Abstract: The present directed to a cordless power tool system including a plurality of cordless power tools, a plurality of fixed voltage and multi-voltage battery packs and a plurality of battery pack chargers. The battery packs include circuitry to indicate various parameters about the battery pack and communicate this indication to the power tools in order to enable the power tools to alter their motor output schemes to improve performance. The indication may include whether the battery pack is a fixed voltage battery pack or a multi-voltage battery pack and when the multi-voltage battery pack is in a first configuration or a second configuration.

Abstract: A method of manufacturing a battery pack including the creation of a support board for enabling conversion of the battery pack from providing a first voltage to providing a second voltage. The support board is created by injection molding about a precut set of power traces for coupling a converting element to a plurality of battery cells. The power traces couple the plurality of battery cells to a set of battery pack terminals. The support board may be mechanically coupled to a battery cell holder.

Abstract: It is common for a power tool system from a manufacturer to include a battery pack that is designed and configured to mate and operate with at least one power tool and a battery charger. However, as systems have evolved it has become desirable to provide a battery pack that is designed and configured to mate and operate with at least one power tool and a first battery charger but not a second battery charger. The present disclosure provides a battery pack including a housing, a terminal block, a plurality of terminals, and a mechanical lockout for allowing engagement with a power tool and a first battery charger while preventing engagement with a second battery charger.

Abstract: A battery terminal having a pair of contact tulips that mate with a device terminal in a mating direction. The first of the pair of contact tulips mates with the device terminal in a first contact plane and the second of the pair of contact tulips mates with the device terminal in a second contact plane. The first contact plane is generally parallel to the contact plane. Both the first and the second contact planes are generally perpendicular to the mating direction. The resistance between the first tulip and the device terminal is approximately half the resistance between the second tulip and the device terminal.

Abstract: The present disclosure is directed to an electric power tool system with cordless power tools and removable, rechargeable battery packs that mate with the power tools to provide stored energy to the power tools. The battery packs may include a first battery pack having a basic interface and a second battery pack having an advanced interface. The power tools may include a first power tool having a basic interface and a second power tool having an advanced interface. The basic interface battery pack may mate with both the basic interface power tool and the advanced interface power tool. The advanced interface battery pack may mate with both the basic interface power tool and the advanced interface power tool.

Abstract: A multi-voltage battery pack including a converting system for converting the battery pack between a low voltage configuration and a high voltage configuration. The converting system includes a converter element moves between a first position and a second position to configure the battery pack between the low voltage configuration and the high voltage configuration. The converter element includes a set of contacts that mates with a set of contact pads to establish the voltage configuration.

Abstract: The present disclosure is directed to a cordless reciprocating saw including a mechanical interface for attaching a removable battery pack. The mechanical interface includes a strike plate to reduce the effects of vibrational forces on the battery pack.

Abstract: The present disclosure is directed to a cordless reciprocating saw including a mechanical interface for attaching a removable battery pack. The mechanical interface includes a strike plate to reduce the effects of vibrational forces on the battery pack.

Abstract: A multi-voltage battery pack including a converting system for converting the battery pack between a low voltage configuration and a high voltage configuration. The converting system includes a converter element moves between a first position and a second position to configure the battery pack between the low voltage configuration and the high voltage configuration. The converter element includes a set of contacts that mates with a set of contact pads to establish the voltage configuration.

Abstract: The present disclosure is directed to a cordless reciprocating saw including a mechanical interface for attaching a removable battery pack. The mechanical interface includes a strike plate to reduce the effects of vibrational forces on the battery pack.

Abstract: A first battery pack that is switchable between a first configuration having a first rated output voltage that corresponds to a first power tool rated operating voltage such that the first battery pack enables operation of the first power tool, and a second configuration having a second rated output voltage that corresponds to a second power tool rated operating voltage such that the first battery pack enables operation of the second power tool.

Abstract: The present invention includes a battery pack for a cordless power tool including a plastic housing including a mechanical interface for mechanically coupling the battery pack to a corresponding mechanical interface of a cordless power tool. The mechanical interface includes a rail, a groove and a sliding surface. The battery pack also includes a bracket encased within the plastic housing wherein the bracket includes a first portion positioned within the rail of the mechanical interface.

Abstract: A battery terminal having a pair of contact tulips that mate with a device terminal in a mating direction. The first of the pair of contact tulips mates with the device terminal in a first contact plane and the second of the pair of contact tulips mates with the device terminal in a second contact plane. The first contact plane is generally parallel to the contact plane. Both the first and the second contact planes are generally perpendicular to the mating direction. The resistance between the first tulip and the device terminal is approximately half the resistance between the second tulip and the device terminal.

Abstract: A first battery pack that is switchable between a first configuration having a first rated output voltage that corresponds to a first power tool rated operating voltage such that the first battery pack enables operation of the first power tool, and a second configuration having a second rated output voltage that corresponds to a second power tool rated operating voltage such that the first battery pack enables operation of the second power tool.

Abstract: The present disclosure is directed to a convertible battery pack having an improved switching circuit. The switching circuit includes a converter element having a plurality of contacts positioned in the converter element such that as the converter element slides within the battery pack the contacts move from a first position to engage a first set of contact pads to a second position to engage a second set of contact pads. The converter element includes a pair of springs for each of the plurality of contacts that force the contacts into engagement with the contact pads but also allow the contacts to adjust for imperfections in the contact pad surface or the manufacturing tolerances of the contact pads or a support board that holds the contact pads.

Abstract: The present invention includes a battery pack for a cordless power tool including a plastic housing including a mechanical interface for mechanically coupling the battery pack to a corresponding mechanical interface of a cordless power tool. The mechanical interface includes a rail, a groove and a sliding surface. The battery pack also includes a bracket encased within the plastic housing wherein the bracket includes a first portion positioned within the rail of the mechanical interface.

Abstract: A power tool system includes a first power tool having a first power tool rated voltage, a second power tool having a second power tool rated voltage that is different from the first power tool rated voltage, and a first battery pack coupleable to the first power tool and to the second power tool. The first battery pack is switchable between a first configuration having a first battery pack rated voltage that corresponds to the first power tool rated voltage such that the first battery pack enables operation of the first power tool, and a second configuration having a convertible battery pack rated voltage that corresponds to the second power tool rated voltage such that the battery pack enables operation of the second power tool.

Abstract: The present invention includes a battery pack for a cordless power tool including a plastic housing including a mechanical interface for mechanically coupling the battery pack to a corresponding mechanical interface of a cordless power tool. The mechanical interface includes a rail, a groove and a sliding surface. The battery pack also includes a bracket encased within the plastic housing wherein the bracket includes a first portion positioned within the rail of the mechanical interface.

Abstract: The present disclosure is directed to a battery pack including a printed circuit board populated with a variety of components. The printed circuit board is partially encapsulated with a low pressure molded material to form at least a portion of a potting boat. The potting boat is filled with an encapsulating material.

Abstract: The present disclosure is directed to a cordless reciprocating saw including a mechanical interface for attaching a removable battery pack. The mechanical interface includes a strike plate to reduce the effects of vibrational forces on the battery pack.