Abstract:
A clutch for use in an open faced fishing reel that when engaged operates as a conventional one-way clutch, with the pins or needles rolling with the shaft and allowing for movement in one direction but binding the shaft to an outer fixed surface, prohibiting rotation, when the shaft is urged in the opposite direction, but when is disengaged, is switchable from one-way action to freewheel action i.e. shaft motion allowed in both directions by separating the outer binding surface from the main housing of the clutch, allowing it to move radially and allow the surface required to bind the shaft to move away from contact with the pins and shaft, thereby allowing the shaft to freewheel. The clutch is particularly well suited for use in a fishing reel.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims the benefit of U.S. Provisional Serial No. 60/222,562 filed Aug. 3, 2000. 
     
    
     
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
         [0002]    Not Applicable.  
         BACKGROUND OF THE INVENTION  
         [0003]    Currently, there are several versions of clutches in fishing reels. Some of these are made “switchable” externally by alternately holding the outer ring of a one-way clutch or letting it freewheel. An exemplary apparatus is disclosed in U.S. Pat. No. 5,570,851, Yamaguchi, et al., assigned to Daiwa Seiko, Inc. (“Yamaguchi &#39;851”). In Yamaguchi &#39;851, a roller-type clutch is provided between the rotor and the reverse rotation prevention member so as to kinematically connect the rotor and the member to each other when the rotor is reversely rotated in such a direction as to unwind a fishing line.  
           [0004]    Other clutches perform a disengagable one-way clutch action internally, that is, urging pins out of contact with the shaft, effectively disabling the one-way action. An example of this mechanism is disclosed in U.S. Pat. No. 5,927,630, Katayama, assigned to Daiwa Seiko, Inc. (“Katayama &#39;630”).  
           [0005]    Both of these methods require manufacture of surfaces hard enough to be able to withstand rolling loads and other forces without degrading those surfaces, for example by gouging or pitting, so that materials such as hardened steel or high performance metal alloy similar to those typically used in the manufacture of ball bearings must be used. The use of these relatively expensive materials leads to greater expense in manufacture. Furthermore, those materials are frequently heavy, increasing the overall weight of the fishing reel, which is an undesirable characteristic. Additionally, the prior art clutches require adding more parts or complex parts to the fishing reel, increasing the overall complexity and manufacturing expense.  
         BRIEF SUMMARY OF THE INVENTION  
         [0006]    The present invention divides the traditional clutch case into two parts, and involves urging the outer ring contact surfaces away radially from a binding position with rolling members or pins and a shaft, thereby rendering the one-way action of the clutch disabled. This solution has several benefits over existing clutches, either externally or internally controlled. The first benefit is that the switchable clutch of the present invention has only one more part than a conventional one-way clutch. The second benefit is that only one relatively simple part needs to move, so multiple parts or a complex single part is not required to change the action. A third benefit is that since the housing half of the case primarily places rolling members in position and does not take significant loads, the housing half can be made out of plastic, carbon fiber, or other non-metal material. This makes for a strong, yet extremely lightweight switchable clutch at a lower cost. Other and further advantages will become apparent to those skilled in the art in light of the following disclosure.  
           [0007]    More specifically, the clutch of the present invention, when engaged, operates like any other one-way clutch. The pins or rolling members roll with the shaft and allow for movement in one direction, but bind the shaft to an outer fixed surface, prohibiting rotation when the shaft is urged in the opposite direction. However, the present invention is made switchable from one-way action to free-wheel action, that is, shaft motion is allowed in both directions by separating the outer binding surface from the main housing of the clutch, allowing it to move radially and allow the surface required to bind the shaft to move away from contact with the rolling members and shaft, thereby allowing the shaft to freewheel. Optionally, stops limit rotation beyond the off position and place the actuator in an optimal “on” position. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0008]    In the drawings, FIG. 1 is a front elevational view of a switchable clutch assembly of the present invention with the pin cover off;  
         [0009]    [0009]FIG. 2 is a perspective view of a switchable clutch assembly of the present invention around a shaft with the pin cover attached;  
         [0010]    [0010]FIG. 3 is a perspective view of a housing member of a switchable clutch of the present invention;  
         [0011]    [0011]FIG. 4 is a perspective view of an actuating member of a switchable clutch of the present invention;  
         [0012]    [0012]FIG. 5 is a detail view of a pin in the on or locked position; and  
         [0013]    [0013]FIG. 6 is a detail view of a pin in the off or free-wheeling position.  
         [0014]    [0014]FIG. 7 is a front elevation view of an alternative embodiment of the switchable clutch assembly with the pin cover off; and  
         [0015]    [0015]FIG. 8 is a perspective view of the alternative embodiment of the switchable clutch assembly of FIG. 7 with the pin cover off. 
     
    
       [0016]    Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0017]    The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what is presently believed to be the best mode of carrying out the invention. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.  
         [0018]    Referring to FIGS. 1, 2 and  3 , a clutch assembly of the present invention is shown generally at reference numeral  1 . Clutch assembly  1  is preferably made of a combination of metal and a lighter weight material such as plastic, although any other suitable materials could be used. Clutch assembly  1  comprises an actuator member  4  and a housing member  6 . Both actuator  4  and housing  6  are adapted to fit around a rotatable shaft  7 . In the preferred embodiment of the present invention, the rotatable shaft  7  is about ten millimeters (about 0.393 inches) in outside diameter, which corresponds in size to a common conventional fishing reel shaft, although other sizes and uses may be possible with this invention. It should be understood that shaft  7 , while shown as a hollow cylinder, may be solid as well. Shaft  7  is free to rotate in either a clockwise or a counterclockwise direction when the clutch is in an “off” or free-wheeling position, as will be described. Referring to FIG. 2, when fully assembled, the internal parts of the clutch are enclosed by a pin cover  3 .  
         [0019]    Cylindrical pins or rolling members,  10 ,  12 ,  14 ,  16 , and  18 , are captured between actuator  4  and housing  6  and held about shaft  7 , as will be more thoroughly described below. Briefly, the pins or rolling members  10 ,  12 ,  14 ,  16  and  18  are held in operative engagement with shaft  7  by resilient or biasing members  30 - 34 , while being free to rotate about their own axes. In the preferred embodiment of the present invention, biasing members  30 - 34  are metal leaf springs, although any number of springs, resilient materials or other biasing members could be utilized. Biasing members are preferably attached to clutch housing  6 , as will be described.  
         [0020]    Referring now to FIG. 3, the housing  6  has a housing fixing member  8  for attachment to a surface. In the preferred embodiment of the present invention, the surface would be an interior face of a fishing reel, through which a rotatable shaft is disposed, although other uses of this invention might involve other methods of fixing the housing including multiple contact points such as may exist with teeth or gears.  
         [0021]    Housing  6  has a back plate  9 , which preferably defines a flat planar surface for abutment with an interior face of a fishing reel. In the preferred embodiment, fixing member  8  is coextensive with back plate  9 . A plurality of housing projections  20 ,  22 ,  24   26  and  28  extend a predetermined distance that is generally normal to the plane defined by back plate  9 . The predetermined distance that each of projections  20 ,  22 ,  24 ,  26  and  28  extend from back plate  9  is preferably approximately equal, such that an imaginary plane defining the top surfaces of projections  20 ,  22 ,  24 ,  26  and  28  would be generally parallel to the plane defined by back plate  9 .  
         [0022]    Each projection  20 ,  22 ,  24 ,  26  and  28  has a generally arcuate outer surface of predetermined angle, and a generally arcuate inner surface of a predetermined angle. Raised portions  50 ,  52 ,  54 ,  56  and  58  may be formed at an end of the generally arcuate surfaces of projections  20 ,  22 ,  24 ,  26  and  28 , respectively.  
         [0023]    Referring now to FIG. 4, actuator  4  has an actuating arm  5  adapted to be movable from a first, “on” or fixed position to a second, “off” or free-wheeling position when associated with the housing  6 . Although the preferred embodiment utilizes an actuating arm  5 , those skilled in the art will appreciate that the actuator could be any other shape, or formed in other conventional ways. The actuator  4  could be a drawn cup, for example.  
         [0024]    Actuator  4  preferably has a generally cylindrical outer surface, although any number of outer surface shapes could be employed. Although generally round, the interior surface of actuator  4  comprises flat inner surfaces  41 ,  43 ,  45 ,  47  and  49 , and indented surfaces  60 ,  62 ,  64 ,  66  and  68 . The flat inner surfaces form an oblique angle with respect to an imaginary line through the flat surface and perpendicular to a radial line through the center of the actuator, although the particular angle of the flat portion is not critical to the functioning of the clutch. In the preferred embodiment, the angle is between about eight and twenty degrees. The indented surfaces  60 ,  62 ,  64 ,  66  and  68  allow movement of the actuator within the housing.  
         [0025]    As can best be seen in FIGS. 1, 5 and  6 , when housing  6  is brought into operable communication with actuator  4 , rolling members  10 ,  12 ,  14 ,  16  and  18  reside in spaces or pockets  40 ,  42 ,  44 ,  46  and  48  defined laterally by the spaces formed between projections  20 ,  22 ,  24 ,  26  and  28 , and defined at their outermost boundary by inner surfaces  41 ,  43 ,  45 ,  47  and  49 , of actuator  4  respectively, and by the external surface of the shaft  7  at their innermost boundary. The interaction between the housing and actuator could, of course, result in various shaped pockets other than the illustrative embodiment.  
         [0026]    [0026]FIGS. 1, 2 and  5 , the clutch is shown in its first, “on” or locked position. In this position, rolling members  10 ,  12 ,  14 ,  16  and  18  are urged via biasing members  30 - 34  against inner surfaces  41 ,  43 ,  45 ,  47  and  49 , and rotatable shaft  7  so as to prevent rotation in one direction. As the actuator  4  is rotated via actuator arm  5  in a clockwise direction as viewed in FIG. 1, for example, the inner surfaces  41 ,  43 ,  45 ,  47  and  49  move and break the previous contact positions with both the rolling members  10 ,  12 ,  14 ,  16  and  18  and rotatable shaft  7  thereby allowing the shaft to freewheel. In a preferred embodiment, further rotation of the actuator  4  is limited within the clutch by the interaction of surfaces such as the raised portions  50 ,  52 ,  54 ,  56  and  58  of housing  6  and the indented surfaces  60 ,  62 ,  64 ,  66  and  68  of the actuator  4 . Rotation of the actuator may, alternately, be limited externally such as may be designed in an urging member that moves actuating arm  5 . A detail of the “on” or locked position can be seen in FIG. 5. Rolling member  10  is held by biasing member  30  in pocket  40 , against top surface  41  of actuator  4  and shaft  7  and away from arcuate concave portion  21  of housing  6 .  
         [0027]    As can best be seen in FIGS. 1 and 6, when the actuator  4  is rotated clockwise, for example, and the inner surfaces  41 ,  43 ,  45 ,  47  and  49  of the actuator move away from a binding position, rolling member  10  is urged by the biasing member  30  toward and into concave portion  21  of housing  6 , lifting rolling member  10  out of engagement with both rotatable shaft  7  and inner surface  41  thus allowing rotatable shaft  7  to turn in either direction, or “free-wheel” in the second, “off” position of the clutch.  
         [0028]    Referring now to FIG. 7 an alternative embodiment of the present clutch  101  has stops  70 ,  71 , and  72 . Stops  70 ,  71  and  72  act to limit further rotation of the actuator. There is a limit to the amount of movement that the actuator can travel beyond its “on” and “off” positions. As a result, the addition of stops either internal to the clutch or externally may assist in accurately placing the actuator in an optimal “on” position and preventing over-rotation, that could result in damage to the clutch once the “off” position has been reached. In this embodiment of the present invention, an over-center spring  202  or similar device may be used to urge an actuator spring arm  200  and housing arm  201  towards the “on” or “off” positions, helping to minimize ineffective intermediate positions. This spring-loaded clutch does not require precise positioning of the actuating arm  105  to place the actuator  104  in an optimal “on” or “off” position. Yet another benefit of a spring-loaded clutch is that too much pressure on actuating arm  105  in either direction could cause part of the housing  104 , particularly projections  120 ,  122 ,  124 ,  126 ,  128 ,  129 , depending on direction, to rub undesirably against the shaft.  
         [0029]    To help further lighten the clutch assembly, the heavier metal parts such as the actuating arm  105  and the actuator spring arm  200  may have interior walls  190  and  192  defining lightening holes  190  and  193  respectively. In most respects, this alternative embodiment is similar in function to the embodiment illustrated by FIGS.  1 - 6 . In this alternative embodiment, there are six rolling members  110 ,  111 ,  112 ,  114 ,  116  and  118 . These rolling members perform the same function as those rolling members  10 ,  11 ,  12 ,  14  and  16  illustrated in the embodiment of FIGS.  1 - 6 . Rolling members  110 ,  111 ,  112 ,  114 ,  116  and  118  are either brought into contact with shaft  107  (in the “on” position of the clutch) or out of contact with the shaft  107  (in the “off” position). Housing projections  120 ,  122 ,  124 ,  126 ,  128  and  129  correspond in function to the housing projections  20 ,  22 ,  24 ,  26  and  28  of FIGS. 1 and 3. Housing fixing member  108  is used for attaching the clutch  101  to a surface.  
         [0030]    Numerous variations will occur to those skilled in the art in light of the foregoing disclosure, without departing from the intended scope of the invention. For example, the number of rolling members used may be more or less than the illustrative embodiment. Likewise, the number of projections may be other than those of the illustrative embodiment. Various methods of fixing the housing  6  and effecting movement of the actuator  4  can be conceived. The arcuate concave area could be any shape that prevents the rolling member from contacting the shaft when urged into the off or unlocked position. The exterior shape of the clutch may be altered. The actuator may be spring-loaded into the “on” or the “off” positions or spring-loaded so that intermediate positions are minimized. Additional formations could be added to assist in accurately controlling rotation of the actuator. Many other applications for the switchable clutch of the present invention besides fishing reels may be used, such as for example xerographic copying machines, facsimile machines, roller skates and the like. These are merely illustrative.