CN102256522A

CN102256522A - Battery powered cordless cleaning system

Info

Publication number: CN102256522A
Application number: CN200980150929XA
Authority: CN
Inventors: B·雷德; M·阿勒曼; D·鲁卡维纳; M·兰德; N·西格尔; J·W·吉二世; J·霍尔特; 马克·巴茨
Original assignee: Royal Appliance Manufacturing Co
Current assignee: Royal Appliance Manufacturing Co
Priority date: 2008-10-16
Filing date: 2009-10-16
Publication date: 2011-11-23
Also published as: EP2337485B1; WO2010045588A1; EP2337485A1; EP3132730A1; CN109528080A; EP3132730B1; EP2337485A4; CN109528080B

Abstract

A cordless, battery-powered system of cleaning products. The system of cleaning products includes devices such as upright vacuums (e.g., a stick vacuum, a lightweight upright vacuum, etc.), a hand-held vacuum, a carpet-cleaner, a canister vacuum, and the like. Each of the devices is powered by a battery pack which is interchangeable among the devices. The battery pack includes a combination of hardware and software for connecting to, identifying, and communicating with the cleaning products to ensure that each of the products receives the power necessary to ensure optimal performance.

Description

Battery-powered cordless cleaning system

Cross Reference to Related Applications

This application is a continuation-in-part application of the previously filed, co-pending U.S. provisional patent application No. 12/405,033 filed on 3/16 of 2009, the entire contents of which are incorporated herein by reference.

The present application also claims the benefit of previously filed, co-pending U.S. provisional patent application No. 61/105,891 filed on day 10/16 2008, U.S. provisional patent application No. 61/105,899 filed on day 10/16 2008, and U.S. provisional patent application No. 61/105,896 filed on day 10/16 2008, the entire contents of which are incorporated herein by reference.

Background

User devices, such as suction cleaners (e.g., vacuum cleaners) having a suction motor and an impeller or fan assembly, are almost without exception limited to corded and AC powered devices. The power required to operate these devices has inhibited the development of cordless vacuum cleaners which provide portability, functionality and adequate suction. Various attempts have been made to introduce a battery pack into a vacuum cleaner. Although some of these attempts have been successful in reducing the AC power dependence of the vacuum cleaner, they still do not provide an adequate solution in many types of devices.

Disclosure of Invention

Cleaning systems include a variety of products having different designs to meet different cleaning needs, and cleaning often requires the use of multiple devices to adequately clean a room or space. Large or small cleaning devices likewise lack portability and consistency of operation. For example, devices for cleaning typically include upright suction cleaners for cleaning large surface areas with significant amounts of debris, and smaller, hand-held cleaning devices for cleaning smaller or confined areas. As another example, a canister type cleaner is used in combination with an upright type cleaning apparatus or a hand cleaner. Regardless of the combination of devices used, the efficiency, portability, and compatibility associated with using multiple devices is hampered by the different power requirements of each device. For example, hand-held cleaners, which are typically battery powered devices, require their own charger or replaceable batteries, and upright cleaners, which are typically corded devices, require the user to be within the power cord of the power outlet.

Embodiments of the present invention provide cordless cleaning systems including devices such as stick cleaners, lightweight upright vacuum cleaners, handheld vacuum cleaners, carpet cleaners, canister vacuum cleaners, and the like. Each device may be powered by a bank of cells that are interchangeable between devices. For example, the battery pack is initially inserted into the stick cleaner, and then removed and inserted into the hand cleaner. The battery pack includes a combination of hardware and software to identify and communicate with various devices to ensure optimal performance. The battery pack also includes additional control electronics that maximize the charge life of the battery pack, allow charging parameters and features to be modified, and ensure accurate charging decisions for the battery pack as a whole and for individual cells within the battery pack.

In one embodiment, the battery pack may be configured to enter a "sleep" mode when not plugged into a battery charger or other active device (e.g., during storage). When in the sleep mode, the power consumption of the battery pack is minimized to maintain battery charging. During the sleep mode, the battery pack removes the power supply from the power terminal and the battery pack control circuit enters a low or reduced power mode to extend the life of the battery. The battery pack may also be configured to enter an "awake" mode when the battery pack is inserted into an electrical device and a voltage (e.g., a logic high voltage) is applied to a serial communication terminal of the battery pack. If no voltage is applied to the serial communication terminal, the battery pack may be configured to wake up from the sleep mode every 1-2 hours to perform voltage level detection and battery cell temperature detection.

In another embodiment, the battery pack may be configured to communicate with a device (e.g., a battery charger, a configuration device, etc.) to adjust or change the charging and/or discharging parameters of the battery pack. Additionally or alternatively, the battery pack controller may be configured to store the cell-specific operating parameters in a memory and to adjust and change the operating parameters based on information received from the device.

In yet another embodiment, the battery pack may be configured to communicate with a device (e.g., a battery charger, a cleaning device, etc.) that includes a fuel gauge that displays the remaining battery charge capacity of the battery pack. The battery pack stores the operating parameters of a particular cell in memory and provides information to the fuel gauge of the device that accurately describes the remaining battery charge capacity of the battery pack. This information is based on operating parameters stored in memory, including, but not limited to, discharge current, charge current, and threshold values.

Additionally, the battery pack is operable to provide power to any of a plurality of additional devices. For example, a battery pack can provide power to any one of a variety of devices having different voltage and current requirements, such as power tools, test and measurement equipment, outdoor power equipment, and vehicles. Power tools include, for example, drills, circular saws, jig saws, band saws, reciprocating saws, screwdrivers, angle files, straight files, hammer mills, tightening wrenches, angle drills, inspection cameras, and the like. Test cartridge measurement devices include digital multimeters, clamp instruments, fork meters, wall scanners, infrared temperature guns, and the like. Outdoor powered equipment includes blowers, chain saws, edgers, hedge trimmers, lawn mowers, trimmers, and the like.

In one embodiment, the present invention provides a cordless cleaning system comprising a rechargeable battery pack, a first cordless cleaning apparatus, and a second cordless cleaning apparatus. The rechargeable battery pack includes a housing and at least two cells within the housing. The first and second cordless cleaning devices are operable to be removably received and driven by the battery pack. The first device is a first type of cleaning device, the second device is a second type of cleaning device, and the first type of cleaning device is different from the second type of cleaning device. At least one of the first and second devices has an upright working position.

In another embodiment, the invention provides a cordless vacuum cleaner. The vacuum cleaner includes a nozzle base, a main body portion, at least one motor, and a switch. The nozzle base includes a suction inlet and the main body portion is operable to receive a lithium-based battery pack removably connected to the vacuum cleaner. The at least one motor is powered by a battery pack and is configured to provide a suction force at the suction inlet. The battery pack is received in a recess disposed on the at least one electric machine. The vacuum cleaner is configurable to operate in a first mode and a second mode, and the switch is configurable to select the first mode or the second mode to selectively provide power to each of the at least one motor.

In yet another embodiment, the present invention provides a cordless vacuum cleaner. The vacuum cleaner includes a nozzle base, a main body portion, a junction (connection) between the nozzle base and the main body portion, a suction source, and a battery pack interface. The nozzle base includes a suction inlet. A suction source provides suction at the suction inlet, and the battery pack interface may be configured to receive a removable, rechargeable lithium-based battery pack. The suction source is driven by a battery pack, and the battery pack is disposed above the suction source. The body portion may also be supported in a vertical position by the junction between the nozzle base and the body portion without the need for external supports.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

Drawings

Fig. 1 illustrates a cordless cleaning system according to an embodiment of the present invention;

fig. 2 is a perspective view of a battery pack according to an embodiment of the present invention;

FIG. 3 is another perspective view of the battery pack of FIG. 2;

FIG. 4 is a partial perspective view of the battery pack of FIG. 2;

FIG. 5 is a side view of a lever according to an embodiment of the present invention;

FIG. 6 is another side view of a lever according to an embodiment of the present invention;

FIG. 7 is a side view of the battery pack of FIG. 2 with the outer housing removed;

FIG. 8 is a perspective view of a latching mechanism according to an embodiment of the present invention;

fig. 9 is a perspective view of the battery pack of fig. 2 with the outer housing removed;

FIG. 10 is another perspective view of the battery pack of FIG. 2 with the outer housing removed

FIG. 11 illustrates a process for removing the battery pack of FIG. 2 from a device according to an embodiment of the invention;

FIG. 12 is a perspective view of a battery charger according to an embodiment of the present invention;

FIG. 13 is a perspective view of the battery pack of FIG. 2 inserted into the battery charger of FIG. 12;

FIG. 14 illustrates a charging circuit for a battery charger according to an embodiment of the present invention;

fig. 15 illustrates control circuitry and interfaces between a battery pack and a device according to an embodiment of the invention;

fig. 16 illustrates a battery pack controller according to an embodiment of the invention;

fig. 17 and 18 show a process for switching the battery pack between a "sleep" mode and an "awake" mode;

FIG. 19 is a perspective view of a cleaning device according to an embodiment of the present invention;

FIG. 20 is a front view of the cleaning device of FIG. 19;

FIG. 21 is a side view of the cleaning device of FIG. 19;

FIG. 22 is a top view of the cleaning device of FIG. 19;

FIG. 23 is a bottom view of the cleaning device of FIG. 19;

FIG. 24 is a perspective view of an interface between the handle portion and the body portion of the cleaning device of FIG. 19, in accordance with an embodiment of the present invention;

FIG. 25 is a waste chamber for the cleaning device of FIG. 19 according to an embodiment of the invention;

FIG. 26 is a perspective view of an interface between a base and a main body portion of the cleaning device of FIG. 19, according to an embodiment of the present invention;

FIG. 27 is a perspective view of a cleaning device according to another embodiment of the present invention;

FIG. 28 is a rear view of the cleaning device of FIG. 27;

FIG. 29 is a top view of the cleaning device of FIG. 27;

FIG. 30 is a bottom view of the cleaning device of FIG. 27;

fig. 31-39 illustrate devices connected to the battery charger of fig. 12 according to embodiments of the present invention.

Detailed Description

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

Embodiments of the invention described herein relate to cordless, battery-powered systems for electronic devices, such as systems for cleaning products. Systems for cleaning products include devices such as upright vacuum cleaners (e.g., stick-type vacuum cleaners, lightweight upright vacuum cleaners, etc.), hand-held vacuum cleaners, carpet cleaners, canister vacuum cleaners, wet/dry cleaners, and the like. Each device is powered by a battery pack that is interchangeable between devices. The battery pack includes a combination of hardware and software for connecting to, identifying, and communicating with the various devices to ensure that the various devices receive the necessary power to ensure optimal performance. For example, the battery pack includes a latch and lever for removably securing the battery pack to the device. The battery pack also includes control electronics that maximize the charging life of the battery pack by operating the battery pack in a "sleep" mode, allow for charging parameter and feature modification, and ensure accurate battery pack charging decisions.

Fig. 1 illustrates a cordless cleaning system 10, the system 10 including a hand-held vacuum cleaner 15, a stick vacuum cleaner 20, a bagless upright vacuum cleaner 25, a battery charger 30, a bag-type upright vacuum cleaner 35, a carpet cleaner 40, and a canister cleaner 45. Each of the devices 15-45 may be connected to the battery pack 50 and powered by the battery pack 50. For example, the battery 50 has nickel metal hydride ("NiMH"), nickel-cadmium ("NiCd"), lithium-cobalt ("Li-Co"), lithium-manganese ("Li-Mn"), Li-Mn spar, or other suitable lithium or lithium-based chemistries. The battery pack 50 has a nominal voltage rating of 4V, 8V, 12V, 16V, 18V, 20V, 24V, 36V, 48V, etc., or any voltage rating therein or greater than 48V. The battery cells in the battery pack 50 have a rated capacity of, for example, 1.2Ah, 1.3Ah, 1.4Ah, 2.0Ah, 2.4Ah, 2.6Ah, 3.0Ah, and the like. The individual cell rated capacities are combined to produce a total battery pack rated capacity based on the individual cell rated capacity and the number of cells within the battery pack 50. In some embodiments, a single cell has 0.348Wh/cm³Although other energy densities may be used in other embodiments. The battery pack 50 can provide, for example, at least 0.084Wh/cm³Total energy density of.

Fig. 2-10 illustrate the battery pack 50 in detail. The battery pack 50 includes an outer housing 55 formed of a first half or casing 60 and a second half or casing 65. The first and

second shells

60, 55 are connected to one another using, for example, screws 70 or other suitable fastening devices or materials. The lever 75 is pivotally mounted to the housing 55 and enables the battery pack 50 to be removed from the various devices in the cordless cleaning system 10. The first end 80 of the lever 75 is pushed or pulled to unlatch or eject the battery pack 50 from the device. In some embodiments, the first end 80 is formed as a protrusion adjacent the groove 85. The protrusion and recess 85 of the first end 80 are sized to receive, for example, a user's finger or another object to rotate the lever 75.

The lever 75 is pivotally mounted to the housing 55. A push rod 90 (fig. 4) is movably mounted to the housing 55 and may be configured to be moved axially by the rotating portion of the lever 75. The latch 95 is extendably, movably mounted to the housing 55, and may be configured to move from a first position (e.g., a latched position) to a second position (e.g., an unlatched position) by movement of the push rod 90. When in the latched position, the latch 95 securely connects the battery pack 50 to the device. Movement of the latch 95 from the first position to the second position allows the battery pack 50 to be removed from the device. In the illustrated embodiment, a single latch is provided. In other embodiments, an additional latch is provided within the battery pack.

As shown in fig. 5 and 6, the lever 75 pivots about the connection point 100. When the first end 80 of the lever 75 is lifted, the second end 105 of the lever 75 pivots downward and contacts the push rod 90. The rotational movement of the lever 75 about the connection point 100 is limited to an angle of between, for example, 0 and about 90 degrees. In some embodiments, the rotational movement is between about 0 degrees and about 45 degrees. In response to contact by lever 75, push rod 90 moves downwardly through aperture 110 (FIG. 3). In some embodiments, the lever 75 also includes a post 115, the post 115 extending from the first end 80 and cooperating with the housing 55 to limit rotational movement of the lever 75.

As shown in fig. 3 and 4, electrical connections to the battery pack 50 are made through the interface 120 and are slightly recessed within the housing 55. The

electrical connectors

125 and 130 are disposed on the bottom side 135 of the housing 55 adjacent the support structure, which protects the

electrical connectors

125 and 130 within the interface 120.

Fig. 7-10 illustrate the battery pack 50 with the housing 55 removed. The battery pack 50 includes one or more battery cells 140 disposed within a housing 55. The push rod 90 is movable between a first position (e.g., a retracted position) and a second position (e.g., a protruding position). When in the retracted position, the push rod 90 is retracted within the housing 55. When in the protruding position, the push rod 90 extends from the housing 55 through the aperture 110. When the push rod 90 extends through the aperture 110, the force of the push rod 90 extending through the aperture 110 assists in the removal of the battery pack 50 from the device.

A biasing element, such as a spring 145, biases the push rod 90 to the retracted position. When the first end 80 of the lever 75 is pulled, the push rod 90 is driven downward against the biasing force of the spring 145 to move the latch 95 from the latched position to the unlatched position. When the lever 75 is moved through a sufficient angular distance, the latch 95 moves from the latched position to the unlatched position and the push rod 90 moves from the retracted position to the protruding position.

Movement of the push rod 90 occurs along a first axis 150 and movement of the latch 95 between the latched and unlatched positions occurs along a second axis 155. In some embodiments, the second axis 155 is oriented approximately orthogonal to the first axis 150. The push rod 90 and the latch 95 are then connected, connected or in contact with each other in a manner such that movement of the push rod 90 along the first axis 150 is converted into movement of the latch 95 along the second axis 155. In one embodiment, the push rod 90 includes a tapered portion 160 that engages a tapered portion of the latch 95 as the push rod 90 moves.

To secure the battery pack 50 to the device, the latch 95 is biased to the latched position by a biasing element, such as a spring 165. Movement of the push rod 90 forces the latch 95 into the unlocked position by overcoming the biasing force of the biasing element 165. For example, when the push rod 90 is moved a sufficient distance (e.g., when the lever 75 is pivotally moved through a sufficient angular distance), the push rod 90 moves the latch 95 from the latched position into the unlatched position. Additionally or alternatively, insertion of the battery pack 50 into the device forces the latch 95 against the biasing element 165 and into the unlocked position. The latch 95 returns to the latched position when the battery pack 50 is fully inserted into the device.

The battery cells 140 are connected in series and physically connected such that the cells 140 are parallel to each other and aligned in a single row. In other embodiments, one or more additional series-connected cell stacks are connected in parallel with the battery cell 140. The interface 120 is also aligned with the unit 140 at the bottom side 135 of the housing 55 (e.g., the small end of the housing 55). This arrangement of battery cells 140 and interface 120 allows the heat generated by cells 140 to be evenly distributed throughout battery pack 50. The battery pack 50 is inserted into the recess of the device with the bottom side 135 of the housing 55 first entering, and in some embodiments more than half of the volume of the battery pack 50 is inserted into the recess.

A process 200 for removing the battery pack 50 from the device is shown in fig. 11. The process 200 includes applying a force to the first end 80 of the lever 75 (step 205). The force applied to the lever 75 forces the lever 75 to pivot about the connection point 100 and the second end 105 (step 210) to engage the push rod 90 (step 215). Rotation of the lever 75 is translated into movement of the push rod 90 along the first axis 150 (step 220) to maintain engagement with the second end of the lever 75. Movement of the push rod 90 moves the latch 95 against the biasing force of the biasing element 165 and along the second axis 155 (step 225) from the latched position to the unlatched position. Once in the unlocked position, the latch 95 allows the battery pack 50 to be removed from the device (step 230).

As previously mentioned, the battery pack 150 may be configured to be connected to any of a number of devices, such as the device shown in the cleaning system 10 of FIG. 1. The battery charger 30 is shown in fig. 12 and includes a charging base 300 that receives the battery pack 50 within a recess 305. An electrical connector 310 connects the battery charger 30 to the battery pack 50. Fig. 13 shows the battery pack 50 connected to the battery charger 30. The battery charger 30 receives power from, for example, an AC or DC power source via a power cord 315. The battery charger 30 converts the received power to a DC power level suitable for charging the battery pack 50. In some embodiments, the battery pack 50 has a ratio of run time to charge time such that a device powered by the battery pack 50 can run for at least four minutes per hour of charge energy. In other embodiments, different ratios of run time to charge time are provided.

The battery charger also includes an LED indicator 320. The LED indicator 320 provides status information to the user regarding the charger 30 and the battery pack 50. For example, if the LED indicator 320 flashes twice after one second goes out, the battery pack 50 is either too hot or too cold. If the LED indicator 320 continuously flashes, the battery charger 30 has detected an error condition or caused internal component damage to the battery pack 50 or the battery charger 30. If the LED indicator 320 remains illuminated after the battery pack 50 is removed, the battery charger 30 either needs to be reset or internal component damage to the battery charger 30 occurs. As the LED indicator 320 is continuously lifted, the battery pack 50 is charging, and if the LED indicator 320 is pulsed between its gradual dimming and brightening, the battery pack 50 is fully charged.

Fig. 14 illustrates a charging circuit 400 for the battery charger 30. Circuit 400 includes a device controller 405, a pulse width modulation ("PWM") module 410, a power supply module 415, a single-ended primary inductor converter ("SEPIC") module 420, a first current feedback scaling module 425, a second current feedback scaling module 430, and a charge output module 435. The battery charger circuit also includes one or more LEDs for indicating the state of charge of the battery, as described above. In other embodiments, other devices (e.g., vacuum cleaners) include features similar to those described below with respect to battery chargers.

The controller 405 includes, among other things, a processing unit (e.g., a microprocessor, etc.), a memory, and a bus. A bus connects the various controller components, such as the memory, to the processing unit. In one embodiment, the memory includes read only memory ("ROM"), random access memory ("RAM"), electrically erasable programmable read only memory ("EEPROM"), or flash memory. The controller 405 also includes an input/output interface and includes a program for communicating information between components within the controller 405. In other embodiments, the controller 405 includes additional, smaller, or different components. The controller 405 may also be configured to communicate with other components or subsystems within the battery charger 30 using a bus or other communication interface. In some embodiments, a microcontroller including memory and a bus is used in place of the controller 405.

The controller 405 may be configured to generate a charging current command signal. The controller 405 sends a charging current command signal to the PWM module 410, and the PWM module 410 generates a PWM signal based on the charging current command signal. The PWM signal is fed from the PWM module 410 to a current source such as a SEPIC converter module 420. The SEPIC converter module 420 may be configured to provide a variable voltage and current source to charge the battery pack 50. In addition, the SEPIC converter module 420 includes a vibrator, a power FET configured as a switching unit, and other support circuitry. The current provided by the SEPIC converter module 420 is based on an analog voltage derived from the charging current command signal and a low pass filter network (not shown). The SEPIC converter module 420 also includes two overvoltage shutdown inputs. The first overvoltage shutdown input is controlled by the controller 405 and the second overvoltage shutdown input is controlled by a comparison circuit that operates independently of the controller 405. The SEPIC converter module 420 provides first and second signals describing the battery charging current to first and second current

feedback scaling modules

425 and 430. Each of the first and second current

feedback proportion modules

425 and 430 includes a single operating range. The current

feedback ratio modules

425 and 430 do not require a range selection signal to properly provide the feedback signal to the components of the battery charger 30.

The first current feedback proportion module 425 provides a first feedback signal to the PWM module 410. The PWM module 410 uses the first feedback signal to tune the PWM signal to the SEPIC converter module 420 to provide a current that accurately responds to the charging current command signal. The second current feedback proportion module 430 provides a second feedback signal to the controller 405. The controller 405 uses the second feedback signal to verify that the current flowing into the battery pack corresponds to the charging current command signal. In some embodiments, the controller 405 adjusts the charging current command signal in response to the second feedback signal.

The battery charger 30 may be configured to monitor the output voltage and output current. If the output current exceeds the predetermined output current limit, the battery charger 30 turns off the SEPIC converter module 420 to interrupt the output current from the power terminal. If the voltage exceeds the predetermined output voltage limit, the battery charger 30 turns off the SEPIC converter module 420 to remove the voltage from the power terminals.

The power module 415 supplies a nominal 18V DC voltage to the battery charger 30. The power module 415 is powered by a mains power supply having a nominal line voltage of between, for example, 100V and 240V AC and about 50-60 Hz. The power module 415 may also be configured to supply a lower voltage to the operating circuitry and components within the battery charger 30.

Fig. 15 illustrates a control circuit 500 for a battery pack, such as battery pack 50. The control circuit 500 includes a cell assembly 505, a battery pack controller 510, a charging control module 515, and a discharging control module 520. The battery pack also includes a first power terminal 525, a second power terminal 530, a serial data line ("SDL") or communication terminal 535, and a product interface 540A. In other embodiments of the present invention, the battery pack includes a plurality of additional power and/or communication terminals (e.g., a plurality of positive terminals). In some embodiments, the battery pack may be configured to provide between 7 and 11 amps of discharge current, and may accommodate between approximately 60 and 70 amps of inrush current. In other embodiments, the battery pack may be configured to provide and accommodate different current ranges. The battery pack may be configured to connect to a device including, for example, battery pack interface 540B, device controller 545, motor 550, and power switch 555.

As shown in fig. 16, the battery controller 510 includes a processor or processing unit (e.g., microprocessor, etc.) 560, a serial data line conditioning module 565, a unit voltage feedback conditioning module 570, a unit discharge equalization module 575, a power supply module 580, a precision voltage reference module 585, a unit temperature conditioning module 590, a memory 595, and one or more buses for interconnecting components and modules within the controller 510. A bus connects the various modules and controller components to the processing unit 560. In one embodiment, memory 595 includes read only memory ("ROM"), random access memory ("RAM"), electrically erasable programmable read only memory ("EEPROM"), or flash memory. The controller 510 also includes input/output interfaces and includes routines for communicating information between components within the controller 510. In other embodiments, the controller 510 includes additional, smaller, or different components. The controller 510 may also be configured to communicate with other components or subsystems within the battery pack using a bus or other communication interface. The software contained in implementing the battery pack is stored in memory 595 of controller 510. Software includes, for instance, firmware, one or more applications, program data, and other program modules. In some embodiments, a microprocessor including a memory and bus is used in place of controller 510. Although controller 510 is illustrated as including a number of additional modules, in other embodiments one or more of modules 565-595 are separate from controller 510 and coupled to controller 510. The power module 580 may be configured to provide a regulated DC voltage to the battery pack.

The battery pack controller 510 may be configured to communicate with a device (e.g., a battery charger, a vacuum cleaner, etc.), measure the voltage of each cell within the cell assembly, measure the discharge current of the battery pack, control a plurality of field effect transistor ("FET") switches, measure the temperature of the cell assembly, and monitor the number of charge or discharge cycles. The battery pack communicates with the device via SDL 535. The SDL is connected to a serial data line conditioning module 565 to condition data transmitted and received by the battery pack. Devices connectable to the battery pack can interrupt the connection of the SDL to the battery pack to reduce leakage current experienced by the battery pack if the battery pack remains connected to the device for an extended period of time and in a sleep mode.

Executable instructions stored within memory 595 of controller 510 may be configured to maintain a count (e.g., a 16-bit count) that describes the number of charge or discharge cycles experienced by the battery pack. Additionally or alternatively, the instructions may be configured to maintain a first count and a second count (e.g., first and second 16-bit counts). The first count records the charge cycle and the second count records the discharge cycle. The charge/discharge count is incremented by 1 each time the battery pack successfully enters a normal discharge or normal charge mode (described below). The count is stored in the memory 595 of the battery pack controller 510.

The battery pack controller 510 may also be configured to store charge and/or discharge operating parameters, unit identification information, and current charge capacity information of the memory 595. The battery pack provides charging and/or discharging operating parameters to a battery charger, a configuration device, or a cleaning device. The operating parameters include, for example, the rated voltage of the battery pack, the manufacturer of the battery pack, the model number for each cell within the battery pack cell assembly, the rated voltage or measurement for each cell within the cell assembly, the cell rated temperature or measurement for each cell within the cell assembly, a data table for correlating cell voltages with discharge current values, and the like. In other embodiments, multiple or different parameters are provided to the battery charger, the configuration device, or the cleaning device.

In addition, the battery pack uses charge and/or discharge operating parameters to provide a device fuel meter with accurate charge capacity estimation. The fuel meter is versatile in that it does not have to be modified or calibrated for the desired discharge current of the device. In this way, the fuel gauge in the device requiring the 15A discharge current can accurately display the charge capacity of the battery pack in the device requiring the 5A discharge current. For example, when the battery pack is inserted into the device, the battery pack controller 510 may be configured to communicate with a fuel gauge within the device via the SDL. The battery pack controller 510 includes a table for correlating cell voltages at a particular discharge current with the remaining charge capacity of the battery pack.

The battery pack continuously monitors and measures its discharge current to identify a portion of the table used to determine the remaining charge capacity of the battery pack. The voltage of each cell within the battery pack is then measured. The lowest cell voltage is used as a pointer in the table. The battery pack uses the lowest cell voltage measurement and the discharge current measurement to determine an estimated battery capacity based on the identification and operating parameter information stored in the memory. The battery pack controller 510 communicates the charge capacity information to a fuel meter (e.g., a fuel meter controller or display device). For example, the estimated battery capacity is delivered as a 2-bit code with four possible capacity levels. In other embodiments of the invention, more bits may be used to increase the accuracy of the battery capacity estimate displayed on the fuel gauge.

The fuel gauge displays the charge capacity of the battery pack without having to perform calculations or measure voltage. In some embodiments, the fuel gauge includes three LEDs. When all three LEDs are illuminated, the battery capacity is greater than or equal to 75%. When the two LEDs are in the illuminated state, the battery pack is greater than or equal to 50%. When one LED is illuminated, the battery capacity is greater than or equal to 25%. If a single LED blinks, the battery capacity is less than 25%. In other embodiments, multiple or smaller LEDs are used, and the LEDs display different ranges of battery capacity. Devices that include a fuel meter can also use cell characteristics within the cell assembly to adjust the operation of the fuel meter so that the fuel meter more accurately describes the charge capacity of the battery pack.

Additionally or alternatively, the device may be configured to communicate with the battery pack to adjust other operations based on operating parameters of the battery pack and the cell. For example, if the voltage of one of the battery cells drops below a predetermined low voltage limit, the battery pack shutdown charge control module 515 and discharge control module 520 terminate the discharge current regardless of the logic level of the SDL or in operative communication with the device controller 545. In some embodiments, the device terminates operation, disables features, or reconfigures itself to operate at different voltages based on information from the battery pack.

Because the battery pack provides information to the device to which the battery pack is connected, the battery charger 30 can be used to charge a variety of different battery packs without the user having to specify the battery pack voltage. The battery charger 30 adjusts, for example, the charging current, charging voltage, and cutoff threshold to accommodate the manufacturer specifications for each cell within the cell assembly. By adjusting the charging and discharging parameters for each cell within the cell assembly, the life and performance of the battery pack may be improved, as well as reducing or eliminating errors associated with incorrect charging and/or discharging parameters.

The cell voltage feedback regulation module 570 may be configured to attenuate and regulate the voltage from each cell within the cell assembly 505 to an appropriate level within the measurement range of an analog-to-digital converter ("ADC") of the battery pack controller 510. The cell voltage feedback regulation module 570 is activated by the battery pack controller 510 when the cell voltage is measured and is turned off by the battery pack controller 510 when the cell voltage is not measured to prevent unnecessary cell discharge. The cell discharge balancing module 575 may be configured to apply nominally equal loads to the cells within the cell assembly 505 to prevent an imbalance in battery cell discharge. The cell discharge equalization module 575 is turned on and off at the same time as the cell voltage adjustment module 570.

The precision voltage reference module 585 may be configured to provide a precision reference voltage to the ADC of the controller 510. The voltage reference is used by the ADC to measure the signal within the battery pack. The precision voltage reference module 585 is activated by the battery pack controller 510 when the ADC takes measurements. The cell temperature adjustment module 590 may be configured to measure the temperature of the cells within the cell assembly using, for example, a thermistor. In some embodiments, the thermistor is thermally connected to the unit using a thermally conductive glue.

The charging control module 515 may be configured to control the time at which the cell assembly 505 is charged. The charging control module 505 controls when the cell assembly 505 is charged. The charge control module 515 includes at least one FET configured as a switch and controlled by the battery pack controller 510. If the FET is "on," cell assembly 505 may be charged. If the FET is "off," the cell assembly 505 cannot be charged. The discharge control module 520 includes at least one FET configured as a switch to control the discharge current from the cell assembly 505. If the FET is "on," cell assembly 505 may be discharged. If the FET is "off," cell component 505 is not discharged. The discharge control module 520 is controlled by the battery pack controller 510.

A process 600 for switching a battery pack between a "sleep" mode and an "awake" mode is shown in fig. 17 and 18. In addition to the low power mode for the battery pack, the sleep mode also provides safety benefits to the battery pack and its user. For example, when in a sleep mode, the battery pack cannot provide any significant power to the external device or its power terminals (e.g., currents in the microampere range). As such, the risk of shorting the power terminals causing fire or similar safety issues is eliminated or significantly reduced. The battery pack enters a sleep mode when it is not plugged into a battery charger or cleaning device (step 605), as described below. During the sleep mode, the discharge control module 520 is turned off (step 610) and the charge control module 515 is turned off (step 615) to prevent the battery pack from drawing any significant current between the positive and negative terminals of the battery pack. Shutting down the charge control module 515 and the discharge control module 520 also removes the ground channels for the battery cells within the battery pack and removes the voltage from the power terminals. Shutting down the charging control module 515 and the discharging control module 520 also prevents the battery pack from supplying power to an external load, being charged by the battery charger 30, or being shorted. When the ground channel is removed, no device can communicate with the battery pack controller 510 because there is no general ground reference. In some embodiments, a small signal level current may flow between the positive terminal and the SDL when the battery pack is in the sleep mode. The sleep clock is then set (step 620). Hardware within the battery pack controller continuously monitors the SDL (step 625). If a high logic level (e.g., a high TTL level) is applied to the SDL, the hardware interrupts the battery pack controller 510 and the controller 510 enters an awake mode (step 630) (FIG. 18). Otherwise, the controller 510 remains in the sleep mode.

While in sleep mode, the battery controller 510 may be configured to compare the sleep clock to a limit (e.g., 60-120 minutes) (step 635). The battery pack wakes up when the sleep clock equals the limit (step 640). The battery pack performs cell voltage detection (step 645) to determine (step 650) whether the cell assembly charge level of the battery pack falls below a threshold level or threshold that inhibits discharge. If the battery pack determines that one or more cells have fallen below the minimum allowable level, the battery pack sets a software flag to prevent discharge (step 655), and the battery pack re-enters sleep mode (step 605). The battery pack removes the software flag after the battery pack has been connected to the battery charger 30. If the cell does not fall below the minimum allowable level, the battery pack may be configured to re-enter the sleep mode (step 605). In some embodiments, the battery pack may be configured to disconnect the positive terminal of the cell assembly to remove voltage from the power terminal, and additional or different hardware is used to switch between the sleep mode and the awake mode. In some embodiments, the different steps described above are combined into a single step, or the steps are performed in a different order. For example, in an alternative embodiment, the sleep mode is entered when the sleep clock is set.

The awake mode and awake procedure described herein are driven by interrupts. As such, the battery pack enters the awake mode without having to wait for a predetermined time period or the battery pack controller 510 to obtain the SDL. If the battery pack is connected to the device with its power switch open, the device connects the SDL of the battery pack to the positive power terminal of the battery pack via the resistor network, and the SDL of the battery pack is pulled high (e.g., to a logic high level). When the battery controller 510 determines that a high logic level is applied to the SDL, the battery enters an awake mode (step 630). The battery pack controller 510 then prevents the SDL from debounce and verifies that the battery pack is connected to the device and causes the power switch to open (step 660). The battery pack controller 510 prevents the SDL from bouncing for a predetermined period of time (e.g., 60ms) to ensure that the voltage at the SDL is not the result of a noise spike.

If the battery pack is not connected to the device or the power switch of the device is not turned on, the battery pack re-enters the sleep mode (step 605). If the battery pack controller 510 determines that the logic level present in the SDL is a result of a connection between the battery pack and a device whose power switch is on, the battery pack enters a normal discharge mode ("NDM") (step 665), and activates or turns on the discharge control module 520 (step 670) and the charge control module 515 (step 675). The active discharge control module 520 and the charge control module 515 provide a common ground reference between the battery pack and the device and provide power to the positive and negative power terminals. Communication between the battery pack and the device then begins. The battery pack may be configured to establish communication with the device controller 545 via the SDL (step 685). If communication is not established, the battery pack re-enters sleep mode (step 605). If communication is established, the battery determines whether the device is a battery charger (step 690). If the device is a battery charger, the battery pack enters a normal charging mode ("NCM") (step 695). If the device is not a battery charger, the battery pack continues to operate in a normal discharge mode (step 700).

In other embodiments of the present invention, the battery pack may be configured to disconnect the positive terminal of cell assembly 505 (e.g., turn off at least one FET) when the battery pack is in a sleep mode. When the battery pack is inserted into the device, the device connects the SDL to the negative terminal of the battery pack to provide a logic low level to the SDL when the device power switch 555 is turned on. The SDL is connected to the negative terminal using a resistor network within the device. The battery pack may be configured to communicate with the device and debounce the SDL, as described above. After debounce, if the logic level of the SDL satisfies a predetermined condition for a low logic level, the battery pack controller 510 turns on the charge and discharge control module to supply or receive current to or from the device.

The battery pack may also be configured to deliver multi-byte messages to devices on the SDL. The device may be configured to receive messages on the SDL and respond to the battery pack controller 510 with messages to relate to, for example, the condition of the battery pack (e.g., charge mode, discharge mode, etc.). The battery pack controller 510 periodically queries the device controller 545 to verify presence and proper function. For example, the battery pack controller 510 sends 5 messages into the SDL during a one second period to initiate communication with the device. If the battery pack controller 510 does not receive an expected response or a valid message from the device controller 545 during this time period, the battery pack controller 510 turns off the charge and discharge control modules 515 and 520, entering a sleep mode without regard to the logic level of the SDL. Turning off the charge and discharge control modules 515 and 520 removes the ground path for the cell assembly 505 to stop power supply to the device.

Additionally or alternatively, if the battery pack and device fail to successfully maintain communication, the battery pack controller 510 turns off the charge and discharge control modules 515 and 520 and enters a sleep mode. For example, the battery pack controller sends a message to the device controller once every second. If the battery pack controller does not receive a valid response to this message within some number of communication cycles (e.g., three communication cycles), the battery pack controller 510 turns off the charge and discharge control modules 515 and 520 and enters a sleep mode. In other embodiments, the battery pack may be configured to disconnect the positive terminal of the cell assembly to stop the supply of power to the device, and the battery pack enters a sleep mode. If the battery pack receives a valid response from the device, the battery pack remains in the awake mode. While in the awake mode, the charge and discharge control modules 515 and 520 remain open, the battery pack provides a connection to the positive terminal of the cell assembly to provide power to the power terminal of the battery pack, and the battery pack can power the device or be charged by the battery charger 30.

The awake mode includes the NDM and the NCM. If the battery pack is connected to the device, communicates with the device via the SDL, and determines that the device is not a battery charger, the battery pack may be configured to operate under NDM. When in NDM, the battery pack verifies that the voltage and temperature of the cells are within predetermined operating limits. If the battery pack sends a message to the device and receives a valid response on the SDL, the battery pack continues to supply power through the power terminal. If the battery pack does not receive a valid response via the SDL for a predetermined number of communication cycles, the battery pack shuts down the charge control module 515 and the discharge control module 520 and enters a sleep mode.

When operating under NDM, the battery pack also continuously monitors the discharge current from its power terminals. If the discharge current is not within the predetermined operating limits for discharge current versus time, the battery pack shuts down the charge control module 515 and the discharge control module 520 to terminate the discharge current and enter a sleep mode regardless of the logic level of the SDL or the presence of active communication with the device controller 545.

The battery pack also monitors the temperature of the battery cells within the cell assembly 505. To compensate for thermal lag within the temperature measurement system of the battery pack, the battery pack applies a temperature calibration factor based on the discharge current using the index value. Only calibration factors are used if the measurement cell temperature is above 25 ℃. If the accurate temperature measurement is not within the predetermined operating temperature limit, the battery pack shuts down the charge control module 515 and the discharge control module 520 to terminate the discharge current and enter a sleep mode regardless of the logic level of the SDL or the presence of active communication with the device controller 545.

The battery pack is continuously in communication with the device while the battery pack is discharging current. For example, the battery pack controller 510 initiates and controls communication with the device. In other embodiments, the device controls communication with the battery pack (e.g., the device functions as a primary device and the battery pack functions as an accessory device). If the device fails to respond to the battery pack within a predetermined number (e.g., three cycles) of consecutive communication cycles, the battery pack shuts down the charge control module 515 and the discharge control module 520 to terminate the discharge current and then returns to the sleep mode.

Additionally, the battery pack also continuously monitors the voltage of the individual cells while the battery pack is discharging current. If the voltage of one of the cells falls below a predetermined low voltage limit, the battery pack shuts down the charge control module 515 and the discharge control module 520 to terminate the discharge current and then enters a sleep mode regardless of the logic level of the SDL or the presence of an active communication with the device controller 545

When the battery pack terminates the current discharge process, the battery pack transmits a termination message to the device on the SDL (indicating the reason the current discharge process was terminated). The battery pack transmits a termination message unless, for example, an overcurrent condition occurs during discharge, which requires the discharge current to terminate within a time period that prevents the battery pack from transmitting the termination message.

Additionally, as a result of connecting to the configuration device, if the battery pack enters the NDM, a particular set of operating parameters is enabled. Configuring the device's ability requires the battery pack to read and/or write values from a single memory location (e.g., a non-volatile memory location) within battery pack memory 595. This capability is particularly advantageous for devices that are assembled in multiple locations or devices that have components that are manufactured in one or more locations but assembled in another location. The ability to adjust the operating parameters allows the devices to operate in unison, allowing for access to charge/discharge information stored in memory, and allowing for modification of, for example, cell-specific charging parameters. The device is configured as a dedicated device or incorporated into a device such as a battery charger 30 or a cleaning device. The configuration device includes a user interface configurable to display operating parameters of the battery pack and allow a user to adjust the operating parameters of the battery pack. The configuration means may be configured to require the battery pack to provide the contents of a particular operating parameter or a particular memory location. The configuration means may also be configured to require the battery pack to adjust the value of a particular operating parameter or a particular memory location to the value provided by the configuration means. For example, calibration data stored in the battery pack memory may be read or modified, or charge/discharge cycle count data may be retrieved. In other embodiments, the configuration device may configure the values of the nucleation memory locations to be adjusted by requiring the battery pack to provide the adjusted memory values to the configuration device.

If the configuration device requests information from the battery pack, the battery pack remains the master during the power-on period. The battery pack initiates communication with the configuration device, and the configuration device responds to the communication from the battery pack. If the configuration means requires the battery pack to provide a value for a particular memory location, the battery pack follows and responds to the requirements on the next communication cycle. In some embodiments, the configuration device initiates communication with the battery pack.

When the battery pack operates at the NCM, the battery pack controls the charging operation. However, the battery charger 30 does not completely give up the charging control of the battery pack. For example, the battery pack determines whether to terminate constant voltage charging during the charging process. The battery pack stores the cell-specific charging parameters in a non-volatile memory and provides charging process information to the battery charger 30 used during the charging process. The battery pack is continuously communicating with the battery charger 30 while the battery pack is receiving charging current. If the battery charger 30 fails to receive a message from the battery pack for a predetermined number of communication cycles, the battery charger 30 turns off the SEPIC converter module 420 and removes the voltage from the charging terminal.

During NCM, the battery pack measures the voltage of the various cells within cell assembly 505. When one of the cells in the cell pack 505 reaches a particular cutoff voltage, the battery pack requires that the battery charger 30 enter a constant voltage charging mode. After the battery charger receives the request to enter the constant voltage charging mode, the charging process is controlled by the battery charger 30.

While in the constant voltage charging mode, the battery charger 30 provides a constant voltage to the terminals of the battery pack and monitors the charging current. If the charging current falls below a predetermined limit, the battery charger 30 terminates the charging process and the battery pack shuts down the charge control module 515 and the discharge control module 520 to terminate the charging current and enter a sleep mode.

The battery pack also measures the temperature of the cells within the cell assembly when in either constant voltage charging mode or constant current charging mode. Based on the cell temperature, the battery pack requires either normal charging parameters (i.e., NCM parameters) or reduced current charging parameters, or the charge and discharge control modules 515 and 520 are turned off to temporarily terminate the charging current until the cell temperature returns to a predetermined operating limit. If the battery pack indicates that the battery charger 30 (e.g., via SDL), the cell temperature within the battery cell assembly is outside of the predetermined temperature range, the battery charger 30 turns on the LED indicator, as previously described, and waits for the cell temperature to normalize the battery pack to again demand the charging current.

Depending on the charging mode (e.g., constant current or constant voltage charging mode), multiple redundant detections are either performed by the battery pack or battery charger 30 while another controls the charging process. During the NCM, the battery charger 30 monitors the total pack voltage and controls the switch from constant current charging mode to constant voltage charging mode if the battery pack does not require a change in charging mode and the battery pack voltage is within predetermined voltage limits for the constant voltage charging mode. Likewise, during the constant voltage charging mode, the battery pack monitors the cell voltage and the total pack voltage. If the cell voltage or the total pack voltage meets a predetermined limit for full charging of the battery pack, the battery pack shuts down the charge and discharge control modules 515 and 520 to terminate the charging current and enter a sleep mode.

The battery pack and battery charger 30 also includes a charging clock. The charge clock is any time that the battery pack is operational to be charged, including periods when the battery cell temperature temporarily disables further charging. If the battery pack charge clock exceeds a predetermined time limit, the battery pack shuts down the charge and discharge control modules 515 and 520 to terminate the charge current and enter a sleep mode. Additionally or alternatively, if the battery charger charging clock exceeds a predetermined time limit, the battery charger 30 passes a message to the battery pack and shuts down the SEPIC converter module 420 to remove the voltage. The battery charger 30 may also be configured to turn the LED indicator 320 on and off to indicate a timeout condition. When the battery pack terminates the charging process, the battery pack communicates a termination message to the battery charger 30 on the SDL to indicate the reason the charging process was terminated.

As previously described, the battery pack 50 may be configured to be connected to any one of a plurality of devices. Figures 19-23 illustrate an electrically driven cleaning device such as a stick vacuum cleaner 20 receiving power from a battery pack 50. In some embodiments, the vacuum cleaner 20 and the battery pack 50 have a combined weight of less than about 7.5 pounds. The vacuum cleaner 20 includes a handle portion 805, a body portion 810, a base or nozzle base 815. In some embodiments, the vacuum cleaner 20 includes a hose or other attachment.

Handle portion 805 includes a first section 820 and a second section 825. The first section 820 is inclined relative to the second section 825 and includes a handle portion 830 (fig. 21). The handle portion 830 is on the opposite side of the first segment 820 as a power switch or selection device 835. In some embodiments, the handle portion 830 extends completely or nearly completely around the first segment 830. The first segment 820 of the handle section 805 also includes a capacitive contact sensor for determining whether a user is contacting the handle section 805. If the user is touching the handle section 805, the vacuum cleaner 20 operates as selected using the power switch 835. If the user does not contact handle portion 805, vacuum cleaner 20 reduces the speed of motor/fan assembly 840. By reducing the speed of the motor/fan assembly 840 (e.g., by reducing the current supplied to the motor/fan assembly 840), the vacuum cleaner 20 can conserve power when a user is away from the vacuum cleaner 20.

In addition, the second section 825 of the handle portion 805 includes a plurality of indicators 845 to provide a user with indications relating to the mode of operation of the vacuum cleaner 20. In some embodiments, the handle portion 805 includes a first LED indicator and a second LED indicator. The first LED indicator provides an indication to the user as to whether suction is activated for the vacuum cleaner 20. The second LED indicator provides an indication to the user as to whether the suction and brush roll of the vacuum cleaner 20 are active. Neither the first nor the second LED indicator is in an illuminated state when the vacuum cleaner 20 is off or in an inactive state. When the vacuum cleaner 20 is in the suction-only mode of operation, the first LED indicator is illuminated. When the vacuum cleaner 20 is in the suction and brush roll mode of operation, the second LED indicator is illuminated. The mode of operation of the vacuum cleaner 20 is set by a power switch 835 that is operable by a user's finger while gripping the first section 820 of the handle section 805. In some embodiments, switch 835 is rolled by a user to a plurality of positions corresponding to the operating mode of vacuum cleaner 20.

In some embodiments, the handle portion 805 is removably connected to the body portion 810. For example, the handle portion 805 may be separated from the body portion 810 for storage or transportation purposes. In this embodiment, the handle portion 805 is connected and secured to the body portion by friction only. In other embodiments, a screw or other suitable fastening member is used to fasten the handle portion 805 to the body portion 810. As shown in fig. 24, the handle portion 805 also includes a plurality of electrical connectors 850 disposed at an interface 855 between the handle portion 805 and the body portion 810. An electrical connector 850 connects the handle portion 805 to the main body 810 so that electrical signals relating to the operation of the vacuum cleaner 20 are provided to the main body 810 to control, for example, the motor/fan assembly 840.

Body portion 810 includes a groove 860, a fuel gauge 865, a motor/fan assembly 840, and a waste chamber 870. In some embodiments, the main body portion 810 also includes a cyclonic separator. The recess 860 is shaped and configured to receive the battery pack 50 and is positioned along a centerline or axis (e.g., a first axis as described below) of the main body portion 810. This arrangement of grooves improves the balance, steering and compactness of the vacuum cleaner 20. The recess 860 includes a plurality of electrical connectors similar to the electrical connectors 310 shown in figure 12 in relation to the battery charger 30 to electrically connect the battery pack 50 to the vacuum cleaner 20. As described above, the fuel gauge 865 may be configured to provide an indication of the charge level of the battery pack 50 inserted into the vacuum cleaner 20 to a user. In the illustrated embodiment, the fuel gauge 865 is placed over the groove 860. The fuel gauge 865 is inclined relative to the second section 825 of the handle portion 805 so that a user can read the fuel gauge 865 during normal operation of the vacuum cleaner 20 without having to turn his or her attention away from operating the vacuum cleaner 20. In some embodiments, the fuel gauge 865 is disposed at the base 815 of the vacuum cleaner 20.

The motor/fan assembly 840 is positioned below the battery pack 50 and the fuel gauge 865. This arrangement between the battery pack 50 and the motor/fan assembly 840 is advantageous because the airflow from the motor/fan assembly 840 provides cooling for the battery pack 50 and the corresponding electronics. In some embodiments, the motor is a vertical brushless DC motor ("BLDC"). In other embodiments, different types of AC or DC motors are used, such as brushed DC motors, stepper motors, synchronous motors, or other motors using permanent magnets. In some embodiments, the main body portion 810 also includes a DIFFUSER, such as the DIFFUSER disclosed in U.S. patent No. 7,163,372 entitled "DIFFUSER for MOTOR FAN ASSEMBLY," which is incorporated herein by reference in its entirety.

A waste chamber 870 is disposed below the motor/fan assembly 840 and is removably connected to the body portion 810. In the illustrated embodiment, the waste chamber 870 is bagless and includes a latching mechanism 875 that secures the waste chamber to the vacuum cleaner 20 (fig. 25). Waste chamber 870 also includes a lower portion having a latch 880 for emptying the contents of waste chamber 870 and an inlet 885 for receiving waste.

The lower end of the body portion 810 includes an interface for connecting the body portion 810 to the base 815. The base 815 includes a corresponding interface for connecting to the body portion 810 (fig. 26). In addition, the interface includes two terminals 890 and 895 for providing power to the base 815 and an outlet 900 for providing waste to the body portion 810. The interface between the main body 810 and the base 815 allows the vacuum cleaner 20 to be upright without the need for external supports. For example, the vacuum cleaner 20 is operable in an upright working position, wherein the vacuum cleaner 20 is operated without a user supporting the handle portion 805 or the main body portion 810. The base 815 can be separated from the body 810 without the use of tools, such as a screwdriver.

The body portion 815 also includes a multi-axis rotational joint 905. In an alternative embodiment, a ball joint is used. The rotational joint 905 allows the handle and

body portions

805, 810 of the vacuum cleaner 20 to rotate relative to the base 815. For example, the rotational joint 805 allows for rotational movement of the handle and

body portions

805, 810 about a first axis 910 parallel to the cleaning surface. Rotational movement about first axis 910 allows handle and

body portions

805, 810 to move from a position approximately perpendicular to base 815 to a position approximately parallel to the ground. For example, the handle and

body portions

805 and 810 of the vacuum cleaner 20 can also be moved through an angle of between about 0.0 ° and about 90.0 ° relative to the base. In other embodiments, the handle and

body portions

805, 810 may be rotated through a greater angle.

The handle and

body portions

805, 810 are also rotatable along a second axis 915. The second axis 915 is approximately perpendicular to the first axis 910 and approximately parallel to the handle and

body portions

805 and 810 of the vacuum cleaner 20. The rotational movement about the second axis 915 provides additional control and maneuverability of the vacuum cleaner 20. The base 815 also includes a first wheel 920 and a second wheel 925 that provide a rolling motion of the vacuum cleaner 20 along the cleaning surface after the user applies an external force. The first and

second wheels

920, 925 are connected to the base 815 along a first axis 910. Base 815 includes a suction inlet 935 on the underside of base 815. The suction inlet 935 includes an aperture or recess 940 that allows larger objects (e.g., cereal or similar sized waste) to enter the suction inlet 935 without requiring the user to lift the vacuum cleaner 20. In some embodiments, the airflow through the base 815 is pre-treated.

Base 815 includes a brush roller motor (not shown) for rotating brush roller 945. In one embodiment, base 815 is implemented in a manner similar to that described in U.S. patent No. 5,513,418 entitled "motor noise WITH switching", the entire contents of which are incorporated herein by reference. In other embodiments, the base is implemented in a manner similar to that described in U.S. patent No. 7,100,234 entitled "sport nowleasiesky," which is incorporated herein by reference in its entirety. The brush roller motor is selectively activatable by a user. For example, when a user selects a suction-only mode of operation for the vacuum cleaner, the brush roll motor is in an off state and the brush roll does not rotate. This mode of operation is typically used to clean surfaces such as, for example, hardwood floors. When the user selects the suction and brush roll mode, the brush roll motor is in an on state and the brush roll rotates. This mode of operation is typically used on carpeted surfaces. In some embodiments, the vacuum cleaner 20 can be configured to provide at least about 6 watts of power at the suction inlet 935 of the base 815.

Figures 27-30 illustrate the battery pack 50 connected to the controlled vacuum cleaner 15. The controlled vacuum cleaner 15 includes a main body 1105, a handle 1110, and a waste chamber 1115. The main body 1105 includes a nozzle 1120, a suction inlet 1125 (fig. 30), a suction motor/fan assembly 1130, and a recess 1135. The recess 1135 is sized and configured to receive the battery pack 50. The battery pack 50 is connected and electrically connected to the controlled vacuum cleaner 15 in a manner similar to that described with reference to the joystick-type vacuum cleaner 20. A handle 1110 is integrated into the body 1105 and is disposed between the recess 1135 and the nozzle 1120. The interface of the handle 1110 and the nozzle 1120 includes a switch 1140 and a fuel gauge 1145. The switch 1140 includes, for example, a first position (e.g., an "on" position) and a second position (e.g., an "off position) to control the operation of the handheld vacuum cleaner 15. In other embodiments, the switch 1140 includes additional positions corresponding to additional modes of operation of the handheld vacuum cleaner 15, such as a tell-to-go setting and a slow speed setting for the motor 1130. The fuel gauge 1145 of the hand-held vacuum cleaner 15 operates in a manner similar to the fuel gauge 865 described with reference to the joystick-type vacuum cleaner 20.

In some embodiments, the handheld vacuum cleaner 15 may be configured to provide at least 13 airwatts of power at the suction inlet 1125. The nozzle 1120 also includes a crevice/brush tool connected to the nozzle 1120. In the illustrated embodiment, the crevice/brush tool 1150 is rotatably connected to the nozzle 1120. When in the storage position, the crevice/brush tool 1150 may be rotated into a cleaning position with the suction inlet 1125 on the underside of the nozzle 1120. When in the use position, the crevice/brush tool 1150 is rotated from the storage position so that it is substantially in front of the suction inlet 1125. In other embodiments, the crevice/brush tool 1150 is removably attachable to the nozzle or other part of the hand-held vacuum cleaner 15. A waste chamber 1115 is interposed between the motor 1130 and the nozzle 1120. The waste chamber 1115 is, for example, frictionally connected to the handheld vacuum cleaner 15 or connected via a latching mechanism. The waste chamber 1115 includes an inlet (not shown) for receiving waste from the nozzle 1120. In the illustrated embodiment, the waste chamber 1115 is bagless. In other embodiments, the waste chamber 1115 includes a bag or similar disposable storage accessory.

Although the battery pack 50 has been described primarily in terms of interconnection and connection to a battery charger, stick vacuum, handheld vacuum, etc., the battery pack 50 may be configured to connect to other devices in the cleaning system 10 shown in FIG. 1. For example, the battery pack 50 may be configured to connect to and drive the bagless upright vacuum cleaner 25, the bag upright vacuum cleaner 35, the carpet cleaner 40, and the canister cleaner 45. In some embodiments, one or more of the devices shown in fig. 1 include a height adjustable handle or body portion. Additionally, the particular manner and skill for connecting the battery pack 50 to these devices is not described. However, in some embodiments, the interconnection between the battery pack 50 and the device is similar to that described with respect to the stick-type vacuum cleaner 20 and the handheld vacuum cleaner 15, although the specific operating parameters and characteristics vary among these devices.

In some embodiments of the present invention, the battery charger 30 is used to provide power to additional devices when the battery pack 50 is not connected to the battery charger 30. For example, the battery charger 30 may be configured to provide power to devices such as those shown in fig. 31-39. The devices include a night light 1200, kitchen clock 1205, alarm clock 1210, audio storage device dock 1215, air ionizer, cooler or fan 1220, LCD screen 1225, USB charging station 1230, indoor weather station 1235, mobile phone charger or horn loudspeaker 1240. In other embodiments, the battery charger 30 may be configured to charge an add-on device. Each of the

devices

1200 and 1240 includes terminals similar to those described with respect to the battery pack 50 for connection to the battery charger 30, or an adapter may be provided for connecting the

devices

1200 and 1240 to the battery charger 30. In some embodiments, the battery charger 30 may be configured to power at least one of the

devices

1200 and 1240 and charge the battery pack 50. In this embodiment, the battery charger 30 includes a recess for receiving the battery pack 50, or the device includes an interface for electrically connecting the battery pack 50 to the battery charger 30.

Thus, in addition, the present invention provides a cordless, battery-powered electronic system, such as a system for cleaning products. Each device is powered by a battery pack that is interchangeable between devices. Various features and advantages of the invention are set forth in the following claims.

Claims

1. A cordless cleaning system, the system comprising:

a rechargeable battery pack having a housing and at least two cells within the housing;

a first cordless cleaning apparatus operable to removably receive and be driven by a rechargeable battery pack;

a second cordless cleaning apparatus operable to removably receive and be driven by a rechargeable battery pack;

wherein the first device is a first type of cleaning device and the second device is a second type of cleaning device, the first type being different from the second type; and

at least one of the first and second devices has an upright working position.

2. The system of claim 1, wherein the battery pack is configured to operate in one of a first mode and a second mode.

3. The system of claim 2, wherein the first mode is a sleep mode.

4. The system of claim 1, further comprising a battery charger external to the first device and the second device, the battery charger operable to receive and charge the rechargeable battery pack.

5. The system of claim 1, wherein the rechargeable battery has a lithium-based chemistry.

6. The system of claim 1, wherein the first device is a stick or upright vacuum cleaner and the second device is a hand-held vacuum cleaner.

7. The system of claim 1, further comprising a third cordless cleaning apparatus operable to receive, and be powered by, a rechargeable battery pack, wherein the third apparatus is a third type of cleaning apparatus, the third type being different from the first type and the second type.

8. The system of claim 1, wherein at least one of the first and second devices is bagless.

9. The system of claim 1, wherein the battery pack is further operable to communicate with at least one of the first device and the second device.

10. The system of claim 1, wherein the rechargeable battery pack has a charge capacity of at least about 10 volts.

11. A cordless vacuum cleaner, comprising:

a nozzle base having a suction inlet;

operable to receive a main body portion removably connectable to a vacuum cleaner;

at least one motor powered by the battery pack and configured to provide suction at the suction inlet;

wherein the battery pack is received in a recess disposed on the at least one electric machine;

the vacuum cleaner is configurable to operate in a first mode and a second mode; and

a switch configurable to select either the first mode or the second mode to selectively provide power to each of the at least one motor.

12. The vacuum cleaner of claim 11, further comprising a fuel gauge configured to indicate a status of the battery pack, the fuel gauge being external to the battery pack and disposed within the main body portion.

13. The vacuum cleaner of claim 11, wherein the nozzle base includes an aperture to allow relatively large objects to enter the suction inlet.

14. The vacuum cleaner of claim 11, wherein the vacuum cleaner is a stick vacuum cleaner.

15. The vacuum cleaner of claim 11, wherein the main body portion is supportable in an upright position by the nozzle base without an external support.

16. The vacuum cleaner of claim 11, wherein the switch is disposed on the handle portion and is operable by a finger of a user.

17. A cordless upright vacuum cleaner, comprising:

a nozzle base having a suction inlet;

a main body portion;

a junction between the nozzle base and the body portion;

a suction source for providing suction at the suction inlet; and

a battery interface configured to receive a removable, rechargeable lithium-based battery;

wherein,

the suction source is powered by the battery pack;

the battery pack interface is arranged above the suction source;

the body portion may also be supported in a vertical position by the junction between the nozzle base and the body portion without the need for external supports.

18. The vacuum cleaner of claim 17, wherein the nozzle base includes an aperture to allow relatively large objects to enter the suction inlet.

19. The vacuum cleaner of claim 17, wherein the battery pack interface includes a recess having a terminal contact.

20. The vacuum cleaner of claim 17, further comprising a fuel gauge external to the battery pack and configurable to indicate a status of the battery pack.