(12) United States Patent (10) Patent No.: US 7,554,290 B2 Johnson et a]. (45) Date of Patent: *Jun. 30, 2009
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1 US B2 (12) United States Patent (10) Patent No.: US 7,554,290 B2 Johnson et a]. (45) Date of Patent: *Jun. 30, 2009 (54) LITHIUM-BASED BATTERY PACK FORA (51) Int. Cl. HAND-HELD POWER TOOL H01M 10/46 ( ) (52) U.S.Cl /112 (75) Inventors: Todd W. Johnson, Wauwatosa, WI (US); (58) Field of Classi?cation Search /112, Dennis J. Grzybowski, New Berlin, WI (US); Mark A. Kubale, West Bend, WI 320/114,116,118,122 See application?le for complete search history. (US); Jay J. Rosenbecker, Menomonee (56) References Cited Falls, WI (US); Karl F. Scheucher, Waite Hill, OH (US); Gary D. Meyer, U.S. PATENT DOCUMENTS Waukesha, WI (US); Jeffrey M. Zeiler, Discovery Bay (HK); Kevin L. Glasgow, Lomira, WI (US) 4,893,067 A l/l990 BhagWat et a1. (73) Assignee: Milwaukee Electric Tool Corporation, Brook?eld, WI (US) ( * ) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(b) by 0 days. (21) Appl.No.: 11/7s0,s29 (22) Filed: Jul. 20, 2007 This patent is subject to a terminal dis claimer. (65) Prior Publication Data US 2008/ A1 Jan. 17,2008 Related U.S. Application Data (63) Continuation of application No. 10/721,800,?led on Nov. 24, 2003, now Pat. No. 7,253,585. (60) Provisional application No. 60/428,356,?led on Nov. 22, 2002, provisional application No. 60/428,358,?led on Nov. 22, 2002, provisional application No. 60/428,450,?led on Nov. 22, 2002, provisional appli cation No. 60/428,452,?led on Nov. 22, 2002, provi sional application No. 60/440,692,?led on Jan. 17, 2003, provisional application No. 60/440,693,?led on Jan. 17, 2003, provisional application No. 60/523,712,?led on Nov. 19, 2003, provisional application No. 60/523,716,?led on Nov. 19, (Continued) FOREIGN PATENT DOCUMENTS CA /1999 (Continued) OTHER PUBLICATIONS JuZkoW, Marc, Development of a BB-2590/U rechargeable lithium ion battery, Journal ofpower Sources, v (1999), p , Elsevier Science SA, (Continued) Primary ExamineriEdward T50 (74) Attorney, Agent, or FirmiMichael Best & Friedrich LLP (57) ABSTRACT A method for conducting an operation including a power tool battery pack. The battery pack can include a housing, a?rst cell supported by the housing and having a voltage, and a second cell supported by the housing and having a voltage. The battery pack also can be connectable to a power tool and be operable to supply power to operate the power tool. The method can include discharging one of the?rst cell and the second cell until the voltage of the one of the?rst cell and the second cell is substantially equal to the voltage of the other of the?rst cell and the second cell. 11 Claims, 68 Drawing Sheets
2 US 7,554,290 B2 Page 2 US. PATENT DOCUMENTS GB /1995 GB /1996 4,973,896 A 11/1990 Shiga et al. GB /1999 5,206,097 A 4/1993 Burns et al. GB /2001 5,268,630 A 12/1993 Bhagwat et al. GB /2001 5,280,229 A l/l994 Faude et al. GB /2004 5,350,993 A 9/1994 Toya et al. ]p /1996 5,355,073 A 10/1994 Nguyen JP /2000 5,371,453 A 12/1994 Fernandez Jp /2001 5,547,775 A 8/1996 Eguchi et al. JP /2001 5,567,542 A 10/1996 Bae JP /2002 5,598,085 A 1/1997 Hasler Jp /2002 5,606,242 A 2/1997 Hull et al. R /2000 5,684,387 A 11/1997 Patino W0 WO 96/ /1996 5,691,620 A 11/1997 Nagai et al. W0 WO 99/ /1999 5,691,623 A 11/1997 Tsantilis W0 WO 00/ /2000 5,710,504 A 1/1998 Pascual et al. W0 WO 01/ /2001 5,744,937 A 4/1998 Cheon 5,757,163 A 5,789,900 A 5/1998 Brotto et al. 8/1998 Haseqawa et al. OTHER PUBLICATIONS 5,835,351 A 11/ 1998 Ulanski et al. Kim, Heesook P., et al., Development of High Power Lithium/ 5,894,212 A 4/ 1999 Balogh Thionyl Chloride Reserve Battery, Proceedings of the Electro 5,986,430 A 11/1999 Fernandez et al. chemical Society, vol , p , ,998,966 A 12/1999 Gaza Sack, Thomas T., J. Croydan Tice, and Ran Reynolds, Segmented 6,002,237 A 12/1999 Gaza Battery Charger for High Energy 28V Lithium Ion Battery, IEEE 6,040,683 A 3/2000 Mottier AESS Systems Magazine, vol. 16, Sep. 2001, p , IEEE, ,084,523 A 7/2000 Gelnovatch et al. Smart, M.C., et al., Performance Characteristics of Yardney 6,124,698 A 9/2000 Sakakibara Lithium-Ion Cells for the Mars 2001 Lander Application, AIAA 6,204,640 B1 3/2001 Sakakibara , vol. 1, p , Society ofautomotive Engineers, Inc., 6,275,004 B1 8/2001 Tamai et al ,329,788 B1 12/2001 Bailey et al. Smart, M.C., et al., Lithium-Ion Cell Technology Demonstration for 6,337,557 B1 1/2002 Kates et al. Future NASA Applications, 37th Intersociety Energy Conversion 6,433,510 B1 8/2002 Ribellino et al. Engineering Conference, Smart-IECEC Paper , p ,452,362 B1 9/2002 Choo 304, IEEE, ,509,114 B1 1/2003 Nakai et al. Stassen, I., and G. Hambitzer, Metallic lithium batteries for high 6,924,620 B2 8/2005 Santana, Jr. power applications, Journal of Power Sources, vol. 105 (2002), p. 7,273,159 B2 9/2007 Brotto , Elsevier Science B.V., / A1 9/ 2002 Schworm et al. Felder, Jason, Bosch Introduces Li-Ion 36V Battery Pack, 2002/ A1 10/ 2002 Judge ThomasNet Industrial NewsRoom, at / A1 5/2003 Takano et al. fu1lstory/801246, Oct. 24, ThomasNet Industrial NewsRoom, DeWalt Launches Nano Tech FORETGN PATENT DOCUMENTS nology Driving Lines of Cordless Tools, Feb. 9, 2007, at DE /1988 thomasnet.com/companystory/ DE / 1996 Craftsman Lithium Revolution Brochure. No Date. DE /2003 Richards, Paul W., et al., A Computer Controlled Power Tool for the Ep /1988 Servicing ofthe Hubble Space Telescope, May 15, 1996, 30th Aero Ep /1991 space Mechanisms Symposium, p Ep /1994 Tailor, Devin, Pistol Grip Tool Technician Manual, Sep. 1997, p. EP / EP / 1997 Hubble Servicing Calls for Dazzling Array of CrewAids and Tools, EP /1997 Spaceport News, Feb. 14, 1997, p. 1,8. EP /2000 Results from Testing of E-One Moli Energy (Canada) Ltd. Prototype EP /2001 Battery Packs by Milwaukee Electric Tool Corporation, Sep. 26, EP / to Oct. 11,2001. EP /2002 Declaration ofgary Meyer Under 37 C.F.R. Section dated Mar. EP / , 2009.
3 US. Patent Jun. 30, 2009 Sheet 1 0f 68 US 7,554,290 B2
4 US. Patent Jun. 30, 2009 Sheet 2 0f 68 US 7,554,290 B2
5 US. Patent Jun. 30, 2009 Sheet 3 0f 68 US 7,554,290 B2 NI (0 6E m
6 US. Patent Jun. 30, 2009 Sheet 4 0f 68 US 7,554,290 B2
7 US. Patent Jun. 30, 2009 Sheet 5 0f 68 US 7,554,290 B2
8 US. Patent Jun. 30, 2009 Sheet 6 0f 68 US 7,554,290 B2
9 US. Patent Jun. 30, 2009 Sheet 7 0f 68 US 7,554,290 B2 NE \> mm 6E N
10 US. Patent Jun. 30, 2009 Sheet 8 0f 68 US 7,554,290 B2 mw m 6E om
11 US. Patent Jun. 30, 2009 Sheet 9 0f 68 US 7,554,290 B2 FIG. 9
12 US. Patent Jun. 30, 2009 Sheet 10 0f 68 US 7,554,290 B2 0 FIG. 10 a 30A
13 US. Patent Jun. 30, 2009 Sheet 11 0f 68 US 7,554,290 B2
14 US. Patent Jun. 30, 2009 Sheet 12 0f 68 US 7,554,290 B2
15 US. Patent Jun. 30, 2009 Sheet 13 0f 68 US 7,554,290 B2.QE 2
16 US. Patent Jun. 30, 2009 Sheet 14 0f 68 US 7,554,290 B2 mom 3.Qt 0% gm
17 US. Patent Jun. 30, 2009 Sheet 15 0f 68 US 7,554,290 B2 r8 iqd. FIG. 15
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19 US. Patent Jun. 30, 2009 Sheet 17 0f 68 US 7,554,290 B C \ V 46A 4613 FIG. 19
20 US. Patent Jun. 30, 2009 Sheet 18 0f 68 US 7,554,290 B2
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