Patent Document

[0001]    This application claims the benefit of U.S. provisional patent application Ser. No. 61/036,720 entitled REMOVABLE BATTERY PACK WITH LATCHING MECHANISM filed Mar. 14, 2008 the entirety of which is hereby incorporated by reference. 
     
    
       [0002]    The present disclosure generally relates to removable battery packs, and more particularly to a removable battery pack having an improved latching mechanism. In particular to one embodiment, a battery pack having an improved latching mechanism is removably disposed in a cleaning appliance with a suction motor impeller assembly (e.g., a stick-type or hand held portable type vacuum cleaner) for powering same. Though the present disclosure will describe a removable battery pack particularly in association with a suction force cleaner, it is to be appreciated that the subject matter described herein has broader applications and may be advantageously employed in related environments and applications (e.g., for use in other powered devices including power tools, radios, power sprayers and the like). 
       TECHNICAL CONSIDERATIONS 
       [0003]    Removable battery packs have been provided in a wide variety of configurations for use with an infinite number of consumer products. As might be expected, there are many different types of battery latching mechanisms for securing removable battery packs to their respective electric powered devices. At least some of these are claimed to allow for easy removal and installation of the battery packs. These are often competing considerations in the design of a particular battery pack and/or a particular powered device that receives and is powered by the battery pack. A further competing consideration is the constant desire to provide battery packs, and devices powered thereby, at a lower cost without degrading the experience of the consumer in using the battery pack together with its powered device (or devices). 
         [0004]    Much attention has been given to the design of removable battery packs for certain categories of consumer products. For example, the art is crowded with many removable battery pack designs and configurations for power tools (e.g., cordless drills and saws). Similarly, much attention has been given to removable battery packs for more sophisticated electronic devices, such as computers, portable DVD players and the like. However, relatively little attention has been paid to the removable battery packs for other types of more common consumer devices, such as suction force cleaners having a suction motor and impeller or fan assembly commonly referred to as vacuum cleaners. For Instead, for example, latching mechanisms for these other types of consumer devices seem to have been more of an afterthought. Often, for these devices, little attention is given to designing a battery pack latching mechanism that provides proper securing of the battery pack to the consumer device it is to power, while ensuring that the battery pack is easily attached and detached from its consumer device. 
       SUMMARY 
       [0005]    According to one aspect of the present disclosure, a removable battery package or pack is provided. More particularly, in accordance with this aspect, the removable battery pack includes a housing and one or more batteries disposed within the housing and electrically connected to an electrical connector. A user contact is movably mounted in the housing for movable cooperation with the rod. Suitably a lever can be pivotally mounted to the housing or a push button or twist lever can be movably mounted to the housing. A rod such as a push rod is movably mounted to the housing. The push rod is adapted to be axially moved by the user contact. An engagement member such as a latch is movably mounted to the housing. The member is adapted to be moved between a latched position and an unlatched position by the push rod, when the push rod is axially moved by the lever or push button or twisted axially by a twist lever. If desired, the latch can be urged by a biasing element toward the latched position and can require axial movement by the push rod to force the latch toward the unlatched position, overcoming the urging of the biasing mechanism. 
         [0006]    In one configuration, axial movement of the push rod can occur along a first axis and movement of the latch between the latched position and the unlatched position can occur along a second axis. In one embodiment, the second axis can be oriented approximately normal relative to the first axis. If desired, a tapered engagement can be provided between the push rod and the latch to translate movement of the push rod along the first axis to movement of the latch along the second axis. 
         [0007]    In one embodiment, the push rod can be movable between a first or retracted position and a second or protruding position. Movement of the push rod from the first retracted position to the second protruding position can move the latch from the latched position to the unlatched position. In the second protruding position, the push rod can extend from the housing for ejecting the housing from an associated device in which the housing is received for powering thereof. If desired, the push rod can be urged toward the first retracted position by a biasing element. Also, if desired, the associated device from which the push rod can eject the housing can be a vacuum cleaner and the one of more batteries contained in the housing can be used to power the vacuum cleaner. 
         [0008]    In any of the foregoing configurations or a separate configuration, a distal end of the lever relative to a pivotal connection of the lever to the housing can be pulled to drive the push rod axially downward to move the latch from the latched position inward into the housing to the unlatched position. 
         [0009]    According to another aspect of the disclosure, a vacuum cleaner having a removable battery pack is provided. More particularly, in accordance with this aspect, the vacuum cleaner includes a housing having a suction inlet. A suction source is disposed within the vacuum cleaner housing for creating a suction source at the suction inlet. A battery pack housing is removably mounted within the vacuum cleaner housing. One or more batteries are disposed within the battery pack housing for powering the suction source. A latching mechanism includes a lever pivotally mounted to the battery pack housing, a push rod movably mounted to the battery pack housing so as to be axially movable by the lever, and a latch urged to a latched position wherein the latch locks the battery pack to the vacuum cleaner housing. An engagement between the push rod and the latch causes the latch to move to an unlatched position from the latched position when the push rod is sufficiently axially moved by the lever. 
         [0010]    In one configuration, a full stroke of the lever can cause the push rod to move the latch to the unlatched position and to protrude from the battery pack housing to eject the battery pack housing from the vacuum cleaner housing. 
         [0011]    According to still another aspect of the disclosure, a removable battery pack for a powered device is provided. More particularly, in accordance with this aspect, the removable battery pack includes a battery pack housing removably mounted within the powered device for providing power thereto. A latching mechanism includes a lever pivotally mounted to the battery pack housing. A push rod is movably mounted to the battery pack housing so as to be axially movable from a first position to a second position upon stroking of the lever. A latch locks the battery pack within the powered device when in a latched position. The latch is movable from the latched position to an unlatched position allowing the battery pack housing to be removed from the powered device upon the push rod being moved axially from the first position to the second position. 
         [0012]    In one configuration, the push rod, when in the second position, can protrude from the battery pack housing. In this configuration, movement of the push rod from the first position to the second position helps to eject the battery pack from the powered device. 
         [0013]    According to still yet another aspect of the instant disclosure, a method for removing a battery pack from a powered device is provided. More particularly, in accordance with this aspect, a lever that is pivotally mounted on the battery pack is pulled or stroked. A push rod that is slidably disposed on the battery pack is axially advanced. Due to a mechanical linkage between the lever and the push rod, pulling of the lever causes axial advancement of the push rod. A latch that is slidably disposed on the battery pack is retracted to release the battery pack from the powered device. Specifically, due to a mechanical arrangement between the latch and the push rod, advancing of the push rod causes retraction of the latch. In one configuration, an ejection of the battery pack from the powered device is assisted by the push rod protruding from the battery pack upon axial advancement thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1A  is a perspective view of a removable battery pack having a release lever, the release lever shown in an actuated or pulled position. 
           [0015]      FIG. 1B  is another perspective view of the removable battery pack of  FIG. 1  showing a latch in a retracted or unlatched position and a push rod in an extended or protruding position. 
           [0016]      FIG. 2  is a perspective view of the removable battery pack seated on a recharging base. 
           [0017]      FIG. 3A  is a perspective view of a vacuum cleaner having a receptacle for receipt of the battery pack. 
           [0018]      FIG. 3B  is a front view of a vacuum cleaner having a battery pack removably disposed in the receptacle for powering the vacuum cleaner. 
           [0019]      FIG. 4  is a side elevation schematic view of the battery pack. 
           [0020]      FIG. 5  is an end elevation schematic view of the battery pack. 
           [0021]      FIG. 6  is an enlarged partial cross-section view of the battery pack shown in  FIG. 5  showing an interface between a spring-biased push rod and a spring-biased latch. 
           [0022]      FIG. 7A  is an underside perspective view of the removable battery pack showing the latch in a locking or latched position and the push rod in a retracted position. 
           [0023]      FIG. 7B  is partial underside perspective view of the removable battery pack showing the latch in the retracted position and the push rod in the protruding position. 
           [0024]      FIG. 8A  is a perspective view of the battery pack shown with a first cover removed to illustrate the longitudinal extent of the push rod and the batteries carried within the battery pack. 
           [0025]      FIG. 8B  is another perspective view of the battery pack shown with a second, opposite cover removed, the first and second covers together forming a housing of the battery pack. 
           [0026]      FIG. 9A  is an enlarged partial perspective view of the battery pack shown with the first cover removed to illustrate the lever in a normal resting position and the push rod in the retracted position. 
           [0027]      FIG. 9B  is another partial perspective view of the battery pack shown with the first cover removed to illustrate the lever in the pulled position, which causes the push rod to be in the protruding position. 
           [0028]      FIG. 10  is a perspective view of a hand held portable suction cleaner with the removable battery in the battery receiving opening and well. 
           [0029]      FIG. 11  is a rear view of the hand held portable suction cleaner of  FIG. 10  with the removable battery in the battery receiving opening and well. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    In the description unless otherwise indicated, all numbers expressing quantities of dimensions, physical characteristics, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical values set forth in the following specification and claims may vary depending upon the desired properties sought to be obtained in the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical value should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass the beginning and ending range values and any and all sub-ranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all sub-ranges-between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all sub-ranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Also as used herein, spatial or directional terms in regards to the position such as “left”, “right”, “inner”, “outer”, “above”, “below”, “top”, “bottom” “over”, “on”, “side”, “front”, “back” and the like have their standard dictionary meanings. 
         [0031]    Referring now to the drawings, wherein the showings are for purposes of illustrating one or more exemplary embodiments of the present disclosure,  FIGS. 1A and 1B  show a removable battery pack  10  for a powered device. The battery pack  10  includes a housing  12  and one or more batteries  14  ( FIG. 8A ) disposed within the housing  12 . The housing  12  can be formed of a first shell or member  12   a  and a second shell or member  12   b , with the members  12   a , 12   b  held together by suitable fasteners  12   c  (e.g., screws). As will be understood and appreciated by those skilled in the art upon reading the present disclosure, a lever  16  is pivotally mounted to the housing  12  for enabling removal of the battery pack  10  from a powered device in which it is received for powering thereof. 
         [0032]    In particular, as will be described in more detail below, a one end  18  of the lever  16 , which is spaced apart relative to a pivotal connection  20  of the lever  16  to the housing  12  (see  FIGS. 8A-9B ), is pullable to unlatch the battery pack  10  from a powered device in which it is received and/or to eject the battery pack  10  from the device in which it is received. The lever  16  can have a movement angle about the pivot point  20  of from greater than one degree to less than 180 degrees and more suitably from 5 to less than 90 degrees. As illustrated, the end  18  of the lever  16  can be formed as a raised portion adjacent a recess  22 , the raised formation of the end  18  and the recess  22  appropriately sized to receive a user&#39;s finger for pivotal lifting of the lever  16 , particularly lifting of the end  18  thereof. 
         [0033]    As is known and understood by those skilled in the art, the battery pack  10  can include appropriate positive and negative terminal connections for electrically connecting the battery pack  10 , and specifically the one or more batteries  14  thereof, to suitable electrical components of a powered device. In one arrangement, as illustrated in  FIGS. 4 and 5 , the electrical connections  24 ,  26  can extend from a bottom side  28  of the battery pack housing  12  and be provided adjacent a supporting structure  30  of the housing  12  for providing structural protection to the terminal connections  24 ,  26 . Alternatively, as shown in  FIGS. 7A and 7B , the terminal electrical connections can be provided through an interface  36  that is slightly recessed within the housing  12  and thereby structurally protected or supported. With reference to  FIG. 2 , the removable battery pack  10  can be received on a charging base  32  for recharging of the one or more batteries  14  of the battery pack  10 . The recharging base  32  can be constructed as is well known by those of skill in the art so as to receive electrical power through a conventional power cord  34  and convert the same into appropriate DC power to be received and stored by the one or more batteries  14  for subsequent powering of a powered device. 
         [0034]    The removable battery pack  10  can be used with a variety of powering devices configured to receive the battery pack  10  and receive power therefrom. For example, with reference to  FIGS. 3A ,  3 B,  10  and  11 , the battery pack  10  can be used in association with a powered device, such as an electrically powered cleaning device such as a vacuum cleaner  40 . As is conventional, the vacuum cleaner  40  includes a vacuum cleaner housing  42  having a suction inlet  44 . A suction source (not shown) is disposed within the vacuum cleaner housing  42  for creating a vacuum at the suction inlet  44 , as is known and understood by those skilled in the art. The vacuum cleaner  40  of the illustrated embodiment of  FIGS. 3A and 3B  for a stick-type vacuum cleaner wherein the housing  42  includes a nozzle base portion  48  disposed at a lower end, pivotally connected to an elongated handle portion  50 . The nozzle portion  48  includes the suction inlet  44  defined therein and the handle portion  50  can house the motor/fan assembly forming the suction source. For a hand held vacuum cleaner as shown in  FIGS. 10 and 11  the handle  50  is integrated into the unit but the nozzle  48  with nozzle inlet  44 , suction fan assembly and removable battery  10  can be arranged in the body or housing  42 . 
         [0035]    The battery pack  10  can be removably mounted to or within the vacuum cleaner  40 . In other words the battery pack  10  can be mounted either in the nozzle base  48  or in the handle portion  50 . The mounting in  FIG. 3A  can be in the opening and well  52  as shown in  FIG. 3B . The one or more batteries  14  disposed within the battery pack housing  12  can be used for powering the suction source of the vacuum cleaner  40 . When the one or more batteries  14  have lost some or all of their charge, the battery pack  10  can be removed from the vacuum cleaner  40  and mounted on the recharging base  32  for recharging of the one or more batteries  14 . 
         [0036]    With reference now to  FIGS. 4-9B , the battery pack  10  can include a latching mechanism comprised of the lever  16  pivotally mounted to the battery pack housing  12 , a push rod  62  movably mounted to the battery pack housing  12  and a latch  64  movably mounted to the battery pack housing  12 . As will be described in more detail below, the push rod  62  is adapted to be axially moved by the lever  16  and the latch  64  is adapted to be moved radially from a latched position to an unlatched position by the push rod  62  when the push rod is axially moved by the lever  16 . In the latched position, the latch  64  can lock the battery pack  10  within its power device (e.g., vacuum cleaner  40 ). 
         [0037]    The latch  64  is movable from its latched position ( FIG. 9A ) to its unlatched position ( FIG. 9B ) allowing the battery pack housing  12  to be removed from its powered device, when the push rod  62  is moved axially from a first position to a second position. In particular, the push rod  62  is movable from its first position to its second position upon stroking of the lever  16  (i.e., fully lifting the end  18  of the lever  16 .) With specific reference to  FIGS. 9A and 9B , lifting end  18  of the lever  16  causes the lever  16  to pivot about pivotal connection  20 . This, in turn, causes lever end  56  to point downwardly, contacting the upper end  58  of the push rod  62  and thereby driving the push rod axially downwardly. In one embodiment (FIGS.  8 A, 8 B) the lever  16  can include legs  74  depending from the end  18 . The legs  74  cooperate with the housing  12  to limit the stroke of the lever  16 . 
         [0038]    As best shown in  FIG. 6 , the latch  64  can be urged to its latched position wherein the latch  64  locks the battery pack  10  within its power device (e.g., to the vacuum cleaner  40  or vacuum cleaner housing  42 ). Specifically, the latch  64  is urged by a biasing element, such as spring  66 , toward the latched position. Axial movement of the push rod  64 , however, can force the latch  64  toward its unlatched position by overcoming the urging of the biasing element  66 . In particular, an engagement between the push rod  62  and the latch  64  can cause the latch  64  to move to the unlatched position (shown in  FIG. 7B ) from the latched position (shown in  FIG. 7A ) when the push rod  64  is sufficiently axially moved (i.e., fully stroked) by the lever  16 . 
         [0039]    As shown in the illustrated embodiments, axial movement of the push rod  62  occurs along a first axis and movement of the latch  64  between the latched position and the unlatched position occurs along a second axis. The second axis can be oriented approximately normal relative to the first axis. As best shown in  FIG. 6 , the engagement between the push rod  62  and the latch  64  can be a tapered engagement which translates movement of the push rod  62  along the first axis to movement of the latch  64  along the second axis. To create this tapered engagement, the push rod  62  can include a tapered portion  68  that engages a cooperating tapered portion  70  of the latch  64  upon axial movement of the push rod  62  to thereby move the latch  64  from its latched position to the unlatched position. 
         [0040]    The first position of the push rod  62  (shown in  FIGS. 7A and 9A ) can be referred to as a retracted position and the second position of the push rod  62  (shown in  FIGS. 7B and 9B ) can be referred to as a protruding position. Thus, the push rod  62  is movable between a first retracted position and a second protruding position. In the first retracted position, the push rod  62  is retracted within the housing  12  (i.e., it does protrude from the housing  12 ). In the second protruding position, the push rod  62  extends from the battery pack housing  12  through aperture  76  defined in the underside  28  of the housing  12  for ejecting the housing  12  from an associated device in which the housing is received for powering thereof. Also, as already mentioned, movement of the push rod  62  from the first retracted position to the second protruding position moves the latch  64  from the latched position to the unlatched position. 
         [0041]    The push rod  62  can be urged toward its first retracted position by a biasing element, such as the illustrated spring  72  (only schematically illustrated in  FIGS. 4 and 5 ). Thus, when the end  18  of the lever  16  is pulled, the push rod  62  is driven axially downward to move the latch  64 , against the bias of the spring, from its latched position inward into the housing  12  to its unlatched position. More specifically, a full stroke of the lever  16  causes the push rod  62  to move the latch  64  to the unlatched position and further causes the push rod  62  to protrude from the battery pack housing  12 , which can be used to assist in the ejection of the battery pack housing  12  from the housing of the powered device in which the battery pack is received (e.g., vacuum cleaner housing  42 ). 
         [0042]    By the foregoing arrangement, a method for removing a battery pack from a powered device can be described. First, the lever  16  that is pivotally mounted on the battery pack  10  can be pulled. Pulling up one end of the lever  16  causes the other end to push down on the push rod  62 , causing it to axially advance. Such axial advancement occurs as a result of the push rod  62  being slidably disposed on the battery pack  10  and mechanically arranged such that a rotating movement of the lever  16  is translated into axial movement of the push rod  62 . The advancing of the push rod  62 , as already described, causes the latch  64  to retract. Retraction of the latch  64  results from the latch being slidably disposed on the battery pack  10  and the tapered engagement between the push rod  62  and the latch  64 . In the unlatched position, the latch  64  allows the battery pack  10  to be removed from its powered device. The battery pack  10  can also be ejected from its powered device via the push rod  62  protruding from the battery pack  10  upon axial advancement thereof. 
         [0043]    Although in the illustrated embodiment, only a single latch  64  is illustrated, it will be appreciated by those with skill in the art that any number of latches  64  can be provided along the push rod  62  and within the housing  12  of the battery pack such that axial movement of the push rod  62  could slidably move any number of latches from respective latched positions to unlatched positions upon sufficient axial movement of the push rod. Also, it should be appreciated that installation of the battery pack  10  into a powered device can operate to force the one or more latches (e.g., latch  64 ) inward against their respective biasing elements allowing the battery pack to be removably secured to a powered device. The configuration of the device and/or the latches can then allow the latches to be returned to their latched positions by the biasing mechanism when the battery pack is fully installed. 
         [0044]    It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also it is to be appreciated that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the present disclosure as recited in the claims and the equivalents thereof.

Technology Category: 1