The present invention relates generally to the field of tools. The present invention relates specifically to a tool, such as a ratchet wrench, with a gearless ratchet mechanism.
One embodiment of the invention relates to a driving tool including a handle coupled to a head. The head includes an outer surface that defines a first dimension, a bore having a surface that defines a second dimension and a clutch mechanism positioned within the bore. The clutch mechanism includes a central body, a plurality of projections extending radially outward from the central body, a plurality of rollers, a drive mechanism supported from the central body and a plurality of springs. Each spring includes a first end and a second end opposing the first end, the first end of each spring coupled to one of the plurality of rollers and the second end of each spring coupled to an adjacent projection.
Another embodiment of the invention relates to a gearless ratchet mechanism for a tool. The gearless ratchet mechanism includes a handle and a head, the head coupled to the handle. The head includes an outer surface that defines a first diameter, a bore positioned within the head and having a cylindrical surface and a clutch mechanism positioned within the bore. The clutch mechanism includes a central body, a plurality of teeth extending radially outward from the central body, a plurality of pins, each pin defining a pin diameter, a drive mechanism supported from the central body and configured to engage a driving tool. The clutch mechanism further includes a plurality of springs. Each spring is coupled to and extends between one of the plurality of pins and a corresponding tooth. Each spring includes a first end engaged with one of the plurality of pins and a second end opposing the first end. When the handle is rotated in a clockwise direction, the plurality of pins engage with the cylindrical surface of the bore such that the drive mechanism is prevented from spinning. When the handle is rotated in a counterclockwise direction the plurality of pins disengage from the cylindrical surface of the bore such that the drive mechanism can spin.
Another embodiment of the invention relates to a driving tool including a handle and a head coupled to the handle. The head includes an outer surface, a bore having a surface and a clutch mechanism positioned within the bore. The clutch mechanism includes a central body, a plurality of teeth extending radially outward from the central body, each tooth including a clockwise facing surface, a plurality of pins, a drive mechanism supported from the central body and configured to engage a socket. The clutch mechanism further includes a plurality of springs. Each spring includes a first end and a second end opposing the first end, the first end of each spring is coupled to one of the plurality of pins and the second end of each spring coupled to an adjacent corresponding tooth. The clutch mechanism further includes a contact angle, the contact angle is defined as the angle between a line joining a first point of contact between one of the plurality of pins and the surface of the bore and a second point of contact between the one of the plurality of pins and the clockwise facing surface of the adjacent corresponding tooth and a radial plane.
Another embodiment of the invention relates to a gearless ratchet mechanism for a tool. The gearless ratchet mechanism includes a handle coupled to a head. The head includes a bore and a clutch mechanism positioned within the bore. The clutch mechanism includes a central body, a plurality of projections, shown as teeth extending radially outward from the central body, a plurality of pins or rollers, a plurality of springs and a drive mechanism. The pins are formed from a first material and an outer race defined by the bore is formed from a second material. The second material has a property (e.g., hardness) different than the property of the first material. The pins have a shape designed to have a contact area such that point loading on the pin is reduced.
Another embodiment of the invention relates to a gearless ratchet mechanism for a tool. The gearless ratchet mechanism includes a handle coupled to a head. The head includes a bore and a clutch mechanism positioned within the bore. The clutch mechanism includes a central body, a plurality of projections, shown as teeth extending radially outward from the central body, a plurality of pins or rollers, a plurality of springs and a drive mechanism. The head further includes an outer surface that at least partially defines a first outer diameter. Each tooth includes a top or upward facing surface, an inner side surface a front side surface and a rear side surface or inner race. A second diameter is defined by the bore and a circular edge of the pin defines a third diameter. The drive mechanism is symmetrical about a plane. An inner contact length is defined between the plane and inner race. A contact angle is defined between a first point of contact between the pin and the bore and a second point of contact between the pin and the inner race.
Additional features and advantages will be set forth in the detailed description which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.
The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments.
This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:
Referring generally to the figures, various embodiments of a gearless ratchet for a tool, such as a ratchet wrench, are shown. Various embodiments discussed herein relate to a gearless ratchet with a design for improved performance including low or zero swing angle and/or decreased part wear. Further, various embodiments relate to a gearless ratchet with features designed to maximize life and strength of the tool. In contrast to the gearless ratchet discussed herein, ratchets that typically include a toothed gear design with a pawl may only be suitable in limited environments due to a discrete number of lockable positions with respect to the tool handle. In small or tight spaces this means a user may have difficulty pivoting the handle back far enough to engage a new tooth. The gearless ratchet discussed herein includes a design for a clutch mechanism that has low or zero arc swing allows for use in more confined work environments.
Further, Applicant has determined that some gearless ratchet designs may have long-term wear across the entire surface of the outer race or bore the clutch mechanism sits within and/or wear in discrete areas of the outer race adjacent to the pins. Both types of wear can cause the clutch mechanism to slip, meaning a decrease in maximum applied torque. Wear in the discrete areas adjacent to the pins may cause the pins to move less smoothly, increasing the friction and/or causing the pins to slip before engaging the clutch body and housing, increasing the swing angle from the desired low or zero-degree swing angle.
In various embodiments, the gearless ratchets discussed herein include clutch designs having pins with geometries believed to increase the contact area between the pin and the outer race and/or through material hardness selection of the pins and outer race. A difference in the material hardness of the pin and outer race can decrease wear on the entire surface of the outer race and/or the discrete areas adjacent to the pins. In some embodiments, the outer race has a hardness greater than the pins and the difference in material hardness allows the spring to push the pins further into an engaged or wedged position as the pin wears down. In other embodiments, the pin has a hardness greater than the outer race and the difference in material hardness reduces the wear on the pin, allowing the pin to maintain its geometry which minimizes the friction between the pin and outer race. Further, Applicant believes wear in discrete areas caused by uneven pin loading (i.e., only some pins engage between the inner and outer races) can be decreased by adding a retaining force via a spring or other component to keep the pins engaged or in a wedged position. The retaining force additionally helps to keep a low or zero-degree swing angle.
Further, Applicant has determined that utilization of the dimensional relationships discussed herein allows for an improved gearless ratchet design. Applicant has identified a range of dimensions for various components of a gearless ratchet mechanism that Applicant believes improves the function of the gearless ratchet mechanism by providing a desired contact angle between the pin or rollers and the outer race to maximize life and strength of the tool. In various embodiments, Applicant has designed the spring to avoid downward sagging and premature bending and/or locking of the clutch mechanism.
Referring to
Clutch mechanism 16 includes a central clutch body 18, a plurality of projections, shown as teeth 20 extending outward from central clutch body 18, a plurality of pins or rollers 22, a plurality of springs, shown as coil spring 24 and a drive, shown as square drive 26. Head 14 further includes a central axis 17 extending through square drive 26. Square drive 26 is supported from and/or coupled to central clutch body 18 and configured to engage a driving tool, socket, etc. Teeth 20 extend radially outward from central clutch body 18. In the orientation of
The clutch mechanism 16 includes the plurality of pins 22 wedged between the clockwise facing surface 30 and the outer surface, shown as cylindrical surface 28 that defines bore 32 (i.e., pins 22 are in an engaged position). In other embodiments, the outer surface may have different shapes (e.g., oblong, polygonal, etc.). In this position, pins 22 prevent square drive 26 from spinning when handle 12 of ratchet wrench 10 is rotated clockwise by a user. When a user rotates ratchet wrench 10 in a counterclockwise direction, pins 22 unwedge (i.e., disengage) from between clockwise facing surface 30 and the outer cylindrical surface 28 and allow the central clutch body 18 and square drive 26 to spin about central axis 17 and with respect to head 14. The pins 22 are biased by a biasing element, shown as compression springs 24 to further reduce the arc swing by maintaining the pins 22 in a position in engagement with outer cylindrical surface 28 and with clockwise facing surface 30 when handle 12 is rotated in a clockwise direction. In operation, pin 22 acts as a bearing, outer cylindrical surface 28 acts as an outer race and clockwise facing surface 30 acts as an inner race. In a specific embodiment, the pins have a generally round shape. In other embodiments the pins may have other shapes (e.g. elliptical, square etc.). In a specific embodiment, there are 6 pins. In other embodiments there may be more of less pins included in the clutch mechanism (e.g. 4, 8, 12 etc.).
In a specific embodiment, the pins 22 are formed from a first material and the outer cylindrical surface 28 is formed from a second material. The second material has a property (e.g. hardness) different than the property of the first material. In specific embodiments, the first material has a first hardness, and the second material has a second hardness greater than the first hardness. In a specific embodiment, the pin is formed from a comparatively softer material and the outer race is formed from a comparatively harder material. In specific embodiments, the first material has a first hardness, and the second material has a second hardness less than the first hardness. In such an embodiment, the pin is formed from a comparatively harder material and the outer race is formed from a comparatively softer material.
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Pins 78 have a generally elliptical shape and include a side surface 84 continuously extending around pin 78. Side surface 84 engages with outer cylindrical surface 28 and defines an outer contact area 79 between pin 78 and outer cylindrical surface 28. The generally elliptical shape of pin 78 allows for increased size of contact area 79 relative to a pin with a generally round shape. An opposing portion of side surface 84 engages with a clockwise facing surface 83 of leaf spring 80 to define a contact area 81 between pin 78 and leaf spring 80. Leaf spring 80 is formed to match the profile of pin 78 ensuring proper positioning and rotation of the elliptical shaped pin. In other embodiments, the leaf spring may be formed to match the profile of an irregularly shaped pin of a different shape (e.g. polygon etc.). Applicant believes the matching of the spring profile to the pin profile provides for improved, more even engagement of the pins. The simultaneous and/or even pin engagement helps to keep a low or zero-degree swing angle.
Referring to
Pins 88 have a generally elliptical shape and include a side surface 102 continuously extending around pin 88. Side surface 102 engages with outer cylindrical surface 28 and defines an outer contact area 89 between pin 88 and outer cylindrical surface 28. An opposing portion of side surface 102 engages with a clockwise facing surface 104 of leaf spring 90 to define a contact area 106 between pin 88 and leaf spring 90. Leaf spring 90 is formed to match the profile of pin 88 ensuring proper positioning and rotation of the elliptical shaped pin 88.
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In a specific embodiment, D1 is a maximum ratchet head size that Applicant believes provides for easy use of ratchet wrench 10 in confined spaces, where clutch mechanism 16 includes six pins 22. In a specific embodiment, D1 is 31.5 mm. In such an embodiment, the maximum outer race diameter D2 is between 75% and 95% of D1, specifically between 80% and 90% of D1 and more specifically between 83% and 85% of D1. In such an embodiment, the maximum D2 is about 26.5 mm (e.g., 26.5 mm plus or minus 0.5 mm). The maximum pin diameter D3 is between 5% and 15% of D1, specifically between 9% and 15% of D1 and more specifically between 12% and 14% of D1. In such embodiments, the maximum D3 is about 4.1 mm (e.g., 4.1 mm plus or minus 0.2 mm). The maximum inner contact length L1 is between 20% and 35% of D1, specifically between 22% and 32% of D1 and more specifically between 26% and 29% of D1. In such embodiments, the maximum L1 is about 8.7 mm (e.g., 8.7 mm plus or minus 0.2 mm).
In another specific embodiment, D1 is a maximum ratchet head size that Applicant believes provides for easy use ratchet wrench 10 in confined spaces, where clutch mechanism 16 includes six pins 22. In a specific embodiment, where D1 31.5 mm Applicant has determined feature sizes to provide a contact angle that produces the desired torque. In such an embodiment, the minimum outer race diameter D2 is between 65% and 85% of D1, specifically between 70% and 80% of D1 and more specifically between 76% and 79% of D1. In such an embodiment, the minimum D2 is about 24.4 mm (e.g., 24.4 mm plus or minus 0.5 mm). The minimum pin diameter D3 is between 5% and 15% of D1, specifically between 5% and 11% of D1 and more specifically between 6% and 7% of D1. In such embodiments, the minimum D3 is about 2.2 mm (e.g., 2.2 mm plus or minus 0.2 mm). The minimum inner contact length L1 is between 20% and 35% of D1, specifically between 25% and 35% of D1 and more specifically between 29% and 31% of D1. In such embodiments, the minimum L1 is about 9.5 mm (e.g., 9.5 mm plus or minus 0.2 mm). In a specific embodiment, D1 is 31.5 mm, D2 is 25.25 mm, D3 is 3 mm and L1 is 9.375 mm.
In various embodiments, ratchet wrench 10 may be shaped to have outer diameters D1 while inner contact length L1 is 8.7 mm with a minimum wall thickness T1 where clutch mechanism 16 includes six pins 22. Applicant has determined feature sizes to provide a contact angle that produces the desired torque for ratchet wrench 10. In a specific embodiment, outer race diameter D2 is between 75% and 95% of D1, specifically between 80% and 90% of D1 and more specifically between 85% and 87% of D1. In such an embodiment, D2 is about 34.5 mm (e.g., 34.5 mm plus or minus 0.5 mm). In a specific embodiment, pin diameter D3 is between 10% and 30% of D1, specifically between 15% and 25% of D1 and more specifically between 19% and 22% of D1. In such an embodiment, D3 is about 8.3 mm (e.g., 8.3 mm plus or minus 0.2 mm). In a specific embodiment, inner contact length L1 is between 10% and 30% of D1, specifically between 15% and 25% of D1 and more specifically between 20% and 23% of D1. In such embodiments, D1 is about 40 mm (e.g., 40 mm plus or minus 0.5 mm).
Applicant has determined component sizes to provide a contact angle that produces the desired torque for ratchet wrench 10 where clutch mechanism 16 includes six pins 22. Inner contact length L1 is 8.7 mm with a minimum wall thickness T1. In a specific embodiment, outer race diameter D2 is between 75% and 95% of D1, specifically between 75% and 85% of D1 and mores specifically between 81% and 83% of D1. In such an embodiment, D2 is about 22.7 mm (e.g., 22.7 mm plus or minus 0.5 mm). In a specific embodiment, pin diameter D3 is between 5% and 15% of D1, specifically between 5% and 10% of D1 and more specifically between 7% and 9% of D1. In such an embodiment, D3 is about 2.2 mm (e.g., 2.2 mm plus or minus 0.2 mm). In a specific embodiment, inner contact length L1 is between 20% and 40% of D1, specifically between 25% and 35% of D1 and mores specifically between 30% and 33% of D1. In such embodiments, D1 is about 27.7 mm (e.g., 27.7 mm plus or minus 0.5 mm).
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Generally conical spring 138 extends along and is aligned with a spring axis and has a greater diameter D4, at the first end than a diameter at the second end of spring 138. The diameter of generally conical spring 138 decreases from the first end of each spring as the spring extends toward the counter-clockwise facing surface 19 of the corresponding tooth 20. In a specific embodiment, the diameter of generally conical spring 138 decreases at a constant rate. In another embodiment the diameter of generally conical spring 138 may decrease at another rate (e.g., exponential, etc.). Applicant believes use of a generally conical spring shape helps to maintain the orientation of the spring and provides stability to the pin. The alignment of generally conical spring 138 with a larger diameter portion engaging with pin 22 retains the spring 138 in place and maintains the spring positioning along the spring axis.
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It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more component or element, and is not intended to be construed as meaning only one. As used herein, “rigidly coupled” refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force.
Various embodiments of the disclosure relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements or components of any of the other embodiments discussed above.
For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.
While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.
In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.
The present application is a continuation of International Application No. PCT/US2022/031589, filed May 31, 2022, which claims the benefit of and priority to U.S. Provisional Application No. 63/224,585 filed on Jul. 22, 2021, and U.S. Provisional Application No. 63/195,463 filed on Jun. 1, 2021, which are incorporated herein by reference in their entireties.
Number | Date | Country | |
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63224585 | Jul 2021 | US | |
63195463 | Jun 2021 | US |
Number | Date | Country | |
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Parent | PCT/US2022/031589 | May 2022 | US |
Child | 17840257 | US |