Abstract:
A power tool and accessory combination. The power tool has multiple terminals to which a battery pack or battery assembly can be connected. The accessory can be electrically connected to an unused tool terminal that is otherwise engageable by a battery pack.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims priority under 35 U.S.C. § 119 to co-pending U.S. Provisional Application Serial. No. 60/497,208, filed Aug. 22, 2003. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to power tools and power tool accessories and, more particularly, to electrical accessories for power tools.  
       BACKGROUND OF THE INVENTION  
       [0003]     Typically, cordless power tools are powered by a removable, rechargeable battery. The battery may be coupled to a terminal assembly on a housing of the power tool.  
         [0004]     Power tools are used for various primary operations including sawing and drilling. Additionally, secondary functions may be performed by an accessory of the power tool. For example, when primary operations are being performed, operators often desire additional illumination of the work area. Such additional illumination may be particularly desirable when working in dark or otherwise poorly-lit areas.  
       SUMMARY OF THE INVENTION  
       [0005]     Currently, power tools are manufactured with a tool housing having multiple terminal assemblies. For example, a handle of a typical power tool housing may include multiple terminal assemblies, any one of which may be connected to a battery pack or battery assembly to provide electrical power to the power tool. With the battery pack connected to any one of the terminal assemblies, the other terminal assembly(ies) on the tool housing are left open and unused.  
         [0006]     Conventional power tools may include accessories, e.g., a work light, vacuum, etc., that are coupled to a tool housing or to a battery pack that is connected to the tool housing. While these accessories may be usable with some existing power tools, these accessories may not be usable with the existing tool terminal assemblies which are engageable by a battery pack.  
         [0007]     The present invention provides a power tool and accessory combination, which substantially alleviates one or more problems with existing power tools and accessories. The present invention provides a power tool that generally has multiple terminals or terminal assemblies to which a battery pack or battery assembly is removably connected. The present invention provides an accessory that is removably electrically connected to an unused tool terminal or terminal assembly that is otherwise engageable by a battery pack.  
         [0008]     More particularly, in some aspects, the present invention provides a housing including a first tool terminal and a second tool terminal electrically communicating with the first tool terminal. The battery assembly is removably coupled to the housing and generally includes a battery terminal engaging one of the first tool terminal and the second tool terminal for electrical communication therewith. The tool accessory generally includes an accessory terminal engaging the other of the first tool terminal and the second tool terminal for electrical communication therewith.  
         [0009]     The tool accessory may include a terminal portion and an operating portion, and the accessory terminal is provided on the terminal portion. The operating portion may include at least one of a light source, an electronic level, a vacuum, a fan, an electromagnet, a motor, a radio, another audio component, a heating element, a battery indicator or display (e.g., a fuel gauge, remaining time of operation, temperature, etc.), a tool operation indicator or display (e.g., speed, time of operation, etc.), a clock, a stud finder, a power supply for a cell phone or other separate electrical device, etc.  
         [0010]     Also, in some aspects, the present invention provides a power tool generally comprising a housing including a main housing portion supporting the motor and a handle portion depending from the main housing portion. The housing also includes a first tool terminal and a second tool terminal, each tool terminal electrically communicating with the other tool terminal and with the electric motor. A battery assembly is removably coupled to the housing and generally includes a main body portion and a terminal portion, the terminal portion including a battery terminal that engages either of the first tool terminal and the second tool terminal for electrical communication therewith to provide electrical power to the electric motor and to the other of the first tool terminal and the second tool terminal. An accessory attachment generally includes an accessory terminal that engages the other of the first tool terminal and the second tool terminal and an operating portion, electrical power being transferred between the operating portion and at least one of the battery assembly and the electric motor.  
         [0011]     In some aspects and in some constructions, the operating portion may operate in response to electrical power provided by the battery assembly. In some aspects and in some constructions, the operating portion may provide electrical power from the battery assembly to another electrical device. In some aspects and in some constructions, the operating portion may provide electrical power to the battery assembly.  
         [0012]     The electrically-powered accessory may include at least one of a light source, an electronic level, a vacuum, a fan, an electromagnet, a motor, a radio, another audio component, a heating element, a battery indicator or display (e.g., a fuel gauge, remaining time of operation, temperature, etc.), a tool operation indicator or display (e.g., speed, time of operation, etc.), a clock, a stud finder, etc.  
         [0013]     The power-transfer accessory may provide power from the battery to another electrical device, such as, for example, a cell phone. The power-transfer accessory may provide power to the battery (for example, to charge the battery) and/or to the electric motor of the power tool (for example, to power the electric motor during charging of the battery or in lieu of power supplied by the battery).  
         [0014]     Further, in some aspects, the present invention provides a method for powering an accessory for a power tool, the accessory including an accessory terminal and an operating portion, the power tool including a first tool terminal, a second tool terminal, and a battery including a battery terminal. The method comprises the acts of selectively engaging the battery terminal with either of the first tool terminal and the second tool terminal to provide electrical power to the power tool and to the other of the first tool terminal and the second tool terminal, and engaging the accessory terminal with the other of the first tool terminal and the second tool terminal to transfer electrical power between the accessory and at least one of the battery and the power tool.  
         [0015]     Additional independent features and independent advantages of the present invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]      FIG. 1  is an exploded perspective view of a power tool embodying aspects of the invention, including a tool housing, a battery assembly, and an accessory in the form of a light.  
         [0017]      FIG. 2  is a rear view of the tool housing of  FIG. 1 .  
         [0018]      FIG. 3  is a rear perspective view of the battery assembly of  FIG. 1 .  
         [0019]      FIG. 4  is a perspective view of the battery assembly and light coupled to the tool housing in a first orientation.  
         [0020]      FIG. 5  is a perspective view of the battery assembly and light coupled to the tool housing in a second orientation.  
         [0021]      FIG. 6   a  is a perspective view of an accessory in the form of an air blower.  
         [0022]      FIG. 6   b  is a perspective view of an accessory in the form of a vacuum.  
         [0023]      FIG. 6   c  is a perspective view of an accessory in the form of an audio component, such as a radio.  
         [0024]      FIG. 6   d  is a perspective view of an accessory in the form of a fan.  
         [0025]      FIG. 6   e  is a perspective view of an accessory in the form of an electronic device.  
         [0026]      FIG. 6   f  is a perspective view of an accessory in the form of a power cord for supplying power from the battery assembly to another electrical device, such as a cell phone.  
         [0027]      FIG. 6   g  is a perspective view of an accessory in the form of a power cord for supplying power to at least one of the battery assembly and the power tool.  
         [0028]      FIG. 7  is a circuit diagram showing portions of the wiring for the tool housing, the battery assembly, and the accessory of  FIG. 1 . 
     
    
       [0029]     Before any constructions or 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 arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other constructions 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.  
       DETAILED DESCRIPTION  
       [0030]     Referring to  FIG. 1 , a power tool  10  according to aspects of the present invention, includes a tool housing  12 , a battery assembly  14 , and an accessory  16 . The tool housing  12  can take on any of a multitude of power tool configurations, such as, for example, a drill, a hammer drill, a rotary hammer, a reciprocating saw, a circular saw, a miter saw, an impact wrench, a work light, etc. For example, as shown in the Figures, tool housing  12  is in the form of a drill. It should be understood that, in other constructions and for some aspects, the power tool  10  may be another type of electrical equipment, such as, for example, video equipment, audio equipment, lawn and garden equipment, a vacuum, a blower, etc.  
         [0031]     The tool housing  12  includes a main housing portion  18  and a terminal portion  20 . The terminal portion  20  includes a first tool terminal or terminal assembly  22  and a second tool terminal or terminal assembly  24  (see  FIG. 2 ). The tool terminals  22  and  24  are oriented on substantially opposite sides of the terminal portion  20 . However, it will be readily apparent that the orientation of the tool terminals  22  and  24  could vary. For example, the tool terminals could be positioned in other locations on the terminal portion  20  of the tool housing  12 , or in entirely different locations on the tool housing  12 . Further, there could be more than just the two tool terminals  22  and  24  shown in the Figures.  
         [0032]     The battery assembly  14  includes a battery terminal or terminal assembly  26  (best seen in  FIG. 3 ) that is formed to mate with either of the tool terminals  22  and  24 . In a first orientation, as shown in  FIG. 4 , the battery assembly  14  is coupled to the tool housing  12  so that the battery terminal  26  (hidden from view in  FIG. 4 ) mates with the first tool terminal  22  (also hidden in  FIG. 4 ) of the terminal portion  20  of the tool housing  12 . In this configuration, electrical energy stored by the battery assembly  14  is supplied to the tool housing  12  through the connection between the battery terminal  26  and the first tool terminal  22  to power an electric motor (not shown) housed within the tool housing  12 . At the same time, the second tool terminal  24  (also hidden in  FIG. 4 ) is also powered through its electrical connection with the first tool terminal  22 .  
         [0033]     Alternatively, the battery assembly  14  can be coupled to the terminal portion  20  of the tool housing  12  as shown in  FIG. 5 . In this orientation, the battery assembly  14  projects from the terminal portion  20  in a substantially rearward direction, with the battery terminal  26  (hidden from view in  FIG. 5 ) mated with the second tool terminal  24  (also hidden in  FIG. 5 ). In this way, electrical energy from the battery assembly  14  is connected through the battery terminal  26  and the second tool terminal  24  to the electric motor housed in the main housing portion  18  of the tool housing  12 . Also, the first tool terminal  22  (also hidden in  FIG. 5 ) is powered through its electrical connection with the second tool terminal  24 .  
         [0034]     With the battery assembly  14  coupled to the tool housing  12  through the second tool terminal  24  (as shown in  FIG. 5 ), the first tool terminal  22  is available to be coupled to the accessory  16 . Similarly, as mentioned above, with the battery assembly  14  coupled to the tool housing  12  through the first tool terminal  22  (as shown in  FIG. 4 ), the second tool terminal  24  is available to be coupled to the accessory  16 .  
         [0035]      FIG. 5  illustrates the battery assembly  14  connected to the second tool terminal  24  and projecting substantially rearwardly from the terminal portion  20 . The accessory  16  includes an operating portion  32  and a terminal portion  34 . The terminal portion  34  includes an accessory terminal or terminal assembly  28  (see  FIG. 1 ) connected to the first tool terminal  22  and extending substantially forwardly from the terminal portion  20  of the tool housing  12 .  
         [0036]     In the illustrated construction, friction between the tool terminal  22  or  24  and the accessory terminal  28  and/or engagement between the tool terminal portion  20  and the accessory terminal portion  34  provides the necessary support to retain the accessory  16  in position. In other constructions (not shown), an additional locking assembly (not shown) and/or an additional support assembly may be provided on the power tool  10 , on the battery assembly  14 , on the accessory  16  and/or on a combination of these components to retain the accessory  16  in position.  
         [0037]     As shown in  FIGS. 1 and 5 , the accessory  16  is a light source, in this case including a flexible neck portion  30  as part of the operating portion  32  to allow the light source to be directed in various directions. However, in other constructions (not shown), the light may not include a flexible neck portion  30 , and the operating portion may be supported by the battery assembly  14  and/or by the tool housing  12 .  
         [0038]     Other accessories could be coupled to the first tool terminal  22  (or to the second tool terminal  24  if the battery assembly  14  is oriented as shown in  FIG. 4 ) and receive power from the battery assembly  14 . For example, the accessory could include an air blower ( FIG. 6   a ); a vacuum ( FIG. 6   b ); a radio ( FIG. 6   c ); another audio component (not shown), such as, for example, an MP3 player, CD player, etc.; a video component (not shown); a fan ( FIG. 6   d ); an electronic device (see  FIG. 6   e ), such as a level, a battery indicator or display (e.g., a fuel gauge, remaining time of operation, temperature, etc.), a tool operation indicator or display (e.g., speed, time of operation, etc.), a clock, a stud finder, etc.; an electromagnet (not shown); a motor (not shown); a heating element (not shown); or any one of other various accessories for use with power tools or other electrical equipment.  
         [0039]     Still other accessories could be coupled to the first tool terminal  22  (or to the second tool terminal  24  if the battery assembly  14  is oriented as shown in  FIG. 4 ) and receive power from the battery assembly  14 . For example, the accessory could include a power cord (see  FIG. 6   f ) for supplying power from the battery assembly  14  to another electrical device, such as a cell phone (as shown), an audio component (not shown), a video component (not shown), etc. Such an accessory includes a power output plug configured to electrically connect with the electrical device in a manner similar to the appropriate power cord for the electrical device. Such an accessory also includes the necessary circuitry and electronics (not shown) to supply power (having the characteristics required by the electrical device) from the battery assembly  14  to the electrical device.  
         [0040]     Yet other accessories could be coupled to the first tool terminal  22  (or to the second tool terminal  24  if the battery assembly  14  is oriented as shown in  FIG. 4 ) and transfer power through the tool terminal  22  or  24  to at least one of the battery assembly  14  and the motor of the power tool  10 . For example, the accessory could include a power cord (see  FIG. 6   g ) for supplying charging power to the battery assembly  14  and/or operating power to the motor of the power tool  10 . Such an accessory includes a power input plug configured to electrically connect with the power source (not shown), such as, for example, AC line power. Such an accessory also includes the necessary circuitry and electronics (not shown but provided in the housing of the power source input plug) to supply power (having the characteristics required by the battery assembly  14  and/or the motor) from power source to the battery assembly  14  and/or to the motor of the power tool  10 . In such constructions, circuitry and electronics may be provided in the power tool  10  and/or in the battery assembly  14  to selectively prevent the supply of power from the battery assembly  14  during any charging of the battery assembly  14  and/or during the supply of power from the other power source (not shown) to the power tool  10 .  
         [0041]     As mentioned above, in  FIG. 5 , the battery assembly  14  is connected to the second tool terminal  24  and extends rearwardly, while the accessory  16  is connected to the first tool terminal  22  and extends forwardly. However, if the battery assembly  14  is connected to the first tool terminal  22  and extends forwardly (as shown in  FIG. 4 ), the accessory  16  can be connected to the second tool terminal  24 , as discussed above. The type of accessory used, and the tool terminal to which the accessory  16  and the battery assembly  14  are coupled, can vary and can be chosen by the user of the power tool  10  based on the user&#39;s desired functionality.  
         [0042]      FIG. 7  illustrates the basic wiring configuration of the power tool  10 . A motor  36  is wired to the tool terminals  22  and  24  and the two tool terminals  22 ,  24  are wired to each other so that when the battery assembly  14  is connected to one of the terminals  22  or  24 , both the motor  36  and other terminal  22  or  24  are powered. In  FIG. 7 , the light accessory  16  is shown positioned to be connected to the first tool terminal  22 , and the battery assembly  14  is positioned to be connected to the second tool terminal  24 . This would result in a tool configuration as shown in  FIG. 5 . However, as discussed, the battery assembly  14  and light accessory  16  could be reversed, and the accessory could be any one of a number of contemplated accessories.  
         [0043]     Also, as discussed above, a cord (see  FIG. 6   g ) with an AC/DC adapter could be configured with a terminal on one end to connect to either of the tool terminals  22  or  24  and on the other end to plug into an alternative power source (e.g., a wall outlet, etc.). The cord would power the electric motor in the tool housing  12  through one of the tool terminals  22 ,  24 . Additionally, the other of the tool terminals  22  or  24  may be powered and could thereby power an accessory or charge a battery assembly connected to the other of the tool terminals  22 ,  24 .  
         [0044]     The foregoing detailed description describes only a few of the many forms that the present invention can take and should, therefore, be taken as illustrative rather than limiting. It is only the claims, including all equivalents, that are intended to define the scope of the invention.