Patent Description:
The present invention relates to battery packs and, more particularly, to a battery pack according to the preamble of claim <NUM>. Such a battery pack is known from document <CIT>.

The present invention provides a battery pack according to claim <NUM>.

Described herein is an interface for an electrical combination. The electrical combination may include a battery pack and an electrical device, the interface being operable to connect the battery pack and the electrical device. The interface may generally include a body and a rail extending along an axis, the rail and the body defining a space therebetween, the space having a first dimension proximate a first axial location, a second dimension at a second axial location, and a third dimension at a third axial location, the first dimension, the second dimension, and the third dimension being different.

In some constructions, the first axial location may be proximate an insertion opening at one axial end, the first dimension being larger than the second dimension and the third dimension. The third axial location may be proximate an opposite axial end, the third dimension being smaller than the second dimension.

The body has a body surface extending along and substantially parallel to the axis, and the rail may have a stepped rail surface extending along the axis, the space being defined between the body surface and the rail surface. The rail surface may have a first rail surface portion proximate the first axial location, a second rail surface portion proximate the second axial location, and a third rail surface portion proximate the third axial location. The first rail surface portion, the second rail surface portion and the third rail surface portion may be substantially parallel to the axis. The rail surface may have a first angled portion connecting the first rail surface portion to the second rail surface portion and a second angled portion connecting the second rail surface portion to the third rail surface portion.

The rail may have a lateral dimension transverse to the axis and to the space, the rail having a first lateral dimension proximate the first axial location, a second lateral dimension proximate the second axial location, and a third lateral dimension proximate the third axial location, the first lateral dimension, the second lateral dimension, and the third lateral dimension being different. The interface may further include an electrical terminal.

Also described herein is an electrical combination that may generally include an electrical device including a device housing providing a device support portion, and a circuit supported by the device housing; and a battery pack including a battery pack housing providing a pack support portion for engagement with the device support portion, a battery cell supported by the housing, power being transferrable between the battery cell and the circuit when the battery pack is connected to the device. One of the device support portion and the pack support portion may include a body and a rail extending along an axis, the rail and the body defining a space therebetween, the space having a first dimension proximate a first axial location, a second dimension at a second axial location, and a third dimension at a third axial location, the first dimension, the second dimension, and the third dimension being different, and the other of the device support portion and the pack support portion including a first portion positionable in the space at the first axial location, a second portion positionable in the space at the second location, and a third portion positionable in the space at the third location.

The rail may have a lateral dimension transverse to the axis and to the space, the rail having a first lateral dimension proximate the first axial location, a second lateral dimension proximate the second axial location, and a third lateral dimension proximate the third axial location, the first lateral dimension, the second lateral dimension, and the third lateral dimension being different. The electrical device may further include a device terminal, and the battery pack may further include a pack terminal electrically connectable to facilitate transfer of power between the electrical device and the battery pack.

In some constructions, the pack support portion may include the body and the rail defining the space therebetween, and the device support portion may include an axially-extending device rail providing the first portion, the second portion, and the third portion.

The device support portion may include a device body, the device rail and the device body defining a second space therebetween, the second space having a fourth dimension proximate a first portion, a fifth dimension proximate the second portion, and a sixth dimension proximate the third portion, the fourth dimension, the fifth dimension and the sixth dimension being different.

The device rail may have a lateral dimension transverse to the axis and to the second space, the device rail having a fourth lateral dimension proximate the first portion, a fifth lateral dimension proximate the second portion, and a sixth lateral dimension proximate the third portion, the fourth lateral dimension, the fifth lateral dimension, and the sixth lateral dimension being different.

Also described herein is a latch mechanism for an electrical combination. The electrical combination may include a battery pack and an electrical device, the latch mechanism being operable to connect the battery pack and the electrical device. The latch assembly may generally include a latching member movable between a latched position, in which the latching member is engageable between the battery pack and the electrical device to inhibit relative movement, and an unlatched position, in which relative movement is permitted; and a switch operable with the latching member, the switch inhibiting power transfer between the battery pack and the electrical device when the latching member is between the latched position and the unlatched position.

The latching member may be engageable in a latching recess to inhibit relative movement between the battery pack and the electrical device, and the switch may be operable to inhibit power transfer before the latching member disengages the latching recess. In the latched position, the switch may be operable to facilitate power transfer.

The latching mechanism may further include an actuator engageable by a user to move the latching member between the latched position and the unlatched position. The actuator may be a primary actuator, and the latch mechanism may further include a secondary actuator operatively coupled to the primary actuator and movable between a first position, in which the secondary actuator inhibits operation of the primary actuator, and a second position, in which the secondary actuator allows operation of the primary actuator. The latching member may be formed of a first material, and the actuator may be formed of a different second material, the first material being harder than the second material. The latching member may include a protrusion engageable with and operating the switch to inhibit power transfer as the latching member moves toward the unlatching position.

Also described herein is an electrical combination that may generally include an electrical device including a device housing providing a device support portion, and a circuit supported by the device housing; a battery pack including a battery pack housing providing a pack support portion for engagement with the device support portion, a battery cell supported by the housing, power being transferrable between the battery cell and the circuit when the battery pack is connected to the device; and a latch mechanism including a latching member movable between a latched position, in which the latching member is engageable between the battery pack and the electrical device to inhibit relative movement, and an unlatched position, in which relative movement is permitted, and a switch operable with the latching member, the switch inhibiting power transfer between the battery pack and the electrical device when the latching member is between the latched position and the unlatched position.

The latching member may be engageable in a latching recess to inhibit relative movement between the battery pack and the electrical device, and the switch may be operable to inhibit power transfer before the latching member disengages the latching recess. The latching member may be supported on the device support portion, and the latching recess may be defined on the pack support portion. In the latched position, the switch may be operable to facilitate power transfer.

The electrical device may further include a device terminal, the battery pack may further include a pack terminal electrically connectable to facilitate transfer of power between the electrical device and the battery pack, and, when the battery pack is connected to the electrical device, the switch may inhibit power transfer between the battery pack and the electrical device before the device terminal and the pack terminal are electrically disconnected.

Also described herein is an ejector for an electrical combination. The electrical combination may include a battery pack and an electrical device. The ejector may generally include an ejection member engageable between the battery pack and the electrical device; a biasing member operable to bias the ejection member toward an ejecting position, in which a force is applied to disengage the battery pack and the electrical device; and a switch operable with the ejection member, the switch deactivating at least a portion of the device as the ejection member moves toward the ejecting position. The ejection member may be movable to a retracted position, opposite the ejecting position, the switch activating at least a portion of the device as the ejection member moves toward the retracted position.

Also described herein is an electrical combination that may generally include an electrical device including a device housing providing a device support portion, and a circuit supported by the device housing; a battery pack including a battery pack housing providing a pack support portion for engagement with the device support portion, a battery cell supported by the housing, power being transferrable between the battery cell and the circuit when the battery pack is connected to the device; and an ejector. The ejector may include an ejection member engageable between the battery pack and the electrical device, a biasing member operable to bias the ejection member toward an ejecting position, in which a force is applied to disengage the battery pack and the electrical device, and a switch operable with the ejection member, the switch deactivating at least a portion of the device as the ejection member moves toward the ejecting position.

The ejection member may movable to a retracted position, opposite the ejecting position, the switch activating at least a portion of the device as the ejection member moves toward the retracted position. The electrical device may further include a device terminal, the battery pack may further include a pack terminal electrically connectable to facilitate transfer of power between the electrical device and the battery pack, and, when the battery pack is connected to the electrical device, the switch inhibits power transfer between the battery pack and the electrical device before the device terminal and the pack terminal are electrically disconnected.

The electrical device may include a first power tool including a first tool housing providing a first tool support portion, and a first motor supported by the first tool housing, the pack support portion being engageable with the first tool support portion, the battery cell being operable to power the first motor when the battery pack is connected to the first power tool, the biasing member having a first stiffness selected based on a characteristic of the first power tool. The electrical combination may further include a second power tool including a second tool housing providing a second tool support portion, and a second motor supported by the second tool housing, the pack support portion being engageable with the second tool support portion, the battery cell being operable to power the second motor when the battery pack is connected to the second power tool; and a second ejector including a second ejection member engageable between the battery pack and the second power tool, a second biasing member operable to bias the second ejection member toward an ejecting position, in which a force is applied to disengage the battery pack and the power tool, the second biasing member having a second stiffness selected based on a characteristic of the second power tool, the second stiffness being different than the first stiffness.

Also described herein is a dual-action latch mechanism for an electrical combination. The electrical combination may include a battery pack and an electrical device, the latch mechanism being operable to connect the battery pack and the electrical device. The latch mechanism may generally include a primary actuator operatively coupled to a latching member movable between a latched position, in which the latching member is engageable between the battery pack and the electrical device to inhibit relative movement, and an unlatched position, in which relative movement is permitted; and a secondary actuator operatively coupled to the primary actuator and movable between a first position, in which the secondary actuator inhibits operation of the primary actuator, and a second position, in which the secondary actuator allows operation of the primary actuator.

The latch mechanism may further include the latching member; and a switch operable with the latching member, the switch inhibiting power transfer between the battery pack and the electrical device when the latching member is between the latched position and the unlatched position. The latching member may be engageable in a latching recess to inhibit relative movement between the battery pack and the electrical device, and the switch may be operable to inhibit power transfer before the latching member disengages the latching recess. In the latched position, the switch may be operable to facilitate power transfer.

The latching member may be formed of a first material, and the actuator may be formed of a different second material, the first material being harder than the second material. The latching member may include a protrusion engageable with and operating the switch to inhibit power transfer as the latching member moves toward the unlatching position.

Also described herein is an electrical combination that may generally include an electrical device including a device housing providing a device support portion, and a circuit supported by the device housing; a battery pack including a battery pack housing providing a pack support portion for engagement with the device support portion, a battery cell supported by the housing, power being transferrable between the battery cell and the circuit when the battery pack is connected to the device; and a dual-action latch mechanism including a primary actuator operatively coupled to a latching member movable between a latched position, in which the latching member is engageable between the battery pack and the electrical device to inhibit relative movement, and an unlatched position, in which relative movement is permitted, and a secondary actuator operatively coupled to the primary actuator and movable between a first position, in which the secondary actuator inhibits operation of the primary actuator, and a second position, in which the secondary actuator allows operation of the primary actuator.

The latch mechanism may further include the latching member, and a switch operable with the latching member, the switch inhibiting power transfer between the battery pack and the electrical device when the latching member is between the latched position and the unlatched position. The latching member may be engageable in a latching recess to inhibit relative movement between the battery pack and the electrical device, and the switch may be operable to inhibit power transfer before the latching member disengages the latching recess. In the latched position, the switch may be operable to facilitate power transfer.

It is described herein a battery pack, according to claim <NUM>, that includes a housing assembly providing a terminal block and a pack support portion engageable along an axis with a device support portion of an electrical device, the housing assembly defining a cavity, the housing assembly having a bottom wall opposite the pack support portion, a first end wall portion opposite the terminal block, connected to the pack support portion, and extending in a plane substantially perpendicular to the axis, and a second end wall connected between the bottom wall and the first end wall portion, the second end wall portion being oriented at an angle between <NUM> degrees and <NUM> degrees relative to the first end wall portion; a plurality of battery cells supported in the cavity; and a pack terminal supported by the terminal block and engageable with a device terminal of the electrical device. The second end wall portion may be oriented at an angle of between about <NUM> degrees and about <NUM> degrees. The second end wall portion may be oriented at an angle of about <NUM> degrees.

Also described herein is a battery pack, according to claim <NUM>, that includes a housing including a support portion connectable to and supportable by an electrical device, the support portion defining a channel operable to receive a projection on the electrical device, the support portion including a plastic material molded to define the channel, and a metal material molded in the plastic material, the metal material defining a C-shaped portion around the channel; a plurality of battery cells supported by the housing; and a battery terminal electrically connected to the plurality of battery cells and connectable to a terminal of the electrical device.

Also described herein is a battery pack, according to claim <NUM>, that includes a housing including a support portion connectable to and supportable by an electrical device, the housing also including a bottom wall opposite the support portion; opposite side walls connected between the bottom wall and the support portion and opposite end walls connected between the bottom wall and the support portion and between the side walls, adjacent walls meeting at an edge; elastomeric material on at least one edge, the elastomeric material being thickest proximate the edge and thinning in a direction away from the edge; a plurality of battery cells supported by the housing; and a battery terminal electrically connected to the plurality of battery cells and connectable to a terminal of the electrical device.

Also described herein is a shock absorption assembly for an interface between a battery pack and an electrical device. The assembly may include a housing assembly including a first housing portion having an outer surface and providing a support portion connectable to and operable to support the battery pack, a second housing portion at least partially around the first housing portion and having an inner surface in facing relationship to the outer surface; a post supported by one of the first housing portion and the second housing portion supporting a post, the other of the first housing portion and the second housing portion defining a recess aligned with the post; and a shock absorption member supported on the post and received in the recess.

Other independent features and independent aspects may become apparent by consideration of the following detailed description and accompanying drawings.

Before any independent 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 independent embodiments and of being practiced or of being carried out in various ways.

Use of "including" and "comprising" and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of "consisting of' and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof.

Also, the functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is "configured" in a certain way is configured in at least that way but may also be configured in ways that are not listed.

Furthermore, some embodiments described herein may include one or more electronic processors configured to perform the described functionality by executing instructions stored in non-transitory, computer-readable medium. Similarly, embodiments described herein may be implemented as non-transitory, computer-readable medium storing instructions executable by one or more electronic processors to perform the described functionality. As used in the present application, "non-transitory computer-readable medium" comprises all computer-readable media but does not consist of a transitory, propagating signal. Accordingly, non-transitory computer-readable medium may include, for example, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a ROM (Read Only Memory), a RAM (Random Access Memory), register memory, a processor cache, or any combination thereof.

Many of the modules and logical structures described are capable of being implemented in software executed by a microprocessor or a similar device or of being implemented in hardware using a variety of components including, for example, application specific integrated circuits ("ASICs"). Terms like "controller" and "module" may include or refer to both hardware and/or software. Capitalized terms conform to common practices and help correlate the description with the coding examples, equations, and/or drawings. However, no specific meaning is implied or should be inferred simply due to the use of capitalization. Thus, the claims should not be limited to the specific examples or to any specific hardware or software implementation or combination of software or hardware.

<FIG> illustrate a battery-receiving portion <NUM> of an electrical device (e.g., a power tool, an outdoor tool, a non-motorized device (e.g., a light, an audio device, etc.), a battery charger, etc.) configured to receive a battery pack <NUM> (e.g., a rechargeable lithium-ion battery pack). As will be described in greater detail below, an interface for the battery pack <NUM> (e.g., the illustrated battery-receiving portion <NUM> (see <FIG>)) includes stepped grooves <NUM> and a latching mechanism <NUM> to facilitate coupling of the battery pack <NUM> to the battery-receiving portion <NUM>. In other embodiments (not shown), the grooves <NUM> may be substantially linear.

With reference to <FIG>, the battery-receiving portion <NUM> includes a cavity <NUM> defined by a lower surface <NUM>, a pair of sidewalls <NUM>, and an end wall <NUM> and having an open end <NUM> opposite the end wall <NUM>. In addition, an upper end wall <NUM> extends above the end wall <NUM> proximate the cavity <NUM>. Device contacts <NUM> are supported on the end wall <NUM> and are configured to mechanically and electrically interface with the battery pack <NUM> to transfer electrical power therebetween.

In the illustrated embodiment, at least a portion of the latching mechanism <NUM> protrudes from the lower surface <NUM> near the open end <NUM>. The latching mechanism <NUM> is configured to engage the battery pack <NUM> to maintain engagement between the battery pack <NUM> and the battery-receiving portion <NUM>. However, in other embodiments (not shown), the latching mechanism <NUM> may be disposed at various locations (e.g., on a sidewall <NUM>, the end wall <NUM>, the upper end wall <NUM>, etc.) such that the latching mechanism <NUM> engages corresponding structure on the battery pack <NUM> to maintain engagement between the battery pack <NUM> and the battery-receiving portion <NUM>.

With specific reference to <FIG>, the battery-receiving portion <NUM> includes stepped grooves <NUM> extending between the open end <NUM> and the end wall <NUM> (e.g., as illustrated, from the open end <NUM> to the end wall <NUM>). The stepped grooves <NUM> are defined by rails <NUM> disposed on the sidewalls <NUM>. The rails <NUM> protrude from the sidewalls <NUM> to define an upper extent of the grooves <NUM> that face the lower surface <NUM>.

As shown in <FIG>, the illustrated rails <NUM> include a number of (e.g., three) generally parallel horizontal portions <NUM> defining distinct vertical clearances C1, C2, C3. Cn of the grooves <NUM> measured between each horizontal portion <NUM> and the lower surface <NUM>. Each horizontal portion <NUM> is connected by an angled portion <NUM> extending obliquely toward the lower surface <NUM> (e.g., when moving from left to right in <FIG>) such that each horizontal portion <NUM> defines a successively smaller clearance, thereby forming the "stepped" configuration of the grooves <NUM>. In the illustrated embodiment, the vertical clearance C1, C2, C3 of each of the horizontal portions <NUM> changes by a constant amount.

In other embodiments (not shown), the rails <NUM> may include two horizontal portions <NUM> or more than three horizontal portions <NUM>. In addition, these portions <NUM> may be disposed at an angle relative to the lower surface <NUM>. In other embodiments, the vertical clearances C1, C2, C3 may vary by different amounts (e.g., the difference in clearance may be greater or less than the difference in adjacent clearances).

A horizontal clearance is measured from the sidewall <NUM> to a periphery of the rails <NUM>. In the illustrated embodiment (see <FIG>), a stepped configuration is provided laterally between the opposite rails <NUM>. The rails <NUM> include a number of (e.g., three) generally parallel axially-extending portions <NUM> defining distinct lateral clearances L1, L2, L3. Ln therebetween. Each portion is connected to an angled portion <NUM> extending obliquely toward the opposite rail <NUM> (e.g., when moving from right to left in <FIG>) such that the opposite portions <NUM> define a successively smaller lateral clearance, thereby forming the "stepped" configuration between the rails <NUM>. In the illustrated embodiment, the lateral clearance L1, L2, L3 between each portion <NUM> changes by a constant amount.

In other embodiments (not shown), the rails <NUM> may include two portions <NUM> or more than three portions <NUM>. In addition, these portions <NUM> may be disposed at an angle relative to the rail <NUM>. In other embodiments, the lateral clearances L1, L2, L3 may vary by different amounts (e.g., the difference in clearance may be greater or less than the difference in adjacent clearances).

As shown in <FIG>, <FIG>, and <FIG>, the latching mechanism <NUM> includes a pivotable actuator or handle <NUM> operatively engaging a latch member <NUM>. The latch member <NUM> is slidably disposed in a bore <NUM> defined in the lower surface <NUM> and is biased by one or more biasing members (e.g., a spring <NUM>, such as a coil spring, a torsion spring, etc.) to protrude through the lower surface <NUM> and into the cavity <NUM>. The latch member <NUM> has an inclined surface <NUM> (e.g., angled about <NUM> degrees to about <NUM> degrees relative to the lower surface <NUM>) facing toward the open end <NUM> and a generally vertically-extending surface <NUM> (e.g., about <NUM> degrees to about <NUM> degrees relative to a vertical axis) facing toward the end wall <NUM>.

The latch member <NUM> is coupled to the spring <NUM>. In some embodiments (not shown), two or more springs <NUM> may be coupled to the latch member <NUM>. In such multi-spring arrangements, each spring <NUM> may be smaller/shorter, leading to a shorter overall height of the latch member <NUM> and the spring <NUM> without a reduction in biasing force.

The handle <NUM> is engaged with the latch member <NUM> via a cam surface <NUM> such that actuation (e.g., clockwise pivoting/rotation of the handle <NUM> with respect to the position shown in <FIG>) of the handle <NUM> causes the latch member <NUM> to translate downward against the bias of the spring <NUM> to withdraw the latch member <NUM> from the cavity <NUM>.

The latching mechanism <NUM> may be constructed for reduced wear. For example, the latch member <NUM> (and/or the latching recess (e.g., the slot <NUM>) with which the latch member <NUM> is engageable) may be formed of or have one or more engagement surfaces including wear-resistant material. In the illustrated construction, the latch member <NUM> includes a polycarbonate (PC)-based material, such as, for example KINGFA® JH830, manufactured by Kingfa Science & Technology Co. , Guangzhou, PRC. The material of the latch member <NUM> may, for example, increase hardness, impact resistance, wear resistance, etc., compared to Acrylonitrile butadiene styrene (ABS) or softer plastics.

The illustrated latching mechanism <NUM> also includes a switch <NUM> (e.g., a micro-switch <NUM>) facilitating electrical coupling/decoupling of the battery pack <NUM> during actuation of the handle <NUM> to withdraw the latch member <NUM> from the cavity <NUM>. In other embodiments, however, the switch <NUM> may be omitted. As will be described in greater detail with respect to <FIG>, the switch <NUM> may act to electrically decouple the battery pack <NUM> from the battery-receiving portion <NUM> and the device prior to removal of the battery pack <NUM> from the battery-receiving portion <NUM>.

With reference to <FIG> and <FIG>, an ejector <NUM> is supported on the end wall <NUM>. The ejector <NUM> includes an ejection member <NUM> biased by a biasing member (e.g., one or more springs (not shown)) to protrude through the end wall <NUM> (as shown in <FIG> and <FIG>). When the battery pack <NUM> is attached to the battery-receiving portion <NUM> (see <FIG>), the ejection member <NUM> is pushed into the end wall <NUM> to compress the biasing member. From this position, the spring ejector <NUM> is configured to exert a force F on the battery pack <NUM> to push the battery pack <NUM> out of engagement with the battery-receiving portion <NUM> (e.g., upon release of the latching mechanism <NUM>).

The stiffness of the ejector spring(s) may be tailored to the electrical device to which the battery pack <NUM> is connected. The stiffness may be based on a characteristic of the electrical device, such as, for example, a weight, mass, size, etc. of the electrical device, a speed of a motor (if provided), vibration generated by operation of the electrical device, etc. For example, for a power tool, such as a core drill, the stiffness of the spring(s) may be greater than that for another electrical device having a lower weight/mass, no motor, generating less vibration, etc. In contrast, for an electrical device, such as a charger, the stiffness may be relatively less to provide a decreased biasing force.

In another example, the biasing force of the ejector spring(s) may be different based on the electrical device. A stationary device, such as a table saw, a battery charger, etc., may require the ejector spring(s) to have increased biasing force to assist with ejection of the battery pack <NUM> from the electrical device, compared to a movable device, such as a handheld power tool, which may be adjusted (e.g., moved to a position) to assist with removal of the battery pack <NUM>.

In the some embodiments (as shown in <FIG>, <FIG> and <FIG>), a switch <NUM> (e.g., an AC switch <NUM>) is incorporated into the ejector <NUM>. The switch <NUM> is configured to activate/deactivate an electrical device (e.g., a battery charger) based on a position of the battery pack <NUM> relative to the battery-receiving portion <NUM>. In one example, pushing the ejection member <NUM> into the end wall <NUM> causes the ejection member <NUM> to engage and activate the switch <NUM>. The switch <NUM> may be activated to permit power to be transferred to a portion of the device (e.g., a master board of a charger, etc.) when the battery pack <NUM> is initially inserted but prior to activation of the device contacts <NUM> (e.g., for charging operations).

<FIG> illustrate a battery pack <NUM> for use with the battery-receiving portion <NUM>, described above. The battery pack <NUM> includes a housing <NUM> defining an internal cavity in which one or more battery cells (not shown) are supported. Each battery cell may have a nominal voltage between about <NUM> V and about <NUM> V and may have a nominal capacity between about <NUM> Ah and about <NUM> Ah (in some cases, between about <NUM> Ah and about <NUM> Ah). The battery cells may be any rechargeable battery cell chemistry type, such as, for example, lithium (Li), lithium-ion (Li-ion), other lithium-based chemistry, nickel-cadmium (NiCd), nickel-metal hydride (NiMH), etc..

The battery cells may be connected in series, parallel, or combination series-parallel to provide the desired electrical characteristics (e.g., nominal voltage, current output, current capacity, power capacity, etc.) of the battery pack <NUM>. The battery cells are coupled to battery contacts <NUM> supported on or within the housing <NUM> and configured to electrically and mechanically engage the device contacts <NUM> to facilitate the transfer of electrical power between the device and the battery pack <NUM>. As will be described in greater detail below, the battery pack <NUM> includes mechanical features configured to engage corresponding features on the battery-receiving portion <NUM> to couple and maintain engagement of the battery-receiving portion <NUM> and the battery pack <NUM>.

The housing <NUM> includes a protrusion <NUM> supporting, at a front end <NUM>, the battery contacts <NUM>. On each lateral side <NUM>, a rail <NUM> extends laterally outwardly and to define a groove <NUM>. Proximate a rear end <NUM>, a top surface <NUM> defines a slot <NUM> sized and shaped to cooperate with the latch member <NUM>.

In the illustrated embodiment, the rails <NUM> include a number of (e.g., three) parallel horizontal portions <NUM> defining distinct vertical clearances C4, C5, C6. Cn of the grooves <NUM> measured between each horizontal portion <NUM> and the body of the housing <NUM>. Each portion <NUM> is connected by an angled portion <NUM> extending obliquely away from the housing <NUM> when moving from the rear end <NUM> toward the front end <NUM> so each horizontal portion <NUM> defines a successively smaller clearance. As illustrated, the rails <NUM>/grooves <NUM> of the battery pack <NUM> form a mated engagement between the rails <NUM>/grooves <NUM> of the battery-receiving portion <NUM>.

A horizontal clearance is measured from the lateral side <NUM> to a periphery of each rail <NUM>. In the illustrated embodiment (see <FIG>), a stepped configuration is provided laterally between the opposite rails <NUM>. The rails <NUM> include a number of (e.g., three) generally parallel axially-extending portions <NUM> defining distinct lateral dimensions L4, L5, L6. Ln therebetween. Each portion is connected to an angled portion <NUM> extending obliquely toward the opposite rail <NUM> (e.g., when moving from right to left in <FIG>) such that the opposite portions <NUM> define a successively smaller lateral dimension, thereby forming the "stepped" configuration between the rails <NUM>. In the illustrated embodiment, the lateral dimension L4, L5, L6 between each portion <NUM> changes by a constant amount.

It should be understood that, if the size and shape of the battery-receiving portion <NUM> is modified, corresponding variations in the size and shape of the battery pack <NUM> may be made. For example, the geometric configuration of the rails <NUM>, <NUM> will be consistently varied in order to maintain the mating engagement between the battery pack <NUM> and the battery-receiving portion <NUM>. It should be understood that, in other constructions (not shown), the orientation of the rails <NUM>, <NUM> may be reversed with the rails <NUM> being directed outwardly and the rails <NUM> being directed inwardly.

With reference to <FIG>, <FIG>, <FIG>, and <FIG>, the battery pack <NUM> is coupled to the battery-receiving portion <NUM> by aligning the rails <NUM> of the battery pack <NUM> with the grooves <NUM> of the battery-receiving portion <NUM>, and subsequently sliding the battery pack <NUM> along a battery insertion axis <NUM> until the device contacts <NUM> engage the battery contacts <NUM>.

In order to allow the sliding of the battery pack <NUM> onto the battery-receiving portion <NUM>, the latch member <NUM> retracts into the bore <NUM> in the lower surface <NUM>. To do so, a user may pivot the handle <NUM> to retract the latch member <NUM> while sliding the battery pack <NUM>, or the user may simply slide the battery pack <NUM> relative to the battery-receiving portion <NUM> such that the front end <NUM> of the protrusion <NUM> engages the inclined surface <NUM>. The angle of the inclined surface <NUM> causes the force exerted by the front end <NUM> to act vertically against the bias of the spring <NUM> such that the latch member <NUM> is "automatically" retracted into the bore <NUM> when the battery pack <NUM> slides through the cavity <NUM>.

The size and shape of the rails <NUM> relative to the grooves <NUM> (and of the rails <NUM> relative to the grooves <NUM>) act to facilitate and guide insertion of the battery pack <NUM> onto the battery-receiving portion <NUM>. The relative clearances defined between the rails <NUM> and the grooves <NUM> decrease as the battery pack <NUM> is inserted further onto the battery-receiving portion <NUM>. In the illustrated embodiment, engagement between the rails <NUM> and the grooves <NUM> (and between the rails <NUM> and the grooves <NUM>) is closest proximate the front end <NUM> and the end wall <NUM> and proximate the rear end <NUM> and the open end <NUM>. This construction may facilitate a tighter, more secure engagement between the battery pack <NUM> and the battery-receiving portion <NUM> as the battery pack <NUM> approaches and reaches full insertion.

In the illustrated embodiment, increased clearance is provided between the rails <NUM> relative to the grooves <NUM> (and of the rails <NUM> relative to the grooves <NUM>) in the region between the front end <NUM>/the end wall <NUM> and the rear end <NUM>/the open end <NUM>. This arrangement may facilitate smooth and easy insertion of the battery pack <NUM> due to, for example, reduced engagement, interference, etc..

When the battery pack <NUM> is fully inserted (<FIG>, <FIG> and <FIG>), the latch member <NUM> protrudes from the lower surface <NUM> to engage the slot <NUM> on the protrusion <NUM> thereby latching the battery pack <NUM> to the battery-receiving portion <NUM> (e.g., in a latched or locked position). The spring <NUM> biases the latching member <NUM> to engage the slot <NUM>, and the vertical surface <NUM> of the latching member <NUM> engages a corresponding surface on the interior of the slot <NUM>. Removal (and ejection) of the battery pack <NUM> along the insertion axis <NUM> is inhibited by the latch member <NUM>. This engagement of the latching member <NUM> may also ensure and maintain close mechanical and electrical connection of the pack contacts <NUM> and the device contacts <NUM>.

<FIG> illustrate operation of the pivot-actuated latching mechanism <NUM>. As the latch member <NUM> is moved from the latched position (<FIG>) to an intermediate position (<FIG>), the switch <NUM> is activated to inhibit the transfer of electrical power between the battery pack <NUM> and the device before the battery pack <NUM> is released by the latching member <NUM> and removable from the battery-receiving portion <NUM> and before the contacts <NUM>, <NUM> disengage. Activation of the switch <NUM> to stop power transfer between the battery pack <NUM> and the device may, for example, prevent arcing between the contacts <NUM>, <NUM> as the battery pack <NUM> is removed.

Further movement of the latching member <NUM> to an unlatched position (<FIG>) removes the latching member <NUM> from the slot <NUM>, and the battery pack <NUM> is permitted to move along the battery insertion axis <NUM> off of the battery-receiving portion <NUM>. The switch <NUM> is maintained in the on position to continue inhibiting the transfer of power between the battery pack <NUM> and the device.

As illustrated in <FIG>, the latch member <NUM> includes a protrusion <NUM> engaging an actuator <NUM> of the switch <NUM>. In the illustrated construction, the intermediate position (<FIG>) in which the switch <NUM> is actuated is approximately halfway between the latched position (<FIG>) and the unlatched position (<FIG>) of the latch member. In other embodiments (not shown), actuation of the switch <NUM> may occur at any point between the latched and unlatched positions of the latch member <NUM>.

<FIG> illustrate operation of the ejector <NUM>. When the battery pack <NUM> is fully inserted onto the battery-receiving portion <NUM> (see <FIG>), the ejection member <NUM> is pushed into the end wall <NUM> and the biasing member is compressed (e.g., the compressed condition of the ejector <NUM>). In the compressed position, the ejection member <NUM> actuates the switch <NUM> to activate the electrical device (e.g., to permit power to be transferred to a portion of the device (e.g., a master board of a charger, etc.)).

When the latching member <NUM> is moved to the unlatched position (see <FIG>), the biased ejection member <NUM> exerts a force F along the direction of the battery insertion axis <NUM> to force the battery pack <NUM> toward disengagement from the battery-receiving portion <NUM> (e.g., the eject position (see <FIG>)). In one example, the ejection member <NUM> forces the battery pack <NUM> to a position in which the battery contacts <NUM> and the device contacts <NUM> become mechanically and electrically disengaged. As mentioned above, prior to this movement, the switch <NUM> has been activated to inhibit the transfer of electrical power between the battery pack <NUM> and the device. Displacement of the ejection member <NUM> to protrude through the end wall <NUM> disengages the switch <NUM> to deactivate a portion of the device (e.g., to inhibit power transfer to a portion of the device (such as the master board)), to disconnect the device contacts <NUM>, or both.

<FIG> illustrate an alternative construction of a battery-receiving portion <NUM> of an electrical device configured to receive a corresponding battery pack <NUM>. The battery-receiving portion <NUM> and the corresponding battery pack <NUM> are similar to the battery-receiving portion <NUM> and the battery pack <NUM> shown in <FIG>, and common elements have the same reference number plus "<NUM>".

The following description will focus on aspects of the battery-receiving portion <NUM> and battery pack <NUM> different than the battery-receiving portion <NUM> and the battery pack <NUM>. It should be noted, however, that features of the battery-receiving portion <NUM> or the battery pack <NUM> may be incorporated or substituted into the battery-receiving portion <NUM> or the battery pack <NUM>, or vice versa.

The battery-receiving portion <NUM> includes a first cavity <NUM> and a second cavity <NUM>. The illustrated cavities <NUM>, <NUM> are aligned but separated by a solid portion <NUM>. The first cavity <NUM> is defined by a first lower surface <NUM>, a pair of sidewalls <NUM>, a first end wall <NUM>, and an open end <NUM> opposite the first end wall <NUM>. The second cavity <NUM> is similarly defined by a second lower surface <NUM>, a pair of sidewalls <NUM>, a second end wall <NUM>, and a third end wall <NUM> opposite the second end wall <NUM>.

In the illustrated embodiment, at least a portion of a latching mechanism <NUM> protrudes from the first lower surface <NUM> and is configured to engage the battery pack <NUM> to maintain a connection between the battery pack <NUM> and the battery-receiving portion <NUM>. However, in other embodiments (not shown), the latching mechanism <NUM> may be disposed at various locations (e.g., on a sidewall <NUM>, the end wall <NUM>, the upper end wall <NUM>, the second cavity <NUM>, etc.) such that the latching mechanism <NUM> engages corresponding features on the battery pack <NUM> (e.g., a slot <NUM>) to maintain engagement between the battery pack <NUM> and the battery-receiving portion <NUM>.

With specific reference to <FIG>, the battery-receiving portion <NUM> includes first grooves 258A defined by first rails 298A disposed along a portion of the sidewalls <NUM> of the first cavity <NUM> from the open end <NUM> to the first end wall <NUM>. Second grooves 258B are defined by second rails 298B disposed along a portion of the sidewalls <NUM> of the second cavity <NUM> from second end wall <NUM> toward the third end wall <NUM>. The illustrated rails 298A, 298B are collinear and collectively define a single battery sliding axis <NUM>.

Device contacts <NUM> are supported on the end wall <NUM> and configured to receive battery contacts <NUM>. An ejector <NUM> is configured to provide assisted removal of the battery pack <NUM> along the battery sliding axis <NUM>.

<FIG> illustrate the battery pack <NUM> for use with the battery-receiving portion <NUM>, described above. The battery pack <NUM> includes a housing <NUM> supporting one or more battery cells (not shown) coupled to the battery contacts <NUM>.

The battery pack <NUM> includes a first protrusion <NUM> and a second protrusion <NUM> defined on the housing <NUM>. Each protrusion <NUM>, <NUM> has lateral sides <NUM>, each including a rail <NUM> outwardly therefrom to define a groove <NUM>. The first protrusion <NUM> further includes a surface <NUM> defining the slot <NUM> to receive the latch member <NUM>. The rails <NUM> of the first protrusion <NUM> and the second protrusion <NUM> are collinear and sized and shaped to be received by the grooves 258A, 258B defined within the first cavity <NUM> and the second cavity <NUM>, respectively.

With reference to <FIG>, the latching mechanism <NUM> is substantially similar to the latching mechanism <NUM> described above. However, in this embodiment, a switch <NUM> is not engaged until the latch member <NUM> is nearly removed from the first cavity <NUM>. The intermediate position (<FIG>) may, for example, correspond to the latching member <NUM> being approximately <NUM>% to <NUM>% removed from the first cavity <NUM>.

As illustrated in <FIG>, the battery-receiving portion <NUM> and the battery pack <NUM> provide a "drop and slide" configuration. That is, to attach the battery pack <NUM> to the battery-receiving portion <NUM>, the battery <NUM> is first "dropped" into the battery-receiving portion <NUM> along a vertical axis such that the first protrusion <NUM> and the second protrusion <NUM> drop into the first cavity <NUM> and the second cavity <NUM>, respectively. Subsequently, the battery pack <NUM> "slides" along the battery sliding axis <NUM> to initiate coupling and latching in a similar manner as described above with respect to <FIG>. In addition, decoupling or removal and ejection of the battery pack <NUM> is similar to the procedure described above with respect to <FIG>.

<FIG> and <FIG> illustrate an alternate construction of a battery-receiving portion <NUM> of an electrical device configured to receive a corresponding battery pack <NUM> (<FIG>). The battery-receiving portion <NUM> and the corresponding battery pack <NUM> are similar to the battery-receiving portions <NUM>, <NUM> and the battery pack <NUM>, <NUM> shown in <FIG> and <FIG>, respectively. Common elements have the same reference number plus "<NUM>" from the battery-receiving portion <NUM> and the battery pack <NUM> and the same reference numeral plus "<NUM>" from the battery-receiving portion <NUM> and the battery pack <NUM>.

The following description will focus on aspects of the battery-receiving portion <NUM> and the battery pack <NUM> different than the battery-receiving portions <NUM>, <NUM> and the battery pack <NUM>. It should be noted, however, that features of the battery-receiving portion <NUM> or the battery pack <NUM> may be incorporated or substituted into the battery-receiving portions <NUM>, <NUM> or the battery pack <NUM>, <NUM>, or vice versa.

With specific reference to <FIG>, the illustrated battery-receiving portion <NUM> includes stepped grooves <NUM> extending along a portion of the sidewalls <NUM> between the open end <NUM> and the end wall <NUM> (e.g., as illustrated, from near the open end <NUM> to the end wall <NUM>). In other embodiments (not shown), the grooves <NUM> may be substantially linear. The stepped grooves <NUM> are defined by rails <NUM> disposed on the sidewalls <NUM>. The rails <NUM> protrude from the sidewalls <NUM> to define an upper extent of the grooves <NUM> that face the lower surface <NUM>. As seen in <FIG>, the rails <NUM> do not extend along a portion of the sidewalls <NUM> proximate the open end <NUM> such that a widened portion <NUM> is defined at the open end <NUM>.

In the illustrated embodiment (see <FIG>), a stepped configuration is provided laterally between the opposite rails <NUM>. The rails <NUM> include a number of (e.g., two) generally parallel axially-extending portions <NUM> defining distinct lateral clearances L1', L2',. Ln' therebetween. Each portion is connected to an angled portion <NUM> extending obliquely toward the opposite rail <NUM> (e.g., when moving from right to left in <FIG>) such that the opposite portions <NUM> define a successively smaller lateral clearance, thereby forming the "stepped" configuration between the rails <NUM>. In addition, a lateral clearance L' is provided between the sidewalls <NUM> in the widened portion <NUM> at the open end <NUM>. In other embodiments (not shown), the rails <NUM> may include more than two portions <NUM>.

<FIG> illustrate a battery pack <NUM> for use with the battery-receiving portion <NUM>, described above. As will be described in greater detail below, the battery pack <NUM> includes mechanical features configured to engage corresponding features on the battery-receiving portion <NUM> to couple and maintain engagement of the battery-receiving portion <NUM> and the battery pack <NUM>.

In the illustrated embodiment, the rails <NUM> include a number of (e.g., three) parallel horizontal portions <NUM> and the body of the housing <NUM> includes a number of (e.g., two) projections <NUM> defining pads or flat surfaces <NUM> facing the rails <NUM>. The grooves <NUM> are defined by distinct vertical clearances C4', C5', C6'. Cn' of the grooves <NUM> measured between each horizontal portion <NUM> and the flat surfaces <NUM> (e.g., C4' and C6') or the body of the housing <NUM> (e.g., C5'). Each portion <NUM> is connected by an angled portion <NUM> extending obliquely away from the housing <NUM> when moving from the rear end <NUM> toward the front end <NUM>. As illustrated, the rails <NUM>/grooves <NUM> of the battery pack <NUM> form a mated engagement between the rails <NUM>/grooves <NUM> of the battery-receiving portion <NUM>.

The illustrated battery pack <NUM> includes a pair of slots 682a, 682b on the surface <NUM> configured to receive the latching member <NUM>. When battery pack <NUM> is connected to the battery-receiving portion <NUM> and the latching mechanism <NUM>, <NUM> is engaged, the latch member <NUM>, <NUM> engages the slot 682a. When the latch member <NUM>, <NUM> is disengaged from the slot 682a, as the battery pack <NUM> is removed from the battery-receiving portion <NUM>, the latch member <NUM>, <NUM> will engage the slot 682b if the handle <NUM>, <NUM> is no longer actuated/has been released. This re-engagement of the latch member <NUM>, <NUM> may inhibit the battery pack <NUM> from being disconnected inadvertently (e.g., if the handle <NUM>, <NUM> was inadvertently actuated).

A horizontal clearance is measured from the lateral side <NUM> to a periphery of each rail <NUM>. In the illustrated embodiment (see <FIG>), a stepped configuration is provided laterally between the opposite rails <NUM>. The rails <NUM> include a number of (e.g., three) generally parallel axially-extending portions <NUM> defining distinct lateral dimensions L4', L5', L6'. Ln' therebetween. Each portion is connected to an angled portion <NUM> extending obliquely toward the opposite rail <NUM> (e.g., when moving from right to left in <FIG>) such that the opposite portions <NUM> define a successively smaller lateral dimension, thereby forming the "stepped" configuration between the rails <NUM>. In the illustrated embodiment, the lateral dimension L4', L5', L6' between each portion <NUM> changes by a constant amount.

Again, it should be understood that, if the size, shape, orientation, etc. of the battery-receiving portion <NUM> is modified, corresponding variations in the size, shape, orientation, etc. of the battery pack <NUM> may be made.

<FIG> illustrate a mating portion of the battery pack <NUM> (e.g., the battery pack <NUM> with the body of the housing <NUM> removed) being coupled to the battery-receiving portion <NUM>. As illustrated, the rails <NUM> of the battery pack <NUM> are aligned with the grooves <NUM> of the battery-receiving portion <NUM>, and, subsequently, the battery pack <NUM> slides along a battery insertion axis <NUM> until the device contacts <NUM> engage the battery contacts <NUM>.

The widened portion <NUM> may facilitate insertion of the battery pack <NUM> by providing extra clearance at the open end <NUM> to reduce the difficulty in aligning the rails <NUM> of the battery pack <NUM> with the grooves <NUM> of the battery-receiving portion <NUM>. Likewise, the larger relative clearances defined between the rails <NUM> and the grooves <NUM>, which decrease as the battery pack <NUM> is inserted further onto the battery-receiving portion <NUM>, may also facilitate insertion of the battery pack <NUM> while providing a tighter, more secure engagement between the battery pack <NUM> and the battery-receiving portion <NUM> by creating tighter clearances (e.g., at C4' and C6') at full insertion of the battery pack <NUM>.

<FIG> illustrates an alternative construction of a slide-actuated latching mechanism <NUM>. The latching mechanism <NUM> may be used with one of the battery-receiving portions <NUM>, <NUM>, <NUM> (e.g., with or in place of latching mechanisms <NUM>, <NUM>).

The illustrated latching mechanism <NUM> includes a laterally-displaceable actuator or button <NUM> operatively engaging a latch member <NUM>. The latch member <NUM> is pivotally disposed in a cavity <NUM> (e.g., defined in the lower surface <NUM>) and is biased by a biasing member (e.g., a torsion spring <NUM>, a coil spring, etc.) to protrude through the lower surface <NUM> and into the cavity <NUM>.

The latch member <NUM> has an inclined surface <NUM> (e.g., angled about <NUM> degrees to about <NUM> degrees relative to the lower surface <NUM>) facing toward the open end <NUM> and a generally vertically-extending surface <NUM> (e.g., about -<NUM> degrees to about <NUM> degrees relative to a vertical axis) facing toward the end wall <NUM>.

The latch member <NUM> is coupled to the spring <NUM> and includes an end <NUM> coupled to the button <NUM> (e.g., via a cam surface). The button <NUM> is engaged with the latch member <NUM> such that actuation (e.g., pressing the button to effect lateral displace to the left in <FIG> to reach the position illustrated in <FIG>) of the button <NUM> causes the latch member <NUM> to pivot against the bias of the spring <NUM> to withdraw the latch member <NUM> from the cavity <NUM>.

The illustrated latching mechanism <NUM> also includes a switch <NUM> (e.g., a micro-switch <NUM>) facilitating electrical coupling/decoupling of the battery pack <NUM> during actuation of the button <NUM> to withdraw the latch member <NUM> from the cavity <NUM>. In other embodiments, however, the switch <NUM> may be omitted. As described above in greater detail, the switch <NUM> may act to electrically decouple the battery pack <NUM> from the battery-receiving portion <NUM> and the device prior to removal of the battery pack <NUM> from the battery-receiving portion <NUM>.

As the latch member <NUM> is moved from the latched position (not shown but similar to the position shown in <FIG>) to an intermediate position (not shown but similar to the position shown in <FIG>), the switch <NUM> is activated to inhibit the transfer of electrical power between the battery pack <NUM> and the device before the battery pack <NUM> is released by the latching member <NUM> and removable from the battery-receiving portion <NUM> and before the contacts <NUM>, <NUM> disengage. Activation of the switch <NUM> to stop power transfer between the battery pack <NUM> and the device may, for example, prevent arcing between the contacts <NUM>, <NUM> as the battery pack <NUM> is removed.

Further movement of the latching member <NUM> to an unlatched position (<FIG>) removes the latching member <NUM> from the slot 682a, 682b, and the battery pack <NUM> is permitted to move along the battery insertion axis <NUM> off of the battery-receiving portion <NUM>. The switch <NUM> is maintained in the on position to continue inhibiting the transfer of power between the battery pack <NUM> and the device.

It should be understood that, in other constructions (not shown), features described as being on one of the battery-receiving portion <NUM>, <NUM>, <NUM> and the battery pack <NUM>, <NUM>, <NUM> (e.g., the "drop and slide" arrangement, the latching mechanism <NUM>, <NUM>, the ejector <NUM>, etc.) may be provided on the other of the battery-receiving portion <NUM> and the battery pack <NUM>.

<FIG> illustrate an alternate construction of a battery-receiving portion <NUM> of an electrical device configured to receive a corresponding battery pack <NUM> (<FIG>). The battery-receiving portion <NUM> and the corresponding battery pack <NUM> are similar to the battery-receiving portions <NUM>, <NUM>, <NUM> and the battery pack <NUM>, <NUM>, <NUM> shown in <FIG>, <FIG>, and <FIG>, respectively. Common elements have the same reference number plus "<NUM>" from the battery-receiving portion <NUM> and the battery pack <NUM>, the same reference numeral plus "<NUM>" from the battery-receiving portion <NUM> and the battery pack <NUM>, and the same reference numeral plus "<NUM>" from the battery-receiving portion <NUM> and the battery pack <NUM>.

The following description will focus on aspects of the battery-receiving portion <NUM> and the battery pack <NUM> different than the battery-receiving portions <NUM>, <NUM>, <NUM> and the battery pack <NUM>, <NUM>, <NUM>. It should be noted, however, that features of the battery-receiving portion <NUM> or the battery pack <NUM> may be incorporated or substituted into the battery-receiving portions <NUM>, <NUM>, <NUM> or the battery pack <NUM>, <NUM>, <NUM>, or vice versa.

With reference to <FIG>, the battery-receiving portion <NUM> is substantially similar, in particular, to the battery-receiving portion <NUM> illustrated in <FIG>. However, the battery-receiving portion <NUM> further includes a dual-action latching mechanism <NUM>. In other words, in order to operate the latching mechanism <NUM> to release the battery <NUM> from the battery-receiving portion <NUM>, two separate actions are required.

As shown in <FIG>, the latching mechanism <NUM> includes a primary actuator or handle <NUM> that supports a secondary actuator <NUM>. The secondary actuator <NUM> includes a user interface <NUM> on a first end and a housing engaging portion <NUM> on an opposite end.

The secondary actuator <NUM> is pivotable between a first position, in which the housing engaging portion <NUM> engages a portion of the lower surface <NUM>, and a second position, in which the housing engaging portion <NUM> extends into a groove or aperture <NUM> in the portion of the lower surface <NUM>. The secondary actuator <NUM> is biased toward the first position by a biasing member <NUM> (e.g., a torsion spring, etc.) to maintain engagement with the lower surface <NUM>.

In the first position, the engagement of the engaging portion <NUM> and the lower surface <NUM> inhibits or prevents movement (e.g., pivoting) of the actuator <NUM> to prevent unlatching of the battery pack <NUM>. A user can apply a force to the user interface <NUM> to pivot the secondary actuator (e.g., in a counterclockwise direction in <FIG>) against the bias of the biasing member <NUM> into the second position. In the second position, the engaging portion <NUM> no longer engages the lower surface <NUM> and is instead aligned with the groove <NUM> thereby providing clearance for the actuator <NUM> to pivot and unlatch the battery pack <NUM>, as described in greater detail below.

The actuator <NUM> operatively engages the latch member <NUM>. The latch member <NUM> is slidably disposed in a bore <NUM> defined in the lower surface <NUM> and is biased by two biasing members (e.g., springs <NUM>, such as a coil spring, a torsion spring, etc.) to protrude through the lower surface <NUM> and into the cavity <NUM>. As seen in <FIG>, the biasing springs <NUM> are located beneath opposing lateral sides of the latch member <NUM>. The latch member <NUM> has an inclined surface <NUM> (e.g., angled about <NUM> degrees to about <NUM> degrees relative to the lower surface <NUM>) facing toward the open end <NUM> and a generally vertically-extending surface <NUM> (e.g., about -<NUM> degrees to about <NUM> degrees relative to a vertical axis) facing toward the end wall <NUM>.

The latch member <NUM> is coupled to the springs <NUM>. In some embodiments (not shown), one spring <NUM> may be coupled to the latch member <NUM> instead of two. In other embodiments (not shown), three or more springs <NUM> may be coupled to the latch member <NUM>. In such multi-spring arrangements, each spring <NUM> may be smaller/shorter, leading to a shorter overall height of the latch member <NUM> and the spring <NUM> without a reduction in biasing force.

The handle <NUM> is engaged with the latch member <NUM> via a cam surface <NUM> such that actuation (e.g., clockwise pivoting/rotation of the handle <NUM> with respect to the position shown in <FIG>) of the handle <NUM> causes the latch member <NUM> to translate downwardly against the bias of the springs <NUM> to withdraw the latch member <NUM> from the cavity <NUM>.

The latching mechanism <NUM> also includes a switch <NUM> (e.g., a micro-switch <NUM>) facilitating electrical coupling/decoupling of the battery pack <NUM> during actuation of the handle <NUM> to withdraw the latch member <NUM> from the cavity <NUM>. In other embodiments (not shown), the switch <NUM> may be omitted. The switch <NUM> may act to electrically decouple the battery pack <NUM> from the battery-receiving portion <NUM> and the device prior to removal of the battery pack <NUM> from the battery-receiving portion <NUM>. The operation of a similar switch <NUM> was described in greater detail with respect to <FIG>.

As seen in the foregoing description, the dual-action latching mechanism <NUM> requires a user to perform two actions in order to unlatch the battery pack <NUM>. More specifically, the user must operate the secondary actuator <NUM> into the second position before the actuator <NUM> may be operated to remove the latch member <NUM> from the cavity <NUM>, to thereby unlatch the battery pack <NUM>. Such a mechanism can, for example, prevent or reduce the likelihood of unintended unlatching of the battery pack <NUM> from the battery-receiving portion <NUM>.

It should be understood that, in other constructions (not shown), features described as being on one of the battery-receiving portion <NUM>, <NUM>, <NUM>, <NUM> and the battery pack <NUM>, <NUM>, <NUM>, <NUM> (e.g., the "drop and slide" arrangement, the latching mechanism <NUM>, <NUM>, the ejector <NUM>, etc.) may be provided on the other of the battery-receiving portion <NUM>, <NUM>, <NUM>, <NUM> and the battery pack <NUM>, <NUM>, <NUM>, <NUM>.

<FIG> illustrate an alternate construction of a battery-receiving portion <NUM> of an electrical device configured to receive a corresponding battery pack <NUM> (<FIG>). The battery-receiving portion <NUM> is similar to the battery-receiving portions <NUM>, <NUM>, <NUM>, <NUM> shown in <FIG>, <FIG>, <FIG>, and <FIG>, respectively. Common elements have the same reference number plus "<NUM>" from the battery-receiving portion <NUM>, the same reference numeral plus "<NUM>" from the battery-receiving portion <NUM>, the same reference numeral plus "<NUM>" from the battery-receiving portion <NUM>, and the same reference numeral plus "<NUM>" from the battery-receiving portion <NUM>.

The following description will focus on aspects of the battery-receiving portion <NUM> different than the battery-receiving portions <NUM>, <NUM>, <NUM>, <NUM>. It should be noted, however, that features of the battery-receiving portion <NUM> may be incorporated or substituted into the battery-receiving portions <NUM>, <NUM>, <NUM>, <NUM>, or vice versa.

With reference to <FIG>, the battery-receiving portion <NUM> is substantially similar, in particular, to the battery-receiving portion <NUM>, <NUM> illustrated in <FIG> and <NUM>-<NUM>, respectively. However, the battery-receiving portion <NUM> further includes an alternate embodiment of a dual-action latching mechanism <NUM>. To operate the dual-action latching mechanism <NUM> to release the battery <NUM> from the battery-receiving portion <NUM>, two separate actions are required.

As shown in <FIG>, the latching mechanism <NUM> includes a primary actuator or handle <NUM> that supports a linearly displaceable secondary actuator <NUM>. The secondary actuator <NUM> includes a user interface <NUM> and a housing engaging portion <NUM>. The secondary actuator <NUM> is linearly displaceable (e.g., slidable) between a first position, in which the housing engaging portion <NUM> engages a portion of the lower surface <NUM>, and a second position, in which the housing engaging portion <NUM> extends into a groove or aperture <NUM> in the portion of the lower surface <NUM>. The secondary actuator <NUM> is biased into the first position by a biasing member <NUM> (e.g., a coil spring, etc.) to maintain engagement with the lower surface <NUM>.

In the first position, the engagement of the engaging portion <NUM> and the lower surface <NUM> inhibits or prevents movement (e.g., pivoting) of the actuator <NUM> to prevent unlatching of the battery pack <NUM>. A user can apply a force to the user interface <NUM> to displace the secondary actuator against the bias of the biasing member <NUM> into the second position. In the second position, the engaging portion <NUM> no longer engages the lower surface <NUM> and is instead aligned with the groove <NUM> thereby providing clearance for the actuator <NUM> to pivot and unlatch the battery pack <NUM>, as described in greater detail below.

The pivotable actuator <NUM> operatively engages the latch member (not illustrated in this embodiment but similar to the latch member <NUM>). The latch member is slidably disposed in a bore <NUM> defined in the lower surface <NUM> and is biased by two biasing members (e.g., springs, such as a coil spring, a torsion spring, etc.) to protrude through the lower surface <NUM> and into the cavity <NUM>. The biasing springs <NUM> are located beneath opposing lateral sides of the latch member. The latch member has an inclined surface <NUM> (e.g., angled about <NUM> degrees to about <NUM> degrees relative to the lower surface <NUM>) facing toward the open end <NUM> and a generally vertically-extending surface <NUM> (e.g., about -<NUM> degrees to about <NUM> degrees relative to a vertical axis) facing toward the end wall <NUM>, similar to the latch members <NUM>, <NUM>, <NUM>.

The latch member is coupled to the springs <NUM>. In some embodiments (not shown), one spring <NUM> may be coupled to the latch member instead of two. In other embodiments (not shown), three or more springs <NUM> may be coupled to the latch member. In such multi-spring arrangements, each spring <NUM> may be smaller/shorter, leading to a shorter overall height of the latch member and the spring <NUM> without a reduction in biasing force.

The handle <NUM> is engaged with the latch member via a cam surface <NUM> such that actuation (e.g., clockwise pivoting/rotation of the handle <NUM> with respect to the position shown in <FIG>) of the handle <NUM> causes the latch member to translate downward against the bias of the springs <NUM> to withdraw the latch member from the cavity <NUM>.

The latching mechanism <NUM> also includes a switch (e.g., a micro-switch; not shown but similar to the switch <NUM>) facilitating electrical coupling/decoupling of the battery pack <NUM> during actuation of the handle <NUM> to withdraw the latch member <NUM> from the cavity <NUM>. In other embodiments (not shown), the switch may be omitted. The switch may act to electrically decouple the battery pack <NUM> from the battery-receiving portion <NUM> and the device prior to removal of the battery pack <NUM> from the battery-receiving portion <NUM>. The operation of a similar switch <NUM> was described in greater detail with respect to <FIG>.

As seen in the foregoing description, the dual-action latching mechanism <NUM> requires a user to perform two actions in order to unlatch the battery pack <NUM>. More specifically, the user must operate the secondary actuator <NUM> into the second position before the actuator <NUM> may be operated to remove the latch member from the cavity <NUM>, to thereby unlatch the battery pack <NUM>. Such a mechanism can, for example, prevent or reduce the likelihood of unintended unlatching of the battery pack <NUM> from the battery-receiving portion <NUM>.

It should be understood that, in other constructions (not shown), features described as being on one of the battery-receiving portion <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and the battery pack <NUM>, <NUM>, <NUM>, <NUM> (e.g., the "drop and slide" arrangement, the latching mechanism <NUM>, <NUM>, the ejector <NUM>, etc.) may be provided on the other of the battery-receiving portion <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and the battery pack <NUM>, <NUM>, <NUM>, <NUM>.

<FIG> illustrate the battery pack <NUM> for use with the battery-receiving portion <NUM>, <NUM>, described above. As will be described in greater detail below, the battery pack <NUM> includes mechanical features configured to engage corresponding features on the battery-receiving portion <NUM>, <NUM> to couple and maintain engagement of the battery-receiving portion <NUM>, <NUM> and the battery pack <NUM>.

In the illustrated embodiment, the rails <NUM> include a number of (e.g., three) parallel horizontal portions <NUM> and the body of the housing <NUM> includes a number of (e.g., two) projections <NUM> defining pads or flat surfaces <NUM> facing the rails <NUM>. The grooves <NUM> are defined by distinct vertical clearances C4", C5", C6". Cn" of the grooves <NUM> measured between each horizontal portion <NUM> and the flat surfaces <NUM> (e.g., C4" and C6") or the body of the housing <NUM> (e.g., C5"). Each portion <NUM> is connected by an angled portion <NUM> extending obliquely away from the housing <NUM> when moving from the rear end <NUM> toward the front end <NUM>. As illustrated, the rails <NUM>/grooves <NUM> of the battery pack <NUM> form a mated engagement between the rails <NUM>, <NUM>/grooves <NUM>, <NUM> of the battery-receiving portion <NUM>, <NUM>.

A horizontal clearance is measured from the lateral side <NUM> to a periphery of each rail <NUM>. In the illustrated embodiment (see <FIG>), a stepped configuration is provided laterally between the opposite rails <NUM>. The rails <NUM> include a number of (e.g., three) generally parallel axially-extending portions <NUM> defining distinct lateral dimensions L4", L5", L6". Ln" therebetween. Each portion is connected to an angled portion <NUM> extending obliquely toward the opposite rail <NUM> (e.g., when moving from right to left in <FIG>) such that the opposite portions <NUM> define a successively smaller lateral dimension, thereby forming the "stepped" configuration between the rails <NUM>. In the illustrated embodiment, the lateral dimension L4", L5", L6" between each portion <NUM> changes by a constant amount.

With reference to <FIG>, the battery pack <NUM> includes a single slot <NUM>. The slot <NUM> is sized and shaped to receive and engage latch member <NUM>, <NUM> to prevent removal of the battery pack <NUM> when the battery pack <NUM> is attached to the battery-receiving portion <NUM>, <NUM>.

<FIG> illustrate an electrical device, such as a battery charger, including a battery-receiving portion <NUM>. As illustrated, the battery-receiving portion <NUM> has a "stepped" configuration provided by stepped rails <NUM>, similar to the stepped rails <NUM>, <NUM>, <NUM>, <NUM>, described above, and configured to receive a battery pack with a complementary configuration, such as the battery pack <NUM>, <NUM>, <NUM>. When connected, the battery charger is operable to charge the battery pack <NUM>, <NUM>, <NUM>.

In other constructions (not shown), the battery-receiving portion <NUM> may have a different configuration, such as a "drop and slide" configuration similar to the battery-receiving portion <NUM>, described above, and be configured to receive a battery pack having a complementary configuration, such as the battery pack <NUM>.

<FIG> and <FIG> illustrate alternative constructions of the battery pack <NUM> and <NUM>, respectively. The battery packs <NUM> and <NUM> are similar to the battery <NUM> described above. Common elements have the same reference number plus "<NUM>" or "<NUM>" respectively, from the battery pack <NUM>. The battery packs <NUM> or <NUM> may include features of the battery packs <NUM>, <NUM>, <NUM>, <NUM>.

Each battery pack <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may include one or more cell strings, each having a number (e.g., <NUM>, <NUM>, <NUM>, etc.) of battery cells connected in series to provide a desired discharge output (e.g., nominal voltage (e.g., <NUM> V, <NUM> V, <NUM> V, <NUM> V, <NUM> V) and current capacity). In the illustrated construction, the battery pack <NUM> includes one string of <NUM> series connected cells (a "20S1P" configuration), while the battery pack <NUM> includes two strings, each having <NUM> series connected cells (a "20S2P" configuration).

Due to the higher number of cells used in the battery pack (e.g., the battery pack <NUM>), the size/weight of the electrical device, the battery pack <NUM> may be more vulnerable to damage. In some constructions (see, for example, <FIG>), the battery-receiving portion <NUM> and/or the battery pack <NUM> may be constructed with one or more of the below-described structures to improve impact resistance.

In one example, as shown in <FIG>, the housing <NUM> of the battery pack <NUM> may be constructed with one or more angled surfaces <NUM> to remove or soften corner shapes. As a result, rather than impacting a sharp or square corner, the battery pack <NUM> may impact on a flat or blunt surface. The angled surface(s) <NUM> may increase the strength of the battery pack <NUM> during impact of loading.

In another example (see <FIG>), the battery pack <NUM> may include elastomeric overmold material <NUM> covering surfaces most likely to be impacted (e.g., exposed edges <NUM> of the housing <NUM>). The overmold material <NUM> may include an elastomeric material such as a thermoplastic elastomer (TPE), polyurethane, rubber, reduce a load experienced during an impact or drop (e.g., a force up to about <NUM> Joules or more). As shown in <FIG>, in the illustrated construction, the overmold material <NUM> is thickest (e.g., about <NUM> or more) along the exposed edges <NUM> of the housing <NUM> and tapers away from these locations (e.g., to a thickness of about <NUM> or less).

In yet another example (see <FIG>), material of the interface between a battery pack <NUM> (e.g. the housing <NUM>, the protrusion <NUM> and the rails <NUM>) and/or the associated electrical device (e.g., the battery-receiving portion <NUM>, the side walls <NUM> and the rails <NUM>) may be reinforced. In the illustrated construction, the material of the housing <NUM> and of the battery-receiving portion <NUM> includes plastic, and the reinforcement <NUM> is formed of metal. As illustrated, the reinforcement <NUM> is molded with the material of the housing <NUM> or of the battery-receiving portion <NUM>. The reinforcement <NUM> may contribute to improved impact resistance and drop strength, resistance to material fatigue from vibration, etc..

<FIG> illustrate reinforcement of the interface of the battery pack <NUM>. The reinforcement <NUM> is provided in areas of the rails <NUM> and the protrusion <NUM>. The illustrated reinforcement <NUM> includes a stamping <NUM> including portions following the cross-section of the rails <NUM>, forming a generally C-shape around the grooves <NUM>. The stamping <NUM> also spans the width of the protrusion <NUM>. In the illustrated construction, the stamping <NUM> is tied directly to bosses <NUM> in the housing <NUM>.

In a further example (see <FIG>), a shock absorption arrangement <NUM> may be provided between the battery pack <NUM> and the electrical device. The arrangement <NUM> may provide impact or drop isolation for the battery pack <NUM> by providing shock absorbing cushions in the interface. The arrangement <NUM> may be provided for shock rather than vibration isolation and provides isolation in all directions.

As shown in <FIG> and <FIG>, the battery-receiving portion <NUM> is provided by a housing <NUM> defining on its outer surface a number of locations (e.g., recesses <NUM>). A projection or post <NUM> is supported at each location (e.g., extends from each recess <NUM>). A shock absorption member <NUM> is supported on each post <NUM>.

An outer housing <NUM> (see <FIG>) and at least partially surrounds the housing <NUM>. The housing <NUM> defines a corresponding number of locations (e.g., recesses <NUM>), each receiving a shock absorption member <NUM>.

The shock absorption members <NUM> are generally puck-shaped and, in the illustrated construction, are formed of an elastomeric material, such as polyurethane. As shown in <FIG>, the shock absorption members <NUM> may have different constructions, depending on the electrical device, the location in the arrangement <NUM>.

Claim 1:
A battery pack (<NUM>) including:
a housing (<NUM>) including a support portion connectable to and supportable by an electrical device, the housing also including a bottom wall opposite the support portion, opposite side walls connected between the bottom wall and the support portion and opposite end walls connected between the bottom wall and the support portion and between the side walls, adjacent walls meeting at an edge (<NUM>);
elastomeric material on at least one edge (<NUM>),
characterized in that
the elastomeric material being thickest proximate the edge and thinning in a direction away from the edge;
wherein the battery pack (<NUM>) further includes a plurality of battery cells supported by the housing (<NUM>); and
a battery terminal electrically connected to the plurality of battery cells and connectable to a terminal of the electrical device,
wherein the support portion includes a body and a rail (<NUM>, <NUM>, <NUM>, <NUM>) extending along an axis (<NUM>,<NUM>), the rail and the body defining a space therebetween, the space having a first dimension proximate a first axial location, a second dimension at a second axial location, and a third dimension at a third axial location, the first dimension, the second dimension, and the third dimension being different, and
wherein the rail (<NUM>, <NUM>, <NUM>, <NUM>) has a stepped rail surface extending along the axis, the stepped rail surface having a first rail surface portion proximate the first axial location, a second rail surface portion proximate the second axial location, and a third rail surface portion proximate the third axial location.