The present invention relates to a stud punch, and in particular, to a battery-operated stud punch.
Presently, manual, or mechanical, stud punches are used by electricians and plumbers to punch holes in steel studs, allowing plumbing, wires, and/or other materials to be run through the studs. Such tools are bulky, expensive, and, in certain scenarios, are difficult to manipulate in confined areas where the studs may be located. For example, typical manual stud punches only allow a user to punch the studs from one direction, thereby limiting or inhibiting the amount of leverage the user may apply to the tool. As such, a manual stud punch typically is only used to punch a hole in a single stud. In addition, while using a manual stud punch, a user can typically only punch holes in twenty to twenty-five gauge steel studs. Typically, only the punch or the die moves when the user actuates the stud punch, requiring the stud to be oriented in one particular orientation.
Furthermore, manual stud punches require a large amount of strength and exertion from the user to punch holes in the studs. If the user is required to punch many holes in a single day or in a short period of time, the user may become susceptible to repetitive stress injury (RSI).
In one embodiment, the invention provides a stud punch head for a power tool. The stud punch head includes a head housing and a first arm movably coupled to the head housing. The first arm supports a punch. The stud punch head also includes a second arm movably coupled to the head housing and relative to the first arm. The second arm supports a die opposite the punch. The stud punch head further includes a drive mechanism positioned at least partially within the head housing and operatively coupled to a motor of the power tool. The drive mechanism is operable to move the first arm and the second arm toward and away from each other.
In another embodiment, the invention provides a power tool including a housing, a motor positioned substantially within the housing, and a stud punch head coupled to the housing. The stud punch head includes a first arm movable with respect to the housing. The first arm supports a punch. The stud punch head also includes a second arm movable with respect to the housing. The second arm supports a die opposite the punch. The stud punch head further includes a drive mechanism operatively coupled to the motor. The drive mechanism is operable to move the first arm and the second arm toward and away from each other
In yet another embodiment, the invention provides a power tool including a housing, a motor positioned substantially within the housing, and a first arm movably coupled to the housing. The first arm supports a punch. The power tool also includes a second arm movably coupled to the housing and relative to the first arm. The second arm supports a die opposite the punch. The power tool further includes a drive mechanism positioned at least partially within the housing and operatively coupled to the motor. The drive mechanism is operable to move the first arm and the second arm between a first position, whereby the punch is spaced apart from the die, and a second position, whereby the die receives a portion of the punch.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting.
The illustrated stud punch 10 includes a housing 14, a motor 18 (
The second portion 34 of the housing 14 includes a handgrip 42 configured to be grasped by a user. A switch assembly 46 is supported on the second portion 34 proximate the handgrip 42 and is actuatable to operate the stud punch 10. The switch assembly 46 includes a trigger 50 that may be depressed by a user to electrically connect the power supply 22 and the motor 18, thereby supplying power to the motor 18.
As shown in
The power supply 22 is coupled to the second portion 34 of the housing 14 to selectively provide power to the motor 18. In the illustrated embodiment, the power supply 22 is a rechargeable battery pack that may be removed from the stud punch 10 and interchanged with another battery pack. For example, the battery pack may be an 18-volt removable power tool battery pack that includes five Lithium-ion battery cells. In other embodiments, the battery pack may include fewer or more battery cells and/or battery cells having a chemistry other than Lithium-ion, such as, for example, Nickel Cadmium or Nickel Metal-Hydride. In yet another embodiment, the power supply 22 may be a dedicated battery contained partially or entirely within the housing 14.
In some embodiments, the stud punch 10 may additionally or alternatively include an electrical cord configured to plug the stud punch 10 directly into a wall outlet to charge the battery pack and/or to provide power to the motor 18. In another embodiment, an overload circuit may be electrically positioned between the power supply 22 and the motor 18 to inhibit the motor 18 from drawing too much current from the power supply 22 and shorting.
As shown in
The front portion 82 of the housing 62 includes a track 90 configured to receive portions of the first and second arms 66, 70 and defining a path along which the arms 66, 70 move (e.g., slide) between an open position, or deactivated position, (
An end bracket, or shoe, 102 is coupled over a portion of the track 90 and the rails 94, 98 to enclose the portions of the arms 66, 70 within the track 90 and inhibit foreign particles (e.g., dust, dirt, chips, etc.) from entering the track 90 and disrupting the movement of the arms 66, 70. The end bracket 102 is also adjustable (i.e., movable toward and away from the front portion 82) to provide a depth guide for the stud punch head 26. During operation of the stud punch 10, the end bracket 102 is pressed, or rests, against a stud to help a user steady the stud punch 10 and punch the stud at a desired punching location. Sliding the end bracket 102 relative to the front portion 82 allows the user to account for different size studs, as well as punching holes at different depths on the stud, while still allowing the user to rest the stud punch 10 against the stud.
The stud punch head 26 also includes a handle 106 coupled to the head housing 62. The illustrated handle 106 extends upward from the stud punch head 26 such that a user can grasp and operate the stud punch 10 in a manner similar to a chainsaw. In some embodiments, a switch (e.g., a dummy switch) may be positioned on the handle 106 and depressible by the user to operate the stud punch 10. In such a construction, both the trigger 50 on the second portion 34 of the housing 14 and the switch on the handle 106 are depressed in order to operate the stud punch 10, ensuring the user grasps the stud punch 10 with both hands during operation. In other embodiments, the switch may be positioned on the first portion 30 of the housing 14 or elsewhere on the stud punch head 26.
Referring to
The drive shaft 114 is rotatably coupled to the gear box 110 and is supported by a ball bearing 122 positioned between the cam 118 and the gear box 110. A needle bearing 126 is positioned on an end of the drive shaft 114 opposite from the gear box 110. The drive shaft 114 is rotated by the motor shaft 54 through the gear box 110 to thereby rotate the cam 118.
The cam 118 is supported within the head housing 62 on the drive shaft 114 between the ball bearing 122 and the needle bearing 126. The illustrated cam 118 includes a D-shaped aperture 128 such that the cam 118 rotates with the drive shaft 114 and, thereby, the motor 18. In other embodiments, the cam 118 may be splined or otherwise fixed to the drive shaft 114 for rotation therewith. In the illustrated embodiment, the cam 118 has a generally propeller-shape and includes two wings 130, 134. Each wing 130, 134 includes an inwardly curved surface 138, an outwardly curved surface 142, and a generally flat end surface 146 connecting the curved surfaces 138, 142. The cam 118 engages a portion of the first arm 66 and the second arm 70 (e.g., at rollers 154, 182 on the arms 66, 70) to slide the arms 66, 70 toward and away from each other as the cam 118 rotates.
Referring to
The roller 154 extends rearwardly from the slide portion 150 and rides along the surfaces 138, 142, 146 of the cam 118. In the illustrated embodiment, the roller 154 includes a shaft 167 and a sleeve 168 surrounding a portion of the shaft 167 such that the sleeve 168 is rotatable relative to the shaft 167. As the cam 118 rotates and the sleeve 168 contacts the surfaces 138, 142, 146, the first arm 66 slides within the track 90 relative to the head housing 62.
The first arm 66 supports a punch 170 on an end opposite from the slide portion 150. The illustrated punch 170 is generally cylindrical and includes a contoured surface 174 to cut or punch a circular hole in a stud. In other embodiments, the punch 170 may be pyramidal, irregular, or the like, to punch a different shaped hole in the stud. In some embodiments, multiple punches 170 may be positioned on the first arm 66 to simultaneously punch multiple holes in the stud.
The second arm 70 is generally C-shaped and, similar to the first arm 66, includes a slide portion 178 configured to be received within the track 90 and a roller 182 for engaging the cam 118. The slide portion 178 includes a groove 186 corresponding to the upper rail 94 such that the groove 186 rides along the rail 94 as the arm 70 moves. The slide portion 178 also includes an aperture 188 for receiving the bolt 164, which limits linear movement of the second arm 70. In the illustrated embodiment, the slide portion 178 of the second arm 70 is positioned on top of the slide portion 150 of the first arm 66 such that the apertures 162, 188 of each arm 66, 70 are generally aligned and the bolt 164 extends therethrough. However, it should be readily apparent to those of skill in the art that the relative positioning of the arms 66, 70 may be reversed. A passage 189, similar to the passage 165 in the first arm 66, extends through the slide portion 178 and communicates with the aperture 188. The passage 189 receives a biasing element 190 (e.g., a coil spring) that contacts the bolt 164 to bias the second arm 70 away from the first arm 66. A set screw 191 is positionable within the passage 189 to retain the biasing element 190 within the passage 189.
The roller 182 extends rearwardly from the slide portion 178 and rides along the surfaces 138, 142, 146 of the cam 118. Similar to the roller 154 of the first arm 66, the roller 182 includes a shaft 191 and a sleeve 192 such that the sleeve 191 contacts cam 118 and is rotatable relative to the shaft 191.
The second arm 70 supports a die 194 at an end opposite from the slide portion 178. The illustrated die 194 is positioned within a bore 196 extending through the second arm 70 such that a plug, chips, and/or shavings cut from a stud may be easily removed from the die 194 and the bore 196. In other embodiments, the die 194 may be integrally formed as a single piece with the bore 196. As shown in
In the illustrated embodiment, a first guide plate 198 is positioned between the second arm 70 and an upper portion of the track 90 and a second guide plate 202 is positioned between the first arm 66 and a lower portion the track 90. The guide plates 198, 202 provide a relatively smooth surface along which the arms 66, 70 slide, reducing friction and wear on the arms 66, 70.
In some embodiments, an insert feeder (not shown) may be positioned on either of the first arm 66 or the second arm 70 to supply an insert (e.g., a plastic bushing, grommet, insulator, etc.) to a stud. As the first and second arms 66, 70 come together and punch a hole in the stud, the insert may be automatically pressed or snapped around the circumference of the hole, reducing any sharp edges that may result from punching the hole.
As shown in
When a user depresses the trigger 50 (and, if necessary, depresses the switch on the handle 106) a punch cycle of the stud punch head 26 begins. The power supply 22 provides power to the motor 18, rotating the motor 18 and, thereby, the motor shaft 54. The motor shaft 54 rotates the gears within the gear box 110 to rotate the drive shaft 114. The drive shaft 114 rotates the cam 118, causing the rollers 154, 182 of the first and second arms 66, 70 to ride along the surfaces 138, 142, 146 of the cam wings 130, 134. As the rollers 154, 182 ride along the surfaces 138, 142, 146, the arms 66, 70 move between the open position (
Referring to
The stud punches 10, 310 provide a power tool that requires less physical exertion by a user as compared to currently available mechanical versions. In addition, the stud punches 10, 310 are configured to receive and punch holes in studs opening in either direction, or even in studs arranged in a back-to-back arrangement. In either arrangement, the stud punches 10, 310 are operable to punch the holes without crushing a flange of the studs. Furthermore, the stud punches 10, 310 are operable to punch holes in at least about sixteen gauge steel studs.
Various features and advantages are set forth in the following claims.
This application claims priority to U.S. Provisional Patent Application No. 60/833,130, entitled “Stud Punch”, filed Jul. 25, 2006 by David B. Griep, Scott D. Bublitz, Edward D. Wilbert, and Jonathan A. Zick, the entire contents of which is hereby incorporated by reference.
Number | Date | Country | |
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60833130 | Jul 2006 | US |