Adapter system for battery-powered tools

What is this patent about?

’766 is related to the field of battery-powered cordless power tools and, more specifically, to an adapter system that allows a user to operate a tool while the battery is physically separated from the tool housing. In standard cordless tool configurations, the weight of the rechargeable battery pack is borne entirely by the user's hand and wrist, leading to significant fatigue during extended use. The invention addresses this ergonomic challenge by providing a tethered connection that relocates the heavy battery to a user's belt or harness without sacrificing the mobility inherent in cordless systems.

The underlying idea behind ’766 is to decouple the electrical and mechanical interfaces of a standard power tool by using a tethered replica of the battery's connection geometry. Instead of relying on a fixed, heavy battery pack attached to the handle, the system uses a lightweight dummy connector that mimics the battery's form factor to plug into the tool, while a separate remote housing accepts the actual battery. This allows the tool to remain balanced and light while drawing power from the original equipment manufacturer (OEM) battery stored elsewhere on the user's body.

The claims of ’766 focus on an adapter system comprising a tool connector, a battery connector, and a conductive cord that bridges the two. The tool connector features a contact member specifically designed to be interchangeably received by the tool’s existing battery receptacle, effectively acting as a surrogate for the battery pack. Crucially, the battery connector at the other end of the cord is configured to receive the same OEM battery contact member that would normally plug into the tool, maintaining full compatibility with the original hardware.

In practice, the system functions as a bridge that extends the tool's internal wiring to a remote location. The tool connector includes a retaining mechanism that locks into the tool handle just as the original battery would, ensuring the electrical contacts remain seated during vigorous movement. The power cord is sized to handle the high current draw typical of motors in drills or saws, and the remote battery connector can be housed in a specialized holster or pouch that clips onto a belt, distributing the weight to the user's hips rather than their arm.

This approach differs from prior art that attempted to connect tools to fixed power sources like automotive batteries or wall outlets, which restricted the user's range of motion. Unlike those systems, ’766 utilizes the OEM battery itself, preserving the tool's intended voltage and portability. By employing a connector that is a physical and electrical twin of the tool's native interface, the invention allows for a seamless transition between standard cordless operation and a weight-reduced, tethered configuration without requiring modifications to the tool or the battery.