POWER TOOL CHUCK

TECHNICAL FIELD

This application relates to chucks, such as keyless chucks, for use with power tools (e.g., drills and screwdrivers).

BACKGROUND

Chucks, including keyless chucks, for retaining tool bits in power tools, such as drills and screwdrivers, are well known in the prior art. Existing chucks tend to have issues with insufficient holding force on tool bits. These chucks also add significant overall axial length to the power tool. It is desirable to have power tool chucks that overcome these deficiencies.

SUMMARY

In one aspect, a power tool chuck includes a chuck body extending along a chuck axis and couplable to an output spindle of a rotary power tool. A longitudinal bore is defined in the body along the axis for receiving a tool bit therein. A plurality of radial slots is defined in the body in communication with the longitudinal bore. A plurality of jaw assemblies is received in the body, each jaw assembly at least partially received in one of the plurality of radial slots and moveable to engage and removably retain the tool bit in the chuck body. A clamping ring is received over the chuck body and the jaw assemblies and rotatable relative to the chuck body and the jaw assemblies to engage and removably retrain the tool bit in the chuck body. The clamping ring and each jaw assembly together define a first clamping interface configured to cause the jaw assembly to clamp the tool bit a first clamping force up to a first maximum clamping force during a first phase of clamping, and a second clamping interface configured to cause the jaw assembly to clamp the tool bit at a second clamping force that is greater than the first maximum clamping force during a second phase of clamping.

Implementations of this aspect may include one or more of the following features.

The first clamping interface may be oriented at a first angle relative to the axis and the second clamping interface is oriented at a second angle relative to the axis that is less than the first angle. The first angle may be approximately 30° to 60° and the second angle may be approximately 1° to 15°.

Each jaw assembly may comprise a first jaw portion and a second jaw portion. The first clamping interface may be defined between the first jaw portion and the clamping ring, and the second clamping interface may be defined between the first jaw portion and the second jaw portion. The first clamping interface may be oriented at a first angle relative to the axis and the second clamping interface may be oriented at a second angle relative to the axis that is less than the first angle. The first angle may be approximately 30° to 60° and the second angle may be approximately 1° to 15°.

The first clamping interface may be defined between the first jaw portion and the second jaw portion, and the second clamping interface may be defined between the first jaw portion and the clamping ring. The first clamping interface may be oriented at a first angle relative to the axis and the second clamping interface may be oriented at a second angle relative to the axis that is less than the first angle. The first angle may be approximately 30° to 60° and the second angle may be approximately 1 to 15.

The clamping ring may be threadably connected to the chuck body. An outer sleeve may be received over the clamping ring so that the outer sleeve and clamping ring rotate together. Relative rotation between the clamping ring and the chuck body may cause the jaw assembly to clamp the tool bit at the first clamping force and the second clamping force. The relative rotation between the clamping ring and the chuck body may encompass holding one of the clamping ring and the chuck body rotationally stationary while rotating the other of the clamping ring and the chuck body. The relative rotation may encompass holding the clamping ring rotationally stationary by a user grasping the outer sleeve while the chuck body rotates by actuating a motor in the power tool. The relative rotation may encompass the outer sleeve being coupled to a lock mechanism that selectively locks the outer sleeve to a housing of the power tool to inhibit rotation of the outer sleeve and the clamping ring, while the chuck body rotates by actuating a motor in the power tool. The relative rotation may encompass rotating the outer sleeve to rotate the clamping ring, while the body is held substantially stationary by a spindle lock in the power tool.

The jaw assembly may be biased away from clamping the tool bit by at least one spring. The at least one spring may comprise a first spring biasing the jaw assembly away from the chuck body in a direction substantially transverse to the axis. The at least one spring may further comprise a second spring biasing the jaw assembly in a direction substantially parallel to the axis. The jaw assembly may comprise a first jaw portion that directly engages the tool bit and a second jaw portion that directly engages the first jaw portion and the clamping ring, wherein the first spring is disposed between the body and the second jaw portion and the second spring is disposed between the first jaw portion and the second jaw portion. The first spring may comprise a compression spring and the second spring may comprise a disc spring.

The clamping ring may comprise an inner ring threadably connected to the chuck body by a first thread and an outer ring received over and threadably connected to the inner ring by a second thread. The clamping ring may further comprise a detent biased by a detent spring and coupling the inner ring to the outer ring so that the inner ring and the outer ring rotate together as a unit when a force on the detent spring is less than or equal to a spring threshold value and the outer ring rotates relative to the inner ring when the force on the detent spring exceeds the spring threshold value. The force on the detent spring may exceed the spring threshold value approximately when the second clamping force exceeds the first maximum clamping force. The first thread may have a coarser thread pitch than does the second thread. The first thread may be configured to cause the inner clamping ring to impart the first clamping force to the jaw assembly and the second thread may be configured to cause the outer clamping ring to impart the second clamping force to the jaw assembly.

In another aspect, a power tool chuck includes a chuck body extending along a chuck axis and couplable to an output spindle of a rotary power tool. A longitudinal bore is defined in the body along the axis for receiving a tool bit therein. A plurality of radial slots is defined in the body in communication with the longitudinal bore. A plurality of jaw assemblies is received in the body, each jaw assembly at least partially received in one of the plurality of radial slots and moveable to engage and removably retain the tool bit in the chuck body. A clamping ring is received over the chuck body and the jaw assemblies and rotatable relative to the chuck body and the jaw assemblies to engage and removably retrain the tool bit in the chuck body. Each jaw assembly defines a first jaw portion and a second jaw portion moveable relative to the first jaw portion, and one of the first jaw portion and the second jaw portion is configured to cause the jaw assembly to clamp the tool bit at a first clamping force up to a first maximum clamping force during a first phase of clamping. The other of the first jaw portion and the second jaw portion is configured to cause the jaw assembly to clamp the tool bit at a second clamping force that is greater than the first maximum clamping force during a second phase of clamping.

Implementations of this aspect may include one or more of the following features. The jaw assembly may have a first clamping interface oriented at a first angle relative to the axis and the second clamping interface oriented at a second angle relative to the axis that is less than the first angle. The first jaw portion may directly engage the clamping ring and the second jaw portion, and the second jaw portion may directly engage the first jaw portion and the tool bit. The first clamping interface may be defined between the first jaw portion and the clamping ring and the second clamping interface may be defined between the second jaw portion and the first jaw portion. The first angle may be approximately 30° to 60° and the second angle may be approximately 1° to 15°. The first clamping interface may be defined between the first jaw portion and the second jaw portion and the second clamping interface may be defined between the first jaw portion and the clamping ring. The first angle may be approximately 30° to 60° and the second angle may be approximately 1° to 15°. The outer sleeve may be received over the clamping ring so that the outer sleeve and clamping ring rotate together. Relative rotation between the clamping ring and the chuck body may cause the jaw assembly to clamp the tool bit at the first force and the second force. The relative rotation between the clamping ring and the chuck body may encompass holding one of the clamping ring and the chuck body rotationally stationary while rotating the other of the clamping ring and the chuck body. The relative rotation may encompass holding the clamping ring rotationally stationary by a user grasping the outer sleeve while the chuck body rotates by actuating a motor in the power tool. The relative rotation may encompass the outer sleeve being coupled to a lock mechanism that selectively locks the outer sleeve to a housing of the power tool to inhibit rotation of the outer sleeve and the clamping ring, while the chuck body rotates by actuating a motor in the power tool. The relative rotation may encompass rotating the outer sleeve to rotate the clamping ring, while the body is held substantially stationary by a spindle lock in the power tool.

The jaw assembly may be biased away from clamping the tool bit by at least one spring. The at least one spring may comprise a first spring biasing the jaw assembly away from the chuck body in a direction substantially transverse to the axis. The at least one spring may further comprise a second spring biasing the jaw assembly in a direction substantially parallel to the axis. The first jaw portion may directly engage the clamping ring and the second jaw portion, the second jaw portion may directly engage the first jaw portion and the tool bit, and the first spring may be disposed between the body and the second jaw portion and the second spring may be disposed between the first jaw portion and the second jaw portion.

The clamping ring may comprise an inner ring threadably connected to the chuck body by a first thread and an outer ring received over and threadably connected to the inner ring by a second thread. The clamping ring may further comprise a spring biased detent coupling the inner ring to the outer ring so that the inner ring and the outer ring rotate together as a unit when a force on the spring is less than or equal to a spring threshold value and the outer ring rotates relative to the inner ring when the force on the spring exceeds the spring threshold value. The force on the spring may exceed the spring threshold value approximately when the second clamping force exceeds the first maximum clamping force. The first thread may have a coarser thread pitch than does the second thread. The first thread may be configured to cause the inner clamping ring to impart the first clamping force to the jaw assembly and the second thread may be configured to cause the outer clamping ring to impart the second clamping force to the jaw assembly.

In another aspect, a power tool chuck includes a chuck body extending along a chuck axis and couplable to an output spindle of a rotary power tool. A longitudinal bore is defined in the body along the axis for receiving a tool bit therein. A plurality of radial slots is defined in the body in communication with the longitudinal bore. A plurality of jaw assemblies is received in the body, each jaw assembly at least partially received in one of the plurality of radial slots and moveable to engage and removably retain the tool bit in the chuck body. A clamping ring is received over the chuck body and the jaw assemblies and rotatable relative to the chuck body and the jaw assemblies to engage and removably retrain the tool bit in the chuck body. The clamping ring comprises an inner ring threadably connected to the chuck body by a first thread and an outer ring received over and threadably connected to the inner ring by a second thread. The first thread is configured to cause the jaw assembly to clamp the tool bit a first clamping force up to a first maximum clamping force when the inner ring rotates relative to the chuck body during a first phase of clamping. The second thread is configured to cause the jaw assembly to clamp the tool bit at a second clamping force that is greater than the first maximum clamping force when the outer ring rotates relative to the inner ring and the chuck body during a second phase of clamping.

Implementations of this aspect may include one or more of the following features. The clamping ring may further comprise a detent biased by a detent spring to couple the inner ring to the outer ring so that the inner ring and the outer ring rotate together as a unit when a force on the spring is less than or equal to a spring threshold value and the outer ring rotates relative to the inner ring when the force on the spring exceeds the spring threshold value. The force on the spring may exceed the spring threshold value approximately when the second clamping force exceeds the clamp threshold value. The first thread may have a coarser thread pitch than does the second thread. The first thread may be configured to cause the inner clamping ring to impart the first clamping force to the jaw assembly and the second thread may be configured to cause the outer clamping ring to impart the second clamping force to the jaw assembly.

Each jaw assembly may define a first jaw portion and a second jaw portion moveable relative to the first jaw portion, the first jaw portion configured to cause the jaw assembly to clamp the tool bit at the first clamping force, and the second jaw portion configured to cause the jaw assembly to clamp the tool bit at the second clamping force. The inner ring and the outer ring may be configured to rotate in unison to cause the jaw assembly to clamp the tool bit at the first clamping force and the second ring may be configured to rotate relative to the first ring to cause the jaw assembly to clamp the tool bit at the second clamping force. The jaw assembly may have a first clamping interface at a first angle relative to the axis and a second clamping interface at a second angle relative to the axis that is less than the first angle. The second jaw portion may directly engage the tool bit and the first jaw portion, and the first jaw portion may directly engage the second jaw portion and the clamping ring. A first clamping interface may be defined between the first jaw portion and the second jaw portion and the second clamping interface may be defined between the first jaw portion and the clamping ring. The first clamping surface may be oriented at a first angle relative to the axis and the second clamping surface may be oriented at a second angle relative to the axis that is less than the first angle.

An outer sleeve may be received over the clamping ring so that the outer sleeve and clamping ring rotate together. The clamping ring may be threadably connected to the chuck body. Relative rotation between the clamping ring and the chuck body may cause the jaw assembly to clamp the tool bit at the first force and the second force. The relative rotation between the clamping ring and the chuck body may encompass holding one of the clamping ring and the chuck body rotationally stationary while rotating the other of the clamping ring and the chuck body. The relative rotation may encompass holding the clamping ring rotationally stationary by a user grasping the outer sleeve while the chuck body rotates by actuating a motor in the power tool. The relative rotation may encompass the outer sleeve being coupled to a lock mechanism that selectively locks the outer sleeve to a housing of the power tool to inhibit rotation of the outer sleeve and the clamping ring, while the chuck body rotates by actuating a motor in the power tool. The relative rotation may encompass rotating the outer sleeve to rotate the clamping ring, while the body is held substantially stationary by a spindle lock in the power tool. The jaw assembly may be biased away from clamping the tool bit by at least one spring. The at least one spring may comprise a first spring biasing the jaw assembly away from the chuck body in a direction substantially transverse to the axis.

In an aspect, a chuck for a power tool includes a chuck body extending along a chuck axis and couplable to an output spindle of a power tool. A longitudinal bore is defined in the body along the axis for receiving a tool bit therein. A plurality of jaws is received in the body and moveable radially but not axially, to engage and removably retain the tool bit in the chuck body. A sleeve is received over the body. A first gear is received in the body and rotatable by rotation of the sleeve or the output spindle. A second gear is received in the body, meshed with the first gear, and coupled to at least one of the plurality of jaws, the second gear configured to rotate and cause the at least one jaw to move radially, but not axially, independently of a chuck key, to engage the tool bit or disengage the tool bit upon rotation of the first gear.

Implementations of this aspect may include one or more of the following features. The first gear may comprise a first bevel gear and the second gear may comprise a second bevel gear. Each of the plurality jaws may be received in a radial opening that is communication with the longitudinal bore. Each of the at least one jaw may be threadably engaged with the second gear so that rotation of the second gear causes radial movement of the at least one jaw. The first gear may be rotatable by rotation of the sleeve or the output spindle independent of a chuck key. The second gear may include a plurality of second gears, with each of the second gears coupled to one of the plurality of jaws. The first gear may comprise a ring shaped bevel gear, and each of the second gears may comprise a bevel gear meshed with the ring shaped bevel gear. The sleeve may be moveable axially between a chuck mode position and a drill mode position. When the sleeve is in the chuck mode position, rotation of the output spindle may cause the first gear to rotate. In the sleeve is in the chuck mode position, the sleeve may rotationally lock the body to a housing of the power tool. When the sleeve is in the drill mode position, rotation of the output spindle may cause the body to rotate and drive a tool bit retained in the longitudinal bore. A brake may be coupled to the sleeve. When the sleeve is in the drill mode position, the brake may rotationally couple the first gear to the body so that the body, the first gear, and the output spindle rotate together. When the sleeve is in the chuck mode position, the brake may decouple the first gear from the body to enable the output spindle and first gear to rotate relative to the body. When the sleeve is in the drill mode position, the sleeve may be rotatable relative to a housing of a power tool to change a clutch setting of the power tool. The power tool housing may include an electronic clutch and the sleeve may be rotatable to change a clutch setting of the electronic clutch when the sleeve is in the drill mode position.

In another aspect, a chuck for a power tool includes a chuck body extending along a chuck axis and couplable to an output spindle of a power tool. A longitudinal bore is defined in the body along the axis for receiving a tool bit therein. A plurality of jaws is received in the body and moveable to engage and removably retain the tool bit in the chuck body. A sleeve is received over the body. A first ring shaped bevel gear is received in the body and rotatable by rotation of the output spindle or the sleeve. A plurality of second bevel gears is received in the body and meshed with the first gear. Each of the second bevel gears is coupled to one of the plurality of jaws. The second gears are configured to rotate and cause the jaws to engage the tool bit or disengage the tool bit upon rotation of the first gear.

Implementations of this aspect may include one or more of the following features. The second gears may be spaced circumferentially around the longitudinal bore. Each of the jaws may be received in a radial opening that is communication with the longitudinal bore. Each of the jaws may be threadably engaged with one of the second gears so that rotation of the second gear causes radial movement of the jaw. The first gear may be rotatable by rotation of the sleeve or the output spindle independent of a chuck key. The sleeve may be moveable axially between a chuck mode position and a drill mode position. When the sleeve is in the chuck mode position, rotation of the output spindle may cause the first gear to rotate. When the sleeve is in the chuck mode position, the sleeve may rotationally lock the body to a housing of the power tool. When the sleeve is in the drill mode position, rotation of the output spindle may cause the body to rotate and drive a tool bit retained in the longitudinal bore. A brake may be coupled to the sleeve. When the sleeve is in the drill mode position, the brake may rotationally couple the first gear to the body so that the body, the first gear, and the output spindle rotate together. When the sleeve is in the chuck mode position, the brake may decouple the first gear from the body to enable the output spindle and first gear to rotate relative to the body. When the sleeve is in the drill mode position, the sleeve may be rotatable relative to a housing of a power tool to change a clutch setting of the power tool. The power tool housing may include an electronic clutch. The sleeve may be rotatable to change a clutch setting of the electronic clutch when the sleeve is in the drill mode position.

In another aspect, a power tool includes a tool housing, a motor disposed in the housing, an output spindle drivingly coupled to the motor and extending along a longitudinal axis, and a controller received in the housing and configured to control power delivery to the motor. An electronic clutch is in communication with the controller and configured to sense a tool operating parameter that correlates to an output torque of the output spindle. The electronic clutch is configured to cause the controller to interrupt or reduce power to the motor when the operating parameter indicates that the output torque exceeds a threshold value. A chuck is coupled to the output spindle. The chuck includes a body extending along the longitudinal axis. A longitudinal bore is defined in the body along the longitudinal axis for receiving a tool bit therein. A plurality of jaws is received in the body and moveable to engage or disengage the tool bit received in the bore. A is sleeve received over the body and is moveable axially between a first position in which the sleeve is configured to enable the jaws to be moved to engage or disengage the tool bit, and a second position in which the sleeve is rotatable to change a setting of the electronic clutch.

Implementations of this aspect may include one or more of the following features. The electronic clutch may include a printed circuit board disposed at least partially around the output spindle. In the second position, the sleeve may engage a wiper to change a position of the wiper along the printed circuit board to change the clutch setting. The drill housing may include a plurality of recesses. In the second position, the sleeve may be coupled to a detent that successively engages one or more of recesses as the sleeve is rotated to provide tactile feedback of the clutch setting. The sleeve may have indicia to indicate the clutch setting. In the first position, the sleeve may fix the chuck body to the tool housing so that operation of the motor causes the jaws to engage or disengage the tool bit.

In another aspect, a chuck constructed in accordance to one example of the present teachings can include a chuck body that supports a plurality of jaws. An outer sleeve is axially fixed with respect to the chuck body. A nut is coupled to the outer sleeve, the nut being movable axially and radially relative to the chuck body. The nut interacts with the jaws such that when the outer sleeve rotates, the nut moves axially and radially relative to the body.

Implementations of this aspect may include one or more of the following features. When the nut moves axially and radially relative to the chuck body, the jaws may move towards or away from one another. The chuck may have a front end at which the jaws extend from the chuck and are configured to hold a bit. The jaws may move away from one another when the nut moves axially toward the front end. The chuck may have a rear end opposite the front end. The jaws may move towards one another when the nut moves axially toward the rear end. The nut may include internal threads. The jaws may include external threads that mesh with the internal threads on the nut.

In another aspect, a power tool constructed in accordance to one example of the present teachings can include a housing, a motor and a chuck. The chuck is configured to hold an accessory. The chuck is selectively driven by the motor. The chuck includes a chuck body; a plurality of jaws disposed at least partially in the chuck body; a chuck sleeve that is axially fixed with respect to the chuck body, and is selectively rotatable with respect to the chuck body; and a nut coupled to the outer sleeve, the nut being movable axially and radially relative to the chuck body. The nut interacts with the jaws such that when that outer sleeve rotates, the nut moves axially and radially relative to the body.

Implementations of this aspect may include one or more of the following features. When the nut moves axially and radially relative to the body, the jaws may move towards or away from one another. The chuck may have a front end at which the jaws extend from the chuck and are configured to hold a bit. The jaws may move away from one another when the nut moves axially toward the front end. The chuck may have a rear end opposite the front end. The jaws may move towards one another when the nut moves axially toward the rear end. The nut may include internal threads. The jaws may include external threads that mesh with the internal threads on the nut.

In another aspect, a chuck constructed in accordance to one example of the present teachings can include a chuck body; a plurality of jaws, the plurality of jaws configured to hold a bit; an outer sleeve, the outer sleeve being axially fixed relative to the chuck body, the outer sleeve also being selectively rotatable with respect to the chuck body; and a nut coupled to the outer sleeve, wherein the nut is located internally of the outer sleeve and is movable axially and radially relative to the chuck body. The nut may include a nut threaded portion on an internal surface of the nut. The jaws may include a jaws threaded portion on an external portion of the jaws. The nut threaded portion may be engaged with the jaws threaded portion. When the outer sleeve rotates, the nut may move axially and radially relative to the body.

Implementations of this aspect may include one or more of the following features. When the nut moves axially and radially relative to the body, the jaws may move towards or away from one another. The chuck may have a front end at which the jaws extend from the chuck and are configured to hold a bit. The jaws may move away from one another when the nut moves axially toward the front end. The chuck may have a rear end opposite the front end. The jaws may move towards one another when the nut moves axially toward the rear end. The chuck may further include a lifter which pushes the jaws away from one another. The jaws may be axially fixed relative to the chuck body. The jaws may be axially fixed relative to the outer sleeve. The nut may have a frustoconical shape.

In another aspect, a chuck constructed in accordance with one example of the present teachings can include a chuck. The chuck includes a chuck body that supports a plurality of jaws. The chuck also includes an outer sleeve is axially fixed with respect to the chuck body and selectively rotatable with respect to the chuck body. The chuck further includes a cam core having a plurality of ramped inner surfaces. The jaws have outer surfaces in contact with the ramped inner surfaces. When the cam core rotates relative to the jaws, the ramped inner surfaces of the cam core push the jaws towards one another or away from one another. The chuck has a front at which the plurality of jaws are configured to hold a bit and a rear, opposite the front. The cam core may move axially rearwardly when the plurality of jaws are tightened around the bit.

Implementations of this aspect may include one or more of the following features. The cam core may have an outer circumferential surface. There may be a slot in the outer circumferential surface. The chuck may further include a connector which selectively transmits force from the outer sleeve to the cam core. The connector may have a first end engaged with the outer sleeve and a second end engaged with the slot. The slot may have a first end and a second end. The second end may be closer to the rear of the chuck than the first end is to the rear of the chuck. The cam core may further include detents biased radially outwardly. The outer sleeve may further include detent recesses which selectively engage the detents.

In another aspect, a power tool constructed in accordance with one example of the present teachings may include a power tool with a chuck. The power tool includes a housing, a motor disposed in the housing and a chuck configured to hold an accessory. The chuck is selectively driven by the motor. The chuck includes a chuck body that supports a plurality of jaws, an outer sleeve that is axially fixed with respect to the chuck body and is selectively rotatable with respect to the chuck body. The chuck also includes a cam core having a plurality of ramped inner surfaces. The jaws have outer surfaces in contact with the ramped inner surfaces. When the cam core rotates relative to the jaws, the ramped inner surfaces of the cam core push the jaws towards one another or away from one another. The chuck has a front at which the plurality of jaws are configured to hold a bit. The chuck has a rear, opposite the front. The cam core moves axially rearwardly when the plurality of jaws are tightened around the bit.

Implementations of this aspect may include one or more of the following features. The cam core may have an outer circumferential surface. There may be a slot in the outer circumferential surface. The chuck may further include a connector which selectively transmits force from the outer sleeve to the cam core. The connector may have a first end engaged with the outer sleeve and a second end engaged with the slot. The slot may have a first end and a second end. The second end may be closer to the rear of the chuck than the first end is to the rear of the chuck. The cam core may also include detents biased radially outwardly. The outer sleeve may further include detent recesses which selectively engage the detents.

In another aspect, a chuck constructed in accordance with one example of the present teachings can include a chuck. The chuck includes a plurality of jaws, a chuck sleeve and a cam core. Each of the plurality of jaws may include a clamping surface configured to engage a bit and each of the plurality of jaws also including an outer surface. The chuck sleeve is selectively rotatable with respect to the plurality of jaws. The cam core has a plurality of ramped surfaces. The chuck has a front end at which the bit is inserted. The chuck has a rear end, opposite the front end, at which the chuck is operatively engaged with a motor of a power tool. Totation of the chuck sleeve in a first direction causes the jaws to move from an open position towards one another to a closed position in which the bit is engaged and held by the jaws. The cam core moves towards the rear end of the chuck when the jaws are tightened on the bit.

Implementations of this aspect may include one or more of the following features. The cam core may be connected to the chuck sleeve by at least one connector. The connector may urge the cam core towards the rear end of the chuck when the jaws are tightened on the bit. The cam core may include a radial outer surface. The cam core may include a slot in the radial outer surface. The slot may include a first end and a second end. The first end of the slot may be closer to the front end of the chuck than the second end of the slot is to the front end of the chuck. The chuck may further include a connector connecting the chuck sleeve and the cam core. An end of the connector may be engaged with and movable along the slot. The cam core may also include detents biased radially outwardly. The chuck sleeve may also include detent recesses which selectively engage the detents. The chuck may be part of a power tool. The power tool may be a powered drill. The powered drill may be powered by a battery pack. The chuck may include three jaws. Each of the three jaws may have an outer surface which is inclined. The detent recesses may include ramped surfaces configured to depress a detent plunger. The cam core may have three ramped surfaces.

Advantages may include one or more of the following. The chucks of this application have improved holding force due, in part, to the mechanical advantage achieved with the bevel gears. In addition, the bevel gears, which cause the jaws to move radially but not axially, reduces the axial length of the chucks, which reduces the overall length of the power tool. In addition, the chucks of this application integrate the clutch setting with the chuck sleeve, further reducing the number of components and overall length of the power tool. The chucks may have improved clamping force due to clamping the tool bit in a first phase with a first clamping force up to a first maximum clamping force and in a second phase with a second clamping force that exceeds the first maximum clamping force. This may be achieved, in part, by having a clamping ring and a jaw assembly together defining first and second clamping interfaces at different angles to the longitudinal axis. In addition, because the jaw assembly movement is primarily in the radial direction, this reduces the axial length of the chuck, which reduces the overall length of the power tool. These and other advantages and features will be apparent from the description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a first embodiment of a power tool and chuck.

FIG. 2 is a side view of the power tool and chuck of FIG. 1, partially in cross-section.

FIG. 3 is an exploded view of the chuck of FIG. 1.

FIGS. 4A-4D are close-up exploded views of the chuck body and jaw assemblies of the chuck of FIG. 1.

FIGS. 5A-5E are exploded views of the chuck of FIG. 1.

FIGS. 6A-6B are cross-sectional views of the chuck of FIG. 1 showing operation of the chuck.

FIG. 7A is a perspective view of the power tool and chuck of FIG. 1, partially in cross-section.

FIG. 7B is a close-up perspective view of the brake assembly of the power tool and chuck of FIG. 1.

FIG. 8 is a side view of a second embodiment of a power tool and chuck.

FIG. 9 is an exploded view of the chuck of FIG. 8.

FIGS. 10A-10C are close-up exploded views of the chuck body and jaw assemblies of the chuck of FIG. 8.

FIGS. 11A-11B are close-up exploded views of the clamp ring of the chuck of FIG. 8.

FIGS. 11C-11D are close-up views of the assembled clamp ring of the chuck of FIG. 8.

FIGS. 12A-12E are exploded views of the chuck of FIG. 8.

FIGS. 13A-13D are cross-sectional views of the chuck of FIG. 8, showing operation of the chuck.

FIG. 14 is a perspective view of an embodiment of a power tool and a chuck.

FIG. 15 is a perspective view of the chuck of FIG. 14.

FIG. 16 is a cross-sectional view of the chuck of FIG. 14.

FIG. 17A is a side view of the spindle and the first bevel gear components of the chuck of FIG. 1.

FIG. 17B is a perspective view of the components of FIG. 16A.

FIG. 17C is a cross-sectional perspective view of the components of FIG. 16A.

FIG. 18A is a perspective view of the components of FIG. 17A with the chuck body added.

FIG. 18B is a cross-sectional perspective view of the components of FIG. 18A.

FIG. 19A is a cross-sectional perspective view of the components of FIG. 18A with the second bevel gears added.

FIG. 19B is a perspective view of the components of FIG. 19A.

FIG. 20A is a perspective view of the components of FIG. 18A with the jaws added.

FIG. 20B is a cross-sectional perspective view of the components of FIG. 20A.

FIG. 21A is a cross-sectional view of the components of FIG. 20A with the front cover added.

FIG. 21B is a cross-sectional perspective view of the components of FIG. 21A.

FIG. 21C is a perspective view of the front cover of FIG. 21A.

FIG. 22A is a cross-sectional view of the components of FIG. 21A with the lever and pin added, shown in the drilling mode.

FIG. 22B is a perspective view of the components of FIG. 22A.

FIG. 23A is a cross-sectional view of the components of FIG. 21A with the lever and pin added, shown in the chuck mode.

FIG. 23B is a perspective view of the components of FIG. 23A.

FIG. 24A is a cross-sectional view of the components of FIG. 22A with the sleeve added, shown in the drilling mode.

FIG. 24B is a perspective view of the components of FIG. 24A.

FIG. 25A is a perspective view of a front of the tool housing of the power tool of FIG. 14.

FIG. 25B is a cross-sectional view of the components of FIG. 25A, shown in the chuck mode.

FIG. 26A and FIG. 26B are exploded perspective views of an electronic clutch of the power tool of FIG. 14.

FIG. 26C is an exploded side view of the electronic clutch of FIGS. 26A and 26B.

FIG. 27A is a perspective view of a portion of the electronic clutch of FIG. 26A.

FIG. 27B is a front view of a portion of the electronic clutch of FIG. 26A.

FIG. 28 is a side view of an exemplary embodiment of a drill that incorporates a chuck according to an exemplary embodiment of the present application;

FIG. 29 is a front perspective view of the exemplary embodiment of the chuck;

FIG. 30 is a cut-away side view of the exemplary embodiment of the chuck;

FIG. 31 is a cut-away perspective view of the exemplary embodiment of the chuck with the chuck sleeve removed;

FIG. 32 is a front view of the exemplary embodiment of the chuck with the chuck sleeve removed;

FIG. 33 is a side perspective view of the exemplary embodiment of the chuck with the chuck sleeve removed;

FIG. 34 is a front perspective view of the exemplary embodiment of the chuck with the chuck sleeve removed;

FIG. 35 is another view of the exemplary embodiment of the chuck with the jaws in a closed position;

FIG. 36 is another view of the exemplary embodiment of the chuck with the jaws in an intermediate position; and

FIG. 37 is a shadow view of the exemplary embodiment of the chuck with the jaws in a fully open position.

FIG. 38 is a side view of an exemplary embodiment of a drill that incorporates a chuck according to an exemplary embodiment of the present application;

FIG. 39 is a perspective view of the exemplary embodiment of the chuck;

FIG. 40 is a front view of the exemplary embodiment of the chuck with a front cover removed;

FIG. 41 is cross-sectional front view of the exemplary embodiment of the chuck;

FIG. 42 is cross-sectional side view of the exemplary embodiment of the chuck;

FIG. 43 is another cross-sectional side view of the exemplary embodiment of the chuck;

FIG. 44 is perspective view of the exemplary embodiment of the chuck with the front cover removed;

FIG. 45 is perspective view of the exemplary embodiment of the chuck with the chuck sleeve and front cover removed;

FIG. 46 is another perspective view of the exemplary embodiment of the chuck with the front cover removed;

FIG. 47 is another perspective view of the exemplary embodiment of the chuck with the front cover removed;

FIG. 48 is a front view of the exemplary embodiment of the chuck with the jaws in a fully open position;

FIG. 49 is a front view of the exemplary embodiment of the chuck with the jaws in an intermediate position;

FIG. 50 is a front view of the exemplary embodiment of the chuck with the jaws in a closed position;

FIG. 51 is a front view of the exemplary embodiment of the chuck with the jaws in a closed position with the chuck in a secured position;

FIG. 52 is a perspective view of the exemplary embodiment of the chuck with the jaws in a fully open position;

FIG. 53 is a perspective view of the exemplary embodiment of the chuck with the jaws in an intermediate position;

FIG. 54 is a perspective view of the exemplary embodiment of the chuck with the jaws in a nearly closed intermediate position;

FIG. 55 is a perspective view of the exemplary embodiment of the chuck with the jaws in a closed position;

FIG. 56 is a perspective view of the exemplary embodiment of the chuck with the jaws in a closed position with the chuck in a secured position;

FIG. 57 is a perspective view of the exemplary embodiment of the chuck with the jaws in a fully open position;

FIG. 58 is a perspective view of the exemplary embodiment of the chuck with the jaws in an intermediate position;

FIG. 59 is a perspective view of the exemplary embodiment of the chuck with the jaws in a nearly closed intermediate position;

FIG. 60 is a perspective view of the exemplary embodiment of the chuck with the jaws in a closed position; and

FIG. 61 is a perspective view of the exemplary embodiment of the chuck with the jaws in a closed position with the chuck in a secured position.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a power tool 10 includes a tool housing 12 that contains a motor 13 and a transmission 15. A handle 14 extends downward from the housing 12 includes a printed circuit board 17 that includes a motor control circuit. Coupled to the handle 14 is a trigger switch 16 that receives a user input and controls power delivery to the motor. Connected to the handle 14, but not shown, is a battery receptacle that receives a battery for powering the motor and/or a power cord for receiving input of AC power. A keyless chuck 20 for removably receiving and retaining a tool bit 5 extends along a longitudinal axis X and is coupled to, and may be integral with, the tool housing 12. Operation of the power tool 10 is accordance with known power tools, such as drills or screwdrivers.

Referring also to FIG. 3, the chuck 20 includes a chuck body 22 that extends generally along a longitudinal axis X. The chuck body 22 includes an input shaft 24 extending along the axis and couplable to an output spindle (not shown) of a power tool 10. Alternatively, the input shaft 24 may be integral with or simply be the output spindle of the power tool 10. The chuck body 22 also includes a generally cylindrical front portion 26 and a flange 28 disposed between the front portion 24 and the input shaft 24. The front portion 26 of the chuck body 22 defines a longitudinal bore 30 along the axis X for receiving the tool bit 5 therein. The chuck body 22 also has a sidewall 32 that defines a plurality (in this case three) radial slots 34 in communication with the longitudinal bore 30. An outer surface 36 of the sidewall 32 has a first thread 38.

A plurality of jaw assemblies 40 (one of which is shown in FIG. 3) are received in the chuck body 22, with each jaw assembly 40 at least partially received in one of the plurality of radial slots 34. Each jaw assembly 40 is moveable to engage and removably retain the tool bit 5 in the bore 30 of the chuck body 22. The jaw assembly 40 is configured to jaw assembly to clamp the tool bit 5, in a first phase, with a first clamping force up to a first maximum clamping force, and, in a second phase, with a second clamping surface that is greater than the first maximum clamping force.

Referring also to FIGS. 4A-4D, each jaw assembly 40 includes a first jaw portion 42 and a separate second jaw portion 44. The first jaw portion 42 is generally wedge shaped, and has a top clamping surface 46 and a bottom clamping surface 48. The second jaw portion 44 is generally rectilinearly shaped and includes a top clamping surface 50 that abuts the bottom clamping surface 48 of the first jaw portion 42, and a bottom clamping surface 51 that is configured to engage the tool bit 5 and that is generally parallel to the longitudinal axis X.

The first jaw portion 42 also includes a generally rectilinear downwardly directed protrusion 52 that is received in a correspondingly shaped top recess 54 in the second jaw portion 44. The first jaw portion 42 further includes a rearwardly directed cylindrical peg 56 that is configured to be received in a corresponding slot 58 in the second jaw portion 44. The second jaw portion 44 includes a rearwardly directed generally T-shaped tang 60 that is configured to be received in a corresponding slot 62 in the flange 28 of the chuck body 22. A first compression spring 64 is disposed between the T-shaped tang 60 and the bottom of the slot 62 and is configured to bias the second jaw portion 44 away from the chuck body 22 in a direction A that is generally transverse (e.g., orthogonal) to the longitudinal axis X. A second disk spring 66 is received over the peg 56 and is configured to bias the first jaw portion 42 in a direction B that is generally parallel to the longitudinal axis X.

Referring also to FIGS. 5A-5E, a generally frustroconical clamping ring 70 is received over the front portion 26 of the chuck body 22 and the jaw assemblies 40. The clamping ring 70 has a generally cylindrical threaded inner surface 76 that is threaded onto the first thread 38 on the front portion 26 of the chuck body 22 so that when the clamping ring 70 rotates relative to the chuck body 22, the clamping ring 70 translates relative to the chuck body 22 along the longitudinal axis X. An outer sleeve 80 is received over the clamping ring 70 and the front portion 26 of the chuck body 22. The outer sleeve 80 has an external gripping surface 82 and a plurality internal of longitudinal grooves 84 that engage a plurality of projections 72 on an outer surface 74 of the clamping ring 70 so that the outer sleeve 80 and clamping ring 70 rotate together. A generally frustroconical nosepiece 86 is received in a front end of the sleeve 80 and is retained on the sleeve 80 and the chuck body 22 by a C-ring 88. The nosepiece 86 may be rotatable relative to the sleeve 80 or may be configured to rotate together with the sleeve 80.

Referring also to FIGS. 6A-6B, the clamping ring 70 further includes an inner clamping surface 78 that abuts the top clamping surface 46 of the first jaw portion 42. When assembled, the inner clamping surface 78 of the clamping ring 70 and the top clamping surface 46 of the first jaw portion together define a first clamping interface 73 that is disposed at a first acute angle ?1 to the longitudinal axis X (e.g., approximately 30° to approximately 60°). The bottom clamping surface 48 of the top jaw portion 42 and the top clamping surface 50 of the bottom jaw portion 44 together define a second clamping interface 75 that is disposed at a second acute angle ?2 to the longitudinal axis X that is less than the first acute angle ?1 (e.g., approximately 1° to approximately 15°).

In operation, the chuck 20 is actuatable to clamp or release a bit between the jaw assemblies 40 when there is relative movement between the clamping ring 70 and outer sleeve 80, on the one hand, and the chuck body 22, on the other hand. Such relative motion can be achieved by holding the outer sleeve 80 and clamping ring 72 rotationally stationary (e.g., by a user grasping the outer sleeve 80 to prevent rotation or by locking the outer sleeve 80 to the tool housing 12, as described below), while actuating the motor to rotate the output spindle of the power tool and the chuck body 22. Alternatively, the output spindle can be coupled to a spindle lock which prevents backdriving of the output spindle when a torque is applied to the chuck 20 by a user. In this manner the chuck body 22 remains rotationally stationary while a user rotates the outer sleeve 80 and clamping ring 70 to clamp or release a tool bit 5 between the jaw assemblies 40.

The clamping of a tool bit 5 between the jaw assemblies 40 occurs in two phases. Referring to FIG. 6A, during a first clamping phase, relative rotation between the clamping ring 70 and the chuck body 22 causes the clamping ring 70 to move axially rearward in a direction C that is parallel to the longitudinal axis X. The inner clamping surface 78 of the clamping ring 70 slides along the top clamping surface 46 of the first jaw portion 42 (i.e., along the first interface 73) in a direction D. At the same time, the disk spring 66 biases the first jaw portion 42 axially forward in a direction E so that no relative motion occurs between the bottom clamping surface 48 of the first jaw portion 42 and the top clamping surface 50 of the second jaw portion 44 (i.e., along the second clamping interface 75). This is because the second clamping interface 75 is orientated at a smaller angle relative to the longitudinal axis X than the first clamping interface 73. Thus, the top jaw portion 42 and bottom jaw portion 44 move radially inward in unison in a direction F that is transverse to the longitudinal axis X and clamps the tool bit 5 with a first clamping force up to a maximum first clamping force.

Referring to FIG. 6B, once the bottom clamping surface 51 of the bottom jaw portion 44 clamps the tool bit 5 with the maximum first clamping force, the second clamping phase begins. As the clamping ring 70 continues to rotate and move axially rearward in the direction C, the friction force between the top clamping surface 46 of the first jaw portion 42 and the clamping surface 78 of the clamping ring 70 (i.e., the first clamping interface 73) exceeds the friction force between the bottom clamping surface 48 of the first jaw portion 42 and the top clamping surface 54 of the second jaw portion 44 (i.e., the second clamping interface 75) and the spring force supplied by the disk spring 66. This causes the relative motion between the clamping ring 70 and the first jaw portion 42 along the first clamping interface 73 to stop, and relative motion of the first jaw portion 42 and the second jaw portion 44 along the second clamping interface 75 to start. Thus, the clamping ring 70 will continue to rotate and translate in the direction C. The first jaw portion 42 will slide along the second clamping interface 75 in a direction G that is parallel to the second angle ?2. This causes the second jaw portion 44 to move in the direction F that is transverse (e.g., orthogonal) to the longitudinal axis X so that the jaw assembly 40 clamps the tool bit 5 at a second clamping force that is greater than the maximum first clamping force. These movements will continue until the disk spring 66 bottoms out or until the force acting on the second clamping interface 75 becomes too great for torque being inputted to continue rotating and translating the clamping ring 70. Thus, the combination of initial tightening along the first clamping interface 73 to a first maximum force and further tightening along the second clamping interface 75 to a force that is greater than the first maximum force provides enhanced holding force on the tool bit 5 in a compact assembly.

Referring also to FIGS. 7A-7B, the power tool 10 may optionally include a brake assembly 90 configured to hold the outer sleeve 80 and clamping ring 70 rotationally stationary relative to the tool housing 12 while tightening or loosening the chuck 20, so that the chuck 20 can be tightened or loosened by activating the motor 13 to rotate the chuck body 22. The brake assembly 90 includes a brake bar 91 having a longitudinally extending portion 92 that is fixed in the tool housing 12 and a flexible tang 97. A button 93 is disposed beneath the chuck 20 and has an inclined surface 94 configured to abut the flexible tang 97 and a spring 95 biasing the button 93 axially forward opposite direction Z. The button 93 is axially moveable in a direction Z generally parallel to the longitudinal axis X. When the button 93 is depressed, the inclined surface 94 of the button 93 forces the tang 92 in a transverse direction Y to engage the outer sleeve 80 of the chuck and hold the outer sleeve 80 (and thus also the clamping ring 70) rotationally stationary relative to the tool housing 10. Thus, when the user actuates the motor 13 while the button 93 is depressed, the motor 13 will cause the chuck body 22 to rotate relative to the clamping sleeve 70, causing tightening or loosening of the jaw assemblies 40 on a tool bit 5. When the button 93 is released, the spring 95 pushes the button axially forward, and the tang 92 moves away from the outer sleeve 80, which enables the tool 10 to operate in its normal drilling or driving mode(s). The button 93 may optionally engage an electrical switch 96 when depressed. The electrical switch 96, if engaged, will cause an electrical signal to be communicated to the controller, so that operation of the motor can be adjusted in the chuck tightening or loosening mode. For example, the controller may cause the motor to operate at a lower speed for greater control when tightening or loosening the chuck.

Referring to FIG. 8, in another embodiment a power tool 110 includes a tool housing 112 that contains a motor and a transmission and a handle 114 that extends downward from the housing 112. Coupled to the handle 114 is a trigger switch 116 that receives a user input and controls power delivery to the motor. Connected to the handle 114, but not shown, is a battery receptacle that receives a battery for powering the motor and/or a power cord for receiving input of AC power. A keyless chuck 120 for receiving a tool bit 105 extends along a longitudinal axis X and is coupled to, and may be integral with, the tool housing 112. Operation of the power tool 10 will be accordance with known power tools, such as drills or screwdrivers.

Referring also to FIG. 9, the chuck 120 includes a chuck body 122 that extends generally along the longitudinal axis X. The chuck body 122 includes an input shaft 124 extending along the axis and couplable to an output spindle (not shown) of the power tool 110. Alternatively, the input shaft 124 may be integral with or simply be the output spindle of the power tool 110. The chuck body 122 also includes a generally cylindrical front portion 126 and a flange 128 disposed between the front portion 124 and the input shaft 124. The front portion 126 of the chuck body 122 defines a longitudinal bore 130 along the axis X for receiving a tool bit therein. The chuck body 122 also has a sidewall 132 that defines a plurality (in this case three) radial slots 134 in communication with the longitudinal bore 130. An outer surface 136 of the sidewall 132 has a first thread 138.

A plurality of jaw assemblies 140 (one of which is shown in FIG. 3) are received in the chuck body 122, with each jaw assembly 140 at least partially received in one of the plurality of radial slots 134. Each jaw assembly 140 is moveable to engage and removably retain the tool bit 105 in the chuck body 122 to cause the jaw assembly to clamp the tool bit at a first clamping force up to a first maximum clamping force, and a second clamping surface that exceeds the first maximum clamping force.

Referring also to FIGS. 10A-10C, each jaw assembly 140 includes a first jaw portion 142 and a separate second jaw portion 144. The first jaw portion 142 is generally wedge shaped, and has a top clamping surface 146 and a bottom clamping surface 148. The second jaw portion 144 is partially wedge shaped and includes a top clamping surface 150 that abuts the bottom clamping surface 148 of the first jaw portion 142, and a bottom clamping surface 151 that is configured to engage the tool bit 105 and that is generally parallel to the longitudinal axis X.

The first jaw portion 142 also includes a downwardly directed protrusion 152 that is received in a correspondingly shaped top recess 154 in the second jaw portion 144. The second jaw portion 144 includes a rearwardly directed generally T-shaped tang 160 that is configured to be received in a corresponding slot 162 in the flange 128 of the chuck body 122. A first compression spring 164 is disposed between the T-shaped tang 160 and the bottom of the slot 162 and is configured to bias the second jaw portion 144 away from the chuck body 122 in a direction A′ that is generally transverse (e.g., orthogonal) to the longitudinal axis X.

Referring also to FIGS. 11A-11D, a clamping ring 170 is received over the front portion 126 of the chuck body 122 and the jaw assemblies 140. The clamping ring 170 has a generally cylindrical inner clamping ring 171 and a generally cylindrical outer clamping ring 173. The inner clamping ring 171 includes an inner thread 175 threaded onto the thread 138 on the front portion 126 of the chuck body 122 so that when the inner clamping ring 171 rotates relative to the chuck body 122, the inner clamping ring 171 translates relative to the chuck body 122 along the longitudinal axis X. The inner clamping ring 171 also has an outer thread 177 having a finer pitch than the inner thread 175. The outer clamping ring 173 has an inner thread 179 configured to be threaded onto the outer thread 177 of the inner clamping ring 171. The outer clamping ring 173 also has an internal clamping surface 172 configured to engage the top clamping surface 146 of the first jaw portion 142.

The inner clamping ring 171 also has a detent 174 that is biased radially outward by a spring 176 and that is received in a pocket 178 in the outer threaded surface 177 of the ring 175. The outer clamping ring 173 includes a plurality of recesses 169 that interrupt the inner thread 179. Each of the plurality of recesses 169 is configured to receive the detent 174. When the detent is received in one of the recesses 169, the inner clamping ring 171 and the outer clamping ring 173 rotate together as a unit. When the relative torque between inner clamping ring 171 and the outer clamping ring 173 overcomes the radial force exerted by the spring 176 on the detent 174, the detent 174 will slip out of the recesses 169, enabling the inner clamping ring 171 to rotate and translate relative to the outer clamping ring 173 by the threaded engagement of the outer thread 177 and the inner thread 179, as discussed further below.

Referring also to FIGS. 12A-12E an outer sleeve 180 is received over the clamping ring 170 and the front portion 126 of the chuck body 122. The outer sleeve 180 has an external gripping surface 182 and a plurality internal of longitudinal grooves 184 that engage a plurality of projections 186 on an outer surface 188 of the clamping ring 170 so that the outer sleeve 180 and clamping ring 170 rotate together. A thrust ring 190 is received over the front portion 126 of the chuck body 122 between the clamping ring 170 and first jaw portion 142 (e.g., as shown in FIG. 13A). A generally frustroconical nosepiece 192 is received in a front end of the sleeve 180 and is retained on the sleeve 180 and the chuck body 122 by a C-ring 194. The nosepiece 192 may be rotatable relative to the sleeve 180 or may be configured to rotate together with the sleeve 180.

Referring also to FIGS. 13A-13D, when assembled, the bottom clamping surface 148 of the top jaw portion 142 abuts the top clamping surface 150 of the bottom jaw portion 144 together define a first clamping interface 181 that is disposed at a first acute angle ?1 to the longitudinal axis X (e.g., approximately 30° to approximately 60°). The inner clamping surface 172 of the clamping ring 170 abuts the top clamping surface 146 of the first jaw portion 142 to define a second clamping interface 175 that is disposed at a second acute angle ?2 to a line L that is parallel to the longitudinal axis X (e.g., approximately 1° to approximately 15°) that is less than the first acute angle ?1.

In operation, the chuck 120 is actuatable to clamp or release the tool bit 105 between the jaw assemblies 140 when there is relative movement between the clamping ring 170 and outer sleeve 180, on the one hand, and the chuck body 122, on the other hand. Such relative motion can be achieved by holding the outer sleeve 180 and clamping ring 170 rotationally stationary (e.g., by a user grasping the outer sleeve 180 to prevent rotation or by locking the outer sleeve 180 to the tool housing 112, as described above with respect to FIGS. 7A-7B), while actuating the motor to rotate the output spindle of the power tool and the chuck body 122. Alternatively, the output spindle can be coupled to a spindle lock which prevents backdriving of the output spindle when a torque is applied to the chuck 120 by a user. In this manner the chuck body 122 remains rotationally stationary while a user rotates the outer sleeve 180 and clamping ring 170 to clamp or release a tool bit between the jaw assemblies 180.

The clamping of the tool bit 105 between the jaw assemblies 140 occurs in two phases. Referring to FIG. 13C, during a first clamping phase, as the outer sleeve 180 rotates relative to the chuck body 120, the detent 174 on the inner clamping ring 171 remains secured in one of the recesses 169 in the outer clamping ring 173 so that the inner clamping ring 171 and the outer clamping ring 173 rotate as a unit relative to the chuck body 122. This rotation of the inner clamping ring 171 and outer clamping ring 173 causes them move axially as a unit rearward in a direction C′ that is generally parallel to the longitudinal axis X. At the same time the inner clamping surface 172 of the outer clamping ring 173 remains frictionally engaged with the top clamping surface 146 on the first jaw portion 142, while the bottom clamping surface 148 of the first jaw portion 142 slides along the top clamping surface 150 of the second jaw portion 144 (i.e., along the first interface 181) in a direction D′. This is because the second clamping interface 175 is orientated at a smaller angle relative to the longitudinal axis X than the first clamping interface 181. The movement of the top jaw portion 142 in the direction D′ pushes the first jaw portion 144 radially inward in a direction E′ that is transverse (e.g., orthogonal) to the longitudinal axis X against the force of the spring. The bottom jaw portion 144 moves radially inward so that its bottom clamping surface 151 clamps the tool bit 105 with a first clamping force up to a maximum first clamping force.

Referring to FIG. 13D, once the bottom clamping surface 151 of the bottom jaw portion 144 clamps the tool bit 105 with the maximum first clamping force, the second clamping phase begins. As the outer sleeve 180 continues to rotate, the detent 174 slips out of the recess 169, allowing the outer clamping ring 173 to rotate relative to the inner clamping ring 171. At the same time, the friction force between the bottom clamping surface 148 of the first jaw portion 142 and the top clamping surface 150 of the second jaw portion 144 (i.e., the first clamping interface 181) exceeds the friction force between top clamping surface 146 of the first jaw portion 142 and the clamping surface 172 of the outer clamping ring 171 (i.e., the second clamping interface 175). This causes the relative motion first jaw portion 142 and the second jaw portion 144 along the first clamping interface 181 to stop, which also causes the axial movement of the inner clamping ring 171 to stop. Instead, the outer clamping ring 173 will rotate and translate relative to the inner clamping ring 171 in the axial direction C′ that is generally parallel to the longitudinal axis. At the same time, there is relative motion between the inner clamping surface 172 of the outer clamping ring 173 and the top clamping surface 146 of the first jaw portion 142 along the second clamping interface 175 in a direction F′ parallel to the second angle ?2. This causes the first jaw portion 142 and the second jaw portion 144 to move in unison in the direction E′ that is transverse (e.g., orthogonal) to the longitudinal axis X. This causes the second jaw portion 144 and, thus the jaw assembly 140, to clamp the tool bit 105 at a second clamping force that is greater than the maximum first clamping force. This movement will continue until the force acting on the second clamping interface 175 becomes too great for torque being inputted to continue rotating and translating the outer clamping ring 173. Thus, the combination of initial tightening along the first clamping interface 173 to a first maximum force and further tightening along the second clamping interface 175 to a force that is greater than the first maximum force provides enhanced holding force on the tool bit in a compact assembly.

Referring to FIGS. 14-16, a power tool 210 includes a tool housing 212 having a rear housing portion 213 that contains a motor (not shown) and a transmission (not shown) and a front housing portion 272 that is coupled to the rear housing portion 213 by a plurality of bolts or screws (not shown). A handle 214 is integral with and extends downward from the rear housing portion 213. Coupled to the handle 214 is a trigger switch 216 that receives a user input and is coupled to a controller (e.g., a microprocessor or control circuit, not shown) that controls power delivery to the motor. A battery receptacle 218 is coupled to the handle 214 and receives a battery (not shown) for providing electrical power to the power tool 210. Alternatively, the battery receptacle may be replaced with a power cord for receiving input of AC power. A chuck 220 for receiving a tool bit 225 extends along a longitudinal axis X and is coupled to, and may be non-removable from, the tool housing 212. Operation of the power tool 10 will be in accordance with known power tools, such as drills or screwdrivers.

Referring also to FIGS. 17A-17C, the transmission includes an output spindle 222 that is rotationally driven by the motor (either directly or indirectly via a plurality of gears that reduce the output speed of the motor). The output spindle 222 includes a shaft 224 extending along the axis X and a disk-shaped flange 226 coupled to the front end of the shaft 224. The chuck 220 includes a first ring-shaped bevel gear 228 affixed to the front of the flange 226 by a set of screws 31 so that the first bevel gear 228 rotates together with the output spindle 222.

Referring also to FIGS. 18A-18C, the chuck 220 further includes a generally cylindrical chuck body 232 extending along the axis X and received over the first bevel gear 228 and the flange 226 of the output spindle 222. The chuck body 232 is axially retained on and rotatable relative to the output spindle 224 and the first bevel gear 228 by a screw 231. A bearing 234 is disposed between the chuck body 232 and the first bevel gear 228. The chuck body 232 defines a longitudinal bore 234 along the axis X for receiving a tool bit 225, and a plurality (in this case three) radial openings 236 in a generally cylindrical sidewall 238 of the chuck body 232. The sidewall 238 also includes a plurality of radial splines 240 evenly spaced about the outer peripheral surface of the rear and of the chuck body 232.

Referring also to FIGS. 19A-19B, each of the radial openings 236 receives a second bevel gear 242 that is meshed with the first bevel gear 228 so that rotation of the first bevel gear 228 causes rotation of the second bevel gears 242. Each second bevel gear 242 is supported in its radial opening 236 by a post 244 received in a bearing 246. Each post 244 defines a threaded opening 248.

Referring also to FIGS. 20A-20B, a chuck jaw 250 is coupled to each of the second bevel gears 242. Each chuck jaw 250 includes a jaw face 252 received in the longitudinal opening of the chuck body and configured to clamp on a tool bit 225. Each chuck jaw 250 includes an externally threaded stem 253 that is threadably received in the internally threaded opening 248 in the post 244 of its respective second bevel gear 242. Referring also to FIGS. 21A-21C, a nose cone 254 is fixed onto the front of the chuck body 232. The nose cone includes six rearward projections 256 defining three sets of channel surfaces 258 that each receive one of the jaws 250 therebetween. When the second bevel gears 242 rotate, the jaws 250 move radially inward, but not axially, to clamp the tool bit 25 or radially outward, but not axially, to release the tool bit 25.

Referring also to FIGS. 22A-22B, a mode change mechanism 260 is received in a side pocket 262 in the chuck body 232. The mode change mechanism 260 includes a lever 264 with a top arm 266 and a bottom arm 268 that pivots about a central pivot 70. The bottom arm 266 is engaged with a pin 277 that moves parallel to the axis X between a rearward position (drill mode) as shown in FIGS. 22A and 22B and discussed further below, and a forward position (chuck mode) as shown in FIGS. 23A-10B. The pin 277 has an inner spline 276 that is engaged with a spline on the chuck body 232 and is biased toward the rearward (drill mode) position by a reset spring 274. In the drill mode (FIGS. 22A-9B), the pin 277 engages the first bevel gear 228 to transmit rotation of the first bevel gear 228 to the chuck body 232 so that the entire chuck body 232 rotates together with the spindle 222. In the chuck mode (FIGS. 23A-23B), the pin 277 moves forward against the force of the spring 274 to disengage from the first bevel gear 228 so that the chuck body 232 does not rotate together with the spindle 222, which enables the spindle 222 to cause the jaws to tighten or loosen, as described further below.

Referring also to FIGS. 24A-24B and 25A-25B, a generally cylindrical sleeve 280 is received over the chuck body 232 and is moveable axially relative to the chuck body 232 between a forward (drill mode) position (FIGS. 24A-24B) and a rearward (chuck mode) position (FIGS. 25A-25B). The sleeve also has a first set of internal teeth 282 that engage the splines 240 on the periphery of the chuck body 232 and a second set of internal teeth 284 that engage sleeve locking teeth 285 on the front housing portion 272, so that the chuck body 232 and the sleeve 280 are rotationally locked to the front housing portion 272 (and thus to the tool housing 12) when the sleeve 280 is pulled into the rearward position (chuck mode), as shown in FIGS. 25A-25B.

In operation, when a user wants to tighten or loosen the jaws 250 on the tool bit 25, the user pulls the sleeve 280 rearward to activate the chuck mode (as shown in FIGS. 25A-25B). In the chuck mode, the first set of internal teeth 282 on the sleeve 280 rotationally fix the sleeve 280 to the chuck body 232 and the second set of internal teeth 284 rotationally fix the sleeve 280 to the sleeve locking teeth 285 on the front housing portion 272. At the same time, the lever 264 pivots in a counter-clockwise direction CCW to disengage the pin 277 from the first bevel gear 228 so that the first bevel gear 228 does not cause the chuck body 232 to rotate. When the user pulls the trigger switch 216, the spindle 222 causes the first bevel gear 228 to rotate, which causes the second bevel gears 242 to rotate. Rotation of the second bevel gears 242 causes the jaws 250 to translate radially inward (to clamp the tool bit) when the motor is rotated in a first (e.g., forward) direction or radially outward (to release the tool bit) when the motor is rotated in a second opposite (e.g., reverse) direction. Alternatively, the jaws can be causes to translate radially inward or outward by rotating the sleeve relative to the tool housing. Operation of the chuck is accomplished independently of using a chuck key.

As shown in FIGS. 24A-24B, when the user is ready to drill or drive a fastener, the user releases the sleeve 280, which moves axially forward due to pivoting of the lever 264 in a clockwise direction CW under the bias of the spring 274. The sleeve 280 is disengaged from the and from the chuck body 232 and the tool housing 212 so that the chuck body 232 can rotate relative to the tool housing 212. At the same time the pin 277 is engaged with the teeth on the first bevel gear 228 and to the chuck body 232, so that rotation of the first bevel gear 228 causes the chuck body 232 to rotate. Thus, when the user pulls the trigger switch 216, the spindle 222, the first bevel gear 228, the second bevel gears 242, and the chuck body 232 all rotate together about the axis X, causing the drill bit to rotate and perform a drilling or driving operation.

Referring also to FIGS. 26A-27B, the power tool 212 optionally may include an electronic clutch 288. The electronic clutch 288 includes the front housing portion 272, which has an annular recess 291 that receives an at least partially ring shaped printed circuit board 290. The printed circuit board 290 has discrete pads or positions 292 corresponding to different electronic clutch settings (e.g., for stopping or slowing the motor when different torque levels are reached). The printed circuit board 290 may also carry a chuck mode switch 2102 that can be depressed when the sleeve 280 is moved rearward into the chuck mode (as described above) so that the electronic clutch 288 is deactivated in the chuck mode. The printed circuit board 290 is coupled to the controller (not shown) by communication and power transmitting wires 293 and an electrical connector 295.

The annular recess 291 also receives an at least partially ring shaped wiper mount plate 296 that carries a wiper 298 on its rear side that faces the printed circuit board 290. The wiper 298 is configured to engage one of the pads 292 on the printed circuit board 290 as the sleeve 280 is rotated relative to the printed circuit board 290 to change the clutch setting. The resistance of the circuit on the printed circuit board 290 changes as the wiper 298 rotates and engages different pads 292, with each pad or resistance corresponding to a different electronic clutch setting. The wires communicate the resistance of the circuit to the controller, which changes the torque setting of the electronic clutch 288 accordingly. For example, the controller may use the resistance to change the clutch setting and the electronic clutch may be operable to stop or reduce power to the motor in accordance with known electronic clutches, such as the embodiments disclosed in U.S. Pat. No. 9,193,055, which is incorporated by reference.

The front housing portion 272 also includes a plurality of dimples 294 disposed in the annular recess 291. The wiper mount plate 296 carries a detent pin 2100 on its rear side that faces the annular recess 291. The detent pin 2100 is biased rearward and configured to engage one of the dimples 294 in the tool housing 212 as the wiper mount plate 296 rotates, providing tactile feedback and detent settings for each of the clutch settings. The wiper mount plate 296 also carries a rearward facing protrusion 2105 configured to depress the chuck mode switch 2102 when the sleeve 280 is pulled rearward into its chuck mode to disable the electronic clutch.

The opposite front side of the wiper mount plate 296 has a plurality of recess 2104 that faces toward the sleeve 280, which is received partially over the front housing portion 272. Each recess 2104 includes a compression spring 2106 is received over a stem 2108 carried on an inner annular inner annular wall 2108 inside the sleeve 280, so that the wiper plate 296 rotates together with the sleeve 280. The springs 2106 bias the sleeve 280 forward, away from the front housing portion 272, into its drill mode position.

When the sleeve 280 is in its forward position (drill mode), as shown in FIGS. 24A-24B, the sleeve 280 can be rotated along with the wiper mount plate 296 and the wiper 298 to change the electronic clutch setting in the controller. As the sleeve 280 is rotated relative to the tool housing 212, the rotational position of the wiper 298 changes, which changes the resistance of the electronic clutch board. The sleeve 280 also has a plurality of indicia 2110 to visually indicate the clutch setting to the user. When the sleeve 280 is pulled to its rearward position (chuck mode), as shown in FIGS. 25A-25B, the protrusion 2105 depresses the chuck mode switch 2102 to disable the electronic clutch 288. At the same time, the, the first set of internal teeth 282 on the sleeve 280 rotationally fix the sleeve 280 to the chuck body 232 and the second set of internal teeth 284 rotationally fix the sleeve 280 to the front housing portion 272 so that the chuck may be tightened or loosened, as described above.

With initial reference to FIG. 28, a drill chuck constructed in accordance to one example of the present teachings is shown and generally identified at reference numeral 310. The drill chuck 310 is shown operatively associated with an exemplary drill 312 that can have a housing 314 including a handle portion 316 and a body portion 318. The exemplary drill 312 can include a battery pack 320 that can be releasably attached to the handle portion 316. It will be appreciated however that while the exemplary drill 312 is shown in FIG. 28 as a cordless battery powered drill, the principles of the drill chuck 310 disclosed herein can also be applicable to other drill configurations, such as corded drills.

A trigger 322 can be provided on the handle portion 316 for selectively providing electric current from the battery pack 320 to a motor 324 provided within the body portion 318 of the housing 314. A transmission device 326 can be drivingly connected to the motor 324. The drill chuck 310 can be driven by the motor 324 through the transmission device 326. The drill 312 may also include a clutch 330. Those skilled in the art will appreciate that other device may be incorporated into the drill 312, such as a hammer drill mechanism or other features that can be utilized in combination with the drill chuck 310 without departing from the scope of the present disclosure.

The chuck 310 is shown in greater detail in FIGS. 29-37. As shown in FIG. 29, the chuck 310 includes a chuck sleeve 350 and a chuck body 3100. Three jaws 3101 project out of the front of the chuck body 3100. Rotating the chuck sleeve 350 relative to the chuck body 3100 opens the jaws 3101 by spreading them apart from one another or closes the jaws 3101 so that they move torwards each other and can hold a bit. Rotating the chuck sleeve 350 in a first direction causes the jaws 3101 to open and rotating the chuck sleeve 350 in a second direction, opposite the first, causes the jaws 3101 to close.

A cross-sectional view of the chuck 310 is shown in FIG. 30. As shown in FIG. 30, the chuck 310 includes a front F a rear R. The jaws 3101 extend at the front F of the chuck 310 and the rear R faces the remainder of the drill 312.

As shown in FIG. 30, the internals of the chuck 310 includes a nut 3120. In the exemplary embodiment, the nut 3120 is torsionally coupled to the sleeve 350, as will be described in further detail below. As also shown in FIG. 30, the chuck 310 includes a rear plate 3130 and a bore hole 3140. The rear plate 3130 forms a back surface for the chuck 310. The chuck 310 is connected to the other parts of the drill 312 at the bore hole 3140, and is operatively connected to the motor 324 through the bore hole 3140. The bore hole 3140 may be threaded to promote connection to the rest of the drill 312, or the chuck 310 may be connected by other means. For example, the bore hole 3140 may be used to effect a frictional or interference fit.

The nut 3120 is frustoconical in shape and includes threads 3121 at its forward end. The threads 3121 are on the inside of nut 3120 and interact with threads 3102 on the outside of the jaws 3101. The chuck 310 also includes three lifters 3110, as will explained in further detail below. The lifters 3110 opening the jaws 3101. The exemplary embodiment includes three lifters 3110.

Due to their torsional connection, when the outer sleeve 350 is rotated, it rotates the nut 3120. The nut rotates and translates due to the ramped threads 3102 and 3121 on the jaws and the nuts, respectively. As the nut 3120 travels axially rearward (towards the drill 312 and the rear plate 3130), the nut 3120 pushes on the jaws 3101, and the jaws 3101 move towards one another in order to close. In this manner, the jaws 3101 can hold a bit (not shown) therebetween.

As the nut 3120 travels axially forwardly, towards the front F of the chuck 310, the lifter 3110 is pushed forwardly. The lifter 3110 interacts with the jaws 3101 in order to push the jaws 3101 away from one another in order to open the jaws 3101. Opening the jaws 3101 allows a bit to be removed or a new bit to be placed between the jaws 3101.

As will be appreciated, the jaws 3101 move only radially inwardly towards a rotational axis A (FIG. 30) of the chuck 310. The jaws 3101 do not move axially forwardly towards the front F of the chuck 310 or rearwardly towards the rear R of the chuck 310. Rather, the nut 3120 moves axially forwardly and rearwardly.

The chuck has a central longitudinal axis A. The jaws 3101 and the chuck 310 generally are centered around axis A. Additionally, the chuck 310 rotates about the axis A when driven by the motor 324. Axis A is also the rotational axis of the chuck sleeve 350 and the nut 3120 when they move relative to the chuck body 3100.

Further explanation of the closing of the jaws 3101 will be explained with reference to FIG. 30. As mentioned above, FIG. 30 is a cross sectional view of the exemplary embodiment of chuck 310. The cross sectional view cuts through the threaded portion 3102 of the jaw 3101 at the bottom of FIG. 30. As shown there, the threads 3102 mesh with the threads 3121 on the nut 3120. As discussed above, the jaws are axially fixed such that they do not move forward or rearward. Conversely, the nut 3120 is able to move axially forward and rearwardly. The nut 3120 is shown in its furthermost rearward position in FIG. 30. In this position, the jaws 3101 are fully closed.

When the chuck sleeve 350 is rotated in a first direction, the nut 3120 rotates with it. This causes the nut 3120 to also move axially forward. As the nut 3120 moves axially forward, the outer surface of the nut 3120 contacts an inner surface of the lifters 3110. Owing to its frustoconical shape, when the nut 3120 moves forward, a wider portion of the nut 3120 contacts the lifters 3110 and pushes the lifters radially outwardly.

As best shown in FIG. 32, the lifters 3110 have keyed portions 3113 and the jaws 3101 have a corresponding keyed portion 3103. The keyed portion 3103 of the jaws 3101 fits into the keyed portions 3113 of the lifters 3110, such that when the lifters move outwardly in the direction O, the keyed portions 3113 of the lifters 3110 pull on the keyed portions 3103 of the jaws 3101 in order to pull the jaws 3101 away from one another. In this way, the chuck jaws 3101 can be opened.

When the chuck sleeve 350 is rotated in a second direction, the nut 3120 rotates with it to close the jaws 3101. As shown in FIGS. 30 and 4 an outer surface of the jaws 3101 with the threads 3102 slopes outwardly in the rearward direction. As the nut 3120 moves from a forward position shown in FIG. 27 towards the rearward position shown in FIG. 30, the nut 3120 interacts with an increasingly wide and outward portion of the jaws 3101. This causes the nut 3120 to push the jaws 3101 inwardly. For example, as shown in FIG. 30, the nut 3120 has pushed against the jaws 3101 such that they are fully closed.

FIGS. 35-37 are a shadow illustration of the chuck with the jaws 3101 at various positions. FIG. 35 illustrates the jaws 3101 in a fully closed position. FIG. 36 illustrates the jaws 3101 in a partially open position. FIG. 37 illustrates the jaws 3101 in a fully open position. As will be appreciated, the jaws 3101 do not necessarily need to be moved to the fully open position in order to insert a bit. Similarly, the jaws 3101 do not have to be in a fully closed position in order to hold a bit.

FIGS. 33 and 34 illustrate the chuck 310 with the chuck sleeve (outer sleeve) 350 and the end plate 3130 removed. As shown in FIGS. 33 and 34, the nut 3120 includes a projection 3124. The nut 3120 also includes a slot 3125. The slot 3125 interacts with a coupling projection 351, as shown in FIG. 30. The coupling projection 351 hits the projection 3124 at either side of the slot 3125 to move the nut 3120 rotationally when the chuck sleeve 350 is rotated. Additionally, as the nut 3120 may move forward relative to the chuck sleeve 350 from the position shown in FIG. 30, the slot 3125 may slide forward on the coupling projection 351. In the exemplary embodiment of the chuck 350, there are a plurality of slots 3125 and a corresponding plurality of coupling projections 351. In the case of the exemplary embodiment, there are six slots 3125 and six coupling projections 351.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

With initial reference to FIG. 38, a drill chuck constructed in accordance to one example of the present teachings is shown and generally identified at reference numeral 410. The drill chuck 410 is shown operatively associated with an exemplary drill 412 that can have a housing 414 including a handle portion 416 and a body portion 418. The exemplary drill 412 can include a battery pack 420 that can be releasably attached to the handle portion 416. It will be appreciated however that while the exemplary drill 412 is shown in FIG. 38 as a cordless battery powered drill, the principles of the drill chuck 410 disclosed herein can also be applicable to other drill configurations, such as corded drills.

A trigger 422 can be provided on the handle portion 416 for selectively providing electric current from the battery pack 420 to a motor 424 provided within the body portion 418 of the housing 414. A transmission device 426 can be drivingly connected to the motor 424. The drill chuck 410 can be driven by the motor 424 through the transmission device 426. The drill 412 may also include a clutch 430. Those skilled in the art will appreciate that other device may be incorporated into the drill 412, such as a hammer drill mechanism or other features that can be utilized in combination with the drill chuck 410 without departing from the scope of the present disclosure.

The chuck 410 is shown in greater detail in FIGS. 39-61. As shown in FIG. 39, the chuck 410 includes a chuck sleeve (or outer sleeve) 450 and a front cover 460. Three jaws 4101 are disposed in a central opening of chuck 410. Rotating the chuck sleeve 450 relative to the jaws 4101 opens the jaws 4101 by spreading them apart from one another or closes the jaws 4101 so that they move towards each other and can hold a bit. Rotating the chuck sleeve 450 in a first direction causes the jaws 4101 to open and rotating the chuck sleeve 450 in a second direction, opposite the first, causes the jaws 4101 to close.

A front view of the chuck 410 with the front cover 640 removed is shown in FIG. 40 and a cross-sectional front view of the chuck 410 is shown in FIG. 41. As shown in FIGS. 40 and 4, the chuck 410 has a main body 470, a cam core 480 and a detent plunger 490 projecting outwardly from the an outer circumferential surface 482 of the cam core 480. As shown in FIG. 41, the detent plungers 490 are biased outwardly by springs. Other biasing members may be used instead of springs 491. The chuck sleeve 450 has detent recesses 451.

As shown in FIG. 40, depending upon the relative positions of the sleeve 450 and the cam core 480, the detent plungers 490 engage the detent recesses 451. Additionally, the detent plungers 490 may engage in with the detent recesses 451 such that when the user rotates the chuck sleeve 450, the cam core 480 rotates along with the chuck sleeve 450 owing to the interaction between the detent plungers 490 and the detent recesses 451. This will occur when the detent plungers 490 are engaged with the detent recesses 451 and the cam core 480 does not experience sufficient resistance to rotation. Once the cam core 480 experiences sufficient resistance to rotation, the sleeve 450 may rotate relative to the cam core 480. For example, when the jaws 4101 of the chuck 410 close about a bit 425, the cam core 480 will be prevented from rotating due to the clamping. When this happens, as the chuck sleeve 450 is further rotated, the detent plungers 490 are depressed against the springs 491 by the chuck sleeve 450 and move out of the detent recesses 451, as is shown by the cross-sectional view of FIG. 41.

As also shown in FIGS. 40 and 41, the cam core 480 has inner ramped surfaces 481 and the chuck jaws 4101 have angled outer surfaces 4102. The angled outer surfaces 4102 are in contact with the inner ramped surfaces 481. As the cam core 480 rotates, the inclined inner surfaces 481 of the cam core 480 press against the outer surfaces 4102, and push the jaws 4101 inwardly. The causes the clamping surfaces 4103 of the jaws 4101 to move towards one another to clamp a bit 425. As will be described in further detail below, the cam core 480 moves in conjunction with rotation of the chuck sleeve 450.

Closing of the jaws 4101 is shown in FIGS. 48-51. FIGS. 48-51 are front views of the chuck 410 with the front cover 460 removed and in various states of closing. FIG. 48 illustrates the chuck 410 with the jaws 4101 in a fully open state (the jaws 4101 are spread the farthest apart from one another). As shown in FIG. 48, the outer surfaces (or rea faces) 4102 of the jaws 4101 are at the deepest portion of the inner surfaces 481 of the cam core 480.

In FIG. 49, the cam core 480 is rotated clockwise CW somewhat as compared to FIG. 48. Clockwise CW here is with reference to viewing the chuck 410 from the front of the chuck 410, as is shown in FIGS. 48-51, and is indicated by arrow CW in FIG. 49. A user is able to effect this rotation of the cam core 480 by rotating the chuck sleeve 450 in the clockwise CW direction. As shown in FIG. 49, rotation of the cam core 480 causes the inner surfaces 481 of the cam core 480 to ramp against the outer surfaces 4102 of the jaws 4101. In particular, a shallow portion of the inner surfaces 481 contacts the outer surfaces 4102 of the jaws 4101 in FIG. 49 as compared to FIG. 48. This pushes the jaws 4101 inwardly, and the clamping surfaces 4103 of the jaws closer to the bit 425.

In FIG. 50, the cam core 480 is rotated further clockwise as compared to FIG. 49. Again, a user causes this movement by rotating the chuck sleeve 450 in a clockwise direction. As shown in FIG. 50, the rotation of the cam core 480 causes the inner surfaces 481 of the cam core 480 to ramp against the outer surfaces 4102 of the jaws 4101 and a shallower portion of the inner surfaces 481 contacts the outer surfaces 4102 of the jaws 4101 in FIG. 50 as compared to FIG. 49. This pushes the jaws 4101 inwardly such that the clamping surfaces 4103 of the jaws 4101 close on the bit 425.

Once the jaws 4101 contact the bit 425, they cannot move further inward. That is, the jaws 4101 clamp around the bit 425 and the bit prevents the jaws 4101 from moving further inwardly. At this point, the user may continue to further rotate the chuck sleeve 450 in a clockwise direction to tighten the jaws 4101 of the chuck 410 around the bit 425 in order to secure or lock the bit 425 in place. As is seen in FIG. 50, the detent plungers 490 begin to hit the ramp 452 of the detent recesses 451.

FIG. 51 is a front view where the chuck sleeve 450 has continued to be rotated after the jaws 4101 have contacted the bit 425. As shown in FIG. 51, the chuck sleeve 450 has continued to rotate, but the cam core 480 has not rotated significantly due to the jaws 4101 contacting the bit 425. The detent plungers 490 have moved out of the detent recesses 451. Although not visible from the front view of FIG. 51, the cam core 480 has moved rearwardly relative to the jaws 4101 chuck body 470 and chuck sleeve 450. Further explanation of this tightening process is described below.

It is noted that the bit 425 shown in the exemplary embodiment is a generic bit. The bit may be a drill bit, a screwdriver bit or other power tool accessory commonly held by a power drill or other power tool. The drill bit or screwdriver bit may have, for example, a cylindrical or a hexagonal outer surface that is clamped by the clamping surfaces 4103 of the jaws 4101 and, for example, a forward end with a screwdriving head or a drilling thread.

FIGS. 42 and 43 are side cross-sectional view of the chuck 410. As shown in FIG. 42, the chuck 410 has a front F and a rear R, and rotates about a central axis A. In the exemplary embodiment, the bit 425 rotates about the central axis A, and the central axis A is aligned with a rotational axis of the motor 424 and the transmission 426.

FIGS. 42 and 43 illustrated contact of the inner surface 481 of the cam core 480 with the outer surface 4102 of the jaws 4101 from another perspective. FIG. 42 illustrates the chuck 410 at a point where the jaws 4101 have contacted the bit 425, similar to FIG. 50. FIG. 43 illustrates the chuck 410 when the sleeve 450 is further rotated after the jaws 4101 have contacted the bit, similar to FIG. 51. As is shown in FIGS. 42 and 43, the cam core 480 moves rearwardly from the position of FIG. 42 to the position of FIG. 43 during tightening of the jaws 4101 on the bit 425. As shown in FIGS. 42 and 6, a front end of the cam core 480 is significantly closer to the front cover 460 in FIG. 42 than in FIG. 43. As is additionally shown in FIGS. 42 and 43, the inner surfaces 481 of the cam core 480 are angled in the front to rear direction as well. As shown in FIGS. 42 and 43, the portion of the inner surfaces 481 in contact with the outer surfaces 4102 of the chuck jaws 4101 taper outwardly from the front to rear. Accordingly, as the cam core 480 moves rearward, the taper of the cam core 480 further urges the jaws 4101 towards one another, and further serves to tighten the clamping of the jaws 4101 on the bit 425.

FIG. 44 is a perspective view of the chuck 410 without the front cover 460. FIGS. 45 and 46 are perspective views of the exemplary embodiment of the chuck 410 without the outer sleeve 450 and front cover 460. As shown in FIG. 44, the chuck sleeve 450 includes holes 455 and connectors 456 in the holes 455. The connectors 456 connect the chuck sleeve 450 and the cam core 480.

As shown in FIGS. 45 and 46, the cam core 480 has a plurality of slots 485 at the cam core 480 outer circumferential surface 482. The slots 485 have a first end 486 and a second end 487. As shown in FIGS. 45 and 46, the connectors 456 include a top 457 that interacts with the sleeve 450 and a bottom 458 which is engaged with the slot 485. In FIG. 45, the connector 456 is at a first end 486 of the slot 485. In FIG. 46, the connector 456 is at the second end 487 of the slot 485. When the connector 456 is sliding in the slot 485 from the first end 486 (as shown in FIG. 45) to the second end 487 (as shown in FIG. 46), the sleeve 450 moves relative to the cam core 480. There is similar relative movement when the connector 456 is slid from the second end 487 to the first end 486.

When the connector 456 is already at one of the ends 486, 487 and is continues to move in the same direction, the cam core 480 moves along with the sleeve 450. For example, when the sleeve 450 is moved counter-clockwise CCW from the position shown in FIG. 45, the sleeve 450 contacts the top 457 of the connector 456 to move the connector 456 counter-clockwise CCW. The bottom 458 of the connector 456 is in contact with the first end 486 of the slot 485, and therefore, also pushes on the cam core 480 via the slot 485. Therefore, the cam core 480 moves along with the sleeve 450 and connector 456.

Similarly, when the sleeve 450 is moved clockwise CW from the position shown in FIG. 46, the sleeve 450 contacts the top 457 of the connector 456 to move the connector 456 clockwise CW. The bottom 458 of the connector 456 is in contact with the second end 487 of the slot 485, and therefore, also pushes on the cam core 480 via the slot 485. Therefore, the cam core 480 moves along with the sleeve 450 and connector 456. The cam core 480 and the chuck sleeve 450 rotate about the previously discussed axis A, shown in FIGS. 42 and 43.

When the connector 456 is moving in the slot 485, the bottom 458 does not contact either the first end 486 or the second end 487 of the slot. Accordingly, force from rotation of the sleeve 450 is not transferred to the cam core 480.

In the exemplary embodiment, there are three connectors 456 and three slots 485. Each of the connectors 456 and slots 485 have the same configuration and operation, and are spread an equidistance around the outer circumference of the cam core 480. Similarly, there are three plunger detents 490 and three detent recesses 451. The three plunger detents 490 are disposed equidistance around the cam core 480 and the detent recesses 451 are disposed equidistance around an inner circumference of the chuck sleeve 450. In many of the Figs., only one connector 456, slot 485, detent 490 or detent recess 451 is shown. While reference may be made to the shown connector 456, slot 485, detent 490 or recess 451, it should be understood that the same elements not shown in a particular view operate in the same manner.

FIG. 47 is a perspective view of the chuck 410 with the sleeve 450 shown, but the front cover 460 not shown. FIG. 47 shows similar positioning to FIG. 46.

FIGS. 52-56 illustrate a perspective view of the chuck 410 attached to a clutch collar 430 with the sleeve 450 in shadow. As mentioned above, the bit 425 is illustrated generically for illustrative purposes, and may be a drill bit, screwdriver bit of other accessory commonly held by a power tool chuck. FIGS. 52-56 illustrate the jaws 4101 of the chuck 410 moving from an open position to a closed position.

FIG. 52 illustrates the jaws 4101 in a fully open position. As shown in FIG. 52, the jaws 4101 do not contact the outer surfaces of the bit 425, so the bit 425 is not held securely by the chuck 410. In FIG. 52, the connector 456 is at a first end 486 of the slot. Additionally, the detent plunger 490 is engaged in the detent recess 451. The outer surfaces 4102 of the jaws 4101 are at a deep part of the cam core surfaces 481, similar to the position shown in FIG. 48 or FIG. 49.

In FIG. 53, the chuck sleeve 450 has been rotated clockwise CW relative to the position in FIG. 52. The cam core 480 moves clockwise CW in conjunction with the sleeve 450 owing to the connection between the detent plunger 490 and the detent recess 451. Additionally, the ends 4102 of the chuck jaws 4101 have moved on the ramped inner surfaces 481 to push the jaws 4101 inwardly toward the bit 425 relative to the position of FIG. 52. As shown in FIG. 53, the connectors 456 remain at the first end 486 of the slot 485. Since the jaws 4101 have not yet contacted the bit 425, the connection of the detent plunger 490 with the detent recess 451 is sufficient such that the chuck sleeve 450 and the cam core 480 move together.

In FIG. 54, the chuck sleeve 450 has been rotated further clockwise CW relative to the position of FIG. 53. Again, the cam core 480 moves clockwise in conjunction with the sleeve 450 owing to the connection between the detent plunger 490 and the detent recess 451. Additionally, the ends 4102 of the chuck jaws 4101 have moved on the ramped inner surfaces 481 to push the jaws 4101 inwardly toward the bit 425 relative to the position of FIG. 53. As shown in FIG. 54, the connector 456 remains in the first end 486 of the slot 485. Since the jaws 4101 have not yet contacted the bit 425, the connection of the detent plunger 490 with the detent recess 451 is sufficient such that the chuck sleeve 450 and the cam core 480 move together.

In FIG. 55, the chuck sleeve 450 has been rotated further clockwise CW relative to the position of FIG. 53. In FIG. 55, the jaws 4101 have now contacted the bit 425. As previously discussed, this causes a resistance to further movement of the cam core 480. Accordingly, as the chuck sleeve 450 is further rotated, the connection between the plunger detents 490 and the detent recesses 451 is no longer sufficient to cause the cam core 480 to move with the chuck sleeve 450 as such movement is blocked by the presence of the bit 425, as the jaws 4101 contact the bit 425 and the inner surfaces 481 of the cam core 480 interact with rear surface 4102 of the jaws 4101 to resist further movement of the cam core 480. Accordingly, the sleeve 450 continues to rotate and the plunger detents 490 move out of the detent recesses 451, as is shown in FIG. 55. Additionally, the connector 456 begins to move in the slot 485 away from the first end 486 of the slot 485.

FIG. 56 shows the chuck sleeve 450 further rotated clockwise CW from the position shown in FIG. 55. As shown in FIG. 56, the jaws 4101 with faces 4103 are holding the bit 425. The connector 456 has reached the second end 487 of slot 485. As discussed previously, when the connector 456 reaches the second end 487 of the slot 485, further force or rotation of the sleeve 450 is transferred to the cam core 480 through the connector. In this case, further rotation of the chuck sleeve 450 in the clockwise CW direction serves to tighten the jaws 4101 on the bit. It is noted that once the jaws 4101 contact the bit 425, the bit 425 provides resistance to further movement of the jaws 4101, and therefore the cam core 480. However, there may be some movement during tightening.

FIGS. 57-61 illustrate a perspective cut-away view of the chuck 410. FIG. 57 illustrates the chuck 410 with the jaws 4101 in a fully open position, and the subsequent FIGs. illustrate the chuck 410 in increasing positions of closing and tightening, until FIG. 61 shows the chuck 410 fully closed and tightened.

As shown in FIG. 58, the jaws 4101 are fully open. The connector 456 is at a first end 486 of the slot 485. In FIG. 58, the sleeve 450 has been rotated clockwise CW with respect to the position shown in FIG. 57. The jaws 4101 have begun to move towards one another. The sleeve 450 and the cam core 480 move together, and the connector 456 remains at the first end 486 of the slot 485. Although not shown, the detent plunger 490 remains engaged with the detent recess 451.

FIG. 59 illustrates the chuck 410 after the sleeve 450 after it has been rotated further clockwise CW relative to FIG. 58. The jaws 4101 have moved further inward so that their faces 4103 contact the bit 25. At this point, the cam core 480 will begin to resist further movement due to the jaws 4101 coming into contact with the bit 425. Accordingly, further movement of the sleeve 450 results in the sleeve 450 moving relative to the cam core 480 and the connector 456 to move in the slot 485.

FIG. 60 illustrates the chuck 410 with the sleeve 450 rotated further clockwise CW relative to FIG. 59. As shown in FIG. 60, the sleeve 450 and connector 456 have moved relative to the cam core 480, whose movement is restrained by the jaws 4101 contacting the bit 425.

FIG. 61 illustrates the chuck 410 with the sleeve 450 rotated further clockwise CW relative to its position in FIG. 60. In FIG. 61 the connector 456 is at the second end 487 of the slot 485 and rotation of the sleeve 450 in the clockwise CW direction tightens the chuck 410, as has been previously discussed.

As will be appreciated, rotating the sleeve 450 in the counter-clockwise direction reverses operation of the chuck 410, so that the jaws 4101 move away from one another to open the chuck 410 and release the bit 425. As the sleeve 450 is moved counter-clockwise, the connector 456 exits the second end 487 of the slot 485 and moves toward the first end 486. As the connectors 456 reach the first end 486 of the slot 485, the detent plungers 490 engage the detent recesses 451. Further counter-clockwise movement of the sleeve 450 then moves the cam core 480 along with the sleeve 450, which moves the jaws 4101 away from one another to loosen or open the chuck 410.

In the exemplary embodiment, the slot 485 is slanted towards the front of the chuck 410. Accordingly, the second end 487 of the slot 485 is closer to the front of the chuck 410 than the second end 486. Thus, as the connector 456 moves in the slot, the cam core 480 is forced backwards towards the remainder of the drill 412. This movement of the cam core 480 backwards is best shown in FIGS. 42 and 6. FIG. 42 illustrates the cam core 480 when the jaws 4101 have engaged the bit 425, but the connector 456 has not yet moved in the slot 485. FIG. 443 illustrates the cam core 480 after the sleeve 450 has been further rotated to tighten the jaws 4101 of the chuck 410 and the connector 456 is in the second end 486 of the slot 485.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Terms of degree such as “generally,” “substantially,” “approximately,” and “about” may be used herein when describing the relative positions, sizes, dimensions, or values of various elements, components, regions, layers and/or sections. These terms mean that such relative positions, sizes, dimensions, or values are within the defined range or comparison (e.g., equal or close to equal) with sufficient precision as would be understood by one of ordinary skill in the art in the context of the various elements, components, regions, layers and/or sections being described.

Example embodiments have been provided so that this disclosure will be thorough, and to fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Numerous modifications may be made to the exemplary implementations described above. These and other implementations are within the scope of this patent application.

Number	Date	Country
62732029	Sep 2018	US
62732035	Sep 2018	US
62732222	Sep 2018	US
62733807	Sep 2018	US
62747357	Oct 2018	US

POWER TOOL CHUCK

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CPC

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Provisional Applications (5)