Housing and gearbox for drill or driver

Abstract

A power tool including a motor, an output member and a transmission disposed between the motor and the output member. The transmission includes a ring gear with opposite axial end faces. The power tool also includes a clutch for limiting an output of the transmission. The clutch includes an annular clutch face disposed about the ring gear. At least a portion of a side of the ring gear is configured such that an included angle between the annular clutch face and the at least a portion of the side of the ring gear is about ninety five degrees to about one hundred fifty degrees.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present teachings.

FIG. 1 is a side view of a power tool constructed in accordance with the present teachings.

FIG. 2 is an exploded perspective view of a portion of the power tool of FIG. 1.

FIG. 3 is an exploded perspective view of a portion of the power tool of FIG. 1 showing a transmission assembly and a hammer drill assembly in accordance with the present teachings.

FIG. 4 is similar to FIG. 3 and shows the transmission assembly in further detail.

FIG. 5 is a side view of a transmission sleeve in accordance with the present teachings.

FIG. 6 is a front view of the transmission sleeve of FIG. 5.

FIG. 7 is a cross-sectional view taken from FIG. 6.

FIG. 8A is a perspective view of the transmission sleeve of FIG. 5 and a cap that may be assembled to a front of the transmission sleeve in accordance with the present teachings.

FIG. 8B is similar to FIG. 8A and shows the cap assembled to the transmission sleeve in accordance with the present teachings.

FIG. 8C shows a detailed assembly view of the cap and the transmission sleeve of FIG. 8B.

FIG. 8D is a side view of the annular flanges of the cap of the transmission sleeve configured to not interfere with motion of a rotary selector cam.

FIG. 9A is a perspective view of the transmission sleeve of FIG. 5 and a thrust washer that is assembled to a rear of the transmission sleeve in accordance with the present teachings.

FIG. 9B is similar to FIG. 9A and shows the thrust washer secured to the transmission sleeve in accordance with the present teachings.

FIG. 10 a is a top view of a speed selector mechanism and an adjuster mechanism assembled to a housing and showing positions that correspond to different speed ratios of the power tool in accordance with the present teachings.

FIG. 11 is a perspective view of the rotary selector cam in accordance with the present teachings.

FIG. 12 is a sectional view taken along the longitudinal axis of the transmission of FIG. 2 showing the transmission assembly positioned to provide a first speed ratio in accordance with the present teachings.

FIG. 13 is a sectional view similar to FIG. 12 and shows the transmission assembly positioned to provide a second speed ratio.

FIG. 14 is a sectional view similar to FIG. 12 and shows the transmission assembly positioned to provide a third speed ratio.

FIG. 15 is an exploded assembly view of an adjustable clutch mechanism in accordance with the present teachings.

FIG. 16 is a perspective view an exemplary alternative tip portion of a clutch pin from the clutch assembly of FIG. 15 showing a ball catch in accordance with the present teachings.

FIG. 16A is a side view of the tip portion of FIG. 16.

FIG. 16B is front view of the tip portion of FIG. 16.

FIG. 16C is a cross-section view taken through FIG. 16A.

FIGS. 17, 17A, 17B and 17C are similar to FIGS. 16, 16A, 16B and 16C, respectively, and show an exemplary alternative tip portion having a two-piece construction in accordance with the present teachings.

FIG. 18A is a perspective view of a ring gear having a clutch face formed thereon showing a wall forming an obtuse angle with the clutch face in accordance with the present teachings.

FIG. 18B is a cross-section view taken through FIG. 18.

FIG. 18C is similar to FIG. 18B and shows the ring gear in further detail.

FIG. 19 is a perspective view of the housing of the power tool above a trigger assembly showing a connection face that receives a connection face on a spindle housing in accordance with the present teachings.

FIG. 20 is a perspective view of the spindle housing of the power tool showing the connection face that may be received by the connection face on the housing of FIG. 19 in accordance with the present teachings.

FIG. 21 is an exploded assembly view of the housing of FIG. 19 and the spindle housing of FIG. 20 showing a boss and a tongue on the spindle housing of FIG. 20 being received by a base and a groove, respectively, formed on the housing of FIG. 19 in accordance with the present teachings.

FIG. 22A is a perspective view of a planet carrier, an anvil and a portion of a spindle lock assembly in accordance with the present teachings.

FIG. 22B is an exploded assembly view of the planet carrier, the anvil and the portion of the spindle lock assembly of FIG. 22A and shows an anvil-specific gasket between the anvil and the planet carrier.

FIG. 23A is a perspective view of a planet carrier, anvil and portion of a spindle lock assembly in accordance with a further aspect of the present teachings.

FIG. 23B is an exploded assembly view of the planet carrier, the anvil and the portion of the spindle lock assembly of FIG. 23A and shows a circular gasket between the anvil and the planet carrier.

FIG. 23C is a perspective view of the anvil of FIGS. 23A and 23B showing the circular gasket.

FIG. 23D is a front view of the anvil of FIG. 23C showing an aperture in which an output spindle may be received in accordance with the present teachings.

Claims

1. A power tool comprising: a handle housing defining a handle, an interior cavity, and a trigger mount, said trigger mount being adapted to receive a trigger therein and including longitudinally extending, laterally spaced-apart grooves;a transmission housing received in said interior cavity, said transmission housing having a first end, a second end, a bore that extends between said first and second ends, and a plurality of teeth formed circumferentially about said bore, said first end having a pair of circumferentially extending slots, said second end having at least one circumferentially extending rib member;a transmission at least partially received in said bore of said transmission housing, said transmission having a thrust washer, a plurality of reduction gear sets and at least one member that is axially movable in said transmission housing to affect a change in an overall gear ratio of said transmission, said at least one member being movable in a first condition, wherein said at least one member is disengaged from said teeth, and a second condition, wherein said at least one member is engaged to said teeth, said thrust washer having a plurality of fingers and being received in said first end of said transmission housing, each of said fingers being received in an associated one of said slots to thereby engage said thrust washer to said transmission housing;an output spindle assembly having a spindle housing and an output spindle rotatably mounted in said spindle housing, said spindle housing including a pair of longitudinally-extending, laterally spaced-apart grooves, said spindle housing being coupled to said handle housing such that each of said longitudinally-extending, laterally spaced-apart tongue members receive an associated one of said longitudinally extending, laterally spaced-apart tongue members;a one-way clutch coupling an output of said transmission to said output spindle, said one-way clutch including a cap member that is snap-fit to said at least one circumferentially extending rib member to thereby cover said second end of said transmission housing; anda torque clutch;wherein one of said planetary gear sets includes a ring gear with first and second axial end faces and wherein said torque clutch includes an annular clutch face that is disposed about said ring gear between said first and second axial end faces and wherein at least a portion of a side of said ring gear is configured such that an included angle between said annular clutch face and said at least a portion of said side of said ring gear is about ninety five degrees to about one hundred fifty degrees.

2. A power tool having a transmission that includes a clutch, the clutch comprising: a gear having gear teeth formed on an inner surface, said inner surface associated with an inner diameter of said gear;an annular clutch face formed on a portion of a face of said gear;an annular wall having a first surface and a second surface, said first surface extends from said clutch face, said second surface extends from said first surface and from said inner surface, wherein said first surface forms an angle obtuse with said face of said gear.

3. The clutch of claim 2, wherein said second surface is generally perpendicular to said inner surface.

4. The clutch of claim 2, wherein a value of said obtuse angle varies with the circumferential position along said clutch face.

5. The clutch of claim 3, wherein a value of said obtuse angle is fixed relative to the circumferential position along said clutch face.

6. The clutch of claim 3, wherein a value of said obtuse angle is in a range of about ninety five degrees to about one hundred fifty degrees.

7. The clutch of claim 6, wherein said value of said obtuse angle is about one hundred eleven degrees.

8. A power tool comprising: a motor;an output member;a transmission disposed between said motor and said output member, said transmission having a ring gear with opposite axial end faces; anda clutch for limiting an output of said transmission, said clutch including an annular clutch face disposed about said ring gear, wherein at least a portion of a side of said ring gear is configured such that an included angle between said annular clutch face and said at least a portion of said side of said ring gear is about ninety five degrees to about one hundred fifty degrees.

9. The power tool of claim 8, wherein said clutch face is integrally formed with said ring gear.

10. The power tool of claim 9, wherein a fillet radius of about at least 0.02 inches (about 0.5 mm) is formed between said annular clutch face and said side of said ring gear.

11. The power tool of claim 8, wherein said transmission includes at least three stages.

12. The power tool of claim 11, wherein said transmission is selectively operable in at least three overall gear ratios.

13. The power tool of claim 11, wherein said transmission includes an output stage and wherein said ring gear is associated with a stage of the transmission other than said output stage.

14. The power tool of claim 8, wherein said included angle is about one hundred eleven degrees.

15. A power tool comprising: a handle housing that defines a handle;a motor received in said handle housing;an output member; anda cassette received in said handle housing, said cassette including a transmission housing, a multi-stage transmission received in said transmission housing, and a thrust washer, said transmission housing having a first end with first and second circumferentially extending channels formed therein, said thrust washer having a body and first and second protrusions that extend radially from said body, each of said first and second protrusions being received in an associated one of said first and second circumferentially extending channels.

16. The power tool of claim 15, wherein a stop member is disposed in each of said first and second circumferentially extending channels, said stop members cooperating with said first and second protrusions to releaseably lock said thrust plate to said transmission housing.

17. The power tool of claim 15, wherein said cassette further includes a spindle lock clutch, said spindle lock clutch including a cap that is snap-fit to said transmission housing.

18. The power tool of claim 17, wherein said spindle lock clutch includes a plurality of wall members, an anvil, a ring structure and a plurality of pins, said wall members being coupled to an output member of said transmission, said anvil being received between said wall members, said ring structure being disposed about said wall members, each of said pins being disposed between an adjacent pair of said wall members, said anvil being coupled to said output member, wherein rotation of said anvil relative to said wall members urges said pins into engagement with said ring structure and said anvil.

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. A power tool comprising: a handle housing that defines a handle;a motor received in said handle housing;an output member; anda cassette received in said handle housing, said cassette including a transmission housing, a multi-stage transmission received in said transmission housing, and a cap, said transmission housing having a first end and a second end, said cap releaseably connected to said transmission housing near said second end with a snap-fit connection.

24. The power tool of claim 23 wherein said second end includes a protrusion that extends radially from an outer surface of said transmission housing near said second end, wherein said protrusion at least partially encircles said housing.

25. The power tool of claim 24 wherein said cap includes a plurality of flanges that extend generally perpendicular from a first face of said cap, said flanges having an inner surface including a groove and wherein said groove at least partially receives said protrusion to releaseably connect said cap to said transmission housing.

26. The power tool of claim 23 further comprising a thrust washer, said transmission housing having said first end with first and second circumferentially extending channels formed therein, said thrust washer having a body and first and second protrusions that extend radially from said body, each of said first and second protrusions being received in an associated one of said first and second circumferentially extending channels.

27. The power tool of claim 26, wherein a stop member is disposed in each of said first and second circumferentially extending channels, said stop members cooperating with said first and second protrusions to releaseably lock said thrust plate to said transmission housing.

28. A power tool comprising: a handle housing defining a handle, an interior cavity, and a trigger mount, said trigger mount being adapted to receive a trigger therein and including longitudinally extending, laterally spaced-apart grooves; andan output spindle assembly having a spindle housing and an output spindle rotatably mounted in said spindle housing, said spindle housing including a pair of longitudinally-extending, laterally spaced-apart tongue members, said spindle housing being coupled to said handle housing such that each of said longitudinally-extending, laterally spaced-apart grooves receive an associated one of said longitudinally extending, laterally spaced-apart tongue members.

29. The power tool of claim 28 wherein said handle housing includes a base portion disposed between said longitudinally extending, laterally spaced-apart grooves, said spindle housing including a rib that extends from said spindle housing, said rib contacts said base portion.

30. The power tool of claim 29 wherein said rib contacts said base portion and deflects a predetermined amount to exert a force on said base portion, a magnitude of said force based on said predetermined amount.

31. A power tool comprising: a handle housing that defines a handle;a motor received in said handle housing;a transmission received in said handle housing, said transmission including a one-way clutch, said one-way clutch includes an anvil;an output spindle;said anvil having a top portion and a bottom portion that extends from said top portion, said anvil defining an aperture into which said anvil receives an end of said output spindle, said bottom portion having a polygonal shape, wherein said aperture in said a gear associated with said transmission has a complementary polygonal shape and receives said bottom portion of said anvil in said aperture defined by said gear, said anvil including a groove formed in a face of said top portion from which said bottom portion extends, said groove generally encircling said bottom portion; anda circular seal member that is received by said groove and disposed between said anvil and said gear.

32. The power tool of claim 31 wherein said aperture in said anvil that receives said output spindle includes a first wall opposite a second wall and a third wall opposite a fourth wall, said third and said fourth walls having a convex shape defining a base and an apex, said apex closer to a center of said aperture formed in said anvil.

33. The power tool of claim 32 wherein said first wall and said second wall have opposed D-shapes.

34. A power tool having a transmission, the transmission comprising: a gear having gear teeth formed on an inner surface of said gear, said inner surface associated with an inner diameter;an annular clutch face formed on a portion of a face of said gear;an adjustment collar connected to a housing a rotatable relative thereto;a pin biased toward said face of said gear, wherein a force exerted against said pin is based on a position of said adjustment collar;a ball catch having at least one tang, said ball catch formed on a first end of said pin; anda ball disposed within said ball catch that rolls against said annular clutch face.

35. A power tool comprising: a handle housing that defines a handle;a motor received in said handle housing;a transmission housing containing a transmission, said transmission housing received in said handle housing, said transmission housing having a first axially extending channel and a second axial extending channel, said transmission including a gear movable between a first position and a second position;a connecting member having a first end, a second and a middle portion, said middle portion coupled to said gear, said first portion extending through said first channel and said second portion extending through said second channel;a selector cam slidingly coupled to an outer surface of said housing, said selector cam having at least a first groove that receives said first end and a second groove that receives said second end, each of said grooves includes a closed structure so that said selector cam contains said first end and said second end of said connecting member regardless of the circumferential position of said selector cam relative to said housing.

36. The power tool of claim 35 wherein movement of said selector cam relative to said housing causes said gear to move relative to said housing.

37. A power tool comprising: a transmission housing received in an interior cavity of a handle housing, said transmission housing having a first end, a second end, a bore that extends between said first and second ends, and a plurality of teeth formed circumferentially about said bore; anda transmission at least partially received in said bore of said transmission housing, said transmission having a plurality of reduction gear sets and at least one member that is axially movable in said transmission housing to affect a change in an overall gear ratio of said transmission, said at least one member being movable in a first condition, wherein said at least one member is disengaged from said teeth, and a second condition, wherein said at least one member is engaged to said teeth, wherein a first portion of said teeth are relatively longer than a second portion of said teeth such that when said at least one member is moved from said first condition to said second condition, said at least one member engages said first portion of said teeth before it engages said second portion of said teeth.