Portable power system and related devices

Abstract

Various embodiments of a portable power ecosystem are provided. The portable power ecosystem includes a first portable power module comprising a first mechanical interface and a first electrical interface and a second portable power module comprising a second mechanical interface and a second electrical interface. The second portable power module is stacked on the first portable power module in a vertical configuration. The first mechanical interface and the second mechanical interface interact to form a mechanical connection between the first portable power module and the second portable power module. The first electrical interface and the second electrical interface interact to form an electrical connection between the first portable power module and the second portable power module. The electrical connection is only able to be formed simultaneously with or after forming the mechanical connection.

Description

PORTABLE POWER SYSTEM AND RELATED DEVICESCROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] The present application claims the benefit of priority to U.S. Provisional Application No. 63 / 735,708, filed December 18, 2024, to U.S. Provisional Application No. 63 / 727,306, filed December 3, 2024, to U.S. Provisional Application No. 63 / 707,412, filed October 15, 2024, and to U.S. Provisional Application No. 63 / 650,237, filed on May 21, 2024, which are incorporated herein by reference in their entireties.BACKGROUND OF THE INVENTION

[0002] The present disclosure is directed generally to power systems and related devices. The present disclosure relates specifically to portable power systems and related devices, including methods of mechanical and electrical connection between modules of such systems and devices.

[0003] Bringing power to a jobsite is difficult, especially when a construction site has not had power routed to it yet. The conventional solution to this problem is bringing gas generators to the jobsite. However, there are problems associated with the use of gas generators, such as emissions in the form of fumes and noise, that make them suitable only for outdoor use. Further, once set up outside, long extension cords have to be routed to the task site from the generator, which creates a tripping hazard. These problems make gas generators a nuisance and potentially safety risk on a job site.SUMMARY OF THE INVENTION

[0004] Embodiments of the present disclose address the problems associated with the use of gas generators. In particular, embodiments of the present disclosure relate to a portable power ecosystem with discrete, modular components that allows users to build the precise portable power system for their unique needs. Embodiments of the presently disclosed ecosystem include multiple components, such battery cores, power management units (with an internal inverter and charger, AC, and DC outputs), battery chargers for various battery voltages, and floor and wall mountingplates. Embodiments of the present disclosed portable power ecosystem provide battery capacity scalability, as well as DC-DC charging for greater efficiency when charging battery packs.

[0005] As will be discussed more fully below, the discrete, modular components are mechanically connected using a cleat and pocket interface (e.g., Packout interface available from Milwaukee Tool) providing an interchangeable and interlocking storage system. In one or more embodiments, the discrete, module components are stackable and encompass such components as toolboxes, mobility solutions, and power tools. Advantageously, the disclosed platform is a robust, easily operable method for stacking, connecting, and disconnecting different products utilizing the same cleat and pocket interface from each other. By leveraging this existing, recognized, popular cleat and pocket interface for making mechanical connections in the portable power ecosystem, the newly disclosed electrical modules can be adopted and integrated into existing cleat and pocket interface products to expand the capabilities of the cleat and pocket interface platform.

[0006] Various embodiments of the invention relate to a portable power systems and related devices. In various embodiments, such portable power systems and related devices include coupling mechanism(s) (e.g., male and / or female coupling components) configured to engage with units of a modular storage system, such as a modular or stackable tool storage system, a modular worksite storage system, a modular transit storage system, etc. In various embodiments, the disclosure relates to portable power systems and related devices that utilize, couple to, or otherwise support rechargeable batteries, such as rechargeable power tool batteries.

[0007] As will be discussed more fully below, descriptions of embodiments of the portable power system detail the placement of the electrical interface, how to make the user experience as seamless and as enjoyable as possible, prevention of access to contacts and hazardous voltage, and maintenance of a high level of compatibility with existing Packout products.

[0008] Aspect 1 relates to a portable power module. The portable power module comprises a first surface extending between a first end and a second end of the portable power module. The second end is spatially disposed from the first end in a first direction, and the first surface comprises a first interface disposed between the first end and the second end. A second surface is opposite to the first surface, and the second surface extends between the first end and the second end. The second surface comprises s second interface configured to mechanically interlock withthe first interface. A plurality of sidewalls connect the first surface and the second surface. The portable power module also comprises a first electrical connector and a second electrical connector. The portable power module is configured to form an electrical connection and a mechanical connection to one or both of a first adjacent portable power module arranged upwardly in a vertical stacking configuration and a second adjacent portable power module arranged downwardly in the vertical stacking configuration. In the mechanical connection, the second interface is configured to mechanically interlock with a first interface of the second adjacent portable power module, or the first interface is configured to mechanically interlock with a second interface of the first adjacent portable power module. In the electrical connection, he first electrical connector is configured to connect with a second electrical connector of one of the first adjacent portable power module, or the second electrical connector is configured to connect with the first electrical connector of the second adjacent portable power module. The electrical connection can only be made at the same time or after the mechanical connection is made.

[0009] Aspect 2 relates to the portable power module of Aspect 1 in which the portable power module further comprises a terminal block disposed on the second end of the portable power module. The terminal block comprises a first connection interface and a second connection interface in which the first connection interface faces opposite to the second connection interface. The first connection interface extends above a plane defined by the first surface in a first position. The first connection interface comprises the first electrical connector, and the second connection interface comprises the second electrical connector.

[0010] Aspect 3 relates to the portable power module of Aspect 2 in which the first electrical connector is a female electrical connector and the second electrical connector is a male electrical connector.

[0011] Aspect 4 relates to the portable power module of Aspect 2 or Aspect 3 in which the electrical connection is formed substantially at the same time as the mechanical connection.

[0012] Aspect 5 relates to the portable power module of any of Aspects 2-4 in which the first connection interface is configured to transition from the first position to a second position substantially flush with or below the first surface.

[0013] Aspect 6 relates to the portable power module of Aspect 5 in which the first connection interface is biased toward the first position.

[0014] Aspect 7 relates to the portable power module of Aspect 5 or Aspect 6 in which the second connection interface is configured to slide back and forth in the first direction and in a second direction opposite to the first direction and in which the second connection interface is biased in the first direction.

[0015] Aspect 8 relates to the portable power module of any of Aspects 2-7 in which the portable power module further comprises a locking tab and a locking power slider. The locking tab is configured to reversibly extend through the second surface and seat within a recess formed in a first surface of the second adjacent portable power module. The locking tab is disposed between the first end of the power module and the second interface, and the locking power slider is configured to translate from a first position in which the locking tab is able to retract from the recess to a second position in which the locking tab is prevented from retracting from the recess. The position of the locking power slider controls whether electrical power is able to flow to the first electrical connector and the second electrical connector.

[0016] Aspect 9 relates to the portable power module of claim 1, further comprising a rotatable handle, the rotatable handle comprising a first end and a second end, wherein the first electrical connector is disposed on the first end of the rotatable handle, wherein the rotatable handle is configured to rotate about the second end toward the first adjacent portable power module to mate with the second electrical connector of the first adjacent portable power module.

[0017] Aspect 10 relates to the portable power module of Aspect 9 in which the rotatable handle and the second electrical connector are disposed on a first sidewall of the plurality of sidewalls, the first sidewall being on the first end of the power module.

[0018] Aspect 11 relates to the portable power module of Aspect 10 in which, to rotate the rotatable handle, the rotatable handle is translated in a second direction opposite to the first direction and in which, to connect the first electrical connector of the power module to the second electrical connector of the first adjacent portable power module, the rotatable handle is translated in the first direction.

[0019] Aspect 12 relates to the portable power module of any of Aspects 9-11 in which the rotatable handle is rotated from a substantially horizontal position to a substantially vertical position to connect the first electrical connector to the second electrical connector of the first adjacent portable power module.

[0020] Aspect 13 relates to the portable power module of any of Aspects 9-12 in which the second electrical connector is disposed between the second end of the rotatable handle and the second surface.

[0021] Aspect 14 relates to the portable power module of Aspect 13 in which the portable power module further comprises a socket cover configured to swing from a closed position covering the second electrical connector to an open position in which the second electrical connector is uncovered.

[0022] Aspect 15 relates to the portable power module of any of Aspects 9-14 in which the portable power module further comprises an arcuate travel guide comprising a first seat and a second seat. The second end of the rotatable handle comprises a detent, and, to form the electrical connection, the rotatable handle is rotated from a first position in which the detent is disposed in the first seat to a second position in which the detent is disposed in the second seat.

[0023] Aspect 16 relates to the portable power module of any of Aspects 9-15 in which the rotatable handle further comprises a protective sheath configured to cover the first electrical connector prior to making the electrical connection.

[0024] Aspect 17 relates to the portable power module of Aspect 16 in which the protective sheath is biased in a position to cover the first electrical connector and in which, in forming the electrical connection, the protective sheath is pushed against the bias such that the first electrical connector is exposed for connection with the second electrical connector of the first adjacent portable power module.

[0025] Aspect 18 relates to the portable power module of any of Aspects 9-17 in which the electrical connection is made after the mechanical connection is made.

[0026] Aspect 19 relates to the portable power module of Aspect 1, further comprising a rotatable handle. The second electrical connector is disposed within the portable power module and is coupled to the first surface, and the first electrical connector is coupled to the second surfaceand configured to extend from within the portable power module through the second surface when the rotatable handle is rotated from a first handle position to a second handle position.

[0027] Aspect 20 relates to the portable power module of Aspect 19 in which the first interface is at least one cleat pocket and the second interface is at least one cleat. The portable power module further comprises a cleat switch, a cleat switch finger, and a backer substrate. The first electrical connector is mounted to the backer substrate, and the cleat switch is configured to rotate out of a negative space of the at least one cleat when the cleat switch engages a cleat of the second adjacent portable power module in making the mechanical connection. Rotation of the cleat switch causes translation of the cleat switch finger, and translation of the cleat switch finger allows translation of the backer substrate so that the first electrical connector is able to extend from within the portable power module through the second surface.

[0028] Aspect 21 relates to the portable power module of Aspect 19 or Aspect 20 in which the portable power module further comprises a first access plate disposed within the portable power module and coupled to the second surface. The first access plate comprises a plurality of apertures, and the first access plate has a first plate position in which the first access plate covers a plurality of openings in the second surface and a second plate position in which the plurality of apertures align with the plurality of openings such that the first electrical connector can extend through the first access plate and the second surface. Rotation of the rotatable handle from the first handle position to the second handle position causes the first access plate to move from the first plate position to the second plate position.

[0029] Aspect 22 relates to the portable power module of Aspect 21 in which the portable power module further comprises a locking tab. The locking tab is configured to reversibly extend through the second surface and seat within a recess formed in a first surface of the second adjacent portable power module. The locking tab is disposed between the first end of the power module and the at least one cleat. The first access plate comprises an arm configured to engage a notch of the locking tab to keep the locking tab in an extended position when the first access plate is in the second plate position.

[0030] Aspect 23 relates to the portable power module of Aspect 1 in which the portable power module further comprises a locking tab configured to reversibly extend through the second surfaceand seat within a recess formed in a first surface of the second adjacent portable power module. The locking tab is coupled to a blade assembly, and the blade assembly comprises a mounting bracket, a plurality of blade contacts for the first electrical connector, and at least one probe. The at least one probe extends a farther distance away from the mounting bracket than each of the plurality of blade contacts. The probe allows the blade contacts to extend through the second surface to mate with a second electrical connector of the second adjacent portable power module only if the probe is able to seat within a cavity formed in a first surface of the second adjacent portable power module.

[0031] Aspect 24 relates to the portable power module of Aspect 1 in which the first electrical connector and the second electrical connector are disposed on a first sidewall of the plurality of sidewalls. The first sidewall is at the first end of the portable power module, and the portable power module further comprises a slidable cover that is configured to slide across the first sidewall to cover and uncover at least one of the first electrical connector and the second electrical connector. The first electrical connector is configured to connect to a first end of a first removable plug in which a second end of the first removable plug is configured to be received by a second electrical connector of the second adjacent portable power module. The second electrical connector is configured to connect to a second end of a second removable plug in which a first end of the second removable plug is configured to be received by a first electrical connector of the first adjacent portable power module.

[0032] Aspect 25 relates to the portable power module of Aspect 24 in which the portable power module further comprises a locking tab. The locking tab is configured to reversibly extend through the second surface and seat within a recess formed in a first surface of the second adjacent portable power module. The slidable cover prevents access to the locking tab when the at least one of the first electrical connector and the second electrical connector is uncovered.

[0033] Aspect 26 relates to the portable power module of Aspect 1 in which the first electrical connector is disposed at a first end of a flexible pigtail connector. The portable power module defines a storage cavity between the first surface and a first sidewall of the plurality of sidewalls. A second end of the flexible pigtail connector is connected to a wall of the storage cavity, and the second electrical connector is disposed on the first sidewall. The flexible pigtail connector isconfigured to bend toward the first adjacent portable power module so that the first electrical connector is able to mate with a second electrical connector of the first adjacent portable power module.

[0034] Aspect 27 relates to the portable power module of Aspect 21 in which the portable power module further comprises a rotatable connector having a first end and a second end. The rotatable connector comprises a rotatable base disposed at the first end and the first electrical connector disposed at the second end. The rotatable base rotates about a stationary base disposed on a first sidewall of the plurality of sidewalls. The rotatable base comprises a first electrical contact and the stationary base comprises a second electrical contact. The first electrical contact is not in electrical communication with the second electrical contact when the rotatable connector is in a first position. The first electrical contact is in electrical communication with the second electrical contact when the rotatable connector is in a second position in which the first electrical connector is configured to engage a second electrical connector of the first adjacent portable power module.

[0035] Aspect 28 relates to a portable power ecosystem. The portable power ecosystem comprises a first portable power module comprising a first mechanical interface and a first electrical interface and a second portable power module comprising a second mechanical interface and a second electrical interface. The second portable power module is stacked on the first portable power module in a vertical configuration. The first mechanical interface and the second mechanical interface interact to form a mechanical connection between the first portable power module and the second portable power module. The first electrical interface and the second electrical interface interact to form an electrical connection between the first portable power module and the second portable power module. The electrical connection is only able to be formed simultaneously with or after forming the mechanical connection.

[0036] Aspect 29 relates to the portable power ecosystem of Aspect 28 in which the first mechanical interface comprises at least one cleat pocket and in which the second mechanical interface comprises at least one cleat. The mechanical connection is formed when the at least one cleat is seated in the at least one cleat pocket.

[0037] Aspect 30 relates to the portable power ecosystem of Aspect 28 or Aspect 29 in which the first electrical interface comprises a first terminal block comprising a first electrical connector. The first electrical connector is disposed in a plane above an upper surface of the first portable power module. The second electrical interface comprises a second terminal block comprising a second electrical connector. The second electrical connector is disposed on a rear surface of the second portable power module, and the rear surface is substantially perpendicular to the upper surface. The electrical connection comprises the second electrical connector of the second terminal block being connected to the first electrical connector of the first terminal block.

[0038] Aspect 31 relates to the portable power ecosystem of Aspect 30 in which the first terminal block is configured to rotate or translate to a position that is substantially flush or below the upper surface.

[0039] Aspect 32 relates to the portable power ecosystem of Aspect 30 or Aspect 31 in which the electrical connection is formed substantially simultaneously with the mechanical connection.

[0040] Aspect 33 relates to the portable power ecosystem of Aspect 28 or Aspect 29 in which the first portable power module further comprises a rotatable handle. The rotatable handle comprises a first end and a second end. The first electrical interface is disposed on the first end of the rotatable handle, and the rotatable handle is configured to rotate about the second end toward the second portable power module to connect the first electrical interface with the second electrical interface.

[0041] Aspect 34 relates to the portable power ecosystem of Aspect 28 or Aspect 29 in which the second portable power module further comprises a rotatable handle. The first electrical interface comprises a first electrical connector disposed within the first portable power module and coupled to an upper surface of the first portable power module. The second electrical interface comprises a second electrical connector coupled to a lower surface of the second portable power module. The second electrical connector is configured to extend from within the second portable power module through the lower surface and connect with the first electrical connector of the first portable power module when the rotatable handle is rotated from a first handle position to a second handle position.

[0042] Aspect 35 relates to the portable power ecosystem of Aspect 33 or Aspect 34 in which the electrical connection is formed after the mechanical connection.

[0043] Aspect 36 relates to the portable power ecosystem of any of Aspects 28-35 in which the portable power ecosystem further comprises a power management unit. The first portable power module and the second portable power module are stacked on the power management unit in a vertical configuration. The power management unit comprises at least one AC power outlet, at least one AC power inlet, at least one DC power outlet, and at least one DC power inlet. The power management unit is configured to control charging and discharging of electrical power for the first portable power module and the second portable power module.

[0044] Aspect 37 relates to the portable power ecosystem of Aspect 36 in which the power management unit comprises a third mechanical interface and a third electrical interface. The third mechanical interface is configured to mate with the first mechanical interface to form a second mechanical connection between the first portable power module and the power management unit. The first electrical interface and the third electrical interface are configured to mate to form a second electrical connection between the first portable power module and the power management unit. The second electrical connection is only able to be formed simultaneously with or after forming the second mechanical connection.

[0045] Aspect 38 relates to the portable power ecosystem of any of Aspects 28-37 in which the portable power ecosystem further comprises an expansion core that provides additional battery capacity to the portable power ecosystem.

[0046] Aspect 39 relates to the portable power ecosystem of any of Aspects 28-38 in which the portable power ecosystem further comprises a charging caddy comprising at least one bay configured to receive a battery pack. The charging caddy is configured to charge the battery pack when the charging caddy is electrically connected to the portable power ecosystem.

[0047] Aspect 40 relates to the portable power ecosystem of Aspect 39 in which the battery pack is handheld power tool battery pack.

[0048] Aspect 41 relates to the portable power ecosystem of Aspect 39 or Aspect 40 in which the at least one bay is disposed at an angle that is transverse to an axis of the vertical stacking configuration, the angle being less than 90°.

[0049] Aspect 42 relates to the portable power ecosystem of any of Aspects 28-41 in which the portable power ecosystem further comprises a dolly configured to transport the first portable power module and the second portable power module.

[0050] Aspect 43 relates to the portable power ecosystem of Aspect 42 in which the dolly comprises a back panel configured to support a plurality of bays where each bay is configured to receive a battery pack of a power tool.

[0051] Aspect 44 relates to the portable power ecosystem of Aspect 43 in which each bay of the plurality of bays is configured to charge the battery pack of the power tool when the battery pack is received in the bay.

[0052] Aspect 45 relates to the portable power ecosystem of any of Aspects 28-44 in which the portable power ecosystem further comprises a battery rack having a first side and a second side. The first side comprises the second mechanical interface, and the second side comprises a sliding mount configured to receive a battery pack.

[0053] Aspect 46 relates to the portable power ecosystem of any of Aspects 28-45 in which the portable power ecosystem further comprises a mounting plate having a first side and a second side. The first side comprises an actuatable locking mechanism configured to engage the second interface, and the second side comprises a lock actuator and a sliding mount configured to receive a battery pack. Actuation of the lock actuator causes the locking mechanism to engage the second interface.

[0054] Aspect 47 relates to the portable power ecosystem of any of Aspects 36-46 in which the portable power ecosystem further comprises an expansion plate. The expansion plate comprises a fourth mechanical interface, a fourth electrical interface, and a power input port. The fourth mechanical interface is configured to receive at least one battery charger, and the battery charger comprises a fifth mechanical interface and a fifth electrical interface. The fourth mechanical interface and the fifth mechanical interface mate to establish a mechanical connection between the expansion plate and the at least one battery charger. The fourth electrical interface and the fifth electrical interface mate to establish an electrical connection between the expansion plate and the at least one battery charger. The power input port is configured to receive electricalpower from the power management unit to charge the at least one battery charger through the expansion plate.

[0055] Aspect 48 relates to the portable power ecosystem of any of Aspects 28-47 in which the portable power ecosystem further comprises a movable screen configured to be attached to a plurality of components within the portable power ecosystem. The movable screen wirelessly communicates with a component of the plurality of components, and based on the wireless communication with the component, the movable screen displays at least one electrical parameter of the component.

[0056] Additional features and advantages will be set forth in the detailed description which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description included, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

[0057] The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0058] This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

[0059] FIGS. 1A-1O depict mechanical engagement of modules using a cleat and pocket interface, according to exemplary embodiments;

[0060] FIGS. 2A-2Z depict a first aspect for providing electrical connection between modules using a rotatable handle that causes male contacts to emerge from one module for insertion into another module, according to exemplary embodiments;

[0061] FIGS. 3A-3D depict a second aspect for providing electrical connection between modules using a locking tab of the mechanical interface, according to exemplary embodiments;

[0062] FIGS. 4A-4K depict a third aspect for providing electrical connection between modules using a rotating handle assembly in which a plug of the handle assembly of the bottom module is inserted into a socket of the top module, according to exemplary embodiments;

[0063] FIGS. 5A-5H depict a fourth aspect for providing electrical connection between modules using a removable cord that connects a first connection interface of a bottom module with a second connection interface of a top module, according to exemplary embodiments;

[0064] FIGS. 6A and 6B depict a fifth aspect for providing electrical connection between modules using a flexible pigtail connector in which the flexible pigtail connector of a bottom module connects to a socket of a top module, according to exemplary embodiments;

[0065] FIGS. 7A-7F depict a sixth aspect for providing electrical connection between modules using a rear terminal block in which engaging the cleat and pocket interface simultaneously creates the electrical connection between modules, according to exemplary embodiments;

[0066] FIGS. 8A-8S depict a seventh aspect for providing electrical connection between modules using a hinged rear terminal block, according to exemplary embodiments;

[0067] FIGS. 9A-9C depict an eighth aspect for providing electrical connection between modules using a rotating connector, according to exemplary embodiments; and

[0068] FIGS. 10A-20 depict various other components of a portable power ecosystem that can be utilized in conjunction with any of the foregoing modules, according to exemplary embodiments.DETAILED DESCRIPTION

[0069] Referring generally to the figures, various embodiments of portable power systems and related devices are provided.

[0070] In specific embodiments, portable power systems and related devices include coupling mechanism(s) (e g., male and / or female coupling component(s)) configured to engage with units of a modular storage system, such as a modular or stackable tool storage system, a modular worksite storage system, a modular transit storage system, etc.

[0071] In various embodiments, portable power systems and related devices utilize, couple to, or otherwise support rechargeable batteries, such as rechargeable power tool batteries.

[0072] In specific embodiments, the portable power system and devices disclosed herein include one or more mechanical couplers located on a surface of the component and that are configured to engage one or more corresponding (e.g., mating) couplers of an adjacent modular unit (e.g., a modular tool storage container, a modular utility module, a modular support component, etc.) In various embodiments, the mechanical couplers described herein and shown in the figures are compatible with the coupling mechanism(s) described in International Patent International Patent Publication No. WO 2017 / 191628, which is hereby incorporated by reference in its entirety. In various embodiments, the mechanical couplers described herein engage with each other to rigidly couple together various components including such coupling structures.

[0073] Additional details are shown and described in the accompanying figures.

[0074] In order to introduce certain concepts related to the portable power ecosystem, the following description of the connection and disconnection between two Packout modules 10A and 10B is provided in relation to FIGS. 1A-1O is provided. This description is generally applicable to any Packout modules, including the modules of the portable power ecosystem described below. For the purposes of the following discussion, in both the connection and disconnection scenarios, the bottom module 10B is static and the top module 10A is dynamic.

[0075] As shown in FIGS. 1A-1E, connecting the two modules 10A, 10B together involves two steps: module drop (FIGS. 1 A-1B) and module slide (FIGS. 1C-1E). In the presently disclosed portable power ecosystem, the modules can be, e.g., a battery core, an inverter, or charger, amongst other possibilities. The following discussion of cleats and cleat pockets is merely exemplary, and other mechanical coupling arrangements may be utilized, such as rails and complementary channels. In general, according to one or more embodiments of the present disclosure, the mechanical coupling will require a module dropping or lowering action followed by a sliding action to mechanically couple the modules to each other. In the module drop step of FIGS. 1 A- 1B, a user aligns an array of cleats 12 of the top module 10A with a corresponding array of cleat pockets 14 of the bottom module 10B in the X and Z axes. According to the present disclosure, a “cleat” is an individual, rigid geometry that extends from a bottom surface 16 of certain modules 10A, 10B configured to be mated with a cleat pocket 14 of another module 10A, 10B. According to the present disclosure, a “cleat pocket” is an individual, rigid geometry that is a cavitationextending into a top surface 18 of certain modules 10A, 10B configured to house a corresponding cleat 12 of another module 10A, 10B. In particular, during the drop step of FIGS. 1A-1B, the cleats 12 will seat in the front half of the respective cleat pocket 14. The user translates the top module 10B in the -Y direction until the cleats 12 contact the bottom of the cleat pockets 14. Once positioned in the cleat pockets 14, further Y translation, X rotation, and Z rotation are constrained.

[0076] In the module slide step of FIGS. 1C-1E, the user translates the top module 10A in the -Z direction to lock the cleats 12 into the cleat pockets 14. In particular, at least one tab 20 extends over a portion of each cleat pocket 14 and engages the cleat 12. In one or more embodiments, each cleat pocket 14 includes two tabs 20 extending over two comers of the cleat pocket 14. When the top module 10A is slid so that the cleat 12 translates in the -Z direction within the cleat pocket 14, the tabs 20 fill negative space 22 (as shown in FIG. IE) of the cleat 14. While the discussion pertained to a single cleat 12 in a corresponding cleat pocket 14, the entire array of cleats 12 on the bottom surface 16 of the top module 10A will simultaneously engage the entire array of cleat pockets 14 on the top surface 18 of the bottom module 10B. The interaction between the array of cleats 12 and the array of cleat pockets 14 constrains X translation and Y rotation.

[0077] In one or more embodiments, as shown in FIGS. 1F-1K, each module 10A, 10B includes a locking mechanism 24 configured to engage an adjacent module 10A, 10B to prevent accidental reverse translation in the +Z direction. In particular, as the top module 10A translates in the -Z direction, a spring-loaded locking tab 26 of the top module 10A is depressed as the locking tab 26 slides over a chamfered edge 28 of the bottom module 10B. As shown, e.g., in FIG. IF, a wall 30 of each module 10A, 10B includes a sliding channel 32 within which the locking tab 26 is configured to translate up and down in the Y direction. A first end 34 of the sliding channel defines a first seat for one end of a compression spring 36. The locking tab 26 includes a corresponding seat 38 for the opposite end of the compression spring 36. The compression spring 36 biases the locking tab 26 in the deployed position (i.e., biasing the locking tab in the -Y direction).

[0078] At a second end 40 of the sliding channel 32 is an opening in the bottom surface 16 such that the locking tab 26, in the deployed state, extends from the sliding channel 32 and beyond the bottom surface 16. Thus, as mentioned, during sliding, a depending end 42 of the locking tab26 engages the chamfered edge 28 of the bottom module 10B. In one or more embodiments, the depending end 42 includes a chamfered surface 44 configured to slide against the chamfered edge28 of the bottom module 10B.

[0079] The wall 30 of the module 10A, 10B includes a first aperture 46, and the locking tab 26 includes a second aperture 48 or depression. To manually move the locking tab 26 against the bias of the compression spring 36, a user can insert a finger through the first aperture 46 and into the second aperture 48 or depression of the locking tab 26. The user can then move the locking tab 26 by pulling against an edge of the second aperture 48 or depression.

[0080] In one or more embodiments, the first aperture 46 defines a range of movement (Y direction translation) of the locking tab 26. In particular, the second aperture 48 or depression may define a smaller opening that the first aperture 46, and the second aperture 48 or depression may include a peripheral flange 50 that engages a perimeter edge 52 of the first aperture 46. That is, the locking tab 26 can be moved in the +Y direction against the bias of the compression spring 36 until the peripheral flange 50 engages the top of the perimeter edge 52 of the first aperture 46, and the locking tab 26 can be moved in the -Y direction as biased by the compression spring 36 until peripheral flange 50 engages the bottom of the perimeter edge 52 of the first aperture 46.

[0081] As the top module 10A continues to translate in the -Z direction, the locking tab 26 slides against the chamfered edge 28, which causes the locking tab 26 to progressively translate in the +Y direction until the locking tab 26 reaches the top surface 18 of the bottom module 10B as shown in FIGS. 1G and 1H. The modules 10A, 10B have formed on the top surface 18 a recess 54 for the depending end 42 of the locking tab 26. Upon alignment of the locking tab 26 with the recess 54, the bias of the compression spring 36 causes the locking tab 26 to translate in the -Y direction until the depending end 42 is seated within the recess 54 as shown in FIG. II. Seating the locking tab 26 in the recess 54 constrains Z translation such that all degrees of freedom are constrained, and the two modules 10A, 10B are connected.

[0082] Disconnecting the two modules 10A, 10B involves three steps: lifting of the locking tab 26, sliding of the top module 10A, and lifting the module 10A as shown in FIGS. 1J-1O. In the step of lifting the locking mechanism 26, the user inserts their finger or fingers through the first aperture 46 and into the second aperture 48 or depression to pull the locking tab 26 in the +Ydirection, unseating the depending end 42 of the locking tab 26 from the recess 54 as shown in FIGS. 1J and IK. This provides a first degree of freedom, namely +Z translation, and allows the top module 10A to slide.

[0083] While the locking tab 26 is lifted, sliding of the top module 10A is initiated. As can be seen in FIGS. IL and IM, the user slides the top module 10A in the +Z direction until the array of cleats 12 disengage the tabs 20 of the corresponding array of cleat pockets 14 and the cleats 12 are in the front half of the cleat pockets 14. Finally, as shown in FIGS. IN and 10, the user lifts the top module 10A up (+Y translation) to separate the top module 10A from the bottom module 10B. In this way, the two modules 10A, 10B are disconnected once the cleats 12 of the top module clear the cleat pockets 14 of the bottom module 10B.

[0084] Having described the mechanical interaction to lock the modules 10A, 10B to each other, various aspects of the interface for forming the electrical connection between the modules 10 A, 10B are now described. Each of the aspects includes some or all of the components described in relation to FIGS. 1A-1O for forming the mechanical interaction, and such components will be identified with the same reference numerals (unless otherwise noted). The description of the modules for each of the respective aspects will utilize reference numerals starting with a different hundreds value (i.e., 100, 300, 400, etc.). However, in general, each of the modules regardless of the aspect for forming the electrical connection is, for example, a battery core, an inverter, or charger, having the same electrical and electronic components necessary to fulfill those functions.

[0085] A first aspect of the modules 100A, 100B will be described more fully in relation to FIGS. 2A-2Z. In the first aspect, the top module 100A electrically connects to a bottom module 100B using a plug that extends from within the top module 100A into a socket of the bottom module 100B upon actuation (in particular, rotation) of a handle on the top module 100A. As will be discussed more fully below, the handle is locked against actuation and the plug is prevented from extending from the top module 100A until the array of cleats 12 of the top module 100A are seated into the corresponding array of cleat pockets 14 of the bottom module 100B.

[0086] FIG. 2A is a perspective view of the module 100 A, 100B according to one or more embodiments of the presently described aspect. The X, Y, Z coordinate system discussed above will be utilized in the description of this aspect and the following aspects. As can be seen in FIG.2A, the module 100 A, 100B includes a top surface 18 having an array of cleat pockets 14 formed therein. The module 100 A includes a bottom surface 16 having an array of cleats 12 (not shown) formed therein. Disposed between the bottom surface 16 and the top surface 18 are a plurality of side walls 30. As can be seen in FIG. 2A, a first wall 102 includes the locking tab 26 having the depending end 42 configured to seat within a recess 54 of an adjacent module 100A, 100B. As mentioned, the locking tab 26 includes the second aperture 48 or depression, accessed through the first aperture 46, for actuation of the locking tab 26 against the bias of the compression spring 36 (not shown). In one or more embodiments of the first aspect, the first wall 102 further includes a handle assembly 104 configured to actuate to deploy the plug through the bottom surface 16 to form the electrical connection between modules 100A, 100B. As shown in FIG. 2A, the moduleIOOA, 100B also includes a socket 106 configured to receive the plug of the adjacent module 100A,IOOB. As will be discussed more fully below, both the plug and socket 106 are covered by respective access plates that are withdrawn from over the respective plug and socket 106 when the array of cleats 12 of one module 100A is seated into the corresponding array of cleat pockets 14 of the adjacent module 100B.

[0087] FIG. 2B provides an exploded view of the components of the module 100A, 100B. As can be seen in FIG. 2B, the module 100A, 100B includes a top housing 108 and a bottom housing 110. The top housing 108 includes the top surface 18 having the array of cleat pockets 14, and the bottom housing includes the bottom surface having the array of cleats 12 (not shown). The top housing 108 and the bottom housing 110 combine to form an enclosure for the electrical and electronic components of the housing as well as the mechanical components described herein for forming the electrical connection between the modules 100A, 100B.

[0088] With respect to FIG. 2B, certain components are identified, and their function will be described more fully below. In particular, FIG. 2B depicts the locking tab 26, which prevents translation of the module 100A, 100B in the +Z direction when seated in the recess 54 of the adjacent module 100A, 100B.

[0089] FIG. 2B also depicts the handle assembly 104. The handle assembly 104 includes a handle cover 112, a handle axle 114, a handle body 116, a handle pin and axle 118, and a Scotch yoke pin 120. The handle cover 112 may be a decorative element fastened to the handle body 116for housing of the handle axle 114. The handle axle 114 connects to the handle pin and axle 118 and is contained within the handle body 116 and the handle cover 112. The handle body 118 contains compression springs and posts that, as will be discussed more fully below, allow for the handle assembly 104 to lock in a vertical or horizontal orientation. As mentioned, the handle body 118 is fastened to the handle cover 112 and houses the handle axle 114. The handle pin and axle 118 is the central axle for rotation of the handle assembly 104, and as will be discussed more fully below, the handle pin and axle 118 limits or allows movement of the access plate for deployment of the plug through the bottom surface 16. The Scotch yoke pin 120 is fastened to a face of the handle pin and axle 118, and posts of the handle pin and axle 118 fasten to the handle body 116. The Scotch yoke pin 120 transforms rotation of the handle assembly 104 into translation of the plug out of the bottom surface 116 of the module 100 A, 100B.

[0090] FIG. 2B also depicts a cleat switch 122 that detects when the cleats 12 of the top module 100A are seated in a corresponding cleat pocket 14 of the bottom module 100B. The cleat switch 122 is connected to a cleat switch arm 124, which is connected to a cleat switch finger 126. The cleat switch arm 124 transfers motion from the cleat switch 122 to the cleat switch finger 126. As will be discussed more fully below, the cleat switch arm 124 is biased using a tension spring. The cleat switch finger 126, depending on its actuation position, blocks or allows translation of the plug in the -Y direction (i.e., blocks or allows deployment).

[0091] Further, FIG. 2B depicts the plug assembly 128. The plug assembly 128 includes a first electrical connector, shown as a plurality of male contacts, and the plug assembly 128 is configured to translate the male contacts to the outside of the module 100A, 100B through the bottom surface 16. The plug assembly 128 is driven by the Scotch yoke pin 120, and the cleat switch finger 126 blocks or allows translation of the plug assembly 128 in the -Y direction.

[0092] The plug assembly 128, when retracted into the module 100A, 100B, is covered by a first access plate 130. The position of the first access plate 130 is controlled by the handle assembly 104. When the handle assembly 104 is in the horizontal position, the first access plate 130 blocks ingress into the module 100A, 100B, and when the handle assembly 104 is in the vertical position, the first access plate 130 translates to allow the male contacts of the plugassembly 128 to exit the top module 100A and mate with a second electrical connector, shown as the female contacts of the socket 106, in the bottom module 100B.

[0093] The module 100A, 100B also includes a socket interface 132 configured to receive the male contacts of the plug assembly 128. In one or more embodiments of the first aspect, the socket interface 132 is fastened to the top housing 108 of the module 100A, 100B. Access to the socket interface 132 is controlled by a second access plate 134. When there is no top module 100A stacked above the bottom module 100B, the second access plate 132 of the bottom module 100B prevents ingress into the bottom module 100B. When a top module 100A is stacked above the bottom module 100B, a cleat pocket switch 136 detects when a cleat 12 has been seated within the cleat pocket 14 and allows for translation of the second access plate 132 to provide ingress of the male contacts of the plug assembly 128 into the socket interface 132. In one or more embodiments of the first aspect, which will be described more fully below, the cleat pocket switch 136 is biased to keep the second access plate 134 in the closed position with a tension spring.

[0094] Having described the components of the modules 100 A, 100B, the operation will be discussed in the following paragraphs. In one or more embodiments, connecting two modules 100A, 100B together involves three stages: (1) modules 100A, 100B provided in disconnected state, (2) modules 100A, 100B are mechanically connected using the cleat and pocket interface, and (3) the modules are electrically connected.

[0095] During first stage, the first and second access plates 130, 134 are in the “closed” position as shown in FIGS. 2C and 2D, respectively. This prevents ingress internal to the module 100A, 100B and blocks deployment of the plug assembly 128 and access to the socket interface 132. Further, as shown in FIG. 2E, the handle assembly 104 can be translated in the + / -Z direction by the user but cannot be rotated about the Z axis. Rotation of the handle assembly 104 is prevented, as shown in FIG. 2F, because a tension spring 138 connected to the cleat switch arm 124 is biasing the cleat switch finger 126 in the +Z direction, which is obstructing the plug assembly 128 from translating in the -Y direction, which is in turn blocking rotation of the handle assembly 104.

[0096] During the second stage, the top module 100A is connected to the bottom module 100B using the cleat and pocket interface as described in relation to FIGS. 1A-1O. As shown in FIG.2G, the tab 20 from the cleat pocket 14 of the bottom module 100B contacts the cleat switch 122, which extends through the bottom surface 16 of the module 100A into the negative space 22 of the cleat 12 of the top module 100A, and causes the cleat switch 122 to rotate in the -X direction. In one or more embodiments, the cleat switch 122 includes an angled contact face 140 connected to a drive pin 142 such that sliding of the tab 20 of the cleat pocket 14 across angled contact face 140 causes proportional rotation of the drive pin 142. That is, the farther that the tab 20 slides across the angled contact face 140, the more the drive pin 142 will rotate in response.

[0097] The drive pin 142 of the cleat switch 122 is connected to an armature 144, which is connected to the cleat switch arm 124. In one or more embodiments, a first portion 146 of the cleat switch arm 124 defines a first slot 148 in which the armature 144 of the cleat switch 122 is seated. In one or more embodiments, the first portion 146 and the armature 144 may define one or more through holes 150 through which a fastener (such as a bolt, screw, or pin) may be inserted to connect the armature 144 and the first portion 146 of the cleat switch arm 124 together. In this way, rotation of the cleat switch 122, through rigid connection to the cleat switch arm 124, causes the cleat switch arm 124 to rotate in the -X direction. In one or more embodiments, a stop 152 extends from an interior of the wall 30 to limit rotation of the cleat switch arm 124 in the -X direction. The stop 152 is positioned such that the cleat switch 122 is able to rotate a sufficient amount to allow the tab 20 of the cleat pocket 14 to fully insert into the negative space 22 of the cleat 12.

[0098] As shown in FIG. 2H, the cleat switch arm 124 drives translation of the cleat switch finger 126 in the -Z direction. In one or more embodiments, the cleat switch arm 124 includes a second portion 152 defining a second slot 152. In one or mor embodiments, the cleat switch finger 126 includes a first end 158 and a second end 160. The first end 158 defines a hook 162 configured to insert into the second slot 152 of the cleat switch arm 124. Thus, as the cleat switch arm 124 rotates, the hook slides within the second slot 156, thereby pulling on the cleat switch finger 126 in the -Z direction. The second end 160 of the cleat switch finger 126 controls whether the plug assembly 128 is able to translate in the -Y direction based on the position of the cleat switch finger 126. That is, translation of the cleat switch finger 126 in the -Z direction removes an obstruction stopping the plug assembly 128 from translating in the -Y direction. Disposed between the firstend 158 and the second end 160 of the cleat switch finger 126 is a first guide housing 166. The first guide housing 166 is attached to a shelf 170 extending from the inner surface of the side wall 30, and the cleat switch finger 126 extends through the first guide housing 166 so that the second end 160 of the cleat switch finger 126 projects from the first guide housing 166. In this way, movement of the cleat switch finger 126 is confined to Z translation through the first guide housing 166.

[0099] Further, as shown in FIG. 2H, the tension spring 138 is held between a first mounting post 172 and a second mounting post 174. In one or more embodiments, the first mounting post 172 is integrally formed with the cleat switch arm 124, and the second mounting post 174 extends from the shelf 170. In this way, the tension spring 138 biases the cleat switch arm 124 in the +Z direction, which in turn biases the cleat switch 122 to the deployed position (extending through the bottom surface 16 of the module 100A).

[0100] As shown in FIGS. 21 and 2J, in the bottom module 100B, the cleat 12 from the top module 100A contacts the cleat pocket switch 136, which drives -Z translation to the cleat pocket switch 136. In one or more embodiments, the cleat pocket switch 136 includes a first end 176 and a second end 178. A bar 180 extends between the first end 176 and the second end 178. At the first end 176, a cross-piece 182 extends from the bar 180, and a stem 184 extends from the crosspiece 182. In one or more embodiments, the cross-piece 182 extends substantially perpendicular to the bar 180, and the stem 184 extends substantially perpendicular to the cross-piece 182 toward the second end 178. The stem 184 is inserted through an opening 186 in the cleat pocket 14. In particular, the opening 186 is positioned such that the stem 184 extends into the cleat pocket 14 beneath a tab 20 in a corner of the cleat pocket 14. In this way, insertion of a cleat 12 into the cleat pocket 14 causes the cleat 12 to press against the stem 184, driving the stem 184 and thus the cleat pocket switch 136 in the -Z direction.

[0101] Extending from the cross-piece 182 between the bar 180 and the stem 184 is a hook 188. A tension spring 190 is attached at one end to the hook 188 of the cleat pocket switch 136 and at the other end to an inner surface of the top housing 108. The bar 180 of the cleat pocket switch 136 extends through a second guide housing 191 mounted to the inner surface of the top housing 108, which restricts movement of the cleat pocket switch 136 to Z translation. The secondend 178 of the cleat pocket switch 136 extends from the second guide housing 191 and is attached to the second access plate 134. In this way, actuation of the cleat pocket switch 136 by the cleat 12 of the top module 100A causes translation of the second access plate 134 to uncover the socket interface 132 of the bottom module 100B. The tension spring 190 biases the cleat pocket switch 136 such that the second access plate 134 is in the closed position, covering the socket interface 132. Thus, the socket interface 132 is only available for connection to the plug assembly 128 when the top module 100A has a cleat 12 seated in the cleat pocket 14 of the bottom module 100B.

[0102] In one or more embodiments, as shown in FIG. 2K, the cleat pocket switch 136 includes a post 192 extending from the second end 178, and the second access plate 134 includes an angled slot 194. The post 192 is disposed within the angled slot 194, and movement of the post 192 in the -Z direction causes translation of the second access plate 134 in the +X direction, which, as shown in FIG. 2L, aligns openings for the socket interface 132 with the openings through the top surface 18 of the top housing 108.

[0103] Thus, once the cleat and pocket interface is engaged and the modules 100A, 100B are mechanically connected, the handle assembly 104 becomes free to rotate to cause the male contacts of the plug assembly 128 to engage the socket interface 132. That is, neither access plate 130, 134 is in a position to prevent ingress into or egress from the module 100A, 100B.

[0104] Finally, during the third stage, the user grabs the handle assembly 104 of the top module 100A as shown in FIG. 2M. The user pulls out the handle assembly 104, which is in the horizontal orientation, in the -Z direction, rotates the handle assembly 90° in the -Z direction to a vertical orientation, and then releases the handle assembly 104. As shown in FIG. 2N, the handle assembly 104 includes the handle cover 112 fastened to the handle body 116. The handle body 116 includes one or more projections 196 that engage corresponding seats 198 formed in the first wall 102. As shown in FIGS. 2L and 2M, there are two sets of seats 198 - one set for the horizontal orientation and one set for the vertical orientation of the handle assembly 104.

[0105] Disposed within the handle body 116 is the handle axle 114. The handle axle 114 includes a plate 200 and a shaft 202 extending substantially perpendicular from the plate 200. The shaft 202 of the handle axle 114 extends through an aperture 204 in the first wall 102 and is configured to rotate therein. The handle axle 114 is fastened to the handle pin and axle 118. Inparticular, the handle pin axle 118 includes a disc 206 having a first side and a second side. At least one post 208, in particular two posts 208, extend from the first side of the disc 206 and through arcuate slots 210 in the first wall 102 and through corresponding openings 212 in handle body 116. The posts 208 are fastened to the plate 200 of the handle axle 114. Surrounding the posts 208 and disposed between the handle body 116 and the plate 200 of the handle axle 114 are compression springs 214. The compression springs 214 bias the handle assembly 104 in the locked position, i.e., with the projections 196 of the handle body 116 disposed in the seats 198 (whether in the horizontal or vertical orientations). In one or more embodiments, the disc 206 is also fastened to the end of the shaft 202 on the interior of the module 100A, 100B. In this way, the disc 206 is disposed on the interior of the first wall 102 and fastened to the handle assembly 104 on the exterior of the first wall 102.

[0106] FIG. 20 depicts an interior view of the first wall 102 of the module 100A, 100B. As can be seen, the Scotch yoke pin 120 is attached to the second side of the disc 206. Further, the disc 206 includes a cam lobe 216. Accordingly, rotation of the handle pin and axle 118 with the handle assembly 104 causes rotation of the Scotch yoke pin 120 and the cam lobe 216 simultaneously. FIG. 20 also shows, in part, the first access plate 130. The first access plate 130 includes a first wall 218 and a second wall 220. In one or more embodiments, the first wall 218 and the second wall 220 join at a comer of the first access plate 130. The first wall 218 is configured to engage the cam lobe 216. A compression spring 222 is disposed between the second wall 220 an interior of a sidewall 30 of the module 100A, 100B.

[0107] The compression spring 222 biases the first access plate 130 in the -X direction. However, the handle assembly 104, when in the horizontal orientation, rotationally positions the disc 206 of the handle pin and axle 118 such that the cam lobe 216 is pressed against the first wall 218, pressing against the biasing of the compression spring 222 to keep the first access plate 130 in a closed position. When the handle assembly 104 is in the vertical orientation, the disc 206 is positioned such that the cam lobe 216 is not in contact with the first wall 218, allowing the compression spring 222 to translate the first access plate 130 to the open position. As can be seen in FIG. 20, movement of the first access plate 130 in the -X direction is limited by a ridge 224 extending from the interior floor of the bottom housing 110. Additionally, in one or moreembodiments, the first access plate 130 is held in place against the floor by an overhang 226 fastened to the floor of the bottom housing 110.

[0108] In operation, the first access plate 130 is opened by actuation of the cleat switch 122, which (through the cleat switch arm 124 and the cleat switch finger 126) causes the second end 160 of the cleat switch finger 126 to move out of the movement path of the plug assembly 128. As will be discussed more fully below, rotation of the handle assembly 104 is only allowed in conjunction with movement of the plug assembly 128, and thus, by allowing movement of the plug assembly 128, the rotation of the handle assembly is also allowed 104, moving the cam lobe 216 away from the first wall 218 so that the compression spring 222 can push the first access plate 130 into the open position.

[0109] FIG. 2P shows the first electrical connector, in particular male contacts, of the plug assembly 128 exposed, i.e., with the first access plate 130 in the open position. In this way, the male contacts of the plug assembly 128 can be deployed through the bottom surface 16 of the module 100A, 100B.

[0110] With reference to FIG. 2Q, in one or more embodiments, the first access plate 130 further includes an arm 228 that extends toward the locking tab 26. As can be seen, the locking tab 26 includes a notch 230. When the first access plate 130 is in the open position, the arm 228 extends into the notch 230, preventing movement of the locking tab 26 in the +Y direction. In this way, once the male contacts of the plug assembly are exposed, the top module 100A is prevented from mechanically disengaging from the bottom module 100B. That is, by holding the locking tab 26 in the deployed position within the recess 54 of the bottom module 100B, the top module 100A cannot slide such that the cleats 12 are able to be removed from the cleat pockets 14. This prevents accidental exposure of the male contacts of the plug assembly and discharge of electrical power.

[0111] Further, in FIG. 2Q, it can be seen that the handle assembly 104 drives translation of the plug assembly 128 within the module 100A, 100B. As can be seen, the plug assembly 128 includes a backer substrate 232 having a slot 234. The Scotch yoke pin 120 is disposed within the slot 234 of the plug assembly 128. The backer substrate 232 also includes two guide arms 236 configured to slide within tracks formed on the interior of the first wall 102. The tracks limitmovement of the plug assembly 128 to translation in the Y direction. Rotation of the handle assembly 104, and thus the handle pin and axle 118, causes the Scotch yoke pin 120 to rotate, which being constrained within the slot 234 drives linear translation of the backer substrate 232 in the -Y direction.

[0112] The plug assembly 128 includes a base 238 that extends from the backer substrate 232. A plurality of male contacts 240 extend from a first side of the base 238, and a plurality of leads 242 extend from the second side of the base 238. The leads are connected to electrical and electronic components within the module 100A to provide electrical communication to the male contacts 240. As shown in FIG. 2R, the male contacts 240 pass through the first access plate 130 and through the bottom surface 16 of the bottom housing 110 of the top module 100A and through the top surface 18 of the top housing 108 of the bottom module 100B. The male contacts 240 further pass through the second access plate 134 and into the socket interface 132 of the bottom module 100B.

[0113] Having described electrically connecting the modules 100A, 100B, disconnecting the modules 100A, 100B is now described. Disconnecting involves three stages: (1) turn handle assembly 104 to electrically disconnect the modules 100A, 100B; (2) mechanically disconnect the cleat and pocket interface; and (3) remove the top module 100A from the bottom module 100B.

[0114] During the first stage, as shown in FIG. 2S, the user grabs the handle assembly 104 of the top module 100A. The user pulls out the handle assembly 104 in the -Z direction, rotates the handle assembly 104 approximately 90° in the +Z direction, and then releases the handle assembly 104. As discussed above, the compression springs internal to the handle assembly 104 bias the projections 196 on the handle body 116 back into the seats 198 (in the +Z direction), and the handle assembly 104 is locked in the horizontal orientation.

[0115] As shown in FIG. 2T, rotation of the handle assembly 104 causes rotation of the Scotch yoke pin 120, which in turn causes lateral translation of the plug assembly 128 in the +Y direction. This withdraws the male contacts 240 of the plug assembly 128 from the socket interface 132 of the bottom module 100B into the interior of the top module 100A, breaking the electrical connection. Additionally, as shown in FIG. 2U, rotation of the handle assembly 104 causes the cam lobe 216 to contact the first wall 218 of the first access plate 130 to push the first access plate130 in the +X direction to the closed position, thereby preventing the male contacts 240 of the plug assembly 128 from deploying from the top module 100A. As shown in FIG. 2 V, the translation of the first access plate 130 in the +X translation also removes the arm 228 of the first access plate 130 from the notch 230 of the locking tab 26, thereby allowing the locking tab 26 to retract when actuated by the user.

[0116] During the second stage, the modules 100A, 100B are disconnected mechanically using the cleat and pocket interface. A detailed discussion of the mechanical disconnection of the cleat and pocket interface can be found in the discussion above related to FIGS. 1A-1O. With respect to the particulars of the present embodiment, actuation of the locking tab 26 in the +Y direction by the user allows the top module 100A to translate in the -Z direction. As the top module 100A slides in the -Z direction as shown in FIG. 2W, the tab 20 of the cleat pocket 14 slides along the angled contact face 140 of the cleat switch 122, and the bias of the tension spring 138 pulls the cleat switch arm 124, causing rotation of the cleat switch 122 back into the negative space 22 of the cleat 14. Eventually, the tab 20 loses contact with the cleat switch 122, which allows the tension spring 138 attached to the cleat switch arm 124 to rotate the cleat switch 122 in the +X direction, which drives +X rotation of the cleat switch 122 and +Z translation of the cleat switch finger 126 as shown in FIG. 2X. The +Z translation of the cleat switch finger 126 causes the second end 160 to obstruct the Y translation of the plug assembly 128, in particular causing the second end 160 of the cleat switch finger 126 to seat beneath the backer substrate 232.

[0117] As shown in FIG. 2Y, the cleat 12 from the top module 100A is removed from the cleat pocket 14 of the bottom module 100B. In this way, the cleat 12 loses contact with the stem 184 of the cleat pocket switch 136. As shown in FIG. 2Z, the tension spring 190 drives +Z translation of the cleat pocket switch 136, and the angled slot 194 of the second access plate 134 converts the +Z translation from the cleat pocket switch 136 to -X translation of the second access plate 134, closing off the opening for the socket interface 132.

[0118] Finally, during the third stage, the top module 100A is translated in the +Y direction by the user to completely disconnect the top module 100A from the bottom module 100B.

[0119] In one or more embodiments, the handle assembly 104 may be configured to actuate a micro switch or a magnetic switch, or the position of the handle assembly 104 may be detectedusing a sensor, such as a magnetic sensor. In this way, the position of the handle assembly 104 (rotation position as well as insertion position) can be used to determine the connection status between the modules 100 A, 100B to control, e.g., the electrical power flow within or between the modules 100A, 100B.

[0120] The aspect described in relation to FIGS. 2A-2Z provides several advantages. For example, the modules 100 A, 100B are protected against ingress in the unconnected state. As discussed, the modules 100A, 100B include access plates that cover the socket interface 132 and plug assembly, preventing unintended access to these components. Once mechanically connected, the second access plate 134 is moved to allow access to the socket interface 132, and after the handle assembly is rotated 104, the plug assembly 128 can exit through the first interface 130. Additionally, the presently described aspect provides mechanical detection of the modules using the cleat switch 122 and the cleat pocket switch 136. These passive features allow for actuation of the various components only when the top module 100A is properly seated on the bottom module 100B. Still further, the described aspect provides locking of the modules 100A, 100B together when the modules 100A, 100B are electrically connected. Specifically, the locking tab 26 cannot be actuated to allow for sliding of the top module 100A from disengagement with the bottom module 100B. The modules 100A, 100B are also fully compatible with existing cleat and pocket interfaces, such as the Packout system available from Milwaukee Tool. That is, the modules 100A, 100B can be stacked on or stack on existing elements having the cleat and pocket interface. One further advantage is the enhanced safety provided by the two-step electromechanical connection, which prevents accidental exposure of the plug assembly 128 and socket interface 132 when the modules 100A, 100B are separated. Notwithstanding, forming the electromechanical connection is not cumbersome for a user as the mechanical connection merely requires normal engagement of the cleat and pocket interface and because the electrical connection only requires the rotation of a handle assembly 104.

[0121] A second aspect of the modules 300A, 300B will be described more fully in relation to FIGS. 3 A-3D. In the second aspect, the top module 300A electrically connects to a bottom module 300B using male pins integrated with the operation of the locking tab. In particular, second aspect integrates the locking tab mechanical connection with the electrical connection.

[0122] As shown in FIG. 3A, the locking tab 26 operates substantially the same as described above in relation to FIGS. 1A-1O. That is, the locking tab 26 has a depending end 42 that slides over a chamfered edge 28 driving the locking tab 26 in the +Y direction until translation in the ‘Z direction aligns the locking tab 26 with a recess 54 in the bottom module and the bias on the locking tab 26 seats the locking tab 26 into the recess 54. With reference to FIG. 3A, the locking tab 26 is coupled to a blade assembly 302 that provides electrical connection between modules. The locking tab 26 includes a front surface 304 and a back surface 306 in which the back surface 306 is opposite to the front surface 304. The locking tab 26 further includes a first side surface 308 and a second side surface 310. In one or more embodiments, the first side surface 308 and the second side surface 310 define a continuous peripheral surface connecting the front surface 304 to the back surface 306

[0123] The blade assembly 302 is configured for translation in the Y direction. In particular, the locking tab 26 includes a first arm 312 that extends from the first side surface 308 and a second arm 314 that extends from the second side surface 310. In one or more embodiments of the second aspect, the first arm 312 and the second arm 314 extend substantially perpendicular to the respective first side surface 308 and the second side surface 310. The blade assembly 302 includes a mounting bracket 316 to which a plurality of male blade contacts 318 are attached. A first compression spring 320 is disposed between the first arm 312 and the mounting bracket 316, and a second compression spring 322 is disposed between the second arm 314 and the mounting bracket 316. The compression springs 320, 322 bias the blade assembly 302 in the -Y direction. Thus, when the locking tab 26 seats in the recess 54, the locking tab 26 also drives the blade assembly 302 in the -Y direction. In one or more embodiments, the locking tab 26 includes a third arm 324 extending from the first side surface 308 and a fourth arm 326 extending from the second side surface 310. The third arm 324 and the fourth arm 326 act as stops to limit the translation of the blade assembly 302 in the -Y direction by contacting the mounting bracket 316.

[0124] FIG. 3B depicts a top module 300A electrically and mechanically connected to a bottom module 300B. As shown in FIG. 3B, the locking tab 26 of the top module 300A seated within the recess 54 of the bottom module 300B. Further, the male blade contacts 318 are inserted into corresponding sockets 328 to provide electrical connection between the modules 300A, 300B.Further, as shown in FIGS. 3A and 3B, the blade assembly 302 includes a probe 330 that extends from the mounting bracket 316 a farther distance that any of the male blade contacts 318. If the bottom module 300B is compatible with the top module 300A, the bottom module 300B includes a cavity 332 that seats the probe 330. Accordingly, the blade assembly 302 will only deploy if the probe 330 is able to seat into a corresponding cavity 332.

[0125] However, as shown in FIG. 3C, if the module beneath the top module 300A is not configured for electrical connection (e.g., is a module having an existing cleat and pocket interface), the blade assembly 302 will attempt to drive downwards in the -Y direction, but the probe 330 will not find a corresponding cavity 332, preventing the male contacts 318 from deploying though the bottom surface 16 of the top module 300A. Notwithstanding, the locking tab 26 will still be able to seat within the recess 54 to lock the top module 300 A to the module beneath it.

[0126] As shown in FIG. 3D, a blade sheath 334 may be provided in one or more embodiments to prevent a user from touching the male contacts 318 when the modules 300A, 300B are not electrically connected. In one or more embodiments, the blade sheath 334 is attached to the locking tab 26 using rail cavities in the locking tab 26 that extrusion in the blade sheath 334 slide along for Y translation. In one or more embodiments, the blade sheath 334 is biased in the -Y direction. In particular, the locking tab 26 may include a first abutment surface 336, which may, for example, be defined by a projection from or a depression into the back surface 306. Further, the blade sheath 334 may define a pocket 338 with a second abutment surface 340. In one or more embodiments, a third compression spring 342 is disposed between the first abutment surface 336 and the second abutment surface 340 and within the pocket 338 to bias the blade sheath 334 in the -Y direction. In this way, the blade sheath 334 shrouds the male contacts 318 to prevent accidental touching of the male contacts 318 while deployed.

[0127] Disconnecting the two modules 300A, 300B with the locking tab 26 and blade assembly 302 is the same process as described above in relation to FIGS. 1A-1O. The user translates the locking tab 26 of the top module 300A in the +Y direction and then translates the top module 300A in the +Z direction. Translating the locking tab 26 of the top module 300A in the +Y direction also drives +Y translation to the blade assembly 302, removing the male contacts318 from the sockets 328 in the bottom module 300B, electrically disconnecting the modules 300A, 300B. Once the two modules 300A, 300B are completely disconnected, the locking tab 26 is biased in the -Y direction by the first and second compression springs 320, 322, and the blade sheath 334 is also biased in the -Y direction by the third compression spring 342 to prevent a user from touching the male contacts 318.

[0128] The second aspect provides several advantages. For example, the modules 300 A, 300B are fully compatible with existing cleat and pocket interfaces. Further, the design has enhanced safety in that the male contacts are shrouded against accidental touching and debris by the blade sheath 334. Additionally, this aspect only involves a single step to provide electromechanical connection between the modules 300 A, 300B.

[0129] A third aspect of the modules 400A, 400B will be described more fully in relation to FIGS. 4A-4K. The modules 400A, 400B mechanically connect using the cleat and pocket interface as described above in relation to FIGS. 1 A-1O.

[0130] FIG. 4A depicts an embodiment of a module 400A, 400B. As will be discussed more fully below, the modules 400A, 400B are mechanically connected using the cleat and pocket interface as discussed above, and the modules 400A, 400B are electrically connected using a rotatable handle assembly 402. The rotatable handle assembly 402 rotates from a horizontal orientation to a vertical orientation for insertion into a socket 404 of the module 400 above it.

[0131] FIG. 4B depicts an exploded view of the components of the module 400A, 400B. As with the previous embodiments, the module 400A, 400B includes a locking tab 26 configured to lock the modules 400A, 400B against relative translation in the Z direction. FIG. 4B also depicts the components of the rotatable handle assembly 402, including an external housing 404 having a first end 406 and a second end 408, a handle plunger 410 and a handle plunger housing 412 both disposed at the first end of the external housing 404, and a plug assembly 414 with a protective sheath 416 both disposed at the second end 408 of the external housing 404. The module 400A, 400B also includes a socket interface 418, which is on the interior of the module 400A, 400B, and a socket cover 420, which is on the exterior of the module 400A, 400B, that is configured to swing from an open position to a closed position about an axis of an axle 422. Further, as shown in FIG.4B, the module 400A, 400B includes a plunger mount 424 configured to connect the handle plunger 410 to the module 400A, 400B.

[0132] FIG. 4C depicts two modules 400A, 400B stacked and mechanically interconnected using the cleat and pocket interface but are not electrically connected. To electrically connect the two modules 400A, 400B together as shown in FIG. 4D, the user flips the socket cover 420 of the top module 400A upwards, rotating it about the axle 422 90° in the -X direction. Simultaneously, the user uses their other hand to grab the rotatable handle assembly 402 of the bottom module 400B, pulls the rotatable handle assembly 402 to translate the rotatable handle assembly 402 in the +Z direction, and rotates the handle assembly 402 90° in the -Z direction as shown in FIG. 4E. The handle assembly 402 is now in the vertical orientation, and the plug assembly 414 at second end 408 of the handle assembly 402 is aligned with the socket interface 418.

[0133] As shown in FIG. 4F, the handle assembly 402 is then pressed in the -Z direction. In one or more embodiments, translation in the -Z direction is biased using a first compression spring 426. In particular, the handle plunger housing 412 is fastened to the first end 406 of the external housing 404 and seated within a cavity 428 on the first wall 102 of the bottom housing 110. The handle plunger 410 is disposed within the handle plunger housing 412 and extends through a first aperture 430 in a rear surface of in the handle plunger housing 412 and a second aperture 432 in the first wall 102. On the interior surface of the first wall 102, the handle plunger 410 is fastened to the plunger mount 424, which is fastened to the interior surface of the first wall 102. The handle plunger 410 includes a shaft 434 that extends from a disc 436. The handle plunger housing 412 is able to translate in the Z direction along the shaft 434. The first compression spring 426 is disposed around the shaft 434 and between the disc 436 and the rear surface of the handle plunger housing 412, which biases the handle assembly in the -Z direction. Thus, after the plug assembly 414 is aligned with the socket interface 418, the handle assembly 402 is biased to urge the plug assembly 414 into electrical connection with the socket interface 418.

[0134] Prior to the plug assembly 414 contacting the socket interface 418, the protective sheath 416 is biased in the -Z direction to shroud the male blade contacts 438 from being exposed so as to prevent accidental touching or electrical discharge. FIG. 4G provides a detail view of this arrangement. As can be seen, the plug assembly 414 is fastened to the second end 408 of theexternal housing 404. The plug assembly 414 includes a plug base 440 from which the male blade contacts 438 extend. The protective sheath 416 includes a cap surface 442 having a plurality of slots 444 configured to allow passage of the male blade contacts 438. A peripheral wall 446 extends from the cap surface 442 and surrounds the male blade contacts 438. A second compression spring 448 is disposed between the plug base 440 and the cap surface 442, biasing the protective sheath 416 away from the plug assembly 414 such that the male blade contacts 438 are within the peripheral wall 446. This prevents large debris and a user’s fingers from accessing the male blade contacts 438.

[0135] During electrical connection, the cap surface 442 of the protective sheath 416 of the handle assembly 402 of the bottom module 400B contacts the first wall 102 of the bottom housing 110 of the top module 400A during -Z translation, compressing the second compression spring 448 so that the male blade contacts pass through the slots 444 of the cap surface 442 and through the first wall 102 into the socket interface 418 of the top module 400A.

[0136] FIG. 4H depicts a mechanical interface between the handle plunger housing 412 and the first wall 102 that ensures proper operation of the handle assembly 402. As shown, the first wall 102 includes an arcuate travel guide 450 with a first seat 452 and a second seat 454. The handle plunger housing 412 includes a detent 456 extending from its outer surface. In the horizontal orientation of the handle assembly 402, the detent is disposed within the first seat 452. This prevents rotation of the handle assembly 402 until the handle assembly 402 is translated in the -Z direction. Once the handle assembly 402 is pulled outwardly in the +Z direction, the detent 456 no longer blocks the handle plunger housing 412 from rotation. Once the handle assembly 402 is rotated into the vertical orientation, the detent 456 aligns with the second seat 454 when reaching the proper position for connection. Thereafter, the handle assembly 402 can only be translated in the -Z direction to connect the plug assembly 414 with the socket interface 418 when the detent 456 is inserted into the second seat 454.

[0137] Electrically disconnecting the modules 400A, 400B from each other is shown in FIGS. 4I-4K. As can be seen, the handle assembly 402 of the bottom module 400B is pulled in the +Z direction to withdraw the plug assembly 414 from the socket interface 418 of the top module 400A as shown in FIG. 41. Thereafter, the handle assembly 402 of the bottom module 400B is rotated90° in the +Z direction to the horizontal orientation, and the socket cover 420 of the top module 400A is closed as shown in FIG. 4J. As shown in FIG. 4K, the first compression spring 436 in the handle plunger housing 412 drives translation to the handle assembly 402 in the -Z direction. Once electrically disconnected, the modules 400A, 400B can be mechanically disconnected by disengaging the cleat and pocket interface as described in relation to FIGS. 1 A-1O.

[0138] In one or more embodiments, the handle assembly 402 may be configured to actuate a switch, such as a micro switch or a magnetic switch, or the position of the handle assembly 402 may be detected using a sensor, such as a magnetic sensor. In this way, the position of the handle assembly 402 (rotation position as well as insertion position) can be used to determine the connection status between the modules 400 A, 400B to control, e.g., the electrical power flow within or between the modules 400A, 400B.

[0139] This third aspect provides several advantages. For example, the socket cover 420 provides protection against accidental ingress into the socket interface 418 in the unconnected state. Further, the protective sheath 416 prevents accidental contact (e.g., by debris or a user’s hand) with the male blade contacts 438 of the plug assembly 414. Additionally, the modules 400A, 400B are fully compatible with the existing cleat and pocket interfaces. Still further, the electrical and mechanical connections require only two steps, including the initial mechanical connection using the cleat and pocket interface and the electrical connection using the twisting of the handle assembly 402.

[0140] A fourth aspect of the modules 500A, 500B will be described more fully in relation to FIGS. 5A-5H. The modules 500A, 500B mechanically connect using the cleat and pocket interface as described above in relation to FIGS. 1 A-1O.

[0141] As can be seen in FIG. 5 A, the module 500A, 500B is connected to an adjacent module 500A, 500B using a removable cord 502. Each module 500A, 500B includes a first connection interface 504 and a second connection interface 506. The second connection interface 506 is reversibly covered with a sliding door 508.

[0142] FIG. 5B provides an exploded view of the components of the module 500A, 500B. As can be seen, the module 500A, 500B includes the locking tab 26 as described above in relation to FIGS. 1 A-1O to prevent relative translation of the modules 500A, 500B in the Z direction. Further,as shown in FIG. 5B, the module 500A, 500B includes a first aperture 510 formed through the first wall 102 in the bottom housing 110. The second connection interface 506 is seated in the first aperture 510. Further, the top housing 108 and the bottom housing 110 combine to form a second aperture 512 in which the first connection interface 504 is seated. The first wall 102 also includes a track 514 along which the sliding door 508 slides. FIG. 5B also depicts the removable cord 502 configured to connect the first connection interface 504 of a bottom nodule 500B with the second connection interface 506 of the top module 500A.

[0143] With reference now to FIG. 5C, a top module 500A is stacked on top of a bottom module 500B. The modules 500A, 500B are mechanically connected using the cleat and pocket interface as discussed above. However, the modules 500A, 500B as shown in FIG. 5C are not yet electrically connected. Further, it can be seen that the sliding door 508 is covering the second connection interface 506 of each module 500A, 500B.

[0144] To electrically connect the two modules 500A, 500B together, the user slides the sliding door 508 of the top module 500A and translates the sliding door 508 as far as it can go in the +X direction as shown in FIG. 5D to expose the second connection interface 506 on the top module 500A. In one or more embodiments, the second connection interface 506 may be a male interface, i.e., containing a plurality of outwardly extending contacts configured for insertion into a socket of the removable cord 502. In such embodiments, the first connection interface 504 may be a female interface, i.e., defining a socket for receiving male contact elements of the removable cord 502. However, in one or more other embodiments, the interfaces 504, 506 may be reversed; although, the sliding door 508 preferably covers the male interface so as to avoid accidental contact with the outwardly extending male contacts.

[0145] As shown in FIG. 5E, electrical connection is made between the modules 500A, 500B by inserting a first end 516 of the removable cord 502 into the first connection interface 504 of the bottom module 500B and a second end 518 of the removable cord 502 into the second connection interface 506. That is, the user translates the removable cord 502 in the -Z direction until the removable cord 502 has both ends 516, 518 fully seated in their respective interfaces 504, 506. The modules 500A, 500B will thus be electrically connected.

[0146] Referring now to FIG. 5F, it can be seen that the sliding door 508 covers access to the locking tab 26. That is, when the sliding door 508 is translated in the +X direction to reveal the second connection interface 506, actuation of the locking tab 26 is blocked. Further, while the removable cord 502 is inserted into the second connection interface 506, the sliding door 508 cannot be translated in the -X direction to uncover access to the locking tab 26. Thus, in order to access the locking tab 26 to mechanically disconnect the modules 500A, 500B, the user must first remove the removable cord 502 by translating the removable cord 502 in the +Z direction, which electrically disconnects the modules 500A, 500B as shown in FIG. 5G.

[0147] Having electrically disconnected the modules 500A, 500B as shown in FIG. 5G, the modules 500A, 500B can then be mechanically disconnected. As shown in FIG. 5H, this involves sliding the sliding door 508 in the -X direction to cover the second connection interface 506 and uncover access to the locking tab 26. Sliding of the sliding door 508 is now possible because the removable cord 502 no longer obstructs translation of the sliding door. To mechanically disconnect the two modules 500A, 500B, the locking tab 26 is actuated in the +Y direction, and the top module 500A can be translated in the +Z direction disengaging the cleat and pocket interface as described above.

[0148] This fourth aspect provides several advantages. In particular, when the removable cord 502 is inserted, the sliding door 508 prevents access to the locking tab 26, mechanically locking the modules 500A, 500B together during electrical communication between the modules 500A, 500B. Further, the modules 500A, 500B are fully compatible with other existing cleat and pocket interfaces. Additionally, the electromechanical connection requires only three steps in which the first step is engagement of the cleat and pocket interface and the electrical connection steps only require sliding of a door 508 across the first wall 102 of the module 500A, 500B and insertion of a removable plug 502.

[0149] A fifth aspect of the modules 600A, 600B will be described more fully in relation to FIGS. 6A and 6B. The modules 600A, 600B mechanically connect using the cleat and pocket interface as described above in relation to FIGS. 1A-1O. The electrical connection between the modules 600A, 600B is provided using a flexible pigtail.

[0150] With reference to FIG. 6A, a partial perspective view of a module 600A, 600B is provided. The module 600A, 600B includes a flexible pigtail connector 602. The flexible pigtail connector 602 has a first end 604 and a second end 606. The first end 604 is connected to the top housing 108 of the module 600A, 600B. In one or more embodiments, the first end 604 may be provided with a strain relief boot 608 to avoid degradation of the connection to the top housing 108. The second end 606 of the pigtail connector 602 is free. That is, the pigtail connector 602 can be bent or flexed to position the second end 606 for connection to another module 600A, 600B. As shown in FIG. 6A, the top housing 108 defines a storage cavity 610 for the pigtail connector 602. The storage cavity 610 has a first wall 612 to which the first end 604 of the pigtail connector 602 is attached. The storage cavity 610 further defines a second wall 614 extending substantially along the length of the pigtail connector 602. The storage cavity 610 further includes a corner wall 616 that is positioned adjacent to the second end 606 of the pigtail connector 602. In this way, the pigtail connector 602 rests on a floor 616 of the storage cavity 610, confined within the first wall 612, the second wall 614, and the corner wall 616. Advantageously, the storage cavity 610 in the top housing 108 contains the pigtail connector 602 within the geometry of the module 600A, 600B overall. The second end 606 of the pigtail connector 602 includes a plug 618 with male contacts.

[0151] The bottom housing 110 includes a socket 620 on the first wall 102. In one or more embodiments, the socket 620 is provided with a socket cover 622 to prevent debris from entering the socket 620 when a pigtail connector 602 is not inserted into the socket 620.

[0152] Additionally, the modules 600A, 600B are provided with a locking tab 26 and a corresponding recess 54 to engage the locking tab 26 to prevent relative translation of the modules 600A, 600B in the Z direction.

[0153] With reference to FIG. 6B, the modules 600A, 600B are electrically connected by flipping opening the socket cover 622 (e.g., by rotating it 90° in the -X direction) and flexing the pigtail connector 602 of the bottom module 600B upwardly in the +Y direction to plug into the socket 620 of the top module 600A by translating the plug 618 in the -Z direction into the socket 620. Once the plug 618 of the bottom module 600B is inserted into the socket 620 of the top module 600A, the modules 600A, 600B are electrically connected.

[0154] In one or more embodiments, the socket 620 of each module 600A, 600B is provided in a recessed region 624 of the bottom housing 110. In this way, socket 620 is also contained within the geometry of the module 600A, 600B such that, when the plug 618 is inserted into the socket 620, the pigtail connector 602 remains within the geometry of the modules 600A, 600B and does not stick out, thereby preventing snags or tripping.

[0155] To electrically disconnect the two modules 600A, 600B from each other, the user grabs the plug 618 of the bottom module 600B at the second end 606 of the pigtail connector 602 and translates the plug 618 in the +Z direction to break the electrical contact with the socket 620 of the top module 600A. Then, the user sets the plug 618 back in the storage cavity 610 of the bottom module 600. The socket cover 622 of the top module 600A flips back down to its original position, rotating 90° in the +X direction, preferably just under the influence of gravity. The user can then actuate the locking tab 26 in the +Y direction to allow for relative translation of the modules 600A, 600B in the Z direction to disengage the cleat and pocket interface as described above.

[0156] This aspect also provides several advantages. For example, the pigtail connector 602 is flexible instead of rigid, which makes the module 600A, 600B less susceptible to vibration. That is, the flexible pigtail connector 602 would be able to tolerate the relative motion between the two modules 600 A, 600B and be able to reliably maintain contact at the interface without loss of power or communications. Further, the pigtail connector 602 is permanently affixed to the housing 108, diminishing the possibility that the pigtail connector 602 could become lost. Additionally, the socket cover 622 prevents ingress of debris to the socket 620 in an unmated state. This aspect also provides full compatibility with existing cleat and pocket interfaces, and the electromechanical connection is provided in two steps: (1) cleat and pocket mechanical engagement and (2) insertion of the plug 618 into the socket 620.

[0157] A sixth aspect of the modules 700A, 700B will be described more fully in relation to FIGS. 7A-7F. The modules 700A, 700B mechanically connect using the cleat and pocket interface as described above in relation to FIGS. 1A-1O. The electrical connection between the modules 700A, 700B is provided using a rear terminal block.

[0158] FIG. 7A depicts a front perspective view of the module 700A, 700B, and FIG. 7B depicts a rear perspective view of the module 700A, 700B. As can be seen in FIGS. 7A and 7B,the first wall 102 (front wall) of the bottom housing 108 includes a locking tab 26 as described above, and a rear wall 702 has mounted thereon a rear terminal block 704. The rear terminal block 704 includes a first connection interface 706 and a second connection interface 708. The first connection interface 706 is disposed at a first end 710 of the rear terminal block 704 extending above a plane defined by the top surface of the module 700A, 700B, and the second connection interface 708 is disposed at a second end 712 of the rear terminal block 704 and may be substantially flush with a plane defined by the bottom surface of the module 700A, 700B. The first connection interface 706 faces the opposite direction from the second connection interface 708. In one or more embodiments, the first connection interface 706 faces toward the first wall 102, whereas the second connection interface faces away from the rear wall 702.

[0159] FIG. 7C depicts an exploded view of the module 700A, 700B. As can be seen, the rear terminal block 704 includes a first portion 714 and a second portion 716. In one or more embodiments, the first portion 714 includes the first connection interface 706 and is fastened to the top housing 108, and the second portion 716 includes the second connection interface 708 and is fastened to the second portion 716. As will be discussed more fully below, translation of the top module 700A in the -Z direction to engage the cleat and pocket interface also engages the second connection interface of the top module 100A with the first connection interface 706 of the bottom module 700B such that the mechanical and electrical connection are established at the simultaneously.

[0160] FIGS. 7D and 7E depict the insertion of the second connection interface 708 of the top module 700A into the first connection interface 706 of the bottom module 700B. Alignment of the cleats and pockets of the top and bottom module 700A, 700B aligns the rear-facing second connection interface 708 with the forward-facing first connection interface 706 such that locking the cleats into the pockets also inserts the second connection interface 708 of the top module 700A into the first connection interface 706 of the bottom module 700B.

[0161] As shown in FIG. 7F, the modules 700A, 700B are electrically disconnected by translating the top module 700A in the +Z direction, causing the second connection interface 708 to disengage the first connection interface 706 of the bottom module 700B. During this action, thecleat and pocket interface of the modules 700A, 700B are also mechanically disconnected as discussed above.

[0162] The sixth aspect also provides several advantages. For example, the modules 700A, 700B are at least partially compatible with other cleat and pocket interfaces for modules that do not have any interference with the rear terminal block 704 on the rear face of the modules 700A, 700b. Additionally, this aspect provides electrical and mechanical connection in a single step.

[0163] A seventh aspect of the modules 800A, 800B will be described more fully in relation to FIGS. 8A-8S. The modules 800A, 800B mechanically connect using the cleat and pocket interface as described above in relation to FIGS. 1A-1O. The electrical connection between the modules 800A, 800B is provided using rear connection interfaces with floating terminals, which, like the previous aspect, causes the electrical connection to be established at the same time as the mechanical connection.

[0164] FIGS. 8 A and 8B depict front and rear perspective views, respectively, of the module 800A, 800B. As can be seen, the module 800 A, 800B includes a first connection interface 802 on a rear wall 804 of the top housing 108. Further, the module 800 A, 800B includes a second connection interface 806 in a recessed region 808 of the rear wall 804 of the bottom housing 110. FIG. 8C is an exploded view of the module 800A, 800B showing the components thereof. FIG. 8C depicts the locking tab 26, which functions as described in the aspects above. In one or more embodiments, the locking tab 26 is fixed in place using a locking power slider 810, which is connected to the bottom housing 110 using a power slider mount 812. FIG. 8C also depicts the first and second connection interfaces 802, 806. The first connection interface 802 has a backplate 814 mounted thereto. The module 800A, 800B further includes a plurality of grommets 816, the function of which will be described more fully below.

[0165] The first and second interfaces 802, 806 are configured to “float.” In particular, the modules 800A, 800B are locked together in a mechanical connection, but there is typically some relative motion between the two modules 800A, 800B, e.g., because of clearances and tolerances built into the fits between components. Such relative motion is exacerbated in high vibration environments. By allowing the interfaces to float, the electrical connection between the modules800A, 800B is not rigid, allowing for a reliable electrical connection despite relative motion between the modules 800 A, 800b.

[0166] With reference to FIG. 8D, the second connection interface 806 is biased in the -Z direction by a compression spring 818. The second connection interface 806 is comprised of socket terminals 820 extending from a mounting block 822. The mounting block 822 is seated within a channel 824 having a first sidewall 826 and a second sidewall 828 connected by a backwall 830. The mounting block 822 includes a first surface 832 and a second surface 834. The socket terminals 820 are disposed on the first surface 832, and the second surface 834 faces the backwall 830. The compression spring 818 is disposed between the backwall 830 and the second surface 834, and the compression spring 818 biases the mounting block 822 away from the backwall 830. Disposed between the first surface 832 and the second surface 834 is an internal track 836. A post 838, such as a screw or pin, extends through the first sidewall 826 into the internal track 836 to limit travel of the mounting block 822 in the -Z direction. Further, the first surface 832 of the mounting block 822 extends a sufficient distance such that the mounting block 822 forms an abutment surface 840 that contacts a top of the first sidewall 826 to limit travel of the mounting block 822 in the +Z direction. The biasing of the second connection interface 806 against the first connection interface 802 ensures flush contact between the connection interfaces 802, 806.

[0167] Additionally, as shown in FIG. 8E, the second connection interface 806 also is provided with clearance in the X and Y direction so that the second connection interface 806 can move in those directions when the connection interfaces 802, 806 are connected. Further, as shown in FIG. 8F, the first connection interface 802 has clearance 843 in the X direction so that the first connection interface 802 can move in the X direction when the first and second connection interfaces 802, 806 are connected.

[0168] FIG. 8G depicts the second connection interface 806 seated inside the first connection interface 802 upon completion of the translation of the top module 800A in the -Z direction during mechanical connection of the cleat and pocket interface. Thus, completion of the mechanical connection also completes the electrical connection of the connection interfaces 802, 806.

[0169] In contrast to previous aspects, the present aspect includes the locking power slider 810 that provides power to the connection interfaces 802, 806. That is, electrical power is not communicated across the connection interfaces 802, 806 until the locking power slider 810 is actuated into the “on” position. In particular, when the locking power slider 810 is in the furthest -X position, the module 800A, 800B is in the “unlocked” and “unpowered” state as shown in FIG. 8H. The user pushes the locking power slider 810 of the top module 800A and translates the locking power slider 810 in the +X direction, which is the “locked” and “powered” state as shown in FIG. 81. As can be seen there, the locking power slider 810 has a finger 844 that, when translated in the +X direction, extends into a cavity 846 of the locking tab 26 and blocks the translation of the locking tab 26 in the Y direction. Accordingly, when the module is in the powered state, the locking tab 26 mechanically locks the top module 800A to the bottom module 800B such that the top module 800A cannot be removed from the bottom module 800B.

[0170] The locking power slider 810 may operate as a direct power switch or trigger a micro switch when translated. Further, the position of the locking power slider 810 can be detected, e.g., using a hall sensor, and based on the sensed position of the locking power slider 810, a microcontroller or other logic-based device can permit or prevent the flow of electrical power within or between the modules 800 A, 800B. In one or more other embodiments, the locking power slider 810 may be a magnetically actuated switch. In general, the locking power slider 810 either directly commutates the flow of electrical power or the position of the locking power slider 810 is communicated to a device the controls the flow of electrical power, e.g., through a power transistor, a relay, etc. The sensed position of the locking power slider 810 can be used for other control functions where it may be desirable or necessary to know whether the modules are connected to each other.

[0171] In one or more embodiments, the module 800A, 800B includes a number of ingress protection features. In particular, the module 800A, 800B, as shown in FIG. 8J, includes a plurality of grommets 816 that are present in a first location in the assembly of the first connection interface 802 between the top housing 108 and the bottom housing 110 to route wires from the first connection interface 802 to the inside of the module 800A, 800B. As shown in FIG. 8K, thegrommets 816 are also located in a second location locations at an interface between the top housing 108 and the bottom housing 110 on an interior of the module 800 A, 800B.

[0172] Further, in one or more embodiments, as shown in FIG. 8L, the fist connection interface 802 includes first water routing paths 848 leading to first weep holes 850. These features provide water egress that drain into the bottom housing 110. Further, as shown in FIGS. 8M and 8N, the bottom housing 108 also has second water routing paths 852 and second weep holes 854 for water egress to drain to the outside of the module 800A, 800B.

[0173] FIGS. 80 and 8P depict the modules 800A, 800B being electrically disconnected. In a first step, the user slides the locking power slider 810 in the -X direction, which is the “unlocked” and “unpowered” state (FIG. 80). The top module 800A is now “off’ and the finger 844 of the locking power slider 810 is removed from the cavity 846 of the locking tab 26, no longer obstructing Y translation of the locking tab 26. To continue disconnecting the modules 800A, 800B from each other, the user translates the top module 800A in the +Z direction to disconnect the second connection interface 806 from the first connection interface 802 (FIG. 8P) and disengage the cleat and pocket interface as discussed above.

[0174] Advantageously, this aspect of the modules 800A, 800B is fully compatible with the cleat and pocket interface. In particular, modules 800A, 800B with these features can stack on top of any existing modules having the cleat and pocket interface. As shown in FIG. 8Q, when attempting to stack another non-power module 856 onto the module 800A, 800B, the cleats 12 from the non-power module 856 contact the first connection interface 802 of the module 800A, 800B during the translation of the non-power module 856 in the -Y direction. As shown in FIG. 8R, the first connection interface 802 is configured to transition to a position in which the first connection interface is flush with or below the top surface 18. The first connection interface 802 can be transitioned in any of a variety of suitable ways. As depicted, the first connection interface 802 is connected to the top surface 18 with hinge joint such that the first connection interface rotates in the -X direction, folding into itself, and out of the way of the non-power module 856. In other embodiments, the first connection interface 802 is disposed on a sliding mechanism such that the first connection interface can be pushed downward and / or backwards on a track defined in the housing, amongst other possibilities.

[0175] The top non-power module 856 is then free to translate in the -Z direction by the user to mechanically connect the non-power module 856 to the module 800A, 800B. Removing the non-power module 856 involves the same steps as discussed above in relation to the disengagement of the cleat and pocket interface as discussed above in relation to FIGS. 1A-1O. Once the non-power module 856 is translated in the +Y direction, the cleats 12 of the non-power module 856 lose contact with the first connection interface 802, and the first connection interface 802 rotates in the +X direction as shown in FIG. 8S. In one or more embodiments, the first connection interface 802 is biased backupward. As shown in FIG. 8S, the biasing force is provided by one or more torsion springs 858, but other biasing elements could be used instead of or in addition to the torsion springs 858, such as another spring type, a magnet, a solenoid, a motor, or other tension / compression devices.

[0176] In one or more embodiments, the position of the first connection interface 802 is determined so that the position information can be used to, e.g., control the electrical power flow within or between the modules 800A, 800B or to non-power module 856. For example, the first connection interface 802 may actuate a switch, such as a micro switch, magnetic switch, or limit switch (e.g., for the tracked embodiment), based on its position, or the position of the first connection interface 802 may be detected using a sensor, such as a magnetic sensor.

[0177] The seventh aspect provides several advantages. For example, the grommets 816 provide ingress protection against external debris entering the interior of the module 800A, 800B. Further, the geometry in the first connection interface 802 and the bottom housing 110 route water near the interface out the back of the module 800A, 800B. Additionally, the locking power slider 810 obstructs translation of the locking tab 26 when the user translates the finger 844 of the locking power slider 810 into cavity 846 of the locking tab 26. In this way, when the two modules 800A, 800B are electrically connected (and the locking power slider 810 is in the furthest +X position), the modules 800A, 800B cannot be mechanically disconnected. Still further, the module 800A, 800B is fully compatible with products including the cleat and pocket interface because, as discussed above, the first connection interface 802 rotates out of the way of an upper module 856. Forming the electromechanical connection only requires two steps, including the mechanical connection of the cleat and pocket interface, which also causes the second connection interface606 to insert into the first connection interface 602, and sliding of the locking power slider 810 to power on the top module 800A.

[0178] An eighth aspect of the module 900A, 900B will be described more fully in relation to FIGS. 9A-9C. The modules 900A, 900B mechanically connect using the cleat and pocket interface as described above in relation to FIGS. 1A-1O. The electrical connection between the modules 900A, 900B is provided using a rotating connector 902.

[0179] With reference to FIG. 9 A, rotating connector 902 includes a first end 904 and a second end 906. The first end 904 includes a rotating base 908 configured to rotate about a stationary base 910 of the module 900A, 900B. As will be discussed more fully below, the rotating base 908 and the stationary base 910 align during rotation of the rotating connector 902 to create electrical communication from the module 900A, 900B through stationary base 910, the rotating base 908, and to a plug 912 at a second end 906 of the rotating connector 902. The module 900A, 900B further includes a receptacle 914 for electrical connection to the plug 912 of the adjacent module 900A, 900B. Further, the module 900A, 900B includes a locking mechanism configured to prevent rotation of the rotating connector 902 unless a locking tab 26 of an adjacent module 900A, 900B is seated in the recess 54. For example, the locking mechanism may be a hook that holds the rotating connector 902 in place and that is disengaged from the rotating connector 902 when the locking tab 26 is seated in the recess 54.

[0180] In FIG. 9A, the rotating connector 902 is in the stowed (horizontal) position in which there is no top module 900A positioned over a bottom module 900B. Thus, there is no locking tab 26 engaging the recess 54 in the top surface 18 of the bottom module 900B. In this position, the locking mechanism will restrict Z translation of the rotating connector 902 such that the rotating connector 902 cannot rotate. The rotating connector 902 is in the -Z position and locked in place until a top module 900A is placed over the bottom module 900B. The stationary base 910 is sealed and powered. The plug 912 is also sealed but not powered.

[0181] As shown in FIG. 9B, the module 900B is the “transition” stage. A top module 900A is placed on top of the bottom module 900B such that the locking tab 26 of the top module 900A is disposed in the recess 54 of the bottom module 900B, which triggers the locking mechanism to stop restricting Z translation of the rotating connector 902. The user grabs the plug 912, translatesthe plug 912 in the +Z direction, then rotates the plug 912 90° in the +Z direction, which causes the rotating base 908 to rotate around the stationary base 910. The stationary base 910 is still sealed and powered, but the plug 912 is no longer sealed and still is not powered. Rotating the rotating base 908 causes internal electrical contacts to radially align with the electrical contacts of the stationary base 910.

[0182] In the “connected” stage, the user translates the rotating connector 902 of the bottom module 900B in the -Z direction and inserts the plug 912 into the receptacle 914 of the top module 900A. As shown in FIG. 9C, as the user translates the rotating connector 902 and the rotating base 908 in the -Z direction, the internal contacts 916, which have been radially aligned, create electrical communication between the stationary base 910 and the rotating base 908 to provide power to the plug 912 after the plug 912 is inserted into the receptacle 914. The modules 900A, 900B are now electrically connected.

[0183] To electrically disconnect the modules 900A, 900B, the user grabs the rotating connector 902 and translates the rotating connector 902 in the +Z direction, withdrawing the plug 912 from the receptacle 914. During this translation in the +Z direction, the internal contact 916 between the stationary base 910 and rotating base 908 loses connection and power is shut off to the plug 912. The user then rotates the rotating connector 902 90° in the -Z direction, and then, the user translates the rotating connector 902 in the -Z direction to place the rotating connector 902 back in the “stowed” stage. The modules 900A, 900B can be mechanically disconnected by disengaging the cleat and pocket interface between the modules 900A, 900B in the manner described above.

[0184] In one or more embodiments, the rotating connector 902 may be configured to actuate a switch, such as a micro switch or a magnetic switch, or the position of the rotating connector 902 may be detected using a sensor, such as a magnetic sensor. In this way, the position of the rotating connector 902 (rotation position as well as insertion position) can be used to determine the connection status between the modules 900 A, 900B to control, e.g., the electrical power flow within or between the modules 900A, 900B.

[0185] The eighth aspect provides several advantages. For example, the rotating base 908 and plug 912 are sealed against the module 900A, 900B to prevent ingress to the interior of the module900A, 900B. Further, the plug 912 does not have power until the plug 912 and receptacle 914 are mated because the internal contacts 916 in the rotating base 908 and stationary base 910 are not connected until the plug 912 is inserted into the receptacle 914. Additionally, the module 900A, 900B is fully compatible with the with existing components having the cleat and pocket interface. The electromechanical connection is formed in two steps, including a first step of engaging the cleat and pocket interface followed by translating and rotating the rotating connector 102 to insert the plug 912 into the receptacle 914.

[0186] In the foregoing description of the portable power modules, reference has been made in various locations to male and female connectors for each of description in relation to the figures. However, in general, the relative position of the male and female electrical connectors can be reversed, and other connector types, such as mixed gender connectors or genderless connectors can be used in stead of gendered connectors. In various embodiments, the connectors may be Anderson-type connectors or may contain both pins (male) and sockets (female) in a single interface, for example.

[0187] Having described example modules of the portable power ecosystem, other components that can be combined in the portable power ecosystem are now described.

[0188] FIGS. 10A and 10B depict an embodiment of a power management unit (PMU) 1000 that can be utilized in the portable power ecosystem according to any of the aspects of the present disclosure. As shown in FIGS. 10A and 10B, the PMU 1000 includes rear terminal blocks, such as described in relation to the sixth aspect and illustrated in FIGS. 7A-7F. As shown, the PMU 1000 can connect two modules using the cleat and pocket interface as described above, one next to the other. Additional modules can be stacked on top of those modules to scale the capacity as needed. The PMU 1000 provides power management to all connected modules. Additionally, in one or more embodiments, the PMU 1000 includes a user interface screen 1002 for receiving information about the status of the system and for controlling the connected modules. Further, in one or more embodiments, the PMU 1000 includes two AC outlets 1004 (e.g., 120V, 20A GFCI outlets) on a front face of the PMU 1000. On a side face, in one or more embodiments, the PMU 1000 includes a DC power outlet 1006 (in particular a DC high power output port), a DC power input 1008, and an AC inlet 1010 (e.g., 120V, 15A).

[0189] FIGS. 11 A and 1 IB depict an embodiment of an expansion core 1100. The expansion core 1100 is a portable battery providing additional battery capacity to the portable power ecosystem. The expansion core 1100 as shown can be connected to the PMU 1000 of FIGS. 10A and 10B using the interface 1102 on the rear surface 1104 of the expansion core 1100 as shown in FIGS. HA and 11B. In one or more embodiments, the expansion core 1100 includes a charge status indicator 1106, such as a plurality of LED lights to indicate how much charge that the expansion core 1100 has remaining. In one or more embodiments, the expansion core 1100 is any one of the portable power modules described above in relation to FIGS. 2A-9B.

[0190] FIGS. 12A and 12B depict a DC-DC charging caddy 1200 for charging of a plurality (in particular four) battery packs for power tools. In one or more embodiments, the caddy 1200 includes a plurality of bays 1202 for connecting power tool battery packs for charging. As can be seen, the caddy 1200 is disposed over half the available interface of the PMU 1000 and the expansion core 1100. Thus, two caddies 1200 could be connected to each of the PMU 1000 and expansion core 1100 using the connection interface 1204. In one or more embodiments, the caddy 1200 is configured to supercharge at least two battery packs at the same time through at least two of the bays 1202. In one or more such embodiments, the caddy 1200 may include a selector switch to designate which bays 1202 receive the supercharging capabilities.

[0191] FIGS. 13A and 13B depict another DC-DC charging caddy 1300 for larger battery sizes (e.g., MX Fuel1Mbatteries available from Milwaukee Tool). As can be seen, the charging caddy 1300 includes two bays 1302 to receive and charge two batteries. In one or more embodiments, the bays 1302 provide up to 18A of charge rate to the batteries. The charging caddy 1300 includes a connection interface 1304 for connection to the PMU 1000, expansion core 1100, or another of the modules described herein.

[0192] FIG. 14 depicts still another embodiment of a DC-DC charging caddy 1400. The charging caddy 1400 includes a singled angled bay 1402 for charging of larger battery types (such as MX Fuel™ batteries available from Milwaukee Tool). In one or more embodiments, the single bay 1402 provides 18A charging (1.5 C charge rate). Advantageously, the bay 1402 may be angled transverse to the axis of the stacking configuration, in particular at an angle of less than 90°, such as at about 25°, to facilitate load of the battery into the bay 1402 when the caddy 1400 is, e.g.,mounted on a wall. In one or more embodiments, the caddy 1400 includes an HMI screen 1404 to provide information and interaction to a user. Further, the caddy 1400 includes a connection interface 1406 for connection to the PMU 1000, expansion core 1100, or another of the modules described herein.

[0193] FIG. 15 depicts an embodiment of a dolly 1500 for transporting the portable power ecosystem 1502. In particular, the dolly 1500 provides a large surface area for attaching elements of the portable power ecosystem to enhance the transportation experience. The rigid construction of the dolly 1500 allows for large stacks of modules to be built on the platform 1502 as well as mounted to the back 1504. In one or more embodiments, the wheels 1506 and axle 1508 are located as close to the center of mass as possible to provide ease of tilt for quick transport. The dolly 1500 can be configured to hold a variety of battery types (e.g., 12V, 18V, or larger batteries). Further, the dolly 1500 can include various structural configurations to enhance usability, such as providing the platform 1502 off the ground for ingress protection and providing a front foot hold to hold the dolly 1500 in place while loading material.

[0194] FIGS. 16A and 16B depict embodiments of a battery rack 1600, in particular for larger battery types (such as MX Fuel™ batteries). As can be seen, the battery rack 1600 includes a plurality of cleats 12 for mounting into corresponding cleat pockets of a cleat and pocket interface as described above. On a side opposite to the cleats 12, the battery rack 1600 includes a sliding mount 1602 configured to receive and hold a battery in the portable power ecosystem.

[0195] FIGS. 17Aand 17B depict another embodiment of abattery rack 1700 having a twisting lock 1702. The battery rack 1700 includes a lock mechanism on one side and a lock actuator on the other side. In the embodiment depicted, the lock actuator is twisted in order to actuate the locking mechanism. In one or more embodiments, the battery rack 1700 includes a sliding mount 1704 configured to receive a battery (e.g., an MX Fuel™ battery). The twisting lock 1702 is configured to secure the battery pack 1700 to a cleat 12 within the portable power ecosystem.

[0196] FIG. 18 depicts an embodiment of an expansion plate 1800 that allows a user to charge more components from a single PMU 1000 (as shown in FIGS. 10A and 10B). In particular the expansion plate 1800 extends recharging via a DC-DC cable connection to allow multiple battery chargers (e.g., caddies 1200, 1300, 1400) to be connected and powered. In one or moreembodiments, the expansion plate 1800 is configured to be wall mounted or floor mounted. In one or more embodiments, the expansion plate 1800 includes mechanical lockouts to allow only specific components to attach (e.g., only components configured to be floor or wall mounted). Further, in one or more embodiments, the expansion plates 1800 can be daisy -chained together using DC-DC cable connections (although the number of daisy chaining can be limited by providing only female DC ports). In the embodiment depicted, the expansion plate 1800 includes three bays 1802, but other embodiments may include fewer or additional bays 1802.

[0197] FIG. 19 depicts an embodiment of a portable power ecosystem 1900 comprising a plurality of modules as described. In particular, the portable power ecosystem 1900 includes a PMU 1000 as the base of the ecosystem 1900, and two expansion cores 1100 are mounted on top of the PMU 100 to expand the capacity of the ecosystem 1900. On the top expansion core 1100, a first charging caddy 1200 is provided for charging of power tool battery packs, and a second charging caddy 1300 is provided for charging of larger battery packs. Additionally, the PMU 1000 is connected to an expansion plate 1800 using a DC-DC connection cable 1902. As can be seen, the expansion plate 1800 has three charging caddies 1200 mounted thereon for charging of a plurality of power tool battery packs. The portable power ecosystem 1900 depicted in FIG. 19 is merely exemplary to demonstrate how modules of the portable power ecosystem 1900 may come together, but the potential combinations are too numerous to fully illustrate. As such, the mechanical and electrical modularity provides increased portability, scalability, and productivity across a wide variety of power needs, which can be reconfigured on the fly as needed for the particular requirements of a jobsite.

[0198] FIG. 20 depicts an embodiment of a portable power ecosystem 1900 having a movable screen 2000. As can be seen, the portable power ecosystem 1900 of FIG. 20 includes a PMU 1000, two battery cores 1100, and two charging caddies 1200 in a stacked configuration. The movable screen 2000 can be attached to any of the components in the system in order to provide the user with easy access to information regarding the system. In particular, the movable screen 2000 may be configured to provide information regarding the module to which the movable screen 2000 is attached. In one or more embodiments, the movable screen 2000 is mechanically attached to eachmodule, and the information output on the movable screen 2000 is wireless communicated to the movable screen 2000.

[0199] It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for description purposes only and should not be regarded as limiting.

[0200] Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.

[0201] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article "a" is intended to include one or more component or element, and is not intended to be construed as meaning only one. As used herein, "rigidly coupled" refers to two components being coupledin a manner such that the components move together in a fixed positional relationship when acted upon by a force.

[0202] Various embodiments of the disclosure relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements or components of any of the other embodiments discussed above.

[0203] For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

[0204] While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

[0205] In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.

Claims

WHAT IS CLAIMED IS:

1. A portable power module, comprising: a first surface extending between a first end and a second end of the portable power module, the second end being spatially disposed from the first end in a first direction, the first surface comprising a first interface disposed between the first end and the second end, a second surface opposite the first surface, the second surface extending between the first end and the second end, the second surface comprising s second interface configured to mechanically interlock with the first interface; a plurality of sidewalls connecting the first surface and the second surface; a first electrical connector; and a second electrical connector; wherein the portable power module is configured to form an electrical connection and a mechanical connection to one or both of a first adjacent portable power module arranged upwardly in a vertical stacking configuration and a second adjacent portable power module arranged downwardly in the vertical stacking configuration; wherein, in the mechanical connection, the second interface is configured to mechanically interlock with a first interface of the second adjacent portable power module or the first interface is configured to mechanically interlock with a second interface of the first adjacent portable power module; wherein, in the electrical connection, the first electrical connector is configured to connect with a second electrical connector of one of the first adjacent portable power module or the second electrical connector is configured to connect with the first electrical connector of the second adjacent portable power module; and wherein the electrical connection can only be made at the same time or after the mechanical connection is made.

2. The portable power module of claim 1, further comprising a terminal block disposed on the second end of the portable power module, the terminal block comprising a first connectioninterface and a second connection interface in which the first connection interface faces opposite to the second connection interface, wherein the first connection interface extends above a plane defined by the first surface in a first position, wherein the first connection interface comprises the first electrical connector, and wherein the second connection interface comprises the second electrical connector.

3. The portable power module of claim 2, wherein the first electrical connector is a female electrical connector and the second electrical connector is a male electrical connector.

4. The portable power module of claim 2 or claim 3, wherein the electrical connection is formed substantially at the same time as the mechanical connection.

5. The portable power module of any of claims 2-4, wherein the first connection interface is configured to transition from the first position to a second position substantially flush with or below the first surface.

6. The portable power module of claim 5, wherein the first connection interface is biased toward the first position.

7. The portable power module of claim 5 or claim 6, wherein the second connection interface is configured to slide back and forth in the first direction and in a second direction opposite to the first direction and wherein the second connection interface is biased in the first direction.

8. The portable power module of any of claims 2-7, further comprising a locking tab and a locking power slider, wherein the locking tab is configured to reversibly extend through the second surface and seat within a recess formed in a first surface of the second adjacent portable power module, the locking tab being disposed between the first end of the power module and the second interface, wherein the locking power slider is configured to translate from a first position in which the locking tab is able to retract from the recess to a second position in which the locking tab isprevented from retracting from the recess and wherein the position of the locking power slider controls whether electrical power is able to flow to the first electrical connector and the second electrical connector.

9. The portable power module of claim 1, further comprising a rotatable handle, the rotatable handle comprising a first end and a second end, wherein the first electrical connector is disposed on the first end of the rotatable handle, wherein the rotatable handle is configured to rotate about the second end toward the first adjacent portable power module to mate with the second electrical connector of the first adjacent portable power module.

10. The portable power module of claim 9, wherein the rotatable handle and the second electrical connector are disposed on a first sidewall of the plurality of sidewalls, the first sidewall being on the first end of the power module.

11. The portable power module of claim 10, wherein, to rotate the rotatable handle, the rotatable handle is translated in a second direction opposite to the first direction and wherein, to connect the first electrical connector of the power module to the second electrical connector of the first adjacent portable power module, the rotatable handle is translated in the first direction.

12. The portable power module of any of claims 9-11, wherein the rotatable handle is rotated from a substantially horizontal position to a substantially vertical position to connect the first electrical connector to the second electrical connector of the first adjacent portable power module.

13. The portable power module of any of claims 9-12, wherein the second electrical connector is disposed between the second end of the rotatable handle and the second surface.

14. The portable power module of claim 13, further comprising a socket cover configured to swing from a closed position covering the second electrical connector to an open position in which the second electrical connector is uncovered.

15. The portable power module of any of claims 9-14, further comprising an arcuate travel guide comprising a first seat and a second seat, wherein the second end of the rotatable handle comprises a detent and wherein, to form the electrical connection, the rotatable handle is rotated from a first position in which the detent is disposed in the first seat to a second position in which the detent is disposed in the second seat.

16. The portable power module of any of claims 9-15, wherein the rotatable handle further comprises a protective sheath configured to cover the first electrical connector prior to making the electrical connection.

17. The portable power module of claim 16, wherein the protective sheath is biased in a position to cover the first electrical connector and wherein, in forming the electrical connection, the protective sheath is pushed against the bias such that the first electrical connector is exposed for connection with the second electrical connector of the first adjacent portable power module.

18. The portable power module of any of claims 9-17, wherein the electrical connection is made after the mechanical connection is made.

19. The portable power module of claim 1, further comprising a rotatable handle, wherein the second electrical connector is disposed within the portable power module and is coupled to the first surface and wherein the first electrical connector is coupled to the second surface and configured to extend from within the portable power module through the second surface when the rotatable handle is rotated from a first handle position to a second handle position.

20. The portable power module of claim 19, wherein the first interface is at least one cleat pocket and the second interface is at least one cleat; wherein the portable power module further comprises a cleat switch, a cleat switch finger, and a backer substrate;wherein the first electrical connector is mounted to the backer substrate, wherein the cleat switch is configured to rotate out of a negative space of the at least one cleat when the cleat switch engages a cleat of the second adjacent portable power module in making the mechanical connection, wherein rotation of the cleat switch causes translation of the cleat switch finger, and wherein translation of the cleat switch finger allows translation of the backer substrate so that the first electrical connector is able to extend from within the portable power module through the second surface.

21. The portable power module of claim 19 or claim 20, further comprising a first access plate disposed within the portable power module and coupled to the second surface, the first access plate comprising a plurality of apertures, wherein the first access plate has a first plate position in which the first access plate covers a plurality of openings in the second surface and a second plate position in which the plurality of apertures align with the plurality of openings such that the first electrical connector can extend through the first access plate and the second surface, and wherein rotation of the rotatable handle from the first handle position to the second handle position causes the first access plate to move from the first plate position to the second plate position.

22. The portable power module of claim 21, further comprising a locking tab, wherein the locking tab is configured to reversibly extend through the second surface and seat within a recess formed in a first surface of the second adjacent portable power module, the locking tab being disposed between the first end of the power module and the at least one cleat, wherein the first access plate comprises an arm configured to engage a notch of the locking tab to keep the locking tab in an extended position when the first access plate is in the second plate position.

23. The portable power module of claim 1, further comprising a locking tab configured to reversibly extend through the second surface and seat within a recess formed in a first surface of the second adjacent portable power module, wherein the locking tab is coupled to a blade assembly, the blade assembly comprising a mounting bracket, a plurality of blade contacts for the first electrical connector, and at least one probe, wherein the at least one probe extends a fartherdistance away from the mounting bracket than each of the plurality of blade contacts and wherein the probe allows the blade contacts to extend through the second surface to mate with a second electrical connector of the second adjacent portable power module only if the probe is able to seat within a cavity formed in a first surface of the second adjacent portable power module.

24. The portable power module of claim 1 , wherein the first electrical connector and the second electrical connector are disposed on a first sidewall of the plurality of sidewalls, the first sidewall being at the first end of the portable power module, wherein the portable power module further comprises a slidable cover that is configured to slide across the first sidewall to cover and uncover at least one of the first electrical connector and the second electrical connector, wherein the first electrical connector is configured to connect to a first end of a first removable plug in which a second end of the first removable plug is configured to be received by a second electrical connector of the second adjacent portable power module, and wherein the second electrical connector is configured to connect to a second end of a second removable plug in which a first end of the second removable plug is configured to be received by a first electrical connector of the first adjacent portable power module.

25. The portable power module of claim 24, further comprising a locking tab, wherein the locking tab is configured to reversibly extend through the second surface and seat within a recess formed in a first surface of the second adjacent portable power module and wherein the slidable cover prevents access to the locking tab when the at least one of the first electrical connector and the second electrical connector is uncovered.

26. The portable power module of claim 1, wherein the first electrical connector is disposed at a first end of a flexible pigtail connector, wherein the portable power module defines a storage cavity between the first surface and a first sidewall of the plurality of sidewalls, wherein a second end of the flexible pigtail connector is connected to a wall of the storage cavity, wherein the second electrical connector is disposed on the first sidewall, and wherein the flexible pigtail connector is configured to bend toward the first adjacent portable power module so that the first electricalconnector is able to mate with a second electrical connector of the first adjacent portable power module.

27. The portable power module of claim 21, further comprising a rotatable connector having a first end and a second end, wherein the rotatable connector comprises a rotatable base disposed at the first end and the first electrical connector disposed at the second end, wherein the rotatable base rotates about a stationary base disposed on a first sidewall of the plurality of sidewalls, wherein the rotatable base comprises a first electrical contact and the stationary base comprises a second electrical contact, wherein the first electrical contact is not in electrical communication with the second electrical contact when the rotatable connector is in a first position, and wherein the first electrical contact is in electrical communication with the second electrical contact with the rotatable connector is in a second position in which the first electrical connector is configured to engage a second electrical connector of the first adjacent portable power module.

28. A portable power ecosystem, comprising: a first portable power module comprising a first mechanical interface and a first electrical interface; a second portable power module comprising a second mechanical interface and a second electrical interface; wherein the second portable power module is stacked on the first portable power module in a vertical configuration; wherein the first mechanical interface and the second mechanical interface interact to form a mechanical connection between the first portable power module and the second portable power module; wherein the first electrical interface and the second electrical interface interact to form an electrical connection between the first portable power module and the second portable power module; and wherein the electrical connection is only able to be formed simultaneously with or after forming the mechanical connection.

29. The portable power ecosystem of claim 28, wherein the first mechanical interface comprises at least one cleat pocket, wherein the second mechanical interface comprises at least one cleat, and wherein the mechanical connection is formed when the at least one cleat is seated in the at least one cleat pocket.

30. The portable power ecosystem of claim 28 or claim 29, wherein the first electrical interface comprises a first terminal block comprising a first electrical connector, the first electrical connector being disposed in a plane above an upper surface of the first portable power module, wherein the second electrical interface comprises a second terminal block comprising a second electrical connector, the second electrical connector being disposed on a rear surface of the second portable power module, the rear surface being substantially perpendicular to the upper surface, and wherein the electrical connection comprises the second electrical connector of the second terminal block being connected to the first electrical connector of the first terminal block.

31. The portable power ecosystem of claim 30, wherein the first terminal block is configured to rotate or translate to a position that is substantially flush or below the upper surface.

32. The portable power ecosystem of claim 30 or claim 31, wherein the electrical connection is formed substantially simultaneously with the mechanical connection.

33. The portable power ecosystem of claim 28 or claim 29, wherein the first portable power module further comprises a rotatable handle, the rotatable handle comprising a first end and a second end, wherein the first electrical interface is disposed on the first end of the rotatable handle, wherein the rotatable handle is configured to rotate about the second end toward the second portable power module to connect the first electrical interface with the second electrical interface.

34. The portable power ecosystem of claim 28 or claim 29, wherein the second portable power module further comprises a rotatable handle, wherein the first electrical interface comprises a firstelectrical connector disposed within the first portable power module and coupled to an upper surface of the first portable power module and wherein the second electrical interface comprises a second electrical connector coupled to a lower surface of the second portable power module, the second electrical connector being configured to extend from within the second portable power module through the lower surface and connect with the first electrical connector of the first portable power module when the rotatable handle is rotated from a first handle position to a second handle position.

35. The portable power ecosystem of claim 33 or claim 34, wherein the electrical connection is formed after the mechanical connection.

36. The portable power ecosystem of any of claims 28 to 35, further comprising a power management unit, wherein the first portable power module and the second portable power module are stacked on the power management unit in a vertical configuration, wherein the power management unit comprises at least one AC power outlet, at least one AC power inlet, at least one DC power outlet, and at least one DC power inlet, and wherein the power management unit is configured to control charging and discharging of electrical power for the first portable power module and the second portable power module.

37. The portable power ecosystem of claim 36, wherein the power management unit comprises a third mechanical interface and a third electrical interface, the third mechanical interface configured to mate with the first mechanical interface to form a second mechanical connection between the first portable power module and the power management unit; wherein the first electrical interface and the third electrical interface mate to form a second electrical connection between the first portable power module and the power management unit; and wherein the second electrical connection is only able to be formed simultaneously with or after forming the second mechanical connection.

38. The portable power ecosystem of any of claims 28 to 37, further comprising an expansion core, the expansion core providing additional battery capacity to the portable power ecosystem.

39. The portable power ecosystem of any of claims 28 to 38, further comprising a charging caddy comprising at least one bay configured to receive a battery pack, wherein the charging caddy is configured to charge the battery pack when the charging caddy is electrically connected to the portable power ecosystem.

40. The portable power ecosystem of claim 39, wherein the battery pack is handheld power tool battery pack.

41. The portable power ecosystem of claim 39 or claim 40, wherein the at least one bay is disposed at an angle that is transverse to an axis of the vertical stacking configuration, the angle being less than 90°.

42. The portable power ecosystem of any of claims 28 to 41, further comprising a dolly configured to transport the first portable power module and the second portable power module.

43. The portable power ecosystem of claim 42, wherein the dolly comprises a back panel configured to support a plurality of bays, each bay configured to receive a battery pack of a power tool.

44. The portable power ecosystem of claim 43, wherein each bay of the plurality of bays is configured to charge the battery pack of the power tool when the battery pack is received in the bay.

45. The portable power ecosystem of any of claims 28 to 44, further comprising a battery rack having a first side and a second side, wherein the first side comprises the second mechanical interface and the second side comprises a sliding mount configured to receive a battery pack.

46. The portable power ecosystem of any of claims 28 to 45, further comprising a mounting plate having a first side and a second side, the first side comprising an actuatable locking mechanism configured to engage the second interface and the second side comprising a lock actuator and a sliding mount configured to receive a battery pack, wherein actuation of the lock actuator causes the locking mechanism to engage the second interface.

47. The portable power ecosystem of any of claims 36 to 46, further comprising an expansion plate, the expansion plate comprising a fourth mechanical interface, a fourth electrical interface, and a power input port, wherein the fourth mechanical interface is configured to receive at least one battery charger, the battery charger comprising a fifth mechanical interface and a fifth electrical interface, wherein the fourth mechanical interface and the fifth mechanical interface mate to establish a mechanical connection between the expansion plate and the at least one battery charger, wherein the fourth electrical interface and the fifth electrical interface mate to establish an electrical connection between the expansion plate and the at least one battery charger, and wherein the power input port is configured to receive electrical power from the power management unit to charge the at least one battery charger through the expansion plate.

48. The portable power ecosystem of any of claims 28 to 47, further comprising a movable screen configured to be attached to a plurality of components within the portable power ecosystem, wherein the movable screen wirelessly communicates with a component of the plurality of components and wherein, based on the wireless communication with the component, the movable screen displays at least one electrical parameter of the component.

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