POWER TOOL BATTERY PACK AND SYSTEM

A power tool system including at least one power tool and a battery pack selectively coupleable with the power tool. The battery pack includes a housing, at least one battery cell housed in the housing, a circuit board housed in the housing, a switch mounted on the circuit board, a button actuatable by a user to actuate the switch mounted on the circuit board and a biasing member which biases the button away from a position of actuating the switch. The biasing member is made of a non-conductive material.

FIELD OF THE INVENTION

The present invention relates to an improved power tool battery pack and power tool system.

BACKGROUND

It may be desirable to provide an improved button for a power tool battery pack.

SUMMARY

According to one exemplary embodiment, there is a battery pack including a housing, at least one battery cell housed in the housing, a wireless transmitter housed in the housing, a button, the button configured to initiate pairing with a separate electronic device and an illumination member for illuminating the button.

The illumination member may be configured to illuminate the button with different colors.

The illumination member may be configured to change illumination of the button in conjunction a state of charge of the battery pack.

The illumination member may comprise at least one of a red LED, a green LED and a blue LED.

The illumination member may comprise a red LED, a green LED and a blue LED.

The wireless transmitter may be configured to send a signal indicative of a charge of the battery pack to the separate electronic device.

The wireless transmitter may be configured to receive a signal from the separate electronic device related to a color for the illumination member.

The battery pack may further comprise a lightpipe configured to transmit light from the illumination member to illuminate the button.

The battery pack may further comprise a microcontroller which controls the at least one LED.

The intensity of the at least one LED may be controlled by electronic switches connected to the at least one LED.

The electronic switches may be controlled by the microcontroller.

The microcontroller may control the electronic switches by pulse width modulation.

The at least one LED may comprise at least two LEDs of different color.

According to an exemplary embodiment there is a power tool, a battery pack coupleable to the power tool to provide electrical power to the power tool, the battery pack including a housing, at least one battery cell housed in the housing, a wireless transmitter housed in the housing, a button, the button configured to initiate a pairing function, and an illumination member for illuminating the button.

The power tool may include a motor and a trigger for operating the motor.

The power tool system may further include an electronic device which is remote from the power tool and battery pack and which is configured to pair with the battery pack according to the pairing function.

The illumination member may be configured to illuminate the button with different colors.

The illumination member may be configured to change illumination of the button in conjunction with a state of charge of the battery pack.

The illumination member may include at least one of a red LED, a green LED and a blue LED.

The illumination member may include a red LED, a green LED and a blue LED.

The wireless transmitter may be configured to send a signal indicative of a charge of the battery pack to the separate electronic device.

The wireless transmitter may be configured to receive a signal from the separate electronic device related to a color for the illumination member.

The power tool system may further include a lightpipe configured to transmit light from the illumination member to illuminate the button.

The battery pack may further include a microcontroller which controls the at least one LED.

The intensity of the at least one LED is controlled by electronic switches connected to the at least one LED.

The electronic switches are controlled by the microcontroller.

The microcontroller controls the electronic switches by pulse width modulation.

The at least one LED comprises at least two LEDs of different color.

The electronic device comprises a screen which is configured to display a state-of-charge of the battery pack.

The state-of-charge displayed by the electronic device corresponds to the state of charge displayed by the button.

A color of the state-of-charge displayed by the electronic device may correspond to a color of the button.

The power tool may be a drill.

The power tool may be a saw.

The power tool may be a sander.

The power tool may be an impact driver.

The electronic device may be a phone, a tablet, a laptop computer or a desktop computer.

According to another aspect of the disclosure, in one exemplary embodiment there is a battery pack including a housing, at least one battery cell housed in the housing; a wireless transmitter housed in the housing; a button, the button configured to initiate pairing with an electronic device so that the battery pack may wirelessly communicate with the electronic device; a connection section including a first electrical connector configured to supply power to a power tool; and a charging port configured to supply power to an external device. The charging port can be in an on state in which the charging port is operable to supply power to the external device and an off state in which the charging port is not operable to supply power to the external device.

The charging port may be configured to change from the on state to the off state after a predetermined amount of time after charging from the charging port begins.

The predetermined amount of time may be equal or less than the watt-hour rating of the battery being charged divided by the voltage times the current out of the USB jack from the battery pack.

The predetermined amount of time may be ten hours or less.

The predetermined amount of time may be eight hours or less.

The predetermined amount of time may be seven hours or less.

The predetermined amount of time may be set by a user of the separate electronic device.

The predetermined amount of time that can be set by the user may have an upper limit.

The predetermined amount of time may be equal to or less than an Amp hour rating of the battery pack divided by a current drawn from the battery pack by the charging port.

The charging port may be a USB port.

According to another aspect, there is an exemplary embodiment of a power tool system which includes a power tool and a battery pack. The battery pack includes a housing, at least one battery cell housed in the housing; a wireless transmitter housed in the housing; a connection section including a first electrical connector configured to supply power to the power tool when the battery pack is connected to the power tool; and a charging port configured to supply power to an external device. The charging port can be in an on state in which the charging port is operable to supply power to the external device and an off state in which the charging port is not operable to supply power to the external device.

The charging port may be configured to change from the on state to the off state after a predetermined amount of time after charging from the charging port begins.

The predetermined amount of time may be ten hours or less.

The predetermined amount of time may be eight hours or less.

The predetermined amount of time may be seven hours or less.

The predetermined amount of time may be set by a user of the separate electronic device.

The predetermined amount of time set by the user may be limited.

The predetermined amount of time may be equal to or less than an Amp hour rating of the battery pack divided by a current drawn from the battery pack by the charging port.

The charging port may be a USB port.

The separate electronic device may include one of a computer, a tablet computer and a phone.

The power tool may be a drill.

According to another aspect, there is a power tool system which includes a plurality of power tools including a drill and at least one battery pack. The battery pack is selectively couplable to the plurality of power tools to provide electrical power to a coupled power tool to which the battery pack is coupled. The battery pack includes a housing, at least one battery cell housed in the housing; a wireless transmitter housed in the housing; a connection section including a first electrical connector configured to supply power to the coupled power tool and a charging port configured to supply power to an external device. The charging port can be in an on state in which the charging port is operable to supply power to the external device and an off state in which the charging port is not operable to supply power to the external device.

The charging port may be configured to change from the on state to the off state after a predetermined amount of time after charging from the charging port begins.

The predetermined amount of time may be set by a user of the separate electronic device.

The predetermined amount of time is equal to or less than an Amp hour rating of the battery pack divided by a current drawn from the battery pack by the charging port.

According to another aspect of the application, there is a power tool system including at least one power tool. A battery pack is selectively coupleable with the power tool and provides power to the power tool. The battery pack includes a housing, at least one battery cell housed in the housing, a circuit board housed in the housing, a switch mounted on the circuit board, a button actuatable by a user to actuate the switch mounted on the circuit board, a biasing member which biases the button away from a position of actuating the switch, a connection section which couples to the power tool and through which power is supplied from the battery pack to the power tool, wherein the connection section includes electrical connectors and the electrical connectors are mounted on the circuit board. The biasing member may be made of a non-conductive material.

The biasing member may be made of an elastic material.

The biasing member may be made of a material with a Shore A durometer of 30 or greater.

The switch may initiate a pairing function of wirelessly pairing the battery pack with another device.

Activation of the switch may initiate operation a charging port.

The battery pack may further include a light which selectively illuminates the button.

The power tool include at least one of a drill and a saw.

According to another aspect of an exemplary embodiment, there is a power tool system including at least one power tool and a battery pack selectively coupleable with the power tool and providing power to the power tool. The battery pack includes a housing, at least one battery cell housed in the housing, a circuit board housed in the housing, a switch mounted on the circuit board, a button actuatable by a user to actuate the switch mounted on the circuit board and a biasing member which biases the button away from a position of actuating the switch. The biasing member may be made of a resilient material.

The biasing member may be made of a non-conductive material.

The biasing member may be made of an elastic material.

The biasing member may be made of a material with a Shore A durometer of 30 or greater.

Activation of the switch may initiate a pairing function of wirelessly pairing the battery pack with another device.

The battery pack may further include a charging port and activation of the switch initiates operation the charging port.

The battery pack may further include a connection section which couples to the power tool and through which power is supplied from the battery pack to the power tool, wherein the connection section includes electrical connectors and the electrical connectors are mounted on the circuit board.

According to another aspect, there is a power tool system including at least one power tool and a battery pack selectively coupleable with the power tool and providing power to the power tool. The at least one power tool may be a drill or a saw. The battery pack includes a housing, at least one battery cell housed in the housing, a circuit board housed in the housing, a switch mounted on the circuit board, a button actuatable by a user to actuate the switch mounted on the circuit board and a connection section which couples to the power tool and through which power is provided from the battery pack to the power tool. The connection section includes electrical connectors. The housing includes a bottom side and a top side and the connection section is disposed on the top side and the button faces in an upward direction.

The button may be disposed on the top side of the housing.

The electrical connectors may be mounted on the circuit board.

Actuation of the button may initiate a pairing function of wirelessly pairing the battery pack with another device.

The battery pack may further include a charging port and activation of the switch initiates operation the charging port.

DESCRIPTION

FIG. 1illustrates an exemplary system1000for enhancing power tools according to the invention. In particular, power tools200may be drill, circular saws, reciprocating saws, jigsaws, miter saws, table saws, etc. Some of the power tools200may be cordless and thus be connectable to power tool battery packs100. Persons skilled in the art shall understand that “battery pack” and “power tool battery pack” as used herein shall mean a set of rechargeable battery cells120disposed in a housing101that for use with a power tool that is powered by an electrical motor, such as a drill200, circular saw, reciprocating saw, jigsaw, etc. Persons skilled in the art shall recognize that power tool battery pack100may be the power tool battery packs disclosed in U.S. Pat. Nos. 7,405,536, 7,618,741, 7,602,146 and/or 8,044,640, which are hereby incorporated in full by reference, modified so as to include a communication circuit, and preferably a wireless communication circuit126, as further explained below.

System1000may also include chargers210for battery packs100, including radio chargers such as the radio charger disclosed in U.S. Pat. No. 6,308,059, which is hereby incorporated in full by reference.

System1000may also include a non-motorized sensing tool220, as described in U.S. Pat. No. 8,251,157, which is hereby incorporated in full by reference. Persons skilled in the art shall recognize that sensing tool220may be an inspection device, a clamp meter, an IR thermometer, an IR camera, an inspection camera, a wall scanner, etc.

System1000may also include a portable power supply215, such as that described in US Publication No. 2011/0090726, filed on Nov. 1, 2010, which is hereby incorporated in full by reference.

System1000may also include a computing device250, such as a personal computer, tablet, mobile telephone, smartphone, etc. Computing device250is preferably connectable to a server270via the internet. Persons skilled in the art will recognize that computing device250preferably connects to the internet via a wireless communication circuit/protocol, such as Wi-Fi, Bluetooth, Zigbee, 3G/4G data systems, etc.

It is desirable that power tools200, battery packs100, non-motorized sensing tools220, portable power supply215and/or chargers210be in communication with computing device250. Preferably such communication will occur via a wireless communication system126, such as Wi-Fi, Bluetooth, Zigbee, infrared light, RF, etc. Persons skilled in the art will recognize that other communication schemes may be used that do not require a direct wired connection between computing device250and the power tools200, battery packs100, non-motorized sensing tools220, portable power supply215and/or chargers210. Such communication schemes may involved transmitting audio signals, using capacitive codes and/or visual codes.

Computing device250may have a program or app that implements the steps shown in the flowchart ofFIG. 3. A user may begin the program at step300by, for example, selecting the appropriate app/program on her computing device250. Alternatively, the program or app can begin automatically upon connection with or request from the power tools200, battery packs100, non-motorized sensing tools220, portable power supply215and/or chargers210.

In response to such selection, computing device250may show several process choices for the user to select (step305). These process choices may include shopping for tools or related products (step310), obtaining service information (step320), refer to construction reference materials (step330), connect to nearby power tools or products (step340), or go back to a home menu to end the app (step350).

For example, if the user selects the shopping process (step310), computing device250may communicate with a server270via the internet (step315) that would provide the user information on the different available products, as well as allow the user to shop online for such products. Persons skilled in the art may recognize that the computing device250may use GPS or cell-location data to identify the closest stores carrying the desired products.

If the user selects the service process (step320), computing device250may communicate with a server270via the internet (step324) that provides the user information on the different available services, including the closest repair/service center, contact information, etc. Persons skilled in the art may recognize that the computing device250may use GPS or cell-location data to identify the closest repair/service center. The user can then call or email the repair/service center (step328) to schedule an appointment. Persons skilled in the art are further referred to U.S. Application No. 61/570,484, filed on Dec. 14, 2011, entitled “System and Method for Interacting With Customer,” which is fully incorporated herein by reference, for further details on the service process.

Persons skilled in the art will recognize that computing device250may transmit data to the repair/service center about battery pack100, power tool200, charger210, portable power supply215and/or non-motorized sensing tool220, such as cycle numbers, clutch activation count, current draw profiles, and other usage data. Similarly, computing device250can transmit such data to other destinations, such as a supervisor's computing device, to alert the supervisor of a user's use or abuse of a battery pack100, power tool200, charger210, portable power supply215and/or non-motorized sensing tool220. Such data can be used to monitor the user's productivity.

Persons skilled in the art will recognize that the computing device250could be used to record noises originating from power tool200and send those noises to the repair/service center for diagnosis of the power tool200. The app could also analyze the noises and provide some troubleshooting advice for power tool200.

If the user selects the reference process (step330), the app would access data stored in memory (step334). Persons skilled in the art will recognize that the memory could be within or without computing device250. Such data could include reference materials, such as handbooks on different construction techniques, the different construction codes, such as the International Building Code, the International Residential Code, the International Plumbing Code, etc. The data could also include other executable routines, like calculator code for converting measurements between different units (e.g., converting feet to meters), calculating stair rise run, baluster spacing, roof pitches, HVAC calculations, etc., as well as different cost estimation tools, landscaping tools, etc.

The user can also choose to connect to nearby power tools, battery packs or other products (step340). If such process is selected, computing device250would proceed to wirelessly contact all nearby power tools, battery packs and other products (step342). Once contact has been made, computing device250would display a list of nearby power tools, battery pack and other products (step344).

It may be preferable to color-code the different listed power tools, battery pack and other products. For example, tools that are owned (or paired) with the user can be shown in green. Tools that can't be contacted or accessed by the user can be shown in red. Tools that are owned by colleagues or a group are shown in yellow. Tools that have not been associated with a particular user can be shown in white.

Similarly, persons skilled in the art will recognize that computing device250may show a list of previously-paired power tools, battery packs and other products, and show the ones that are nearby in one color, while showing the others in another color. In this manner, the user will know which power tools, battery packs and other products are within a certain radius, thus conducting a quick inventory check.

The user can then select a particular power tool, battery pack or other product (step346). Once a particular power tool, battery pack or other product is selected, computing device250can display different attributes for such product for review. For example, in the case of battery pack100, some of the attributes can include an identifying name (e.g., “Danny's Pack 1”), a picture icon, device model, the charge status, password (for accessing the tool information through another user's phone), temperature, number of charge cycles, etc. Persons skilled in the art will recognize that this information is kept in memory128of the battery pack100, which is then transmitted via the wireless communication circuit126to computing device250, possibly upon a direct request from computing device250.

Persons skilled in the art will recognize that some of the attributes can be modified. For example, the identifying name and the picture icon can be modified by the user by selecting a modification process (steps347,348) and inputting the new information. This data can then be wirelessly transmitted to the battery pack100for storage within a memory128. Persons skilled in the art will recognize that the user can input the new information (as well as other commands, etc.) via a keyboard or touchscreen in computing device250and/or by giving verbal commands which are recognized by the computing device250.

In addition to modifying data related to the battery pack identity, a user can modify data related to the performance of battery pack100via computing device250. For example, a user can program the battery pack100to announce when it is at full charge. This announcement can be communicated via the display of computing device250, haptic feedback of computing device250and/or battery pack100, and/or sound emitted by the computing device250and/or transmitted via a speaker or piezo127of battery pack100.

Similarly, the user can program battery pack100(or portable power supply215) to announce when it is near discharge, when it is hot, when it is outside of communication range with computing device250, etc. Persons skilled in the art will recognize that this can be accomplished by monitoring the outputs of voltage monitor115, current sensor145, temperature143, etc. in battery pack100.

The user can also disable (and enable) the battery pack100via computing device250. Persons skilled in the art will recognize that “enable” and “disable” refer to the ability of battery pack100to provide power to a power tool200and/or the ability of battery pack100to receive power from a charger to charge battery cells120. The ability (or inability) to provide power to a power tool200can be enabled or disabled by controlling driver circuit141to maintain semiconductor device130ain an on- or off-state, respectively. Similarly, the ability (or inability) to receive charging power to charge battery cells120can be enabled or disabled by controlling driver circuit141to maintain semiconductor device130bin an on- or off-state, respectively.

The user can also program battery pack100so that it is only enabled (and thus providing power and/or accepting charging power) when it is within vicinity of computing device250. This can be accomplished by computing device250sending a ping signal to battery pack100. If battery pack100receives the ping signal, then battery pack100continues to provide power and/or accept charging power. However, if battery pack100does not receive a ping signal for a predetermined period of time, battery pack100can assume that it is outside of communication range with computing device250and disable itself (thus not providing power or accepting charging power).

The user can also program battery pack100so that it is only enabled (and thus providing power and/or accepting charging power) when certain conditions are met. For example, battery pack100would be enabled for up to a predetermined number of charge cycles, a predetermined time period or number of uses, and then disabled until reset by the user via computing device250.

Persons skilled in the art will recognize that, while the above description is particular to battery packs, the same functionality can be provided for portable power supply215, including the ability to enable/disable portable power supply215, etc.

Similarly, a power tool200, non-motorized sensing tool220and/or chargers210provided with a programmable control and wireless communication circuit may also be contacted via computing device250. For example, power tool200can store tool usage patterns, tool conditions, etc., which can be transmitted to computing device250and to a server270for further analysis, etc. As disclosed above, computing device250can display such information. For example, computing device250can display the speed (rpm), bevel angles, miter angles, brush wear, the presence or condition of a guard and/or attachment, etc. of the power tool200.

Like battery pack100, power tool200may be programmed to change different attributes or features. For example, a user can set the maximum motor speed or power, or provide a predetermined output (such as half the motor speed or power) when not within the vicinity of computing device250, etc. Similarly, it may be desirable to control any adjustable feature in a power tool via computing device250. For example, the computing device250may adjust output pressure in compressors, the amount of grease outputted by a grease gun when the trigger is pulled (persons skilled in the art will recognize that computing device250can set a grease gun's pump to run for X pump cycles whenever the trigger is pulled; the higher the number of pump cycles per trigger pull, the larger the amount of grease outputted), the speed of a flywheel-based nailer (such as the one disclosed in U.S. Pat. No. 7,137,541, which is wholly incorporated herein by reference) in order to adjust for a different nail size or material in which the nail is being driven into, or a desired temperature for a heated jacket (such as the one disclosed in US Publication No. 2011/0108538, which is wholly incorporated herein by reference).

Another embodiment of a tool200which can be used in the present system is inflator225, which is shown inFIG. 11. When the inflator is used with the present system, various tasks for the inflator can be handled by the app. For example, a user may set the inflator's target pressure (psi) on computing device250and the inflator can inflate a ball or other item until the target pressure is reached. The inflator status can be monitored on the computing device250, namely the current pressure (psi). A user can use the computing device250to start or stop the inflator. The inflator225can cause the computing device250to display an alert when the inflation process is complete. The inflator225can send information about recommended pressure (psi) levels for various jobs such as inflating car tires to the computing device250and can provide instructions for using the inflator225. The inflator225can also transmit a temperature of the inflator225to the computing device, the inflator would have a temperature sensor as is known in the art for monitoring a temperature of the inflator225(seeFIG. 14). The inflator of the present application can be any of various types, including the types shown in U.S. Pat. No. 8,418,713, which is herein incorporated by reference; U.S. Pat. No. 6,095,762, which is here in incorporated by reference; and International Patent Application Publication No. WO/06095144, which is herein incorporated by reference.

Use of the app on the computing device250for operating the inflator is shown inFIGS. 12-14. As shown inFIG. 12A, the inflation pressure is set by a user of the app to 32 PSI. The inflator225transmits the current pressure of 22 PSI to the computing device250and the computing device250displays the current pressure of 22 PSI. The inflator also transmits a status of “Inflating” which the computing device250displays. As shown inFIG. 12B, as the pressure changes, the current pressure data sent from the inflator225to the computing device250changes and the information displayed on the computing device25changed according (i.e., to 30 PSI). As shown inFIG. 13, when the current pressure equals the inflation pressure setting of 32 PSI, the app shows that the inflation is “Complete”.

The user can also enable and disable different modes of operation, such as allowing/not allowing power tool200to rotate in a reverse direction. As mentioned above, the user can enter such commands via a keyboard or touchscreen on computing device250and/or by providing verbal commands recognized by computing device250.

Alternatively, computing device250can be used to determine the appropriate attribute or feature to modify. For example, computing device250can scan a visual code (such as a bar code or QR code) on an accessory, such as a grinding wheel, via its camera, determine the identity of the accessory and modify the attributes of the power tool200accordingly. In such manner, computing device250can determine that, for example, a small grinding wheel has been installed on grinder/power tool200and that the maximum speed should be 10000 rpm. Computing device250would then program grinder/power tool200to not exceed such maximum speed. This would allow a user to use a grinder as a polisher (and vice versa) by selecting the appropriate speed for the desired accessory.

Computing device250could also scan the accessory itself with its camera, such as the shape of a drill bit or router bit, determine the identity and attributes of the accessory based on the resulting image and program power tool200to match the attributes of the accessory. Alternatively, computing device250could scan the workpiece or an identifying code thereon which identifies the type of material constituting the workpiece. Persons skilled in the art will recognize that recognition software can be used to determine the identity of the accessory based on the shape of the accessory. Computing device250can then access a database within the computing device250or in a separate server connectable via a telecommunications network, such as a cellular network, to obtain the information on the different attributes of the accessory.

In addition to information as to the specific accessory, the database may provide the app with information requests. For example, for a particular router bit, the database may instruct the app to ask the user what type of wood is being shaped with the router bit. The app can then customize the power tool settings depending on the type of wood selected by the user, allowing for a more efficient work operation. The app could also indicate whether the router bit is not recommended for that particular type of wood, and/or whether a different router bit is better for shaping that particular type of wood.

Persons skilled in the art will recognize that, if computing device250has an RFID system, computing device250could read an RFID tag disposed on the accessory, then access the database to obtain the attributes of the accessory, and then modify/program power tool200accordingly.

Computing device250may also be used to modify the different trigger profiles of power tool200as described in US Patent Application Publication No. 2011/0254472, filed on Apr. 7, 2011, entitled “Power Tool Having a Non-Linear Trigger-Speed Profile,” which is hereby fully incorporated by reference. A user can use computing device250to select between the different trigger profiles applicable to power tool200. Alternatively, the user can use computing device250to program a customized trigger profile.

Other customizable features on power tools and other products may include the blink patterns of LEDs, the time period that an LED remains on after releasing a trigger switch, audio beeping patterns for particular conditions in products with speakers or piezos, the selected radio station and/or volume on a radio charger210, etc. The app can also turn on and off the power tool200or accessories thereof like a dust collector, open/close gates therein, etc.

If the power tool200has servos that can be used to adjust different features of power tool200(such as the miter saw disclosed in US Patent Publication No. 2001/0000856, filed on Jan. 5, 2001, and wholly incorporated herein by reference), the app can be used to adjust the different features by controlling the servos. For example, the user can select a bevel angle on the computing device250and the app will control the bevel angle servo to the desired location. In this manner, the user can program a list of desired workpieces, i.e., a cut list, and the app can control the miter saw/power tool200to obtain those cuts. Similarly, the servos can be used to adjust the stroke length in a saw that allows for such adjustment, such as in reciprocating saws or jigsaws.

It may be beneficial to provide servos to perform functions that are difficult to do, like opening a blade clamp on a grinder or a recip saw. Rather than requiring the user to torque open a blade clamp, the user would select such operation in the app.

Computing device250can also be programmed to control an apparatus, such as the router disclosed in US Patent Publication No. 2006/0206233, filed on Mar. 9, 2005, which is wholly incorporated herein by reference. The app can control such apparatus to obtain the cuts selected by the user.

Persons skilled in the art will recognize that these features may be programmed individually, e.g., changing the maximum motor speed, and/or in bulk by selecting a particular setting. In other words, the user can select a LAG bolt setting where the maximum motor speed is adjusted, a particular trigger profile is selected, and a particular alert is chosen, all by selecting one setting on computing device250.

Similarly, an owner of power tool200can select settings for different users according to their level of skill. For example, the owner may have a standard setting for experienced users and a lowered power setting for less skilled users. In this manner, the owner can change the torque output or the start-up speed curve (and other attributes) of a rotary hammer/power tool200to a setting that is manageable by an inexperienced user, such as a soft-start setting.

Persons skilled in the art will recognize that, if each individual carries an ID or RFID tag that can be scanned or recognized by the computing device250or power tool200, the computing device250(and/or power tool200) can detect when power tool200is used by a new user (due to the presence of the new ID/RFID tag). Computing device250(and/or power tool200) can then change the settings of power tool200to accommodate the new user. Furthermore, computing device250could show a how-to-use video or provide other information to the new user, especially if the new user is noted to be an inexperienced user.

A user can even select specific alerts for the power tool200, as she did for battery pack100. For example, the user can program computing device250to display a warning when a specific condition occurs. These conditions may include brush wear beyond a selected threshold, high current draw (possibly representing an overload condition), etc.

Persons skilled in the art will recognize that these alerts can have a visual component, such as an alert window displayed on the screen of computing device250, and/or an audio component, such as a sound or song (possibly selected by the user) played through the speaker(s) of computing device250or a radio charger210, or through an earphone connected to computing device250. Persons skilled in the art will recognize that such earphone could be wireless connected to computing device250via BlueTooth, or could be connected via a wire to the computing device250.

Furthermore, a user can also use computing device250to locate the selected power tool, battery pack or other product (step349). Due to the wireless communication between computing device250and battery pack100, it is possible to send a command from computing device250to battery pack100to start emitting a sound via speaker/piezo127, so as to assist in locating such battery pack100. It is also possible to have the computing device250poll all nearby battery packs100for a particular state. Thus computing device250can determine the battery pack with the highest/lowest charge, highest/lowest temperature, most charge cycles, etc., then send a command to the particular battery pack100to start emitting a sound.

The user can also select going back to a home menu to end the app (step350). This would end the app (step355) and go to a home menu of the computing device250.

The app can also monitor the battery pack100, charger210and/or power tool200(step360). The app can enter a monitoring state automatically and/or when selected by the user. During this monitoring process, the app can keep track of power tool usage, present current draw, etc. and store and/or use that information for analysis by a service department. In this manner, the service department can determine whether a power tool200has been abused.

The app can also use that information to better utilize the power tool200. For example, the app can receive PWM, voltage and/or current draw information from battery pack100and/or power tool200and establish a macro that would allow the user to repeat the current draw. Persons skilled in the art will recognize that such current draw profile can represent a torque curve for driving a fastener into a surface. Having a repeatable draw profile will allow the user to easily set a custom torque setting.

Persons skilled in the art will recognize that an app can be looking for similar patterns and adjust battery pack100and/or power tool200accordingly for better efficiency, effectively learning the user's use patterns. The app can do such analysis on data patterns, or even in real time. For example, the app can receive current information, trigger position and/or speed information, and run power tool200using that information to maximize run-time. Other information that the app can monitor includes bias force/bias load, gear settings, battery voltage, the presence of on-tool guard or side handles, etc.

Persons skilled in the art will recognize that, if the app monitors the presence of on-tool guards or side handles, the app can prevent use of the power tool200if the guards or side handles are not detected, and/or limit the power output for better control. Persons skilled in the art will also recognize that the presence of these guards and side handles can be detected by providing, for example, switches on power tool200that get activated once the guards or side handles are installed.

Similarly, if the app monitors motor current draw and gear setting, the app can select and/or indicate the best gear ratio (or speed setting) to run at optimum efficiency. If the motor is drawing a lot of current and the transmission is set at a high speed, the app may alert the user to switch to a lower speed or may switch the gear setting automatically.

Persons skilled in the art will understand that the app can limit the power tool's output speed and torque by monitoring bias force/bias load if the app determines that the bias load is not adequate to keep a screwdriver bit engaged to a screw. The app could also turn off or delay the impacts provided by the transmission of power tool200.

The app can also use the sensors in the computing device250to determine working conditions and adjust the usage of battery pack100and/or power tool200. For example, if the user wears the computing device250on his wrist and the app notices a sudden movement (by monitoring the accelerometers in the computing device250), the app can shut down the power tool200by turning off battery pack100or power tool200, or limit the amount of power provided by battery pack100or to power tool200. The accelerometers in the computing device250can also be used to monitor vibration. When a certain threshold of vibration is reached, the user can be alerted to take a rest break.

Similarly, the app can adjust the brightness of the LEDs in power tool200according to the output from the ambient light sensors of computing device250. For example, if the ambient light sensors of computing device250detect a dark environment, the app can increase or decrease the brightness of the LEDs.

Additionally, the app can use the on-board microphone of computing device250to listen to the ambient noise. The app can then create an opposite soundwave and play it through an on-board speaker and/or transmit it to the radio charger210. Persons skilled in the art will recognize that playing an opposite soundwave will cancel or lower the ambient noise.

The computing device250can also control power tool200and/or charger210according to the use of the computing device250. For example, if computing device250receives a phone call, the app can turn off power tool200and/or lower the volume on radio charger210.

Persons skilled in the art will understand that computing device250can also be used for controlling multiple items at the same time. For example, when the app detects a power tool200being turned on, such as when the user pulls on a trigger, the app can increase the volume on radio charger210.

The app can also transmit data (step370) about battery pack100, power tool200, charger210, portable power supply215and/or non-motorized sensing tool220to specific destinations. For example, a wall scanner220may transmit data about a scanned wall via computing device250to an archive or to a store website. Similarly, the image data received from an IR camera can be sent to the computing device250and made part of a document drafted in computing device250, which in turn can be emailed or transmitted to a client.

FIG. 4shows an app according to another exemplary embodiment of the present application. The app and other parts work the same as that shown inFIGS. 1-3unless indicated otherwise. According to the exemplary embodiment shown inFIG. 4, the app may be programmed to indicate a relative location and/or distance of the power tool200from the computing device250. According to an exemplary embodiment, the app may cause the computing device250to provide a display or sound based upon a measurement of the power present in a signal, such as a Received Signal Strength Indicator (RSSI). The RSSI is a measurement of the strength of a received radio signal and the higher the RSSI, the stronger the signal. In the case of the present embodiment, the higher the RSSI measured by the computing device250, the stronger the signal being received by the computing device250from the power tool200and/or the tool battery100. The computing device250can provide various indications based on the strength of the RSSI.

The RSSI of the signal provided from the power tool200to the computing device250can be indicated by the computing device250in any of a variety of ways. For example, the screen251color252can change from a red color as the RSSI moves from a relatively weak signal to a yellow color when the computing device250receives an intermediate RSSI and a green color as the computing device250receives a relatively high RSSI. In another exemplary embodiment, a speaker of the computing device250and/or a speaker or piezo127of the battery pack100may provide a sound such as a beep through the computing device speaker254at varying frequencies as the computing device250receives a higher or lower RSSI value from the power tool200or battery pack100. In another exemplary embodiment, differing distance253measurements can be shown on the screen251depending upon the RSSI value. These exemplary embodiments may be combined or done separately. For example, as shown inFIG. 4, a color indication252may be displayed at the same time as a distance display253.

RSSI scales can vary. For example, in a first wireless transmission system, the RSSI may vary from a value of 0 to 100 and in another transmission system the RSSI may vary from 0 to 127. An example of the various potential displays based on the RSSI received by the computer device250is shown in the table below in which an RSSI scale of 0-100 is used. The present application uses an exemplary 0-100 RSSI scale unless otherwise noted.

Of course, the values shown in the table are merely examples. For example, four or more different sound frequencies may be used or the sound frequency may be continuously variable. Similarly, more colors or other indications may be used. Additionally, different or more ranges of RSSI may be used.

In addition or alternatively to the above, the battery pack100or tool200may provide an indication based on the RSSI received by the power tool200and/or battery pack100from the computing device250. For example, the battery pack100may emit a beep or other sound from the speaker or piezo127when the battery pack100detects a RSSI signal from the computing device250of greater than 0. Different levels or thresholds may also be set. For example, the battery pack100may emit the sound only when the RSSI is greater than 0. Alternatively, the battery pack100may emit the sound only when the RSSI is greater than 10 or greater than 20. In other embodiments, the battery pack may emit a sound only when the RSSI.

According to another exemplary embodiment, the sound may change in volume or frequency as the RSSI changes. For example, the decibel or frequency of the beep or other sound provided by the battery pack100may vary according to the chart below.

Of course, the values shown in the table are merely examples. For example, four or more different sound frequencies may be used or the sound frequency may be continuously variable. Similarly, greater or continually varying decibel levels may be used. Additionally, different or more ranges of RSSI may be used.

Although the above embodiments have been described with respect to an RSSI signal, other signals such as, for example, a Received Channel Power Indicator (RCP) signal may be used. As with the RSSI, various different indications can be made by the computing device250, battery pack100or the power tool200based upon the level of the signal.

In another exemplary embodiment, the power tool battery pack may further include an LED display for displaying a state-of-charge of the battery pack on the battery pack. These exemplary embodiments of the battery pack are shown inFIGS. 5A-7B. The power tool battery pack100includes a set of rechargeable battery cells120disposed in a housing101. The housing includes guide rails104for connecting with a power tool and a latch105for securing the battery to the power tool. The latch105can be moved by depression of the latch actuator106(shown inFIG. 7A), which may be integral with the latch105. A battery pack with guide rails such as those shown these figures is more fully shown and described in U.S. Pat. No. 6,729,413, which is incorporated herein by reference.

FIG. 7Ais an illustrative drawing showing an inside of the battery pack100. As shown, the pack includes a plurality of rechargeable battery cells120. A cradle16sits over the battery cells120and a printed circuit board (PCB)140is connected to the cradle16. Electrical connectors (not shown) are mounted on the PCB140and connect with power tools through the connection section103. A battery pack of this general construction is shown and described in more detail in U.S. Pat. No. 9,065,106, which is incorporated herein by reference.

In the exemplary embodiment, the battery pack includes an RGB LED consisting of three discrete LEDs—a red LED, a green LED and a blue LED. The LEDs and electronic switches are shown inFIG. 6. As shown inFIG. 6, there is a red LED511, a green LED512and a blue LED513. The LEDs511-513are controlled by electronic switches521,522and523. The electronic switches521,522and523are connected to and operated by the control125shown inFIG. 2to selectively light the LEDs511-513to produce varying intensities and colors. Specifically, gates of the electronic switches521-523are connected to the control125. As previously discussed, the control125is connected to a wireless communicator126that sends and receives data from the computing device250. The computing device250has an application that can display a state of charge on a color gradient graph. The application can match the perceived color of the LEDs511-513to the RGB color value of the state-of-charge-of the battery that is displayed on the color gradient graph in the application. The control125may do this through pulse width modulation of the gates of the electronic switches to vary the duty cycle of the various LEDs511-513to change the LED display's perceived color value. In this case, the computing device250sends the RGB color info to the battery pack through the wireless communicator126and that information is sent to the electronic control125. The electronic control125then varies the duty cycle to match the RGB color value.

FIGS. 5A-5Dshow different locations for the LED displays530,531,532,533.FIG. 5Aillustrates an LED display530on a rear of the battery pack100. In this instance, the display530is separate from a pairing button540which activates pairing of the battery pack100to the electronic device250through the wireless communicator126. When the display530is located on the rear of the battery pack100, the battery pack may require an additional printed circuit board (FOB)150for mounting of the LEDs511-513, as is shown inFIG. 7B.

FIG. 5Billustrates an LED display531on a top surface of the battery pack100near a side. In this case, the LED display531also serves as a button for the pairing function. The LED display531may be actuated from above (i.e., it is top actuated).

FIG. 5Cillustrates an LED display532which is also located on a top surface of the battery pack100near a side. As with the LED display531, the LED display532serves a dual function as a pairing function button. The LED display may be actuated from above (i.e., it is top actuated). Additionally, the display532includes an icon551and is surrounded by a display portion552. The icon551and the display portion552may be illuminated according to the same color scheme and intensity or may be controlled to separately. For example, the icon551and display portion552may both be illuminated according to a state-of-charge of the battery, as described above. Alternatively, only the display portion552may be illuminated according to a state-of-charge of the battery pack100. In that instance, the icon551could be illuminated according to its pairing function. Alternatively or additionally, the icon551may be illuminated according to a pairing function when a pairing function is occurring and according to a state-of-charge of the battery pack100when no pairing function is taking place.

FIG. 5Dillustrates an LED display533which is also located on a top surface of the battery pack100near a side. As with the LED displays531and532, the LED display533serves a dual function as a pairing function button. The LED display may be actuated from a side (i.e., it is side actuated). Additionally, the display533includes an icon561and is surrounded by a display portion562. As with the LED display532, described above, the icon561and the display portion562may be illuminated according to the same color scheme and intensity or may be controlled to separately.

FIG. 7Aillustrates a battery pack100with the housing101removed. As shown inFIG. 7A, the pair button524and the red, blue and green LEDs511,512,513are mounted on a main printed circuit board140. Light from the LEDs511,512,513are directed via a lightpipe (not shown) to light the LED displays531,532,533. The location of the button524and LEDs511,512,513shown inFIG. 7Acorrespond to a placement that for LED displays531,532,533ofFIGS. 5B-5D. As can be seen, these display placements allow for the LEDs511,512,513and button524to be placed on the main printed circuit board (PCB)140. The particular placement of the LEDs511,512,513and button524can be changed. For example, the LEDs511,512,513may, for example, surround the button524and/or be formed in a triangular arrangement or be in a diagonal line.

As shown inFIG. 7B, the battery pack100may also include a second PCB150. The second PCB150can accommodate a pairing button524and the three LEDs511,512,513thereon so that the LED display530and button540can be disposed on a rear of the battery as shown inFIG. 5A. As previously discussed,FIG. 5Ashows a separate button540and display530. However, the display and button could be combined as shown inFIGS. 5B-5Dand maintained at this position.

FIG. 8illustrates a computing device250with a screen251showing five different indicators related to the battery pack100to illustrate features of an embodiment of the app. Particularly, the app may display a remaining charge bar701which represents a state-of-charge of the battery. The app may include a charge cycle display702. The charge cycle display includes a number of bars, each indicating one charge cycle. Each charge cycle represents the battery having been charged once. The height of each bar represents the amount of charge the battery receives in each charge cycle. As the charge cycle display702is filled up from left-to-right, it indicates to a user that the battery pack has been through a number of charging cycles. The battery pack will eventually wear down after a number of charging cycles. The width of the charge cycle display702may represent a maximum recommended number of charging cycles for the battery pack100.

Indicator703indicates a storage temperature of the battery pack100. A battery pack100may wear down quicker if it is stored at high temperatures. The line shown in indicator703can move higher when the battery is stored at a higher temperature and lower when the battery is stored at a lower temperature. In this manner, a user can see if the battery pack100is being stored at an undesirable temperature.

Indicator704indicates a remaining capacity of the battery pack100. As a battery pack100is used, charged, stored, ages and the like, the capacity of the battery pack100shrinks. For example, if a battery pack100starts at a first time at a capacity of 100% at a second time, later on, the battery pack may only have a remaining capacity of 90%. That is, when fully charged at the second time, the battery pack would only have 90% of the charge that the battery pack100had when fully charged at the first time.

Indicator705includes a current health of the battery pack. The current health is a composite of the indicators701-704. That is, the app calculates a current health705based on some combination of the remaining charge, charge cycles, storage temperature and remaining capacity. In one embodiment, the current health705may be based on all of the factors shown by indicators701-704. In another embodiment, the current health705may be based on some subset of those factors, for example only the factors shown by indicators702-704. Additionally, each factor may be weighted equally or the factors may have different weights. Alternatively or additionally, if any factor does not meet a minimum requirement that could disproportionately affect the current health rating. For example, if the remaining capacity is below a certain level, (e.g., 80% or 70%, etc.), the current health may be shown as an F, fail or error, regardless of the other factors. In some instances the measuring the charge cycles may include measuring the number of insertions of the battery pack into a battery charger. For example, each time the battery pack is inserted into an active battery charger, the battery pack100may sense the insertion and record the insertion number in its memory. The number of insertions can then be displayed to a user on the computing device250. The battery pack100may sense each insertion in various ways, for example by sensing a flow of current charging the pack or via an ID line on the battery pack. One of the connectors103may constitute an ID line and when a voltage is applied to the ID line that can be read by the pack, for instance, by an analog to digital converter inside the pack. The analog to digital converter being connected to the controller125and the appropriate connector103.

FIGS. 9A-9Cshows other representations of the app on the computing device250performing various functions.FIG. 9Aillustrates a batter charging screen which indicates that the battery pack100is currently being charged. In this case, the battery pack100being charged is identified as battery1to identify a first battery. The state of charge is indicated by a circular indicator706. The indicator706may be displayed in various colors, including to match the LED displays on the battery mentioned previously.

FIG. 9Billustrates a state of charge of a second battery pack100that is identified as battery2to differentiate the particular pack being charged from battery1. Again, the state of charge is shown on indicator706.FIG. 9Cillustrates battery2in a nearly fully charged state.

FIGS. 10A-10Cillustrate further representations of the app on the computing device250performing various functions.FIG. 10Aillustrates a lock function icon707having been activated. The icon707activates disable function, which has been previously described.FIG. 10Billustrates a locate icon708being activated. The locate icon708activates the locate function discussed previously having been activated.FIG. 10Cillustrates a locate screen indicating a location information regarding the tool or battery pack. The locate function was described in further detail previously. The screen may blink lighter, differently in different colors or in some other manner to indicate that a user is getting closer or farther away from the tool. These figures also include a community button710to allow community or social functions on the app to be activate; a health button709which allows alerts regarding the battery health previously discussed with reference toFIG. 8to be shown. The community or social functions may include items such as the shopping process or the service process described above. There is further a register icon711allowing a user to register the tool; a settings icon712allowing a user to choose various settings, such as what alerts or health indicators can be displayed; and an add tool icon713so that tools can be added, as previously discussed.

FIGS. 15-17illustrate an exemplary embodiment of a mechanical functioning of the button531shown inFIG. 5B. As previously discussed, a microswitch524may be mounted on a circuit board140. As shown inFIGS. 15-17, the button531is levered about a pivot543at a first end541of the lever. The pivot543may be a projection from the cradle16. Near the second end542of the button531, there is an actuating projection545. When a user pushes on the button531, it pivots about the pivot543and the actuating projection545contacts and actuates the microswitch524.

As shown inFIGS. 15-17, a biasing member525in the form of an O-ring biases the button531away from the circuit board140such that the actuating projection545is biased to a position where it does not actuate the microswitch524. The O-ring525may be made of an elastic, resilient, non-conductive material such as rubber or silicone rubber. The material of the O-ring525may have a durometer of Shore A30or higher, or a Shore A of 40 or higher. For example, the O-ring may have a Shore A durometer of 60.

A button construction as shown in the exemplary embodiment ofFIGS. 15-17may be advantageous for several reasons. As shown inFIGS. 15-17, the O-ring525is disposed in contact with circuit board140. When a rubber O-ring is used as a biasing member, its non-conductive nature prevents the part from causing an electrical short. Additionally, rubber O-ring525is readily available and easily mounted on projection544. Furthermore, the amount of space which is available for the microswitch524is limited and using a resent biasing member provides sufficient tension to bias the button531sufficiently and over a number of cycles. Although a rubber O-ring is shown in this particular exemplary embodiment, other constructions are contemplated. For example, a rubber piece in a different shape could be used. Additionally, a different material could be used for the biasing member525.

As can be appreciated, the battery packs of the exemplary embodiments of the present application are intended to be coupled with electrically powered products such as power tools, outdoor power tools, home products and the like. Particularly, a rail from the power tool or other product will slide into the slot610and between a lower rail611and an upper surface612of the battery pack. Such a structure is shown in, for example, U.S. Pat. No. 6,729,413, which is incorporated by reference. A housing or other feature of the power tool product may also project outwardly. The button531of the exemplary embodiment is constructed so that it does not interfere with coupling of such a power tool product with the battery pack100.

Accordingly, the button531of the exemplary embodiment does not project higher than the upper surface612of the battery pack which forms a lower end of the slot610. In alternative embodiments, the button531may project only slightly above the lower end of the slot610, for example, it may project up to 5 mm or up to 10 mm above the lower end of the slot610.

Additionally, as shown, the button531is located on a sloping side portion613which slopes downwardly and away from the center of the battery pack towards the side620of the battery pack100. This helps facilitate the button531not interfering with engagement of the battery pack100with tools.

The circuit board140may have an extension portion142as shown inFIG. 15. The extension portion142extends the circuit board out towards the side620of the battery pack100. As shown inFIG. 15, the extension portion142accommodates the switch524as well as the O-ring biasing member525. An outer edge of the extension portion142can extend so that it is very close to an inner portion of the side620of the housing101in the same horizontal plane. For example, the extension portion142can extend so that an outer edge of the extension portion142is 20 mm or less, 15 mm or less or 10 mm or less from an inner portion of the side620of the housing101in the same horizontal plane. In turn, the microswitch524can also be located close to an inner portion of the side620of the housing101that is in the same horizontal plane. For example, the microswitch524can be located such that a center of the switch is 25 mm or less, 20 mm or less or 15 mm or less from an inner portion of the side620of the housing101in the same horizontal plane.

The power tool battery pack100can be connected to a power tool to provide electrical power to the power tool through a connection section103through which electrical connectors130(FIG. 15) can be accessed. Additionally, battery pack100includes a charging connector or port102. In the exemplary embodiment, the charging connector is a USB port which receives a USB cord110. Other types of charging connectors could alternatively be used. The charging connector102allows the battery pack100to charge or power batteries and devices other than those with which it is designed to mate with through the connection section103(i.e., external devices). For example, the battery pack100may be connected to a phone or tablet computer through the USB cord100in order to allow the battery pack100to charge the phone or tablet computer.

FIG. 18is a simplified electrical diagram of an internal configuration of one of the battery packs andFIG. 19is an illustration of a computing device and battery pack.FIG. 20illustrates the battery pack charging an external device. In the embodiments ofFIGS. 18, 19 and 20, the battery pack100is used as an exemplary battery pack. However, the features illustrated therein can be used with any of the battery packs described herein. Also, the features of the battery pack shown inFIGS. 18-20and those shown inFIG. 2can be combined in various ways.

As shown inFIG. 18, the packs include cells120which provide power to the power tool through electrical connectors130and/or to an external device to be charged through a voltage regulator124connected to a charging port102. In this exemplary embodiment, the charging port is a USB port102. The pack includes a controller125in the form of a microcontroller, a wireless communicator126, a memory128and a current sensor145. As discussed previously, the battery pack includes a PCB140and the components may be mounted on the PCB140. If the battery pack includes second PCB150, one or more of the components may be mounted on that PCB150.

As shown inFIG. 18, the microcrontroller125is connected to a MOSFET switch122of the USB Port102. The microcontroller125can control the switch122to enable and disable the USB Port102. The wireless communicator126is operable to communicate with external computing devices, such as computing device250shown inFIG. 19. As is well known in the art, computing device250itself includes wireless communication capabilities and provide commands, data or other information to the battery pack100through the wireless communicator126and the microcontroller125may control the battery pack100accordingly.

As discussed above, the battery pack100includes a pairing switch524. When the user depresses the pairing switch524a pairing sequence is initiated which can pair the battery pack100with the computing device250as is known in the art. In the exemplary embodiment, wireless communication may take place according to Bluetooth standards, but other wireless communication is also contemplated as part of this disclosure.

In one exemplary embodiment, the USB Port102may be disabled via the switch122after a pre-determined amount of time. For example, the USB Port102may be turned on by a user-actuable switch. As discussed above, the user actuatable button may by the activate the same switch as is used for pairing (i.e, switch524). Additionally or alternatively, there may be a separate charging port button123. User actuation of the switch524or123will enable the USB Port102by toggling the MOSFET switch122. The USB Port102will then be enabled to charge an external device350for a predetermined amount of time. After the predetermined amount of time elapses, the microcontroller125can toggle the MOSFET switch122to disable the USB Port102. This prevents the battery cells120from becoming drained or having an undervoltage situation. In exemplary embodiments of the invention, the predetermined amount of time may be 10 hours or less; 9 hours or less; 8 hours or less; 7 hours or less; or 6 hours or less. The predetermined amount of time may be determined in a variety of ways. A predetermined amount of time of 8 hours or less provides significant charging to an external device350while avoiding an undervoltage situation. The external device350may be any number of devices which needs electrical charge. For example, these could include a phone, laptop computer, tablet computer, lights, batteries and the like. It could also charge a screwdriver that includes the appropriate input, such as Black & Decker cordless screwdriver BDCS30C.

Additionally or alternatively to being activated by switch524or charging port switch123, the USB port102may be activated by the external computing device250. A user of the computing device250can enter a command to turn on the USB port102. The command is received through the wireless communicator126and the microcontroller125can toggle the MOSFET switch122to enable the USB port102. The USB port102can then remain enabled for a predetermined amount of time, as discussed above.

The computing device250may also be used to program the predetermined amount of time. For example, rather than having an automatic predetermined amount of time such as 6 hours, the computing device250may be used to set a predetermined amount of time. The set time may be chosen from a selection of specific choices. For example, a user may be given a select number of choices and be able to select a predetermined amount of time as 2 hours, 3 hours, 4 hours, 5 hours, 6 hours or 7 hours. The user may also be able to input any selection for the predetermined amount of time.

In some instances it may be useful to have a maximum limit to the predetermined amount of time a user may input. For example, the user may be able to input any predetermined amount of time up to a maximum limit of 6 hours. The maximum limit can thus ensure that an undervoltage or other over-drainage of the battery cells120is avoided. The maximum limit may be, for example, 10 hours, 9 hours, 8 hours, 7 hours, 6 hours, 5 hours, 4 hours, 3 hours or 2 hours. In any of the embodiments, the amount of time remaining before the USB port102is disabled may be displayed on the computing device250. U.S. Patent Application Publication No. 2014/0107853 is hereby incorporated by reference and discloses computing devices which display the charging of a battery pack. The features of those applications may be incorporated into the present system. For example, the computing device250of the present application may display both the state of charge of the battery pack100and the amount of time remaining before the charging port102is disabled. This can be done simultaneously or a user may toggle between the displaying the amount of time remaining and the state of charge.

In one exemplary embodiment, it the predetermined amount of time may be determined according to the amp-hour rating of the battery pack and the current drawn from the battery pack by the voltage regulator124. The predetermined amount of time or the maximum limit may be set at a value equal to or greater than the watt-hour rating of a battery of the external device350being charged divided by the current times the voltage of the USB port102. This may be, for example, 2 hours or greater; 3 hours or greater; or 4 hours or greater.

In another exemplary embodiment, the predetermined amount of time or maximum limit of the predetermined amount of time may be equal to or less than a wattage of the battery pack100divided by a power consumption of the voltage regulator124. As with an above example, this can prevent undervoltage or overdraining of the battery cells120of the battery pack100. The predetermined amount of time or maximum limit of the predetermined amount of time may also be set slightly higher. For example, it may be set equal to or less than 1.2 times; 1.3 times or 1.4 times a wattage of the battery pack100divided by a power consumption of the voltage regulator124. In one example, the battery pack100has a maximum initial voltage of 20V and an amp-hour rating of 1.5 Amp-hours (Ah). In an example, the voltage regulator draws 300 mA of current and receives the 20V input voltage. The battery pack100wattage is the battery pack100voltage (i.e., 20V) multiplied by the battery pack amp hour rating (1.5 Ah). Accordingly, a wattage of the battery pack100divided by a power consumption of the voltage regulator124is equal to 5 hours. The predetermined amount of time or maximum limit of the predetermined amount of time may thus be set at 5 hours or less. It may also be set at something higher such as 6 hours or less (1.2×); 6½ hours or less (1.3×) or 7 hours or less (1.4×).

The computing device250may also be used to set the amount of current drawn from the voltage regulator124. For example, the electronic device may be configured to allow a user to set the current drawn from the voltage regulator124to 300 mA, 400 mA, 500 mA or some other setting. The computing device250may be configured to allow the user to set the charging rate for the USB port102. For example, the user may be able to set the USB port102so that it charges with a 1A current. Other rates may also be set, for example, it may set a rate that is 2 A or less; 1.5 A or less; 1 A or less or 500 mA or less.

The USB port102may also be disabled by simply pressing the user actuable button123and/or524a second time. In one embodiment, depressing the button may override the predetermined time. For example, if the USB port102is set to charge for a predetermined time of 6 hours, the USB port102may stay enabled for 6 hours or until a user actuates one of the buttons (123and/or524, as appropriate according to the embodiment) to disable the USB port102. Similarly, a user may use the computing device250to disable the USB port102before the predetermined time elapses.

Depending upon the type of charging port102, the voltage at which charging is done at the charging port102is done may be modified by modifying the voltage regulator124. For example, the user may set the charging voltage to 3V, 5V, 10V, 12V, or 20V.

The battery pack may also be modified to include multiple charging ports102. The multiple charging ports102may all be controlled independently by separate voltage regulators. For example, if a battery pack has two charging ports, one may be controlled by the user through the computing device250so that it charges at a first current and first voltage and the second charging port may be set by the user to charge at a second current and second voltage.

Various embodiments have been described. It should be understood that features of the various embodiments may be combined or used separately.