Abstract:
An anvil assembly for a rotary tool is provided. The anvil assembly includes an anvil body having a cylindrical portion operably coupled to the rotary tool&#39;s drive mechanism and having a drive output portion configured to releasably engage a corresponding socket thereon. The anvil body may also have a transition region between a shape of the drive output portion and a shape of the cylindrical portion, wherein the transition region gradually transitions the shape of the drive output portion to the shape of the cylindrical portion. A collar may be releasably coupled to the anvil body, the collar having a first end and a second end, the first end configured to engage the shape of the drive output portion and the second end configured to engage the cylindrical portion, wherein the first end has a flat face defining a shoulder for contacting the socket releasably engaged on the anvil body.

Description:
BACKGROUND 
     Technical Field 
       [0001]    The present disclosure relates to rotary tools, and in particular to anvil geometry of rotary tools. 
       State of the Art 
       [0002]    A powered rotary tool may be used in conjunction with a corresponding mated socket to manipulate many different types of workpieces, for example, mechanical fasteners, such as bolts, nuts, etc. These rotary tools employ a rotating mass, such as a shaft or anvil, on which the mated socket is releasably coupled, which anvil is accelerated by a motor or other power source within the rotary tool, to apply torque to the socket to thereby manipulate the workpiece. 
         [0003]    Conventionally, the anvil of the rotary tool has a cylindrical portion and a square-shaped portion. With regard to the cylindrical portion, the mating part of the motor or other drive means within the rotary tool is cylindrical and therefore requires the corresponding portion of the anvil to be likewise cylindrical. However, to impart rotational force to the socket, the opposing end of the anvil must exhibit flat or square- shaped surfaces to engage with the corresponding flat or square-shaped surfaces of the socket and cause it to turn. 
         [0004]    Conventional anvils also include a shoulder positioned somewhere between the cylindrical portion and the square-shaped portion, with the shoulder being a sloping surface to transition the anvil from the square shape to the cylindrical shape and to contact the socket placed on the anvil. Because of the change in geometry at or near the shoulder, or the transition between the square and cylindrical shapes, the shoulder may create a weak point in the anvil where stress concentrations may initiate points of failure. 
         [0005]    It would therefore be advantageous to address these concerns and provide an anvil that decreases the amount of stress concentrations thereon. 
       SUMMARY 
       [0006]    The present disclosure relates to rotary tools, and in particular to anvil geometry of rotary tools and an anvil assembly for rotary tools. 
         [0007]    An aspect of the present disclosure includes an anvil assembly for a rotary tool, the assembly comprising: an anvil body having a cylindrical portion operably coupled to a drive mechanism of the rotary tool and having a drive output portion configured to releasably engage a corresponding socket thereon; a transition region between a shape of the drive output portion and a shape of the cylindrical portion, wherein the transition region gradually transitions the shape of the drive output portion to the shape of the cylindrical portion; and a collar releasably coupled to the anvil body, the collar having a first end and a second end, the first end configured to engage the shape of the drive output portion and the second end configured to engage the cylindrical portion, wherein the first end has a flat face defining a shoulder for contacting the socket releasably engaged on the anvil body. 
         [0008]    Another aspect of the present disclosure includes an anvil assembly of a rotary tool, the assembly comprising: an anvil body having a cylindrical portion operably coupled to a drive mechanism of the rotary tool and a drive output portion configured to releasably engage a corresponding socket thereon; a transition region between a shape of the drive output portion and a shape of the cylindrical portion, wherein the transition region gradually transitions the shape of the drive output portion to the shape of the cylindrical portion; and a shoulder for contacting the socket releasably engaged on the anvil body, wherein the shoulder and the anvil body are releasably coupled together. 
         [0009]    Another aspect of the present disclosure includes an anvil assembly of a rotary tool, the assembly comprising: an anvil body having a cylindrical portion operably coupled to a drive mechanism of the rotary tool and a drive output portion configured to releasably engage a corresponding socket thereon; a collar releasably coupled by press fit to the anvil body, the collar having a first end and a second end, the first end configured to physically engage a shape of the drive output portion and the second end configured to physically engage the cylindrical portion, wherein the first end defines a shoulder for contacting the socket releasably engaged on the anvil body. 
         [0010]    The foregoing and other features, advantages, and construction of the present disclosure will be more readily apparent and fully appreciated from the following more detailed description of the particular embodiments, taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members: 
           [0012]      FIG. 1  is a partial, side perspective view of an illustrative embodiment of a conventional anvil of a rotary tool. 
           [0013]      FIG. 2  is a cross-sectional side view of an embodiment of a rotary tool anvil assembly for a rotary tool in accordance with the present disclosure. 
           [0014]      FIG. 3  is a side perspective view of an embodiment of a component of a rotary tool anvil assembly for a rotary tool in accordance with the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0015]    A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures listed above. Although certain embodiments are shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present disclosure will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of embodiments of the present disclosure. 
         [0016]    As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise. 
         [0017]    With reference to  FIG. 1 , a conventional rotary tool  2 , such as an impact wrench and the like, may have a rotating mass therein that is accelerated by the motor. The rotating mass stores energy, then suddenly delivers the stored energy to an output shaft of the rotary tool to create a high-torque impact. This impact, or rotational force or energy, is exerted on a body mass extending out of the motor housing, such as an anvil  3 , which typically has a cylindrical shaft portion  4  and a drive output portion  5 . 
         [0018]    The cylindrical shaft portion  4  is shaped in a cylinder so that the bearings or bushings that cause the shaft to rotate can do so with a smooth motion, facilitating more of the force being transferred to the tooling, and therefore the part that the operator wishes to rotate. However, in order for the rotational force to be transferred to the tooling, such as a socket wrench, the opposing end of the cylindrical shaft, or the drive output portion  5 , is configured in a specific shape. The most common shape is a square, although other shapes, such as pentagons, can be used. Thus, the cylindrical shaft portion  4  is transitioned from a cylindrical shape into a shape of the drive output portion  5 . 
         [0019]    The transition from the cylindrical shaft portion  4  to the drive output portion  5  is typically achieved in a transition portion  6  having a shoulder  7 . The shoulder  7  is typically an angled surface that abruptly changes slope from the cylindrical shaft portion  4  to the drive output portion  5 . As such, points  8  on the anvil  3  where the drive output portion  5  meets the shoulder  7  typically define abrupt geometric changes or sharp discontinuities of slope that create potential weaknesses in the mechanical integrity of the anvil  3 , or otherwise concentrate operational stresses on the anvil  3 , either of which could lead to failure of the anvil  3  over time. 
         [0020]    Yet, conventional rotary tools  2  are purposefully designed with the shoulder  7  having sharp discontinuities of slope and abrupt changes in geometry to provide a physical shoulder  7  against which a socket may rest. For example, a socket may be inserted on the drive output portion  5 , such that a user may manipulate the rotary tool  2  to spin the drive output portion  5  and thus the socket to impart force to a workpiece, such as a bolt, nut, etc. Because the shoulder  7  abruptly changes geometry at the point  8 , the end of the socket may rest against, or at least abut, the shoulder  7  to prevent the socket from axially advancing further up the drive output portion  5  toward the cylindrical shaft portion  4 . In this way, the shoulder  7  functions to position the socket appropriately on the anvil  3  during operation of the rotary tool  2 . 
         [0021]      FIGS. 2 and 3  depict illustrative embodiments of a rotary tool anvil assembly  10  of the present invention. The embodiments may each comprise various structural and functional components that complement one another to provide the unique functionality and performance of the anvil assembly  10 , the particular structure and function of which will be described in greater detail herein. For example, embodiments of the anvil assembly  10  may comprise an anvil body  20  and a collar  30 , among other component parts. 
         [0022]    Embodiments of the anvil assembly  10  may comprise an anvil body  20 . The anvil body  20  may be an elongated member having a cylindrical portion  22  on an end and a drive output portion  24  on an opposing end, with a transition region  26  positioned therebetween. The anvil body  20  may be a substantially rigid body. The anvil body  20  may also be an integral body, with the cylindrical portion  22 , the drive output portion  24 , and the transition region  26  being formed of a single integral piece. The anvil body  20  may have an axis about which the anvil body  20  rotates, the axis of the anvil body  20  corresponding to the axis of rotation of the rotary tool  2 . The anvil body  20  may be configured to receive rotational input from the drive system or motor of the rotary tool  2 , such that the anvil body  20  may be powered by the rotary tool  2 . 
         [0023]    Embodiments of the anvil assembly  10  may comprise the cylindrical portion  22  of the anvil body  20  being shaped in the form of a cylinder to receive, accommodate and otherwise facilitate the rotational input of the drive system or motor of the rotary tool  2  to the anvil body  20 . The cylindrical portion  22  may further comprise an annular ridge  28  therein. The annular ridge  28  may be a rise or increase in the diameter of the cylindrical portion  22 , such that the cylindrical portion  22  may have a first diameter  21  and a second diameter  23 , with the second diameter  23  being larger than the first diameter  21 . The second diameter  23  may be sized and configured to communicate with the diameter of the drive system or motor of the rotary tool  2 , whereas the first diameter  21  may be sized and configured to communicate with the transition region  28  and a collar  30 , to be described in detail herein. 
         [0024]    Embodiments of the anvil assembly  10  may comprise the drive output portion  24  of the anvil body  20  being positioned on an opposing end of the anvil body  20  from the cylindrical portion  22  and configured in a predetermined or desired size and shape. The size and shape may be chosen, or otherwise manufactured, to correspond to a hollow or opening of a socket, such that the drive output portion  24  may be inserted into and engage the hollow or opening of the socket to thereby drive the socket in its intended operation on a workpiece, such as a bolt, nut, etc. For example, the drive output portion  24  may be shaped in the shape or form of a square having flat or horizontal surfaces  25  configured to engage the corresponding flat or horizontal surfaces of the hollow or opening of the socket. In this way, once the socket is engaged on the drive output portion  24 , the rotation of the anvil body  20  from the rotation of the drive system of the rotary tool  2  may cause the flat or horizontal surfaces  25  to physically contact the corresponding flat or horizontal surfaces of the hollow or opening of the socket to drive the rotation of the socket. 
         [0025]    Embodiments of the anvil assembly  10  may comprise a transition region  26  positioned between the drive output portion  24  and the cylindrical portion  22 . The transition region  26  may be configured to transition the width  27  of the drive output portion  24  to the first diameter  21  of the cylindrical portion  22 . Thus, the transition region  26  may increase in dimension in an axial direction from the drive output portion  24  to the first diameter  21  of the cylindrical portion  22 . For example, the transition region  26  may have an initial dimension that matches the width  27  of the drive output portion  24 , and that initial dimension may gradually increase in size in the axial direction until the dimension of the transition region  26  matches the size of the first diameter  21 . In some embodiments, the transition region  26  may therefore be described as increasing in dimension in a substantially smooth manner in an axial direction. Additionally, in some embodiments, the transition region  26  may be described as increasing in dimension in a substantially continuous manner without abrupt changes in slope in an axial direction. Additionally, in some embodiments, the transition region  26  may be described as being substantially void of sharp discontinuities while increasing in dimension in an axial direction. Additionally, in some embodiments, the transition region  26  may be described as exhibiting smooth curvilinear blending while increasing in dimension in an axial direction. 
         [0026]    Embodiments of the anvil assembly  10  may comprise the difference between the width  27  of the drive output portion  24  and the first diameter  21  of the cylindrical portion  22  being the transition difference T. In some embodiments, the transition difference T may be less than half the size of the width  31  of the collar  30 , which may be measured between the first diameter  21  and the exterior surface  33  of the collar  30 . As such, over the axial length of the transition region  26 , or at least a portion thereof, the transition region  26  increases in dimension, according to the description herein, by the transition difference T. The transition difference T may be held to a minimum by the cylindrical portion  22  having the first diameter  21  that is smaller than the second diameter  23 . With the transition difference T kept relatively small, the transition region  26  may likewise be kept to a small incline or gradual rise, as described herein. Accordingly, due to the improved geometry of the transition region  26 , the typical weak points  8 , owing to sharp inclines, sharp slope changes, and sharp discontinuities, that are found in conventional anvils  3 , are eliminated from the anvil body  20 . As such, the anvil body  20  does not incur the concentrated stresses and strains that conventional anvils  3  can experience. 
         [0027]    Embodiments of the anvil assembly  10  may comprise a collar  30 . The collar  30  may be an elongated body  32  having, generally, the shape of an annulus when viewed along an axis of rotation. The axis of rotation of the collar  30  may correspond to the axis of rotation of the anvil body  20  and the axis of the drive system or motor of the rotary tool  2 . The collar  30  may be a substantially rigid body having a first end  34  and a second end  36  that opposes the first end  34 . The second end  36  may be open, such that the collar  30  may be inserted over at least portions of the anvil body  20  through the open second end  36 . The first end  34  may have a face  38 . The face  38  may define a substantially flat surface. The surface of the face  38 , in some embodiments, may be oriented substantially orthogonally to the axis of rotation of the collar  30 , and thus the axis of rotation of the anvil body  20  and the rotary tool  2 . In this way, the face  38  may be substantially perpendicular to the drive output portion  24  and/or the flat surfaces  25  thereof. The face  38  may further define an opening  40 . The opening  40  may axially extend entirely through the face  38  such that the opening  40  communicates with the interior of the collar  30 . The opening  40  may be configured in a size and shape to match or otherwise correspond to the size and shape of the drive output portion  24 . The opening  40  may further comprise interior surfaces  42  that may be oriented in parallel with the axis of rotation of the collar  30 , and thus the axis of rotation of the anvil body  20  and the rotary tool  2 . In this way, the interior surfaces  42  may be substantially parallel to the drive output portion  24  and/or the flat surfaces  25  thereof. The interior surfaces  42  may be configured to engage the surfaces of the anvil body  20 . The collar  30  may further comprise an exterior surface  33  that may be cylindrically shaped due to the annular shape of the body  32 . As a result, the face  38  may be a flat face extending from the surface of the rigid body  20  up to the exterior surface  33  of the collar  30 . 
         [0028]    Embodiments of the anvil assembly  10  may comprise the collar  30  being inserted over portions of the anvil body  20  to releasably couple thereto. For example, the second end  36  of the collar  30  may be inserted onto the anvil body  20  and axially transitioned down the anvil body  20  until the second end  36  physically contacts the annular ridge  28  and/or the interior of the collar  30  proximate the second end  36  physically engages the first diameter  21  of the cylindrical portion  22 . The collar  30  may engage the first diameter  21  by press fit. In like manner, the first end  34  of the collar  30  may be inserted over the rigid body  20  and axially advanced so that the opening  40  physically contacts or otherwise engages the drive output portion  24 . The collar  30  may have an axial length that permits the second end  36  to physically contact the annular ridge  28  while the interior surfaces  42  of the opening  40  physically contact or otherwise engage the drive output portion  24  proximate where the drive output portion  24  transitions to the transition region  26 . The exterior surface  33  of the collar  30  and the exterior surface  29  of the cylindrical portion  22  may be configured to be flush with one another in a radial direction. 
         [0029]    With the collar  30  engaged on the rigid body  20 , the face  38  may be positioned with respect to the rigid body  20 , and, in particular, to the drive output portion  24 , such that the face  38  may function as a stop or shoulder, similar to the shoulder  7  of a conventional rotary tool  2 . Yet, because the face  38  is separate and apart from the geometry of the rigid body  20 , the face  38  may function as a shoulder without the rigid body  20  exhibiting sharp changes in slope or abrupt discontinuities, as described herein. As a result, the anvil assembly  10  is advantageous over conventional anvils  3  due to the rigid body  20  being substantially void of conventional weak points  8  that would otherwise expose or suspect conventional anvils  3  to failure, while at the same time providing the shoulder (i.e., face  38 ) against which a socket can rest or contact when the socket is releasably coupled to the drive output portion  24 . 
         [0030]    The materials of construction of the anvil assembly  10  and its various component parts may vary considerably, depending on the temperatures and pressures to which they will be subjected and the nature of the applications for which they will be used. For example, materials used for other rotary power tool shaft mechanisms, such as metals, metal alloys and the like may be employed. Further, operation under certain conditions may dictate the use of other materials known for such purposes. 
         [0031]    Furthermore, the components defining the above-described anvil assembly  10  may be purchased pre-manufactured or manufactured separately and then assembled together. However, any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, 3-D printing, and/or the like. If any of the components are manufactured separately, they may then be coupled with one another in any manner, such as with adhesive, a weld, a fastener (e.g. a bolt, a nut, a screw, a nail, a rivet, a pin, and/or the like), wiring, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material forming the components. Other possible steps might include sand blasting, polishing, powder coating, zinc plating, anodizing, hard anodizing, and/or painting the components for example. 
         [0032]    While this disclosure has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the present disclosure as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure, as required by the following claims. The claims provide the scope of the coverage of the present disclosure and should not be limited to the specific examples provided herein.