EP4635683A1

EP4635683A1 - A power tool

Info

Publication number: EP4635683A1
Application number: EP24170490.7A
Authority: EP
Inventors: Arthur Lauer; Mr. Klaus-Dieter Arich; Ashwin RAJENDRAN; Timo RAAB
Original assignee: Black and Decker Inc
Current assignee: Black and Decker Inc
Priority date: 2024-04-16
Filing date: 2024-04-16
Publication date: 2025-10-22
Also published as: WO2025219095A1

Abstract

A power tool comprises a housing, a motor mounted in the housing, a battery electrically connected to the motor, a first handle mounted to the housing, and at least one wireless communication module configured to communicate with at least one external device. The wireless communication module is mounted in the first handle. This configuration allows for improved communication with external devices and reduced interference from the motor's electromagnetic field.

Description

Field

The technology relates to the field of power tools, specifically focusing on wireless communication capabilities and electromagnetic field shielding within the design and construction of power tool handles.

Background

Power tools have become increasingly connectable to external devices to provide enhanced functionality and user experience. For example, users can wirelessly connect their smartphones, tablets, or other devices to the power tool for remote control, fault diagnosis, and access to user manuals for using or repairing the power tool. This is achieved through the integration of wireless communication interfaces within the power tool, which enable communication with external devices.
However, the electromagnetic field generated by the power tool during use can interfere with the electronics of the wireless communication interface and disrupt the wireless signal. This interference can cause signal degradation or loss, resulting in unreliable wireless communication between the power tool and external devices. Furthermore, the electromagnetic field generated by the power tool can also disrupt the wireless signal itself, causing communication instability between the power tool and external devices. This disruption can lead to dropped connections or reduced signal strength, affecting the overall functionality of the connected devices.
In some prior art, such as US 7,022,924 , a mains-powered router with a transmitter mounted in a handle is disclosed. The transmitter is configured to communicate with an external power supply to control the power tool when a user pushes a button mounted in the handle. However, once the transmitter sends a signal, the power to the router is no longer provided, and the transmitter can no longer send a wireless signal.
There is a need for an improved power tool with a wireless communication interface that can maintain stable and reliable communication with a plurality of external devices, even in the presence of electromagnetic field interference generated by the power tool during use.

Summary

According to a first aspect of the disclosure, a power tool comprises a housing, a motor mounted in the housing, a battery electrically connected to the motor, a first handle mounted to the housing, and at least one wireless communication module configured to communicate with at least one external device, wherein the wireless communication module is mounted in the first handle. This arrangement allows for improved communication between the power tool and external devices, as well as a more compact and efficient design.
Optionally in some examples, the power tool further comprises a controller connected to the motor and the wireless communication module, wherein the controller is configured to control the motor based on communication with the external device. This allows for more precise and efficient control of the motor, resulting in improved performance and energy efficiency.
Optionally in some examples, the first handle comprises a first handle portion and a second handle portion, the first handle portion and the second handle portion being configured to mount together to form the first handle. This modular design allows for easier assembly and disassembly of the handle, as well as potential customization and replacement of handle components.
Optionally in some examples, the wireless communication module is positioned in an enclosed space defined by the first handle portion and the second handle portion when assembled. This provides additional protection for the wireless communication module and helps to maintain the compact and efficient design of the power tool.
Optionally in some examples, the first handle comprises electromagnetic field (EMF) shielding positioned between the wireless communication module and the motor. This shielding helps to reduce interference between the motor and the wireless communication module, resulting in more reliable communication with external devices.
Optionally in some examples, the EMF shielding is selected from a group consisting of conductive paint, ferrite beads, shielding tape, conductive fabric, conductive foam, metal or metallic plates, electromagnetic shielding films, and conductive mesh sheets. This provides a variety of options for effective EMF shielding, allowing for customization and optimization of the power tool design.
Optionally in some examples, the wireless communication module comprises a first wireless communication module and a second wireless communication module, the first wireless communication module being configured to communicate with the external device and the second wireless communication module being configured to communicate with another external device. This allows for simultaneous communication with multiple external devices, increasing the versatility and functionality of the power tool.
Optionally in some examples, the first wireless communication module is a Bluetooth Low Energy module, and the second wireless communication module is a Wireless Tool Control module. This combination of communication modules allows for efficient communication with a wide range of external devices, including smartphones, tablets, and other power tools.
Optionally in some examples, the first wireless communication module is positioned further away from the motor than the second wireless communication module. This positioning helps to reduce interference between the motor and the wireless communication modules, resulting in more reliable communication with external devices.
Optionally in some examples, the other external device in communication with the second wireless communication module is one or more of a workshop vacuum cleaner, an illuminate device, a worksite radio, a display, or another power tool. This allows for seamless integration and control of multiple devices within a workshop or worksite, improving overall efficiency and productivity.
Optionally in some examples, the external device in communication with the first wireless communication module is one or more of a smartphone, tablet, laptop, smartwatch, industrial control system, home automation system, vehicle control system, and environmental monitoring system. This allows for a wide range of potential applications and uses for the power tool, increasing its versatility and value to users.
Optionally in some examples, the housing further comprises a mesh or metallic layer facing the first handle with the wireless communication module for additional shielding from electromagnetic fields. This additional shielding helps to further reduce interference between the motor and the wireless communication module, resulting in more reliable communication with external devices.
Optionally in some examples, the first handle is formed from one or more of plastic, rubber or silicone grip, thermoplastic elastomer (TPE), composite materials, and/or thermoplastic polyurethane (TPU). This provides a variety of options for handle materials, allowing for customization and optimization of the power tool design for user comfort and durability.
Optionally in some examples, the first handle portion and the second handle portion are configured to mount together in a clam shell arrangement. This design allows for easy assembly and disassembly of the handle, as well as potential customization and replacement of handle components.
Optionally in some examples, the second handle portion comprises a projecting handle stem configured to engage the housing. This design allows for a secure connection between the handle and the housing, ensuring stability and durability during use.
According to a second aspect of the disclosure, a handle subassembly for a power tool comprises a first handle portion, a second handle portion configured to mount together with the first handle portion to form a handle, at least one wireless communication module configured to communicate with at least one external device, and an enclosed space defined by the first handle portion and the second handle portion when assembled, wherein the wireless communication module is mounted in the enclosed space. This handle subassembly allows for easier assembly and integration of the wireless communication module into the power tool, as well as potential customization and replacement of handle components.

Brief Description of the Drawings

Examples are described in more detail below with reference to the appended drawings.

Figure 1 is a front view of a power tool according to an example;
Figure 2 is a front cross-sectional view of a power tool according to an example;
Figure 3 is a plan view of a power tool according to an example;
Figure 4 is a side view of a power tool according to an example;
Figure 5 is an exploded perspective view of the handle subassembly comprising at least one communication module according to an example; and
Figure 6 is a cross-sectional view of the handle subassembly comprising at least one communication module according to an example.

Detailed Description

The detailed description set forth below provides information and examples of the disclosed technology with sufficient detail to enable those skilled in the art to practise the disclosure.
Figure 1 shows a front view of a power tool 100 according to an example. Figures 2, 3 and 4 also respectively show a front cross-sectional view, a plan view, and a side view of the same power tool 100. The power tool 100 as shown in Figure 1 is a router 100. Whilst the power tool 100 can be a router 100, in other examples any other type of power tool 100 can be used such as a plunge saw, a drill, a multitool, or an oscillating tool mounted on a plunge base portion 106. Hereinafter, the term power tool 100 will be used.
The power tool 100 comprises a housing 102. The housing 102 comprises a clam shell type construction having two halves which are fastened together. The halves of the housing 102 are fastened together with screws but in alternative examples any suitable means for fastening the housing 102 together may be used such as glue, clips, bolts and so on. For the purposes of clarity, the fastenings in the housing 102 are not shown. The housing 102 extends along a longitudinal axis B-B. The longitudinal axis B-B as shown in Figure 1 is also the rotational axis B-B of the power tool 100.
A motor 120 (best shown in Figure 2) is mounted in the housing 102 for driving a tool holder, e.g., a collet 104. The motor 120 is optionally mounted within a motor housing (not shown). The motor housing may be mounted to the housing 102. The motor 120 may be any suitable type of electric motor, such as a brushed or brushless DC motor, an AC motor, a stepper motor, or other types of motors known in the art. Optionally, the motor housing is mounted to the housing 102 via dampeners e.g. rubber mounts (not shown) to reduce the vibration transmitted from the motor 120 to the housing 102 and, in turn, to the user.
The motor 120 is operatively connected to the collet 104 through a drive shaft 156, which transmits the rotational movement of the motor 120 directly to the tool holder e.g., the collet 104. The drive shaft 156 may comprise one or more bearings to decrease friction and ensure smooth rotation of the collet 104.
The motor 120 may comprise various cooling components, such as fans or cooling fins, to dissipate heat generated during operation. These cooling components may be encased within the motor housing or the housing 102 of the power tool 100 and may be integrated into the design of the motor 120 itself.
A cutting tool bit (not shown) can be mounted in the collet 104 for engaging a workpiece (not shown). Typically, the cutting tool is a cutting tool bit for a power tool 100. In some examples the cutting tool bit is a router bit such as an upcut spiral router bit, a downcut spiral router bit, a straight router bit, a cove router bit, a chamfer router bit, a rabbeting router bit, a roundover router bit, a beading router bit, an ogee router bit or a panel raising router bit. Any other suitable router cutting tool bit can be mounted in the collet 104.
The collet 104 may be a cylindrical component that contains an inner bore to accommodate and grip the shank of the cutting tool bit. The collet 104 is known and will not be discussed in any further detail.
As shown in Figure 1, the power tool 100 comprises a base portion 106 for engaging the workpiece. The base portion 106 comprises a base aperture 126 through which the cutting tool bit can project e.g., when the user plunges the housing 102 towards the base portion 106 and then the cutting tool bit projects through the base aperture 126. The base portion 106 is mounted to the housing 102 via first and second guide posts 108, 110. The first and second guide posts 108, 110 are slidably mounted to the housing 102 for adjusting the relative distance of the base portion 106 from the collet 104. In some examples, the first and second guide posts 108, 110 are removable. This means that the power tool 100 can be used without the base portion 106 engaging the workpiece.
The housing 102 comprises a first handle 112 and a second handle 114 for the user to grip during operation. The first handle 112 and the second handle 114 have a different arrangement. In some examples, a main trigger switch 116 for operating the power tool 100 is mounted within the second handle 114. In some examples, the second handle 114 also comprises a lock button 118 for selectively locking the main trigger switch 116 into an "ON" status. This means that the user does not have to constantly keep pressure maintained on the main trigger switch 116 during operation of the power tool 100. In some examples, the main trigger switch 116 can be replaced with a momentary switch (not shown).
The user can hold both the first handle 112 and the second handle 114 to grip the power tool 100 during operation thereof. The first handle 112 and the second handle 114 optionally comprise a clam shell arrangement. As shown in Figures 3 and 4, the first handle 112 and the second handle 114 comprise a "T-shaped" profile. This means that the first handle 112 and the second handle 114 have an ergonomic profile and are comfortable when the user wraps their fingers and thumbs around the first and second handles 112, 114.
Indeed, the first handle 112 and the second handle 114 are separate handle elements that are mountable to the housing 102. Accordingly, the separate parts of the first handle 112 on the second handle 114 can be assembled before the first and second handles 112, 114 are mounted on the housing 102.
In some examples, the first and second handles 112, 114 are mounted to the housing 102 with one or more screw fastenings. In some other examples, any other type of fastening arrangement can be used, e.g., adhesive, clips, or clamps or a friction fit etc.
The motor 120 is electrically connected to an electric power source 122. In some examples, the electric power source 122 is a mains electrical supply. In some other examples, the electrical power source 122 is preferably a battery 122 as shown in e.g., Figure 1. The battery 122 can be removably mountable to the housing 102 or integral to the housing 102. In some examples, the power tool 100 can be powered either from both a battery 122 and / or a mains electrical supply. The motor 120 is connected to a controller 130 (best shown in Figure 2) mounted on a PCB in the housing 102. The controller 130 is configured to issue control instructions to the motor 120 in dependence of the user actuating the main trigger switch 116.
The battery 122 as shown in Figure 1 is securely mounted to a top portion 124 of the housing 102. The battery 122 is configured to power the motor 120 and other electronic components. The battery 122 may comprise lithium-ion cells, nickel-metal hydride cells, or any other type of rechargeable or non-rechargeable power source.
The power tool 100 as shown in Figure 1 is optionally a plunge router 100. However, in some examples, the power tool 100 is not a plunge router 100. Accordingly, the power tool 100 can be selectively operated in different modes. In a first mode, the power tool 100 is in a locked position. In the locked position, the first and second guide posts 108, 110 are fixed with respect to the housing 102. This means that the housing 102 and the collet 104 are fixed with respect to the base portion 106. Accordingly, the cutting tool (not shown) can be maintained at a set height above the workpiece. This means that the user of the power tool 100 can select how far the cutting tool projects through the aperture in the base portion 106.
In a second mode, the power tool 100 is in an unlocked position. In the unlocked position the first and second guide posts 108, 110 are slidable with respect to the housing 102. This means that the user can push down on the first and second handles 112, 114 and the first and second guide posts 108, 110 slide into or through the housing 102. In this way, the distance between the base portion 106 and the housing 102 can be adjusted. This means that the user can position the power tool 100 above the workpiece and then push the housing 102 towards the workpiece and the cutting tool plunges into the workpiece.
As discussed hereinafter, the power tool 100 is configured to be set in a plurality of unlocked positions for different operation modes of the power tool 100.
The user can select between the locked and unlocked position of the power tool 100 by using a locking system (not shown) mounted on the power tool 100. In some examples, the locking system is actuatable with a locking lever 134.
Figure 1 shows the locking lever 134 in a locked position. In some examples, the locking lever 134 is in the locked position in a vertical orientation. The locking lever 134 is mechanically coupled to the first and / or second guide posts 108, 110 such that relative movement of the first and second guide posts 108, 110 is prevented when the locking lever 134 is in the locked position.
In some examples, the locking lever 134 actuates a locking bolt (not shown) to engage the first guide post 108 or the second guide post 110. In this way, the locking bolt exerts a frictional force against the first or second guide posts 108, 110 when the locking lever 134 is in the locked position. Alternatively, the locking bolt can engage a detent or a hole in the first guide post 108 or the second guide post 110.
Accordingly, when the locking lever 134 is in the locked position the locking bolt clamps against or engages the first or second guide posts 108, 110 preventing relative movement therebetween. In some examples the locking lever 134 optionally engages a reciprocal hole or detent (not shown) in the second guide post 110 and the housing 102. In other examples, an additional second locking bolt (not shown) is used to also engage with the first guide post 108 such that both the first and the second guide posts 108, 110 are locked at the same time. In other examples, other mechanisms can be used to lock the first and second guide posts 108, 110 such as a latch-catch mechanism, a ball bearing engaging a detent in the first and second guide posts 108, 110 or any other suitable mechanism.
The locking lever 134 is moveable between the locked position shown in Figure 1 and an unlocked position (not shown). In some examples, the locking lever 134 is rotatable between the locked position and the unlocked position about a rotational axis of the locking lever 134. In some other examples, the locking lever 134 is slidable between the locked position and the first and second unlocked positions. Mechanical linkages (not shown) may be coupled between the locking lever 134 and the locking bolt for actuating engagement between the locking bolt and the first and second guide posts 108, 110.
When the user plunges the housing 102 towards the base portion 106, the collet 104 and the cutting tool project through the base aperture 126. A housing return spring 128 is optionally shown in Figure 2 as is fixed with respect to the first guide post 108 at a first spring end 140 and connected to the housing 102 at a second spring end 142. In some examples the housing return spring 128 is fixed with respect to the first guide post 108 at a first spring end 140 with a first C-clip (not shown) and fixed with respect to the housing 102 at a second spring end 142 with a second C-clip (not shown). Other types of fasteners can be used instead of the first and second c-clips. Accordingly, when the housing 102 is moved towards, the base portion 106, the housing return spring 128 extends and exerts a return force on the housing 102 to return the unplunged position (e.g., the power tool 100 as shown in Figure 1). The housing return spring 128 is shrouded with a bellows 144 to prevent ingress of dirt, debris, or moisture into the housing return spring 128 or other parts of the power tool 100.
In order to adjust the depth of the plunge e.g., how far the collet 104 projects through the base aperture 126, the housing 102 comprises a depth rod 152. The depth rod 152 is configured to engage one or more depth screws 154 of a plunge depth stop mounted on the base portion 106. When the housing 102 is plunged towards the base portion 106, the housing 102 is prevented from moving further towards the base portion 106 when the depth rod 152 engages the depth screws 154 of the plunge depth stop. The amount the depth rod 152 extends towards the base portion 106 is adjustable by the user. Furthermore, the amount the depth screws 154 project towards the housing 102 from the base portion 106 are also adjustable by the user. For the purposes of clarity only one of the depth screws 154 are labelled. The plunge depth stop, the depth screws 154 and the depth rod 152 are known and will not be described in any further detail.
Turning back to Figure 1, the power tool 100 comprises a dust extraction conduit 136. The dust extraction conduit 136 is connectable to a vacuum source such as a workshop vacuum. The first guide post 108 is hollow and comprises a first guide post conduit 138 which is in fluid communication with the dust extraction conduit 136 at a first end of the first guide post 108. The second end of the first guide post 108 is in fluid communication with the base portion 106 and the cutting tool. In this way, the first guide post conduit 138 couples the vacuum source via the dust extraction conduit 136 to the base portion 106. This means cutting chips and other debris from the workpiece can be collected and extracted during operation.
In some examples, as discussed below, the power tool 100 is in wireless communication with the workshop vacuum. Accordingly, the power tool 100 may be configured to wirelessly communicate and control the workshop vacuum. For example, the workshop vacuum may automatically turn on when the power tool 100 issues a control signal or message to the workshop vacuum. This is discussed in more detail below.
The base portion 106 provides a stable and flat surface in a plane parallel with axis A-A (as shown in Figure 2). The base portion 106 is arranged to be positioned and secured against the workpiece during operation of the power tool 100. The base portion 106 may comprise a first base side 158 facing away from the workpiece, and a second base side 160 facing towards the workpiece. The base portion 106 may be formed from any suitable material such as metal, plastic, composite, or any combination thereof. The dimensions and geometrical features of the base portion 106 may be configured to ensure proper compatibility with a variety of accessories, as discussed below.
The base portion 106 may optionally comprise a plurality of mounting features, such as holes, slots, or recesses, which enable the secure attachment of other components such as a sub-base adapter 162. These mounting features may be arranged in a predetermined pattern or layout, which corresponds to complementary features on the sub-base adapter 162 for proper alignment and mounting.
The base portion 106 of the power tool 100 may be integrally formed with the housing 102 or may be a separate component that is securely attached or connected to the main body of the housing 102 as shown in the accompanying Figures. Figure 1 shows the first guide post 108 and the second guide post 110 fixed with respect to the base portion 106.
Reference will now be made to Figures 5 and 6 to describe the first handle 112 of the power tool 100 in more detail. Figure 5 is an exploded perspective view of a handle subassembly 516 comprising at least one wireless communication module 506, 508 according to an example. Figure 6 is a cross-sectional view of the handle subassembly 516 comprising the at least one wireless communication module 506, 508 according to an example.
The first handle 112 is formed from a first handle subassembly 516 as shown in Figure 5. The handle subassembly 516 of the power tool 100 comprises various components and configurations that contribute to its functionality and ease of use.
In one example, the handle subassembly 516 includes a first handle portion 500 and a second handle portion 502, which are designed to mount together to form the first handle 112. The handle subassembly 516 also comprises at least one wireless communication module 506, 508, which is configured to communicate with at least one external device. An enclosed space 514 is defined by the first handle portion 500 and the second handle portion 502 when assembled, wherein the at least one wireless communication module 506 is mounted in the enclosed space 514.
In some examples, the handle subassembly 516 comprises a single wireless communication module 506. However, in other examples, there can be a plurality of different wireless communications modules 506, 508 each configured to communicate with different external devices.
The at least one wireless communication module 506, 508 will be referred to as the first wireless communication module 506 or the second wireless communication module 508 where relevant. However, it is noted that there can be any suitable number of wireless communication modules 506, 508 mounted in the handle subassembly 516.
In some examples, the first handle portion 500 may be made from various materials, such as plastic, rubber or silicone grip, thermoplastic elastomer (TPE), composite materials, and/or thermoplastic polyurethane (TPU). The choice of material can provide advantages such as durability, comfort, and ease of manufacturing. The design of the first handle portion 500 may be ergonomic, allowing for a comfortable grip and ease of use during operation of the power tool 100.
The second handle portion 502 is configured to mount together with the first handle portion 500 to form the first handle 112. In some examples, the second handle portion 502 may be made from the same materials as the first handle portion 500, providing similar advantages in terms of durability, comfort, and ease of manufacturing.
In one example, the second handle portion 502 comprises a projecting handle stem 510, which is configured to engage the housing 102 of the power tool 100. This engagement allows for a secure connection between the handle subassembly 516 and the housing 102, ensuring stability and proper alignment during operation. The projecting handle stem 510 also positions the first handle 112 and the first and second wireless communication modules 506, 508 are positioned further from the motor 120.
The projecting handle stem 510 may be designed to securely fit into a corresponding recess or opening in the housing 102. The attachment of the first handle 112 to the housing 102 may be further secured using screws or other fastening means, ensuring a stable and secure connection between the handle and the housing 102.
The handle subassembly 516 may comprise a first and a second wireless communication modules 506, 508, which is configured to communicate with at least one external device. In some examples, the first or the second wireless communication modules 506, 508 may be a Bluetooth Low Energy module, a Wi-Fi module, a Zigbee module, a cellular module, an RFID module, or any other suitable wireless communication technology. The first wireless communication module 506 enables the power tool 100 to connect with external devices such as smartphones, tablets, laptops, smartwatches, industrial control systems, home automation systems, vehicle control systems, and environmental monitoring systems. This connectivity allows for remote control, monitoring, and data collection, providing increased functionality and versatility for the power tool 100.
For example, the user may use software on the external device for instructions on how to use the power tool 100 in response to a message or signal wirelessly transmitted from the controller 130 of the power tool 100 via the first wireless communication module 506. Alternatively, the external device may provide information relating to fault diagnostics and repair of the power tool 100 in response to a message or signal wirelessly transmitted from the controller 130 of the power tool 100 via the first wireless communication module 506.
In one example, the first wireless communication module 506 is positioned in the enclosed space 514, which is defined by the first handle portion 500 and the second handle portion 502 when assembled. This positioning provides a simpler assembly process for the power tool 100 because the first wireless communication module 506 can be assembled separately from the main housing 102.
In one example, the assembly of the handle subassembly 516 involves mounting the first handle portion 500 and the second handle portion 502 together, placing the first and second wireless communication modules 506, 508 in the enclosed space 514, and integrating the electromagnetic field (EMF) shielding 512.
In some examples, the first handle portion 500 and the second handle portion 502 are configured to mount together to form the first handle 112. The mounting process may involve aligning the first handle portion 500 and the second handle portion 502 in a clam shell arrangement, wherein the first handle portion 500 and the second handle portion 502 are positioned to face each other and are secured together using screws or other fastening means. Alternatively, the handle subassembly 516 is fastened together with adhesives, clips, or other attachment mechanisms to secure the connection between the first handle portion 500 and the second handle portion 502.
As mentioned above, the first wireless communication module 506 is positioned within the enclosed space 514 when assembled. The enclosed space 514 provides a protected environment for the first wireless communication module 506, shielding it from external contaminants, such as dust, moisture, and debris, which may be encountered during the operation of the power tool 100. The enclosed space 514 also helps to isolate the first wireless communication module 506 from the motor 120 and other components of the power tool 100, reducing the potential for electromagnetic interference and improving the reliability and performance of the first wireless communication module 506.
The enclosed space 514 is arranged to snugly accommodate the first wireless communication module 506 therewithin. The enclosed space 514 may comprise ribs, pegs or other features mounted on the first handle portion 500 and / or the second handle portion 502 to receive the first wireless communication module 506. Figure 5 shows a first mounting rib 518 and a second mounting rib 520 for receiving the first wireless communication module 506 therebetween.
The first wireless communication module 506 can be gripped between the first mounting rib 518 and the second mounting rib 520. This can make assembly of the handle subassembly 516 easier because the first wireless communication module 506 is correctly aligned and held in place.
In some examples, the first wireless communication module 506 may be additionally or alternatively mounted within the enclosed space 514 using clips, brackets, or other attachment mechanisms that securely hold the module in place. The first wireless communication module 506 may also be mounted using adhesives or other bonding materials that provide a secure and stable connection between the module and the handle subassembly 516.
In addition, the first handle portion 500 and the second handle portion 502 may comprise ribs 518, 520, pegs or other features mounted on the first handle portion 500 and / or the second handle portion 502 to receive the second wireless communication module 508. In this way, the first handle portion 500 can receive one of the first wireless communication module 506 and the second wireless communication module 508 between the mounting ribs 518, 520 and the second handle portion 502 can receive the other of the first wireless communication module 506 and the second wireless communication module 508 between the mounting ribs 518, 520. This means that both the first and second wireless communication modules 506, 508 are held in place in the first handle portion 500 and the second handle portion 502. The first and second wireless communication modules 506, 508 then remain in the correct alignment when the handle subassembly 516 is assembled.
In some examples, the handle subassembly 516 may comprise EMF shielding 512, which is positioned between the first and / or second wireless communication modules 506, 508 and the motor 120. The EMF shielding 512 serves to protect the first and second wireless communication modules 506, 508 from electromagnetic interference generated by the motor 120, ensuring that the first and second wireless communication modules 506, 508 can maintain reliable communication with external devices during the operation of the power tool 100.
The EMF shielding 512 may be selected from various materials, such as conductive paint, ferrite beads, shielding tape, conductive fabric, conductive foam, metal or metallic plates, electromagnetic shielding films, and conductive mesh sheets. The choice of material for the EMF shielding 512 may depend on factors such as the specific type of the first or second wireless communication modules 506, 508 used, the operating environment of the power tool 100, and the desired level of protection against electromagnetic interference.
In some examples, the EMF shielding 512 may be integrated into the handle subassembly 516 by applying the shielding material directly to the inner or outer surfaces of the second handle portion 502. Preferably, the EMF shielding 512 is not applied to the first handle portion 500 e.g., the side of the first handle 112 which faces away from the motor 120. Alternatively, the EMF shielding 512 may be provided as a separate component that is mounted within the enclosed space 514 on the side of the first wireless communication module 506 that faces the motor 120.
The integration of EMF shielding 512 within the handle subassembly 516 provides several advantages, including improved reliability and performance of the first wireless communication module 506, reduced potential for electromagnetic interference, and increased protection for the first and second wireless communication modules 506, 508 from external contaminants and environmental factors.
In some examples, the housing 102 may additionally or alternatively comprise a mesh or metallic layer (not shown) facing the first handle 112 with the first wireless communication module 506. This layer provides further shielding from electromagnetic fields generated by the motor 120, helping to ensure that the first wireless communication module 506 can effectively communicate with external devices without interference.
The mesh or metallic layer may be formed from a variety of materials, such as metal or metallic plates, conductive mesh sheets, or other suitable materials that provide effective shielding from electromagnetic fields. The layer may be integrated into the housing 102 during the manufacturing process or may be added as a separate component during assembly. For example, the layer can be a metallized sticker which is adhered to the housing 102. The metallized sticker can have a dual purpose in that it also displays information to the user about the power tool 100 as well as providing EMF shielding 512 to the first and second wireless communication modules 506, 508.
The inclusion of an additional mesh or metallic layer in the housing 102 provides several advantages. For example, the additional shielding from electromagnetic fields helps to ensure that the first and second wireless communication modules 506, 508 can effectively communicate with external devices, even in the presence of a strong electromagnetic field generated by the motor 120. Additionally, the integration of the mesh or metallic layer into the housing 102 helps to maintain the compact size of the power tool 100, ensuring that it remains easy to handle and operate by the user.
In some examples, the motor 120 is mounted within the housing 102 such that it is positioned at a predetermined distance from the first and second wireless communication modules 506, 508. This positioning helps to minimise the potential for interference from the electromagnetic field generated by the motor 120, ensuring that the first and second wireless communication modules 506, 508 can effectively communicate with external devices.
The positioning of the motor 120 relative to the first wireless communication module 506 may be further optimised by considering factors such as the size and shape of the housing 102, the size and power of the motor 120, and the specific requirements of the first and second wireless communication modules 506, 508.
In one example, the power tool 100 comprises a controller 130 that is connected to the motor 120 and the first and second wireless communication modules 506, 508. The controller 130 is optionally configured to control the motor 120 based on communication with the at least one external device. This configuration allows for improved control and customization of the operation of the power tool 100, as well as enhanced user interaction and feedback through the external device.
For example, the electrical connection between the controller 130 and the motor 120 enables the controller 130 to regulate the operation of the motor 120, such as adjusting parameters of the motor 120 such as speed, torque, or direction, based on the received input from the external device. The electrical connection between the controller 130 and the first wireless communication module 506 allows the controller 130 to receive and transmit data to and from the external device, facilitating communication and control between the power tool 100 and the external device.
In some examples, the controller 130 is configured to control the motor 120 based on communication with the at least one external device. This may comprise receiving input from the external device, such as user commands or sensor data, and adjusting the operation of the motor 120 operation. For example, the controller 130 may receive a command from the external device to increase the speed of the motor 120, and in response, the controller 130 may adjust the operation of the motor 120 to achieve the desired speed. This allows for more precise and customised control of the power tool 100, as well as the ability to adapt the tool's operation to specific tasks or conditions.
The controller 130 may also be configured to transmit data to the external device, such as information about the operation of the power tool 100, status, or performance. This data may be displayed on the external device, providing the user with real-time feedback and enabling them to monitor and adjust the operation of the power tool 100 as needed. This feature enhances the user's experience and interaction with the power tool 100, as well as improving the overall efficiency and effectiveness of the tool's operation.
In some examples, the power tool 100 may comprise a first wireless communication module 506 and a second wireless communication module 508, each configured to communicate with different external devices or using different communication protocols. The controller 130 may be configured to manage the communication between these multiple modules and the external devices, as well as coordinating the control of the motor 120 based on the received input from the various devices. This allows for increased versatility and adaptability of the power tool 100, as it can be controlled and monitored by a wider range of external devices and systems.
In some examples, the at least one external device with which the first wireless communication module 506 is configured to communicate may include, but is not limited to, smartphones, tablets, laptops, smartwatches, industrial control systems, home automation systems, vehicle control systems, and environmental monitoring systems. This wide range of compatible external devices allows for increased versatility and adaptability of the power tool 100, as it can be controlled and monitored by various devices and systems, depending on the user's needs and preferences.
In some examples, the first wireless communication module 506 may comprise different types of communication modules, such as Bluetooth Low Energy, Wi-Fi, and Wireless Tool Control modules. These different communication protocols enable the power tool 100 to communicate with a variety of external devices and systems, further increasing its versatility and adaptability. Additionally, the use of multiple communication protocols may allow for improved communication reliability and performance, as the power tool 100 can switch between different protocols depending on the specific requirements or conditions of the communication environment.
In one example, the first wireless communication module 506 may be configured to communicate with a smartphone, tablet, laptop, or smartwatch. These external devices can provide a user interface for controlling and monitoring the power tool 100, such as adjusting motor speed, torque settings, or receiving diagnostic information. The user interface may be provided through a dedicated application or software running on the external device, allowing the user to interact with the power tool 100 wirelessly. This can provide increased convenience, safety, and efficiency during operation.
In some examples, the first wireless communication module 506 may be configured to communicate with industrial control systems, home automation systems, or vehicle control systems. This can enable the power tool 100 to be integrated into a larger system, allowing for centralised control and monitoring of multiple power tools and other devices. For instance, an industrial control system may monitor the usage and performance of multiple power tools 100 in a workshop, providing real-time data to optimise workflow and maintenance schedules. Similarly, a home automation system may allow a user to remotely control and monitor the power tool 100 from a central hub or mobile device, providing increased convenience and safety.
The first wireless communication module 506 may comprise various types of communication modules, such as Bluetooth Low Energy, Wi-Fi, or Wireless Tool Control modules. In one example, the first wireless communication module 506 may be a Bluetooth Low Energy module, which can provide low-power, short-range communication with external devices, such as smartphones, tablets, laptops, or smartwatches. This can enable efficient communication with minimal impact on the battery life of both the power tool 100 and the external device.
In some examples, the first wireless communication module 506 may be configured to transmit and receive when the power tool 100 is not being used. In this way, the power tool 100 can operate in a standby or "low power" mode whereby the first wireless communication module 506 can draw power from the battery 122 even when the power tool 100 is not powering the motor 120. Similarly, the second wireless communication module 508 may also be configured to transmit and receive when the power tool 100 is not being used.
In another example, the first wireless communication module 506 may be a Wi-Fi module, which can provide longer-range communication with external devices, such as industrial control systems, home automation systems, or vehicle control systems. This can enable the power tool 100 to be integrated into a larger network, allowing for more advanced control and monitoring capabilities.
In yet another example, there may be a first wireless communication module 506 as described above and a second wireless communication module 508 may be a Wireless Tool Control module. The second wireless communication module 508 can be configured to communicate with and control a separate power tool, such as a workshop vac unit (not shown). This can enable the power tool 100 to automatically activate or deactivate the separate power tool in response to certain conditions or events, such as starting or stopping the motor 120 of the power tool 100. This can provide increased convenience, efficiency, and safety during operation. Alternatively, the controller 130 is configured to communicate via the second wireless communication module 508 to one or more of an illumination device, a worksite radio, a display, or another power tool 100. This increases the versatility of the power tool 100 in the workshop or worksite.
The power tool 100 may comprise multiple wireless communication modules, such as a first wireless communication module 506 and a second wireless communication module 508, with each module configured for different communication protocols or functions. Whilst Figures 5 and 6 only show a first wireless communication module 506 and a second wireless communication module 508, there can be any suitable number of wireless communication modules 506, 508 mounted in the first handle 112.
For example, the first wireless communication module 506 may be a Bluetooth Low Energy module for communication with smartphones, tablets, laptops, or smartwatches, while the second wireless communication module 508 may be a Wireless Tool Control module for communication with and control of a separate power tool 100. This can provide increased versatility and functionality for the power tool 100.
In some examples, the second wireless communication module 508 may be positioned further away from the motor 120 than the first wireless communication module 506, reducing potential interference from the electromagnetic field generated by the motor 120. This can improve the reliability and performance of the first wireless communication between the power tool 100 and the external devices.
In some examples, the first and second wireless communication modules 506, 508 are positioned adjacent to each other when mounted in the handle subassembly 516. This makes the first handle 112 more compact.
In some examples, the first and second wireless communication modules 506, 508 may operate on different frequencies. Furthermore, the first and second wireless communication modules 506, 508 may operate on different wireless protocols. This may help the first and second wireless communication modules 506, 508 from interfering with each other. In some examples, the first and second wireless communication modules 506, 508 may transmit at different times to each other.
The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises," "comprising," "includes," and/or "including" when used herein specify the presence of stated features, integers, actions, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and/or groups thereof.
It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure.
Relative terms such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical" may be used herein to describe a relationship of one element to another element as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealised or overly formal sense unless expressly so defined herein.
It is to be understood that the present disclosure is not limited to the aspects described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the present disclosure and appended claims. In the drawings and specification, there have been disclosed aspects for purposes of illustration only and not for purposes of limitation, the scope of the disclosure being set forth in the following claims.

Claims

A power tool (100) comprising:
a housing (102);

a motor (120) mounted in the housing (102);

a battery (122) electrically connected to the motor (120);

a first handle (112) mounted to the housing (102); and

at least one wireless communication module (506) configured to communicate with at least one external device, wherein the at least one wireless communication module (506) is mounted in the first handle (112).
The power tool (100) according to claim 1, further comprising a controller (130) connected to the motor (120) and the at least one wireless communication module (506), wherein the controller (130) is configured to control the motor (120) based on communication with the at least one external device.
The power tool (100) according to claim 1 or 2, wherein the first handle (112) comprises a first handle portion (500) and a second handle portion (502), the first handle portion (500) and the second handle portion (502) being configured to mount together to form the first handle (112).
The power tool (100) according to any one of claims 1 to 3, wherein the at least one wireless communication module (506) is positioned in an enclosed space (514) defined by the first handle portion (500) and the second handle portion (502) when assembled.
The power tool (100) according to any one of claims 1 to 4, wherein the first handle (112) comprises electromagnetic field (EMF) shielding (512) positioned between the at least one wireless communication module (506) and the motor (120).
The power tool (100) according to claim 5, wherein the EMF shielding (512) is selected from the group consisting of conductive paint, ferrite beads, shielding tape, conductive fabric, conductive foam, metal or metallic plates, electromagnetic shielding films, and conductive mesh sheets.
The power tool (100) according to any one of claims 1 to 6, wherein the at least one wireless communication module (506) comprises a first wireless communication module (506) and a second wireless communication module (508), the first wireless communication module (506) being configured to communicate with the at least one external device and the second wireless communication module (508) being configured to communicate with another external device.
The power tool (100) according to claim 7, wherein the first wireless communication module (506) is a Bluetooth Low Energy module, and the second wireless communication module (508) is a Wireless Tool Control module.
The power tool (100) according to claim 7 or 8, wherein the first wireless communication module (506) is positioned further away from the motor (120) than the second wireless communication module (508).
The power tool (100) according to any of claims 7 to 9 wherein the other external device in communication with the second wireless communication module (508) is one or more of a workshop vacuum cleaner, an illumination device, a worksite radio, a display, or another power tool.
The power tool (100) according to any one of claims 1 to 10, wherein the at least one external device in communication with the first wireless communication module (506) is one or more of a smartphone, tablet, laptop, smartwatch, industrial control system, home automation system, vehicle control system, and environmental monitoring system.
The power tool (100) according to any one of claims 1 to 11, wherein the housing (102) further comprises a mesh or metallic layer facing the first handle (112) with the at least one wireless communication module (506) for additional shielding from electromagnetic fields.
The power tool (100) according to any one of claims 1 to 12, wherein the first handle (112) is formed from one or more of plastic, rubber or silicone grip, thermoplastic elastomer (TPE), composite materials, and / or thermoplastic polyurethane (TPU).
The power tool (100) according to any one of claims 3 to 13, wherein the first handle portion (500) and the second handle portion (502) are configured to mount together in a clam shell arrangement.
The power tool (100) according to any one of claims 3 to 14, wherein the second handle portion (502) comprises a projecting handle stem (510) configured to engage the housing (102).
A handle subassembly (516) for a power tool (100) comprising:
a first handle portion (500);

a second handle portion (502) configured to mount together with the first handle portion (500) to form a handle (112);

at least one wireless communication module (506) configured to communicate with at least one external device; and

an enclosed space (514) defined by the first handle portion (500) and the second handle portion (502) when assembled, wherein the at least one wireless communication module (506) is mounted in the enclosed space (514).