Patent Application
20200306942
The present invention relates to sound damping for power tools.
Fastening tools, such as nailers, are used in the construction trades. However, many fastening tools which are available are insufficient in design, expensive to manufacture, heavy, not energy efficient, lack power, have dimensions which are inconveniently large and cause operators difficulties when in use. Further, many available fastening tools do not adequately guard the moving parts of a nailer driving mechanism from damage.
Additionally, many power tools, such as fastening tools, emit excess sound and/or noise. Such excess sound and/or noise can be unpleasant to the user and others within a hearing distance thereof.
Further, many fastening tools which are available are inconveniently bulky and have systems for driving a fastener which have dimensions that require the fastening tool to be larger than desired. For example, drive systems having a motor which turns a rotor can require clutches, transmissions, control systems and kinetic parts which increase stack up and limit the ability of a power tool to be reduced in size while retaining sufficient power to achieve a desired performance.
There is a strong need for a fastening tool having an improved motor and drive mechanism. A strong need also exists for a fastening tool which has improved sound characteristics.
A power tool, such as a fastening tool, can have one or more sound damping members which can control, manage, reduce and eliminate undesired sound and/or noise emitted from such tools. Herein, “sound” and “noise” are used synonymously.
In an embodiment, the fastening tool can have an electric motor having a rotor which has a rotor shaft which is coupled to a flywheel. The flywheel can have a sound damping member. The sound damping member can have a sound damping material. In an embodiment, the sound damping member can be a sound damping tape. The sound damping member can have a polymer. The sound damping member can be a powder coat and/or a powder coating applied to at least a portion of a power tool member, piece and/or structure, such as a flywheel and/or housing. The powder coat can be a coating which covers a surface of a power tool part in-part or wholly.
In an embodiment, the sound damping member can have one or a plurality of layers. The sound damping member can be a single material and/or a single layer, or the sound damping member can be a laminate having a plurality of layers of the same or different materials.
Herein, a vibration absorption member is a type of sound damping member. In an embodiment, the sound damping member vibration absorption member. In an embodiment, the vibration absorption member can have one or a plurality of layers. The vibration absorption member can be a single material and/or a single layer, or the sound damping member can be a laminate having a plurality of layers of the same or different materials.
In non-limiting example, the flywheel having the sound damping member can have a vibration damping ratio of 0.050% or greater. In another non-limiting example, The frequency response for a flywheel having a sound damping member can be less than 800 (m/s{circumflex over ( )}2)/lbf in a range from 20 Hz to 20,000 Hz.
The electric motor can have an inner rotor. The flywheel can have a portion which is cantilevered over at least a portion of the electric motor. The flywheel can have a contact surface adapted to impart energy from the flywheel when contacted by a moveable member.
In an embodiment, a power tool can have an electric motor having a rotor having a rotor shaft. The rotor shaft coupled to a metal flywheel which can have a contact surface adapted to impart energy from the metal flywheel when contacted with a moveable member. The metal flywheel can have a sound damping member which can receive at least a vibrational energy from the metal flywheel. The metal flywheel can have a vibration absorption member which can receive at least a vibrational energy from the metal flywheel. The metal flywheel can have a portion which is cantilevered over at least a portion of the electric motor. The portion which is cantilevered can overlap at least a portion of the electric motor. The metal flywheel's portion which is cantilevered over at least a portion of the electric motor can be adapted to rotate radially about at least a portion of the electric motor.
In an embodiment, the sound damping member can be affixed to an inner surface of the portion of the metal flywheel which is cantilevered over at least a portion of the electric motor. The sound damping member can comprise a plurality of layers, or be a laminate. The sound damping member can have a sound damping material. In an embodiment, the sound damping member can have a metal layer.
In an embodiment, the power tool can have a sound damping member which is a laminate and which is adhered to at least a portion of the power tool. In an embodiment, the power tool having a sound damping member can be a nailer. In an embodiment, the power tool having a sound damping member can be an impact driver.
In an embodiment, a power tool can have an electric motor having a rotor which has a rotor shaft. The rotor shaft can be coupled to a flywheel which can have a potion which is cantilevered over at least a portion of the rotor. The flywheel can also have a contact surface adapted to impart energy from the flywheel when contacted by a moveable member. The overlapping portion can be adapted to rotate radially about at least a portion of the motor. The power tool can have a motor which has an inner rotor, or a motor which has an outer rotor. The flywheel can have a portion which is cantilevered over at least a portion of the rotor.
In an embodiment, a power tool can have an electric motor having a motor housing and a rotor having a rotor shaft. The rotor shaft can be coupled to a flywheel which can have a potion which is cantilevered over at least a portion of the motor housing. The flywheel can also have a contact surface adapted to impart energy from the flywheel when contacted by a moveable member. The overlapping portion can be adapted to rotate radially about at least a portion of the motor housing. The power tool can have a motor which has an inner rotor, or a motor which has an outer rotor.
The power tool can have an overlapping portion which supports a flywheel ring which can have a contact surface. Optionally, the contact surface can have a geared portion. The contact surface can optionally have at least one grooved portion. The contact surface can optionally have at least one toothed portion.
In an embodiment, the power tool can have a flywheel ring and a rotor shaft which rotate in a ratio in a range of 0.5:1.5 to 1.5:0.5; such as in a range of 1:1.5 to 1.5:1. In an embodiment, the power tool can have a flywheel ring and a rotor shaft which rotate in a ratio of about 1:1. In an embodiment, the power tool can have a flywheel ring and a rotor shaft which rotate in a ratio of 1:1. The power tool can also have a flywheel ring which rotates at a speed in a range of from about 2500 rpm to about 20000 rpm. The power tool can also have a flywheel ring which rotates at a speed in a range of from about 5600 rpm to about 10000 rpm. In another embodiment, the power tool can have a flywheel ring which has a contact surface which has a speed in a range of from about 20 ft/s to about 200 ft/s. In yet another embodiment, the power tool can have a flywheel ring which has an inertia in a range of from about 10 J(kg*m{circumflex over ( )}2) to about 500 J(kg*m{circumflex over ( )}2).
In an embodiment, the power tool can have a flywheel ring which rotates in a plane parallel to a driver profile centerline plane. The power tool can also have a moveable member which is a driver blade which has a driving action which is energized by a transfer of energy from a contact of the driver blade with the flywheel. The power tool can also have a moveable member which is a driver profile which has a driving action which is energized by a transfer of energy from a contact of the driver profile with the flywheel.
The power tool can be a cordless power tool. The power tool can be a cordless nailer and can be adapted to drive a nail. The power tool can also be driven by a power cord, or be pneumatic, or receive power from another source.
In an embodiment, a fastening device can have a motor having a cantilevered flywheel. The cantilevered flywheel can have a contact surface adapted for frictional contact with a driving member adapted to drive a fastener. The fastening device can have a motor which has an inner rotor, or a motor which has an outer rotor. The motor can be a brushed motor or a brushless motor. The motor can be an inner rotor motor which can be a brushed motor or an outer rotor motor which can be a brushed motor. The motor can be an inner rotor motor which can be a brushless motor or an outer rotor motor which can be a brushless motor.
In an embodiment, the fastening device can also have a cupped flywheel. The cupped flywheel can have a flywheel ring. In an embodiment, at least a portion of the cupped flywheel can be cantilevered over at least a portion of the motor and/or motor housing. The cupped flywheel can have a contact surface. The cupped flywheel can have a geared flywheel ring. Herein, a grooved surface of a flywheel ring is considered to be a type of gearing; and a grooved surface to be a type of geared surface.
In an embodiment, the cupped flywheel can have a mass in a range of from about 1 oz to about 20 oz. In another embodiment, the fastening device can have a cantilevered flywheel which can have a diameter in a range of from about 0.75 to about 12 inches. The cantilevered flywheel can be adapted to rotate at an angular velocity of from about 500 rads/s to about 1500 rads/s. The cantilevered flywheel can be adapted to have a flywheel energy in a range of from about 10 j to about 1500 j.
In an embodiment, the fastening device can have a driving member which is driven with a driving force of from about 2 j to about 1000 j. In another embodiment, the fastening device can have a driving member which is driven at a speed of from about 10 ft/s to about 300 ft/s. The fastening device can have a driving member which is a driver blade. The fastening device can have a driving member which is a driver profile.
The fastening device can have a direct drive mechanism. In an embodiment, the direct drive mechanism can have a cantilevered flywheel. In another aspect, the fastening device can have a drive mechanism which is clutch-free.
The fastening device can be a nailer and can be adapted to drive a fastener which is a nail.
In an embodiment, a power tool can have a motor having a rotor and a flywheel adapted for turning by the rotor. The flywheel can have a flywheel portion which is positioned radially over at least a portion of the motor. In an embodiment, the flywheel portion can be at least a part of a flywheel ring, or can be a flywheel ring. In an embodiment, the flywheel portion can be at least a part of a flywheel body, or a flywheel body. In an embodiment, the flywheel portion can be at least a part of a cupped flywheel, or a cupped flywheel.
In an embodiment, the power tool can have a flywheel which is a cupped flywheel. The flywheel body can have a flywheel inner circumference which is configured radially about at least a portion of the motor. In another embodiment, the power tool can have a flywheel which is a cupped flywheel and which has a flywheel ring having at least a part which positioned radially over at least a portion of the motor.
In an embodiment, the power tool can have a motor housing which houses at least a portion of the motor and a flywheel portion which is positioned radially over at least a portion of the motor housing.
In an embodiment, the power tool can have a flywheel adapted for clutch-free turning by the motor. In another embodiment, the power tool can have a flywheel adapted for transmission-free turning by the motor. In yet another embodiment, the power tool can have a flywheel which can be adapted for turning by the rotor in a ratio of 1 turn of the flywheel to 1 turn of the rotor. In even another embodiment, the power tool can have a flywheel which can be adapted for turning by the rotor in a ratio of 1.5 turn of the flywheel to 1 turn of the rotor to 1.0 turn of the flywheel to 1.5 turn of the rotor.
In an embodiment, the power tool can be a fastening device. In another embodiment, the power tool can be a fastening device adapted to drive a nail into a workpiece.
In an embodiment, a power tool can have a motor having a rotor axis and a flywheel adapted for turning by the motor. The flywheel can have a flywheel portion coaxial to the rotor axis and which is at least in part located over at least a portion of the motor. The power tool can have a flywheel body having a flywheel body portion which radially surrounds at least a portion of the motor. The power tool can have a cupped flywheel having a cupped flywheel portion which radially surrounds at least a portion of the motor. The power tool can have a cupped flywheel having a flywheel ring and in which a portion of the flywheel ring is adapted to rotate coaxial to the rotor axis. The power tool can have a flywheel portion which has a flywheel contact surface which is adapted to rotate coaxial to the rotor axis. In an embodiment, the flywheel contact surface which can be adapted to have a velocity of at least 10 ft/s and in which the flywheel contact surface can be adapted to revolve coaxially about the rotor axis.
In an embodiment, the power tool can have a flywheel portion which is a cantilevered portion. The power tool can have a flywheel portion which is cantilevered over at least a portion of the motor. The flywheel portion which is cantilevered over at least a portion of the motor can have a contact surface.
In another embodiment, the power tool can have a flywheel portion which is cantilevered over at least a portion of the motor and can have a geared flywheel ring. In yet another embodiment, the power tool can have a motor housing which houses at least a portion of the motor and in which the flywheel has a flywheel inner circumference which is configured radially about at least a portion of the motor and which has a flywheel motor clearance of greater than 0.02 mm.
The power tool can be a fastening device.
In addition to the disclosure of articles, apparatus and devices herein, this disclosure encompasses a variety of methods of use and construction of the disclosed embodiments. For example, a method for driving a fastener, can have the steps of: providing a motor and a cantilevered flywheel adapted to be turned by the motor; providing a driving member adapted to drive a fastener into a workpiece; providing a fastener to be driven; configuring the cantilevered flywheel such that at least a portion of the cantilevered flywheel can be reversibly contacted with a portion of the driving member; operating the cantilevered flywheel at an inertia of from about 2 j to about 500 j; causing the driving member to reversibly contact at least a portion of the cantilevered flywheel; imparting a driving force in a range of from about 1 j to about 475 j to the driving member from the cantilevered flywheel; and driving the fastener into the workpiece. The motor which is provided can have an inner rotor or an outer rotor. Additionally, the motor provided can be a brushed motor or a brushless motor.
In an embodiment, the method of driving a fastener can also have the step of operating the cantilevered flywheel at a speed in a range of from about 2500 rpm to about 20000 rpm. In an embodiment, the method of driving a fastener can also have the step of operating the cantilevered flywheel at an angular velocity in a range of from about 250 rads/s to about 2000 rads/s.
In another embodiment, the method of driving a fastener can also have the steps of providing a fastener which is a nail; and driving the nail into the workpiece.
The present invention in its several aspects and embodiments solves the problems discussed herein and significantly advances the technology of fastening tools. The present invention can become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 7C1 is a sectional view of an embodiment of a sound damping laminate having a reinforced backing layer;
FIG. 7C2 is a sectional view of a multilayered sound damping laminate;
FIG. 16A1 is a exploded view of the drive assembly having the cupped flywheel and a sound damping tape;
FIG. 16A2 is a side view of the exploded view of the drive assembly of FIG. 16A1 having the cupped flywheel and the sound damping tape;
FIG. 16A3 is a side view of the drive assembly of FIG. 16A1 having the cupped flywheel and the sound damping tape;
FIG. 16A4 is a sectional view of the drive assembly of FIG. 16A1 having the cupped flywheel which has the sound damping tape;
Throughout this specification and figures like reference numbers identify like elements.
In an embodiment, one or more sound damping materials can be used to reduce the sound emitted from a power tool during its operation. In an embodiment, a power tool can have a sound damping material which can reduce or eliminate sound from the power tool. In an embodiment, the power tool can be a fastening tool. In another embodiment, the power tool can be an impact driver, or other power tool.
In an embodiment, the power tool can have a broad variety of designs and can be powered by one or more of a number of power sources. For example, power sources for the fastening tool can be manual or use one or more of a pneumatic, electric, battery, combustion, solar or other source of energy, or multiple sources of energy. In an embodiment, both battery and electric power can be employed in the same power tool. The fastener can be cordless or can have a power cord. In an embodiment, the fastening tool can have both a cordless mode and a mode in which a power cord is used.
In an embodiment, the power tool can be driven by an inner rotor motor 500 and a flywheel 700 which can be a cantilevered flywheel 899 (e.g.
The disclosed use of the cantilevered flywheel 899, such as the cupped flywheel 702 achieves numerous benefits, such as allowing brushed motors to be used, significant reductions in manufacturing cost, smaller and lighter power tools. In embodiments, the inner rotor motor 500 with the flywheel 700 can drive a clutch-free (clutchless) and/or transmission-free direct drive mechanism. The inner rotor motor 500 with the cantilevered flywheel 899 achieves an efficient direct drive system for a flywheel to drive action in a power tool and/or fastening device.
The power tool drive mechanism disclosed herein can be used with a broad variety of fastening tools, including but not limited to, nailers, drivers, riveters, screw guns and staplers. Fasteners which can be used with the magazine 100 (e.g.
In an embodiment in which the fastening tool is a nailer. Additional areas of applicability of the present invention can become apparent from the detailed description provided herein. The detailed description and specific examples herein are not intended to limit the scope of the invention. This disclosure and the claims of this application are to be broadly construed.
Nailer 1 has a housing 4 and a motor having an inner rotor, herein as “inner rotor motor 500”, (e.g.
Nailer 1 has a nosepiece assembly 12 which is coupled to housing 4. The nosepiece can be of a variety of embodiments. In a non-limiting example, the nosepiece assembly 12 can be a fixed nosepiece assembly 300 (e.g.
The magazine 100 can optionally be coupled to housing 4 by coupling member 89. The magazine 100 has a nose portion 103 which can be proximate to the fixed nosepiece assembly 300. The magazine 100 can engage the fixed nosepiece assembly 300 at a nose portion 103 of the magazine 100 which has a nose end 102. In an embodiment, the fixed nosepiece assembly 300 can fit with the magazine 100 by a magazine interface 380. In an embodiment, the magazine screw 337 can be screwed to couple the fixed nosepiece assembly 300 to the magazine 100, or unscrewed to decouple the magazine 100 from the fixed nosepiece assembly 300.
The magazine 100 can be coupled to a base portion 8 of a handle 6 at a base portion 104 of magazine 100 by base coupling member 88. The base portion 104 of magazine 100 is proximate to a base end 105. The magazine can have a magazine body 106 with an upper magazine 107 and a lower magazine 109. An upper magazine edge 108 is proximate to and can be attached to housing 4. The lower magazine 109 can have a lower magazine edge 101.
The magazine 100 can include a nail track 111 sized to accept a plurality of nails 55 therein (e.g.
The magazine 100 can hold a plurality of nails 55 (
In non-limiting example, the sound damping material 1010 can be used to reduce noise emitted from any one or more of the flywheel 700, the flywheel assembly 705, the driver assembly 800 and the driver return system 900. In another embodiment, the sound damping material 1010 can be used to reduce noise emitted from any one or more of the motor, the inner rotor motor 500, brushed motor 501, a brushless motor, the motor housing 510 and the motor housing 4. In an embodiment, the sound damping material 1010 can have the form of a sound damping member 1015. In an embodiment, the sound damping member 1015 can be a vibration absorption member 1020. A vibration absorption member 1020 can have the sound damping material 1010.
The sound damping material 1010 can have one or more of a variety of constituents such as in non-limiting example a polymer, an acrylic polymer, a urethane, an acrylic, a viscoelastic acrylic polymer, a viscoelastic material, a crosslinked elastomer, a polyester, an adhesive, an ultra-high adhesion (UHA™) removable adhesive (UHA™ is a trademarked product of Avery Dennison, 207 Goode Avenue, Glenndale, Calif. 91205, phone (626) 304-2000, such as Avery Dennison tape product FT 0951), UHA™ adhesive, a foam, a metal, a foil, a sound damping foil, an aluminum foil, a dead soft aluminum foil, a film and a cloth.
The sound damping member 1015 can be a vibration absorption member 1020 which can be made from a sound damping material 1010 which can absorb vibrations from one or more power tool parts, such as the flywheel 700. A vibration absorption member 1020 is a type of sound damping member. In an embodiment, a vibration absorption member 1020 can absorb vibrations from a member to which it is attached, or from elsewhere.
In an embodiment, the sound damping member 1015 can have one or more of a foil vibration damping portion, a foam vibration damping portion and a foam sheet vibration damping portion. In non-limiting example, the sound damping member 1015 can have one or more of a low-temperature vibration damping portion, a general purpose vibration damping portion, a high-temperature vibration damping portion, a foil vibration damping portion, a foam vibration damping portion, and a foam sheet vibration damping portion.
The sound damping member 1015 can be permanently or reversibly affixed to, mounted on, supported by and/or adjacent to one or more of the following: a stationary member and/or part of the power tool; a portion of a housing, such as the housing 4; a portion of a motor and/or a motor cover, such as the motor housing 510; and a moving and/or rotating member of the power tool, such as one or more of the flywheel 700, the cupped flywheel 702, the cantilevered flywheel 899 and the driver profile 610. In an impact driver, The sound damping member 1015 can be permanently or reversibly affixed to, mounted on, supported by and/or adjacent to one or more of the hammer 1111, the anvil 2222 and the impact driver motor 20 (
In an embodiment, the sound damping member can convert vibrational energy which it receives from a part, piece and/or member to heat. In an embodiment, the heat generated through conversion from vibrational energy by the sound damping member is cooled by the flow of air across and/or in contact with the sound damping member. In an embodiment the sound damping member can be a radiator and/or cooling member.
In an embodiment, the sound damping member can be the vibration absorption member which can convert vibrational energy which it receives from a part, piece and/or member to heat. In an embodiment, the heat generated through conversion from vibrational energy by the vibration absorption member is cooled by the flow of air across and/or in contact with the vibration absorption member. In an embodiment the vibration absorption member can be a radiator and/or cooling member.
In an embodiment, the sound damping member 1015 can have a thickness in a range of from 0.01 mm to 15.0 mm, or greater; such as 0.025 mm to 0.2 mm, or 0.10 to 0.25 mm, or 0.20 mm to 0.45 mm, or 0.3 to 1.5 mm, or 0.50 mm to 2.0 mm, or 1.5 mm to 3 mm, or 2.0 mm to 4 mm, or 3 mm to 6 mm, or 5 mm to 10 mm or greater.
In an embodiment the sound damping member 1015 can have a backing material 1350 (e.g. FIG. 7C1), optionally in the form of a backing layer 1352 (FIG. 7C2). The backing can be thin, light, firm, strong, stiff, heavy-duty, waterproof, magnetic or protective. The backing can be reinforced internally and/or externally.
In an embodiment, the sound damping member 1015 can have a linered construction in which a releasable liner is adhered to the adhesive surface 1051 of the sound damping material 1010 prior to applying the adhesive surface 1051 to a member and/or surface of a power tool. In non-limiting example, the sound damping tape 1050 can have a liner reversibly against the adhesive surface prior to use or application of the tape. In this example, the liner can be removed to allow application of the sound damping tape to a piece, part, member or surface of a tool, or at least a portion thereof.
In an embodiment, the sound damping member 1015 can have a backing material 1350 which can have a thickness in a range of from 0.025 mm to 10.0 mm or thicker, such as 0.025 mm to 0.19 mm, or 0.10 to 0.25 mm, or 0.20 mm to 0.34 mm, or 0.25 to 1.0 mm, or 0.50 mm to 2.0 mm, or 1.5 mm to 3 mm, or 2.0 mm to 4 mm, or 3 mm to 6 mm, or 5 mm to 10 mm or greater.
In an embodiment, the sound damping member 1015 can have a sound damping laminate 1310. The sound damping laminate 1310 can have a number of laminate layers which can be made of the same or different materials.
In an embodiment, sound damping laminate 1310 can have a metal laminate 1317, such as for non-limiting example a foil laminate 1318. In other non-limiting examples, the sound damping laminate 1310 can have one or more of a metal laminate layer, an aluminum laminate layer, a copper laminate layer, an urethane laminate layer, a polymer laminate layer, a cross-linked material polymer layer, a vibration absorbing laminate layer, a sound absorbing laminate layer and an acrylic laminate.
FIG. 7C1 shows a sectional view of an embodiment of a sound damping laminate having a reinforced backing layer. The sound damping member 1015 can have a laminate and/or multilayered structure. The laminated structure can be a sound damping laminate 1310. The sound damping tape 1050 can also have a laminate and/or multilayered structure. FIG. 7C1 is an example of a sound damping laminate 1310 of the sound damping member 1015 and/or of the sound damping tape 1050. In non-limiting example, the sound damping laminate 1310 can have: a first laminate layer 1311, which for example can have a first sound damping material 1011; a second laminate layer 1312, which for example can have a hardened material layer 1320; and a third laminate layer 1313, which for example can have a backing material 1350 which can have a reinforcing material 1360.
FIG. 7C2 shows a sectional view of a multilayered sound damping laminate. The sound damping laminate 1310 can have many layers; for example 1 . . . n layers, with n being a large number, such as up to 25 layers, or up to 10 layers. The respective layers can be the same or different from one another and can have the same or different materials and/or compositions. The respective layers can have the same or different physical properties, and the respective layers can serve the same or different functions.
FIG. 7C2 shows a sectional view of the sound damping laminate 1310 which can form the sound damping member 1015 and/or of the sound damping tape 1050. The sound damping laminate 1310 of
The sound damping material can be affixed to one or more portions of the flywheel 700, the cupped flywheel 702 or the cantilevered flywheel 899.
In the example embodiment of
The driving action of the driver profile 610 can be used to drive a fastener, such as a nail 53, into a workpiece.
Numeric values and ranges herein, unless otherwise stated, are intended to have associated with them a tolerance and to account for variances of design and manufacturing. Thus, a number is intended to include values “about” that number. For example, a value X is also intended to be understood as “about X”. Likewise, a range of Y-Z, is also intended to be understood as within a range of from “about Y-about Z”. Unless otherwise stated, significant digits disclosed for a number are not intended to make the number an exact limiting value. Variance and tolerance is inherent in mechanical design and the numbers disclosed herein are intended to be construed to allow for such factors (in non-limiting e.g., ±10 percent of a given value). Example numbers disclosed within ranges are intended also to disclose sub-ranges within a broader range which have an example number as an endpoint. A disclosure of any two example numbers which are within a broader range is also intended herein to disclose a range between such example numbers. Likewise, the claims are to be broadly construed in their recitations of numbers and ranges.
In the embodiment of
There is no limitation to the speed at which any of the many types and variations of flywheels operate. For example, any of the flywheels disclosed herein can be operated at any rotational speed in the range of from 2500 rpm to 20000 rpm, or greater. In an embodiment, cupped flywheel 702 can be operated at a rotational speed of from less than 2500 rpm to 20000 rpm, or greater. For example, cupped flywheel 702 can be operated at a rotational speed of 1000 rpm, 2500 rpm, 5000 rpm, 5600 rpm, 7500 rpm, 8000 rpm, 9000 rpm, 10000 rpm, 12000 rpm, 12500 rpm, 13000 rpm, 14000 rpm, 15000 rpm, 17500 rpm, 18000 rpm, 20000 rpm, 25000 rpm, 30000 rpm, 32000 rpm, or greater.
There is also no limitation to the angular velocity at which any of the many types and variations of flywheels operate. For example, any of the flywheels disclosed herein can be operated at any rotational speed in the range of from 250 rads/s to 3000 rads/s, or greater. In an embodiment, the cupped flywheel 702 can be operated at a rotational speed of from less than 250 rads/s to 3000 rads/s, or greater. For example, the cupped flywheel 702 can be operated at a rotational speed of 200 rads/s, 300 rads/s, 400 rads/s, 500 rads/s, 600 rads/s, 700 rads/s, 800 rads/s, 900 rads/s, 1000 rads/s, 1200 rads/s, 13000 rads/s, 1400 rads/s, 1500 rads/s, 1600 rads/s, 1750 rads/s, 2000 rads/s, 2200 rads/s, 2500 rads/s, 3000 rads/s, or greater.
There is also no limitation to the velocity of a flywheel portion and/or a portion of the contact surface 715 at which any of the many types and variations of flywheels operate. For example, any of the flywheels disclosed herein can be operated such that the velocity of a flywheel portion and/or a portion of contact surface 715 is in a range of from less than 5 ft/s to 400 ft/s, or greater. For example cupped flywheel 702 can be operated such that velocity of a flywheel portion and/or a portion of contact surface 715 is 2.5 ft/s, 5 ft/s, 7.5 ft/s, 9 ft/s, 10 ft/s, 15 ft/s, 20 ft/s, 25 ft/s, 30 ft/s, 50 ft/s, 75 ft/s, 90 ft/s, 100 ft/s, 125 ft/s, 150 ft/s, 175 ft/s, 190 ft/s, 200 ft/s, 250 ft/s, 300 ft/s, 350 ft/s, 400 ft/s, or greater.
There is no limitation to the mass which any of the many types and variations of flywheels disclosed herein can have. For example, any of the flywheels disclosed herein can have a mass in a range of from less than 1 oz to greater than 50 oz. For example the cupped flywheel 702 can have a mass of less than 0.5 oz, 1.0 oz, 0.75 oz, 1 oz, 2 oz, 3 oz, 4 oz, 5 oz, 7.5 oz, 9 oz, 10 oz, 12 oz, 14 16 oz, 18 oz, 20 oz, 25 oz, 30 oz, 40 oz, 50 oz, or greater. In another example, the cupped flywheel 702 can have a mass of less than 10 g, 25 g, 28 g, 50 g, 75 g, 100 g, 150 g, 200 g, 250 g, 300 g, 500 g, 750 g, 900 g, 1000 g, 1250 g, 1500 g, 2000 g, or greater.
There is no limitation to the inertia of any of the many types and variations of flywheels. For example, any of the flywheels disclosed herein can be operated to have any inertia in the range of from less than 10 J(kg*m{circumflex over ( )}2) to 500 J(kg*m{circumflex over ( )}2), or greater. For example cupped flywheel 702 can have an inertia of less than 5 J(kg*m{circumflex over ( )}2), 7.5 J(kg*m{circumflex over ( )}2), 10 J(kg*m{circumflex over ( )}2), 25 J(kg*m{circumflex over ( )}2), 50 J(kg*m{circumflex over ( )}2), 75 J(kg*m{circumflex over ( )}2), 90 J(kg*m{circumflex over ( )}2), 100 J(kg*m{circumflex over ( )}2), 150 J(kg*m{circumflex over ( )}2), J(kg*m{circumflex over ( )}2), 200 J(kg*m{circumflex over ( )}2), 250 J(kg*m{circumflex over ( )}2), 300 J(kg*m{circumflex over ( )}2), 350 J(kg*m{circumflex over ( )}2), 400 J(kg*m{circumflex over ( )}2), 450 J(kg*m{circumflex over ( )}2), 500 J(kg*m{circumflex over ( )}2), 600 J(kg*m{circumflex over ( )}2), or greater.
There is also no limitation regarding the flywheel energy which any of the many types and variations of flywheels can possess. For example, any of the flywheels disclosed herein can have a flywheel energy of any value in the range of from less than 10 j to 1500 j, or greater. For example cupped flywheel 702 can have a flywheel energy of less than 5 j, 10 j, 20 j, 50 j, 100 j, 150 j, 200 j, 250 j, 300 j, 350 j, 400 j, 450 j, 500 j, 550 j, 600 j, 650 j, 700 j, 750 j, 800 j, 900 j, 1000 j, 1100 j, 1250 j, 1500 j, 2000 j, or greater.
There is no limitation to the driving force which can be imparted to the driver profile 610 and/or the driver blade 54. For example, any of the flywheels disclosed herein can impart a driving force in a range of from less than 2 j to 1000 j, or greater. For example cupped flywheel 702 can impart a driving force to the driver profile 610 and/or the driver blade 54 of less than 1 j, 2 j, 4 j, 8 j, 10 j, 15 j, 20 j, 25 j, 50 j, 75 j, 90 j, 100 j, 125 j, 150 j, 175 j, 200 j, 250 j, 300 j, 350 j, 400 j, 500 j, 1000 j, 15000 j, or greater.
There is no limitation to the torque generated by the inner rotor motor 500. For example, any of the flywheels disclosed herein can be driven by the inner rotor motor 500 which can generate a torque in the range of from less than 0.005 Nm to 10 Nm, or greater. For example, the inner rotor motor 500 can generate any torque in the range of from less than 0.005 Nm, 0.01 Nm, 0.05 Nm, 0.075 Nm, 0.09 Nm, 0.1 Nm, 1.5 Nm, 2 Nm, 2.5 Nm, 3 Nm, 3.5 Nm, 4 Nm, 4.5 Nm, 5 Nm, 6 Nm, 7 Nm, 10 Nm, or greater.
There is no limitation to the velocity of the driver profile 610 at which any of the many types and variations of flywheels operate. For example, any of the driver profile 610 disclosed herein can be operated at any velocity in the range of from less than 10 ft/s to 400 ft/s, or greater. For a power tool and/or fastening device having the cupped flywheel 702 can have the driver profile 610 which can have a velocity of for example, 2.5 ft/s, 5 ft/s, 7.5 ft/s, 9 ft/s, 15 ft/s, 20 ft/s, 25 ft/s, 30 ft/s, 50 ft/s, 75 ft/s, 90 ft/s, 100 ft/s, 125 ft/s, 150 ft/s, 175 ft/s, 190 ft/s, 200 ft/s, 250 ft/s, 300 ft/s, 350 ft/s, 400 ft/s, or greater.
In the example of
In an embodiment, the radial centerline 1602 of the flywheel ring 750 and the centerline of the driver profile centerline 1502 can be parallel. In an embodiment, the radial centerline 1602 of the flywheel ring 750 and the centerline of the channel centerline 429 can be parallel. In an embodiment, the driver profile centerline 1502 and the channel centerline 429 can be parallel. In an embodiment, the driver profile centerline 1502 and the driver blade centerline 1554 can be parallel. In an embodiment, the driver profile centerline 1502 and driver blade centerline 1554 can be collinear. In an embodiment, the driver profile centerline 1502, the driver blade centerline 1554 and the channel centerline 429 can be collinear.
There is no limitation to the geometries that can be used regarding the coordination of the components of the drive mechanism disclosed herein. In another embodiment, the driver blade centerline 1554 can be coplanar with the flywheel ring centerline plane 1600. This allows for many configurations of the driver blade 54 and flywheel 700 to achieve a successful driving of the driver blade 54. In another embodiment, the driver profile centerline 1502 can be coplanar with the flywheel ring center line plane 1600. Many configurations of the driver profile 610 and flywheel 700 can achieve a successful driving of the driver profile 610. In another embodiment, the channel centerline 429 can be coplanar with the flywheel ring center line plane 1600. Many configurations of the channel 52 and flywheel 700 can achieve a successful driving of a nail 53.
While the embodiment of
There is also no limitation to an angle of contact which generates friction and/or otherwise transfers energy between the flywheel 700 and the driver profile 610 and/or driver blade 54.
FIG. 16A1 is a exploded view of the drive assembly having the cupped flywheel 702, which is also configured as the cantilevered flywheel 899 and the sound damping member 1015 which is optionally the sound damping tape 1050. FIG. 16A1 shows a cantilevered flywheel assembly 1899 having a frame 1260 with a frame cover 1275 which supports a flywheel assembly 705 and a motor assembly 508. The cantilevered flywheel assembly 1899 can also have an end cap 1295.
The non-limiting example of FIG. 16A1 shows a flywheel assembly 705 which has a flywheel 700 and which is the cantilevered flywheel assembly 1899 having the cantilevered flywheel 899. In the embodiment of FIG. 16A1, the cantilevered flywheel 899 is shown as the cupped flywheel 702. The flywheel assembly 705 can be at least in part supported by a retaining ring 1265 and a bearing ball 521. The sound damping member 1015, which can be the sound damping tape 1050, is shown configured and adhered to the flywheel ring inner surface 1706 of the cupped flywheel 702.
The motor assembly 508 can have the inner rotor motor 500 which has a magnet ring 531, which can at least in part surround an armature 535, as well as having an upper brush box 532, a lower brush box 533 and an end bridge 537 configured with a bearing plug 523 and an end bridge screw 538. Motor control elements and systems can broadly vary. The example of FIG. 16A1 shows motor control components which include a thermistor 539, a hall sensor 1285 which can be mounted on a pc board 1290 and which can be engaged with a hall sensor board mount 1280. The end bridge 537 can optionally be secured by one or more of an end bridge screw 538 and can be covered at least in part by the end cap end cap 1295.
FIG. 16A2 is a side view of the exploded view of the drive assembly of FIG. 16A1 having the cupped flywheel 702 and the sound damping tape 1050.
FIG. 16A3 is a side view of the drive assembly of FIG. 16A1 when assembled and having the cupped flywheel 702 and the sound damping tape 1050. The drive assembly can have a flywheel assembly 705 and a motor assembly 508 supported by a frame 1260 having a frame cover 1275. The drive assembly can be covered at least in part by the end cap 1295.
FIG. 16A4 is a sectional view of the assembled drive assembly of FIG. 16A1 having the cupped flywheel 702 and the sound damping tape 1050. FIG. 16A4 shows a flywheel assembly 705 which is the cantilevered flywheel assembly 1899 and which has a cupped flywheel 702 which is the cantilevered flywheel 899 which can have the flywheel ring 750. The cantilevered flywheel 899 has the sound damping member 1015 having the sound damping material 1010. The sound damping member 1015 is shown as the sound damping tape 1050.
The sound damping tape 1050 is shown to have an adhesive surface 1051 adhered and/or affixed to the flywheel ring inner surface 1706. The sound damping tape 1050 is show to extend along at least a portion of, or all of, the flywheel ring inner circumference 707. The cantilevered flywheel 899 to which the sound damping tape 1050 is affixed cantilevers over at least a portion of the magnet ring 531 (e.g. FIG. 16A4) and/or the motor housing 510 (e.g.
In an embodiment, the sound damping member and/or material can have an adhesion to steel in a range of from 25 N/100 mm to 100 N/100 mm or greater; such as 25 N/100 mm to 50 N/100 mm, 30 N/100 mm to 70 N/100 mm, 50 N/100 mm to 100 N/100 mm, or 75 mm to 100 N/125 mm or greater. In an embodiment the adhesion to steel at a temperature in a range of from −32° C. (negative 32° C.) to 80° C. can be from 25 N/100 mm to 100 N/100 mm or greater; such as 25 N/100 mm to 50 N/100 mm, 30 N/100 mm to 70 N/100 mm, 50 N/100 mm to 100 N/100 mm, or 75 mm to 100 N/125 mm or greater. In an embodiment the adhesion to steel at a temperature in a range of from −25° C. (negative 25° C.) to 50° C. can be from 25 N/100 mm to 100 N/100 mm or greater; such as 25 N/100 mm to 50 N/100 mm, 30 N/100 mm to 70 N/100 mm, 50 N/100 mm to 100 N/100 mm, or 75 mm to 100 N/125 mm or greater. In an embodiment, the adhesion to steel at a temperature in a range of from 0° C. to 40° C. can be from 25 N/100 mm to 100 N/100 mm or greater, such as 25 N/100 mm to 50 N/100 mm, 30 N/100 mm to 70 N/100 mm, 50 N/100 mm to 100 N/100 mm, or 75 mm to 100 N/125 mm or greater.
The contact surface 715 in its many types and variations can impart energy to the driver profile 610 and/or driver blade 54. The interface between the contact surface 715 and the driver profile 610 and/or driver blade 54 can have a breadth of variety. For example, the interface can produce a frictional contact (e.g.
This disclosure is not limited to a cup-shaped flywheel. The flywheel 700 can be any type of flywheel which supports the contact surface 715 in a cantilevered position about at least a portion of the inner rotor motor 500 and/or the motor housing 510.
There is no limitation regarding the relative geometries of the features of the cupped flywheel 702.
The cupped flywheel 702 can have a flywheel length 711 which in projection can be composed of a flywheel ring length 754, a flywheel body length 712 of flywheel body 710 and a flywheel bearing length 772. A flywheel cup length 714 can have a length which in its projection can be composed of the flywheel ring length 754 and the flywheel body length 712. Optionally, the flywheel bearing can be flat with the flywheel face 703, not have a projection and not contribute to the flywheel length 711. In other embodiments, the flywheel bearing is not used and has no contribution to the flywheel length 711.
The application and use of a flywheel 700 which is a cantilevered flywheel 899, such as cupped flywheel 702 is not limited by this disclosure. In addition to a nailer 1, the cantilevered flywheel 899 which can be driven by an inner rotor motor 500 can be used with any power tool which can receive power from a flywheel directly or by means of a mechanism receiving power from the cantilevered flywheel 899.
The cantilevered flywheel 899 can be used in any appliance which can receive power from a flywheel.
When a resistance to turning of a fastener reaches an hammer retraction resistance, the hammer 1111 will move axially away from a portion of the anvil base 202 along output spindle axis 1000 with the guidance of one or more hammer bearings 1102 and the guide groove and be allowed to clear the anvil in a manner in which the hammer 1111 can rotate faster than the anvil 2222 for at least a part of a revolution of the hammer 1111. Then, the hammer 1111 can move axially along output spindle axis to return to a position to impact against and impart rotational energy to anvil 2222. This impacting sequence can be repeated until a driver release condition exists, or the trigger is released.
Undesired sound and/or noise can be emitted from the impact driver and/or impact mechanism during operation. The application of one or more sound damping members and/or vibration absorption members significantly reduces and/or eliminates such undesired sound.
The anvil 2222 of
Example 1 and Example 2 regard comparative testing between a cupped flywheel 702 without a sound damping member 1015 and a cupped flywheel with a sound damping member 1015. The embodiment of the sound damping member 1015 tested in Example 1 and Example 2 is a vibration absorption member 1020.
Example 1 and Example 2 followed a Vibration And Sound Evaluation Procedure (“VASE Procedure”) which has the following steps:
Step 1. Suspend a part by a means that does not influence the vibration and sound reaction and/or response (string, small wire, etc.) when the part, such as the cupped flywheel 702, is struck by a modal hammer 2530. As shown in
Step 2. Attach the accelerometer 2520 to the part, such as the cupped flywheel 702, in a position that does not influence the vibration and sound reaction and/or response when the part is struck by the modal hammer 2530. In Example 1 and Example 2 the accelerometer 2520 was reversibly attached to the flywheel face 703 at a point proximate to the flywheel bearing 770 and not on the resonating region of the flywheel body 710, as shown in
Step 3. Impact the part on the outer surface of the flywheel ring 750 with a modal hammer 2530 having a output to a spectrum analyzer. The striking force is normalized by dividing the acceleration (response) by the force (input) of the modal hammer 2530 strike. This data analysis and normalization is achieved by:
Sub-step 3.1. Acquire a signal from the accelerometer and hammer;
Sub-step 3.2. Apply a transfer function or frequency response used to normalize the results, to acceleration/force;
Step 4. Average the results of the data output from Step 3 for a number of trials 1 . . . n, e.g. n=5 trials, were n can be from 2 to a large number, such as 50 trials.
The results for Example 1 and Example 2 from the VASE Procedure identify resonances and damping. The respective data results disclosed herein of Example 1 and Example 2 are the averaged results respectively of the output data from 5 trials for each of Example 1 and Example 2.
The data results for Example 1 are the averaged results of the output data from 5 strikes (also herein as, 5 trials) of the cupped flywheel 702 without a sound damping member 1015 by the modal hammer, i.e. n=5. In Example 1, each strike of the modal hammer and the results produced from that 1 strike are 1 trial.
The data results for Example 2 are the averaged results of the output data from 5 strikes (5 trials) of the cupped flywheel 702 with the sound damping member 1015 by the modal hammer, i.e. n=5. In Example 2, each strike of the modal hammer and the results produced from that 1 strike are 1 trial.
For Example 1,
In an embodiment, the sound damping member, which can be a vibration absorption member, provides vibration damping in a frequency range of at least 80 Hz to 50,000 Hz, such as 1000 Hz to 20,000 Hz, or 500 Hz to 15,000 HZ, or 500 Hz to 15,000 Hz, or 1000 Hz to 10,000 Hz, or 1000 Hz to 8,000 Hz, or 1000 Hz to 5,000 Hz, or 500 Hz to 30,000 Hz, or 500 Hz to 20,000 Hz.
In an embodiment, the sound damping member provides sound damping of noise from a part which is damped in a frequency range of at least 80 Hz to 50,000 Hz, such as 1000 Hz to 20,000 Hz, or 500 Hz to 15,000 HZ, or 500 Hz to 15,000 Hz, or 1000 Hz to 10,000 Hz, or 1000 Hz to 8,000 Hz, or 1000 Hz to 5,000 Hz, or 500 Hz to 30,000 Hz, or 500 Hz to 20,000 Hz.
In an embodiment a decrease in emitted noise from the part and/or vibration of the part can be reflected in a vibration damping ratio. The vibration damping ratio is a measure of the decrease in signal amplitude as a function of time. The vibration damping ratio herein is calculated as follows: Vibration damping ratio=actual damping/critical damping, taken at the resonant frequency.
In example 1 and example 2, the frequency response and vibration damping ratio were tested using a Bruel & Kjaer Noise and Vibration Measurement System (BK NVMS) (433 Vincent Street West, West Leederville, Wash. 6007) which receives input from a modal hammer. Further, in Example 1 and Example 2, a BK NVMS acquisition system was employed in conducting the data analysis and vibration damping ratio calculations.
A vibration damping ratio 0.039% was found for the cupped flywheel 702 without a sound damping member 1015 tested in Example 1.
In Example 1 and Example 2 the frequency response H1 is normalized as acceleration/pounds force, i.e. (m/s{circumflex over ( )}2)/lbf (also “(m/s2)/lbf”).
As shown in
The Delta f 3 dB values found in Example 1 and Example 2 were compared.
The results of Example 1 and Example 2 evidence that the application of a sound damping member 1015 significantly reduces the magnitude of the vibration produced by a power tool and the amplitude of the sound produced by the vibration, as described in the present application. It has also been found that the magnitude of the vibration of a sound producing part, such as the cupped flywheel 702, can be reduced to a large degree, such as up to 80% reduction. For example, the maximum magnitude of a vibration produced by a power tool component or power tool may be reduced by 30% or more; 40% or more; 50% or more; 60% or more; 70% or more; or 80% or more, as compared to a power tool or component without a sound damping member. A sound produced can therefore be reduced. For example, a maximum amplitude of the sound can be reduced by 30% or more; 40% or more; 50% or more; 60% or more; 70% or more; or 80% or more, as compared to a power tool or component without a sound damping member.
The results of Example 1 and Example 2 evidence that the application of a sound damping member 1015 which is a vibration absorption member 1020 can significantly reduce the magnitude of the vibrations produced by a power tool and the noise and/or sound generated by such vibrations.
In non-limiting example, a hearing range for humans can be 20 Hz to 20,000 Hz and can be more sensitive in a narrower range, such as 100 Hz to 15,000 Hz or 1,000 Hz to 4,000 Hz. By reducing the magnitude of sound produced by the power tool, the maximum value of the sound expressed as acceleration per pound-force (m/s2)/lbf over these frequency ranges can be kept at or below 1,000 (m/s2)/lbf; at or below 800 (m/s2)/lbf at or below 600 (m/s2)/lbf at or below 500 (m/s2)/lbf. As shown in
Further, vibrations of the cupped flywheel 702 over the frequency ranges of 20 Hz to 20,000 Hz, or 100 Hz to 15,000 Hz or 1,000 Hz to 4,000 Hz can be kept at or below 1,000 (m/s2)/lbf, such as at or below 800 (m/s2)/lbf, at or below 600 (m/s2)/lbf, at or below 500 (m/s2)/lbf, or at or below 500 (m/s2)/lbf. As shown in
Decreasing the maximum magnitude of a sound and/or vibration produced by the power tool over the frequency ranges disclosed herein above can provide a more pleasant user experience by achieving a quieter operation of the power tool.
It has been found that the vibration damping ratio can be greatly improved by use of a sound damping member 1015, which can be a vibration damping member 1020. In non-limiting example, the vibration damping ratio can be increased by 50% or more, or 100% or more, by using a sound damping member 1015 as compared to not using a sound damping member 1015. When the vibration damping ratio is so increased, it can be greater than 0.05%; greater than 0.07%, or greater than 0.09%. As is evidenced by Example 2, the a vibration damping ratio of 0.105% was achieved by using a sound damping member 1015, which was a vibration absorption member 1020. Increasing the vibration damping ratio by the use of a sound damping member 1015, which can be a vibration absorption member 1020, greatly reduces the time during which a noise and/or vibration causing noise can have a significant resonance, as evidenced in the results disclosed in
The scope of this disclosure is to be broadly construed. It is intended that this disclosure disclose equivalents, means, systems and methods to achieve the devices, activities and mechanical actions disclosed herein. For each mechanical element or mechanism disclosed, it is intended that this disclosure also encompass and teach equivalents, means, systems and methods for practicing the many aspects, mechanisms and devices disclosed herein. Additionally, this disclosure regards a sound damping member, a vibration absorption member and a motor having a cantilevered flywheel and their many aspects, features, elements uses and applications. Such devices can be dynamic in their use and operation, this disclosure is intended to encompass the equivalents, means, systems and methods of the use of the power tool and its many aspects consistent with the description and spirit of the technologies, devices, operations and functions disclosed herein. The claims of this application are to be broadly construed.
The description of the inventions herein in their many embodiments is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| PCT/CN2015/076257 | Apr 2015 | CN | national |
This application is a continuation of U.S. patent application Ser. No. 14/747,410 entitled “Sound Damping for Power Tools”, filed Jun. 23 2015, which is a continuation-in-part of and U.S. patent application Ser. No. 14/444,982 entitled “Power Tool Drive Mechanism” filed Jul. 28, 2014, now U.S. Pat. No. 10,022,048. This application also claims benefit of PCT Application No. PCT/CN2015/076257 entitled “Sound Damping for Power Tools” filed Apr. 10, 2015. All of the above applications are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14747410 | Jun 2015 | US |
| Child | 16901658 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14444982 | Jul 2014 | US |
| Child | 14747410 | US |
