Patent Description:
Electrical devices, such as power tools, are often powered using batteries. In some electrical devices, batteries can be charged in-situ and without removal. However, in the field of power tools, batteries are typically configured to be removed from the power tool and charged separately. Because batteries for power tools are removable, when a battery is discharged it can be instantly replaced with a fully charged battery, thus avoiding the need to wait for the tool to charge and thereby reducing downtime.

In order to reduce the need to have a separate battery for different power tools, it is common for different types of power tool to be equipped with a common battery interface, comprising an assembly of battery terminals, so that they can receive the same type of battery. Many power tools require not only supply and return power terminals, but also a number of communications terminals and/or supply terminals for different levels of power output (e.g. low, medium or high power), and therefore the terminal assembly may comprise a relatively large number of electrical terminals. However, when the number of terminals is increased, the width of the terminal assembly must be increased to accommodate enough space between each adjacent terminal so that it can be received into a corresponding receptacle to complete the electrical connection between the battery and the power tool. The width of the terminal assembly may therefore be relatively large in relation to the power tool, and thus the battery may be bulky in comparison to the power tool.

Electrical assemblies are known from <CIT> and <CIT>, wherein the latter is showing the preamble of claim <NUM>.

It is an object of the invention to obviate or mitigate one or more disadvantages, whether identified herein or elsewhere, of known terminal assemblies and/or methods of manufacture. It is a further object of the invention to provide an alternative terminal assembly and/or method of manufacture.

According to a first aspect of the invention, there is provided a method of manufacturing a terminal assembly for an electrical device, comprising: providing a die defining a mould cavity; providing a first terminal defining a first terminal axis and having a first support portion extending away from the first terminal axis; providing a second terminal defining a second terminal axis and having a second support portion extending away from the second terminal axis; arranging the first terminal in a first vertical position by supporting the first support portion on the die; and arranging the second terminal in a second vertical position above the first vertical position by supporting the second support portion on the die.

Because the first and second support portions extend away from the first and second terminal axes, the first and second support portions may engage the die at positions that are horizontally offset from the first and second terminal axes. Put another way, because the support portions extend away from the terminal axes, the support portions may form a cantilevered configuration relative to the terminal axes such that the weight of the terminals can be supported at a position horizontally offset from the terminal axes. As such, the first and second terminals can be positioned above and below one another in the die whilst still being in contact with the die so as to support the first and second terminals in the appropriate position for injection moulding. In particular, the use of the support portions permits the region of space between the first and second terminals to be substantially empty, and therefore this region of space can be filled with a material to form a body of the terminal assembly. The moulding process can be carried out in a single step with the moulding of any other terminals in the terminal assembly, thus reducing the number of moulding steps required, reducing complexity, and saving time and costs. Furthermore, by supporting the terminals on the die, the die is able to act as a datum to more precisely control the vertical positions of the terminals.

The term "terminal" will be understood to encompass an electrical connector configured to engage another electrical connector so as to permit electrical communication therebetween. For example, a terminal may be a plug or a socket.

The term "terminal axis" will be understood to encompass a longitudinal axis defined by the portions of the terminals which are configured to form an electrical connection with a corresponding terminal of different device to which the terminal assembly is connected. For example, the terminal may be a longitudinally extending plug (i.e. male terminal), and the terminal axis may be the axis defined by the plug.

The term "support portion" will be understood to encompass a portion of the terminal that is configured to mechanically mount the terminal to another object; or, put another way, a part of the terminal suitable for transferring at least some of weight of the terminal to another object.

The term "extending away" will be understood to encompass the support portions extending in a direction that is non-parallel to the terminal axis. For example, one or more of the support portions may extend in a direction generally perpendicular to its associated terminal axis.

By "vertical position" it is encompasses a position within a vertical plane relative to the die. The die may define a height, a width and a length, and the vertical plane may be the plane parallel to the height of the die. That is to say, the vertical plane need not be a true vertical plane that is aligned with the Earth's force of gravity, but may be a plane that is orthogonal in relation to a width of the die.

The first terminal axis and the second terminal axis may lie within a common plane. That is to say, the first and second axes may be substantially aligned with one another such that they extend within the same plane, for example a vertical plane. Where the axes are aligned with one another in a vertical plane, the first terminal will be positioned exactly below the second terminal, and thus the width of the terminal assembly can be reduced.

The method may further comprise: holding the first terminal in the first vertical position using a first holding member. It will be appreciated that, in general, a holding member encompasses any suitable means for holding a terminal in a desired position. The holding member helps to support some of the weight of the terminal so as to maintain the terminal in the required position.

The step of holding the first terminal may comprise: clamping the first support portion against the die using a distal end of the first holding member. The first holding member may be positioned vertically above the first support portion.

The step of holding the first terminal may further comprise: receiving the first terminal within a recess defined by a distal end of a third holding member. The third holding member may be positioned vertically lower than the first support portion.

The method may further comprise: holding the second terminal in the second vertical position using a second holding member. The step of holding the second terminal may comprise: receiving the second terminal within a recess defined by a distal end of the second holding member. The second holding member may be positioned vertically above the second support portion.

The step of holding the second terminal may further comprise: receiving the second terminal within a recess defined by a distal end of a fourth holding member. The fourth holding member may be positioned vertically lower than the second support portion.

The first terminal may comprise a generally flat plate. The flat plate may be generally L-shaped. The flat plate may be formed by stamping. In other constructions the terminal may be substantially any suitable shape, for example cylindrical, prismatic or the like.

The first support portion may comprise a first tab. The tab may be formed from a bent portion of the flat plate defining the terminal. The plate may define a first plane, and wherein the first tab may extend at an angle relative to the first plane. The first plane may be the central plane of the plate. The tab may extend generally perpendicular to the plate.

The first tab may be formed on an upper edge of the first terminal. When the first tab is formed on the upper edge of the first terminal, the first terminal may downwardly depend from the first tab such that the first terminal is supported at a position vertically below the first tab and a support surface of the die.

The method may further comprise: bending the first tab about an axis parallel to the first plane. Because the axis is parallel to the first plane, the tab will extend in a direction generally orthogonal to the first plane, and away from the flat plate defining the terminal. Furthermore, bending a portion of the terminal to form the support portion is a simple process, which can be manufactured cheaply.

The second terminal may comprise a generally flat plate. The second support portion may comprise a second tab. The plate may define a second plane, and wherein the second tab extends at an angle relative to the second plane.

The tab may be formed on a lower edge of the second terminal. When the second tab is formed on the lower edge of the second terminal, the second terminal may upwardly depend from the second tab such that the second terminal is supported at a position vertically above the second tab and the support surface of the die. The method may further comprise: bending the second tab about an axis parallel to the second plane.

The first support portion may engage the die at a first horizontal position and the second support portion engages the die at a second horizontal position. That is to say, the first tab and the second tab may be spaced apart from one another in a horizontally extending plane. Because the first and second tabs are horizontally spaced apart from one another, the first and second tabs may be accessed from above, for example by the first and/or second holding members so as to clamp the tabs against the die and fix the position of the terminals within the mould cavity. The first and second tabs may be arranged so they do not overlap.

The first terminal and/or the second terminal may be generally L-shaped.

The method may further comprise: enclosing the mould cavity; injecting a material into the mould cavity to encapsulate at least a portion of the first terminal and at least a portion of the second terminal; and curing the material to form a solid.

According to a second aspect of the invention, there is provided an electrical device comprising a terminal assembly manufactured using the method of the first aspect of the invention. The electrical device may be one of a battery, a charger, or a power tool, or may be any other suitable electrical device.

According to a third aspect of the invention there is provided a terminal assembly comprising: a first terminal defining a first terminal axis; and a second terminal defining a second terminal axis; wherein the first terminal is arranged in a first vertical position and the second terminal is arranged in a second vertical position above the first vertical position. Because the first terminal and the second terminal are vertically above and below one another, the width of the terminal assembly can be reduce. Therefore the power tool and/or battery can be made less bulky.

The first terminal axis and the second terminal axis may lie within a common vertical plane. The first terminal may have a first support portion extending away from the first terminal axis. The first support portion may be formed on an upper edge of the first terminal. The first terminal may comprise a generally flat plate defining a first plane. The first support portion may comprise a first tab. The first tab extends at an angle relative to the first plane. The first tab may extend generally orthogonal to the first plane. The first terminal may be a communication terminal.

The second terminal may have a second support portion extending away from the second terminal axis. The second support portion may be formed on a lower edge of the second terminal. The second terminal may comprise a generally flat plate defining a second plane. The second support portion may comprise a second tab. The second tab may extend at an angle relative to the second plane. The second tab extends generally orthogonal to the second plane. The second terminal may be a temperature terminal.

The terminal assembly may further comprise a third terminal horizontally spaced apart from the first and second terminals by a first distance (L1). The first distance (L1) may be around <NUM>. The third terminal may comprise a vertically-aligned flat plate. The third terminal may be a negative power terminal.

The terminal assembly may further comprise a fourth terminal horizontally spaced apart from the first and second terminals by a second distance (L2). The second distance (L2) may be around <NUM>. The fourth terminal may be on an opposite side of the first and second terminals to the third terminal. The fourth terminal may comprise a horizontally aligned flat plate. The fourth terminal may be a charging terminal.

The terminal assembly may further comprise a fifth terminal horizontally spaced apart from fourth terminal by a third distance (L3). The third distance (L3) may be around <NUM>. The fifth terminal may be on an opposite side of the fourth terminal to the first and second terminals. The fifth terminal may comprise a vertically-aligned flat plate. The fifth terminal may be a positive power terminal. The fifth terminal may be horizontally spaced apart from the first and second terminals by a fourth distance (L4). The fourth distance (L4) may be around <NUM>.

The terminal assembly of the third aspect of the invention may be manufactured according to the first aspect of the invention. The terminal assembly of the third aspect of the invention may have any of the structural features of the terminal assembly manufactured according to the method of the first aspect of the invention.

According to a fourth aspect of the invention, there is provided an electrical coupling assembly comprising: a first electrical receptacle configured to receive a first terminal of a terminal assembly; and a second electrical receptacle configured to receive a second terminal of the terminal assembly; wherein the first electrical receptacle is positioned vertically above the second electrical receptacle. Because the first electrical receptacle is positioned above the second electrical receptacle, the width of the electrical coupling assembly is reduced, and therefore the battery and/or power tool can be made less bulky.

The first electrical receptacle may be a communication receptacle. The second electrical receptacle may be a temperature receptacle. The first and second electrical receptacles may lie within a common vertical plane.

The electrical coupling assembly may further comprise a third electrical receptacle configured to receive a third terminal of the terminal assembly. The third electrical receptacle may be horizontally spaced apart from the first and second terminals by a first distance (L1). The first distance (L1) may be around <NUM>. The third electrical receptacle is a negative power receptacle.

The electrical coupling assembly may further comprise a fourth electrical receptacle configured to receive a fourth terminal of the terminal assembly. The fourth electrical receptacle may be horizontally spaced apart from the first and second electrical receptacles on an opposite side of the first and second electrical receptacles to the third terminal by a second distance (L2). The second distance (L2) may be around <NUM>. The fourth electrical receptacle may be a charging receptacle.

The electrical coupling assembly may further comprise a fifth electrical receptacle configured to receive a fifth electrical terminal of the terminal assembly. The fifth electrical receptacle may be horizontally spaced apart from fourth electrical receptacle on an opposite side of the fourth electrical receptacle to the first and second electrical receptacles by a third distance (L3). The third distance (L3) may be around <NUM>. The fifth electrical receptacle may be a positive power receptacle.

According to a fifth aspect of the invention there is provided an electrical device comprising the electrical coupling assembly of the fourth aspect of the invention. The electrical device may be a battery, a charger, or a power tool.

According to a sixth aspect of the invention there is provided an electrical device comprising the terminal assembly of the third aspect of the invention. The electrical device may be a battery, a charger, or a power tool.

The invention is described in detail below with reference to the accompanying drawings, in which:.

<FIG> shows an electrical combination <NUM> of a power tool <NUM> and a removable battery pack <NUM>. The power tool <NUM> of <FIG> is an impact wrench, however it will be appreciated that the power tool <NUM> may be substantially any power tool requiring battery power. For example, the power tool <NUM> may be: a screwdriver, a drill driver, an impact driver, a hammer drill, a jigsaw, a bolt cutter, an offset shear, a planer, a table saw, a miter saw, a grinder, a circular saw, a reciprocating saw, a rotary cutter, a scroll saw, a fan, a caulk gun, a drain auger, a hot glue gun, a transfer pump, a blower, a vacuum cleaner, a propane heater, a cement mixer, a sander, a router, a buffer, a nailer, a staple gun, a light, a speaker, a compressor, an inflator, or the like. In yet further embodiments, the electrical combination <NUM> may comprise a battery charger in place of the power tool <NUM>, the battery charger being configured to charge the battery <NUM>.

<FIG> shows the power tool <NUM> with the battery pack <NUM> removed. The power tool <NUM> defines socket <NUM> positioned at a lower end of the power tool <NUM>. The socket <NUM> is configured to receive and form an electrical connection with the battery pack <NUM>. The socket <NUM> comprises a pair of longitudinally extending rails <NUM> defining recesses <NUM> for receiving corresponding rails of the battery pack <NUM>. <FIG> and <FIG> show the socket <NUM> in more detail from below. The socket <NUM> defines a front portion <NUM> and a rear portion <NUM> positioned at an opposite end of the socket <NUM> to the front portion <NUM>. The front portion <NUM> is open for receiving the battery pack <NUM>. The socket <NUM> further comprises a terminal assembly <NUM> housed at the rear portion <NUM> of the socket <NUM>. The terminal assembly <NUM> is configured to provide an electrical connection with the battery pack <NUM>.

The terminal assembly <NUM> is shown in isolation in <FIG>. The terminal assembly <NUM> comprises: a body <NUM>, a first terminal <NUM> which is a communication terminal, a second terminal <NUM> which is a temperature terminal, a third terminal <NUM> which is a battery pack negative power terminal, a fourth terminal <NUM> which is a charging terminal, and a fifth terminal <NUM> which is a battery pack positive power terminal. The terminals <NUM>-<NUM> are arranged on a front facing side <NUM> of the body <NUM>, such that the terminals <NUM>-<NUM> are exposed below the power tool <NUM> within the socket <NUM>. The terminals <NUM>-<NUM> are male terminals (i.e. plug terminals), and are configured to be received by corresponding female terminals of the battery pack <NUM>. The terminals <NUM>-<NUM> form temporary (i.e. detachable or removable) electrical connections with the corresponding terminals on the battery pack <NUM> for providing power to the power tool <NUM> when the battery pack <NUM> is received within the socket <NUM>. The terminals <NUM>-<NUM> are formed from a material having high electrical conductivity, such as metal, for example copper, brass, phosphor bronze or the like.

Referring to <FIG>, the third terminal <NUM> is horizontally spaced apart from the first and second terminals <NUM>, <NUM> by a first distance L1 of around <NUM>. The centre of the fourth terminal <NUM> is horizontally spaced apart from the first and second terminals <NUM>, <NUM> by a second distance L2 of around <NUM>. The fifth electrical terminal <NUM> and the centre of the fourth terminal <NUM> are horizontally spaced apart by a third distance L3. In some embodiments, the third distance L3 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>). The first and second terminals <NUM>, <NUM> and the fifth terminal <NUM> are horizontally spaced apart by a fourth distance L4. In some embodiments, the fourth distance L4 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>). The third terminal <NUM> and the centre of the fourth terminal <NUM> are horizontally spaced apart by a fifth distance L5. In some embodiments, the fifth distance L5 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>). The third terminal <NUM> and the fifth terminal <NUM> are horizontally spaced apart by a sixth distance L6. The sixth distance L6 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>).

Each of the terminals <NUM>-<NUM> comprises a corresponding connection portion <NUM>-<NUM> positioned on an upward facing side <NUM> of the body <NUM>. In particular, the first terminal <NUM> comprises a fist connection portion <NUM>, the second terminal <NUM> comprises a second connection portion <NUM>, the third terminal <NUM> comprises a third connection portion <NUM>, the fourth terminal <NUM> comprises a fourth connection portion <NUM>, and the fifth terminal <NUM> comprises a fifth connection portion <NUM>. The connection portions <NUM>-<NUM> are configured to form permanent electrical connections, formed for example by soldering, with the internal electrical components of the power tool <NUM>. The connections portions <NUM>-<NUM> are disposed within the interior of the power tool <NUM>, and are not accessible to the user.

In some embodiments, the fourth terminal <NUM> is also configured to operate as a low-power terminal. The fourth terminal <NUM> can be configured to provide charging current to the battery pack <NUM> when the terminal assembly is part of a battery pack charger. The fourth terminal <NUM> can be configured to receive power from the battery pack <NUM> when the power tool <NUM> is a low power device (i.e., a device requiring a comparatively low discharge current from the battery pack <NUM>), such as a light, a fan, or the like.

In some embodiments, the second terminal <NUM> is configured as the communication terminal and the first terminal <NUM> is configured as a bypass terminal. In such embodiments, the bypass terminal <NUM> is configured to bypass, for example, a current sensing circuit. As a result, current sensing circuitry within the battery pack <NUM> can be avoided by the power tool <NUM> if the power tool <NUM> is configured to use the bypass terminal <NUM> instead of the battery pack negative power terminal <NUM>. When the first terminal <NUM> is configured as a bypass terminal, it is used, for example, by high current draw devices to prevent the battery pack <NUM> from unnecessarily shutting down the battery pack <NUM> due to high current, or from adding resistance (i.e., a current sensing resistor) to the battery pack's <NUM> discharge circuit, which can limit the output current capability of the battery pack <NUM>.

In some embodiments, the terminal assembly <NUM> includes each of terminals <NUM>-<NUM>, but one or more of the terminals <NUM>-<NUM> are non-functional or nonoperational. For example, by including all of the terminals <NUM>-<NUM> in the terminal assembly <NUM>, a more secure connection between the battery pack <NUM> and the power tool <NUM> can be achieved. In some embodiments, one or more of the terminals <NUM>-<NUM> in the terminal assembly <NUM> are not present, but the general shape of the terminal assembly body <NUM> remains substantially the same. As a result, the shape of the body <NUM> helps to securely connect the terminal assembly <NUM> to the power tool <NUM> in the absence of one or more of the terminals <NUM>-<NUM>.

As shown most clearly in <FIG>, the first terminal <NUM> and the second terminal <NUM> are aligned with one another in the vertical direction. That is to say, the first and second terminals lie within the same vertical plane. Because the first and second terminals <NUM>, <NUM> lie within the same plane, this means that the width of the terminal assembly <NUM> (i.e. the horizontal direction in the perspective of <FIG>) can be reduced. By reducing the width of the terminal assembly, the widths of socket <NUM> and the battery pack <NUM> can also be reduced, so that the battery pack is not too bulky in relation to the power tool <NUM>.

The terminal assembly <NUM> is typically manufactured using injection moulding, which involves the use of a two-piece die forming a hollow mould cavity. The split line of the cavity is arranged along the width of the terminal assembly <NUM> (i.e. horizontally in <FIG>). However, because the first and second terminals <NUM>, <NUM> are aligned in a common plane that is normal to the split plane (i.e. in the same vertical plane), it is difficult to support the first and second terminals <NUM>, <NUM> in the correct position for moulding. Without support, the first and second terminals <NUM>, <NUM> will fall under their own weight and out of their required positions. The terminals <NUM>, <NUM> of any subsequently manufactured terminal assembly <NUM> would be out of position and therefore not be able to be received within the corresponding sockets of the battery pack <NUM>.

One possible solution to the problem of holding the terminals <NUM>, <NUM> is to mould the two terminals <NUM>, <NUM> together in a sub assembly, so that the position of the terminals <NUM>, <NUM> relative to one another is fixed. The sub assembly can then be subsequently moulded into the completed terminal assembly <NUM>. However, this additional moulding step increases the complexity, manufacturing time and costs of the terminal assembly <NUM>.

<FIG> shows an arrangement of the terminals <NUM>-<NUM> of the terminal assembly <NUM> with the terminal assembly body <NUM> removed. The perspective of <FIG> is as if the power tool <NUM> and terminal assembly <NUM> of <FIG> were placed upside-down. This corresponds to the arrangement of the terminals <NUM>-<NUM> during manufacture. References to vertically above and below henceforth refer to the perspective shown in <FIG> (and not <FIG>).

As shown in <FIG>, the terminals <NUM>-<NUM> are generally flat L-shaped plates. The first terminal <NUM> defines a fist terminal axis <NUM>. The first terminal axis <NUM> is the axis defined by the part of the first terminal <NUM> that protrudes from the body <NUM> of the terminal assembly <NUM> and into the socket <NUM> for forming an electrical connection with the battery pack <NUM>. Likewise, the second terminal <NUM> defines a second terminal axis <NUM> which is the axis defined by the part of the second terminal <NUM> that protrudes into the socket <NUM>. The first support portion <NUM> extends away from a plane defined by the first terminal <NUM> in a direction generally orthogonal to the plane. Likewise, the second support portion <NUM> extends away from a plane defined by the second terminal in a direction generally orthogonal to that plane. However, it will be appreciated that in alternative embodiments the first and second support portions <NUM>, <NUM> may extend away from their associated support axes at any suitable angle.

The first and second terminal axes <NUM>, <NUM> are aligned in the same vertical plane, orthogonal to the width direction of the terminal assembly <NUM>. The first terminal <NUM> comprises a first support portion <NUM> extending away from the first terminal axis <NUM>, and the second terminal <NUM> comprises a second support portion <NUM> extending away from the second terminal axis <NUM> in generally the same direction as the first support portion <NUM>. The first and second support portions <NUM>, <NUM> extend generally normal to the plane defined by the two terminal axes <NUM>, <NUM> (or, put another way, generally horizontally). The first support portion <NUM> is formed on an upper edge <NUM> of the first terminal <NUM> and the second support portion <NUM> is formed on a lower edge <NUM> of the second terminal <NUM>. The first and second support portions <NUM>, <NUM> generally lie within a common plane normal to the plane defined by the first and second terminal axes <NUM>, <NUM> (or, put another way, at the same height in the vertical direction). However, the support portions <NUM>, <NUM> are spaced apart from one another within the common plane so that they do not overlap.

<FIG> shows a perspective view of the first and second terminals <NUM>, <NUM> supported by a support surface <NUM>. The support surface <NUM> is part of a die <NUM> defining a mould cavity. The mould cavity is a region of empty space forming a negative image of the body <NUM> of the terminal assembly <NUM>. During manufacture, the mould cavity is filled with a material, for example a polymer material, which when cured forms the body <NUM>. The support surface <NUM> is a generally horizontal, upwardly facing surface of a boss <NUM> extending into the mould cavity. The boss <NUM> defines a side wall <NUM> extending generally parallel to the plane defined by the terminal axes <NUM>, <NUM> (or, put another way, generally vertically). The side wall <NUM> and support surface <NUM> define an edge <NUM> therebetween.

During use, the support portions <NUM>, <NUM> of the first and second terminals <NUM>, <NUM> engage the support surface <NUM> so that the support portions <NUM>, <NUM> rest on top of the support surface <NUM>. The support surface <NUM> therefore acts as a datum against which the positions of the first terminal <NUM> and the second terminal <NUM> can be controlled. Because the first support portion <NUM> is formed on the upper edge <NUM> of the first terminal <NUM>, this permits the first terminal <NUM> to be supported at a position generally vertically below the support surface <NUM>. Likewise, because the second support portion <NUM> is formed on the lower edge <NUM> of the second terminal <NUM>, this permits the second terminal <NUM> to be supported at a position vertically above the support surface <NUM>. In particular, the first and second support portions <NUM>, <NUM> are formed so that they comprise respective bent portions <NUM>, <NUM>. The radius of the bent portions <NUM>, <NUM> can be adjusted to determine the distance above or below the support surface <NUM> that the first and second terminals <NUM>, <NUM> will sit.

The support portions <NUM>, <NUM> extend in a direction generally normal to the side wall <NUM> of the boss <NUM>. As such, the support portions <NUM>, <NUM> extend from the support surface <NUM>, past the edge <NUM> and into the region of space next to the side wall <NUM>. Consequently, the first and second terminals <NUM>, <NUM> are supported in the space next to the side wall <NUM>, with the second terminal <NUM> being arranged vertically above the first terminal <NUM>. During subsequent injection moulding, liquid polymer material will fill the region of space next to the side wall <NUM> to encapsulate at least a portion of each of the first and second terminals. As such, the first and second terminals can be moulded together with the remaining terminals in a single injection moulding step, and without the need for any partial moulding steps or sub-assemblies. As would be known to the skilled person, the die <NUM> will also comprise recesses for receiving the portions of the first and second terminals <NUM>, <NUM> that protrude from the body <NUM> of the terminal assembly <NUM> so that these portions of the first and second terminals <NUM>, <NUM> are not encapsulated by polymer material.

In order to better hold the first and second terminals <NUM>, <NUM> in position, once the support portions <NUM>, <NUM> are engaged with the support surface <NUM>, the support portions <NUM>, <NUM> may then be held against the support surface using one or more holding members. <FIG> shows a schematic perspective view of the first and second terminals <NUM>, <NUM> in vertical alignment with one another with the die <NUM> removed for clarity. With reference to <FIG> and <FIG>, the first support portion <NUM> is pressed against the support surface <NUM> using a first holding member <NUM> in the form of a longitudinally extending pin which engages the first support portion <NUM> at a distal end. The first holding member <NUM> clamps the first support portion <NUM> against the die <NUM> so that the first terminal <NUM> is firmly held in position and is prevented from accidentally moving during the moulding process. A second holding member <NUM> engages the second terminal <NUM> to hold the second terminal in position. In the example embodiment, the second holding member <NUM> is an elongate rod having a distal end defining a recess <NUM> shaped to receive an upper edge of the second terminal <NUM>. Both the first and the second holding members <NUM>, <NUM> are received within corresponding holes in an upper die (not shown) such that the first and the second holding members <NUM>, <NUM> engageable with the first and second terminals <NUM>, <NUM> in the vertical direction (i.e. normal to the split line of the mould cavity. Because the support portions <NUM>, <NUM> extend away from the terminals <NUM>, <NUM> and are spaced apart from one another on the support surface <NUM>, this allows the both terminals <NUM>, <NUM> to be engaged from above simultaneously (which would not be possible if the terminals <NUM>, <NUM> did not comprise support portions <NUM>, <NUM>). Put another way, the support portion <NUM>, <NUM> form cantilevers which extend away from the terminal axes <NUM>, <NUM> so support the terminals <NUM>, <NUM> at positions horizontally offset from the support surface <NUM> of the die <NUM>.

A third holding member <NUM> is provided for holding the first terminal <NUM> from underneath. The third holding member <NUM> is an elongate rod defining a recess <NUM> for receiving a lower edge of the first terminal <NUM>. A fourth holding member <NUM> is provided for holding the connection portion <NUM> of the second terminal <NUM>. The fourth holding member is an elongate rod and defines a longitudinally extending recess within which the connection portion <NUM> of the second terminal <NUM> is received. Use of the first to fourth holding member <NUM>, <NUM>, <NUM>, <NUM> provides further support to the first and second terminals <NUM>, <NUM> to prevent accidental movement of the terminals <NUM>, <NUM>.

Although the second terminal is shown as being supported by its upper edge by the second holding member <NUM>, it will be appreciated that in alternative embodiments the second holding member <NUM> may engage the support portion <NUM> directly (i.e. in the same fashion as the first holding member <NUM> and the first support portion <NUM>. It will be appreciated that in general it is not necessary for the support portions <NUM>, <NUM> to be directly engaged by the holding members, and that the provision of the support portions will provide at least some mechanical support to the terminals <NUM>, <NUM> as well as precisely controlling the vertical position of the terminals <NUM>, <NUM>.

The surface area of the first and second support portions <NUM>, <NUM> must be wide enough to provide a sufficient area for surface contact between the support portions <NUM>, <NUM> and the support surface <NUM>. In the illustrated example, the thickness of the terminals is around <NUM> and the width of the support portions <NUM>, <NUM> is around <NUM>.

The support portions <NUM>, <NUM> are formed as generally rectangular tabs, however in alternative embodiments the support portions <NUM>, <NUM> may have substantially any suitable shape, for example semi-circular, triangular, or the like. The first and second support portions <NUM>, <NUM> extend in generally the same direction, however in alternative embodiments the support portions <NUM>, <NUM> may extend in different directions. In such cases, the support portions may be supported be separate support surfaces <NUM>. There is no need for the support surface <NUM> to be contiguous, and in some embodiments the support surface <NUM> may be defined by multiple surfaces. Where there are multiple support surfaces, the support surfaces need not all be disposed at the same height as one another (that is, they need not all lie in the same plane). In general, it will be appreciated that the support surfaces may be configured at any suitable height for providing support to the associated terminal.

<FIG> shows a flow diagram of a method of manufacturing a terminal assembly such as the terminal assembly <NUM> as described in detail above. In step S1, a die defining a mould cavity is provided. In step S2, a first terminal having a first support portion is provided. The first terminal may be for example the first terminal <NUM> and the first support portion may be the first support portion <NUM> of the terminal assembly <NUM> described above. In step S3, a second terminal having a second support portion is provided. The second terminal may be for example the second terminal <NUM> and the second support portion may be the second support portion <NUM> of the terminal assembly <NUM> described above. In step S4, the first support portion is supported on a die so as to arrange the first terminal in a first vertical position. In step S5, the second support portion is supported on the die so as to arrange the second terminal in a second vertical position above the first vertical position. The die may be, for example, the die <NUM> discussed above. Furthermore the first and/or second terminals may be supported on a support surface, such as the support surface <NUM> discussed above.

Although the invention has been illustrated using two terminals, it will be appreciated that the invention may be utilized to manufacture terminal assemblies having substantially any number of terminals. It will further be appreciated that although the invention has been illustrated using an assembly of male terminals, in alternative embodiments the method can be applied to female terminals.

As shown in <FIG>, the battery pack <NUM> includes a housing <NUM>. The housing <NUM> includes a top housing portion <NUM> and a bottom housing portion <NUM>. Although the battery pack <NUM> is illustrated in <FIG> includes the top housing portion <NUM> and the bottom housing portion <NUM>, in some embodiments, the battery pack <NUM> includes a left housing portion and a right housing portion. The battery pack <NUM> also includes a support section <NUM> for supporting the battery pack <NUM> on, and coupling the battery pack <NUM> to, a device such as the power tool <NUM>. The support section <NUM> includes a first rail <NUM> and a second rail <NUM> for slidably attaching the battery pack <NUM> to the device. The support section <NUM> is connectable to a complementary socket <NUM> on the device (e.g., a battery pack receiving portion of a power tool). The battery pack <NUM> also includes a button <NUM> and a latch or coupling mechanism <NUM> for selectively coupling the battery pack <NUM> to, or releasing the battery pack <NUM> from, the device. In some embodiments, the button <NUM> and coupling mechanism <NUM> are considered to be included in the battery pack support section <NUM>.

The battery pack <NUM> includes an electrical coupling assembly <NUM> comprising plurality of electrical receptacles within the support section <NUM> that are operable to electrically connect one or more battery cells within the battery pack <NUM> to the device. An electrical receptacle as described herein encompasses an electrical terminal which is configured to receive a corresponding electrical terminal to create an electrical connection therebetween. The electrical receptacles may comprise female electrical terminals configured to receive corresponding male electrical terminals. As illustrated in <FIG>, the plurality of electrical receptacles includes a first electrical receptacle <NUM> which is a communication receptacle, a second electrical receptacle <NUM> which is a temperature receptacle, a third electrical receptacle <NUM> which is a battery pack negative power receptacle, a fourth electrical receptacle <NUM> which is a charging receptacle, and a fifth electrical receptacle <NUM> which is a battery pack positive power receptacle. The first to fifth electrical receptacles are supported within corresponding recesses defined by the housing <NUM>, the recesses being open in the direction of receipt of the corresponding first to fifth electrical terminals of the power tool <NUM> (that is to say, in the direction in which the battery pack <NUM> is coupled to the power tool <NUM>).

Referring to <FIG>, the third electrical receptacle <NUM> is horizontally spaced apart from the first and second electrical receptacles <NUM>, <NUM> by a first distance L1 of around <NUM>. The fourth electrical receptacle <NUM> is horizontally spaced apart from the first and second electrical receptacles <NUM>, <NUM> by a second distance L2 of around <NUM>. The fifth electrical receptacle <NUM> and the fourth electrical receptacle <NUM> are horizontally spaced apart by a third distance L3. In some embodiments, the third distance L3 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>). The first and second electrical receptacles <NUM>, <NUM> and the fifth electrical receptacle <NUM> are spaced apart by a fourth distance L4. In some embodiments, the fourth distance L4 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>). The third electrical receptacle <NUM> and the fourth electrical receptacle <NUM> are horizontally spaced apart by a fifth distance L5. In some embodiments, the fifth distance L5 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>). The third electrical receptacle <NUM> and the fifth electrical receptacle <NUM> are horizontally spaced apart by a sixth distance L6. The sixth distance L6 is between about <NUM> to about <NUM> (e.g., about <NUM> or <NUM>).

The battery pack <NUM> is removably and interchangeably connected to a device, such as the power tool <NUM>, to provide operational power to the device. The first to fifth electrical receptacles <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of the battery pack <NUM> are configured to mate with the corresponding (and respectively numbered) first to fifth electrical terminals <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of the power tool <NUM>. The battery pack <NUM> substantially encloses and covers the terminals on the power tool when the battery pack <NUM> is positioned within the socket <NUM> of the power tool <NUM> (i.e., the battery pack <NUM> functions as a cover for the socket <NUM>). Once the battery pack <NUM> is disconnected from the power tool <NUM>, the terminals on the power tool <NUM> are generally exposed to the surrounding environment. As shown in <FIG>, the battery pack <NUM> is designed to substantially follow the contours of the power tool <NUM> to match the general shape of an outer casing of a handle of the power tool <NUM>, and the battery pack <NUM> generally increases (i.e., extends) the length of the grip of the power tool <NUM> (e.g., a portion of the power tool below a motor).

As illustrated in <FIG>, the bottom housing portion <NUM> of the housing <NUM> includes four fasteners <NUM> for fastening the bottom housing portion <NUM> to the top housing portion <NUM>. For example, in some embodiments, the fasteners <NUM> are screws that extend vertically through apertures in the bottom housing portion <NUM> to engage a threaded aperture in the top housing portion <NUM>. In other embodiments, the top housing portion <NUM> and the bottom housing portion <NUM> are fastened together in a different manner, such as using an adhesive or a fastener other than a screw.

With reference to <FIG>, the support section <NUM> is configured to accommodate device interfaces for a variety of different devices. For example, the device interfaces can vary based on which terminals (e.g., male terminals) are used to connect to the electrical receptacles (e.g., female terminals) of the battery pack <NUM>. The interfaces can also vary in size. For example, the support section <NUM> has a support portion length, LSP. A central recess <NUM> within the support section <NUM> has a central recess length, LCR. In some embodiments, the central recess length, LCR, is between about <NUM> to about <NUM> (e.g., about <NUM>). In some embodiments, a device interface is approximately the same size as the support portion length, LSP. In some embodiments, the support portion length, LSP, is between about <NUM> to about <NUM> (e.g., about <NUM>). In other embodiments, a device interface is approximately the same size as the central recess length, LCR. Accordingly, the battery pack <NUM> is configured to accommodate device interfaces of different sizes.

Claim 1:
A method of manufacturing a terminal assembly for an electrical device, comprising:
providing a die (<NUM>) defining a mould cavity;
providing a first terminal (<NUM>) defining a first terminal axis (<NUM>) and having a first support portion (<NUM>) extending away from the first terminal axis;
providing a second terminal (<NUM>) defining a second terminal axis (<NUM>) and having a second support portion (<NUM>) extending away from the second terminal axis;
arranging the first terminal in a first vertical position by supporting the first support portion on the die; characterized by arranging the second terminal in a second vertical position above the first vertical position by supporting the second support portion on the die.