Switch devices for power tools

This application claims priority to Japanese patent application serial numbers 2009-003636 and 2009-014081, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to switch devices for operating electric power tools, such as hand-held disk grinders for stone cutting use and others.

2. Description of the Related Art

A known hand-held disk grinder includes a body part, a gear head, and a handle. The body part is provided therein an electric motor serving as a driving source. The gear head is mounted to the front portion of the body part, and the handle is mounted to the rear portion of the body part.

The gear head includes a gear case, in which a gear train is provided for reducing the rotation of the electric motor. The rotation after reduction by the gear train is transmitted to a spindle, to which a disk-shaped grindstone is mounted.

The handle can be held by a user of the electric power tool with his or her hand, and the lower portion thereof is provided with a switch lever that can be pulled or slid by the user between an ON position and an OFF position using his or her finger tip. When the user moves the switch lever to the ON position by pulling it using his or her finger tip while holding the handle (i.e., grasping the switch lever together with the handle), a power supply circuit is turned ON so that the electric motor in the body part is started. In response to starting of the electric motor, the rotation thereof is transmitted to the spindle via a driving head so that the grindstone is rotated. When the switch lever is released from being pulled, the switch lever is responsively returned to the OFF position by a spring biasing force or others, and the power supply circuit is thus cut off, whereby the electric motor is stopped.

As such switch devices having switch levers, those provided with on-lock and off-lock mechanisms have been proposed. With the on-lock mechanism, the switch lever is locked in the ON position, and with the off-lock mechanism, the switch lever is locked in the OFF position. With the on-lock mechanism provided as such, the switch lever is held at the ON position without need of being held in the state after being pulled by the user, and the electric motor is locked in the state of activation. This accordingly increases the workability of the electric power tool, i.e., the ease of use of the switch device, so that the long-hour work can be performed with ease, for example. On the other hand, with the off-lock mechanism, after being once locked in the OFF position, the switch lever is not allowed to move to the ON position even if the user pulls the switch lever. This accordingly prevents the electric motor from being accidentally started.

For performing such a switching operation between the on-lock and off-lock mechanisms, DE3638952C2 proposes a lock operation member that utilizes the movement of the switch lever itself, and Japanese Laid-Open Patent Publication No. 9-290377 (Japanese Patent No. 2977076) proposed to use a lever, a push button, or others that are provided separately from the switch lever.

According to the known switch devices provided with both the on-lock and off-lock mechanisms, it is possible to improve the workability of the electric power tool and ease of use of the switch devices, and at the same time it is possible to prevent the electric power tool from being accidentally activated or to prevent the switch devices from being accidentally turned ON.

However, the known switch devices provided with both the on-lock and off-lock mechanisms are operated substantially in the same direction to release the off-lock mechanism and to activate the on-lock mechanism. Therefore, there has been a possibility that the user erroneously operates the switch devices to release the off-lock mechanism and to activate the on-lock mechanism as a series of operation.

Thus, when the user wants to use the electric power tool by releasing the switch lever from being in the off-lock state, i.e., in the state where the switch lever is not allowed to move to the ON position for operation due to the off-lock mechanism, he or she may accidentally activate the on-lock mechanism irrespective of his or her intention of operating the switch lever to only release it from being in the off-lock state, thereby locking the switch lever in the ON position. If this happens, even if the user stops pulling the switch lever to stop the electric power tool, the electric power tool remains in the state of activation. Hence, the known switch devices have the problem of the difficulty in specifically responding to the user's intension in terms of switching between the operation of releasing the switch lever from being in the off-lock state and the operation of putting the switch lever in the on-lock state.

Therefore, there is a need in the art for a switch device that includes both on-lock and off-lock mechanisms and can reliably respond to a user's intension in terms of switching between the operation of releasing the switch lever from being in the off-lock state and the operation of bringing the switch lever into the on-lock state.

SUMMARY OF THE INVENTION

One aspect according to the present invention includes a switch device for a power tool. The switch device includes a switch lever operable to move between an ON position for activating the power tool and an OFF position for stopping activation of the power tool. An on-lock mechanism can lock the switch lever in the ON position. An off-lock mechanism can lock the switch lever in the OFF position. The operation for making the on-lock mechanism effective and the operation for releasing the off-lock mechanism are performed by operating an operation member in different directions from each other or by operating two separate operation members.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an electric power tool (disk grinder) in its entirety including a switch device according to a first embodiment of the invention;

FIG. 2 is a vertical sectional view of a handle including the switch device of the first embodiment, and showing an off-lock state of the switch device;

FIG. 3 is another vertical sectional view of the handle including the switch device of the first embodiment, and showing the state where the switch device is released from the off-lock state and a switch lever is operated to tilt toward an ON position;

FIG. 4 is a further vertical sectional view of the handle including the switch device of the first embodiment, and showing an on-lock state of the switch device;

FIG. 5 is a vertical sectional view of a handle including a switch device according to a second embodiment of the present invention, and showing an off-lock state of the switch device;

FIG. 6 is another vertical sectional view of the handle including the switch device of the second embodiment, and showing the state where the switch is released from the off-lock state and a switch lever is operated to tilt toward an ON position;

FIG. 7 is a further vertical sectional view of the handle including the switch device of the second embodiment and showing an off-lock state of the switch device;

FIG. 8 is a vertical sectional view of a handle including a switch device according to a third embodiment of the present invention and showing an off-lock state of the switch device;

FIG. 9 is another vertical sectional view of the handle including the switch device of the third embodiment, and showing the state where the switch is released from the off-lock state and a switch lever is operated to tilt toward an ON position;

FIG. 10 is a cross sectional view of the handle taken along line X-X in FIG. 9 and showing the positional relationship between a lock operation member in the off-lock position and an engagement protrusion portion as viewed from the front side;

FIG. 11 is a further vertical sectional view of the handle including the switch device of the third embodiment and showing an on-lock state of the switch device;

FIG. 12 is a vertical sectional view of a handle including a switch device according to a fourth embodiment of the present invention and showing an off-lock state of the switch device;

FIG. 13 is another vertical sectional view of the handle including the switch device of the fourth embodiment, and showing the state in which the switch is released from the off-lock state and a switch lever is positioned in an OFF position;

FIG. 14 is a further vertical sectional view of the handle including the switch device of the fourth embodiment, and showing the state where the switch lever is tilted toward the ON position;

FIG. 15 is still further vertical sectional view of the handle including the switch device of the fourth embodiment, and showing an on-lock state of the switch device;

FIG. 16 is a vertical sectional view of a handle including a switch device according to a fifth embodiment of the present invention, and showing an off-lock state of the switch device;

FIG. 17 is another vertical sectional view of the handle including the switch device of the fifth embodiment, and showing the state where a switch lever is operated to tilt toward an ON position;

FIG. 18 is a further vertical sectional view of the handle including the switch device of the fifth embodiment, and showing an on-lock state of the switch device;

FIG. 19 is a vertical sectional view of a switch device according to a sixth embodiment of the present invention, and showing an off-lock state of the switch device;

FIG. 20 is a sectional view of the switch device taken along line 20-20 in FIG. 19, and showing a switch lever in a plan view;

FIG. 21 is sectional view of the switch device taken along line 21-21 in FIG. 19, and showing a lock operation member as viewed from the front side;

FIG. 22 is another vertical sectional view of the switch device of the sixth embodiment, and showing the state where the switch device is released from the off-lock state and the switch lever is positioned in the OFF position;

FIG. 23 is a sectional view of the switch device taken along line 23-23 in FIG. 22, and showing the switch lever in a plan view;

FIG. 24 is a further vertical sectional view of the switch device of the sixth embodiment, and showing the state where the switch device is released from the off-lock state and the switch lever is operated to tilt toward an ON position;

FIG. 25 is a sectional view of the switch device taken along line 25-25 in FIG. 24 and showing the switch lever in a plan view;

FIG. 26 is a further vertical sectional view of the switch device of the sixth embodiment, and showing an on-lock state of the switch device;

FIG. 27 is a sectional view of the switch device taken along line 27-27 in FIG. 26, and showing the switch lever in a plan view;

FIG. 28 is a vertical sectional view of a switch device according to a seventh embodiment of the present invention, and showing an off-lock state of the switch device;

FIG. 29 is another vertical sectional view of the switch device of the seventh embodiment, and showing the state where the switch device is released from the off-lock state and the switch lever is positioned in an ON position;

FIG. 30 is a further vertical sectional view of the switch device of the seventh embodiment, and showing an on-lock state of the switch device; and

FIG. 31 is an exploded perspective view of the switch device, and showing only a switch base and a switch lever.

DETAILED DESCRIPTION OF THE INVENTION

Each of the additional features and teachings disclosed above and below may be utilized separately or in conjunction with other features and teachings to provide improved switch devices and power tools having such switch devices. Representative examples of the present invention, which examples utilize many of these additional features and teachings both separately and in conjunction with one another, will now be described in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Only the claims define the scope of the claimed invention. Therefore, combinations of features and steps disclosed in the following detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Moreover, various features of the representative examples and the dependent claims may be combined in ways that are not specifically enumerated in order to provide additional useful embodiments of the present teachings.

In one embodiment, a switch device for a power tool includes a switch lever, an on-lock mechanism, an off-lock mechanism and a single lock operation member. The switch lever is operable to move between an ON position for activating the power tool and an OFF position for stopping activation of the power tool. The on-lock mechanism can lock the switch lever in the ON position. The off-lock mechanism can lock the switch lever in the OFF position. The single lock operation member is operable in a first direction for making the on-lock mechanism effective and is operable in a second direction for releasing the off-lock mechanism. The first direction and the second direction are different from each other.

With this arrangement, because the first direction and the second direction are different from each other, the use of the power tool can clearly distinguish between the operation for making the on-lock mechanism effective and the operation for releasing the off-lock mechanism. Therefore, it may not occur that the releasing the off-lock state (i.e., the state in which the off-lock mechanism is effective) is unintentionally changed to the on-lock state (i.e., the state in which the on-lock mechanism is effective). As a result, the user's intended operation can be reliably reflected.

The first direction and the second directions may be opposite to each other. With this arrangement, the two different operations may not be unintentionally made in series with each other.

The lock operation member may be a separate member from the switch lever. With this arrangement, it is possible to further reliably reflect the user's intended operation.

In another embodiment, there are provided a first operation member operable in a first direction for making the on-lock mechanism effective and a second operation member operable in a second direction for releasing the off-lock mechanism. The first operation member and the second operation members are separate members from each other.

Also with this arrangement, the use of the power tool can clearly distinguish between the first operation for making the on-lock mechanism effective and the second operation for releasing the off-lock mechanism. Therefore, it may not occur that the releasing the off-lock state (i.e., the state in which the off-lock mechanism is effective) is unintentionally changed to the on-lock state (i.e., the state in which the on-lock mechanism is effective). As a result, the user's intended operation can be reliably reflected.

In the case of the above configuration, the second direction may intersect with a direction for operating the switch lever between the ON position and the OFF position. This arrangement allows the first and second operations to be made as a series of operations, for example, by forwardly sliding the switch lever for releasing the off-lock state and thereafter moving the switch lever to the ON position in a direction intersecting with the sliding direction. Therefore, the off-lock releasing operation and the switch-on operation can be quickly performed as a series of operations. Hence, the operability of the switch device can be improved.

The first operation member may be a separate member from the switch lever. This arrangement enables to perform the off-lock releasing operation as an operation clearly distinguished from the operation of the switch lever. Therefore, the operator's intention can be further reliably reflected.

It may be also possible that the first and second operation members are separate members from the switch lever.

Embodiments of the present invention will now be described with reference to FIGS. 1 to 31.

First Embodiment

FIG. 1 shows an electric power tool 1 provided with a switch device 10 according to a first embodiment of the present invention. The electric power tool 1 is a hand-held disk grinder, and is provided with a tool body 2, a gear head 3, and a handle 4. The tool body 2 is coupled with The gear head 3 is coupled to the front portion of the tool body 2, and the handle 4 is mounted to the rear portion of the tool body 2.

The tool body 2 is provided therein an electric motor 5. The rotation of the electric motor 5 is transmitted to a spindle 7 after being reduced by a gear train 6 that is provided in the gear head 3. At the tip end of the spindle 7, a disk-shaped grindstone 8 is attached.

The handle 4 has a handle case 4a with the size and length enabling a user to easily hold by his or her hand, and extends rearwardly from the rear portion of the tool body 2. A power cord 9 for the supply of electric power extends into the rear end portion of the handle 4. With the power supplied from the power cord 9, the electric motor 5 of the tool body 2 is activated to rotate.

The handle 4 is provided, on its lower surface side, the switch device 10 of the first embodiment. FIGS. 2 to 4 show the detailed configuration of the switch device 10 of the first embodiment. This switch device 10 includes a switch base 19, a switch lever 11, and a switch body 12. The switch base 19 is fixed inside of the handle case 4a, and the switch lever 11 is supported to be able to tilt vertically with respect to the switch base 19. The switch body 12 is turned ON and OFF in response to the operation of the switch lever 11.

The switch body 12 is held between the switch base 19 and the handle case 4a, and is positioned at substantially the center of the handle case 4a. The switch body 12 is turned ON when an operating knob 12a is pushed upward, and is turned OFF when the operating knob 12a is protruded downward by a spring biasing force. When the switch body 12 is turned ON, a power supply circuit is turned ON for activating the electric motor 5. In other words, when the switch body 12 is turned ON, the switch body 12 outputs an ON signal to the power supply circuit, so that an electric power is supplied to the electric motor 5. When the switch body 12 is turned OFF, the electric motor 5 is stopped. In other words, when the switch body 12 is turned OFF, the switch body 12 outputs an OFF signal to the power supply circuit, so that no electric power is supplied to the electric motor 5.

Various configurations of the switch lever 11 used for turning ON and OFF the switch body 12, and on-lock and off-lock mechanisms for restricting the movement of the switch lever 11 will now be described.

The switch lever 11 is so supported as to extend in the forward and rearward directions substantially along the lower side of the switch base 19. The switch base 19 is provided with, at the rear portion thereof, a support protrusion portion 19a having a semicircular cross section. By way of the support protrusion portion 19a, the switch lever 11 is so supported as to be able to tilt in the vertical direction. Between the switch lever 11 and the switch base 19, a compression spring 13 is disposed. By the action of the compression spring 13, the switch lever 11 is biased in the direction to be tilted toward the lower side (the side of the OFF position), i.e., the side opposite to the direction of an arrow C.

When a user grips the handle 4 and operates the switch lever 11 with his or her finger to tilt it toward the upper side, i.e., the side of the ON position, against the action of the compression spring 13, the operating knob 12a of the switch body 12 is pushed upward so that the switch body 12 is turned ON. In response to the activation of the switch body 12, the electric motor 5 is activated or started. When the user removes his or her fingertip from the switch lever 11, the switch lever 11 is forced to return to the lower side, i.e., to the OFF position, by the action of the compression spring 13. When the switch lever 11 is returned to the OFF position, the operating knob 12a of the switch body 12 protrudes downward so that the switch body 12 is turned OFF. When the switch body 12 is turned OFF, the electric motor 5 is stopped.

The switch lever 11 is provided with both the on-lock and off-lock mechanisms. With the on-lock mechanism, the switch lever 11 is locked in an ON position, and with the off-lock mechanism, the switch lever is locked in an OFF position. These mechanisms share the same lock operation member 15.

The lock operation member 15 is supported at the front side of the switch lever 11. A tip end portion 15b of this lock operation member 15 protrudes downward through a window portion 11b, which is provided in the lower surface of the switch lever 11. The lock operation member 15 is so supported as to be able to tilt in the forward and rearward directions relative to the switch lever 11 via a shaft portion 15a. This lock operation member 15 is biased by the action of a torsion spring 16 in a counterclockwise direction as viewed in FIG. 2 such that the tip end portion 15b moves to the rear side, i.e., the side of the off-lock position. The front upper portion of the lock operation member 15 is integrally provided with an L-shaped engagement protrusion portion 15c.

A lock base 17 is attached to the front portion of the switch base 19. This lock base 17 is fixed along the front portion of the switch lever 11 to extend in the vertical direction. At the front lower portion of the lock base 17, a restriction protrusion portion 17a is so provided as to protrude forwardly. This restriction protrusion portion 17a enters a restriction window portion 11c provided at the front portion of the switch lever 11. Within a range allowed for the restriction protrusion portion 17a to move in the vertical direction in the restriction window portion 11c, the switch lever 11 can tilt in the vertical direction. By way of the restriction protrusion portion 17a, the switch lever 11 is restricted with respect to the range for tilting in the vertical direction.

The lock base 17 is integrally provided with, at the lower portion on the rear surface thereof, an engagement protrusion portion 17b. Toward this engagement protrusion portion 17b, a leaf spring 18 attached to the upper portion of the lock base 17 extends.

With the switch device 10 of the first embodiment configured as described above, in the state that the user is not operating the switch lever 11 at all as shown in FIG. 2, the switch lever 11 is positioned in the OFF position on the lower side by the biasing force of the compression spring 13. In the state that the switch lever 11 is positioned in the OFF position, the lock operation member 15 is kept in the off-lock position where the tip end portion 15b is moved to the rear side by the biasing force of the torsion spring 16.

In the state that the lock operation member 15 is positioned in the off-lock position, the engagement protrusion portion 15c comes to the lower side of the engagement protrusion portion 17b of the lock base 17. Therefore, at this off-lock position, the engagement protrusion portion 15c is restricted from being displaced upward by the engagement protrusion portion 17b of the lock base 17 so that the switch lever 11 is brought to the off-lock state, where the switch lever 11 cannot be operated to tilt to the side of the ON position (in the direction of arrow C in FIG. 2). With the switch lever 11 being in the off-lock state, the switch lever 11 is prevented from being turned ON accidentally.

For releasing the switch lever 11 from being in the off-lock state, there needs to operate the lock operation member 15 to tilt in the direction of displacing the tip end portion 15b thereof toward the front side against the action of the torsion spring 16, i.e., in the off-lock release direction indicated by arrow A. As shown in FIG. 3, when the lock operation member 15 is operated to tilt in the off-lock release direction, the engagement protrusion portion 15c thereof moves away from the lower side of the engagement protrusion portion 17b of the lock base 17. Accordingly, the switch lever 11 is brought into the state where the switch lever 11 is allowed for operation to be tilted toward the side of the ON position indicated by arrow C. While the lock operation member 15 being held in the state tilted in the off-lock release direction indicated by arrow A, operating the switch lever 11 to tilt toward the ON position on the upper side indicated by arrow C causes the operating knob 12a to be pushed, so that the switch body 12 is turned ON, thereby activating the electric motor 5.

While the lock operation member 15 being held to be tilted toward the off-lock release direction, operating the switch lever 11 to tilt from the OFF position toward the ON position causes the engagement protrusion portion 15c to pass a position on the rear side of the engagement protrusion portion 17b of the lock base 17 and to be displaced upward. When the switch lever 11 has been tilted to the ON position, i.e., the ON state, the engagement protrusion portion 15c of the lock operation member 15 slidably contacts with the leaf spring 18. The biasing force of this leaf spring 18 is set to be larger than that of the torsion spring 16. Therefore, in this stage, even if the operation of tilting the lock operation member 15 in the off-lock release direction is stopped, the lock operation member 15 is held in the off-lock release position, i.e., the position shown in FIG. 3, due to the biasing force of the leaf spring 18.

When the user stops the operation of tilting the switch lever 11 to the side of the ON position using his or her fingertip, the switch lever 11 is forced to return to the OFF position on the lower side by the action of the compression spring 13. When the switch lever 11 has returned to the OFF position on the lower side, the engagement protrusion portion 15c of the lock operation member 15 passes a position on the rear side of the engagement protrusion portion 17b of the lock base 17. Because the lock operation member 15 is being biased toward the off-lock side by the action of the torsion spring 16, in response to the tilting movement of the switch lever 11 to the side of the OFF position, the lock operation member 15 returns to the off-lock position as the engagement protrusion portion 15c passes a position on the rear side of the engagement protrusion portion 17b. In the state that the lock operation member 15 has returned to the off-lock position as described above, the switch lever 11 is not allowed to be tilted toward the side of the ON position (in the direction of arrow C). This function may be called an off-lock function.

In addition to the off-lock function, the switch device 10 of this embodiment has an on-lock function. As shown in FIG. 3, by tilting the switch lever 11 toward the ON position indicated by arrow C while the lock operation member 15 being held to be tilted toward the off-lock release position indicated by arrow A, the switch body 12 is turned ON so that the electric motor 5 can be activated. Thereafter, as shown in FIG. 4, the lock operation member 15 is operated to tilt to the side of the on-lock position indicated by arrow B, i.e., in the direction of displacing the tip end portion 15b thereof to the rear side. With this on-lock operation, the user's operation force of tilting the lock operation member 15 and the biasing force of the torsion spring 16 may exceed the biasing force of the leaf spring 18 so that the engagement protrusion portion 15c reaches to a position above the engagement protrusion portion 17b while pushing the leaf spring 18 to the front side. As a result, when the tilting operation of the switch lever 11 to the side of the ON position is stopped with the lock operation member 15 held in the on-lock position, the biasing force of the compression spring 13 applied to the switch lever 11 acts to press from above the engagement protrusion portion 15c to engage it with the engagement protrusion portion 17b of the lock base 17. With this engagement from above of the engagement protrusion portion 15c of the lock operation member 15 with the engagement protrusion portion 17b of the lock base 17, the switch lever 11 is restricted from tilting to the side of the OFF position. Because the switch lever 11 is held in the ON position with the restriction not to tilt to the side of the OFF position, the switch body 12 is held in the ON state so that the electric motor 5 is locked in the state of activation. With the switch lever 11 being locked in the ON position, the user no more needs to pull the switch lever 11 for locking the electric motor 5 in the state of activation, so that he or she can comfortably performs the grinding operation by gripping the handle 4.

In the on-lock state of the switch lever 11, if the user grips upward the switch lever 11 again for operation, the engagement protrusion portion 15c of the lock operation member 15 moves away upward with respect to the engagement protrusion portion 17b of the lock base 17. This accordingly causes the engagement protrusion portion 15c to be pushed to the rear side by the biasing force of the leaf spring 18, and in response thereto, the lock operation member 15 is tilted in the direction of displacing the tip end portion 15b thereof to the front side against the action of the torsion spring 16, i.e., in the direction of arrow A in FIG. 3. In this way, because the lock operation member 15 returns to the position shown in FIG. 3, if the user releases the switch lever 11 from his or her griping operation, the switch lever 11 returns to the OFF position on the lower side by the action of the compression spring 13, so that the switch body 12 is turned OFF. Moreover, the lock operation member 15 returns to the off-lock position where the tip end portion 15b thereof is displaced to the rear side by the biasing force of the torsion spring 16, and accordingly the switch device 10 returns to the off-lock state, i.e., initial state.

As described above, with the switch device 10 of the first embodiment, tilting the lock operation member 15 in the off-lock release direction indicated by arrow A enables to release the switch lever 11 from being in the off-lock state. Moreover, with the switch lever 11 held in the ON position, tilting the lock operation member 15 in the on-lock direction indicated by arrow B enables to change the state of the switch lever 11 into the on-lock state. Therefore, the operation direction of the lock operation member 15 to release the switch lever 11 from being in the off-lock state, i.e., in the direction of arrow A, is opposite to the operation direction of the lock operation member 15 to change the state of the switch lever 11 into the on-lock state, i.e., in the direction of arrow B. This difference in direction can prevent an accidental operation, in which, after the lock operation member 15 is operated to tilt in the off-lock release direction indicated by arrow A, the lock operation member 15 is operated continuously to tilt in the same direction and thus bringing the switch lever 11 into the on-lock state. Thus, in order to change the state of the switch lever 11 into the on-lock state, the lock operation member 15 is required to be operated to tilt in the opposite direction, i.e., in the direction indicated by arrow B, so that the user's intended operation can be reliably reflected.

Second to sixth embodiments will now described with reference to FIGS. 5 to 27. These embodiments are modifications of the first embodiment. Therefore, in FIGS. 5 to 27, like members are given the same reference numerals as the first embodiment and an explanation of these members will not be repeated.

Second Embodiment

FIGS. 5 to 7 show a switch device 20 according to the second embodiment. In the first embodiment, the engagement protrusion portion 15c provided at the lock operation member 15 serves to perform both the on-lock and off-lock functions, but in the second embodiment, these functions are performed by a different mechanism from the engaging protrusion 15c.

Similarly to the first embodiment, a switch lever 21 is supported to be able to tilt in the vertical direction between the upper ON position and the lower OFF position by way of the support protrusion portion 19a. The support protrusion portion 19a is disposed at the rear portion of the switch base 19. The switch lever 21 is biased in the direction of moving toward the lower OFF position by the action of the compression spring 13, which is disposed between the switch lever 21 and the switch base 19.

On the front lower surface of the switch lever 21, a lock operation member 22 is so supported as to be able to tilt in the forward and rearward directions via a shaft 27. A tip end portion 22a of this lock operation member 22 protrudes downward through a window portion 21b, which is provided at the front portion of the switch lever 21. This lock operation member 22 is biased by the action of a torsion spring 26 in the direction of displacing the tip end portion 22a toward the front side, i.e., clockwise direction in FIG. 5. In this respect, the biasing direction of the torsion spring 26 is opposite to that of the torsion spring 16 of the first embodiment.

The lock operation member 22 is integrally provided with, on the upper portion thereof, an engagement arm portion 22b that extends upward. The tip end portion of this engagement arm portion 22b is provided with an engagement portion 22c that is bent into an L shape. On the rear side of the engagement arm portion 22b, a slider 23 is disposed. This slider 23 is supported by the switch base 19 in such a manner that it can slide in the forward and rearward directions. Between a rear engagement portion 23b of this slider 23 and the switch base 19, a compression spring 24 is disposed. By the action of this compression spring 24, the slider 23 is biased in the direction of displacing toward the front side.

The biasing force of the compression spring 24 is set to be larger than that of the torsion spring 26, which serves to bias the lock operation member 22 in the clockwise direction. Therefore, the engagement arm portion 22b of the lock operation member 22 is pushed toward the front side by the slider 23 so that the lock operation member 22 is biased in the direction of displacing the tip end portion 22a thereof toward the rear side against the action of the torsion spring 26, i.e., toward the side of the off-lock position.

The inner surface of the switch lever 21 located below the slider 23 is integrally provided with an engagement protrusion portion 21d. This engagement protrusion portion 21d is formed like a column extending upward. As shown in FIG. 5, this engagement protrusion portion 21d is located below the rear engagement portion 23b of the slider 23 in the state that the slider 23 has moved toward the front side.

The front portion of the switch base 19 is provided with an engagement protrusion portion 25, which is bent into an L shape. This engagement protrusion portion 25 protrudes upward of the lock operation member 22.

As shown in FIG. 5, in the state that the user grips the handle 4 but does not operate the switch lever 21, the switch lever 21 is positioned in the OFF position on the lower side by the action of the compression spring 13. If the lock operation member 22 is not operated when the switch lever 21 is positioned in the OFF position, the lock operation member 22 is held in the off-lock position where the tip end portion 22a thereof is displaced to the rear side by the engagement arm portion 22b that is pushed toward the front side by the slider 23. In the state that the lock operation member 23 is positioned in the off-lock position, the engagement protrusion portion 21d is positioned directly below the rear engagement portion 23b of the slider 23. A space between the rear engagement portion 23b and the engagement protrusion portion 21d is set to be very narrow. Accordingly, the switch lever 21 is in the off-lock state in which the tilting operation toward the ON position indicated by arrow C in FIG. 5 is restricted.

For releasing the switch lever 21 from the off-lock state, the lock operation member 22 must be tilted in the off-lock release direction indicated by arrow A in FIG. 6. When the lock operation member 22 is operated to tilt in the off-lock release direction, the sum of the operation force of tilting the lock operation member 22 and the biasing force of the torsion spring 26 may exceed the biasing force of the compression spring 24 so that the slider 23 moves toward the rear side against the biasing force of the compression spring 24.

When the slider 23 is moved toward the rear side, the rear engagement portion 23b thereof is moved away from the upper side of the engagement protrusion portion 21d toward the rear side, whereby the switch lever 21 can be operated to tilt toward the side of the ON position indicated by tarrow C. As the switch lever 21 is operated to tilt toward the ON position, the operating knob 12a of the switch body 12 is pushed by the switch lever 21 and the switch body 12 is turned ON, thereby activating the electric motor 5. As shown in FIG. 6, when the switch lever 21 is operated to tilt toward the ON position, the engagement protrusion portion 21d thereof comes to the front side of the rear engagement protrusion portion 23b of the slider 23. Therefore, the slider 23 is restricted from moving toward the front side.

In the state that the lock operation member 22 is positioned in the off-lock release position by operating the switch lever 21 to tilt toward the ON position, if the user stops the operation of tilting the switch lever 21 toward the ON position, the switch lever 21 returns to the OFF position again by the action of the compression spring 13 and the switch body 12 is thus turned OFF, thereby stopping the electric motor 5.

On the other hand, as shown in FIG. 7, if the lock operation member 22 is operated to tilt toward the on-lock position indicated by arrow B against the action of the torsion spring 26 in the state where the switch lever 21 has been tilted to the ON position, the engagement portion 22c thereof is displaced to be positioned above the engagement protrusion portion 25 on the side of the switch base 19. Therefore, by the engagement of the engagement portion 22c from above with the engagement protrusion portion 25, the lock operation member 22 is held in the on-lock position of FIG. 7, and the switch lever 21 is locked in the ON position while the tilting movement toward the side of the OFF position being restricted (on-lock state).

If the switch lever 21 in the on-lock state is operated to tilt further, the engagement portion 22c is disengaged from the engagement protrusion portion 25 because the lock operation member 22 is biased toward the side of the off-lock position by the action of the torsion spring 26. As a result, the switch lever 21 returns toward the side of the OFF position by the action of the compression spring 13. When the switch lever 21 returns toward the side of the OFF position, the engagement protrusion portion 21d is moved away from the front side of the rear engagement portion 23b, thereby causing movement of the slider 23 toward the front side by the action of the compression spring 24.

Moreover, because the engagement portion 22c of the lock operation member 22 is disengaged from the engagement protrusion portion 25, the lock operation member 22 returns again to the direction of displacing the tip end portion 22a thereof toward the front side, i.e., in the clockwise direction. In addition, the engagement arm portion 22b of the lock operation member 22 is pushed by the slider 23 toward the front side, and the lock operation member 22 returns to the off-lock position shown in FIG. 5 so that the switch lever 21 is locked in the OFF position.

Also with the switch device 20 of the second embodiment configured as described above, the off-lock release direction (direction of arrow A) of the lock operation member 22 is opposite to the operation direction for changing the state of the switch lever 21 into the on-lock state (direction of arrow B).

This difference in direction can prevent an accidental operation, in which, after the lock operation member 22 is operated to tilt in the off-lock release direction indicated by arrow A, the lock operation member 22 is operated continuously to tilt in the same direction and thus bringing the switch lever 21 into the on-lock state. Thus, in order to change the state of the switch lever 21 into the on-lock state, the lock operation member 22 is required to be operated to tilt in the opposite direction, i.e., direction indicated by arrow B, and thus the user's intended operation can be reliably reflected.

Third Embodiment

FIGS. 8 to 11 show a switch device 30 according to a third embodiment of the present invention. Similar to the switch device 10 of the first embodiment, the switch device 30 of the third embodiment is configured such that a single piece of a lock operation member 32 can be operated for releasing the off-lock state and for changing into the on-lock state.

The lock operation member 32 is supported at the front portion of a switch lever 31 via a shaft 33. This lock operation member 32 can tilt in the forward and rearward directions about the shaft 33. The lock operation member 32 is biased in the direction of displacing its tip end portion 32d toward the rear side (side of the off-lock position) by the action of a compression spring 35, which is disposed between the front portion of the lock operation member 32 and a spring support portion 31a of the switch lever 31.

The lock operation member 32 is provided with a first engaging arm 32a and a second engagement arm 32b. The first engagement arm 32a extends upward. The upper portion of the first engagement arm 32a is provided with an engagement portion 32c, which is bent forwardly into an L shape.

The second engagement arm 32b is so supported as to be able to tilt in the forward and rearward directions via the shaft 33. This second engagement arm 32b is biased in the direction of displacing the front portion thereof toward the front side by the action of a torsion spring 34. The second engagement arm 32b is so disposed as to extend upward along the rear side of the first engagement arm 32a. As shown in FIG. 8, this second engagement arm 32b is held in a position along the rear side of the first engagement arm 32a by the action of the torsion spring 34. Moreover, as shown in FIG. 11, the second engagement arm 32b is allowed to tilt in the direction of displacing the upper portion thereof toward the rear side, i.e., direction of moving away from the first engagement arm 32a, against the action of the torsion spring 34.

As shown in FIG. 8, the switch lever 31 is held in the OFF position by the spring biasing force of the compression spring 13 when it is not pulled for operation. The lock operation member 32 is held in the off-lock position by the spring biasing force of the compression spring 35 when it is not operated. In the state that the lock operation member 32 is positioned in the off-lock position, above the second engagement arm 32b, two engagement protrusion portions 37 are located. These two engagement protrusion portions 37 are integrated with the switch base 19, and a space between the second engagement arm 32b and the engagement protrusion portions 37 is set to be very narrow. Therefore, when the lock operation member 32 is not operated, the switch lever 31 is held in the off-lock state in which the switch lever 31 is restricted not to be operated toward the side of the ON position.

In order to pull the switch lever 31 to the side of the ON position, the lock operation member 32 is operated to tilt in the off-lock release direction indicated by arrow A in FIG. 9, so that the first and second engagement arms 32a and 32b are tilted together in the direction of displacing the upper portions thereof toward the rear side. Such a tilting operation of the lock operation member 32 in the off-lock release direction is made against the action of the compression spring 35.

If the lock operation member 32 is operated to tilt in the off-lock release direction, the tip end portion of the second engagement arm 32b is displaced toward the rear side of the engagement protrusion portions 37 so that the switch lever 31 is allowed for tilting toward the side of the ON position. If the switch lever 31 is operated to tilt toward the ON position, similar to the first embodiment, the operating knob 12a is pushed and the switch body 12 is turned ON, thereby activating the electric motor 5.

As shown in FIG. 10, the two engagement protrusion portions 37 are so disposed as to separately protrude downward while they are spaced from each other in their width direction, i.e., in the right and left directions in FIG. 10. The first engagement arm 32a on the front side is set to have a narrow width so as to be capable of entering the space between the engagement protrusion portions 37. On the other hand, the second engagement arm 32b on the rear side is set to have a broad width so as to be opposed to and extend between the engagement protrusion portions 37. Accordingly, as shown in FIG. 9, if the switch lever 31 is operated to tilt toward the side of the ON position in the state that the lock operation member 32 has been tilted in the off-lock release direction, the first engagement arm 32a enters into the space between the engagement protrusion portions 37 and causes no interference therewith. On the other hand, if the switch lever 31 is operated to tilt toward the ON position while the switch lever 31 being in the off-lock release state, both of the engagement protrusion portions 37 come in contact with the front surface of the second engagement arm 32b, thereby restricting the second engagement arm 32b from tilting toward the front side. Because the second engagement arm 32b is restricted not to tilt toward the front side, as shown in FIG. 11, the operation of tilting the lock operation member 32 in the direction of arrow B is made against the biasing force of the torsion spring 34.

As shown in FIG. 11, in the state that the switch lever 31 has been tilted to the ON position, if the lock operation member 32 is tilted in the direction of arrow B against the biasing force of the torsion spring 34, the first engagement arm 32a is tilted toward the front side so that the engagement portion 32c thereof is engaged with an engagement protrusion 38 that is provided integrally with the switch base 19. With the engagement portion 32c of the first engagement arm 32a engaged with the engagement protrusion 38, the lock operation member 32 is locked in the on-lock position of FIG. 11, and thus the switch lever 31 is locked in the ON position.

If the switch lever 31 in the on-lock state is gripped more firmly, the first engagement arm 32a is disengaged from the engagement protrusion 38. Therefore, the lock operation member 32 returns to the position shown in FIG. 9 by the biasing force of the torsion spring 34 so that the switch lever 31 is released from the on-lock state. Therefore, releasing the pulling operation of the switch lever 31 causes the switch lever 31 to return to the OFF position by the biasing force of the compression spring 13.

As described above, also with the switch device 30 of the third embodiment configured as described above, the operation direction of the lock operation member 31 for releasing it from the off-lock state (the direction of arrow A) is opposite to the operation direction thereof for changing the state of the switch lever 31 into the on-lock state (the direction of arrow B). This difference in direction allows the user to clearly distinguish between the off-lock release operation and the on-lock switching operation so that the switch device 30 can reliably reflect the user's intention in terms of operation.

Fourth Embodiment

Next, FIGS. 12 to 15 show a switch device 40 according to a fourth embodiment of the present invention. The switch device 40 is configured to include the switch base 19, a switch lever 41, and the switch body 12. The switch lever 41 is supported to be able to tilt in the vertical direction between the OFF and ON positions via the support protrusion portion 19a, which is provided at the rear portion of the switch base 19. On the front portion of this switch lever 41, a lock operation member 43 is so supported as to be able to tilt in the forward and rearward directions via a shaft 44. This lock operation member 43 is biased by the action of a torsion spring 45 in the direction of displacing a tip end portion 43a toward the front side. The lock operation member 43 is provided with an on-lock arm 43b. On the other hand, on the lower surface side of the switch base 19, a slider 46 having a rectangular frame-like shape is so supported as to be able to slide in the forward and rearward directions. This slider 46 is biased toward the front side by a compression spring 48, which is disposed between the slider 46 and the switch lever 41.

By the biasing force of the torsion spring 45, the on-lock arm 43b of the lock operation member 43 is pressed toward the rear side against a front frame portion 46a of the slider 46. On the other hand, the slider 46 is biased toward the front side by the action of the compression spring 48. The pressing force toward the rear side of the on-lock arm 43b against the slider 46, i.e., the biasing force of the torsion spring 45, is set to be smaller than the biasing force of the compression spring 48 applied from the rear side. With such a setting, a biasing force that is subtraction of the biasing force of the torsion spring 45 from that of the compression spring 48 acts on the lock operation member 43 in the counterclockwise direction so that the lock operation member 43 is held in the off-lock position shown in FIG. 12.

The inner surface of the switch lever 41 located below the slider 46 is integrally provided with first and second protrusion portions 47 and 49 that extend upward. The first protrusion portion 47 extends to a position opposed to the operating knob 12a of the switch body 12 with a small space. The second protrusion portion 49 is so formed as to be shorter (lower as viewed in FIG. 12) than the first protrusion portion 47.

In the state that the switch lever 41 is positioned in the OFF position and the lock operation member 43 is held in the off-lock position, the rear frame portion 46b of the slider 46 comes above the second protrusion portion 49, and therefore, the switch lever 41 is not allowed to be tilted toward the side of the ON position. This corresponds to the off-lock state.

As shown in FIG. 13, if the lock operation member 43 is operated to tilt toward the off-lock release side, i.e., in the direction of arrow A, causing the tip end portion 43a thereof to be displaced toward the front side, the operating force of the lock operation member 43 acts on the slider 46 via the on-lock arm 43b so that the slider 46 is pushed toward the rear side against the action of the compression spring 48. As the slider 46 is displaced toward the rear side, the rear frame portion 46b is moved toward the rear side from the above of the second protrusion portion 49 so that the switch lever 41 is allowed to be tilted toward the side of the ON position. As shown in FIG. 14, if the switch lever 41 is operated to tilt toward the ON position, the operating knob 12a of the switch body 12 is pushed by the first protrusion portion 47 so that the switch body 12 is turned ON and the electric motor 5 is activated.

In the state that the switch lever 41 has been tilted to the ON position, the switch lever 41 is held in the off-lock release state even in the case that the operation of tilting the lock operation member 43 in the direction of arrow A is stopped. This is because the lock operation member 43 is biased by the action of the torsion spring 45, and thus the second protrusion portion 49 enters the front side of the rear frame portion 46b of the slider 46 to thereby restrict the slider 46 from moving toward the front side. In this off-lock release state, if the turn-ON operation of the switch lever 41 is released, the switch lever 41 returns to the OFF position by the action of the compression spring 13. As the switch lever 41 returns to the OFF position, the second protrusion portion 49 moves downward away from the front side of the rear frame portion 46b of the slider 46. Therefore, the slider 46 returns to the front side by the biasing force of the compression spring 48.

As the slider 46 returns toward the front side, the rear frame portion 46b is brought to be positioned above the second protrusion portion 49, and the on-lock arm 43b is pushed toward the front side by the front frame portion 46a so that the lock operation member 43 returns to the off-lock position against the action of the torsion spring 45. As a result, the switch lever 41 returns to the off-lock state shown in FIG. 14.

As shown in FIG. 13, in the state that the switch lever 41 has been tilted to the ON position, if the lock operation member 43 is operated to tilt toward the on-lock switching side indicated by arrow B in FIG. 15 against the action of the torsion spring 45, an L-shaped engagement portion 43c is engaged with an L-shaped engagement portion 42. The engagement portion 43c is provided at the tip end of the on-lock arm 43b, and the engagement portion 42 is provided integrally with the switch base 19. With this engagement, the lock operation member 43 is held in the on-lock position, and the switch lever 41 is locked in the ON position. With the switch lever 41 locked in the ON position, the switch body 12 is locked in the ON state so that the electric motor 5 is locked in the state of activation.

When the switch lever 41 is operated to tilt further, the engagement portion 43c of the on-lock arm 43b is disengaged from the engagement portion 42 so that the lock operation member 43 returns to the position shown in FIG. 14 by the biasing force of the torsion spring 45. With this disengagement between the engagement portion 43c and the engagement portion 42, the switch lever 41 is released from the on-lock state. Accordingly, when the tilting operation of the switch lever 41 is released, the switch lever 41 returns to the OFF position by the action of the compression spring 13.

Also with the switch device 40 of the fourth embodiment configured as described above, the operation direction of the lock operation member 43 for releasing the switch lever 41 from the off-lock state (the direction of arrow A) is opposite to the operation direction for changing the state of the switch lever 41 into the on-lock state (the direction of arrow B). This difference in direction allows the user to clearly distinguish between the off-lock release operation and the on-lock switching operation in terms of the operation direction of the lock operation member 43. Therefore, the user is inhibited from performing the on-lock switching operation continuously after the off-lock release operation, and in this respect, the switch device 40 can reliably reflect the user's intention in terms of operation.

Fifth Embodiment

Next, FIGS. 16 to 18 show a switch device 50 according to a fifth embodiment of the present invention. A switch lever 51 of the switch device 50 is so supported as to be able to tilt in the vertical direction via the support protrusion portion 19a, which is provided at the rear portion of the switch base 19. The switch base 19 is fixed to the handle case 4a. The switch body 12 is held between the switch base 19 and the handle case 4a, and is positioned substantially at the center of the handle case 4a.

At the front portion of the switch lever 51, a lock operation member 52 is supported. The lock operation member 52 of the fifth embodiment is supported by the switch lever 51 via two shafts 53 and 54 that are positioned on the front side and the rear side, respectively. Opposite end portions of each of the shafts 53 and 54 respectively protrude from the right and left side portions of the lock operation member 52. The protruded end portions of each of the shafts 53 and 54 are respectively inserted into right and left guide grooves 51a, which are disposed at the right and left side portions of the switch lever 51, respectively. By the right and left guide grooves 51a, the lock operation member 52 is so supported as to be able to slide within a fixed range in the forward and rearward directions. Front portions 51b of the right and left guide grooves 51a are each bent downward into an L shape.

Between the lock operation member 52 and the front portion of the switch lever 51, a compression spring 55 is disposed. By the action of this compression spring 55, the lock operation member 52 is biased in the direction of displacing toward the rear side, i.e., toward the off-lock position. As shown in FIG. 16, in the state that the lock operation member 52 is positioned in the off-lock position, the front and rear shafts 53 and 54 are respectively located in the guide grooves 51a. When the lock operation member 52 is moved to slide toward the front side against the action of the compression spring 55, the opposite end portions of the front shaft 53 are allowed to enter the front portions 51b of the guide groove portions 51a, respectively. In this state, the lock operation member 52 can be tilted in the counterclockwise direction in FIG. 16 via the rear shaft 54, i.e., in the on-lock switching direction.

In the state that the lock operation member 52 is positioned in the off-lock position by the action of the compression spring 55, an engagement protrusion portion 56 comes above the lock operation member 52. The engagement protrusion portion 56 is formed to be integral with the switch base 19 and protrudes downward therefrom. Because of abutment of the engagement protrusion portion 56 to the upper portion of the lock operation member 52, the switch lever 51 is held in the off-lock state, where the switch lever 51 is not allowed to be tilted toward the side of the ON position.

For releasing the switch lever 51 from the off-lock state, the lock operation member 52 must be slid in the off-lock release direction indicated by arrow A in FIG. 17 (toward the front side) by grasping the tip end portion 52b of the lock operation member 52. This accordingly causes the movement of the engagement protrusion portion 56 from the above of the lock operation member 52 toward the rear side so that the switch lever 51 can be tilted toward the ON position. FIG. 17 shows the state in which the switch lever 51 has been tilted to the ON position. As the switch lever 51 is operated to tilt toward the ON position, the switch body 12 is turned ON, and the electric motor 5 is activated.

If the user releases the operation of tilting the switch lever 51 toward the ON position, the switch lever 51 returns to the OFF position shown in FIG. 16 by the biasing force of the compression spring 13.

At the upper portion of the lock operation member 52, an L-shaped engagement portion 52c is provided. As shown in FIG. 17, in the state that the switch lever 51 is positioned in the ON position, if the lock operation member 52 is operated to tilt in the on-lock switching direction indicated by arrow B in FIG. 18, the engagement portion 52c is engaged with an engagement protrusion 57 provided integrally with the switch base 19 so that the switch lever 51 is locked in the ON position. With the switch lever 51 locked in the ON position, the switch body 12 is held in the ON state, and the electric motor 51 is locked in the state of activation.

The lock operation member 52 is operated to tilt toward the side of the on-lock position, i.e., the direction of arrow B, about the rear shaft 54 by moving the end portions of the front shaft 53 into the front groove portions 51b. The state of engagement between the engagement portion 52c and the engagement protrusion 57 is kept by the indirect action of the compression spring 55.

If the switch lever 51 is gripped more firmly, the engagement portion 52c is disengaged from the engagement protrusion 57 so that the switch lever 51 is released from the on-lock state. As the switch lever 51 is released from the on-lock state in this way, the lock operation member 52 returns to the side opposite to the direction of arrow B by the biasing force of the compression spring 55, and at the same time the lock operation member 52 is displaced toward the rear side and comes in contact with the engagement protrusion portion 56. Therefore, the switch lever 51 is allowed to return to the OFF position.

As the switch lever 51 returns to the OFF position, the lock operation member 52 is displaced by the biasing force of the compression spring 55 from the front side of the engagement protrusion portion 56 to the lower side thereof, so that the lock operation member 52 returns to the off-lock position shown FIG. 16.

Also with the switch device 50 of the fifth embodiment configured as described above, the operation direction of the lock operation member 52 for releasing the switch lever 51 from the off-lock state (the direction of arrow A) is opposite to the operation direction for changing the state of the switch lever 51 into the on-lock state (the direction of arrow B). This difference in direction allows the user to clearly distinguish between the off-lock release operation (the direction of arrow A) and the on-lock switching operation (the direction of arrow B) in terms of the operation direction of the lock operation member 52. Therefore, the user is prevented from performing the on-lock switching operation continuously after the off-lock release operation, and in this respect, the switch device 50 reliably reflects the user's intention in terms of operation.

Sixth Embodiment

Next, FIGS. 19 to 26 show a switch device 60 according to a sixth embodiment of the present invention. This switch device 60 of the sixth embodiment is configured to include the switch base 19, a switch lever 61, and the switch body 12, which are mounted within the handle case 4a. Similar to the embodiments described above, the switch body 12 is held between the switch base 19 and the handle case 4a, and is positioned substantially at the center of the handle case 4a.

The switch lever 61 is supported at the rear portion of the switch base 19 via a shaft 62 so that the switch lever 61 can tilt in the vertical direction. Between the switch lever 61 and the switch base 19, the compression spring 13 is disposed. By the action of the compression spring 13, the switch lever 61 is biased toward the OFF position on the lower side.

At the front portion of the switch lever 61, a lock operation member 63 is supported such that it can move in the width direction of the switch lever 61. This lock operation member 63 has a stepped configuration with a small-diameter portion 63a and a large-diameter portion 63b. The small-diameter portion 63a protrudes from the left side portion of the switch lever 61. The large-diameter portion 63b protrudes from the right side portion of the switch lever 61. As shown in FIG. 21, the lock operation member 63 is biased in the protruding direction of the small-diameter portion 63a, i.e., downward in FIG. 20, and rightward in FIG. 21, by the action of a torsion spring 64, which is disposed between the lock operation member 63 and the switch lever 61.

The large-diameter portion 63b of the lock operation member 63 is provided with a relief portion 63c and an engagement portion 63d. The relief portion 63c is formed by removing a rear part of the large-diameter portion 63b throughout the vertical length. The relief portion 63c is formed within a fixed range in the axial direction, i.e., in the vertical direction in FIG. 20. On the right end portion of the relief portion 63c, an engagement portion 63d is provided. This engagement portion 63d is formed by removing a rear upper part of the large-diameter portion 63b.

In connection with the relief portion 63c and the engagement portion 63d, the switch base 19 is provided with an engagement arm 65. This engagement arm 65 extends downward from the lower surface of the switch base 19. When the relief portion 63c is positioned on the lower side of this engagement arm 65, the switch lever 61 is allowed to be tilted toward the side of the ON position. On the other hand, when the engagement portion 63d is positioned on the lower side of the engagement arm 65, the engagement arm 65 may abut to the engagement portion 63d so that the switch lever 61 is restricted from being tilted toward the side of the ON position, i.e., in the direction of arrow C in FIG. 19. As shown in FIG. 20, when the small-diameter portion 63a protrudes from the left side portion of the switch lever 61, the engagement portion 63d is positioned on the lower side of the engagement arm 65 so that the switch lever 61 is restricted from being tilted toward the side of the ON position. Accordingly, as shown in FIG. 20, when the small-diameter portion 63a of the lock operation member 63 protrudes from the left side portion of the switch lever 61, the lock operation member 63 is in the off-lock state. Thus, the lock operation member 63 is biased toward the side of the off-lock position by the action of the torsion spring 64 described above, so that the off-lock mechanism is realized.

On the other hand, as shown in FIG. 23, when the small-diameter portion 63a of the lock operation member 63 is pushed toward the right side against the action of the torsion spring 64, i.e., in the direction of arrow A in FIG. 23, the large-diameter portion 63b protrudes from the right side portion of the switch lever 61. As a result, the relief portion 63c comes to the lower side of the engagement arm 65. In this state, the engagement arm 65 is allowed to pass downward through the relief portion 63c so that the switch lever 61 is brought into the off-lock release state. Thus, the switch lever 61 is allowed to be tilted toward the side of the ON position. In this off-lock release state, as shown in FIG. 24, operating the switch lever 61 to tilt or to be pulled toward the side of the ON position, i.e., in the direction of arrow C by the fingertip of the user causes the operating knob 12a to be pushed, so that the switch body 12 is turned ON, thereby activating the electric motor 5.

A stopper arm 67 is disposed at the inner surface of the switch lever 61 in the vicinity of the small-diameter portion 63a of the lock operation member 63. This stopper arm 67 extends in the width direction, i.e., in the vertical direction in FIGS. 20, 23, 25, and 27, of the switch lever 61 from the left inner surface of the switch lever 61 toward the right inner surface thereof. The stopper arm 67 is integrally provided with, at the tip end thereof, a stopper claw portion 67a. The stopper claw portion 67a is so provided as to extend toward the side of the lock operation member 63, i.e., toward the rear side.

On the front side of this stopper arm 67, a restriction arm 68 is disposed. This restriction arm 68 extends downward from the lower surface of the switch base 19 and is formed integrally therewith. Therefore, the stopper arm 67 extends in the horizontal direction to intersect like a cross with the restriction arm 68 extending in the vertical direction. At a portion opposing to the stopper claw portion 67a of the stopper arm 67, i.e., at the side portion of the large-diameter portion 63b of the lock operation member 63, a flat stopper surface 63f is formed. Moreover, as will be described later, if the switch lever 61 is pulled toward the ON position, the stopper arm 67 is displaced upward, and is brought into slide contact with the rear surface of the restriction arm 68. In this state, the stopper arm 67 is pushed toward the rear side by the resilient force of the restriction arm 68.

Therefore, releasing the switch lever 61 from the off-lock state by pushing the small-diameter portion 63a of the lock operation member 63, and thereafter, in this off-lock release state, by operating the switch lever 61 to tilt toward the ON position, as shown in FIGS. 24 and 25, the stopper claw portion 67a of the stopper arm 67 is resiliently pressed against the stopper surface 63f of the large-diameter portion 63b. With the stopper claw portion 67a being pressed against the stopper surface 63f, the lock operation member 63 is held in the off-lock release position against the action of the torsion spring 64. In this way, after the switch lever 61 has been operated to tilt to the ON position by pushing the lock operation member 63 toward the off-lock release position in the direction of arrow A, this lock operation member 63 is held in the off-lock release position, i.e., the position shown in FIG. 25, by the stopper claw portion 67a. The user thus can remove his or her fingertip from the small-diameter portion 63a of the lock operation member 63.

If the pulling operation of the switch lever 61 is released, the switch lever 61 returns to the OFF position on the lower side by the action of the compression spring 13, and the switch body 12 is thus turned OFF, so that the electric motor 5 is stopped. Moreover, if the switch lever 61 returns to the OFF position on the lower side, the stopper arm 67 moves downward away from the restriction arm 68, and thus no pressing force is applied. As a result, due to the resilient force of the stopper arm 67, the stopper claw portion 67a moves forwardly. Because the stopper claw portion 67a is released from the pressing condition against the stopper surface 63f, due to the biasing force of the torsion spring 64, the lock operation member 63 returns to the off-lock position where the side of the small-diameter portion 63a protrudes from the left side portion of the switch lever 61. Accordingly, the switch lever 61 returns to the off-lock state, where the tilting operation toward the side of the ON position is restricted.

Next, as shown in FIGS. 25 and 26, in the state that the switch lever 61 has been tilted to the ON position, if the large-diameter portion 63b of the lock operation member 63 is pushed in the direction of arrow B in FIG. 27, the switch lever 61 is locked in the ON position, i.e., the on-lock state. In this on-lock state, pushing the lock operation member 63 in the reverse direction, i.e., in the direction of arrow D causes the switch lever 61 to be released from the on-lock state.

At the front portion of the switch base 19, an on-lock arm 66 is provided. This on-lock arm 66 extends downward to rear a position on the front side of the lock operation member 63. At the lower end portion of this on-lock arm 66, an engagement claw portion 66a is provided. This engagement claw portion 66a is so provided as to extend toward the side of the lock operation member 63, i.e., toward the rear side. On the other hand, the large-diameter portion 63b of the lock operation member 63 is provided with a lock concave portion 63e. As shown in FIG. 26, this lock concave portion 63e is of the size allowing insertion of the engagement lug portion 66a of the on-lock arm 66 in order to restrict any downward displacement of the lock operation member 63 and eventually the switch lever 61. On the left end portion of the lock concave portion 63e, an inclined guide surface 63g is provided for the movement of the engagement claw portion 66a in the removal direction by the movement of the lock operation member 63.

As shown in FIGS. 24 and 25, in the state that the lock operation member 63 is positioned in the off-lock release position and the switch lever 61 is positioned in the ON position, the engagement claw portion 66a of the on-lock arm 66 is pressed against the peripheral surface of the large-diameter portion 63b of the lock operation member 63. The engagement claw portion 66a is resiliently pressed against the peripheral surface of the large-diameter portion 63b by the resilient force of the on-lock arm 66. In this stage, the engagement claw portion 66a is not yet entered in the lock concave portion 63e.

Next, as shown in FIG. 27, if the large-diameter portion 63b of the lock operation member 63 is pushed in the direction of arrow B, the lock concave portion 63e moves to be positioned directly behind the engagement lug portion 66a of the on-lock arm 66. Then, the engagement claw portion 66a is fitted into the lock concave portion 63e by the resilient force of the on-lock arm 66. When the engagement claw portion 66a of the on-lock arm 66 is fitted into the lock concave portion 63e of the large-diameter portion 63b, as shown in FIG. 26, the large-diameter portion 63b of the lock operation member 63 is brought to be supported by the engagement claw portion 66a from the below. As a result, the switch lever 61 is restricted from being moved toward the side of the OFF position, thereby being brought into the on-lock state.

In this on-lock state, if the small-diameter portion 63a of the lock operation member 63 is pushed again in the direction of arrow D against the action of the torsion spring 64, the switch lever 61 can be released from the on-lock state. When the lock operation member 63 is displaced upward in FIG. 27, the engagement claw portion 66a of the on-lock arm 66 slides on the inclined guide surface 63 so that the engagement claw portion 66a moves away from the lock concave portion 63e. When the small-diameter portion 63a has been pushed up to a position where it does not protrude from the left side portion of the switch lever 61, the on-lock arm 66 is bent or flexed toward the front side against the resilient force thereof, and the engagement claw portion 66a is removed completely from the lock concave portion 63e, thereby being again elastically pressed against the peripheral surface of the large-diameter portion 63b as shown in FIG. 25. In this state, the lock operation member 63 and eventually the switch lever 61 are allowed to be displaced downward so that the switch lever 61 is released from the on-lock state.

As described above, also with the switch device 60 of the sixth embodiment, pushing the lock operation member 63 in the off-lock release direction indicated by arrow A can release the switch lever 61 from the off-lock state. Moreover, in the state that the switch lever 61 has been tilted to the ON position, if the lock operation member 63 is pushed in the on-lock direction indicated by arrow B, the switch lever 61 can be changed in state to the on-lock state. Therefore, the operation direction of the lock operation member 63 for releasing the switch lever 61 from the off-lock state (the direction of arrow A) is opposite to the operation direction thereof for changing the state of the switch lever 61 to the on-lock state (the direction of arrow B).

This difference in direction can prevent an accidental operation, in which moving the lock operation member 63 in the off-lock release direction indicated by arrow A causes the switch lever 61 to be brought into the on-lock state when the lock operation member 63 is continuously moved in the same direction. According to the above embodiment, for changing the switch lever 61 to the on-lock state, the lock operation member 63 is required to be moved in the opposite direction indicated by arrow B, and in this respect, the switch device 60 can reliably reflect the user's intention in terms of operation.

The above first to sixth embodiments have been described with regard to the configuration in which, for a single piece of the lock operation member, the operation directions for releasing the switch lever from the off-lock state and the operation direction for changing the state to the on-lock state are opposite to each other. Alternatively, two separate lock operation members may be provided respectively for these operations and the same effects as above can be achieved by this arrangement. For example, the switch lever may be used as a lock operation member for releasing the switch lever from the off-lock state, and another operation member separately provided from the switch lever may be used as a lock operation member for changing the state of the switch lever into the on-lock state. This alternative embodiment will be described as follows as a seventh embodiment.

Seventh Embodiment

A seventh embodiment according to the present invention will now be described with reference to FIGS. 28 to 31, which show a switch device 70 according to the seventh embodiment.

In this embodiment, a window portion 79a is formed substantially centrally of a switch base 89 that corresponds to the switch base 19 of the above embodiments. The operation knob 12a of the switch body 12 extends downward through the window portion 79a toward a switch lever 71 that corresponds to the switch lever 11.

The switch lever 71 is supported to extend in forward and rearward directions along the lower side of a switch base 79 that corresponds to the switch base 19. More specifically, the rear portion of the switch lever 71 is coupled to the rear portion of the switch base 79 via a shaft 74, so that the switch lever 71 can tilt vertically about an axis of the shaft 74. The shaft 74 is inserted into an elongated slot 71b formed in the rear portion of the switch lever 71 and extending in forward and rearward directions. Therefore, the switch lever 71 can slide in forward and rearward directions relative to the switch base 79 within a predetermined range in addition to the tilting movement about the shaft 74.

At the left and right sides of the front side portion of the switch lever 71, a pair of left and right restriction arms 71c are provided. The left and right restriction arms 71c extend upward in parallel with each other. Engaging claws 72d are provided at the upper end portions of the respective restriction arms 71c. On the other hand, at the front portion of the switch base 79, insertion slots 79b are formed to correspond to the restriction arms 71c. The insertion slots 79b extend in forward and rearward directions in parallel with each other. The restricting arms 72c are inserted into the respective insertion slots 79b to extend upwardly from below of the switch base 79 so as to be assembled therewith. The engaging claws 71d of the restriction arms 71c engage with an upper surface of the switch base 79, so that the restriction arms 71c are prevented from being removed from the insertion slots 79b.

Therefore, the switch lever 71 can tilt vertically relative to the switch base 79 within such a range that the restriction arms 71c can move vertically within the respective insertions slots 79b. In addition, the switch lever 71 can slide in forward and rearward directions relative to the switch base 79 within such a range that the restriction arms 71c can move in forward and rearward directions within the insertion slots 79b.

Two compression springs 73 and 78 are disposed between the switch lever 71 and the switch base 79. The compression spring 73 is disposed vertically between the switch lever 71 and the switch base 79 so that the switch lever 71 is biased in a direction of tilting toward an OFF position on the lower side (in an opposite direction to the direction indicated by arrow C. The compression spring 78 is disposed in forward and rearward directions (i.e., substantially horizontally) between the switch lever 71 and the switch base 79, so that the switch lever 71 is biased in a direction of sliding toward an off-lock position on the rear side (i.e., a direction opposite to the direction indicated by arrow A).

An on-lock mechanism and an off-lock mechanism are assembled with the switch lever 71. The on-lock mechanism serves to lock the switch lever 71 in an ON position and the off-lock mechanism serves to lock the switch lever 71 in the OFF position. These mechanisms are configured such that different operation members perform releasing the off-lock state and switching to the on-lock state. In this embodiment, release of the on-lock state is achieved by the sliding operation of the switch lever 71 and switching to the on-lock state is achieved by operating an on-lock operation member 75 that will be described later.

The on-lock operation member 75 is supported at a position on the front side of the switch lever 71. A tip end portion 75b of the on-lock operation member 75 extends downwardly through a window portion 71a provided at the lower surface of the switch lever 71. The on-lock operation member 75 is supported via a support shaft 75a such that the on-lock operation member 75 can tilt in forward and rearward directions. In addition, the on-lock operation member 75 is biased by a torsion spring 76 in a counterclockwise direction as viewed in FIG. 28, i.e., a direction of displacing the tip end portion 75b toward the rear side (the side of the on-lock releasing position).

An engaging arm 75c is integrally provided at the front portion of the on-lock operation member 75 and extend upward. An on-lock claw 75d is provided integrally at an upper portion of the engaging arm 75c and extends rearward.

To correspond to the engaging arm 75c, a lock arm 77 is integrally provided at the front portion of the switch base 79 and extends downwardly from the lower surface of the switch base 79. A lock claw 77a is integrally provided at the lower portion of the front surface of the lock arm 77.

With the switch device 70 of this embodiment, if the operator does not operate the switch lever 71, the switch lever 71 is held at the OFF position on the lower side by the biasing force of the compression spring 73 and at the off-lock position on the rear side by the biasing force of the compression spring 18 (see FIG. 28). In the state that the switch lever 71 is positioned at the OFF position, the on-lock operation member 15 is held at the on-lock releasing position, where the tip end portion 75b is displaced rearwardly, by the biasing force of the torsion spring 76.

In the initial state where the on-lock operation member 75 is held at the on-lock releasing position, the lock arm 75 is positioned directly above the engaging arm 75c. Therefore, in this state, the operation for tilting the switch lever 71 from the off-lock position on the rear side toward the side of the ON position (i.e., upward) is restricted because the upward movement of the engaging arm 75c is restricted by the lock arm 77. Thus, the switch lever 71 cannot be tilted toward the side of the ON position (in the direction indicated by arrow C in FIG. 29). As a result, the off-lock state is achieved, so that an accidental ON operation of the switch lever 71 can be prevented.

On the other hand, if the switch lever 71 is slide in the direction indicated by arrow A in FIG. 29 against the biasing force of the compression spring 78, the engaging arm 75c moves forwardly away from the lock arm 77 so that the switch lever 71 is allowed for tilting toward the side of the ON position (the direction indicated by arrow C). Thus, the off-lock release state is achieved. Tilting the switch lever 71 toward the ON position (the direction indicated by arrow C) by firmly gripping the switch lever 71 continuously after releasing the off-lock state causes the operation knob 12a to be pushed so that the switch body 12 is turned ON, thereby activating the electric motor 5.

If the user releases the tilting operation of the switch lever 71 toward the side of the ON position, which is performed using his or her fingertip, the switch lever 71 returns to the OFF position on the lower side. If the user also releases the sliding operation of the switch lever 71 toward the front side after the switch lever 71 has returned to the OFF position, the switch lever 71 returns to the off-lock position on the rear side by the biasing force of the compression spring 78. When the switch lever 71 returns to the off-lock position, the engaging arm 75c is positioned directly below the lock arm 77, so that the off-lock state is resulted. In the off-lock state, the pulling operation of the switch lever 71 toward the side of the ON position is inhibited.

In addition to the off-lock function described above, the switch device 70 of this embodiment can perform the on-lock function. In the state the switch lever 71 has been slid to the off-lock releasing position as indicated by arrow A in FIG. 29, if the switch lever 71 is tilted to the ON position as indicated by arrow C, the switch body 12 is turned ON for activating the electric motor 5. Thereafter, the on-lock operation member 75 may be tilted toward the on-lock position as indicated by arrow B, i.e., the direction of displacing the tip end portion 75b toward the front side.

As a result of the tilting movement toward the on-lock position of the on-lock operation member 75, the on-lock claw 75d of the engaging arm 75c moves to a position on the upper side of the lock claw 77a of the lock arm 77. When the user weakens the gripping force toward the side of the ON position of the switch lever 71 while maintaining the on-lock operation of the on-lock operation member 15, the on-lock claw 75d is brought to engage with the lock claw 77a of the lock arm 77, in such a manner that on-lock claw 75d is pressed against the lock claw 77a from above, by the biasing force of the compression spring 73 applied to the switch lever 71. Because the on-lock claw 75d of the engaging arm 75c engages with the lock claw 77a of the lock arm 77 from above, the on-lock operation member 75 is held in the on-lock position, and at the same time, the tilting movement of the switch lever 71 toward the OFF position can be restricted.

Because the switch lever 71 is restricted from movement toward the OFF position and is held in the ON position, the switch body 72 is held in the ON state. Therefore, the electric motor 5 is locked in the activated state. With the switch lever 71 locked in the ON position, the operator can lock the electric motor 5 in the activated state without need of pulling the switch lever 71. Therefore, it is possible to easily perform the operation of the power tool by gripping the handle 4.

In the on-lock state, if the use grips the switch lever 71 upward again, the lock-in claw 75d of the on-lock operation member 75 moves upward, so that the engaging state of on-lock claw 75d with the lock claw 77a of the lock arm 77 is released. Then, the on-lock operation member 75 returns in a such direction that the tip end portion 75b is displaced rearwardly (in the counterclockwise direction or the direction toward the on-lock releasing position). As shown in FIG. 29, when the on-lock operation member 75 returns to the on-lock releasing position, the switch lever 71 can be returned toward the OFF position on the lower side. After the switch body 72 has been returned to the OFF position by returning the switch lever 71 to the switch lever 71, if the forward sliding operation of the switch lever 71 is stopped, the switch lever 71 returns to the off-lock position on the rear side by the biasing force of the compression spring 78.

As shown in FIG. 28, when the switch lever 71 returns to the off-lock position on the rear side, the engaging arm 75c of the on-lock operation member 15 is again brought into a position directly below the lock arm 77. As a result, the switch device 70 returns to the off-lock state or the initial state.

As described above, according to the switch device 70 of this embodiment, slidably moving the switch lever 75 toward the off-lock releasing position indicated by arrow A in FIG. 29, the off-lock state of the switch lever 71 can be released. In addition, in the state that the switch lever 71 is held in the ON position, operating the on-lock operation member 75 to tilt in the on-lock direction indicated by arrow B in FIG. 30 can switch the switch lever 71 to the on-lock state. In this way, the switch lever 71 that is operated for releasing the off-lock mechanism is a separate member from the on-lock operation member 75 that is operated for making the on-lock mechanism effective. Therefore, the off-lock releasing operation and the on-lock switching operation can be performed while these operations are clearly distinguished by the user. Hence, unintentional switching to the on-lock state after the operation for releasing the on-lock state can be reliably prevented. As a result, the switch device 70 can reliably reflect the user's intention in terms of operation.

The above seventh embodiment may be modified further. For example, although the switch lever 71 is used as an operation member for releasing the off-lock state of the switch device 70, a separated member from the switch lever 71 can be used as the off-lock releasing member.

In addition, although the switch lever 71 is operated to slide for releasing the off-lock state, the off-lock state of the switch lever 71 can be released by a tilting movement, in particular, in the case that a separate member from the switch lever 71 is used for releasing the off-lock state as described above.

Further, in the case that a separate member from the switch lever 71 is used for releasing the off-lock state, it is possible to construct such that the switch lever 71 is slid forwardly or rearwardly for changing to the on-lock state.

Although a disk grinder is exemplified as an example of the electric power tool in the above embodiments, the switch device of the present invention may be widely applicable to any other electric power tools, such as an electric drill used for boring, an electric screwdriver used for driving screws, and a circular saw used for cutting.

Number	Date	Country	Kind
2009-003636	Jan 2009	JP	national
2009-014081	Jan 2009	JP	national

Switch devices for power tools

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CPC

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Abstract

Description

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Priority Claims (2)