Abstract:
An electrical combination includes a power tool having a body, a motor supported by the body, a support portion, and a drive mechanism driven by the motor such that the drive mechanism is operable to drive a tool element. The electrical combination also includes a battery operable for coupling to the power tool via the support portion. The battery is electrically connectable with the motor to selectively supply power to the motor. A single latch is positioned on the support portion of the power tool. The single latch is moveable between a locked position to secure the battery to the power tool and an unlocked position to allow removal of the battery from the support portion of the power tool.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 60/891,318 filed on Feb. 23, 2007. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to power tools and battery packs, and, more particularly, to a latch for a battery pack. 
       SUMMARY 
       [0003]    In some embodiments, the invention provides an electrical combination including a power tool and a battery pack. The power tool can include a housing, a hand grip, a motor, a spindle driven by the motor, and a first connecting configuration for receiving the battery pack. 
         [0004]    The battery pack can be operable to supply electrical power to the motor and can include a second connecting configuration configured to engage the first connecting configuration. The power tool can also or alternatively include a locking assembly for locking the battery pack to the power tool. The locking assembly can include a movable locking member supported in the housing and a movable actuator supported in the housing for moving the locking member between locked and unlocked positions. 
         [0005]    In one embodiment, the invention provides an electrical combination including a power tool having a body, a motor supported by the body, a support portion, and a drive mechanism driven by the motor. The drive mechanism is operable to drive a tool element. The electrical combination also includes a battery operable for coupling to the power tool via the support portion and being electrically connectable with the motor such that the battery selectively supplies power to the motor. A single latch is positioned on the support portion of the power tool. The single latch is moveable between a locked position to secure the battery to the power tool and an unlocked position to allow removal of the battery from the support portion of the power tool. 
         [0006]    In another embodiment, the invention provides a power tool including a motor, a drive mechanism driven by the motor to drive a tool element, and a body supporting the motor and the drive mechanism and having a grip surface and a connecting configuration for supporting a removeable battery. The connecting configuration supports a single latch moveable between a locked position and an unlocked position relative to the connecting configuration to allow locking and removal of the battery to and from the connecting configuration. 
         [0007]    In another embodiment, the invention provides a method of operating a power tool including a motor, a drive mechanism driven by the motor to drive a tool element, and a body supporting the motor and the drive mechanism and having a grip surface and a connecting configuration for supporting a removeable battery, the connecting configuration supporting a single latch moveable between a locked position and an unlocked position relative to the connecting configuration. The method includes the act of moving the single latch from the locking position toward the unlocking position with a single finger of an operator&#39;s hand such that the other fingers of the operator&#39;s hand can grip the battery to remove the battery from the connecting configuration. 
         [0008]    In another embodiment, the invention provides a method of manufacturing a power tool designed to operate upon engagement with a removable battery. The method includes the acts of providing a motor, coupling a drive mechanism to the motor for driving a tool element, and providing a body designed to support the motor and the drive mechanism. The body has a grip surface and a connecting configuration for supporting the battery. The connecting configuration includes a single latch moveable between a locked position and an unlocked position relative to the connecting configuration to allow locking and removal of the battery to and from the connecting configuration. 
         [0009]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of a battery pack and a portion of a power tool according to some embodiments of the present invention. 
           [0011]      FIG. 2  is an exploded perspective view of the battery pack and the portion of the power tool shown in  FIG. 1 . 
           [0012]      FIG. 3  is a cross-sectional view of the battery pack and the portion of the power tool shown in  FIG. 1 . 
           [0013]      FIG. 4  is an enlarged perspective view of a portion of a latching configuration of the power tool shown in  FIG. 1 . 
           [0014]      FIG. 5  is an enlarged perspective view of the portion of the latching configuration shown in  FIG. 4  in a locked position. 
           [0015]      FIG. 6  is an enlarged perspective view of the portion of the latching configuration shown in  FIG. 4  in an unlocked position. 
           [0016]      FIG. 7  is an enlarged perspective view of a portion of a latching configuration of s power tool according to an alternative embodiment of the present invention and with the connecting configuration in a locked position. 
           [0017]      FIG. 8  is an enlarged perspective view of the portion of the latching configuration shown in  FIG. 7  in an unlocked position. 
           [0018]      FIG. 9  is an enlarged perspective view of a portion of a latching configuration of a power tool according to another alternative embodiment of the present invention and with the connecting configuration in a locked position. 
           [0019]      FIG. 10  is an enlarged perspective view of the portion of the latching configuration shown in  FIG. 9  in an unlocked position. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” and “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
         [0021]    Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
         [0022]    In addition, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “front,” “rear,” “top,” “bottom,” “lower”, “up,” “down,” etc.) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. The elements of the present invention can be installed and operated in any orientation desired. In addition, terms such as “first” and “second” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance. 
         [0023]      FIGS. 1-6  illustrate an electrical combination  10 . The electrical combination  10  can include a power tool  12  (partially shown in  FIGS. 1-3 ), such as, for example, a drill, a hammer drill, or an impact wrench, and a battery pack  14 . In other embodiments, the power tool  12  can be another hand-held power tool, such as, for example, a reciprocating saw, a router, a drill, a screwdriver, a grinder, a sander, a circular saw, a band saw, or another handheld power tool. 
         [0024]    The power tool  12  includes a housing assembly  16  having a main operator&#39;s handle portion or hand grip  22 . The housing assembly  16  houses a drive mechanism, a motor, and a spindle. Together, the drive mechanism, the motor, and the spindle are operable to rotate a tool element (not shown) generally about a tool axis for working on a workpiece (also not shown). In other embodiments, the drive mechanism, the motor, and the spindle can also or alternatively reciprocate the tool element along the tool axis for working on a workpiece. 
         [0025]    In the illustrated embodiment of  FIGS. 1-6 , the hand grip  22  is formed of two grip halves  22   a  and  22   b , which together at least partially define a support portion or connecting configuration  24  for removably supporting the battery pack  14  below the hand grip  22 . In other embodiments, the hand grip  22  can be formed as a single integral member, or alternatively, can be formed from three or more interconnected members. Alternatively or in addition, the connecting configuration  24  and the elements of the connecting configuration  24  can have other positions and orientations with respect to the hand grip  22 . For example, the connecting configuration  24  can be located on a rearward surface of the hand grip  22 . In other embodiments, the connecting configuration  24  can be located on other portions of the power tool  12 , such as, for example, on an upper surface, a side surface, or a forward surface of the power tool  12 . 
         [0026]    As shown in  FIGS. 1-6 , the connecting configuration  24  can include grooves  26  and projections  28 , both of which can be operable to engage a connecting configuration  30  of the battery pack  14 . In the illustrated embodiment of  FIGS. 1-6 , grooves  26  extend horizontally along a lower portion of the connecting configuration  24  and the projections  28  extend horizontally along the lower portion of the connecting configuration  24  and inwardly into the grooves  26  to define guide rails for matingly engaging corresponding guide rails  78  on the battery pack  14 . In other embodiments, the connecting configuration  24  can include other grooves  26  and/or other projections  28  having the same or different orientations and configurations. 
         [0027]    The connecting configuration  24  of the power tool  12  can also include a terminal assembly positioned between forward ends of the grooves  26  and projections  28  and electrically connected to an electrical circuit, which extends through the power tool  12  and is electrically connected to the motor. In other embodiments, the terminal assembly or a portion of the terminal assembly can be positioned in the projections  28 . 
         [0028]    The connecting configuration  24  of the power tool  12  can also or alternatively include a latching assembly  38  for locking the battery pack  14  to the power tool  12 . In the illustrated embodiment, the latching assembly  38  can include a locking member  40  supported in a recess  42  defined between the grip halves  22   a ,  22   b . As shown in  FIG. 2 , the recess  42  opens toward a forward end of the power tool  12 . During operation and as explained in greater detail below, the locking member  40  is movable relative to the power tool  12  axially through the recess  42  along a locking axis  46  (see  FIG. 3 ), which is generally perpendicular to a battery insertion axis  48  defined by the grooves  26  and projections  28  of the power tool  12 . 
         [0029]    As best shown in  FIG. 1-6 , the locking member  40  can include an actuator  50  formed on an upper surface and extending outwardly from the recess  42  for engagement by an operator&#39;s finger or thumb. In the illustrated embodiment, the actuator  50  is positioned between the grip halves  22   a ,  22   b  and is also aligned with a grip axis  52 . In some such embodiments, the actuator  50  and the locking member  40  are moveable in a direction substantially parallel to a connecting plane defined between the handle halves  22   a ,  22   b . In other embodiments, the actuator  50  can have other orientations and locations. 
         [0030]    In some embodiments, such as the illustrated embodiment of  FIGS. 1-6 , the locking member  40  includes a locking projection  56 , which is engageable with the connecting configuration  30  of the battery pack  14  to secure the battery pack  14  to the power tool  12 . As shown in  FIGS. 1-6 , the locking projection  56  extends outwardly from the recess  42  through a forward opening  58  defined between the handle halves  22   a ,  22   b  and includes a sloped forward surface  60 . In other embodiments, the locking projection  56  can have other orientations and locations. 
         [0031]    As shown in  FIGS. 1-6 , the locking member  40  can also include an outwardly extending rib  62 , which is engageable with a corresponding rib  64  extending outwardly from the handle halves  22   a ,  22   b  and extending around at least a portion of the perimeter of the recess  42 . The engagement between the rib  62  of the locking member  40  and the rib  64  of the handle halves  22   a ,  22   b  maintains the locking member  40  in the locking recess  42 . 
         [0032]    In some embodiments, such as the illustrated embodiment of  FIGS. 1-6 , the connecting configuration  24  of the power tool  12  can include a biasing or elastic member  66 . As shown in  FIG. 1-6 , the elastic member  66  can be a leaf spring having a rearward end  68  supported in a recess  70  defined in one or both of the handle halves  22   a ,  22   b  and a forward end  72  extending into an opening  74  defined in a rearward end of the locking member  40 . In this manner, the elastic member  66  can bias the locking member  40  and the locking projection  56  upwardly toward a locked position. 
         [0033]    In other embodiments, the connecting configuration  24  can include one or more other elastic members  66 , such as, for example, coil springs, other leaf springs, and other resilient and/or deformable bodies. Alternatively or in addition, the elastic member  66  or a portion of the elastic member  66  can be positioned under the locking member  40  or to one side of the locking member  40  and/or can be integrally formed with the locking member  40 . 
         [0034]    As shown in  FIGS. 1-6 , the connecting configuration  30  of the battery pack  14  can include outwardly extending guide rails  78  extending horizontally along an upper surface of the battery pack  14  and protrusions  80  formed along and extending outwardly along exterior sides of the guide rails  78 . The guide rails  78  and the protrusions  80  are operable to inter-engage with the grooves  26  and projections  28  on the connecting configuration  24  of the housing assembly  16  to removably support the battery pack  14  on the power tool  12 . In other embodiments, the guide rails  78  and the protrusions  80  can have other relative positions and orientations within the connecting configuration  30  of the battery pack  14 . 
         [0035]    The connecting configuration  30  can also include a terminal assembly  84 , which can be electrically connected to the terminal assembly  34  of the power tool  12  to supply electrical power to the electrical circuit of the power tool. In some embodiments, the terminal assembly  84  can be positioned on an upper surface of the battery pack  14  between forward ends of the guide rails  78 . In other embodiments, the terminal assembly  84  or a portion of the terminal assembly can be supported in the guide rails  78  of the battery pack  14 . In these embodiments, at least a portion of the terminal assembly  34  of the power tool  12  can be supported in the projections  28  of the power tool  12  for engagement with the terminal assembly  84  or the portion of the terminal assembly  84  supported in the battery pack  14 . 
         [0036]    The connecting configuration  30  of the battery pack  14  can also include a locking recess  88  formed in a forward portion of the battery pack  14  between the guide rails  78 . In the illustrated embodiment of  FIGS. 1-6 , the locking recess  88  opens rearwardly (i.e., toward a rear end of the battery pack  14 ). As shown in  FIG. 3 , the connecting configuration  30  of the battery pack  14  can also include a locking rib  90  extending outwardly into the locking recess  88  for engagement with the locking projection  56  of the locking member  40 . 
         [0037]    In operation, the battery pack  14  is aligned with the power tool along a connection axis  92  so that the guide rails  78  and the protrusions  80  of the battery pack  14  are aligned with the projections  28  and grooves  30  of the power tool  12 . The battery pack  14  is then moved rearwardly along the connecting axis  92  to interconnect the guide rails  78  and the protrusions  80  of the battery pack  14  and the projections  28  and grooves  30  of the power tool  12 . As the battery pack  14  is moved onto the connecting configuration  24  of the power tool  12 , the terminal assembly of the power tool  12  is electrically connected to the terminal assembly  84  of the battery pack  14 . 
         [0038]    Alternatively or in addition, as the battery pack  14  is moved rearwardly along the connecting axis  92 , the sloped forward surface  60  of the locking projection  56  engages the locking rib  90 , causing the locking projection  56  to move downwardly along the locking axis  46  toward an unlocked position and to compress the elastic member  66 . As the battery pack  14  continues to move rearwardly along the connecting axis  92 , the forward surface  60  of the locking projection  56  moves past the locking rib  90  and the locking projection  56  lockingly engages a forward edge of the locking rib  90 , securing the battery pack  14  to the power tool  12 . 
         [0039]    To remove the battery pack  14  from the power tool  12 , an operator grips the hand grip  22  with a first hand and grips a forward end of the battery pack  14  with a second hand. With the second hand, the operator also contacts the actuator  50  and moves the actuator  50  and the locking projection  56  downwardly along the locking axis  46  toward an unlocked position, in which the locking projection  56  is moved out of engagement with the locking rib  90  of the battery pack  14 . The operator can then slide the battery pack  14  along the guide rails  78  and away from the power tool  12 . Alternatively, the operator can remove the battery pack  14  from the power tool  12  with a single hand. In these embodiments, the operator grips opposite sides of the battery pack  14  with a thumb and the second an/or third fingers of one hand. The operator can then depress the actuator  50  with the index finger of the same hand. Because the actuator is positioned in a central position on the power tool  12 , the operator can easily operate the actuator  50  with either hand while gripping the power tool  12  with the other hand. 
         [0040]      FIGS. 7 and 8  illustrate another embodiment of a latching assembly  238  of a power tool. The latching assembly  238  shown in  FIGS. 7 and 8  is similar in many ways to the illustrated embodiments of  FIGS. 1-6  described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment of  FIGS. 7 and 8  and the embodiments of  FIGS. 1-6 , reference is hereby made to the description above accompanying the embodiments of  FIGS. 1-6  for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment of  FIGS. 7 and 8 . Features and elements in the embodiment of  FIGS. 7 and 8  corresponding to features and elements in the embodiments of  FIGS. 1-6  are numbered in the 200 series. 
         [0041]    The latching assembly  238  can include a locking member  240  supported in a recess defined between the grip halves  22   a ,  22   b  of the power tool  12 . As shown in  FIGS. 7 and 8 , the locking member  240  can include an actuator  250  formed on an upper surface for engagement by an operator&#39;s finger or thumb and an outwardly extending locking protrusion  256 , which is engageable with the connecting configuration  30  of the battery pack  14  to secure the battery pack  14  to the power tool  12 . 
         [0042]    As shown in  FIGS. 7 and 8 , the latching assembly  238  can also include an elastic member  266  having a left side  286  engageable in a first recess defined between the first and second handle halves  22   a ,  22   b  of the power tool  12 , a right side  272  engageable in a second recess defined between the first and second handle halves  22   a ,  22   b  of the power tool  12 , and a central portion  296  positioned between the left and rights sides  266 ,  272  and moveable axially along locking axis  246  with the locking member  240 . 
         [0043]      FIGS. 9 and 10  illustrate another embodiment of a latching assembly  338  of a power tool. The latching assembly  338  shown in  FIGS. 9 and 10  is similar in many ways to the illustrated embodiments of  FIGS. 1-8  described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment of  FIGS. 9 and 10  and the embodiments of  FIGS. 1-8 , reference is hereby made to the description above accompanying the embodiments of  FIGS. 1-8  for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment of  FIG. 9 . Features and elements in the embodiment of  FIGS. 9 and 10  corresponding to features and elements in the embodiments of  FIGS. 1-8  are numbered in the 300 series. 
         [0044]    The latching assembly  338  can include a locking member  340  supported in a recess defined between the grip halves  22   a ,  22   b  of the power tool  12 . As shown in  FIG. 9 , the locking member  340  or a portion of the locking member  340  can be formed from an elastic material such that a left side  386  is engageable in a first recess defined between the first and second handle halves  22   a ,  22   b  of the power tool  12 , a right side  372  is engageable in a second recess defined between the first and second handle halves  22   a ,  22   b , and a central portion  396  positioned between the left and rights sides  366 ,  372  is moveable axially along locking axis  246  with the locking member  340 . Although not shown, the locking member  340  can include an outwardly extending locking projection, which is engageable with the battery pack  14  to secure the battery pack  14  to the power tool  12 . 
         [0045]    Although particular embodiments of the present invention have been shown and described, other alternative embodiments will be apparent to those skilled in the art and are within the intended scope of the present invention.