Electrical transmission or interconnection systems – Miscellaneous systems – Power packs
Reexamination Certificate
1999-07-14
2001-01-30
Jackson, Stephen W. (Department: 2836)
Electrical transmission or interconnection systems
Miscellaneous systems
Power packs
C320S113000, C200S043170, C200S321000
Reexamination Certificate
active
06181032
ABSTRACT:
TECHNICAL FIELD
This invention relates generally to portable electrical power tools, and specifically to interfaces for releasably connecting power control modules to electrical appliances, and to methods of connecting such interfaces.
BACKGROUND OF THE INVENTION
Electrical power tools are in widespread use, and with improving battery technology, cordless tools are becoming lighter, more efficient and more common. Any given user may have several such tools for performing different functions around the home, garden or job site. There have been many attempts at designing such tools to be modular, in order to avoid unnecessary duplication of hardware common to all of a user's power tools.
The design of the interface between common and specific modules is critical to the safety and reliability of such a modular system. When transferring electrical power or signals across such an interface, care should be taken to ensure reliable electrical contact. In addition, the modules should lock together in a manner which avoids inadvertent separation.
Modular cordless systems, in which a common module contains a storage battery and task-specific modules contain electric motors, require electrical power to be transferred across the module interface. It is important in many applications that motors of such tools not be inadvertently energized during assembly and disassembly of the common module, or battery pack, with any given task-specific module, or tool chassis.
SUMMARY OF THE INVENTION
The invention features an improved interface for releasably connecting an electrical appliance and a power control module having a power control trigger and being adapted to provide electrical power to a motor of the appliance.
According to one aspect of the invention, the interface (which defines an interface plane between the appliance and power control module) includes a flange extending from one of the module and appliance and arranged to be inserted through an aperture in the other of the module and appliance as the module and appliance are moved toward the interface plane in a disengaged position. The other of the module and appliance defines a corresponding slot to receive the flange as the module and appliance are subsequently slid across one another along the interface plane to an engaged position. The interface also includes a latch extending from one of the module and appliance to engage a detent of the other of the module and appliance, to releasably retain the module and appliance in their engaged position. A first electrical contact, attached to one of the module and appliance, is arranged to engage a second electrical contact attached to the other of the module and appliance with the module and appliance in their engaged position, to transfer electrical power from the module to the appliance.
In some embodiments, the interface also includes an actuator extending from the power control module and operable by the trigger. The actuator is arranged to engage an electrical switch mechanism of the appliance to control a flow of electrical current from the power control module to the appliance.
The actuator, in some instances, is a lever extending from the power control module and adapted to move in a direction along the interface plane to depress the electrical switch mechanism as the trigger is actuated.
In some cases, one of the module and appliance also includes a latch release mechanism exposed for manual operation to and adapted to release the latch to enable the module and appliance to be moved to their disengaged position. Preferably, the latch release mechanism is constructed and arranged to physically block operation of the actuator while the latch release mechanism is operated. It is also preferred that the actuator be constructed and arranged to physically block operation of the latch release mechanism while the trigger is actuated.
The latch release mechanism may include a pair of depressible buttons, which may be connected by a resilient member, disposed on opposite sides of one of the module and appliance, for example.
In some preferred configurations, the interface is constructed and arranged to allow moving the module and appliance to their engaged position without operating the latch release mechanism.
In some cases, the actuator is constructed to engage and retain the latch release mechanism in a non-latched position when the trigger is pulled while the latch release mechanism is in its non-latched position. For example, the actuator may define an undercut engageable by a hooked protrusions extending from opposing ears of the latch release mechanism.
In a presently preferred embodiment, the latch and latch release mechanism are components of the appliance.
In some embodiments, one of the module and appliance has two flanges extending in opposite directions generally parallel to the interface plane and perpendicular to the slot. The other of the module and appliance defines two slots, arranged in opposition, for receiving the flanges with the module and appliance in their engaged position.
The one of the module and appliance having the two flanges also has, in some configurations, an auxiliary flange spaced apart from, and parallel to, the two flanges. The other of the module and appliance further defines a third slot, of different dimensions than the other two slots, for receiving the auxiliary flange as the module and appliance are moved to their engaged position.
Preferably, the interface is constructed and arranged to permit the flange to be inserted through the aperture with the module and appliance in only one orientation.
In some preferred interfaces, the first and second electrical contacts extend along the interface plane such that the contacts slide across one another as the module and appliance are moved toward their engaged position.
According to a second aspect of the invention, the interface includes a wide dovetail portion extending from the appliance and arranged to be inserted, through an aperture in the power module, toward the interface plane with the module and appliance in a disengaged position. The power module defines a first slot to receive the wide dovetail portion of the appliance as the power module and appliance are subsequently slid across one another along the interface plane to an engaged position. The interface also includes an actuator extending from the power control module and operable by the trigger. The actuator is arranged to engage an electrical switch mechanism of the appliance to control a flow of electrical current from the power control module to the appliance. Furthermore, the interface includes a latch extending from the appliance to engage a detent of the power module, to releasably retain the module and appliance in their engaged position. The latch is operable by a latch release mechanism exposed for manual operation on the appliance. The interface also includes an electrical contact attached to the power module and arranged to engage an electrical contact of the appliance with the module and appliance in their engaged position, to transfer electrical power from the module to the appliance.
In some cases, the power module also defines a second slot, spaced apart from the first slot along the interface plane and adapted to receive a narrow dovetail portion extending from the appliance, as the module and appliance are slid along the interface plane toward their engaged position. Preferably, the wide dovetail portion is between about 75 and 85 millimeters in width, as measured across the interface plane, and the narrow dovetail portion is between about 55 and 65 millimeters in width, as measured across the interface plane.
According to a third aspect of the invention, the interface includes flanges on each of the power control module and appliance, a latch pawl, electrical contacts on each of the power control module and appliance, an actuator, and a latch release. The flanges are arranged to overlap as the power module is slid along the interface plane, to an engaged position on the appliance. The latch pawl extends from the appli
Marshall James D.
Milligan Michael A.
Stones Kevin
Black & Decker Inc.
Fish & Richardson P.C. P.A.
Jackson Stephen W.
Roberto Rios
LandOfFree
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