to converge until forming a pinch point 3069. In other words, the pinch point 3069 is located closer to the base 3063 than to the distal end 3065 .

[0104] In some embodiments, the inner protrusion 3070 is configured to limit the insertion depth of the first connector 36. In other embodiments, the inner protrusion 3070 is configured to complement or clamp onto the connector 36. In such alternative embodiments, the clamping force of the inner protrusion 3070 may be different from the clamping force applied by the outer protrusion 3066. In doing so, the user receives tactile feedback to determine how far the connector 36 has been inserted. More specifically, the clamping force applied by the inner protrusion 3070 may be greater than that applied by the outer protrusion 3066.

[0105] 10A-10C illustrate another embodiment of a terminal 4000. The terminal 4000 is substantially similar to the terminal 3000 described above, and only the differences will be described in detail herein. The terminal 4000 includes an inner terminal 4062 having a pair of interlocking inner protrusions 4070. Stated differently, the protrusions 4070 are shaped to extend across the centerline 4071 of the terminal 4000, with the protrusions 4070 originating on one side of the centerline 4071 and terminating on the opposite side of the centerline 4071. The inner protrusions 4070 also receive the first connector 36, increasing the contact area between the second terminal 4000 and the first connector 36. In some embodiments, the inner protrusions 4070 also limit the insertion depth of the first connector 36.

[0106] 11-12 illustrate another embodiment of a terminal 5000. The terminal 5000 may replace either the second terminal 40 or the first terminal 38 of the electrical interface 17. The terminal 5000 is formed from a single sheet of material (e.g., metal) and includes a pair of outer projections 5066, a pair of inner projections 5070 nested within the outer projections 5066, and a mounting portion 5097. The outer projections 5066 are configured to receive the first connector 36 and electrically connect to the circuit board 18, as shown in FIG. 12. In some embodiments, the inner projections 5070 are configured to limit the insertion depth of the first connector 36 into the second terminal 5000. In other embodiments, the inner projections 5070 function as a second clamping point to increase the surface area of ​​the electrical connection and improve the retention strength of the terminal 5000. The inner protrusion 5070 is nested within the outer protrusion 5066, allowing the second terminal 5000 to increase the contact area without increasing the length of the outer protrusion 5066 (e.g., in a direction parallel to the insertion direction A) or compromising the area of ​​each contact region. The mounting portion 5097 electrically connects and supports the second terminal 5000 to the circuit board 18.

[0107] 11 and 12 , the terminal 5000 is configured so that the outer projection 5066, the inner projection 5070, and the mounting portion 5097 can all be formed from a single sheet of material by bending the single sheet. More specifically, the outer projection 5066 has a first or distal end 5081 that forms a first clamping or pinch point 5083, and a second end 5085 opposite the first end 5081. The inner projection 5070 begins at the second end 5085 of the outer projection 5066 and is folded back 180 degrees from there, such that the inner projection 5070 is nested within the outer projection 5066 while generally extending in the same direction as the outer projection 5066. Stated another way, the inner protrusion 5070 also includes a distal end 5087 that forms a second clamping or pinch point 5089, and a second end 5091 opposite the first end 5087. As shown in FIG. 12 , the second end 5091 of the inner protrusion 5070 and the second end 5085 of the outer protrusion 5066 are connected such that the inner protrusion 5070 and the outer protrusion 5066 can be formed from a single monolithic piece of material. In some embodiments, the connection between the two second ends 5085, 5091 is formed by bending the monolithic material 180 degrees.

[0108] The terminal 5000 also includes a crossover or bridge portion 5093 that extends between and connects the two outer projections 5066. The crossover is positioned so as not to interfere with the gap 5050 into which the connector 38 is inserted. In the illustrated embodiment, the bridge 5093 is positioned and shaped (e.g., adjacent the second end 5085 of the outer projections 5066) so that the two individual outer projections 2066 are connected and thus may be formed from a single piece of monolithic material. More specifically, the bridge 5093 may include two approximately 90-degree bends at either end thereof to enable the outer projections 5066 to be positioned generally parallel to and spaced apart from one another.

[0109] 13-14 show another embodiment of an electrical interface 6017. The electrical interface 6017 is substantially similar to the electrical interface 17 described above, and therefore only the differences will be described in detail herein. The electrical interface 6017 can replace the electrical interface 17 of 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.

[0110] In the illustrated embodiment, the first terminal 6038 and the second terminal 6040 are configured such that the first terminal 6038 and the second terminal 6040 can each receive different connector 36 structures to form different types of electrical connections. Specifically, the first terminal 6038 can receive the first connector 6036 from the power tool 12, while the second terminal 6040 can receive either the first connector 6036 or the second connector 6037 from the power tool housing 6012 (described below).

[0111] Further, each first terminal 6038 may form only a single electrical connection point (e.g., the first terminal 6038 may form a single electrical circuit), while each second terminal 6074 may form one or more electrical connection points (e.g., the second terminal 6074 may form two or more independent electrical circuits). When docked to the attachment point 6015, the first terminal 6038 may form a single electrical connection with both the first connector 6036 and the second connector 6037, while the second terminal 6040 may form a single electrical connection with the first connector 6036 and two electrical connections with the second connector 6040.

[0112] The terminal 6040 includes an outer terminal 6060 and an inner terminal 6062 nested within and electrically insulated from the outer terminal 6060. The outer terminal 6060 includes a first pair of legs 6064 soldered to the circuit board 18 and a pair of outer protrusions 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 to the circuit board 18.

[0113] The inner terminal 6062 includes a second pair of legs 6068 soldered to the circuit board 18 at a different position from the first pair of legs 6064, and a pair of inner protrusions 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 only to receive the second connector 6037 and to electrically connect to the second connector 6037.

[0114] As shown in FIG. 16A , the second connector 6037 is installed within the second terminal 6040, and both the outer terminal 6060 and the inner terminal 6062 engage to form an electrical connection (see, e.g., connection point C between the connector 6037 and the outer terminal 6060, and connection point D between the connector 6037 and the inner terminal 6062). In contrast, FIG. 16B shows that the first connector 6036 is installed within the second terminal 6040 and only forms an electrical connection with the outer terminal 6060 (see connection point E between the outer terminal 6060 and the connector 6036). More specifically, because 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 only engages with the outer terminal 6060 of the second terminal 6040.

[0115] 14, the second terminal 6040 includes a shim or insulator 6072 disposed between the inner terminal 6062 and the outer terminal 6060 so that the two terminals remain electrically insulated from one another. In the illustrated embodiment, the shim 72 is made of mica. In other embodiments, the shim 72 may be made of any electrically insulating material.

[0116] 15 illustrates another embodiment of an attachment point 6015 for a power tool 12. The attachment point 6015 here includes one or more first connectors 6036 having a first insertion length 6039 (e.g., the length of the connectors 6036 measured in the insertion direction A) and 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. In use, the first connectors 6036 have an insertion length 6039 that is sufficient to form an electrical connection with the second terminal 6040 and the outer terminal 6060 of the first terminal 6038, but not with the inner terminal 6062 of the second terminal 6040. In contrast, the second connector 6037 has an insertion length 6041 sufficient to form an electrical connection with the second terminal 6040 and the inner terminal 6062 and outer terminal 6060 of the first terminal 6038 .

[0117] 17-19B illustrate another embodiment of an electrical interface 7017. The electrical interface 7017 is substantially similar to the electrical interface 6017 described above, and therefore only the differences will be described in detail herein. The electrical interface 7017 may replace the electrical interface 17 of the battery pack 10. The electrical interface 7017 includes a second terminal 7040 including an outer terminal 7060 and an inner terminal 7062. The outer terminal 7060 includes a first pair of legs 7064 and a pair of outer protrusions 7066 soldered to the circuit board 18. As shown in FIGS. 18 and 19, the inner terminal 7062 includes a second pair of legs 7068 and a pair of inner protrusions 7070 soldered to the circuit board 18.

[0118] Compared to the outer terminal 7060, the inner terminal 7062 includes a different arrangement of the second pair of legs 7068 to reduce the overall footprint of the second terminal 7040 on the circuit board 18. More specifically, the illustrated outer terminal 7060 defines a length envelope 7061 extending in the insertion direction A (see FIG. 19A ). The inner terminal 7062 is configured such that the second pair of legs 7068 are disposed entirely within the length envelope 7061 of the outer terminal 7060. In yet other embodiments, the overall length 7063 (measured parallel to the insertion direction A) of the outer terminal 7060 is greater than the overall length 7065 (measured parallel to the insertion direction A) of the inner terminal 7062. In yet other embodiments, both the pinch point 7067 and the second pair of legs 7068 of the inner terminal 7062 are included within the length envelope 7061 of the outer terminal 7060.

[0119] As shown in FIG. 19A, the second terminal 7040 is configured to receive the second connector 6037, which is electrically connected to both the outer protrusion 7066 and the inner protrusion 7070.

[0120] While the illustrated inner projections 7070 are shown as essentially horizontal, such that the bases or joints 7069 between the projections 7070 and the projections 7070 are offset horizontally (e.g., parallel to the insertion direction A) from one another, with the joints 7069 themselves oriented perpendicular to the insertion direction (see FIG. 18 ), it should be understood that in other embodiments, the projections 7070 may be vertical in configuration. In such embodiments, the joints 7069 and the projections 7070 are offset vertically (e.g., perpendicular to the insertion direction A), with the joints 7069 themselves positioned adjacent to and extending parallel to the circuit board 18 parallel to the insertion direction A (see FIG. 18 ). Such a layout allows for shorter lead wires extending to the legs 7068. The vertical layout also allows the inner projections 7070 to conform to the shape of the connector, maximizing the contact area for terminals of a given length.

[0121] 20 and 22A-22B illustrate another embodiment of an electrical interface 11017. The electrical interface 11017 is substantially similar to the electrical interface 7017 described above, and therefore only the differences will be discussed in detail herein. The electrical interface 11017 may replace the electrical interface 17 of the battery pack 10. The electrical interface 11017 includes one or more first terminals 11038 and one or more second terminals or stack terminals 11074.

[0122] Each first terminal 11038 includes a single electrical connection point (e.g., the first terminal 11038 may form a single electrical circuit), while each second terminal 11074 includes multiple electrical connection points (e.g., the second terminal 11074 may form two or more independent electrical circuits). More specifically, the second terminal 11074 includes multiple electrical connection points 11039A, 11039B, and each electrical connection point 11039A, 11039B may be individually accessed through a corresponding slot 32 in the battery housing 14 without making electrical connection with the other connection points 11039A, 11039B. More specifically, each connection point 11039A, 11039B defines a unique insertion axis 11041A, 11041B (extending parallel to the insertion direction A) that is offset from the insertion axes 11041A, 11041B of all other electrical connection points 11039A, 11039B. 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. Stated differently, 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 from the circuit board 18 that is greater than the first distance. Furthermore, in the illustrated embodiment, the two insertion axes 11041A, 11041B lie on a common plane oriented perpendicular to the circuit board 18.

[0123] 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. As shown in FIG. 20 , the upper terminal 11082 defines a first insertion axis 11041A spaced a first distance from the circuit board 18, while the lower terminal 11084 defines a second insertion axis 11041B spaced a second distance from the circuit board 18 that is less than the first distance. Furthermore, the upper terminal 11082 also has an insertion distance that is greater than the insertion distance of the lower terminal 11084.

[0124] In use, as shown in Figure 22A (discussed below), when the stacked terminal 11074 receives the split connector 11042, 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). As shown in Figure 22B (discussed below), when the stacked terminal 11074 receives the first connector 11036, the lower terminal 11084 receives and electrically connects with the first connector 11036, and the upper terminal 11082 (see connection J) is left unconnected.

[0125] FIG. 21 illustrates another embodiment of an attachment point 11015 for a power tool 12. The attachment point 11015 is substantially similar to the attachment point 15 described above, and therefore only the differences will be described in detail herein. The attachment point 11015 includes one or more split connectors 11042 and one or more first connectors 11036. Each split connector 11042 includes a plurality of individual, electrically isolated connection elements 11078, 11080 that extend generally parallel to but offset from one another in the insertion direction A. More specifically, the individual connection elements 11078, 11080 are positioned such that, when the battery 10 is coupled to the attachment point 11015 for the power tool 12 in the insertion direction A, each connection element 11078, 11080 corresponds to and is coaxial with a corresponding insertion axis 11041A, 11041B. Each connecting element 11078, 11080 also has an insertion length that corresponds to the insertion depth of the corresponding terminal 11082, 11084.

[0126] Each first connector 11036 forms a single electrical connection point. During use, the first terminal 11038 is configured to receive the first connector 11036 therein. In some embodiments, the connector 11036 has a connector height (e.g., connector height perpendicular to the insertion direction A) large enough to overlap both the upper terminal 11082 and the lower terminal 11084 of the split terminal 11074. As such, the first connector 11036 can be configured to electrically connect with one or both terminals 11082, 11084 of the split terminal 11074, depending on its insertion distance. In embodiments where the insertion distance of any one connector 11036 exceeds the insertion length of both terminals 11082, 11084, the connector can be electrically connected to both terminals 11082, 11084 simultaneously, but in other embodiments where the insertion distance is greater than the insertion depth of one terminal but less than the insertion depth of the other, the first connector 11036 can be electrically connected only to the shallower of the two terminals.

[0127] 23A-23B show another embodiment of a circuit board 8018. The circuit board 8018 is substantially similar to the circuit board 18 described above, and therefore only the differences will be described in detail herein. The circuit board 8018 can replace the circuit board 18 of the battery pack 10. The circuit board 8018 includes an electrical interface 8017 that houses 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 enclosed by the upper PCB cover 8098. The upper PCB cover 8098 is made of a thermally conductive but electrically non-conductive material. The upper PCB cover 8098 is configured to dissipate heat generated at the rear end of the second terminal 8040. The lower PCB cover 8099 is also made from the same material as the upper PCB cover 8098 and is configured to dissipate heat from the pair of legs 8064 of the second terminals 8040. Additionally, the upper PCB cover 8098 and the lower PCB cover 8099 are manufactured using low-pressure overmolding.

[0128] 24A-24B show another embodiment of a circuit board 9018. The circuit board 9018 includes similar components to the circuit board 8018, and therefore only the differences will be described in detail herein. The upper and lower PCB covers 9098, 9099 are thicker than the upper and lower PCB covers 8098, 8099. The additional material on the upper and lower PCB covers 9098, 9099 increases the thermal mass and provides a higher heat dissipation capability than the upper and lower PCB covers 9098, 9099. FIG. 25A shows the lower PCB cover 9099, and FIG. 25B shows the circuit board 9018 without the lower PCB cover 9099.

[0129] 26A-29 illustrate another embodiment of a battery pack 10010. The battery pack 10010 is substantially similar to the battery pack 10 described above, and only the differences will be described in detail herein. As shown in FIGS. 26A-26B , 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 in electrical communication with both the circuit board 10018 and the one or more battery cells. The tool engagement portion 10016 includes first spaced-apart housing walls or ribs 10020 extending parallel to the insertion direction A and second spaced-apart housing walls or ribs 10021 also extending parallel to the insertion direction A. The first rib 10020 and the second rib 10021 each define a groove 10022 that also extends parallel to the insertion direction A. The grooves 10022 each include at least one window 10086 that opens to the interior cavity of the housing 10014 of the battery pack 10010. In use, the grooves 10022 are configured to receive the rails 10030 from the power tool 10012 when the battery pack 10010 is coupled to the power tool 10012. In other embodiments, the grooves 10022 may be formed in the power tool 10012 while the rails 10030 are disposed on the battery pack 10010.

[0130] 27A-27C, the circuit board 10018 of the battery pack 10010 includes a plurality of first terminals 10038 and a plurality of side terminals 10088 angled relative to the first terminals 10038. More specifically, each of the first terminals 10038 may be accessed through a slot 10032 formed in the housing 10014 of the battery pack 10010 that is oriented at least partially perpendicular to the insertion direction A (e.g., a connector is introduced parallel to the insertion direction A). In contrast, the side terminals 10088 are accessible through a window 10086 that is not oriented perpendicular to the insertion direction A. In the illustrated embodiment, the window 10086 that provides access to the side terminals 10088 is oriented parallel to the insertion direction A and is positioned completely within one of the two grooves 10022.

[0131] In 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 in an insertion direction A. In contrast, side terminals 10088 are disposed in windows 10086 of the groove 10022 and are configured to receive a plurality of side connectors 10089 from the power tool 10012. In use, the side connectors 10089 are configured to make sliding contact with the side terminals 10088 (e.g., slide along a surface of the terminals 10088 oriented parallel to the insertion direction A), such that a biasing force acting perpendicular to the insertion direction A pushes or otherwise urges the connectors 10089 into contact with the terminals 10088. In the illustrated embodiment, the connector 10089 is configured to apply a contact force (e.g., inward toward the terminals 10088) to make the desired contact, although in other embodiments the terminals 10088 may be biased outward into engagement with the connector 10089. In still other embodiments, both the connector 10089 and the terminals 10088 may be biased into engagement with one another.

[0132] 26A and 27B, a positive side terminal 10090 of the plurality of side terminals 10088 is disposed on a first spaced-apart wall 10020 and is soldered to a separate area of ​​the circuit board 10018. In this configuration, the positive side terminal 10090 can be operated separately from any of the first terminals 10038. As shown in FIGS. 26B and 27C, a negative side terminal 10092 of the plurality of side terminals 10088 is disposed on a second spaced-apart wall 10021 and is soldered to a first pair of legs 10048 of one of the first terminals 10038. In this configuration, the side terminal 10088 is connected in parallel with at least one of the first terminals 10038.

[0133] Figures 28 and 29 show that the side connector 10089 is positioned on the rail 10030 of the mounting point 10015 and is configured to engage with the side terminal 10088 when the battery pack 10010 is fully attached to the power tool housing 10012.

[0134] 27B, the positive side terminal 10090 includes a shield 10094 for physically isolating and electrically insulating the side terminal 10088 from the first terminal 10038. The shield 10094 prevents short circuits between the side terminal 10088 and the first terminal 10038 and seals the interior cavity of the battery pack 10010 from dust and dirt entering through the window 10086.

[0135] FIG. 30 illustrates various alternative embodiments of terminals 40K-U. The second terminals 40K-U may replace any of the terminals previously described. Terminal 40K includes a pair of spaced-apart terminal walls 42K, a pair of legs 64K, a rear wall 65K, and a pair of protrusions 66K. The spaced-apart terminal walls 42K have a greater thickness than the pair of protrusions 66K. Terminal 40L includes similar components to second terminal 40K, except that the pair of protrusions 66L and the pair of spaced-apart walls 65L, 42L have the same thickness. Terminal 40M includes similar components to terminals 40K, 40L, except that the transition between the pair of spaced-apart terminal walls 42M and the rear wall 65M has a larger radius of curvature than the second terminals 40K, 40L. Additionally, the projection 66M decreases in thickness as it moves away from the spaced-apart terminal wall 42M. Terminal 40N has similar components to terminals 40K-M, but instead of the spaced-apart terminal walls 42K-M, it has a pair of bridged terminal walls 43N. The bridged wall 43N also has a through-hole 45N on its top surface and does not include a rear wall. Terminal 40O has similar components to second terminal 40N, but the through-hole 45O is countersunk. Terminal 40P has similar components to terminals 40N and 40O, but the thickness of the pair of bridged terminal walls 43P is greater than the thickness of the corresponding projection 66P. Terminal 40Q has similar components to terminals 40N-P, but the through-hole 45Q includes a curved countersunk hole. Terminal 40R has similar components to terminals 40N-Q, but the through-hole 45R includes a countersunk hole. Terminal 40S has the same components as second terminals 40N-R, but does not have a through-hole in bridged terminal wall 43S. However, terminal 40S has a rear wall 65S. Terminal 40T has the same components as terminal 40S, but has a rear wall 65T that is a multi-layer metal sheet.

[0136] 34A-34C illustrate an alternative embodiment of a terminal 40U. More specifically, the terminal 40U is generally formed from a piece of solid metal material (e.g., copper, aluminum, etc.) and fabricated and / or machined to define a groove 41U therein sized to receive a corresponding blade or connector 43U. By being formed from a solid material instead of a sheet material (e.g., metal), the illustrated terminal 40U can accommodate relatively large current rates. As shown, the resulting groove 41U may be supplemented with a spring 45U (e.g., a canted spring) disposed 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 gold or the like to reduce current resistance and corrosion.

[0137] 35A-35C illustrate alternative embodiments of terminals 40V, 40W that are generally cylindrical in structure. A first terminal 40V includes a series of pivotable conductors 41V movably attached to the terminal 40V to accommodate size and positional changes between the male connector 43V and the female terminal 40V. While in the structure shown in FIG. 35A both the connector 43V and the terminal 40V are shown with conductors 41V therein, it should be understood that in other embodiments only one or the other may include such conductors 41V.

[0138] 35B and 35C show another embodiment in which a coil spring 47W (e.g., a canted spring) is incorporated into either the terminal 40W or the connector 51W. The coil spring 47W operates as discussed above and is configured to help retain the connector 51W within the terminal 40W and to improve electrical conductivity between the two elements.

[0139] Various features and advantages of the invention are set forth in the following claims.

Claims

1. 1. A battery pack for use with a power tool having an electrical connector, comprising: a housing containing 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 coil spring disposed at least partially within the gap, the coil spring configured to engage with the electrical connector of the power tool to form an electrical connection when the electrical connector is at least partially disposed within the gap, at least one terminal wall defining a groove therein and the coil spring being at least partially disposed within the groove; a terminal separator including tabs that mechanically retain the coil spring within the groove. Battery pack.

2. The battery pack of claim 1 , wherein the coil spring is canted.

3. 2. The battery pack of claim 1, wherein the electrical connector is introduced into the gap in a first insertion direction, and the coil spring is angled to provide compression in a direction perpendicular to the first insertion direction.

4. 10. The battery pack of claim 1, further comprising a circuit board disposed in the housing in electrical communication with the one or more battery cells and the first terminal.

5. 5. The battery pack of claim 4, wherein the first terminal comprises a pair of legs attached to the circuit board.

6. 10. The battery pack of claim 1, wherein both terminal walls define a groove therein, and the coil spring is at least partially disposed within both grooves.

7. 2. The battery pack of claim 1, wherein the first terminal defines a mid-plane disposed equidistant from both terminal walls, and the coil spring is disposed on either side of the mid-plane.

8. The battery pack of claim 1 , wherein the coil springs are arranged in a U-shape.

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