Abstract: A battery pack including a battery cell assembly, the battery cell assembly having a battery cell with a first end and a second end. A circuit board is adjacent to the battery cell and extending from the first end to the second end. A first electrical connector is disposed at the first end and connects a first end of the circuit board to the first end of the battery cell. A second electrical connector is disposed at the second end and connects a second end of the circuit board to the second end of the battery cell. A third electrical connector is disposed at the first end of the circuit board, the third electrical connector can be electrically connected to a powered device so that power from the battery cell may be provided to the powered device through the third electrical connector. A housing houses the battery cell assembly.

Abstract: A battery pack including a battery cell assembly, the battery cell assembly having a battery cell with a first end and a second end. A circuit board is adjacent to the battery cell and extending from the first end to the second end. A first electrical connector is disposed at the first end and connects a first end of the circuit board to the first end of the battery cell. A second electrical connector is disposed at the second end and connects a second end of the circuit board to the second end of the battery cell. A third electrical connector is disposed at the first end of the circuit board, the third electrical connector can be electrically connected to a powered device so that power from the battery cell may be provided to the powered device through the third electrical connector. A housing houses the battery cell assembly.

Abstract: A power tool system including at least one power tool and a battery pack selectively coupleable with the power tool. The battery pack includes a housing, at least one battery cell housed in the housing, a circuit board housed in the housing, a switch mounted on the circuit board, a button actuatable by a user to actuate the switch mounted on the circuit board and a biasing member which biases the button away from a position of actuating the switch. The biasing member is made of a non-conductive material.

Abstract: A battery pack can include a temperature sensor that can provide an output that is indicative of a temperature associated with the battery pack. A battery management unit can directly measure the temperature sensor when the battery pack is by itself or engaged with a tool. A charger can directly read the temperature sensor when the battery pack is engaged with the charger. Thus, the temperature sensor can be shared by the battery pack and the charger. The battery pack can utilize a same terminal that provides access to the temperature sensor to indicate a stop-charge signal. The charger can read the stop-charge signal on the same terminal used to directly access the temperature sensor.

Abstract: A method comprises discharging each of a plurality of cells of a battery pack, stopping the discharging of a selected cell of the plurality of cells when the selected cell reaches a predetermined capacity, and charging the plurality of cells after the discharging has stopped for all of the plurality of cells.

Abstract: A method comprises discharging each of a plurality of cells of a battery pack, stopping the discharging of a selected cell of the plurality of cells when the selected cell reaches a predetermined capacity, and charging the plurality of cells after the discharging has stopped for all of the plurality of cells.

Abstract: A power tool for operating on a workpiece, the power tool having a housing and a motor disposed within the housing. A controller is connected to the motor and receives user inputs for turning on the motor and a power tool battery pack is connected to the controller and the motor. At least one light is connected to the controller for illuminating the workpiece. The controller can turn on the light in a predetermined pattern to alert the user to a tool condition, such as the charge level being below a predetermined level.

Abstract: A method for operating a driving tool, such as a fastening tool, that has a driver, a motor assembly with a motor and an output member, and an electrical power source. The methodology includes transmitting electrical power to the motor to rotate the output member and thereafter adjusting one or more control parameters if a rotational speed of the output member is not within a predetermined operating range.

Abstract: A method for monitoring the voltage of each of a plurality of cells of a battery pack is provided. The method may include monitoring a voltage potential for each of a plurality of cells in a battery pack utilizing a single channel of battery control unit within the battery pack. If, during discharge of the battery, e.g., the battery is being used to power a hand tool, the voltage potential of any cell is determined by the battery control unit to be below a predetermined minimum voltage, the battery control unit discontinues a current flow from battery pack to the tool.

Abstract: A driving tool having a driver, a power source, a sensor and a controller. The power source selectively provides an input to the driver to cause the driver to translate along an axis. The sensor senses a condition in the power source that is indicative of a level of kinetic energy of an element in the power source and generates a sensor signal in response thereto. The controller is coupled to the power source and the sensor and is responsive to the sensor signal for deactivating the power source to inhibit the power source from providing the input to the driver when the level of kinetic energy of the element in the power source is below a predetermined threshold. A method for operating a driving tool is also provided.

Abstract: A control module is included in a battery charger that is adapted to charge a plurality of battery packs of different types or a power tool that is adapted to be powered by at least one of the battery packs. The control module includes a remote sensing module that communicates remotely with one of the battery packs. The control module also includes a battery pack connection module that determines that the one of the battery packs is in electrical communication with at least one of the battery charger and the power tool. The control module also includes a battery pack identification (ID) module that determines a first type of the battery pack based on remote sensing module signals. The control module also includes a charge control module that determines at least one of a charge setting and a discharge setting for the battery pack based on the first type.

Abstract: A battery pack can include a temperature sensor that can provide an output that is indicative of a temperature associated with the battery pack. A battery management unit can directly measure the temperature sensor when the battery pack is by itself or engaged with a tool. A charger can directly read the temperature sensor when the battery pack is engaged with the charger. Thus, the temperature sensor can be shared by the battery pack and the charger. The battery pack can utilize a same terminal that provides access to the temperature sensor to indicate a stop-charge signal. The charger can read the stop-charge signal on the same terminal used to directly access the temperature sensor.

Abstract: A method for monitoring the voltage of each of a plurality of cells of a battery pack is provided. The method may include monitoring a voltage potential for each of a plurality of cells in a battery pack utilizing a single channel of battery control unit within the battery pack. If, during discharge of the battery, e.g., the battery is being used to power a hand tool, the voltage potential of any cell is determined by the battery control unit to be below a predetermined minimum voltage, the battery control unit discontinues a current flow from battery pack to the tool. Additionally, during charging of the battery pack, if a voltage differential between any one of the cells and any other one of the cells is determined to be above a predetermined maximum differential, the battery control unit reduces the voltage potential stored in the cell having the higher voltage potential.

Abstract: A battery pack can include a temperature sensor that can provide an output that is indicative of a temperature associated with the battery pack. A battery management unit can directly measure the temperature sensor when the battery pack is by itself or engaged with a tool. A charger can directly read the temperature sensor when the battery pack is engaged with the charger. Thus, the temperature sensor can be shared by the battery pack and the charger. The battery pack can utilize a same terminal that provides access to the temperature sensor to indicate a stop-charge signal. The charger can read the stop-charge signal on the same terminal used to directly access the temperature sensor.

Abstract: A rechargeable battery pack for a power tool can have a data terminal that provides a signal that is indicative of whether the voltage is below a threshold and can serve as both a pre-charge signal for a charger and as a stop-discharge signal for a power tool. A charger can include a power supply circuit and a voltage detection circuit. A charger control module can receive a signal indicative of the voltage of the battery pack and determine a pre-charge time based on the voltage and can monitor a change in the voltage of the battery pack during the pre-charge operation and stop the pre-charge operation based on the change in voltage and the time period.

Abstract: A battery pack may include a plurality of battery cells; a discharge switch in series with the battery cells, a temperature sensor configured to sense temperature in the battery pack, and a battery control unit adapted to receive a signal indicative of temperature from the temperature sensor and operable to control the switch to interrupt current flow from the battery cells when the temperature exceeds an over-temperature threshold. The battery control unit may be adapted to receive a reset signal and operable to control the switch to restore current flow upon receipt of the reset signal and when the temperature is below an operating temperature threshold.

Abstract: A battery charger is provided for implementing a charging method having a stepped output current. The battery charger includes: a power supply circuit that receives an AC input signal and outputs a DC output signal. The power supply circuit includes a power supply controller configured to receive a feedback signal indicative of current being output by the power supply circuit via an amplifier and operates to control current output by the power supply circuit in accordance with the feedback signal. A charger controller is interfaced with the power supply controller to implement a charging method having a stepped output current. The charger controller may set the output current level by adjusting gain of an operational amplifier having a negative feedback configuration with the feedback signal input to a non-inverting input terminal of the operational amplifier, where the charger controller sets the output current level by changing the resistance at an inverting input terminal of the operational amplifier.

Abstract: A battery charger comprises a first electrical contact that receives a positive contact of an attached battery pack; a second electrical contact that receives a negative contact of the attached battery pack; a plurality of inter-cell electrical contacts that selectively receive inter-cell contacts of the attached battery pack; a measurement module; and a control module. The inter-cell contacts of the attached battery pack are connected to nodes between cells of the attached battery pack.

Abstract: A rechargeable battery pack for a power tool can have a data terminal that provides a signal that is indicative of whether the voltage is below a threshold and can serve as both a pre-charge signal for a charger and as a stop-discharge signal for a power tool. A charger can include a power supply circuit and a voltage detection circuit. A charger control module can receive a signal indicative of the voltage of the battery pack and determine a pre-charge time based on the voltage and can monitor a change in the voltage of the battery pack during the pre-charge operation and stop the pre-charge operation based on the change in voltage and the time period.

Abstract: A battery pack can include a temperature sensor that can provide an output that is indicative of a temperature associated with the battery pack. A battery management unit can directly measure the temperature sensor when the battery pack is by itself or engaged with a tool. A charger can directly read the temperature sensor when the battery pack is engaged with the charger. Thus, the temperature sensor can be shared by the battery pack and the charger. The battery pack can utilize a same terminal that provides access to the temperature sensor to indicate a stop-charge signal. The charger can read the stop-charge signal on the same terminal used to directly access the temperature sensor.