Battery For A Power Tool With A Battery Pack Ejector

FIELD AND BACKGROUND OF THE INVENTION

0001The present invention relates to power tools and, more particularly, to battery operated power tools which include a mechanism for ejecting the battery from the tool.

0002In the power tool field, as battery technology improves, tradesmen are turning to battery operated tools. As the tradesmen utilize the battery operated tools, they desire tools with increased power, extended battery life, and longer durability. However, as tradesmen require more power and extended battery life, battery size and weight increase. As this occurs, it is desirable to have additional help to eject the batteries from the power tools.

0003Various types of battery ejectors exist in the field. Ordinarily, the batteries are surrounded by the housing and the biasing mechanism applies a force on the battery or battery pack near the electrical contact area. This is illustrated in U.S. Pat. No. 4,146,682 to Nakao; U.S. Pat. No. 5,681,667 to Bunyea et al; U.S. Pat. No. 5,225,293 to Mitchell et al; and U.S. Pat. No. 5,637,417 to Engmark et al.

0004U.S. Pat. No. 6,223,835 to Habedank et al, which is assigned to the assignee of the present invention, discloses a mechanism for assisting an ejecting battery from a power tool. The mechanism includes a cap which is biased by a spring or springs which are positioned within the housing. The cap acts upon the battery to apply a removal force onto the battery. Here, the top of the battery and the end of the battery are surrounded by the power tool housing.

0005The cited art does not provide a solution for ejecting a battery which is freely suspended by its coupling mechanism. In this case, the battery is supported on only one side and the remaining battery extends from the housing of the power tool. The majority of battery ejectors for these types of batteries are like those illustrated in U.S. Pat. No. 5,213,913. Here, the latching mechanisms, when moved, allow gravity to drop the battery from the housing. Thus, there was no need for a biasing force to remove the battery pack from the tool housing.

SUMMARY OF THE INVENTION

0006The present invention provides the art with a battery ejection mechanism which is utilized on batteries which are suspended from the power tool. The suspended battery includes rails which enable the battery to slide onto the power tool. The biasing member is positioned adjacent to the battery rails for ejecting the battery. Also, the biasing member is positioned in alignment such that the biasing member contacts the face of the rail mechanism of the battery to eject the battery. The battery is partly ejected from the tool housing so that it can be removed from the housing.

0007In accordance with a first aspect of the present invention, a mechanism for ejecting a battery comprises a frame with a cavity in the frame to receive a battery pack. A receiving member extends from the frame and is adjacent the cavity. The receiving member meshes with a member on the battery pack to maintain the battery pack in the cavity. A biasing member is positioned in the cavity adjacent the receiving member. The biasing member ejects the battery pack from the ejecting mechanism. A member to retain the biasing member in the cavity is secured to the frame. The member guides the meshing portion of the battery pack with the receiving member into contact with the biasing member such that when the battery pack is locked onto the frame, the biasing member is in a compressed condition and when the battery pack is in an unlocked positioned the biasing member ejects the battery pack from the frame. The cavity is defined by a pair of opposing side walls and an end wall adjoining the opposing side walls and an end wall adjoining the opposing side walls. The receiving member includes a pair of rails extending from each side wall. The rails oppose one another. Channels are formed adjacent the side walls and between the rails and frame to receive mating rails on the battery pack. The biasing retaining member is adjacent the channel. The biasing retaining member is a tab extending from the side wall of the frame. The biasing member includes a pair of helical springs. The helical springs extend from the end wall and are aligned coincident with the channel.

0008In accordance with a second aspect of the invention, a power tool comprises a housing with a motor in the housing. An output is coupled with the motor. An activation member is included to activate the motor. A mechanism on the housing receives a battery pack. The mechanism includes a frame, with a receiving member and an adjacent cavity. The receiving member meshes with a member on the battery pack to hold the battery pack in the cavity. A biasing member is positioned in the cavity adjacent the receiving member. The biasing member ejects the battery pack from the ejecting mechanism. A member to retain the biasing member in the cavity is secured to the frame. The member guides the meshing portion of the battery pack with the receiving member into contact with the biasing member such that when the battery pack is locked onto the frame, the biasing member is in a compressed condition and when the battery pack is in an unlocked positioned the biasing member ejects the battery pack from the frame. The cavity is defined by a pair of opposing side walls and an end wall adjoining the opposing side walls. The receiving member includes a pair of rails extending from each side wall. The rails oppose one another. Channels are formed adjacent the side walls and between the rails and frame to receive mating rails on the battery pack. The biasing retaining member is adjacent the channel. The biasing retaining member is a tab extending from the side wall of the frame. The biasing member includes a pair of helical springs. The helical springs extend from the end wall and are aligned coincident with the channel. A battery pack is received in the battery pack receiving mechanism. The battery pack includes a pair of rails mating in the channels. The battery pack rails include an upper portion and a lower portion and a channel between the upper and lower portions. The extending tabs extend into the channel of the battery pack rails. The battery pack rails include end faces that abut the helical springs. The battery rails slide in the channels and the frame rails freely suspend the battery pack from the tool housing. The helical springs are positioned in the tool electrical connector housing.

0009From the following detailed description, taken in conjunction with the drawings and subjoined claims, other objects and advantages of the present invention will become apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

0010<figref idref="DRAWINGS">FIG. 1</figref> is a bottom perspective view of a power tool in accordance with the present invention.

0011<figref idref="DRAWINGS">FIG. 2</figref> is a side perspective view of the battery receiving mechanism of the drill of <figref idref="DRAWINGS">FIG. 1</figref>.

0012<figref idref="DRAWINGS">FIG. 3</figref> is an enlarged perspective view of a portion of the receiving element of <figref idref="DRAWINGS">FIG. 2</figref>.

0013<figref idref="DRAWINGS">FIG. 4</figref> is a cross-section view of <figref idref="DRAWINGS">FIG. 1</figref>.

0014<figref idref="DRAWINGS">FIG. 5</figref> is a perspective view of the battery removed from the tool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

0015Turning to the figures, particularly <figref idref="DRAWINGS">FIG. 1</figref>, a power tool is illustrated and designated with the reference numeral <b>10</b>. The power tool <b>10</b> includes a housing <b>12</b> which includes a motor portion <b>14</b> and a handle portion <b>16</b> as well as a base portion <b>18</b>. A motor <b>20</b> is positioned in the housing <b>12</b>. An output <b>22</b> is coupled with the motor <b>20</b> and in this case includes a chuck <b>24</b>. An activation member <b>26</b> is positioned on the handle portion. The activation member is electrically coupled with the motor <b>20</b> as well as with a battery pack <b>30</b> which supplies the power to the power tool <b>10</b>.

0016The housing base portion <b>18</b> includes a battery pack receiving frame <b>32</b>. The battery pack receiving frame <b>32</b> includes a pair of opposing side walls <b>34</b> and <b>36</b> as well as an end wall <b>38</b>. The side walls <b>34</b>, <b>36</b> and end wall <b>38</b> define a battery receiving cavity <b>40</b>. The cavity <b>40</b> is limited on the frame by a top wall or base <b>42</b>. Each side wall <b>34</b>, <b>36</b> includes a rail <b>44</b>, <b>46</b>. The rails <b>44</b>, <b>46</b> extend longitudinally along the frame from an end of the housing base portion <b>18</b> towards the end wall <b>38</b>. Channels <b>48</b>, <b>50</b> are formed between the rails <b>44</b>, <b>46</b> and the top wall <b>42</b>. The channels <b>48</b>, <b>50</b> receive the battery pack <b>30</b>.

0017An electrical connector housing <b>52</b> is coupled with the housing base portion <b>18</b> adjacent the end wall <b>38</b>. The electrical connector housing <b>52</b> includes electrical connectors <b>54</b>, <b>56</b> which couple with electrical connectors of the battery pack <b>30</b>. The electrical connector housing <b>52</b> includes bores <b>58</b>, <b>60</b> which receive helical springs <b>62</b>, <b>64</b>. Spring guides <b>66</b>, <b>68</b> are positioned at the bottom of the bores <b>58</b>, <b>60</b> to guide the helical springs <b>62</b>, <b>64</b>. Also, the guides <b>66</b>, <b>68</b> maintain the springs in the bores <b>58</b>, <b>60</b> during assembly. Tabs <b>70</b>, <b>72</b> extend from the side walls <b>34</b>, <b>36</b> of the receiving frame <b>32</b>. The tabs <b>70</b>, <b>72</b> capture the helical springs <b>62</b>, <b>64</b> to maintain the springs <b>62</b>, <b>64</b> in the bores <b>58</b>, <b>60</b>. The tabs <b>70</b>, <b>72</b> are positioned between the rails and the top wall <b>42</b> aligned with the channels <b>48</b>, <b>50</b> as seen in <figref idref="DRAWINGS">FIG. 3</figref>. The tabs <b>70</b>, <b>72</b> are tapered from the frame <b>32</b> to the free end. Also, the tabs <b>70</b>, <b>72</b> are tapered along their thickness as seen in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>. The tapers assist in guiding the battery pack <b>30</b>.

0018The battery pack <b>30</b> includes a housing <b>74</b> with a plurality of batteries (not shown) positioned within the housing. A release button <b>76</b> which is coupled with a latch <b>78</b> is positioned on the housing <b>74</b>. The latch <b>78</b> secures the battery pack <b>30</b> to the top wall <b>42</b> of the housing base portion <b>18</b>. The battery housing <b>74</b> includes rails <b>80</b>, <b>82</b> longitudinally extending along the top surface of the battery pack <b>30</b>. The rails define channels <b>84</b>, <b>86</b> which mesh with the rails <b>44</b>, <b>46</b> of the housing base portion <b>18</b>. The rails <b>80</b>, <b>82</b> include upper surfaces <b>88</b>, <b>90</b> and lower surfaces <b>92</b>, <b>94</b>. The upper and lower surfaces define channels <b>96</b>, <b>98</b>. The rails <b>80</b>, <b>82</b> are received in the channels <b>48</b>, <b>50</b> of the housing base receiving frame <b>32</b>. The battery pack <b>30</b> includes electrical connectors <b>104</b>, <b>106</b>. The electrical connectors <b>104</b>, <b>106</b> are received in the electrical connectors <b>54</b>, <b>56</b> for powering the power tool <b>10</b>.

0019The battery pack <b>30</b> is coupled with the housing receiving frame <b>32</b> as follows. The battery pack rails <b>80</b>, <b>82</b> are positioned in the frame channels <b>48</b>, <b>50</b>. The battery pack <b>30</b> is slid, rail upon rail, into the receiving frame <b>32</b> until the latch <b>78</b> secures in a catch <b>79</b> in the top wall <b>42</b>. As this occurs, the battery rail faces <b>100</b>, <b>102</b> abut the helical springs <b>62</b>, <b>64</b>. Prior to this happening, the battery rail channels <b>96</b>, <b>98</b> receive the extending tabs <b>70</b>, <b>72</b>. The tabs <b>70</b>, <b>72</b> guide the rails <b>80</b>, <b>82</b> into contact with the springs <b>62</b>, <b>64</b>. The contacting of the springs <b>62</b>, <b>64</b> by the battery rail faces <b>100</b>, <b>102</b> occurs prior to the latch locking in the catch of the top wall <b>42</b>. Accordingly, the springs <b>62</b>, <b>64</b> compress into the bores <b>58</b>, <b>60</b>.

0020To release the battery pack <b>30</b> from the power tool <b>10</b>, the button <b>76</b> is moved downwardly. As this occurs, the latch <b>78</b> also moves downwardly removing the latch from the catch <b>79</b> on the top wall <b>42</b>. As this occurs, the battery pack <b>30</b> is no longer locked in position on the power tool housing receiving frame <b>32</b>. At that time, the springs <b>62</b>, <b>64</b>, which are designed to have enough force to overcome the weight of the battery pack <b>30</b> and the terminal friction, eject the battery pack <b>30</b> away from the electrical connector housing <b>52</b>. The battery pack <b>30</b> is ejected partially from the battery pack receiving frame <b>32</b>. Also, the ejection disconnects the battery pack from the terminals.

0021While the above detailed description describes the preferred embodiment of the present invention, the invention is susceptible to modification, variation and alteration without deviating from the scope and fair meaning of the subjoined claims.