Electrofusion tool

Abstract

A device includes a housing and a battery interface on the housing configured to removably receive a rechargeable battery pack. The device includes leads receptacles on the housing configured to removably receive electrical leads to transfer current from the rechargeable battery pack to the electrical leads. The device includes an electronic display on the housing. The device includes an electronic controller electrically coupled to the battery interface, the leads receptacles, and the electronic display, the electronic controller is configured to: determine a state of charge of the rechargeable battery pack received at the battery interface, receive coupling data, determine a number of remaining fusions based on the state of charge and the coupling data; and display, on the electronic display, the number of remaining fusions based on the state of charge and the coupling data.

Description

Attorney Docket No. 066042-2014-W001ELECTROFUSION TOOLRELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 702,193, filed October 2, 2024. The entire disclosure of the above application is incorporated by reference.BACKGROUND

[0002] Polyethylene (PE) piping systems are widely used in water, gas, and industrial fluid distribution due to their flexibility, corrosion resistance, and long service life. These systems consist of high-density PE pipes and fittings that can be joined using methods like electrofusion or butt fusion, creating leak-proof connections. Common applications include municipal water supply, natural gas distribution, wastewater management, and protective conduits for cables.SUMMARY

[0003] An electrofusion tool may be used to create secure, leak-proof joints between polyethylene (PE) pipes and fittings by applying controlled electrical current to embedded heating elements within the fitting. Once the pipe and fitting are properly aligned and clamped, the tool activates the heating coils, melting the inner surface of the fitting and the outer surface of the pipe. As the materials cool, they fuse together to form a strong, homogenous joint suitable for high-pressure and underground applications.

[0004] Current electrofusion tools face several practical challenges in the field. Most units rely on AC power, which may not be readily available at remote or outdoor job sites, limiting their usability. Battery-powered alternatives are generally not feasible due to concerns over limited capacity and range anxiety during extended operations. Additionally, these tools often lack intuitive interfaces or real-time feedback mechanisms, making it difficult for users to monitor welding status, troubleshoot issues, or confirm successful joint completion.

[0005] Despite their effectiveness in joining polyethylene (PE) pipes, current electrofusion tools face several practical challenges in the field. Most units rely on AC power, which may not be readily available at remote or outdoor job sites, limiting their usability. Battery-powered1MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 alternatives are generally not feasible due to concerns over limited capacity and range anxiety during extended operations. Additionally, these tools often lack intuitive interfaces or real-time feedback mechanisms, making it difficult for users to monitor welding status, troubleshoot issues, or confirm successful j oint completion.

[0006] Accordingly, there is a need for an electrofusion tool that is battery-operated, minimizes concerns about unexpected power loss during operation, and provides clear, accessible status information to the user throughout the welding process.

[0007] In some aspects, the techniques described herein relate to an electrofusion tool used in joining pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the electrofusion tool including: a housing; a battery interface on the housing and configured to removably receive a rechargeable battery pack; leads receptacles on the housing and configured to removably receive electrical leads to transfer current from the rechargeable battery pack to the electrical leads; an electronic display on the housing; and an electronic controller electrically coupled to the battery interface, the leads receptacles, and the electronic display, the electronic controller configured to: determine a state of charge of the rechargeable battery pack received at the battery interface; receive coupling data; determine a number of remaining fusions based on the state of charge and the coupling data; and display, on the electronic display, the number of remaining fusions based on the state of charge and the coupling data.

[0008] In some aspects, the techniques described herein relate to a method for operating an electrofusion tool to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the method including: determining, using an electronic controller of the electrofusion tool, a state of charge of a rechargeable battery pack received at a battery interface of the electrofusion tool; receiving, at the electronic controller, coupling data; determining, using the electronic controller, a number of remaining fusions based on the state of charge and the coupling data; and displaying, on an electronic display of the electrofusion tool, the number of remaining fusions based on the state of charge and the coupling data.

[0009] In some aspects, the techniques described herein relate to an electrofusion tool used in joining pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the electrofusion tool including: a housing; a battery interface on the housing and configured to2MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 removably receive a rechargeable battery pack; leads receptacles on the housing and configured to removably receive electrical leads to transfer current from the rechargeable battery pack to the electrical leads; a full color electronic display on the housing; a start button on the housing configured to be actuable by a user; and an electronic controller electrically coupled to the battery interface, the leads receptacles, the start button, and the full color electronic display, the electronic controller configured to: detect actuation of the start button; provide a fusion current from the rechargeable battery pack received at the battery interface in response to detecting actuation of the start button; display, on the full color electronic display, fusion data while providing the fusion current; display, on the full color electronic display, a red background color when displaying the fusion data; display, on the full color electronic display, cooling data after the fusion current is stopped; and display, on the full color electronic display, a blue background color when displaying the cooling data.

[0010] In some aspects, the techniques described herein relate to a method for operating an electrofusion tool to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the method including: detecting, using an electronic controller of the electrofusion tool, actuation of a start button on the electrofusion tool; providing, using the electronic controller via electrical leads, a fusion current from a rechargeable battery pack received at a battery interface of the electrofusion tool in response to detecting actuation of the start button; displaying, on a full color electronic display of the electrofusion tool, fusion data while providing the fusion current; displaying, on the full color electronic display, a red background color when displaying the fusion data; displaying, on the full color electronic display, cooling data after the fusion current is stopped; and displaying, on the full color electronic display, a blue background color when displaying the cooling data.

[0011] In some aspects, the techniques described herein relate to an electrofusion tool used in joining pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the electrofusion tool including: a housing; a battery interface on the housing and configured to removably receive a rechargeable battery pack; leads receptacles on the housing and configured to removably receive electrical leads to transfer current from the rechargeable battery pack to the electrical leads; a start button on the housing configured to be actuable by a user; an electronic display on the housing; and an electronic controller electrically coupled to the battery interface,3MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 the leads receptacles, the start button, and the electronic display, the electronic controller configured to: detect actuation of the start button; provide a fusion current from the rechargeable battery pack received at the battery interface in response to detecting actuation of the start button; display, on the electronic display, a fusion countdown from a fusion time in response to detecting actuation of the start button; and display, on the electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.

[0012] In some aspects, the techniques described herein relate to a method for operating an electrofusion tool to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the method including: detecting, using an electronic controller of the electrofusion tool, actuation of a start button on the electrofusion tool; providing, via electrical leads of the electrofusion tool, a fusion current from a rechargeable battery pack received at a battery interface of the electrofusion tool in response to detecting actuation of the start button; displaying, on an electronic display of the electrofusion tool, a fusion countdown from a fusion time in response to detecting actuation of the start button; and displaying, on the electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a perspective view of an electrofusion tool in accordance with some embodiments.

[0014] FIG. 2 is another perspective view of the electrofusion tool of FIG. 1, illustrating a user interface and electrical leads electrically connectable to a pipe fitting in accordance with some embodiments.

[0015] FIG. 3 is another perspective view of the electrofusion tool of FIG. 1, illustrating the user interface in accordance with some embodiments.

[0016] FIG. 4 is a plan view of the electrofusion tool of FIG. 1, illustrating the user interface in accordance with some embodiments.4MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0017] FIG. 5 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0018] FIG. 6 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0019] FIG. 7 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0020] FIG. 8 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0021] FIG. 9 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0022] FIG. 10 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0023] FIG. 11 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0024] FIG. 12 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0025] FIG. 13 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0026] FIG. 14 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0027] FIG. 15 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0028] FIG. 16 illustrates various aspects and functionality of the user interface in accordance with some embodiments.5MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0029] FIG. 17 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0030] FIG. 18 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0031] FIG. 19 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0032] FIG. 20 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0033] FIG. 21 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0034] FIG. 22 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0035] FIG. 23 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0036] FIG. 24 illustrates various aspects and functionality of the user interface in accordance with some embodiments.

[0037] FIG. 25 is a simplified block diagram of the electrofusion tool of FIG. 1 in accordance with some embodiments.

[0038] FIG. 26 is a flowchart of a method for operating the electrofusion tool of FIG. 1 to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process.

[0039] FIG. 27 is a flowchart of a method for operating the electrofusion tool of FIG. 1 to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process.

[0040] FIG. 28 is a flowchart of a method for operating the electrofusion tool of FIG. 1 to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process.6MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001DETAILED DESCRIPTION

[0041] FIG. 1 illustrates a battery-operated electrofusion tool 10 including a housing 12. The electrofusion tool 10 includes electrical leads 14 (FIG. 2) extending from the electrofusion tool 10 and a battery pack 18 that is selectively coupled to a power module 16 of the electrofusion tool 10. The power module 16 includes a battery interface (i.e., on the housing 12) configured to removably receive the battery pack 18. The battery pack 18 is, for example, a lithium-ion chemistry based rechargeable battery pack having a nominal voltage of about 72 Volts, the battery pack 18 may have different chemistries or nominal voltages. The battery pack 18 provides power to the electrofusion tool 10 and voltage across the electrical leads 14 through the power module 16. The battery pack 18 is disposed within a battery compartment 19 via a door 20 that is closable with an over-center latch 21. In other embodiments, the electrofusion tool 10 may be powered from a wall outlet or other suitable power source. A scanner 22 (FIG. 3) is connected to the electrofusion tool 10 for scanning a barcode encoded with pipe fitting characteristics (e.g., voltage required, voltage time, curing time, etc.) of a pipe fitting. In one example, the electrofusion tool 10 includes an interface to receive a connection to the scanner 22. In another examples, the scanner 22 is a wireless scanner which may be connected using a wireless interface of the electrofusion tool 10.

[0042] With reference to FIGS. 1-3, the scanner 22 and the electrical leads 14 may be stored in a storage compartment 26 of the electrofusion tool 10. The electrofusion tool 10 includes a leads receptacles 15 on the housing 12 configured to removably receive the electrical leads 14 such that the electrical leads 14 may be disconnected and stored in the storage compartment 26 when not in use. The leads receptacles 15 transfer current from the rechargeable battery pack 18 to the electrical leads 14. The storage compartment 26 may be opened and accessible by a user by opening a door 30. The door 30 may be maintained in a closed position via an over-center latch 34 (FIG. 2). A user may grasp a handle 38 to carry and maneuver the electrofusion tool 10 around a jobsite.

[0043] As shown in FIGS 2-4, a user interface 42 is disposed within the storage compartment 26. The user interface 42 controls the electrofusion tool 10 and the electrofusion process. The user interface 42 includes an electronic display 46 (e.g., LCD display, LED display, or the like),7MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 a depressible power button 50, a controller D-pad 54 (e.g., navigation buttons), an emergency stop switch 58, a start fusion button 62, and a stop fusion button 66. The emergency stop switch 58 may be pressed in case of an emergency to manually shutdown the electrofusion tool 10. The emergency stop switch 58 can be pressed again to turn the electrofusion tool 10 on again. In other words, the emergency stop switch 58 is a kill switch. The power button 50, on the other hand, is depressible to arm the battery pack 18 and boot up the electrofusion tool 10. The power button 50 includes a back-lit LED to illuminate the power button 50. The D-pad 54 includes an up arrow, a down arrow, a right arrow, a left arrow, and a confirmation button. The arrows move the cursor (FIG. 7, 10-21) through various menus and the confirmation button allows the user to confirm inserted data, move forward or backward a step, selects output, and other similar actions. However, the confirmation button does not start a fusion process. A fusion process may commence via the start fusion button 62, at which point an audio tone with alarm. To stop / cancel a fusion process, the stop fusion button 66 may be pressed, at which point an alarm tone with alarm.

[0044] The size of the illustrated electronic display 46 is approximately 55.5 millimeters in width and 42.8 millimeters in height, while in other embodiments, the electronic display 46 may be a different size. More specific dimensions of the various menus within the electronic display 46 are detailed in FIG. 7. For example, any given cell being selected is approximately 55.5 millimeters in width and 5.7 millimeters in height. The electronic display 46 may also display various icons, such as those shown in FIG. 8. The electronic display 46 may be a full color display as shown in FIGS. 5-24.

[0045] The user interface 42 also includes a battery life indicator 70 to display to a user the remaining battery life of the battery pack 18. The battery life indicator 70 includes four red LEDs, where all four LEDs lit up is indicative of a 77%-100% battery life, three LEDs lit up is indicative of a 55%-77% battery life, two LEDs lit up is indicative of a 32%-55% battery life, and one LEDs lit up is indicative of a 10%-32% battery life. One blinking LED at a first rate (4 times, 2 Hz) is indicative of a 0%-10% battery life, whereas one blinking LED at a second, faster rate (8 times, 4 Hz) is indicative of less than 0% battery life.8MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0046] The scanner 22 has its own battery charge status 74 (FIG. 6). A green LED is lit when the scanner 22 has 26%-100% battery life, a yellow LED is lit when the scanner 22 has 11%-25% battery life, and a red LED lit when the scanner 22 has 3%- 10% battery life. When the battery life is less than 3%, the red LED blinks. If a fault is triggered, the LED blinks in an alternating fashion between red and green. During charging, the LED may have breathing cycle such that the LED is solid for 300 milliseconds (ms) and fades on and off for 270 ms. When an overtemperature condition is detected, the LED blinks between red and off.

[0047] Regarding the layout of the user interface 42, the electronic display 46 and the D-pad 54 are adjacent each other and disposed below (from the frame of reference of FIG. 4) both the power button 50 and the battery life indicator 70. Also, the start fusion button 62 and the stop fusion button 66 are below both the electronic display 46 and the D-pad 54. As such, the electronic display 46 and the D-pad 54 are disposed between the power button 50 / battery life indicator 70 and the start fusion button 62 / stop fusion button 66. A Bluetooth connectivity (i.e., One-Key™) indicator 78 with back-lit LED. The electronic display 46, the power button 50, the D-pad 54, the start fusion button 62, and the stop fusion button 66 are all disposed on a user interface panel 82. The Bluetooth connectivity indicator 78 is also disposed on the user interface panel 82. However, the emergency stop switch 58 is not disposed on the user interface panel 82. Instead, the emergency stop switch 58 is disposed immediately adjacent to the user interface panel 82.

[0048] FIG. 25 is a simplified block diagram of the electrofusion tool 10 of FIG. 1, according to some embodiments. The electrofusion tool 10 includes a controller 100 (e.g., an electronic controller). The controller 100 is electrically and / or communicatively connected to a variety of modules or components of the electrofusion tool 10. For example, the illustrated controller 100 is electrically connected to a battery interface 105, leads receptacles 15, user inputs 110, one or more sensors or sensing circuits 115, one or more indicators 120, the electronic display 46, a power input 125, and a switching network 130. The controller 100 includes combinations of hardware and software that are operable to, among other things, control the operation of the electrofusion tool 10, monitor the operation of the electrofusion tool 10 using, for example, the one or more sensors or sensing circuits, activate the one or more indicators 120 (e.g., an LED, an audio output device, etc ), provide status indications on the electronic display 46, and / or the like.9MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0049] The controller 100 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 100 and / or the electrofusion tool 10. For example, the controller 100 includes, among other things, a processing unit 135 (e.g., a microprocessor, a microcontroller, or another suitable programmable device), a memory 140, input units 145, and output units 150. The processing unit 135 includes, among other things, a control unit 155, an ALU 160, and a plurality of registers 165 (shown as a group of registers in FIG. 25) and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.). The processing unit 135, the memory 140, the input units 145, and the output units 150, as well as the various modules or circuits connected to the controller 100 are connected by one or more control and / or data buses (e.g., common bus 170). The control and / or data buses are shown generally in FIG. 25 for illustrative purposes. The use of one or more control and / or data buses for the interconnection between and communication among the various modules, circuits, and components would be known to a person skilled in the art.

[0050] The memory 140 is a non-transitory computer readable medium and includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as a ROM, a RAM (e g., DRAM, SDRAM, etc ), EEPROM, flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic memory devices. The processing unit 135 is connected to the memory 140 and executes software instructions that are capable of being stored in a RAM of the memory 140 (e.g., during execution), a ROM of the memory 140 (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. Software included in the implementation of the electrofusion tool 10 can be stored in the memory 140 of the controller 100. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 100 is configured to retrieve from the memory 140 and execute, among other things, instructions related to the control processes and methods described herein. In other constructions, the controller 100 includes additional, fewer, or different components.10MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0051] In some embodiments, the electrofusion tool 10 includes the battery interface 105 including a combination of mechanical components (e.g., rails, grooves, latches, etc.) and electrical components (e.g., one or more terminals) configured to and operable for interfacing (e.g., mechanically, electrically, and communicatively connecting) the electrofusion tool 10 with the battery pack 18. For example, power provided by the battery pack 18 to the electrofusion tool 10 is provided through the battery interface 105 to the power input 125. The power input 125 includes combinations of active and passive components to regulate or control the power received from the battery pack 18 prior to power being provided to the controller 100. The battery interface 105 also supplies power via the power input 125 to the switching network 130 to provide power to the leads 14 via the leads receptacles 15. The battery interface 105 also includes, for example, a communication line 175 for providing a communication line or link between the controller 100 and the battery pack 18.

[0052] The user inputs 110 include, for example, the power button 50, the controller D-pad 54, the emergency stop switch 58, the start fusion button 62, the stop fusion button 66, and or the like. When either of these switches / buttons is actuated or released, a corresponding signal is received by the controller 100 to perform the related action. In some examples, certain switches / buttons may be connected directly to relays that provide or interrupt power from the power input 125 to the leads 14 and / or the controller 100. The one or more sensors 115 include, for example, a voltage sensor, a temperature sensor, a current sensor, or the like. The indicators 120 include, for example, the one or more light-emitting diodes (“LEDs”), an audio output device, or the like described above. The indicators 120 can be configured to display conditions of, or information associated with, the electrofusion tool 10. In one example, the indicators 120, for example, an audio output device, can be used to play audio tones to provide warnings or status updates.

[0053] The switching network 130 provides operating power to the leads 14 based on control signals from the controller 100. The switching network 130 includes one or more electronic switches (e.g., FETs, bipolar junction transistors, and the like) that controls the current flow to the leads 14 based on, for example, pulse-width modulated (PWM) signals. The switching network 130 is electrically connected to the leads 14 via the leads receptacles 15. The switching network 130 is also electrically and communicatively connected to the controller 100.11MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0054] FIG. 9 illustrates example audio tones provided during various operations of the electrofusion tool 10 via the audio output device. When the start fusion button 62 is actuated, the controller plays a first audio tone 905 at a frequency of about 3 kHz for about 500 milliseconds. The fusion process begins (i.e., current is provided) after the audio tone ends. Three seconds before fusion is completed and cooling beings, the controller 100 provides audio tones 910 at a frequency of about 3 kHz at a 75% duty cycle (for example, on for 750 ms and off for 250 ms). The audio tones 910 are repeated until the cooling period ends. When the stop fusion button 66 is actuated, the controller 100 provides a second audio tone 915 at a frequency of about 3 kHz for about 500 ms. For any fault, warning, or other alerts, the controller 100 may provide audio tones 920 at a frequency of about 3 kHz. The audio tones 920 include three tones that are played for 450 ms each with a gap of 135ms between each tone. The controller 100 plays a final tone after the three tones for 1 second. Referring to FIG. 22, the audio tones 920 may be provided in conjunction with on screen icons.

[0055] FIG. 10 illustrates an example process 1000 for initializing the electrofusion tool 10. As shown in FIG. 10, initially the electronic display 46 is blank or unpowered (at step 1002) until the power button 50 is actuated. When the power button 50 is actuated, controller 100 displays a welcome screen (at step 1004), and a language selection screen (at step 1006) in succession on a white background on the electronic display 46. A user may navigate through the language selection screen and select a language using the D-Pad 54. After the language selection, the controller 100 displays a date setting screen (at step 1008) on the electronic display 46. The user may set the date using the D-Pad 54. Once the language and date are set, the electrofusion tool 10 may be operated for pipe fittings. The controller 100 provides an instruction to scan the barcode on the fitting and / or connect electrical leads 14 (at step 1010) on the electronic display 46.

[0056] FIG. 11 illustrates an example process 1100 for operating the electrofusion tool 10 to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process. As shown in FIG. 11, initially the electronic display 46 is blank or unpowered (at step 1102) until the power button 50 is actuated. When the power button 50 is actuated, controller 100 displays a welcome screen (at step 1104), and one or more warnings (at step 1106) in succession on a red background on the electronic display 46. FIG. 15 illustrates one example of a warning provided12MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 on the electronic display 46. The electrofusion tool 10 may need to be calibrated at regular intervals. The calibration may have an expiration date. The controller 100 provides the warnings 1500, for example, at 90 days before expiration and on the date of expiration. In some examples, the warning tone 920 may be played during these warning screens. The controller 100 may prevent fusion operation when the calibration has expired. Additional examples of warning provided are illustrated in FIG. 23.

[0057] Returning to FIG. 11, a user may navigate through the welcome screen and the warning screens using the D-Pad 54. After the warnings, the controller 100 may detect whether the electrical leads 14 are connected to the leads receptacle 15. The controller 100 provides an instruction to connect the leads (at step 1108) on the electronic display 46 when the controller 100 detects that the electrical leads 14 are not connected to the electrofusion tool 10. The controller 100 provides an instructions to scan the barcode on the fitting (at step 1108) on the electronic display 46. The instructions may be displayed at the same time as shown at step 1108.

[0058] As noted above, users of battery-powered electrofusion tools cannot reliably predict whether the tool will complete a job or stop midway due to battery depletion. As shown in FIG. 11, the controller 100 may use the electronic display 46 to provide an indication regarding the number of remining fusions. FIG. 26 illustrates a flowchart of an example method 200 for operating the electrofusion tool 10 to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process. The method 200 may be implemented by the controller 100 to provide the indication of number of remaining fusions. In the example illustrated, the method 200 includes determining, using the electronic controller 100, a state of charge of the battery pack 18 received at the battery interface 105 of the electrofusion tool 10 (at block 210). In one example, the controller 100 determines the state of charge by measuring a voltage of the battery pack 18 using a voltage sensor (e.g., one or more sensors 115) and determining the state of charge based on the voltage. In another example, the controller 100 receives the state of charge from a controller of the battery pack 18 via the communication line 175.

[0059] The method 200 includes receiving, at the controller 100, coupling data (at block 220). In one example, the scanner 22 is used to scan the barcode on a fitting. The controller 100 receives the barcode from the scanner 22 and determines the coupling data based on the13MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 information received from the barcode. In another example, a user may provide the coupling data manually using the user interface 42. The controller 100 may detect a selection for entering barcode information manually. As shown in FIG. 12, the user may use the D-Pad 54 to select “enter manually” option for the bar code at step 1108. The controller 100 may receive a barcode based on actuation of the D-pad 54. Referring to FIG. 12, the user may press up and down arrows to cycle through numbers 1-9 for each digit of the barcode displayed (at step 1200) on the electronic display 46. The user may press the left and right arrows to navigate to the previous and next digits. The controller 100 may determine the coupling data based on the barcode that was manually entered. When the barcode is fully entered, the option to confirm on the electronic display 46 may be highlighted. When the user selects the confirm (e.g., checkmark), the controller 100 uses the entered barcode to retrieve coupling data. The coupling data includes, for example, the amount of current and the fusion time needed to complete the fusion. Returning to FIG. 11, the controller 100 may display the coupling data (at step 1110) including the fusion time on the electronic display 46. In some examples, in addition to coupling data, the controller 100 may also receive an operator ID (e.g., badge ID) and a job number from the user as shown in FIG. 13. The operator ID identifies an operator of the electrofusion tool 10 to ensure that the operator has the required training and is working within a required schedule. The job number may be the number of jobs performed during an operators shift. The operator ID may be scanned using the scanner 22, for example, by scanning a barcode on a badge of the operator. The job number may be manually entered using the D-Pad 54 and / or may be scanned using stickers. A traceability code may also be scanned using the scanner 22 and / or entered manually using the D- Pad 54 as shown in FIG. 14.

[0060] The method 200 also includes determining, using the electronic controller 100, a number of remaining fusions based on the state of charge and the coupling data (at block 230). The number of remaining fusions can be determined by calculating the rate of depletion of the state of charge per job and using the rate of depletion to calculate the number of remaining fusions. The method 200 includes displaying, on an electronic display 46, the number of remaining fusions based on the state of charge and the coupling data (at block 240). The controller 100 causes the electronic display 46 to display the number of fusions. In some examples, the controller 100 prevents a start of the fusion if the SOC of the battery pack does not support a completion of the fusion process. For example, the fusion process may be stopped14MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 even when the discharge from the battery pack is not stopped due to a low SOC condition when the SOC does not support completion of the current operation. Returning to FIG. 11, the controller 100 displays the remaining fusions at step 1110. The user may navigate back to the previous screens using the D-Pad 54. At step 1110, the electronic display 46 may include the barcode number, the fitting type / manufacturer, the voltage and amperage to complete the fitting, the ambient temperature, the fusion time, and the number of fusions remaining based on SOC. At step 1110 the coupling data may be displayed on a white background (e.g., first background color). Referring to FIG. 16, the traceability code, the operator ID, and the job number may be provided before the coupling data is displayed. The traceability code, the operator ID, and the job number may be optional features that can be toggled on and off from the main menu as shown in FIG. 20.

[0061] When using electrofusion tools, users typically initiate the fusion process and then proceed to perform other tasks while the fusion completes. However, there is currently no convenient or reliable way for users to determine when the fusion process has finished. This lack of visibility can lead to inefficiencies, delays, or missed opportunities to promptly inspect or proceed with subsequent steps in the workflow. FIG. 27 illustrates a flowchart of an example method 300 for operating the electrofusion tool 10 to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process. The method 300 may be implemented by the controller 100. In the example illustrated, the method 300 includes detecting, using the electronic controller 100, actuation of the start fusion button 62 (at block 310). Returning to FIG. 11, the user may actuate the start fusion button 62 after step 1110.

[0062] The method 300 includes providing, using the electronic controller 100 via the electrical leads 14, a fusion current from the battery pack 18 in response to detecting actuation of the start fusion button 62 (at block 320). The electronic controller 100 controls the switching network 130 to provide the desired amount of current for the fusion time based on the coupling data. The electronic controller 100 generates PWM signal (s) to control the switching circuit to provide the fusion current.

[0063] The method 300 includes displaying, on the electronic display 46, fusion data while providing the fusion current (at block 330). As shown in FIG. 11, the controller 100 displays the15MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 fusion data (at step 11 14) on the electronic display 46 in response to start of the fusion process. The fusion data may be similar to the coupling data as displayed at step 1114. In some examples, the fusion data may additionally display a fusion status (e.g., fusion in progress, cooling, complete, etc.). The method 300 includes displaying, on the electronic display 46, a red background color when displaying the fusion data (at block 340). As shown in FIG. 11, the controller 100 displays the fusion data on a red background. During the fusion process, a user may cancel the fusion process by actuating the cancel button 66. When the cancel button 66 is actuated, the controller 100 cancels the fusion process and displays a fusion warning (at step 1116). The fusion process may also be canceled by pulling the electrical leads 14 from the leads receptacle 15. The controller 100 cancels the fusion process and displays a leads warning (at step 1118) when the electrical leads 14 are detected as being removed. When the fusion time is complete, the controller 100 stops the fusion current and displays a complete screen on the red background for a small amount of time (e.g., 2 seconds). The controller 100 may also play an audio tone when the fusion current is stopped.

[0064] The method 300 includes displaying, on the electronic display 46, cooling data after the fusion current is stopped (at block 350). When the fusion is complete, the controller 100 stops the fusion current and displays the cooling data (at step 1120). The cooling data may display a countdown of the cooling time. The method 300 includes displaying, on the electronic display 46, a blue background color when displaying the cooling data (at block 360). As shown in FIG. 11, the controller 100 displays the cooling data on a blue background. The red-blue contrast allows a user to clearly know the current status of the fusion process even from a distance without needing to read the small print on the electrofusion tool 10. During the cooling process, a user may cancel the fusion process by actuating the cancel button 66. When the cancel button 66 is actuated, the controller 100 cancels the cooling process and displays a cooling warning (at step 1122) and may also provide an audio tone. The cooling process may also be canceled by pulling the electrical leads 14 from the leads receptacle 15. The controller 100 cancels the cooling process and displays a leads warning (at step 1124) when the electrical leads 14 are detected as being removed. When the cooling time is complete, the controller 100 may display a complete screen (at step 1126) on the electronic display 46 for an amount of time and may return to step 1108. In some examples, the main menu of the electrofusion tool 10 may be inaccessible during certain steps. During the inaccessible times, the opaqueness of the main16MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 menu option may be decreased, for example, from 100% white to 40% white as shown at step 1112.

[0065] FIG. 28 illustrates a flowchart of an example method 400 for operating the electrofusion tool 10 to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process. The method 400 may be implemented by the controller 100. In the example illustrated, the method 400 includes detecting, using the electronic controller 100, actuation of the start fusion button 62 (at block 410) and providing, using the electronic controller 100 via the electrical leads 14, a fusion current from the battery pack 18 in response to detecting actuation of the start fusion button 62 (at block 420). The electronic controller 100 controls the switching network 130 to provide the desired amount of current for the fusion time based on the coupling data in response to actuation of the start fusion button 62. The electronic controller 100 generates PWM signal(s) to control the switching circuit to provide the fusion current.

[0066] The method 400 includes displaying, on the electronic display 46, a fusion countdown from a fusion time in response to detecting actuation of the start button (at block 430). As shown in FIG. 11, the controller 100 displays a fusion countdown (at step 1114) on the electronic display 46 in response to start of the fusion process. The fusion countdown counts down time from the fusion time. The countdown may be updated every second. The countdown timer may be displayed in addition to the other fusion data on the electronic display 46. The method 400 includes displaying, on the electronic display 46, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown (at block 440). As shown in FIG. 11, the controller 100 displays the fusion progress bar below the fusion countdown (at step 1114). Updating the fusion progress bar may include filling or depleting the progress bar according to the fusion countdown. In the example illustrated, the fusion progress bar is filled according to the fusion countdown. That is, as the time is being counted down, the fusion progress bar is filled. In some examples, the controller 100 outputs, using the audio output device (e.g., the indicator(s) 120), a fusion complete audio tone in response to completion of the fusion countdown.17MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0067] In some example, a cooling countdown and a cooling progress bar are similarly provided during the cooling process. The controller displays a cooling countdown on the electronic display 46 in response to start of the cooling process. The cooling countdown counts down time from the cooling time. The countdown may be updated every second. The countdown timer may be displayed in addition to the other cooling data on the electronic display 46. In some examples, the controller 100 may display, on the electronic display 46, a cooling time for a predetermined amount of time before displaying the cooling countdown and after completion of the fusion countdown. The controller 100 also displays, on the electronic display 46, a cooling progress bar corresponding to the cooling countdown such that the cooling progress bar is updated according to the cooling countdown. As shown in FIG. 11, the controller 100 displays the cooling progress bar below the cooling countdown (at step 1120). Updating the cooling progress bar may include filling or depleting the progress bar according to the cooling countdown. In the example illustrated, the cooling progress bar is filled according to the cooling countdown. That is, as the time is being counted down, the cooling progress bar is filled. In some examples, the controller 100 outputs, using the audio output device (e.g., the indicator(s) 120), a cooling complete audio tone in response to completion of the cooling countdown.

[0068] In some examples, the fusion time may be updated based on the capabilities of the electrofusion tool 10. Referring to FIG. 17, the controller 100 displays the fusion time as a nominal fusion time corresponding to the coupling data before the start fusion button 62 is actuated on the electronic display 46 (at step 1710). When the start fusion button 62 is actuated, the controller 100 automatically (i.e., without user intervention) updates the fusion time. The controller 100 may determine an adjusted fusion time different from the nominal fusion time based on one or more parameters of the battery pack 18. The controller 100 displays the fusion time as an adjusted fusion time in response to detecting actuation of the start button on the electronic display 46 (at step 1720). The fusion countdown is performed from the adjusted fusion time (at step 1730). The adjusted fusion time may be displayed before the countdown is started and before the fusion current is provided to the electrical leads 14. In some examples, the cooling time may also be adjusted similarly. When a cooling time is not specified, the controller 100 displays an instruction to check fitting manufacture for cooling time (at step 1740). The controller 100 may use a default cooling time when a cooling time is not specified.18MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001

[0069] In some examples, the scanner 22 is a wireless scanner that communicates with the electrofusion tool 10 using a Bluetooth connection. In these examples, the wireless scanner can be paired with the electrofusion tool 10 by displaying a barcode on the electronic display 46 as shown in FIG. 20. Referring to FIG. 24, a first icon 2400 is shown when the scanner 22 when the scanner is connected and a second icon 2410 is shown when the scanner 22 is disconnected or cannot be found.

[0070] In some examples, the electrofusion tool 10 may log each job in the memory 140 or in a removable memory. Referring to FIG. 18, the controller may provide a warning when the fusion log is full. The fusion log can be exported to an external device (e.g., USB drive) or deleted from memory. Referring to FIG. 19, the fusion log can be accessed using a fusion history option. In some examples, only some of the previous fusion logs can be exported rather than all of the logs of stored on the electrofusion tool 10. An about screen maybe displayed to show details of the electrofusion tool 10 and any corresponding firmware. In some examples, the operator ID may be toggled between ON, OFF, and LOG ONLY. When LOG ONLY is selected, the operator ID may be needed only when accessing or exporting the fusion log. As shown in FIG. 21, various settings of the electrofusion tool 10 can be adjusted using the setting menu. Referring to FIG. 24, an additional warning may be provided when the electrical leads 14 are not removed after each job and the user may be prevented from selecting the “start new fusion” operation until the electrical leads 14 are removed.19MBF\066042\2014\41533280. v2- 10 / 1 / 25

Claims

Attorney Docket No. 066042-2014-W001CLAIMS1. An electrofusion tool used in joining pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the electrofusion tool comprising: a housing; a battery interface on the housing and configured to removably receive a rechargeable battery pack; leads receptacles on the housing and configured to removably receive electrical leads to transfer current from the rechargeable battery pack to the electrical leads; an electronic display on the housing; and an electronic controller electrically coupled to the battery interface, the leads receptacles, and the electronic display, the electronic controller configured to: determine a state of charge of the rechargeable battery pack received at the battery interface; receive coupling data; determine a number of remaining fusions based on the state of charge and the coupling data; and display, on the electronic display, the number of remaining fusions based on the state of charge and the coupling data.

2. The electrofusion tool of claim 1, further comprising: an interface configured to connect to a barcode scanner, wherein the electronic controller is electrically connected to the interface and further configured to: receive, via the interface, a barcode from the barcode scanner; and determine the coupling data based on the barcode.

3. The electrofusion tool of claim 1, wherein the electronic display is a full color electronic display, and wherein the electronic controller is further configured to display the coupling data on the electronic display.

4. The electrofusion tool of claim 3, wherein the electronic controller is further configured to:20MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 determine a fusion time based on the coupling data; and display, on the electronic display, the fusion time.

5. The electrofusion tool of claim 4, further comprising: a start button on the housing configured to be actuable by a user, wherein the electronic controller is electrically coupled to the start button and further configured to: detect actuation of the start button after display of the coupling data; provide a fusion current from the rechargeable battery pack received at the battery interface in response to detecting actuation of the start button; and display, on the electronic display, a fusion countdown from the fusion time in response to detecting actuation of the start button.

6. The electrofusion tool of claim 5, wherein the electronic controller is further configured to: display, on the electronic display, the fusion time as a nominal fusion time corresponding to the coupling data before the start button is actuated; determine an adjusted fusion time different from the nominal fusion time based on one or more parameters of the rechargeable battery pack received at the battery interface; and display, on the electronic display, the fusion time as an adjusted fusion time in response to detecting actuation of the start button, wherein the fusion countdown is performed from the adjusted fusion time.

7. The electrofusion tool of claim 5, further comprising an audio output device, wherein the electronic controller is electrically coupled to the audio output device and configured to: output, using the audio output device, a fusion complete audio tone in response to completion of the fusion countdown.

8. The electrofusion tool of claim 5, wherein the electronic controller is further configured to: display, on the electronic display, a first background color when displaying the coupling data; and21MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 display, on the electronic display, a red background color when displaying the fusion countdown, wherein the first background color is different from the red background color.

9. The electrofusion tool of claim 5, wherein the electronic controller is further configured to: display, on the electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.

10. The electrofusion tool of claim 8, wherein the electronic controller is further configured to: display, on the electronic display, a cooling countdown from a cooling time; display, on the electronic display, a blue background color when displaying the cooling time; and display, on the electronic display, a cooling progress bar corresponding to the cooling countdown such that the cooling progress bar is updated according to the cooling countdown.

11. The electrofusion tool of claim 10, wherein the electronic controller is further configured to: display, on the electronic display, the cooling time for a predetermined amount of time before displaying the cooling countdown and after completion of the fusion countdown.

12. The electrofusion tool of claim 10, further comprising an audio output device, wherein the electronic controller is electrically coupled to the audio output device and configured to: output, using the audio output device, a cooling complete audio tone in response to completion of the cooling countdown.

13. The electrofusion tool of claim 1, further comprising: navigation buttons provided on the housing adjacent the electronic display, the navigation buttons configured to be actuated by a user, wherein the electronic controller is further configured to: detect a selection for entering barcode information manually;22MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 receive a barcode based on actuation of the navigation buttons; and determine the coupling data based on the barcode.

14. A method for operating an electrofusion tool to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the method comprising: determining, using an electronic controller of the electrofusion tool, a state of charge of a rechargeable battery pack received at a battery interface of the electrofusion tool; receiving, at the electronic controller, coupling data; determining, using the electronic controller, a number of remaining fusions based on the state of charge and the coupling data; and displaying, on an electronic display of the electrofusion tool, the number of remaining fusions based on the state of charge and the coupling data.

15. The method of claim 14, further comprising: receiving, via an interface, a barcode from a barcode scanner; and determining, using the electronic controller, the coupling data based on the barcode.

16. The method of claim 14, wherein the electronic display is a full color electronic display, the method further comprising: displaying the coupling data on the electronic display.

17. The method of claim 16, further comprising: determining, using the electronic controller, a fusion time based on the coupling data; and displaying, on the electronic display, the fusion time.

18. The method of claim 17, further comprising: detecting, using the electronic controller, actuation of a start button on the electrofusion tool after display of the coupling data; providing, via electrical leads, a fusion current from the rechargeable battery pack in response to detecting actuation of the start button; and23MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 displaying, on the electronic display, a fusion countdown from the fusion time in response to detecting actuation of the start button.

19. The method of claim 18, further comprising: displaying, on the electronic display, the fusion time as a nominal fusion time corresponding to the coupling data before the start button is actuated; determining, using the electronic controller, an adjusted fusion time different from the nominal fusion time based on one or more parameters of the rechargeable battery pack; and displaying, on the electronic display, the fusion time as an adjusted fusion time in response to detecting actuation of the start button, wherein the fusion countdown is performed from the adjusted fusion time.

20. The method of claim 18, further comprising: outputting, using an audio output device of the electrofusion tool, a fusion complete audio tone in response to completion of the fusion countdown.

21. The method of claim 18, further comprising: displaying, on the electronic display, a first background color when displaying the coupling data; and displaying, on the electronic display, a red background color when displaying the fusion countdown, wherein the first background color is different from the red background color.

22. The method of claim 18, further comprising: displaying, on the electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.

23. The method of claim 22, further comprising: displaying, on the electronic display, a cooling countdown from a cooling time; displaying, on the electronic display, a blue background color when displaying the cooling time; and24MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 displaying, on the electronic display, a cooling progress bar corresponding to the cooling countdown such that the cooling progress bar is updated according to the cooling countdown.

24. The method of claim 23, further comprising: displaying, on the electronic display, the cooling time for a predetermined amount of time before displaying the cooling countdown and after completion of the fusion countdown.

25. The method of claim 23, further comprising: outputting, using an audio output device of the electrofusion tool, a cooling complete audio tone in response to completion of the cooling countdown.

26. The method of claim 14, further comprising: detecting, using the electronic controller, a selection for entering barcode information manually; receiving, at the electronic controller, a barcode based on actuation of navigation buttons provided on the electrofusion tool; and determining, using the electronic controller, the coupling data based on the barcode.

27. An electrofusion tool used in joining pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the electrofusion tool comprising: a housing; a battery interface on the housing and configured to removably receive a rechargeable battery pack; leads receptacles on the housing and configured to removably receive electrical leads to transfer current from the rechargeable battery pack to the electrical leads; a full color electronic display on the housing; a start button on the housing configured to be actuable by a user; and an electronic controller electrically coupled to the battery interface, the leads receptacles, the start button, and the full color electronic display, the electronic controller configured to: detect actuation of the start button;25MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 provide a fusion current from the rechargeable battery pack received at the battery interface in response to detecting actuation of the start button; display, on the full color electronic display, fusion data while providing the fusion current; display, on the full color electronic display, a red background color when displaying the fusion data; display, on the full color electronic display, cooling data after the fusion current is stopped; and display, on the full color electronic display, a blue background color when displaying the cooling data.

28. The electrofusion tool of claim 27, wherein the electronic controller is further configured to: receive coupling data; display, on the full color electronic display, the coupling data; and display, on the full color electronic display, a first background color when displaying the coupling data, wherein the first background color is different from the red background color and the blue background color.

29. The electrofusion tool of claim 28, further comprising: an interface configured to connect to a barcode scanner, wherein the electronic controller is electrically connected to the interface and further configured to: receive, via the interface, a barcode from the barcode scanner; and determine the coupling data based on the barcode.

30. The electrofusion tool of claim 28, further comprising: navigation buttons provided on the housing adjacent the full color electronic display, the navigation buttons configured to be actuated by a user, wherein the electronic controller is further configured to: detect a selection for entering barcode information manually; receive a barcode based on actuation of the navigation buttons; and26MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 determine the coupling data based on the barcode.

31. The electrofusion tool of claim 28, wherein the electronic controller is further configured to: determine a fusion time based on the coupling data; display, on the full color electronic display, the fusion time before detecting actuation of the start button; and display, on the full color electronic display, a fusion countdown from the fusion time in response to detecting actuation of the start button, wherein the fusion data includes the fusion countdown.

32. The electrofusion tool of claim 31, wherein the electronic controller is further configured to: display, on the full color electronic display, the fusion time as a nominal fusion time corresponding to the coupling data before the start button is actuated; determine an adjusted fusion time different from the nominal fusion time based on one or more parameters of the rechargeable battery pack received at the battery interface; and display, on the full color electronic display, the fusion time as an adjusted fusion time in response to detecting actuation of the start button, wherein the fusion countdown is performed from the adjusted fusion time.

33. The electrofusion tool of claim 31, further comprising an audio output device, wherein the electronic controller is electrically coupled to the audio output device and configured to: output, using the audio output device, a fusion complete audio tone in response to completion of the fusion countdown.

34. The electrofusion tool of claim 31, wherein the electronic controller is further configured to: display, on the full color electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.27MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W00135. The electrofusion tool of claim 31, wherein the electronic controller is further configured to: display, on the full color electronic display, a cooling countdown from a cooling time, wherein the cooling data includes the cooling countdown; and display, on the full color electronic display, a cooling progress bar corresponding to the cooling countdown such that the cooling progress bar is updated according to the cooling countdown.

36. The electrofusion tool of claim 35, wherein the electronic controller is further configured to: display, on the full color electronic display, the cooling time for a predetermined amount of time before displaying the cooling countdown and after completion of the fusion countdown.

37. The electrofusion tool of claim 35, further comprising an audio output device, wherein the electronic controller is electrically coupled to the audio output device and configured to: output, using the audio output device, a cooling complete audio tone in response to completion of the cooling countdown.

38. A method for operating an electrofusion tool to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the method comprising: detecting, using an electronic controller of the electrofusion tool, actuation of a start button on the electrofusion tool; providing, using the electronic controller via electrical leads, a fusion current from a rechargeable battery pack received at a battery interface of the electrofusion tool in response to detecting actuation of the start button; displaying, on a full color electronic display of the electrofusion tool, fusion data while providing the fusion current; displaying, on the full color electronic display, a red background color when displaying the fusion data;28MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 displaying, on the full color electronic display, cooling data after the fusion current is stopped; and displaying, on the full color electronic display, a blue background color when displaying the cooling data.

39. The method of claim 38, further comprising: receiving, at the electronic controller, coupling data; displaying, on the full color electronic display, the coupling data; and displaying, on the full color electronic display, a first background color when displaying the coupling data, wherein the first background color is different from the red background color and the blue background color.

40. The method of claim 39, further comprising: receiving, via an interface, a barcode from a barcode scanner; and determining, using the electronic controller, the coupling data based on the barcode.

41. The method of claim 39, further comprising: detecting, using the electronic controller, a selection for entering barcode information manually; receiving, at the electronic controller, a barcode based on actuation of navigation buttons provided on the electrofusion tool; and determining, using the electronic controller, the coupling data based on the barcode.

42. The method of claim 39, further comprising: determining, using the electronic controller, a fusion time based on the coupling data; displaying, on the full color electronic display, the fusion time before detecting actuation of the start button; and displaying, on the full color electronic display, a fusion countdown from the fusion time in response to detecting actuation of the start button, wherein the fusion data includes the fusion countdown.29MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W00143. The method of claim 42, further comprising: displaying, on the full color electronic display, the fusion time as a nominal fusion time corresponding to the coupling data before the start button is actuated; determining, using the electronic controller, an adjusted fusion time different from the nominal fusion time based on one or more parameters of the rechargeable battery pack; and displaying, on the full color electronic display, the fusion time as an adjusted fusion time in response to detecting actuation of the start button, wherein the fusion countdown is performed from the adjusted fusion time.

44. The method of claim 42, further comprising: outputting, using an audio output device of the electrofusion tool, a fusion complete audio tone in response to completion of the fusion countdown.

45. The method of claim 42, further comprising: displaying, on the full color electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.

46. The method of claim 42, further comprising: displaying, on the full color electronic display, a cooling countdown from a cooling time, wherein the cooling data includes the cooling countdown; and displaying, on the full color electronic display, a cooling progress bar corresponding to the cooling countdown such that the cooling progress bar is updated according to the cooling countdown.

47. The method of claim 46, further comprising: displaying, on the full color electronic display, the cooling time for a predetermined amount of time before displaying the cooling countdown and after completion of the fusion countdown.

48. The method of claim 46, further comprising:30MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 outputting, using an audio output device of the electrofusion tool, a cooling complete audio tone in response to completion of the cooling countdown.

49. An electrofusion tool used in joining pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the electrofusion tool comprising: a housing; a battery interface on the housing and configured to removably receive a rechargeable battery pack; leads receptacles on the housing and configured to removably receive electrical leads to transfer current from the rechargeable battery pack to the electrical leads; a start button on the housing configured to be actuable by a user; an electronic display on the housing; and an electronic controller electrically coupled to the battery interface, the leads receptacles, the start button, and the electronic display, the electronic controller configured to: detect actuation of the start button; provide a fusion current from the rechargeable battery pack received at the battery interface in response to detecting actuation of the start button; display, on the electronic display, a fusion countdown from a fusion time in response to detecting actuation of the start button; and display, on the electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.

50. The electrofusion tool of claim 49, wherein the electronic controller is further configured to: receive coupling data; determine a fusion time based on the coupling data; and display, on the electronic display, the fusion time.

51. The electrofusion tool of claim 50, further comprising:31MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 an interface configured to connect to a barcode scanner, wherein the electronic controller is electrically connected to the interface and further configured to: receive, via the interface, a barcode from the barcode scanner; and determine the coupling data based on the barcode.

52. The electrofusion tool of claim 50, further comprising: navigation buttons provided on the housing adjacent the electronic display, the navigation buttons configured to be actuated by a user, wherein the electronic controller is further configured to: detect a selection for entering barcode information manually; receive a barcode based on actuation of the navigation buttons; and determine the coupling data based on the barcode.

53. The electrofusion tool of claim 50, wherein the electronic display is a full color electronic display and wherein the electronic controller is further configured to display the coupling data on the electronic display.

54. The electrofusion tool of claim 50, wherein the electronic controller is further configured to: display, on the electronic display, the fusion time as a nominal fusion time corresponding to the coupling data before the start button is actuated; determine an adjusted fusion time different from the nominal fusion time based on one or more parameters of the rechargeable battery pack received at the battery interface; and display, on the electronic display, the fusion time as an adjusted fusion time in response to detecting actuation of the start button, wherein the fusion countdown is performed from the adjusted fusion time.

55. The electrofusion tool of claim 49, further comprising an audio output device, wherein the electronic controller is electrically coupled to the audio output device and configured to: output, using the audio output device, a fusion complete audio tone in response to completion of the fusion countdown.32MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W00156. The electrofusion tool of claim 50, wherein the electronic controller is further configured to: display, on the electronic display, a first background color when displaying the coupling data; and display, on the electronic display, a red background color when displaying the fusion countdown, wherein the first background color is different from the red background color.

57. The electrofusion tool of claim 56, wherein the electronic controller is further configured to: display, on the electronic display, a cooling countdown from a cooling time; display, on the electronic display, a blue background color when displaying the cooling time; and display, on the electronic display, a cooling progress bar corresponding to the cooling countdown such that the cooling progress bar is updated according to the cooling countdown.

58. The electrofusion tool of claim 57, wherein the electronic controller is further configured to: display, on the electronic display, the cooling time for a predetermined amount of time before displaying the cooling countdown and after completion of the fusion countdown.

59. The electrofusion tool of claim 57, further comprising an audio output device, wherein the electronic controller is electrically coupled to the audio output device and configured to: output, using the audio output device, a cooling complete audio tone in response to completion of the cooling countdown.

60. A method for operating an electrofusion tool to join pipe ends of plastic pipes together via a pipe fitting during an electrofusion process, the method comprising: detecting, using an electronic controller of the electrofusion tool, actuation of a start button on the electrofusion tool;33MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 providing, via electrical leads of the electrofusion tool, a fusion current from a rechargeable battery pack received at a battery interface of the electrofusion tool in response to detecting actuation of the start button; displaying, on an electronic display of the electrofusion tool, a fusion countdown from a fusion time in response to detecting actuation of the start button; and displaying, on the electronic display, a fusion progress bar corresponding to the fusion countdown such that the fusion progress bar is updated according to the fusion countdown.

61. The method of claim 60, further comprising: receiving, at the electronic controller, coupling data; determining, using the electronic controller, a fusion time based on the coupling data; and displaying, on the electronic display, the fusion time.

62. The method of claim 61, further comprising: receiving, via an interface, a barcode from a barcode scanner; and determining, using the electronic controller, the coupling data based on the barcode.

63. The method of claim 61, further comprising: detecting, using the electronic controller, a selection for entering barcode information manually; receiving, at the electronic controller, a barcode based on actuation of navigation buttons provided on the electrofusion tool; and determining, using the electronic controller, the coupling data based on the barcode.

64. The method of claim 61, wherein the electronic display is a full color electronic display, the method further comprising: displaying the coupling data on the electronic display.

65. The method of claim 61, further comprising: displaying, on the electronic display, the fusion time as a nominal fusion time corresponding to the coupling data before the start button is actuated;34MBF\066042\2014\41533280. v2- 10 / 1 / 25Attorney Docket No. 066042-2014-W001 determining, using the electronic controller, an adjusted fusion time different from the nominal fusion time based on one or more parameters of the rechargeable battery pack; and displaying, on the electronic display, the fusion time as an adjusted fusion time in response to detecting actuation of the start button, wherein the fusion countdown is performed from the adjusted fusion time.

66. The method of claim 60, further comprising: outputting, using an audio output device of the electrofusion tool, a fusion complete audio tone in response to completion of the fusion countdown.

67. The method of claim 61, further comprising: displaying, on the electronic display, a first background color when displaying the coupling data; and displaying, on the electronic display, a red background color when displaying the fusion countdown, wherein the first background color is different from the red background color.

68. The method of claim 67, further comprising: displaying, on the electronic display, a cooling countdown from a cooling time; displaying, on the electronic display, a blue background color when displaying the cooling time; and displaying, on the electronic display, a cooling progress bar corresponding to the cooling countdown such that the cooling progress bar is updated according to the cooling countdown.

69. The method of claim 68, further comprising: displaying, on the electronic display, the cooling time for a predetermined amount of time before displaying the cooling countdown and after completion of the fusion countdown.

70. The method of claim 68, further comprising: outputting, using an audio output device of the electrofusion tool, a cooling complete audio tone in response to completion of the cooling countdown.35MBF\066042\2014\41533280. v2- 10 / 1 / 25

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