U.S. patent application number 10/931602 was filed with the patent office on 2005-02-10 for housing with functional overmold.
Invention is credited to Bowers, Michael C., Hagan, Todd A., Milbourne, Rodney, Potter, Christine.
Application Number | 20050028997 10/931602 |
Document ID | / |
Family ID | 25507881 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050028997 |
Kind Code |
A1 |
Hagan, Todd A. ; et
al. |
February 10, 2005 |
Housing with functional overmold
Abstract
A hand-held power tool having a housing, which has first and
second shell members and an end cap, and a trigger. The first and
second shell members define a handle portion that is configured to
be engaged by a first hand of a user. The trigger is coupled to the
handle portion and configured to be operated by the first hand of
the user. The end cap is removably coupled to the first and second
shell members and defines an auxiliary gripping structure that is
remote from the handle portion and configured to be selectively
engaged by a second hand of the user to aid in operating the power
tool. The end cap has a structural portion and an overmold portion
that is formed from a resilient material. The overmold portion is
at least partially interposed between the structural portion and
the second hand.
Inventors: |
Hagan, Todd A.; (Windsor,
PA) ; Potter, Christine; (Baltimore, MD) ;
Bowers, Michael C.; (Littlestown, PA) ; Milbourne,
Rodney; (Abington, MD) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
25507881 |
Appl. No.: |
10/931602 |
Filed: |
September 1, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10931602 |
Sep 1, 2004 |
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09963905 |
Sep 26, 2001 |
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6805207 |
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60263379 |
Jan 23, 2001 |
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Current U.S.
Class: |
173/178 ;
173/216 |
Current CPC
Class: |
F16H 2200/0039 20130101;
B25B 23/14 20130101; B25F 5/001 20130101; F16H 35/10 20130101; F16H
2200/0043 20130101; B25F 5/02 20130101; Y10T 29/4987 20150115; F16H
2200/201 20130101; F16H 2200/0034 20130101; B25F 5/006 20130101;
B25B 21/00 20130101; F16H 3/66 20130101 |
Class at
Publication: |
173/178 ;
173/216 |
International
Class: |
B25B 013/12 |
Claims
1. A hand-held power tool having a housing and a trigger, the
housing including first and second shell members and an end cap,
the first and second shell members defining a handle portion that
is configured to be engaged by a first hand of a user, the trigger
being coupled to the handle portion and configured to be operated
by the first hand to permit the user to control the operation of
the power tool, the end cap being removably coupled to the first
and second shell members and defining an auxiliary gripping
structure that is remote from the handle portion the auxiliary
gripping structure being generally convex in shape and configured
to be selectively engaged by a second hand of the user to aid in
operating the power tool, the end cap having a structural portion
and an overmold portion, the overmold portion being formed from a
resilient material and molded onto the structural portion, the
overmold portion being at least partially interposed between the
structural portion and the second hand.
2. The power tool of claim 1, wherein the resilient material is a
vibration damping material that is configured to attenuate
vibrations that are transmitted between the structural portion and
the second hand.
3. The power tool of claim 2, further comprising a driveline having
a motor and a transmission, and wherein the overmold portion also
attenuates vibrations transmitted between the driveline and the
structural portion.
4. The power tool of claim 1, wherein the power tool is a rotary
power tool.
5. The power tool of claim 4, wherein the power tool is selected
from a group comprising drill/drivers and hammer drills.
6. The power tool of claim 1, wherein the overmold portion includes
an isolator portion for contacting a structure within an interior
portion of the power tool, the isolator portion attenuating
vibrations transmitted between the structure and the structural
portion.
7. The power tool of claim 1, wherein the overmold portion includes
a seal portion for contacting a structure within an interior
portion of the power tool, the seal portion forming a seal between
the structure and the structural portion.
8. The power tool of claim 1, wherein each of the first and second
shell members includes a shell structure and a shell overmold, the
shell overmold being overmolded onto the shell structure and
covering at least a portion of the handle portion.
9. The power tool of claim 8, wherein the shell overmold of each of
the first and second shell members abuts an exterior surface of the
end cap.
10. The power tool of claim 1, wherein the overmold portion is
formed on a rearward facing portion of the power tool.
11. The power tool of claim 1, wherein the resilient material is a
thermoplastic.
12. The power tool of claim 11, wherein the thermoplastic is a
thermoplastic elastomer.
13. A hand-held power tool having a housing and a trigger, the
housing defining a handle portion, which is configured to be
engaged by a first hand of a user, and an auxiliary gripping
structure, the trigger being coupled to the handle portion and
configured to be operated by the first hand to permit the user to
control the operation of the power tool, the gripping structure
being spaced apart from the handle portion and configured to be
selectively engaged by a second hand of the user to aid in
operating the power tool, wherein the auxiliary gripping structure
includes an overmold that is discrete and separate from the handle
portion.
14. The hand-held power tool of claim 13, wherein the housing
comprises first and second shell members that collectively define a
chamber into which a motor is at least partially disposed.
15. The hand-held power tool of claim 14, wherein the auxiliary
gripping structure is an end cap that closes a portion of the
chamber defined by the first and second shell members.
16. The hand-held power tool of claim 15, wherein the auxiliary
gripping structure is removable from the first and second shell
members.
17. The hand-held power tool of claim 15, wherein at least one vent
is formed in the structural portion to vent an interior portion of
the housing.
18. The hand-held power tool of claim 17, wherein the overmold
member does not extend about a perimeter of the vent.
19. The hand-held power tool of claim 13, wherein the overmold
member covers only a portion of an outer surface of the structural
member.
20. The hand-held power tool of claim 19, wherein the overmold
member extends through a plurality of holes that are formed in the
structural member.
21. The hand-held power tool of claim 20, wherein the overmold
forms a plurality of spaced-apart bumper members.
22. The hand-held power tool of claim 13, wherein the auxiliary
gripping structure includes a structural member onto which the
overmold is coupled.
23. The hand-held power tool of claim 13, wherein the overmold is
located on a rearward facing portion of the power tool.
24. The hand-held power tool of claim 13, wherein the resilient
material is a thermoplastic.
25. The hand-held power tool of claim 24, wherein the thermoplastic
is a thermoplastic elastomer.
24. A hand-held power tool comprising: a housing having first and
second housing shells and an end cap, each of the first and second
housing shells including a shell structure and a shell overmold,
the shell structure defining a handle portion, the shell overmold
at least partially covering the handle portion, the end cap closing
an end of a cavity formed by the first and second housing shells,
the end cap including an end cap structure and a resilient end cap
overmold, the end cap defining an auxiliary gripping structure
having a generally convex shape; a motor at least partially
disposed in the cavity defined by the first and second housing
shells; a drill chuck coupled to the motor; and a trigger coupled
to the housing and configured to be actuated by a user when a first
hand of the user is grasping the handle portions of the first and
second housing shells, wherein the auxiliary gripping structure is
adapted to be engaged by a palm of a second hand of the user.
25. The hand-held power tool of claim 24, further comprising a
battery pack that is coupled to the motor and the trigger.
Description
PRIORITY & CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S.
application Ser. No. 09/963,905 field Sep. 26, 2001 entitled
"Housing With Functional Overmold", which claims the benefit of
U.S. Provisional Application No. 60/263,379, filed Jan. 23, 2001.
Other features of the present invention are discussed and claimed
in commonly assigned: copending U.S. application Ser. No.
10/384,809 entitled "Multispeed Power Tool Transmission"; copending
U.S. application Ser. No. 10/792,659 entitled "Multispeed Power
Tool Transmission"; copending U.S. application Ser. No. 10/755,250
entitled "First Stage Clutch"; U.S. Pat. No. 6,676,557 entitled
"First Stage Clutch", U.S. Pat. No. 6,431,289 entitled "Multispeed
Power Tool Transmission"; and U.S. Pat. No. 6,502,648 entitled 360
Degree Clutch Collar.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to housings for
devises such as power tools, including rotatable drills, power
screwdrivers and cutting tools. More particularly, the present
invention relates to a housing having an overmold portion in which
the overmold portion performs an auxiliary function.
[0004] 2. Discussion
[0005] Modern manufactures of power tools typically seek to provide
powerful and robust tools that are both ergonomically configured
and which offer exceptionally high value at a relatively
inexpensive price. Often times, however, the goal of a robust,
ergonomic configuration seems to be at odds with the offering of
the tool at a relatively inexpensive price as additional processes,
such as overmolding, or a multiplicity of parts that do not appear
to add significant value, such as vibration isolators and seals,
are required.
[0006] The overmolding of the grip of a hand tool is known in the
art for purposes of reducing the transmission of vibration to the
user's hand. In these situations, the outer surface of the grip of
the tool is overmolded with a resilient material; the overmolded
portion tends to damp the vibrations that are transmitted between
the housing of the tool and the user's hand. The overmolded portion
does not effect the operation of the tool per se, and as such, the
use of overmolding tends to be limited to a relatively small area
on the exterior of the tool so as to minimize the cost of the tool.
More specifically, the overmolding operation is typically employed
in a non-functional manner which adds cost to the article of
manufacture without adding a commensurate amount of value.
[0007] While parts, such as isolators and even seals, may be
necessary for the proper operation of the power tool, their
discrete nature nonetheless increases the cost of the power tool,
both in terms of materials and in assembly labor. Furthermore, the
proliferation of component parts is known to have a detrimental on
defect rates and warranty costs. Accordingly, there remains a need
in the art for a functional overmold which adds value to the
article of manufacture in an amount commensurate with its cost.
SUMMARY OF THE INVENTION
[0008] In one form, the present teachings provide a hand-held power
tool having a housing, which has first and second shell members and
an end cap, and a trigger. The first and second shell members
define a handle portion that is configured to be engaged by a first
hand of a user. The trigger is coupled to the handle portion and
configured to be operated by the first hand of the user. The end
cap is removably coupled to the first and second shell members and
defines an auxiliary gripping structure that is remote from the
handle portion and configured to be selectively engaged by a second
hand of the user to aid in operating the power tool. The end cap
has a structural portion and an overmold portion that is formed
from a resilient material. The overmold portion is at least
partially interposed between the structural portion and the second
hand.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Additional advantages and features of the present invention
will become apparent from the subsequent description and the
appended claims, taken in conjunction with the accompanying
drawings, wherein:
[0010] FIG. 1 is a side view of a power tool constructed in
accordance with the teaching of the present invention;
[0011] FIG. 2 is an exploded perspective view of a portion of the
power tool of FIG. 1;
[0012] FIG. 3 is a perspective view of a portion of the housing of
the power tool of FIG. 1 illustrating the rear of the end cap
assembly;
[0013] FIG. 4 is a front view of the end cap assembly;
[0014] FIG. 5 is a section view taken along the line 5-5 of FIG.
4;
[0015] FIG. 6 is a rear view of a portion of the power tool of FIG.
1 with the end cap assembly removed;
[0016] FIG. 7 is a side view of a portion of the power tool of FIG.
1 with the end cap assembly removed;
[0017] FIG. 8 is a view similar to that of FIG. 4, but illustrating
the end cap shell prior to the overmolding operation;
[0018] FIG. 9 is a view similar to that of FIG. 5, but illustrating
the end cap shell prior to the overmolding operation;
[0019] FIG. 10 is a view similar to that of FIG. 4, but
illustrating an alternate construction of the overmold member;
[0020] FIG. 11 is a partial sectional view of a portion of a power
tool that employs an end cap assembly having an overmold member
constructed in the manner illustrated in FIG. 10;
[0021] FIG. 12 is an exploded perspective view of a portion of the
power tool of FIG. 1, illustrating the transmission assembly in
greater detail;
[0022] FIG. 13 is an exploded perspective view of a portion of the
power tool of FIG. 1, illustrating the reduction gearset assembly,
the transmission sleeve, a portion of the housing and a portion of
the clutch mechanism in greater detail;
[0023] FIG. 13a is a sectional view taken along a longitudinal axis
of the second ring gear;
[0024] FIG. 13b is a sectional view taken along a longitudinal axis
of the third ring gear;
[0025] FIG. 14 is a side view of the transmission sleeve;
[0026] FIG. 15 is a rear view of the transmission sleeve;
[0027] FIG. 16 is a sectional view taken along the line 16-16 of
FIG. 15;
[0028] FIG. 17 is a sectional view taken along the line 17-17 of
FIG. 15;
[0029] FIG. 18 is an exploded view of the reduction gearset
assembly;
[0030] FIG. 19 is a sectional view taken along a longitudinal axis
of the power tool of FIG. 1 illustrating a portion of the reduction
gearset assembly in greater detail;
[0031] FIG. 20 is a front view of a portion of the first reduction
carrier;
[0032] FIG. 21 is a sectional view taken along a longitudinal axis
of the power tool of FIG. 1 illustrating a portion of the reduction
gearset assembly in greater detail;
[0033] FIG. 22 is a rear view of a portion of the third reduction
carrier;
[0034] FIG. 23 is an sectional view taken along the longitudinal
axis of the power tool of FIG. 1 and illustrating the transmission
assembly as positioned in the first speed ratio;
[0035] FIG. 24 is a sectional view similar to that of FIG. 23 but
illustrating the transmission assembly as positioned in the second
speed ratio;
[0036] FIG. 25 is a sectional view similar to that of FIG. 23 but
illustrating the transmission assembly as positioned in the third
speed ratio;
[0037] FIG. 26 is a top view of a portion of the power tool of FIG.
1 illustrating the speed selector mechanism in greater detail;
[0038] FIG. 27a is a side view of the rotary selector cam;
[0039] FIG. 27b is a top view of the rotary selector cam;
[0040] FIG. 27c is a sectional view taken through along the central
axis of the speed selector mechanism;
[0041] FIG. 28 is a rear view of the output spindle assembly;
[0042] FIG. 29 is an exploded perspective view of the clutch
mechanism;
[0043] FIG. 29a is a perspective view of a portion of the clutch
mechanism illustrating another configuration of the clutch
member;
[0044] FIG. 29b is an exploded perspective view illustrating a
multi-piece construction for the first ring gear and clutch
member;
[0045] FIG. 30 is a schematic illustration of the adjustment
structure in an "unwrapped" state;
[0046] FIG. 31 is a schematic illustration similar to that of FIG.
30 but showing an alternate construction of the adjustment profile;
and
[0047] FIG. 32 is a schematic illustration similar to that of FIG.
30 but showing a portion of another alternate construction of the
adjustment profile;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Overview
[0048] With reference to FIGS. 1 and 2 of the drawings, a power
tool constructed in accordance with the teachings of the present
invention is generally indicated by reference numeral 10. As those
skilled in the art will appreciate, the preferred embodiment of the
present invention may be either a cord or cordless (battery
operated) device, such as a portable screwdriver or drill. In the
particular embodiment illustrated, power tool 10 is a cordless
drill having a housing 12, a motor assembly 14, a multi-speed
transmission assembly 16, a clutch mechanism 18, an output spindle
assembly 20, a chuck 22, a trigger assembly 24 and a battery pack
26. Those skilled in the art will understand that several of the
components of power tool 10, such as the chuck 22, the trigger
assembly 24 and the battery pack 26, are conventional in nature and
need not be described in significant detail in this application.
Reference may be made to a variety of publications for a more
complete understanding of the operation of the conventional
features of power tool 10. One example of such publications is
commonly assigned U.S. Pat. No. 5,897,454 issued Apr. 27, 1999, the
disclosure of which is hereby incorporated by reference as if fully
set forth herein.
[0049] Housing 12 includes an end cap assembly 30 and a handle
shell assembly 32 that includes a pair of mating handle shells 34.
Handle shell assembly 32 includes a handle portion 36 and a drive
train or body portion 38. Trigger assembly 24 and battery pack 26
are mechanically coupled to handle portion 36 and electrically
coupled to motor assembly 14. Body portion 38 includes a motor
cavity 40 and a transmission cavity 42. Motor assembly 14 is housed
in motor cavity 40 and includes a rotatable output shaft 44, which
extends into transmission cavity 42. A motor pinion 46 having a
plurality of gear teeth 48 is coupled for rotation with output
shaft 44. Trigger assembly 24 and battery pack 26 cooperate to
selectively provide electric power to motor assembly 14 in a manner
that is generally well known in the art so as to control the speed
and direction with which output shaft 44 rotates.
[0050] Transmission assembly 16 is housed in transmission cavity 42
and includes a speed selector mechanism 60. Motor pinion 46 couples
transmission assembly 16 to output shaft 44, transmitting a
relatively high speed, low torque drive input to transmission
assembly 16. Transmission assembly 16 includes a plurality of
reduction elements that are selectively engaged by speed selector
mechanism 60 to provide a plurality of speed ratios. Each of the
speed ratios multiplies the speed and torque of the drive input in
a predetermined manner, permitting the output speed and torque of
the transmission assembly 16 to be varied in a desired manner
between a relatively low speed, high torque output and a relatively
high speed, low torque output. The transmission output is delivered
the output spindle assembly 20, to which the chuck 22 is coupled
for rotation, to permit torque to be transmitted to a tool bit (not
shown). The clutch mechanism 18 is coupled to transmission assembly
16 and is operable for limiting the magnitude of the torque
associated with the drive input to a predetermined, selectable
torque limit.
Functional Overmold
[0051] With specific reference to FIGS. 2 through 9, end cap
assembly 30 is shown to include an end cap shell 100 and an
overmold member 102. In the example provided, the end cap shell 100
is injection molded from a plastic material, such as ABS. The end
cap shell 100 defines an end cap cavity 104 that is sized to
receive the portion of the motor assembly 14 that extends
rearwardly of the handle shell assembly 32. A plurality of first
and second radial tab apertures 108 and 110 and the abutting face
128 are formed into the forward face 114 of the end cap shell 100
and a plurality of screw bosses 116 are formed into the perimeter
of the end cap shell 100. Each of the first and second radial tab
apertures 108 and 110 is sized to receive one of the first radial
tabs 120 and second radial tabs 122, respectively, that are formed
into the rearward face 124 of the handle shells 34. The first and
second radial tab apertures 108 and 110 cooperate with the first
and second radial tabs 122 to properly align the end cap shell 100
to the handle shell assembly 32, as well as to inhibit relative
rotation therebetween. An arcuate portion 128 of the forward face
114 of the end cap shell 100 is angled to match the abutting face
132 of the rearward face 124 of the handle shells 34. The screw
bosses 116 permit the end cap shell 100 to be fixedly coupled to
the motor cover 136 via a plurality of screws 138. The geometry of
the motor cover 136 is such that it is constrained to the handle
shells 34. As such, fastening of the end cap shell 100 to the motor
cover 136 operates to fixedly retain the end cap shell 100 against
the rearward face 124 of the handle shell assembly 32, as well as
to close off the rear handle aperture 139 in the handle shell
assembly 32.
[0052] A plurality of side apertures 140 are formed into the sides
of the end cap shell 100 to permit air to flow through the handle
shell assembly 32 and cool the motor assembly 14 in a manner that
is well known in the art. A plurality of rear apertures 144 are
formed into the rear of the end cap shell 100, with each of the
rear apertures 144 including a recessed portion 146 that extends
only partially into the outer surface 148 of the end cap shell 100
and a through-portion 150 that extends completely through the end
cap shell 100. A pair of retaining tabs 152 are formed to extend
from the interior surface 154 of the end cap shell 100 inwardly
into the end cap cavity 104. A channel 156 is formed into the
interior surface 154 of the end cap shell 100 and intersects each
of the rear apertures 144 and the retaining tabs 152.
[0053] The overmold member 102 is formed from a resilient material,
such as thermoplastic elastomer (e.g., HYTREL.RTM. manufactured by
E. I. du Pont de Nemours and Company) and is simultaneously formed
and coupled to the end cap shell 100 in an injection molding
operation. In the particular example provided, the overmold member
102 includes a plurality of bumper members 170, a pair of isolators
172 and a linking member 174. Each of the bumper members 170
extends from a point roughly coincident with the interior surface
154 of the end cap shell 100 to a point rearwardly of the outer
surface 148 of the end cap shell 100 by about 0.5 mm to about 1.5
mm and preferably about 0.75 mm. Construction in this manner
permits the bumper members 170 to provide a degree of shock
absorption which reduces the likelihood of damaging the end cap
shell 100 in the event that the tool 10 is dropped. Furthermore, it
is sometimes necessary for an operator to apply a relatively high
force to the tool 10, as when employing a hole saw to drill large
diameter holes. In such situations, the operator is inclined to
press onto the rear of the tool 10 to apply a force that is in-line
with the axis of the chuck 22. In such situations, the bumper
members 170 provide the operator with a relatively soft and
comfortable surface which tends to resist slipping as well as
attenuate the vibrations that are transmitted to the operator.
[0054] The isolators 172 are formed about the retaining tabs 152 on
the interior surface 154 of the end cap shell 100. In the example
provided, each of the isolators 172 includes an annular member 180
that extends forwardly of the interior surface 154 of the end cap
shell 100. Construction in this manner permits the end cap shell
100 to engage the isolators 172 to the outer diameter 14a and the
rear surface 14b of the motor housing 14c to fixedly retain the
motor 14d within the motor cover 136. This prevents the components
of the motor assembly 14 from moving along the longitudinal axis of
the tool 10, as well as dampens vibrations that are created during
the operation of the motor assembly 14. The linking member 174 is
fixedly coupled to each of the bumper members 170 and the isolators
172. The linking member 174 provides a flow path through which the
resilient material flows during the formation of the bumper members
170 and the isolators 172. The linking member 174 also
interconnects the bumper members 170 and the isolators 172, thereby
rendering their removal from the end cap shell 100 more
difficult.
[0055] Those skilled in the art will appreciate that this aspect of
the present invention may be incorporated into various other
positions within the handle assembly 32 for sealing between two or
more components, dampening vibrations or positioning one component
relative to another. One such example is illustrated in FIGS. 10
and 11 where the isolators 172 are modified to extend around the
perimeter of a portion of the end cap cavity 104 and sealingly
contact the rear surface 14b of the motor 14d. The isolators 172
seal the interface between the end cap shell 100 and the motor
assembly 14, while the bumper members 170 seal the rear apertures
144 in the end cap shell 100. The space 188 defined by the
isolators 172 is then filled with grease or another suitable
lubricant, which lubricates a motor armature bearing 190.
Transmission Assembly
[0056] With reference to FIG. 12, the transmission assembly 16 is
shown to be a three-stage, three-speed transmission that includes a
transmission sleeve 200, a reduction gearset assembly 202 and the
speed selector mechanism 60. With additional reference to FIGS. 13
through 17, the transmission sleeve 200 includes a wall member 210
that defines a generally transmission bore or hollow cavity 212
into which the reduction gearset assembly 202 is disposed. The
transmission sleeve 200 includes a body 214 and a base 216. The
body 214 of the transmission sleeve 200 is fairly uniform in
diameter and generally smaller in diameter than the base 216. The
inside diameter of the base 216 is sized to receive the cylindrical
nose portion 220 of the motor cover 136.
[0057] A plurality of raised lands 226 are formed into the base
216. The raised lands 226 define a plurality of first grooves 228
in the outer surface 230 of the base 216 and a plurality of second
grooves 232 in the inner surface 234 of the base 216. The first
grooves 228 are configured to receive the alignment ribs 238 that
are formed into the inner surface 242 of the handle shells 34 to
align the transmission sleeve 200 to the handle shells 34 and
inhibit relative rotation between the transmission sleeve 200 and
the housing 12. Preferably, the first grooves 228 and alignment
ribs 238 are configured in a manner that the transmission sleeve
200 can only be assembled to the handle shells 34 in one
orientation (i.e., the configuration of the first grooves 228 and
alignment ribs 238 prevents the transmission sleeve 200 from being
rotated 180.degree. out of position relative to the handle shells
34). The second grooves 232 will be discussed in greater detail,
below.
[0058] The body 214 of the transmission sleeve 200 is shown to
include a cylindrical body portion 246 and a pin housing portion
248. In the particular embodiment illustrated, the cylindrical body
portion 246 includes a selector cam guide 250, a plurality of
lubricant grooves 252 and first and second sets of ring engagement
teeth 254 and 256, respectively. The selector cam guide 250 is
generally rectangular in cross section, extending outwardly from
the top of the outer surface 258 of the body portion 246. The
lubricant grooves 252 are formed concentrically around the upper
half of the perimeter of the body portion 246. The lubricant
grooves 252 have a depth of about 0.01 inch to about 0.030 inch to
hold a lubricant, such as grease, on the upper half of the
perimeter of the body portion 246. The operation of the selector
cam guide 250 and the lubricant grooves 252 will be discussed in
detail, below.
[0059] A raised bead 264 segregates the interior of the body
portion 246 into first and second housing portions 260 and 262,
respectively. The first set of ring engagement teeth 254 are formed
onto the inner surface 266 of the body portion 246 and extend
rearwardly from the raised bead 264 toward the base 216. The second
set of ring engagement teeth 256 are also formed into the inner
surface of the body portion 246 but extend forwardly from the
raised bead 264. The teeth 268 of the first and second sets of ring
engagement teeth 254 and 256 are uniformly spaced around the inner
surface 266 of the body portion 246. The configuration of each
tooth 268 in the first and second sets of ring engagement teeth 254
and 256 is similar in that each tooth extends from the raised bead
264, has a pair of parallel engagement surfaces 270 and terminates
at a tip portion 272. The tip portion 272 of each tooth 268 is both
rounded and tapered to enhance the ability with which it will mesh
with a portion of the reduction gearset assembly 202 as will be
described in detail, below.
[0060] The pin housing portion 248 extends downwardly from the body
portion 246 over a significant portion of the length of the body
portion 246. An actuator aperture 274 is formed into the pin
housing portion 248 and extends rearwardly through the base 216 of
the transmission sleeve 200. In the particular embodiment
illustrated, the actuator aperture 274 is stepped, having a first
portion 276 with a first diameter at the rear of the transmission
sleeve 200 and a second portion 278 with a smaller second diameter
at the front of the transmission sleeve 200. In the example shown,
the first portion 276 of the actuator aperture 274 breaks through
the wall of the first housing portion 260 and forms a groove 280
into the inner surface 234 of the base 216. The pin housing portion
248 will be discussed in further detail, below.
[0061] A pair of first clip slots 284 and a pair of second clip
slots 286 are formed into the transmission sleeve 200, extending
along the sides of the transmission sleeve 200 in a manner that is
parallel the longitudinal axis of the transmission sleeve 200. The
first pair of clip slots 284 is formed through the sides of the
body portion 246 rearwardly of the raised bead 264 and extends
rearwardly toward the base 216. The depth of the first pair of clip
slots 284 is such that they do not extend through the portion of
the wall member 210 that defines the base 216. The second pair of
clip slots 286 are also formed through the sides of the body
portion 246 beginning forwardly of the raised bead 264 and
extending through the front face 288 of the transmission sleeve
200.
[0062] With reference to FIGS. 12, 13, 18 and 23, the reduction
gearset assembly 202 includes a first reduction gear set 302, a
second reduction gear set 304 and a third reduction gear set 306.
The second and third reduction gear sets 304 and 306 are operable
in an active mode and an inactive mode. Operation in the active
mode causes the reduction gear set to perform a speed reduction and
torque multiplication operation, while operation of the reduction
gear set in an inactive mode for causes the reduction gear set to
provide an output having a speed and torque that is about equal to
the speed and torque of the rotary input provided to that reduction
gear set. In the particular embodiment illustrated, each of the
first, second and third reduction gear sets 302, 304 and 306 are
planetary gear sets. Those skilled in the art will understand,
however, that various other types of reduction gear sets that are
well known in the art may be substituted for one or more of the
reduction gear sets forming the reduction gearset assembly 202.
[0063] As shown, the first reduction gear set 302 includes a first
reduction element or ring gear 310, a first set of planet gears 312
and a first reduction carrier 314. The first ring gear 310 is an
annular structure, having a plurality of gear teeth 310a formed
along its interior diameter. A clutch face 316 is formed into the
outer perimeter of the front face 318 of the first ring gear 310
and will be discussed in greater detail, below. The first ring gear
310 is disposed within the portion of the hollow cavity 212 defined
by the base 216; the front face 318 of the first ring gear 310
contacts a step 320 formed into the transmission sleeve 200,
thereby limiting the ability of the first ring gear 310 to move
forwardly into the hollow cavity 212.
[0064] The first reduction carrier 314 is formed in the shape of a
flat cylinder, having plurality of pins 322 that extend from its
rearward face 324. A plurality of gear teeth 314a are formed into
almost the entire outer perimeter of the first reduction carrier
314, with a valley 314b being formed between each pair of adjacent
gear teeth 314a. Due to the spacing of the gear teeth 314a, one of
the valleys (i.e., valley 314b') is relatively larger than the
remaining valleys 314b due to the omission of a tooth 314a in the
outer perimeter of the first reduction carrier 314. In the
particular embodiment illustrated, the gear teeth 314a of the first
reduction carrier 314 are configured so as not to be meshingly
engagable with the gear teeth 310a of the first ring gear 310.
[0065] With specific reference to FIGS. 19 and 20, the profile of
the gear teeth 314a is illustrated in greater detail. As shown,
each gear tooth 314a terminates at a gradual radius 326 at the
forward face 328 of the first reduction carrier 314 but terminates
abruptly at the rearward face 324 of the first reduction carrier
314. A radius 330 is also formed on the valleys 314b between the
gear teeth 314a.
[0066] Returning to FIGS. 12, 13, 15, 18 and 23, a first thrust
washer 332 having a first annular portion 334, a second annular
portion 336 and a plurality of retaining tabs 338 is positioned
rearwardly of the first reduction gear set 302. The retaining tabs
338 engage the second grooves 232 in the base 216 of the
transmission sleeve 200 and as such, relative rotation between the
first thrust washer 332 and the transmission sleeve 200 is
inhibited. The inside diameter of the base 216 is sized to receive
the motor cover 136 and as such, the front face 340 of the motor
cover 136 inhibits the axial movement of the first thrust washer
332. The first annular portion 334 contacts the rear face 342 of
the first ring gear 310, providing a wear surface and controlling
the amount by which the first ring gear 310 is able to move in an
axial direction. The second annular portion 336 is spaced axially
apart from the first annular portion 334, extending forwardly of
the first annular portion 334 to provide a wear surface for the
first set of planet gears 312 that also controls the amount by
which they can move in an axial direction.
[0067] The first set of planet gears 312 includes a plurality of
planet gears 344, each of which being generally cylindrical in
shape, having a plurality of gear teeth 344a formed into its outer
perimeter and a pin aperture 346 formed its their center. Each
planet gear 344 is rotatably supported on an associated one of the
pins 322 and the first reduction carrier 314 and is positioned such
that its teeth 344a meshingly engage the teeth 314a of the first
ring gear 310. A raised portion 348 is formed into the front and
rear face 350 and 352 of each planet gear 344 that inhibits the
teeth 344a from rubbing on the first reduction carrier 314 and the
first thrust washer 332 and creating dust or chips that would
impair the performance of the transmission assembly 16 and reduce
its operating life. As the teeth 46a of the motor pinion 46 on the
output shaft 44 are also meshingly engaged with the teeth 344a of
the planet gears 344, the motor pinion 46 serves as a sun gear for
the first reduction gear set 302.
[0068] The second reduction gear set 304 is disposed within the
portion of the hollow cavity 212 defined by the first housing
portion 260 and includes a second sun gear 358, a second reduction
element or ring gear 360, a second set of planet gears 362 and a
second reduction carrier 364. The second sun gear 358 is fixed for
rotation with the first reduction carrier 314. The second sun gear
358 includes a plurality of gear teeth 358a that extend forwardly
of the forward face 328 of the first reduction carrier 314.
[0069] The second ring gear 360 is an annular structure, having a
plurality of gear teeth 360a formed along its interior diameter.
The gear teeth 360a may be heavily chamfered at the rear face 366
of the second ring gear 360 but terminate abruptly at the front
face 368. More preferably, a heavy radius 369 is formed onto the
rear face 366 and the sides of each of the gear teeth 360a, with
the heavy radius 369 being employed rather than the heavy chamfer
as the heavy radius 369 on the gear teeth 360a provides for better
engagement between the second ring gear 360 and the first reduction
carrier 314.
[0070] A plurality of sleeve engagement teeth 370 are formed into
the outer perimeter of the second ring gear 360; the sleeve
engagement teeth 370 extend forwardly toward the front face 368 of
the second ring gear 360 and terminate at a tip portion 372 that is
rounded and tapers forwardly and inwardly. An annular clip groove
374 is also formed into the outer perimeter of the second ring gear
360. In the example illustrated, the clip groove 374 is a
rectangular slot having a pair of sidewalls 376. The clip groove
374 will be discussed in greater detail, below.
[0071] The second reduction carrier 364 is formed in the shape of a
flat cylinder, having plurality of pins 378 that extend from its
rearward face 380. The second set of planet gears 362 is shown to
include a plurality of planet gears 382. Each planet gear 382 is
generally cylindrical in shape, having a plurality of gear teeth
382a formed into its outer perimeter and a pin aperture 384 formed
its center. Each planet gear 382 is rotatably supported on an
associated one of the pins 378 and the second reduction carrier 364
is positioned such that the gear teeth 382a of the planet gears 382
meshingly engage the gear teeth 360a of the second ring gear 360.
The gear teeth 358a of the second sun gear 358 are also meshingly
engaged with the gear teeth 382a of the planet gears 382.
[0072] The third reduction gear set 306 is disposed within the
portion of the hollow cavity 212 defined by the second housing
portion 262 and includes a third sun gear 398, a third reduction
element or ring gear 400, a third set of planet gears 402 and a
third reduction carrier 404. The third sun gear 398 is fixed for
rotation with the second reduction carrier 364. The third sun gear
398 includes a plurality of gear teeth 398a that extend forwardly
of the front face 406 of the second reduction carrier 364.
[0073] The third ring gear 400 is an annular structure, having a
plurality of gear teeth 400a formed along its interior diameter.
The gear teeth 400a may be heavily chamfered at the front face 412
of the third ring gear 400, but terminate abruptly at the rear face
414. More preferably, a heavy radius 407 is formed onto the front
face 412 and the sides of each of the gear teeth 400a, with the
heavy radius 407 being employed rather than the heavy chamfer as
the heavy radius 407 on the gear teeth 400a provides for better
engagement between the third ring gear 400 and the third reduction
carrier 404. A plurality of sleeve engagement teeth 418 are formed
into the outer perimeter of the third ring gear 400; the sleeve
engagement teeth 418 extend rearward toward the rear face 414 of
the third ring gear 400 and terminate at a tip portion 420 that is
rounded and tapers rearwardly and inwardly. An annular clip groove
422 is also formed into the outer perimeter of the third ring gear
400. In the example illustrated, the clip groove 422 is a
rectangular slot having a pair of sidewalls 424. The clip groove
422 will be discussed in greater detail, below.
[0074] The third reduction carrier 404 is formed in the shape of a
flat cylinder, having plurality of pins 428 that extend from its
rearward face 430. A plurality of gear teeth 404a are formed into
almost the entire outer perimeter of the third reduction carrier
404, with a valley 404b being formed between each pair of adjacent
teeth 404a. Due to the spacing of the teeth 404a, one of the
valleys 404b (i.e., valley 404b') is relatively larger than the
remaining valleys 404b due to the omission of a tooth 404a in the
outer perimeter of the third reduction carrier 404. In the
particular embodiment illustrated, the gear teeth 404a of the third
reduction carrier 404 are configured so as not to be meshingly
engagable with the gear teeth 382a of the second planet gears
382.
[0075] With brief additional reference to FIGS. 21 and 22, the
profile of the gear teeth 404a is illustrated in greater detail. As
shown, the rear face 430 of the third reduction carrier 404 is
chamfered and a heavy radius 434 is formed into each of sides of
the teeth 404a and valleys 404b. Each gear tooth 404a terminates
abruptly at the forward face 436 of the third reduction carrier
404.
[0076] Returning back to FIGS. 12, 13, 15, 18 and 23, the third set
of planet gears 402 is shown to include a plurality of planet gears
438. Each planet gear 438 is generally cylindrical in shape, having
a plurality of gear teeth 438a formed into its outer perimeter and
a pin aperture 440 formed through its center. Each planet gear 438
is rotatably supported on an associated one of the pins 428 and the
third reduction carrier 404 is positioned such that the gear teeth
438a of the planet gears 438 meshingly engage the gear teeth 400a
of the third ring gear 400. A raised portion 442 is formed into
each of the front and rear faces of the planet gears 438 which
inhibits the gear teeth 438a from rubbing on the third reduction
carrier 404 and creating dust or chips that would impair the
performance of the transmission assembly 12 and reduce its
operating life. A second thrust washer 450 is disposed around the
third sun gear 398 and the teeth 398a of the third sun gear 398 are
meshingly engaged with the gear teeth 438a of the planet gears 438.
The second thrust washer 450 includes a plurality of retaining tabs
452 that are configured to engage corresponding tab grooves 454
(FIG. 13) that are formed in the inner surface 266 of body portion
246 of the transmission sleeve 200. The retaining tabs 452 and the
tab grooves 454 cooperate to inhibit relative rotation between the
second thrust washer 450 and the transmission sleeve 200.
[0077] The output spindle assembly 20 includes a transmitting means
458 for coupling a spindle 460 for rotation with the third
reduction carrier 404 so as to transmit drive torque from the
reduction gearset assembly 202 to the chuck 22. Such transmitting
means 458 are well known in the art and easily adapted to the
transmission assembly of the present invention. Accordingly, a
detailed discussion of the transmitting means 458 need not be
included herein.
[0078] With reference to FIGS. 13, 13a, 13b, 16, 17, 18 and 23
through 28, the speed selector mechanism 60 is movable between a
first position 500, a second position 502 and a third position 504
and includes a switch portion 510 for receiving a speed change
input and an actuator portion 512 for manipulating the reduction
gearset assembly 202 in accordance with the speed change input. The
actuator portion 512 is operatively coupled to the reduction
gearset assembly 202 and moves the second and third reduction gear
sets 304 and 306 between the active and inactive modes in response
to movement of the switch portion 510 between the first, second and
third positions 500, 502 and 504. In the particular embodiment
illustrated, the actuator portion 512 includes a rotary selector
cam 520, a plurality of wire clips 522 and a spring member 523.
Each of the wire clips 522 is formed from a round wire which is
bent in the shape of a semi-circle 524 with a pair of tabs 526
extending outwardly from the semi-circle 524 and positioned on
about the centerline of the semi-circle 524. The semi-circle 524 is
sized to fit within the clip grooves 374 and 422 in the second and
third ring gears 360 and 400, respectively. In this regard, the
semi-circle 524 neither extends radially outwardly of an associated
one of the ring gears (360, 400), nor binds against the sidewalls
(376, 424) of the clip grooves (374, 422). In the example provided,
the sidewalls (376, 424) of the clip grooves (374, 422) are spaced
apart about 0.05 inch and the diameter of the wire forming the wire
clips 522 is about 0.04 inch.
[0079] The tabs 526 of the wire clips 522 extend outwardly of the
hollow cavity 212 into an associated one of the clip slots (284,
286) that is formed into the transmission sleeve 200. The tabs 526
are long enough so that they extend outwardly of the outer surface
258 of the body 214 of the transmission sleeve 200, but not so far
as to extend radially outwardly of the portion of the first clip
slots 284 in the base 216 of the transmission sleeve 200.
Configuration of the wire clips 522 in this manner facilitates the
assembly of the transmission assembly 16, permitting the wire clips
522 to be installed to the second and third ring gears 360 and 400,
after which these assemblies are inserted into the hollow cavity
212 along the longitudinal axis of the transmission sleeve 200.
[0080] With specific reference to FIGS. 13 and 27a through 27c, the
rotary selector cam 520 is illustrated to include an arcuate
selector body 530, a switch tab 532 and a plurality of spacing
members 534. A pair of first cam slots 540a and 540b, a pair of
second cam slots 544a and 544b, a spring aperture 546 and a guide
aperture 548 are formed through the selector body 530. The selector
body 530 is sized to engage the outside diameter of the body
portion 246 of the transmission sleeve 200 in a slip-fit manner.
The guide aperture 548 is generally rectangular in shape and sized
to engage the front and rear surfaces of the selector cam guide
250. The guide aperture 548 is considerably wider than the width of
the selector cam guide 250, being sized in this manner to permit
the rotary selector cam 520 to be rotated on the transmission
sleeve 200 between a first rotational position, a second rotational
position and a third rotational position. The selector cam guide
250 and cooperates with the guide aperture 548 to limit the amount
by which the rotary selector cam 520 can be rotated on the
transmission sleeve 200, with a first lateral side of the selector
cam guide 250 contacting a first lateral side of the guide aperture
548 when the rotary selector cam 520 is positioned in the first
rotational position, and a second lateral side of the selector cam
guide 250 contacting a second lateral side of the guide aperture
548 when the rotary selector cam 520 is positioned in the third
rotational position.
[0081] Each of the first cam slots 540a and 540b is sized to
receive one of the tabs 526 of the wire clip 522 that is engaged to
the second ring gear 360. In the particular embodiment illustrated,
first cam slot 540a includes a first segment 550, a second segment
552 and an intermediate segment 554. The first segment 550 is
located a first predetermined distance away from a reference plane
558 that is perpendicular to the longitudinal axis of the rotary
selector cam 520 and the second segment 552 is located a second
distance away from the reference plane 558. The intermediate
segment 554 couples the first and second segments 550 and 552 to
one another. The configuration of first cam slot 540b is identical
to that of first cam slot 540a, except that it is rotated relative
to the rotary selector cam 520 such that each of the first, second
and intermediate segments 550, 552 and 554 in the first cam slot
540b are located 180.degree. apart from the first, second and
intermediate segments 550, 552 and 554 in the first cam slot
540a.
[0082] Each of the second cam slots 544a and 544b is sized to
receive one of the tabs 526 of a corresponding one of the wire
clips 522. In the particular embodiment illustrated, second cam
slot 544a includes a first segment 560, a second segment 562, a
third segment 564 and a pair of intermediate segments 566 and 568.
The first and third segments 560 and 564 are located a third
predetermined distance away from the reference plane and the second
segment 562 is located a fourth distance away from the reference
plane 558. The intermediate segment 566a couples the first and
second segments 560 and 562 to one another and the intermediate
segment 568 couples the second and third segments 562 and 566
together. The configuration of second cam slot 544b is identical to
that of second cam slot 544a, except that it is rotated relative to
the rotary selector cam 520 such that each of the first, second,
third and intermediate segments 560, 562, 564 and 566 and 568 in
the second cam slot 544b are located 180.degree. apart from the
first, second, third and intermediate segments 560, 562, 564 and
566 and 568 in the second cam slot 544a.
[0083] With the tabs 526 of the wire clips 522 engaged to the first
cam slots 540a and 540b and the second cam slots 544a and 544b, the
rotary selector cam 520 may be rotated on the transmission sleeve
200 between the first, second and third positions 500, 502 and 504
to selectively engage and disengage the second and third ring gears
360 and 400 from the first and third reduction carriers 314 and
404, respectively. During the rotation of the rotary selector cam
520, the first cam slots 540a and 540band the second cam slots 544a
and 544b confine the wire tabs 526 of their associated wire clip
522 and cause the wire tabs 526 to travel along the longitudinal
axis of the transmission sleeve 200 in an associated one of the
first and second clip slots 284 and 286. Accordingly, the rotary
selector cam 520 is operative for converting a rotational input to
an axial output that causes the wire clips 522 to move axially in a
predetermined manner. A lubricant (not specifically shown) is
applied to the lubricant grooves 252 formed into body portion 246
of the transmission sleeve 200 is employed to lubricate the
interface between the transmission sleeve 200 and the rotary
selector cam 520.
[0084] Positioning the rotary selector cam 520 in the first
rotational position 500 causes the tabs 526 of the wire clip 522
that is engaged to the second ring gear 360 to be positioned in the
first segment 550 of the first cam slots 540a and 540b and the tabs
526 of the wire clip 522 that is engaged to the third ring gear 400
to be positioned in the first segment 560 of the second cam slots
544a and 544b. Accordingly, positioning of the rotary selector cam
520 in the first rotational position causes the second and third
ring gears 360 and 400 to be positioned in meshing engagement with
the second and third planet gears 362 and 402, respectively.
Simultaneously with the meshing engagement of the second and third
ring gears 360 and 400 with the second and third planet gears 362
and 402, the sleeve engagement teeth 370 and 418 of the second and
third ring gears 360 and 400, respectively, are positioned in
meshing engagement with the first and second sets of ring
engagement teeth 254 and 256, respectively, to inhibit relative
rotation between the second and third ring gears 360 and 400 and
the transmission sleeve 200 to thereby providing the transmission
assembly 16 with a first overall gear reduction or speed ratio 570
as shown in FIG. 23. Those skilled in the art will understand that
the tip portion 272 of the teeth 268 of the first and second sets
of ring engagement teeth 254 and 256 and the tip portions 372 and
420 of the sleeve engagement teeth 370 and 418, respectively, are
rounded and tapered so as to improve their capability for meshing
engagement in response to axial repositioning along a longitudinal
axis of the transmission assembly 16.
[0085] Positioning the rotary selector cam 520 in the second
rotational position 502 causes the tabs 526 of the wire clip 522
that is engaged to the second ring gear 360 to be positioned in the
first segment 550 of the first cam slots 540a and 540b and the tabs
526 of the wire clip 522 that is engaged to the third ring gear 400
to be positioned in the second segment 562 of the second cam slots
544a and 544b. Accordingly, positioning of the rotary selector cam
520 in second rotational position causes the second ring gear 360
to be in meshing engagement with the second planet gears 362 and
the third ring gear 400 in meshing engagement with both the third
planet gears 402 and the third reduction carrier 404. Positioning
of the rotary selector cam 520 in the second rotational position
502 also positions the sleeve engagement teeth 370 of the second
ring gear 360 in meshing engagement with the first set of ring
engagement teeth 254 while the sleeve engagement teeth 418 of the
third ring gear 400 are not meshingly engaged with the second set
of ring engagement teeth 256. As such, relative rotation between
the second ring gear 360 and the transmission sleeve 200 is
inhibited, while relative rotation between the third ring gear 400
and the transmission sleeve 200 is permitted to thereby provide the
transmission assembly 16 with a second overall gear reduction or
speed ratio 572 as illustrated in FIG. 24.
[0086] Positioning the rotary selector cam 520 in the third
rotational position 504 causes the tabs 526 of the wire clip 522
that is engaged to the second ring gear 360 to be positioned in the
second segment 552 of the first cam slots 540a and 540b and the
tabs 526 of the wire clip 522 that is engaged to the third ring
gear 400 to be positioned in the third segment 564 of the second
cam slots 544a and 544b. Accordingly, positioning of the rotary
selector cam 520 in the third rotational position causes the second
ring gear 360 to be in meshing engagement with both the second
planet gears 362 and the first reduction carrier 314 while the
third ring gear 400 in meshing engagement with only the third
planet gears 402. Positioning the rotary selector cam 520 in the
third rotation position 504 also positions the sleeve engagement
teeth 370 on the second ring gear 360 out of meshing engagement
with the first set of ring engagement teeth 254 and the sleeve
engagement teeth 418 on the third ring gear 400 in meshing
engagement with the second sets of ring engagement teeth 256 to
inhibit relative rotation between the second ring gear 360 and the
transmission sleeve 200 and permit relative rotation between the
third ring gear 400 and the transmission sleeve 200 to provide the
transmission assembly 16 with a third overall gear reduction or
speed ratio 574.
[0087] In the example shown in FIGS. 13, 27b and 28, the spring
member 523 is formed from a flat rectangular piece of spring steel
and includes a flattened Z-shaped portion 580 and a raised portion
584. The flattened Z-shaped portion 580 is configured to wrap
around two reinforcement bars 586 that extend into the spring
aperture 546, thereby permitting the raised portion 584 to be
maintained at a predetermined position and also to transmit a
spring force between the rotary selector cam 520 and the spring
member 523. With additional reference to FIG. 28, the raised
portion 584 of the spring member 523 is sized to engage internal
notches 590 formed in the housing 592 of the output spindle
assembly 20. Lands 594 that are circumferentially spaced from the
rotary selector cam 520 are formed between the notches 590. When
the output spindle assembly 20 is positioned over the transmission
assembly 16 and the speed selector mechanism 60 is positioned in
one of the first, second and third rotational positions 500, 502
and 504, the raised portion 584 of the spring member 523 engages an
associated one of the notches 590. The force that is generated by
the spring member 523 when the raised portion 584 is moved
downwardly toward the rotary selector cam 520 in response to
contact between the raised portion 584 and the land 594 acts to
inhibit unintended rotation of the speed selector mechanism 60.
Furthermore, placement of the raised portion 584 in a notch 590
provides the user with a tactile indication of the positioning of
the rotary selector cam 520.
[0088] In the particular embodiment illustrated in FIGS. 13 and
27c, switch portion 510 is shown to include an arcuate band 600
having a raised hollow and rectangular selector button 602 formed
therein. The arcuate band 600 is formed from a plastic material and
is configured to conform to the outer diameter of the rotary
selector cam 520. The open end of the selector button 602 is
configured to receive the switch tab 532, thereby permitting the
switch portion 510 and the rotary selector cam 520 to be coupled to
one another in a fastenerless manner. The plurality of spacing
members 534 are raised portions formed into the rotary selector cam
520 that are concentric to and extend radially outwardly from the
selector body 530. The spacing members 534 elevate the arcuate band
600 to prevent the arcuate band from contacting the wire tabs 526
in the first cam slots 540a and 540b. The spacing members 534 may
also be employed to selectively strengthen areas of the rotary
selector cam 520, such as in the areas adjacent the first cam slots
540a and 540b.
[0089] Those skilled in the art will understand that the rotary
selector cam 520 (i.e., the first cam slots 540a and 540b and the
second cam slots 544a and 544b) could be configured somewhat
differently so as to cause the second ring gear 360 meshingly
engages both the second planet gears 362 and the first reduction
carrier 314 while the third ring gear 400 meshingly engages both
the third planet gears 402 and the third reduction carrier 404 to
thereby providing the transmission assembly 16 with a fourth
overall gear reduction or speed ratio.
[0090] Those skilled in the art will also understand that selector
mechanisms of other configurations may be substituted for the
selector mechanism 60 illustrated herein. These selector mechanisms
may include actuators that are actuated via rotary or sliding
motion and may include linkages, cams or other devices that are
well known in the art to slide the second and third ring gears 360
and 400 relative to the transmission sleeve 200. Those skilled in
the art will also understand that as the second and third ring
gears 360 and 400 are independently movable between the active and
inactive modes (i.e., the placement of one of the second and third
ring gears 360 and 400 does not dictate the positioning of the
other one of the second and third ring gears 360 and 400), the
switch mechanism 60 could also be configured to position the second
and third ring gears 360 and 400 independently of one another.
Clutch Mechanism
[0091] In FIGS. 23, 26 and 28 through 30, the clutch mechanism 18
is shown to include a clutch member 700, an engagement assembly 702
and an adjustment mechanism 704. The clutch member 700 is shown to
be an annular structure that is fixed to the outer diameter of the
first ring gear 310 and which extends radially outwardly therefrom.
The clutch member 700 includes an arcuate clutch face 316 that is
formed into the front face 318 of the first ring gear 310. The
outer diameter of the clutch member 700 is sized to rotate within
the portion of the hollow cavity 212 that is defined by the base
216 of the transmission sleeve 200. With specific brief reference
to FIG. 29, the clutch face 316 of the example illustrated is shown
to be defined by a plurality of peaks 710 and valleys 712 that are
arranged relative to one another to form a series of ramps that are
defined by an angle of about 18.degree.. Those skilled in the art
will understand, however, that other clutch face configurations may
also be employed, such as a sinusoidally shaped clutch face 316'
(FIG. 29a).
[0092] While the first ring gear 310 and the clutch member 700 have
been illustrated as a one piece (i.e., unitarily formed)
construction, those skilled in the art will understand that they
may be constructed otherwise. One such embodiment is illustrated in
FIG. 29b wherein the first ring gear 310' is shown to include an
annular collar 1000 and a plurality of tab apertures 1002. The
annular collar 1000 is illustrated to include a plurality of ramps
1004 that have dual sloping sides, but is otherwise flat. The first
ring gear 310' is otherwise identical to the first ring gear 310.
An annular damper 1008 abuts the annular collar 1000 and includes a
plurality of tab members 1010 that engage the tab apertures 1002 in
the first ring gear 310' to prevent the damper 1008 from rotating
relative to the first ring gear 310'. The damper 1008 includes a
body portion 1012 that is configured to match the contour of the
annular collar 1000 and as such, includes a plurality of mating
ramped portions 1014 that are configured to engage each of the
ramps 1004. The damper 1008 is formed from a suitable impact
dampening material, such as acetyl. The clutch member 700', which
is an annular member that is formed from a wear resistant material,
such as hardened 8620 steel, is disposed over the damper 1008. Like
the damper 1008, the clutch member 700' includes a plurality of tab
members 1020, which lock into the tab apertures 1002 to prevent
rotation relative to the first ring gear 310', and a plurality of
mating ramped portions 1022. The mating ramped portions 1022 of the
clutch member 700', however, matingly engage the mating ramped
portions 1014 of the damper 1008. While the construction in this
manner is more expensive relative to the previously described
embodiment, it is more tolerant of high impact forces that are
associated with the operation of the clutch mechanism 18.
[0093] In the particular embodiment illustrated, the engagement
assembly 702 includes a pin member 720, a follower spring 722 and a
follower 724. The pin member 720 includes a cylindrical body
portion 730 having an outer diameter that is sized to slip-fit
within the second portion 278 of the actuator aperture 274 that is
formed into the pin housing portion 248 of the transmission sleeve
200. The pin member 720 also includes a tip portion 732 and a head
portion 734. The tip portion 732 is configured to engage the
adjustment mechanism 704 and in the example shown, is formed into
the end of the body portion 730 of the pin member 720 and defined
by a spherical radius. The head portion 734 is coupled to the end
of the body portion 730 opposite the tip portion 732 and is shaped
in the form of a flat cylinder or barrel that is sized to slip fit
within the first portion 276 of the actuator aperture 274.
Accordingly, the head portion 734 prevents the pin member 720 from
being urged forwardly out of the actuator aperture 274.
[0094] The follower spring 722 is a compression spring whose
outside diameter is sized to slip fit within the first portion 276
of the actuator aperture 274. The forward end of the follower
spring 722 contacts the head portion 734 of the pin member 720,
while the opposite end of the follower spring 722 contacts the
follower 724. The end portion 740 of the follower 724 is
cylindrical in shape and sized to slip fit within the inside
diameter of the follower spring 722. In this regard, the end
portion 740 of the follower acts as a spring follower to prevent
the follower spring 722 from bending over when it is compressed.
The follower 724 also includes a follower portion 744 having a
cylindrically shaped body portion 746, a tip portion 748 and a
flange portion 750. The body portion 746 is sized to slip fit
within the first portion 276 of the actuator aperture 274. The tip
portion 748 is configured to engage the clutch face 316 and in the
example shown, is formed into the end of the body portion 746 of
the follower 724 and defined by a spherical radius. The flange
portion 750 is formed at the intersection between the body portion
746 and the end portion 740. The flange portion 750 is generally
flat and configured to receive a biasing force that is exerted by
the follower spring 722.
[0095] The adjustment mechanism 704 is also shown to include an
adjustment structure 760 and a setting collar 762. The adjustment
structure 760 is shaped in the form of a generally hollow cylinder
that is sized to fit a housing portion 766 of the output spindle
assembly 20. The adjustment structure 760 includes an annular face
768 into which an adjustment profile 770 is formed. The adjustment
profile 770 includes a first adjustment segment 772, a last
adjustment segment 774, a plurality of intermediate adjustment
segments 776 and a ramp section 778 between the first and last
adjustment segments 772 and 774. In the embodiment illustrated, a
second ramp section 779 is included between the last intermediate
adjustment segment 776z and the last adjustment segment 774. Also
in the particular embodiment illustrated, the portion of the
adjustment profile 770 from the first adjustment segment 772
through the last one of the intermediate adjustment segments 776z
is formed as a ramp having a constant slope. Accordingly, a
follower 780 that is coupled to the housing portion 766 of the
output spindle assembly 20 is biased radially outwardly toward the
inside diameter of the adjustment structure 760 where it acts
against the plurality of detents 782 that are formed into the
adjustment mechanism 704 (e.g., in the setting collar 762). The
follower 724 and plurality of detents 782 cooperate to provide the
user of tool 10 with a tactile indication of the position of the
adjustment profile 770 as well as inhibit the free rotation of the
adjustment structure 760 so as to maintain the position of the
adjustment profile 770 at a desired one of the adjustment segments
772, 774 and 776.
[0096] The setting collar 762 is coupled to the exterior of the
adjustment structure 760 and includes a plurality of raised
gripping surfaces 790 that permit the user of the tool 10 to
comfortably rotate both the setting collar 762 and the adjustment
structure 760 to set the adjustment profile 770 at a desired one of
the adjustment segments 772, 774 and 776. A setting indicator 792
is employed to indicate the position of the adjustment profile 770
relative to the housing portion 766 of the output spindle assembly
20. In the example provided, the setting indicator 792 includes an
arrow 794 formed into the housing portion 766 of the output spindle
assembly 20 and a scale 796 that is marked into the circumference
of the setting collar 762.
[0097] During the operation of the tool 10, an initial drive torque
is transmitted by the motor pinion 46 from the motor assembly 14 to
the first set of planet gears 312 causing the first set of planet
gears 312 to rotate. In response to the rotation of the first set
of planet gears 312, a first intermediate torque is applied against
the first ring gear 310. Resisting this torque is a clutch torque
that is applied through the clutch mechanism 18. The clutch torque
inhibits the free rotation of the first ring gear 310, causing the
first intermediate torque to be applied to the first reduction
carrier 314 and the remainder of the reduction gearset assembly 202
so as to multiply the first intermediate torque in a predetermined
manner according to the setting of the switch mechanism 60. In this
regard, the clutch mechanism 18 biases the first reduction gearset
302 into a mode that permits torque multiplication and speed
reduction.
[0098] The magnitude of the clutch torque is dictated by the
adjustment mechanism 704, and more specifically, the relative
height of the adjustment segment 772, 774 or 776 that is in contact
with the tip portion 732 of the pin member 720. Positioning of the
adjustment mechanism 704 at a predetermined one of the adjustment
segments 772, 774 or 776 pushes the pin member 720 rearwardly in
the actuator aperture 274, thereby compressing the follower spring
722 and producing the a clutch force. The clutch force is
transmitted to the flange portion 750 of the follower 724, causing
the tip portion 748 of the follower 724 to engage the clutch face
316 and generating the clutch torque. Positioning of the tip
portion 748 of the follower 724 in one of the valleys 712 in the
clutch face 316 operates to inhibit rotation of the first ring gear
310 relative to the transmission sleeve 200 when the magnitude of
the clutch torque exceeds the first intermediate torque. When the
first intermediate torque exceeds the clutch torque, however, the
first ring gear 310 is permitted to rotate relative to the
transmission sleeve 200. Depending upon the configuration of the
clutch face 316, rotation of the first ring gear 310 may cause the
clutch force to increase a sufficient amount to resist further
rotation. In such situations, the first ring gear 310 will rotate
in an opposite direction when the magnitude of the first
intermediate torque diminishes, permitting the tip portion 748 of
the follower 724 to align in one of the valleys 712 in the clutch
face 316. If rotation of the first ring gear 310 does not cause the
clutch force to increase sufficiently so as to fully resist
rotation of the first ring gear 310, the first reduction gearset
302 will rotate so as to limit the transmission of torque to the
first reduction carrier 314.
[0099] Configuration of the clutch mechanism 18 in this manner is
highly advantageous in that the clutch torque is sized to resist
the first intermediate torque, as opposed to the output torque of
the tool 10 that is generated by the multi-reduction transmission
assembly 16 and transmitted through the chuck 22. In this regard,
the clutch mechanism 18 may be sized in a relatively small manner,
thereby improving the ability with which it can be incorporated or
packaged into the tool 10. Furthermore, as the speed or gear ratios
are changed after or down stream of the first ring gear 310, the
clutch mechanism 18 is operable over a relatively large span of
output torques. In comparison with conventional clutch mechanisms
that operate to limit the output torque of a transmission, these
devices are typically operable over a relatively narrow torque
band, necessitating a change in their clutch spring if a
considerable shift in the magnitude of the output torque is
desired. In contrast, the clutch mechanism 18 of the present
invention can accommodate a considerable shift in the magnitude of
the output torque of the tool 10 by simply operating the
transmission assembly 16 in a different (i.e., lower or higher)
gear ratio.
[0100] In the operation of rotary power tools such as tool 10, it
is frequently desirable to change between two clutch settings, as
when the tool 10 is used to both drill a hole and thereafter
install a screw in that hole. Accordingly, the adjustment mechanism
704 may be rotated relative to the output spindle assembly 20 to
position the adjustment mechanism 704 at a desired one of the
adjustment segments 772, 774 and 776 to perform the first operation
and thereafter rotated to a second one of the adjustment segments
772, 774 and 776 to perform the second operation. In contrast to
the known clutch arrangements, the adjustment mechanism 704 of the
present invention is configured such that the adjustment structure
760 and the setting collar 762 are rotatable through an angle of
360.degree.. Assuming the adjustment structure 760 to be positioned
at an intermediate adjustment segment 776x, rotation of the
adjustment mechanism 704 through an angle of 360.degree. would
rotate the adjustment structure 760 past the other intermediate
adjustment segments 776, as well as the first and last adjustment
segments 772 and 774 and the ramp section 778 such that the
adjustment structure 760 would again be positioned at the
intermediate adjustment segment 776x. The feature is especially
convenient when it is necessary to change the clutch setting
between a relatively high clutch setting and a relatively low
clutch setting. In this regard, the ramp section 778 permits the
setting collar 762 (and adjustment structure 760) to be rotated
from highest clutch setting, corresponding to the last adjustment
segment, to the lowest clutch setting, corresponding to the first
clutch setting, without positioning the clutch mechanism 18 in one
of the intermediate clutch settings. Accordingly, the user of the
tool 10 is able to vary the clutch setting from its maximum setting
to its minimum setting (and vice versa) by rotating the setting
collar 762 a relatively small amount.
[0101] While the adjustment profile 770 has been described thus far
as having a constant slope, those skilled in the art will
appreciate that the invention, in its broader aspects, may be
constructed somewhat differently. For example, the adjustment
profile 770' may be formed such that each of the first, last and
intermediate adjustment segments 772', 774' and 776' is detented as
illustrated in FIG. 31. In this arrangement, the detents 782 in the
adjustment structure 760 and the follower 780 in the housing
portion 766 of the output spindle assembly 20 are unnecessary as
the adjustment segments 772', 774' and 776' will cooperate with the
engagement 702 to provide the user of the tool 10 with a tactile
indication of the position of the adjustment profile 770', as well
as inhibit the free rotation of the adjustment structure 760.
[0102] Another example is illustrated in FIG. 32 wherein the
adjustment profile 770" is generally similar to the adjustment
profile 770 except that the ramp section 779 has been omitted so
that the last intermediate adjustment segment 776z is immediately
adjacent the last adjustment segment 774.
[0103] While the invention has been described in the specification
and illustrated in the drawings with reference to a preferred
embodiment, it will be understood by those skilled in the art that
various changes may be made and equivalents may be substituted for
elements thereof without departing from the scope of the invention
as defined in the claims. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the invention without departing from the essential scope
thereof. Therefore, it is intended that the invention not be
limited to the particular embodiment illustrated by the drawings
and described in the specification as the best mode presently
contemplated for carrying out this invention, but that the
invention will include any embodiments falling within the
description of the appended claims.
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