BATTERY PACK

A battery pack includes a housing, a flexible button, and a switch. The housing includes an opening and a groove. The groove is disposed at least partially about the opening. The flexible button is molded onto the housing in the opening. The flexible button includes a user engagement portion, a sidewall, a lip, and a post. The sidewall extends from the user engagement portion into the housing. The lip extends laterally from the sidewall. The lip includes a ridge protruding into the groove of the housing. The post extends from the user engagement portion. The switch is disposed in the housing. The switch is positioned to be engaged by the post.

FIELD

The present disclosure relates to battery packs, and more particularly to battery packs configured to interface with power tools.

BACKGROUND

Many manufacturing processes are slowed due to complex assemblies (e.g., buttons in housings) due to steps required to assemble, fasten, and test multiple pieces together. Therefore, it is beneficial for the housing of battery packs to be formed such that it is easy to mold or assemble periphery components to the housing.

SUMMARY

The disclosure provides, in one aspect, a battery pack with a housing, a flexible button, and a switch. The housing includes an opening and a groove. The groove is disposed at least partially about the opening. The flexible button is molded onto the housing in the opening. The flexible button includes a user engagement portion, a sidewall, a lip, and a post. The sidewall extends from the user engagement portion into the housing. The lip extends laterally from the sidewall. The lip includes a ridge protruding into the groove of the housing. The post extends from the user engagement portion. The switch is disposed in the housing. The switch is positioned to be engaged by the post.

In another independent aspect, the disclosure provides a battery pack with a housing, a light pipe, a retention member, and a light-emitting diode (LED). The housing defines a passage therein. The light pipe is disposed in the passage. The light pipe includes a base and an emission surface. The emission surface is opposite the base. The retention member is coupled to the housing. The retention member includes a protrusion extending over at least a portion of the base to retain the light pipe in the passage. The LED is disposed in the housing. The LED is positioned to emit light into the base of the light pipe. The light exits the light pipe through the emission surface.

In another independent aspect, the disclosure provides a battery pack with a housing, a light pipe, a retention member, a light-emitting diode (LED), a flexible button, and a switch. The housing defines a passage therein. The light pipe is supported within the passage. The light pipe includes a base and an emission surface. The emission surface is opposite the base. The retention member is coupled to the housing. The retention member includes a protrusion extending over at least a portion of the base to retain the light pipe in the passage. The LED is positioned to emit light into the base of the light pipe. The light exits the light pipe through the emission surface. The flexible button is molded onto the housing in the opening. The flexible button includes a user engagement portion, a sidewall, a lip, and a post. The sidewall extends from the user engagement portion into the housing. The lip extends laterally from the sidewall. The lip includes a ridge protruding into the groove of the housing. The post extends from the user engagement portion. The switch is disposed in the housing. The switch is positioned to be engaged by the post.

DETAILED DESCRIPTION

With reference toFIG.1, an embodiment of a battery pack10is shown. The battery pack10is configured to power a variety of power tools and to be charged by a charger. The battery pack10includes a housing12, a flexible button14, a plurality of light pipes16, a plurality of terminals18, and a release mechanism20. The battery pack10can also power any other electronic device configured to interface with the battery pack10through the terminals18. In the current embodiment, the release mechanism20includes two instances of a button and a connected hook to releasably couple the battery pack to an appropriate device.

With reference toFIG.2, the housing12has an inner cavity22, wherein a circuit board24is disposed. The circuit board24contains at least one light-emitting diode (LED)26configured to illuminate the light pipes16in response to a control signal from a microcontroller. A switch30is positioned on the circuit board24to be engaged by the flexible button14.

With specific reference toFIG.3, the housing12has a passage32and an opening34defining at least one groove36therein. The passage32extends into the cavity22. In some embodiments, the passage32also extends to the outer surface of the housing12. The opening34and groove36define a peripheral wall38that extends into the cavity22around the opening34. The groove36surrounds the perimeter of the opening34. In other embodiments, the groove36may partially surround the perimeter of the opening34.

With reference toFIG.4, the button14is molded into the opening34and groove36defined within the housing12. The button includes a user engagement portion40, a sidewall42, a lip44, and a ridge46. In some embodiments, the button14is molded as a unitary piece and is configured to move toward the cavity22when the user engagement portion40is pressed. A sidewall42extends from the user engagement portion40along the peripheral wall38into the cavity22. Holding the button14onto the housing12, a lip44extends radially outward from the sidewall42, further defining at least one ridge46that extends into the groove36. Additionally, a post48extends from the user engagement portion40toward the cavity22. In this embodiment, the post48engages the switch30when the user engagement portion40is depressed.

In some embodiments, depressing the user engagement portion40deforms the user engagement portion40and allows the sidewall42to bend away from the peripheral wall38of the housing12. In other embodiments, the sidewall42shifts along the surface of the peripheral wall38toward the cavity22. In yet another embodiment, the sidewall42remains fixed against the peripheral wall38.

With reference toFIG.5, the current embodiment includes a plurality of connected light pipes16, wherein each light pipe16aserves a similar purpose and are parallel to one another. In other embodiments, only a single light pipe16ais present. The light pipes16have a base50that includes a protrusion52extending radially outward from each respective light pipe16a.Additionally, the base50includes a rail54extending along the protrusions52of each light pipe16a.The rail54is used to combine each light pipe16ainto a single interconnected piece along the base50. The base50serves as the light-receiving end of the light pipe16a,with each light pipe16ahaving a respective light receiving base50a.In the current embodiment, the light receiving base50ais rectangular and ends on a flat end. In other embodiments, the light receiving base50ais conical and can be positioned to encase the body of the LED26.

Opposite the base50, each light pipe16aincludes an emission surface58. A light pipe body56extends between the base50and the emission surface58for each light pipe16a.The emission surface58serves as the user-facing end of the light pipe16a.In the current embodiment, the emission surface58is angled relative to the base and is textured to facilitate diffusion of the light traveling through the light pipe body56and exiting the emission surface58. The texture on the emission surface58may include dimples, grooves, dents, scratches, or the like. In some embodiments, the emission surface58may be a different material than that of the base50, rail54, or body56. Still other embodiments may include voids, impurities, or the like disposed within the light pipe body56nearer to the emission surface58than to the base50. Still other embodiments could use, for instance, a film.

With reference toFIG.6, a retention member60is disposed within the cavity22of the housing12. The retention member60is configured to hold the light pipes16within the housing12using a plurality of L-shaped hook-like protrusions62engaging the protrusions52of the base50. In some embodiments, the protrusions62may have a different shape, or not be protrusions at all. For instance, some embodiments could include a bar, lump, ledge, or the like. In addition to supporting the light pipes, the retention member60supports the release mechanism20within the housing12. The retention member60is removably fastened to the housing12using at least one fastener extending through a corresponding fastening hole64.