Inductive Charging Holster for Power Tool

Abstract

A wireless charging system for a power tool includes a charging module, docking frame, and tool holder. The charging module has a charging surface and an inductive charging device for charging a power tool resting on the charging surface, and is mounted in the docking frame, which is mounted in a mounting interface of the tool holder such that the charging surface is at an angle. The tool holder further includes a holding portion extending from a downward portion of the mounting interface such that the holding portion transversely supports the power tool. A soft insert structure received in the holding portion forms an interference fit with the power tool and applies a load to the power tool toward the charging surface that urges the power tool to an optimal location for charging, relative to the inductive charging device.

What is claimed is: 
     
         1 . A wireless charging system, comprising:
 a tool holder, including:
 a mounting interface; and 
 a holding portion extending from an end region of the mounting interface; and 
   a charging module that is removably mountable in the mounting interface of the tool holder, and that includes:
 a charging surface that is angled relative to the holding portion when the charging module is mounted in the mounting interface of the tool holder; and 
 an inductive charging device configured to wirelessly charge a wirelessly rechargeable battery of a device when the device is positioned on the charging surface so that the battery is within a wireless charging tolerance zone of the charging module; 
   wherein the holding portion is shaped so as to at least partially engage a body of the device when the device is resting on the charging surface, such that the holding portion acts as a lateral support for the device; and   wherein the holding portion is configured to apply a load to the body of the device when the device is resting on the charging surface such that the device is (i) at least partially compressed between the holding portion and the charging surface, and (ii) urged toward a location whereat the battery of the device is within the wireless charging tolerance zone of the charging module.   
     
     
         2 . The system of  claim 1 , wherein:
 the holding portion includes a cavity formed from a material that is soft relative to the tool holder;   the cavity shaped so as to form an interference fit with at least a portion of the body of the device; and   the cavity is configured to apply at least a portion of the load to the body of the device when the device is resting on the charging surface of the charging module.   
     
     
         3 . The system of  claim 2 , wherein the soft material of the cavity is fixed to a rigid shell that is removably mountable in the holding portion. 
     
     
         4 . The system of  claim 1 , wherein the tool holder further includes a pushing mechanism that, when the charging module is mounted in the mounting interface of the tool holder, is configured to apply a further load directly to the charging module that urges the charging module toward the holding portion such that, when the device is resting on the charging surface of the charging module, the further load of the pushing mechanism is applied to the device in opposition to the load applied by the holding portion. 
     
     
         5 . The system of  claim 4 , wherein the pushing mechanism includes at least one spring configured to bias the charging module toward the holding portion. 
     
     
         6 . The system of  claim 4 , wherein the pushing mechanism includes an adjustment member that enables a user to select a magnitude for the further load. 
     
     
         7 . The system of  claim 1 , wherein the tool holder further includes at least one stop member that has a shape configured to engage at least a portion of the body of the device, and that delimits an extent that the device is moveable toward the holding portion. 
     
     
         8 . The system of  claim 1 , wherein the mounting interface of the tool holder includes a docking frame that is removably mountable in the tool holder, and that includes a receiving interface configured to removably receive the charging module such that when the docking frame is mounted in the tool holder, and when the charging module is received in the docking frame, the charging module is mounted in the tool holder. 
     
     
         9 . The system of  claim 1 , wherein at least a portion of walls of the tool holder have a double-walled structure including:
 a first layer; and   a second layer separated from the first layer by a gap.   
     
     
         10 . The system of  claim 9 , wherein the tool holder further includes a damping material disposed within the gap. 
     
     
         11 . The system of  claim 1 , further comprising:
 a strap configured to restrain the device within the tool holder.   
     
     
         12 . A wireless charging system, comprising:
 a tool holder, including:
 a first mounting interface; and 
 a holding portion extending from an end region of the mounting interface; 
   an insert structure that is removably mountable in the holding portion of the tool holder, and that includes a cavity formed from a material that is soft relative to the tool holder;   a docking frame removably mountable in the first mounting interface, the docking frame including a second mounting interface; and   a charging module that is removably mountable in the second mounting interface, and that includes:
 a charging surface that is angled relative to the holding portion when the charging module is mounted in the second mounting interface, and the docking frame is mounted in the first mounting interface; and 
 an inductive charging device that defines a wireless charging tolerance zone; 
   a power tool that includes a wirelessly rechargeable battery;   wherein:
 the holding portion is shaped so as to at least partially engage a body of the power tool when the power tool is resting on the charging surface, such that the holding portion acts as a lateral support for the power tool; 
 the cavity of the insert structure is shaped so as to form an interference fit with at least a portion of the body of the power tool when the insert structure is mounted in the tool holder and the power tool is resting on the charging surface; 
 the cavity, when engaged in the interference fit with the power tool, is configured to apply a load to the power tool in a direction toward the charging surface such that the power tool is (i) at least partially compressed between the holding portion and the charging surface, and (ii) urged toward a location whereat the battery of the device is within the wireless charging tolerance zone of the charging module; and 
 the inductive charging device is configured to wirelessly charge the wirelessly rechargeable battery of the power tool when the wirelessly rechargeable battery is within the wireless charging tolerance zone of the inductive charging device. 
   
     
     
         13 . The system of  claim 12 , wherein the docking frame further includes a pushing mechanism that, when the charging module is mounted in the second mounting interface of the docking frame and the docking frame is mounted in the first mounting interface of the tool holder, is configured to apply a further load directly to the charging module that urges the charging module toward the holding portion such that, when the power tool is resting on the charging surface of the charging module, the further load of the pushing mechanism is applied to the power tool in opposition to the load applied by the holding portion. 
     
     
         14 . The system of  claim 13 , wherein the pushing mechanism includes at least one spring configured to bias the charging module toward the holding portion. 
     
     
         15 . The system of  claim 13 , wherein at least one of (i) the insert structure and (ii) the pushing device is configured to enable a user to select a magnitude of the compression of the power tool between the holding portion and the charging surface. 
     
     
         16 . The system of  claim 12 , further comprising:
 a clamping device including at least one clamping arm that is actuatable between:
 a first position whereat, when the power tool is resting on the charging surface, the at least one clamping arm engages the body of the power tool to hold the power tool captive within the tool holder, and 
 a second position whereat, when the power tool is resting on the charging surface, the at least one clamping arm is released from the power tool. 
   
     
     
         17 . The system of  claim 12 , further comprising:
 a strap configured to restrain the power tool within the tool holder.   
     
     
         18 . The system of  claim 12 , wherein at least a portion of walls of the tool holder have a double-walled structure including:
 a first layer; and   a second layer separated from the first layer by a gap.   
     
     
         19 . The system of  claim 18 , wherein the tool holder further includes a damping material disposed within the gap. 
     
     
         20 . The system of  claim 12 , wherein the tool holder further includes at least one stop member that has a shape configured to engage at least a portion of the body of the power tool, and that delimits an extent that the power tool is moveable toward the holding portion.