Patent Application
20250108427
The present invention relates generally to the field of tools. The present invention relates specifically to a knockout tool with a punch and die used for forming a hole through a material, such as through cutting or shearing.
One embodiment of the invention relates to a knockout tool. The knockout tool includes a longitudinal axis, a body, a die plug, a die, a thrust bearing, a punch, and a drive component. The body includes a first end centered on and extending along the longitudinal axis, and a second end opposite the first end and aligned with the first end along the longitudinal axis. The die plug is coupled to the first end of the body, and the die is coupled to the die plug. The thrust bearing is positioned between the die plug and the die such that at least a portion of the thrust bearing can rotate between the die and die plug with respect to the longitudinal axis. The punch is coupled to the second end of the body. The punch includes a cutting end configured to be received in the die. The drive component extends through the first end of the body and is received int eh die plug. The drive component is configured to rotate with respect to the longitudinal axis. When the drive component is rotated in a first direction, the die plug and thrust bearing convert rotational movement of the drive component into linear movement and move the die into engagement with the punch along the longitudinal axis.
Another embodiment of the invention relates to a hole forming tool including a body, a punch, and a die. The body includes a first end centered on a longitudinal axis, and a second end opposite the first end and aligned with the first end along the longitudinal axis. The punch is coupled to the second end of the body, and the die is coupled to the first end of the body and centered on the longitudinal axis. The die includes a first side and a second side opposite the first side along the longitudinal axis. The first side faces away from the first end of the body and is configured to receive the punch. A die plug is coupled to the first end of the body, and a thrust bearing is positioned between the die plug and the second side of the die. At least a portion of the thrust bearing can rotate between the die and the die plug with respect to the longitudinal axis. A drive component extends through the first end of the body and is received in the die plug. The drive component is configured to rotate with respect to the longitudinal axis. When the drive component is rotated in a first direction, the die plug and thrust bearing convert rotational movement of the drive component into linear movement such that the drive component moves axially along the longitudinal axis and moves the die into engagement with the punch.
Another embodiment of the invention relates to a tool. The tool includes a body with a first end centered on a longitudinal axis and a second end opposite the first end and aligned with the first end along the longitudinal axis. A die plug is positioned adjacent to the first end of the body. A die is coupled to the die plug such that the die plug is positioned between the die and the first end of the body along the longitudinal axis. A thrust bearing is positioned between the die plug and the die. At least a portion of the thrust bearing can rotate between the die and die plug with respect to the longitudinal axis. A drive component extends through the first end of the body and is received in the die plug such that the die plug is coupled to the first end of the body. The drive component is configured to rotate with respect to the longitudinal axis. A punch is coupled to the second end of the body. The punch comprises a cutting end configured to be received in the die. When the drive component is rotated in a first direction, the die plug and thrust bearing convert rotational movement of the drive component into linear movement such that the drive component moves the die plug, thrust bearing, and die axially along the longitudinal axis towards the punch.
Additional features and advantages will be set forth in the detailed description which follows and will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and/or shown in the accompany drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.
The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments. In addition, alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.
This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:
Referring generally to the figures, various embodiments of a knockout tool are shown. Applicant believes that the knockout tools discussed herein provide for various advantages over typical knockout tools, such as the benefit of punching a hole in a material without the need for a pilot hole to guide the die and punch. Making a pilot hole can generate metal shavings, which may be undesirable when deposited in certain places, like a circuit box.
Specifically, the knockout tools discussed herein utilize a thrust bearing, die plug, and drive component, which allow for the drive component to push the die into engagement with the punch while minimizing the transfer of rotational movement from the drive component to the die. This arrangement keeps the punch and die aligned without the need for a pilot hole to guide or assist the punch. Additionally, the drive component (e.g., a square drive) is configured such that the knockout tools can be used with a power tool (e.g., an impact driver) or manually (e.g., via a wrench or ratchet hand tool, or otherwise without the aid of a power tool).
In various embodiments, the punch and die are detachably coupled to the body of the knockout tool, which allows for the punch and die to be changed between multiple sizes. This interchangeability allows for the knockout tool to make holes of varying sizes to suit the various needs of a user.
Referring to
Body 102 has a first end 114 and a second end 116 opposite from first end 114. First end 114 is centered on longitudinal axis 118 and second end 116 is aligned with first end 114 along longitudinal axis 118. Specifically, first end 114 has a first through-hole or first bore 117 which is centered on longitudinal axis 118, and second end 116 has a second through-hole or second bore 119 centered on longitudinal axis 118.
As shown, body 102 is generally C-shaped, with a center portion 120 located between first end 114 and second end 116. Center portion 120 is spaced apart from longitudinal axis 118 in a direction substantially perpendicular to longitudinal axis 118. In this way, center portion 120 is spaced from and substantially parallel to longitudinal axis 118. Center portion 120 is connected to first end 114 by curved section 122, and center portion 120 is connected to second end by curved section 124.
Center portion, 120, first end 114, and second end 116 define a throat configured to receive a material/workpiece for knockout tool 100 to punch a hole in. The throat has a depth defined by a distance 123 between a top surface 121 of center portion 120 and longitudinal axis 118 (as shown in
Die 104 is detachably, or removably, coupled to first end 114 through thrust bearing 110 and die plug 112. Die 104 is centered on longitudinal axis 118. Die 104 includes a first side 126 configured to receive punch 106, and a second side 128 opposite from the first side 126 which abuts thrust bearing 110. First side 126 faces away from first end 114 of body 102. Die 104 may be removably coupled to thrust bearing 110 to allow for different sized dies to be secured on first end 114 to allow a user to make different sized holes to suit the user's specific needs. In a certain embodiment, an O-ring may be used to retain die 104 on die plug 112 such that die 104 and thrust bearing 110 will not slip off of die plug 112 during use.
Die plug 112 is attached to the side of thrust bearing 110 opposite die 104 and positioned adjacent to first end 114 of body 102 such that die plug 112 is positioned between die 104 and first end 114. Thrust bearing 110 is positioned between die plug 112 and die 104 and has at least a portion that can rotate between die 104 and die plug 112 with respect to longitudinal axis 118. Die plug 112 includes a projection 113 and a recess 115. Projection 113 is adjacent to and extends through thrust bearing 110. As shown in
Recess 115 is adjacent to first end 114 of body 102. Recess 115 is configured to receive a draw stud or drive component, such as drive component 108 or 208, to couple die plug 112 to first end 114. In particular, die 104 is detachably, or removably, coupled to first end 114 by drive component 108. Die 104 further includes an opening 130 in first side 126. Opening 130 is centered on longitudinal axis 118 and is sized to receive punch 106. In this way, opening 130 may have a width equal to or greater than a width of punch 106. Die 104 further includes an opening 131 formed on second side 128 that is configured to receive projection 113.
In certain embodiments, die plug 104 may be interchangeable to accommodate for the different sized dies. In such embodiments, projection 113 has a diameter that varies with the diameter of opening 131 such that projection 113 has a diameter less than or equal to the diameter of opening 131. In another certain embodiment, opening 131 is 7/16 inches. In another certain embodiment, opening 131 is ¾ inches. In a certain embodiment, the size of the dies range from ¾ inches to 2 inches and two die plugs are used to mount these dies to first end 114. More specifically, a first die plug has a projection with a diameter less than or equal to 7/16 inches, and a second die plug has a projection with a diameter less than or equal to ¾ inches.
Punch 106 is coupled to second end 116 and centered on longitudinal axis 118. Punch 106 has a cutting end 132 which is oriented towards opening 130 of die 104. Cutting end 132 is configured to be receive in die 104. Opening 130 and cutting end 132 are aligned along longitudinal axis 118 such that cutting end 132 is received in opening 130 when die 104 is moved towards punch 106. Cutting end 132 includes at least one cutting tip 133 used to punch holes in a material. As shown, punch 106 includes two angled cutting tips 133 that extend away from cutting end 132 towards die 104 along longitudinal axis 118.
Punch 106 includes a punch lock or punch retainer 134. Punch retainer 134 assists in aligning punch 106 with opening 130 and securing punch 106 to second end 116 of body 102. Punch retainer has a mounting end 140 and a distal end 142 opposite from mounting end 140. Mounting end 140 is configured to couple to punch 106. Punch retainer 134 extends through second end 116 of body 102. Specifically, second end 116 of body 102 includes second bore 119 that receives punch retainer 134. Punch retainer 134 is positioned within second bore 119.
As shown, punch retainer 134 has an outer surface 143 with tapered shape, such that an outer dimension of punch retainer 134 decreases along its length in a direction towards die 104. In this way, mounting end 140 has a smaller width than distal end 142. In a certain embodiment, mounting end 140 has a smaller radius than distal end 142. The tapered shape of outer surface 143 allows for punch retainer 134 to be secured in second bore 119 when punch 106 is mounted on punch retainer 134. In this way, punch 106 and distal end 142 can retain punch retainer 134 from sliding out of either side of second bore 119. Additionally, outer surface 143 of punch retainer 134 may be coupled to an inner surface of second bore 119 to secure punch retainer 134 within second bore 119.
Punch 106 is detachably, or removably, coupled to second end 116 of body 102 through punch retainer 134. Punch 106 includes a mounting channel 138 that is configured to receive and retain mounting end 140 of punch retainer 134. To mount punch 106 on punch retainer 134, mounting end 140 is inserted into and secured within mounting channel 138. As shown, mounting end 140 has a threaded outer surface which corresponds to a threaded inner surface of mounting channel 138. Mounting channel 138 may be twisted into threaded engagement with mounting end 140 of punch retainer 134. In particular, punch 106 and punch retainer 134 are coupled together through threaded engagement of the threaded inner surface and threaded outer surface. In this way, different sized punches can be secured on second end 116 to allow a user to make different sized holes to suit the user's specific needs.
Drive component 108 extends through first end 114 along longitudinal axis 118. Drive component 108 is configured to rotate with respect to longitudinal axis 118. Drive component 108 is configured such that it can be rotated with a power tool (e.g., a driving tool, an impact driver) or manually (e.g., via a wrench or ratchet hand tool, or otherwise without the aid of a power tool).
In certain embodiments, the size of drive component 108 varies with the size of punch 106. In a certain embodiment, punch 106 has a ½ inch diameter and the drive component 108 has a 7/16 inch diameter. In another certain embodiment, punch 106 may have a diameter from ¾ inch to 2 inches and the drive component has a ¾ inch diameter.
As shown in
Drive receiver 146 is coupled to drive shaft 144 and configured to engage a driving tool. When engaged with drive receiver 146, the drive tool can rotate drive component 108. As shown, drive component 108 is a square drive and, more specifically, a ½ inch square drive. Drive receiver 146 is shown with a hexagonal shaped end.
In various embodiments, the drive receiver has a drive recess, such as drive receiver 246 shown in
Referring to
When drive component 108 rotates within die plug 112, it may cause die plug 112 to rotate with it. As die plug 112 moves, it interfaces with thrust bearing 110. The rolling elements in thrust bearing 110 will rotate with the rotational movement of die plug 112 and reduce the transfer of rotational friction generated by die plug 112 and drive component 108. In this way, thrust bearing 110 transfers the axial movement of drive component to die 104, while minimizing the transfer of rotational movement. This moves die 104 along longitudinal axis 118 and into engagement with punch 106.
When a material, such as a sheet of metal, is placed between die 104 and punch 106, the movement of opening 130 of die 104 towards cutting end 132 of punch 106 to punch a hole in the material as die 104 and punch 106 are pressed together. The cut-out from the material may be retained within opening 130 of die 104 until punch 106 and die 104 are disengaged. Punch 106 and die 104 may be disengaged by rotating drive component 108 in the opposite direction of the first direction.
In certain embodiments, die 104 and punch 106 are interchangeable such that a user may make different sized holes to suit the user's specific needs. Specifically, as shown, knockout tool 100 in sized to receive a die and punch which can punch holes between ½ inch and 1 inch.
Referring to
As shown, knockout tool 300 includes an O-ring 360. O-ring 360 is positioned within die 304 adjacent to second side 328. In particular, O-ring 360 is positioned within opening 331. When projection 313 of die plug 312 is positioned within opening 331 of die 304, O-ring 360 secures die 304 and thrust bearing 110 on die plug 312. O-ring 360 engages with an outer surface of projection 313 and an inner surface of opening 331 to retain die 304 on die plug 312.
It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more component or element, and is not intended to be construed as meaning only one.
For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. As used herein, “rigidly coupled” refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force.
While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.
In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.
The present application claims the benefit of and priority to U.S. Provisional Application No. 63/587,540 filed on Oct. 3, 2023, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63587540 | Oct 2023 | US |
