Abstract:
An apparatus is disclosed including a motor housing structured to receive at least a portion of an electric motor, a tool housing including a first half and a second half, wherein the tool housing defines an end taper, a tool attachment in mechanical communication with the electric motor, and a retention member including an inner taper structured to interface with the end taper of the tool housing to resist relative motion between the tool housing and the motor housing.

Description:
CROSS-REFERENCE 
     The present application claims the benefit of U.S. Provisional Patent Application No. 61/693,635 filed on Aug. 27, 2012, and the benefit of U.S. Provisional Patent Application No. 61/694,062, filed on Aug. 28, 2012, both of which are hereby incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to power tools, and more particularly, but not exclusively, to a housing construction for an electrically driven power tool. 
     BACKGROUND OF THE INVENTION 
     Hand-held power tool housing construction remains an area of interest. Many current electrically driven power tool housings fail to provide adequate strength. Some current designs provide for a one-piece tubular housing to bolster strength; however, this design may not lend itself well to battery powered tools due to various complexities involved in assembling the electronic components therein. Therefore, further technological developments are desirable in this area. 
     BRIEF SUMMARY OF THE INVENTION 
     One embodiment of the present invention is a housing construction for a power tool. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for providing a unique housing for an electrically driven power tool that includes a split housing, a substructure, and a reinforcing superstructure. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The description herein makes reference to the accompanying figures wherein like reference numerals refer to like parts throughout the several views, and wherein: 
         FIG. 1A  is an exploded perspective view of one embodiment of a power tool housing. 
         FIG. 1B  is an exploded view of one form of a gear assembly. 
         FIG. 2  is a cross sectional view of one embodiment of power tool housing. 
         FIG. 3  is a cross sectional view of yet another embodiment of a power tool housing. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
       FIG. 1A  illustrates one embodiment of a power tool assembly  100 . The power tool assembly  100  includes a tool housing  130 , a substructure  104 , a gear assembly  106 , a superstructure  108 , and a tool head  112 . The tool housing  130 , substructure  104 , and superstructure  108  include a variety of unique features to strengthen the power tool assembly  100 . 
     The tool housing  130  can be divided into two portions, for example, a first half  116  and a second half  118  as shown. The first and second halves  116 ,  118  can be coupled to form the tool housing  130 . In one form, the first and second halves  116 ,  118  are joined in a manner such that a clamshell style tool housing  130  is formed. The tool housing  130  can be constructed from a variety of materials including various composites, polymers, or any other material suitable for the construction of the tool housing  130 , which can be determined based upon for example a force to be applied to the tool housing  130 . 
     In the illustrated embodiment, a plurality of ribs  114   a  extend from an inner surface of the tool housing  130 . As shown, the first half  116  and the second half  118  can each include a plurality of radially inwardly extending ribs  114   a  and recessed grooves  114   b . The radially inwardly extending ribs  114   a  need not encircle the full interior of the tool housing  130 . The substructure  104  includes a plurality of ribs and grooves  120   a ,  120   b  respectively that are sized to receive the ribs and grooves  114   a ,  114   b  extending from the inner surface of the tool housing  130 . In some forms, the substructure  104  can additionally and/or alternatively include a plurality of ribs  120   a  which interlock between the plurality of ribs  114   a  extending from the inner surface of the tool housing  130 . When the first and second halves  116 ,  118  of the tool housing  130  are assembled together, the ribs  114   a  of the tool housing  130  mate with the grooves  120   b  of substructure  104  to prevent or resist relative axial movement between the tool housing  130  and the substructure  104 . It is contemplated that the substructure  104  and the tool housing  130  can be configured to mate in a variety of fashions, through protrusions received in grooves, through an extension disposed in a channel, or any other type of configuration such that the tool housing  130  and the substructure  104  interlock to resist axial movement relative to each other. 
     The substructure  104  receives at least a portion of the motor  102  in an inner cavity of the substructure  104 . The substructure  104  can be substantially tubular in shape; however, any shape may be utilized such that the substructure  104  can mate with the tool housing  130  and can at least partially house the motor  102 . In one form, the substructure  104  can fully encompass the motor  102 . The substructure  104  can be constructed of various metals, such as steel or the like, and can be constructed through various processes, including, but not limited to casting or progressive die forming. In one form, the substructure  104  is constructed of one or more materials that are stronger than the materials from which the tool housing  130  is constructed. 
     The motor  102  is an electrically powered motor. The motor  102  can take any configuration such that the motor  102  converts electrical energy into mechanical energy. This mechanical energy can be transferred through a gear assembly  106 , and other assemblies, to drive a tool head  112 . The motor  102  can be at least partially retained by a motor retainer  132  or the like. The motor retainer  132  can aid in the prevention of rotation of the motor  102  relative the substructure  104 . 
     The motor  102  can be in electrical communication with a battery pack  124  through a wiring harness and motor controller  126 . The battery pack  124  can be semi-permanently affixed to the power tool assembly  100  such that the entire power tool assembly is placed in a charger or has a charger coupled thereto, or the battery pack  124  can be removable from the power tool assembly  100  to allow for quick battery changes and charging at a remote charging station. 
     Referring more closely to  FIGS. 1A and 1B , a motor  102  output can be placed in mechanical connection with a gear assembly  106  comprising a plurality of gears  138 . In one form, a ring gear stop  134  resists axial movement of a ring gear housing  136  and therefore axial movement of the gear assembly  106 . While the mechanical connection between the motor  102  output and the tool head  112  has been illustrated in the form of a ring gear housing  136  including a gear assembly  106 , the application is not intended to be limited thereto. It is contemplated that any mechanical connection, including a direct connection, may be utilized to transfer power from the electric motor  102  to the tool head  112 . 
     The tool head  112  provides an output for a tool bit, socket, or the like. The tool head  112  is illustrated as a ratchet in  FIG. 1A . The tool head  112  can be utilized to tighten and loosen a variety of threaded fasteners, such as nuts, bolt heads, or the like. The tool head  112  can be coupled to the power tool assembly in a variety of manners, such as through a tool head fastener  142 . 
     The tool assembly  100  can be operated in both a powered mode and in a manually-operated mode. In a powered mode, an operator holds a tool grip  128  while the tool head  112  delivers torque to a fastener, using the mechanical power that the electric motor  102  has delivered. In the manually-operated mode, the operator manipulates the tool grip  128  like a socket wrench, applying force to the handle, and using the power tool assembly  100  as a moment arm for creating and delivering torque to the fastener. In some forms, various motor  102  and gearing  106  configurations can be utilized to switch between the manual and powered mode. 
     The superstructure  108  and the tool housing  130  include respective tapers  210  and  212 . The taper  210  of the superstructure  108  applies a force against the taper  212  of the tool housing  130  to retain the first and second housing portions  116 ,  118  together and to resist or prevent movement of the tool housing  130  relative to the substructure  104 . As described in greater detail below, a suitable nut  110  can be used to compress the taper  210  of the superstructure  108  against the taper  212  of the tool housing  130 .  FIG. 2  shows one example of the taper  212  of the tool housing  130  in relation to the taper  210  of the superstructure  108 . The taper  210  of the superstructure  108  can take any form such that it is operable to apply a radially inward force to the taper  212  of the tool housing  130 . The superstructure  108  can include a clamp ring, a snap ring, or any other structure that includes a taper  210  that is suitable to exert a radially inward force on a taper  212  of the tool housing  130 . The superstructure  108  can be constructed of various materials, including metals such as aluminum or steel, that exhibit a greater material strength than a material strength of the tool housing  130 . In a specific form, the superstructure  108  can be formed through a casting process, such as die casting. 
     In the illustrated embodiment, the substructure  104  has a threaded projecting portion  214 . The nut  110  has corresponding threads  240  and can be fastened to the substructure projecting portion  214  such that, when tightened, the nut  110  exerts an axial force upon the superstructure  108 . The taper  210  of the superstructure  108 , in turn, exerts an axial and radial force upon the taper  212  of the tool housing  130 . The radial force on the tool housing  130  radially clamps, that is compresses, the first and second halves  116 ,  118  of the tool housing  130  together, preventing or resisting the first and second halves  116 ,  118  from coming apart. In one form, where mating ribs/grooves  114   a ,  114   b  and ribs/grooves  120   a ,  120   b  respectively are present, the axial force on the tool housing  130  is transmitted to the ribs/grooves  114   a ,  114   b  to axially urge the ribs/grooves  114   a ,  114   b  against the ribs/grooves  120   a ,  120   b  with which they mate to prevent or resist axial movement of the tool housing  130  relative to the substructure  104 . 
     Referring again to  FIG. 2 , in one form a ring gear stop  202  is attached to the substructure  104 . The ring gear stop  202  can be connected to the substructure  104  such as through a weld  204  or the like. The ring gear housing  136  can include a plurality of outer threads  208  which are received by a plurality of inner threads  218  of the substructure  104 . The ring gear housing  136  can be threaded such that it abuts the ring gear stop  202 . 
     Referring now to  FIG. 3 , in some forms, the tool head fastener  142  can be directly fastened to the tool substructure  104  such as through tool head fastener threads  312 . In this form, the ring gear housing  136  is placed in an abutting relationship  312  with the substructure  104 . Additionally, various portions  302  can be formed integrally with the substructure  104  rather than being welded or attached, as was described with reference to  FIG. 2 . Although specific illustrative examples have been given, as was previously aforementioned, it is contemplated that the tool head  112  is mechanically interconnected to the electric motor  102  in any suitable manner such that the electric motor  102  can transfer power to the tool head  112 . 
     The electric motor  102  can generate heat during use. To evacuate this heat, exhaust vents  308  can be disposed in the motor  102 . A vent  310  can additionally be located in the substructure  104  and a vent  306  can be located in the tool housing  130  allowing heated air  304  to exit from the motor  102 . As is illustrated, the vents  308 ,  310 ,  306  can be axially and radially aligned such that air can flow directly radially outward. In some forms, this will allow a user to view the vent  308  of the motor  102  through the vent  306  in the tool housing  130 . In further forms, multiple flowpaths can be disposed in the motor  102 , the tool housing  130 , and the substructure  104  to provide for both an inlet air flow and an exhaust air flow. For example, the tool housing  130  can include a first flowpath in fluid communication with a second flowpath located in the motor  102 , and the second flowpath can be in fluid communication with the intake and or the exhaust of the motor  102 . The first flowpath can be at least partially radially aligned with the second flowpath, and the second flowpath can be at least partially radially aligned with the intake and/or exhaust of the motor  102 . Any number of airflow paths are contemplated to provide cooling to the motor  102 . 
     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.