The present invention relates to caulk guns and, more particularly, to a power operated caulk gun which also is operable in manual mode.
Motorized caulk guns which include a piston rod acting on the internal piston of a caulk cartridge are known. An example of such a gun is shown in U.S. Pat. No. 4,264,021, in which a piston rod extends through and is driven by a drive plate. The drive plate is further driven by a cam mounted on a gear, with the gear driven by the motor. Though this system provides for power operation, it suffers from the drawback that the rate of advance of the piston is inconsistent since the drive plate is necessarily out of contact with the cam surface at some time during each rotation of the gear on which the cam is mounted. In addition, the trigger mechanism functions only to control the motor, and does not otherwise control movement of the piston rod. As a result, no manual operation of the caulk gun is possible.
The present invention in one embodiment is directed to a fluid discharger having a housing. A plunger including a rod is disposed adjacent to a mass of fluid receivable in the housing. The plunger is movable in a first direction to act upon and discharge the fluid from the housing. A first plate and a second plate each have an opening, and the plunger rod is disposed through the openings. The first and second plates have a first position relative to the plunger rod. The first plate has an associated first cam follower and the second plate has an associated second cam follower. The discharger includes a first translationally movable and rotatable cam and a second translationally movable and rotatable cam. Translational movement of the first and second cams causes translational movement of the first and second plates, respectively, to move the first and second plates into a second position relative to said plunger rod. When the first and second plates are in the second position, rotation of the first cam and the second cam causes the first and second plates to push the plunger in the first direction to discharge fluid, with the pushing provided to the plunger by the first plate alternating with the pushing provided on said plunger by the second plate.
The present invention provides the art with a powered caulk gun which regulates flow to provide an even bead. In addition, the caulk gun is controlled to prevent oozing after the trigger is released. In one embodiment, the oozing is prevented upon trigger release, even if the motor remains on. The invention also provides a manual as well as powered operation mode.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
a is an enlarged exaggerated view of the drive mechanism of
b is an enlarged exaggerated view of the drive mechanism as shown in
a is a top plan view of the switching device;
a is a partially exploded perspective view of a second embodiment of the present invention;
b is a cross-section view of the second embodiment of the present invention;
a is a graph showing the varying thickness of a cam shown in
b is a perspective showing the varying thickness of the cams.
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Turning to the figures, a motorized caulk gun is illustrated and designated with the reference numeral 10. Caulk gun 10 includes housing 12 which receives conventional caulk cartridge or tube 14 having nozzle 15. Tube 14 includes internal piston 40 disposed behind a mass of caulk such that when piston 40 moves within tube 14, caulk is expelled from nozzle 15. Housing 12 contains plunger mechanism 16 which drives internal piston 40, and motor drive 18 including motor 62 which activates plunger mechanism 16. Motor drive 18 and plunger mechanism 16 are actuated by trigger mechanism 20.
Housing 12 is of a clam shell design including halves 22 and 24. Housing 12 includes front section 26 which receives caulk tube 14 and midsection 25 which includes handle portion 28. Midsection 25 contains plunger mechanism 16. Housing 12 includes rear section 30 which houses motor drive 18. Conventional on/off switch 32 is mounted on rear portion 30 and serves as a master control switch for the gun such that when switch 32 is in the on position, the motor may be switched on by actuation of trigger 78 as explained further below, and when switch 32 is in the off position, the motor cannot be operated. Batteries 34 are housed adjacent the motor drive 18 to provide power to motor 62.
Plunger mechanism 16 includes plunger rod 36 having piston 38 mounted at one end so as to be disposed adjacent internal piston 40 of caulking tube 14. Plunger rod 36 extends through openings 50 in a pair of pinch plates 42 and 44. Springs 52 and 54 are disposed about plunger rod 36 and between an internal element of the housing and the pinch plates and bias the pinch plates in one axial direction. For example, the springs bias plate 42 and 44 towards the rear of the housing, or towards the left as shown in
Motor drive 18 includes motor 62 with output shaft 64 coupled with shaft 66 of the trigger mechanism in a splined fit so as to allow axial (or lateral) movement of shaft 66. In a preferred embodiment, shaft 66 is movable axially 4-8 mm. Shaft 66 is supported by bearings in the housing and has cams 68 and 70 fixedly disposed thereon such that the cams rotate and move translationally with the shaft. In particular, cams 68,70 move axially when shaft 66 is moved axially. Cams 68 and 70 increase in thickness in the circumferential direction to provide ramped cam surfaces 72 and 74. With reference to
Trigger 78 is mechanically linked to shaft 66 via lever 80 in a conventional manner such that when the trigger is pressed, shaft 66 is moved laterally forwardly in the housing. Lever 80 pivots about pivot pin 82. Adjustment mechanism 76 which may be a screw is disposed in the housing adjacent the distal end of shaft 66. The screw acts as a stopper for lateral movement of shaft 66 such that by adjustment of the screw position, the maximum distance of axial travel allowed for shaft 66 may be set. Lever 80 also actuates switch 84 which, when master on/off switch 32 is in the on position, activates the motor and causes rotation of shaft 66.
The caulk gun functions as follows: In the initial position, before trigger 78 is squeezed, both cams 68 and 70 are in their rearward-most position, as shown in
As shown in
Substantially simultaneously, switch 84 will be switched on, and shaft 66 and thus cams 68 and 70 rotate. Since as noted, cams 68 and 70 are 180° out of phase, roller 56 of one pinch plate will ride along up ramp 73 of its cam to thus increase its tilt, while roller 56 of the other pinch plate will ride along down ramp 75 (which may also include a flat portion) to thus decrease its tilt under the spring bias. At any time during the rotation, the pinch plate 42 or 44 which is undergoing increasing tilting acts to push plunger rod 36 laterally to the right, such that piston 38 acts upon caulk tube piston 40 to squeeze the caulk from nozzle 15. The other pinch plate is moving in the opposite direction relative to the plunger rod axis and is either releasing its pinch or may be out of contact altogether with the rod. In either case, the other pinch plate has no effect upon the rod during the time when it is moving along the down ramp.
For example, during the one half rotation of shaft 66 from the position shown in
Since the cams are 180° out of phase, plunger rod 36 is always being pushed by one pinch plate. When the cam follower of that active plate reaches the maximum camming surface of its cam, the cam follower of the inactive plate reaches the minimum camming surface of its cam. As soon as the active plate cam follower moves past the maximum point and begins to ride along the down ramp and that plate becomes inactive, the follower of the previously inactive cam plate begins to ride along the up ramp of its cam to thereby make its associated plate the active plate. In this manner, plates 42 and 44 alternately serve to provide for axial movement of plunger rod 36, and do so in a smooth and continuous manner, with no gap periods during which the rod is not moved. Thus, a continuous stream of caulk is squeezed from nozzle 15.
Although in the disclosed embodiment each cam has a single up ramp and a single down ramp, each cam could have multiple up ramps and down ramps, so long as the up ramps of one cam are disposed on the shaft out of phase with the up ramps of the other cam. For example, if each cam included two up ramps and two down ramps, then during each rotation of the shaft each cam would provide two periods of pushing action on the plunger rod and would have two periods of providing no pushing action. Similarly, although in the disclosed embodiment only two pinch plates and cams are shown, any number could be used, with a corresponding adjustment between the ratio of the arc defined by the up ramp to the arc defined by the down ramp for each cam. For example, if three cams and pinch plates were used, each cam would have an up ramp defining 120° of its surface, and the remaining 240° would define a down ramp. The cams would be disposed on the shaft such that the up ramps were spaced about the shaft axis in a non-overlapping manner. Once again, at any given time during rotation, the cam follower of only one of the plates would be riding on an up ramp and thus would be experiencing positive camming, and only that pinch plate would exert a translational force on plunger rod 36.
When pressure is released from trigger 78, the motor is de-energized stopping rotation of shaft 66. As this happens, shaft 66 and cams 68 and 70 are moved rearwardly, and pinch plates 42, 44 are moved under the spring bias to a neutral position substantially perpendicular to plunger rod 36, allowing rod 36 to move freely through center openings 50. The pressure created in the caulk tube due to the compression of the caulk, along with the reversing action of the pinch plates on plunger rod 36 as the plates are biased back to the substantially vertical position as the upper ends contact ribs 26 (
In the embodiments described above, with switch 32 in the off position, when trigger 78 is squeezed shaft 66 is moved forwardly through the mechanical link provided by lever 80. Plunger rod 36 also is moved forwardly, even without the camming action provided by rotation of cams 68,70 due simply to the contact of the cams on the followers of pinch plates 42, 44 in the axial direction. However, when trigger 78 is released, pinch plates 42, 44 are restored to their initial position by the bias springs and the fact that the upper ends of the plates contact ribs 26, which causes plunger rod 36 to move back towards its initial position since when the cams are not rotated, neither cam provides a forwardly acting force on plunger rod 36. As result, forward movement of plunger rod 36 is mostly nullified, and trigger 78 could not be used effectively to manually squeeze the caulk from caulk tube 14.
In order to provide for manual dispensing of the caulk by action of trigger 78, plunger rod 36 must be maintained in position each time the trigger is released. Structure 100 for providing this function is shown in
The position of pinch plate 102 is controlled by slider switch 105 disposed in the housing. When slider switch 105 is in the rearward position, pinch plate 102 is moved to the inclined position securing plunger rod 36 against rearward movement and allowing manual mode of operation. When slider switch 105 is moved forwardly, pinch plate 102 is pushed forwardly to compress spring 104. Plate 102 assumes a neutral or perpendicular position which enables plunger rod 36 to move freely through aperture 106 and the caulk gun is set for motorized operation.
In a preferred embodiment, slider switch 105 simultaneously controls operation of the caulk gun master on/off switch 32 as well, such that when slider switch 105 is in the rearward or off position, switch 32 is in the off position precluding motor 62 from operating at any time that pinch plate 102 is in contact with plunger rod 36. That is, the motor cannot be inadvertently activated at any time when the caulk gun is in manual mode. Such inadvertent activation would preclude operation of the anti-oozing feature described above since if switch plate 102 is engaged with plunger rod 36 during motorized driving of rod 36, rod 36 would not be able to move backwardly under the urging of the springs acting on plates 42, 44 once the trigger is released. By ensuring that motorized operation is possible only when rod 36 is free to move backwardly upon release of the trigger, the anti-oozing feature is always engaged when the gun is used in motorized mode.
As described above, adjustment screw 76 acts as an abutment to the end of shaft 66 to thereby provide a maximum for the lateral movement of shaft 66. During rotation of cams 68,70, as each follower rides along a cam to push the plunger rod 36 against the caulk tube piston, there is a reaction force which may cause the user to feel a pulsing action. As a result, it may be difficult to maintain trigger 78 at a steady position to provide constant flow rate. The provision of screw 76 as a stop helps the user hold trigger 78 at a steady position to provide constant flow.
Although in the above embodiments caulk gun 10 has been described as including master on/off switch 32, such a switch could be eliminated altogether, in which case the operation of motor 62 would be controlled only by trigger 78 through switch 84. Whenever trigger 78 was pulled past a predetermined position, motor 62 would actuate. Further pulling of trigger 78 would cause plates 42 and 44 to move to their shaft gripping position and caulk would be dispensed. As a further alternative, switch 84 could be eliminated and only master on/off switch 32 would be provided. In this case, switch 32 would be switched on to activate motor 62, which would continually rotate shaft 66 and cams 68 and 70. Trigger 78 would be squeezed to dispense caulk and released to cause dispensing to cease, with the anti-oozing action as described above. Trigger 78 would not control operation of motor 62.
Turning to
Cam rollers 156 and 160 roll upon cam surfaces 162 and 172 of radial lifting cams 168 and 170. As described above, the cam surfaces are disposed so as to be 180° out of phase with each such that one roller is being cammed forwardly while the other cam rides along a region of decreasing slope. As a result, pinch plates 142 and 144 act in an alternative manner to drive plunger rod 36 forwardly.
Cams 162 and 164 are mounted on common shaft 180 which is driven by motor 62. Motor 62 includes linkage 182, such as worm gear or a spur gear arrangement, to drive gear 184 fixed to shaft 186 which, in turn, drives shaft 180 though further intermediate gears. Squeezing of the trigger causes shaft 180 to move in a direction perpendicular to its axis to provide translational movement of cams 162, 164 in a direction perpendicular to their rotational axes.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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Number | Date | Country |
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2 400 717 | Sep 2001 | CA |
35 35 229 | Apr 1987 | DE |
36 02 975 | Aug 1987 | DE |
Number | Date | Country | |
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20070102457 A1 | May 2007 | US |