POWER TOOL

A screwdriver including an output member, a motor configured to selectively drive the output member, a battery and an actuation collar. The actuation collar is movable in a forward direction towards the output member to actuate the screwdriver.

FIELD OF THE INVENTION

The present invention relates to power tools such as a screwdriver.

BACKGROUND

There are various existing battery powered tools. The prior art tools are actuated in various ways. For example,FIG.14illustrates a power tool in the form of a battery powered wrench110. The wrench110has a collar130that is biased forward and may be pulled rearward to actuate the tool. Pulling the collar130backward “B” may actuate the tool by actuating a microswitch or magnetic switch, upon which the motor is activated to drive an output member. The collar130is pulled in a rearward direction and the collar does not determine or adjust a direction of the output.

It is desired to provide a powered tool with an improved construction.

SUMMARY

According to one aspect, there is an exemplary embodiment of a power tool in the form of a screwdriver. The screwdriver includes an output member, a motor configured to selectively drive the output member, a battery and an actuation collar. The actuation collar is movable in a forward direction towards the output member to actuate the screwdriver.

The screwdriver may further include a nosepiece between the collar and the output member.

The screwdriver may further include a circuit board disposed in the nosepiece.

The screwdriver may further include an actuator on the circuit board, wherein movement of the actuation collar in the forward direction causes actuation of the actuator.

The actuator may be a microswitch.

The collar may further include a projection configured to selectively contact the actuator.

The collar may be rotatable to at least three positions.

The at least three positions may include a lock-off position, a forward operation position and a reverse operation position.

According to one aspect, there is an exemplary embodiment of a power tool including a body, a motor housed in the body, a power source, an output member selectively driven by the motor, and an actuation collar configured to actuate the power tool.

The actuation collar may be rotatable between a forward operation position and a reverse operation position.

In the forward operation position, the actuation collar may be slidable in a forward direction towards the output member and the power tool is actuated to drive the output member in forward rotation.

In the reverse operation position, the actuation collar may be slidable in the forward direction in order to and the power tool is actuated to drive the output member in reverse rotation.

The actuation collar may be biased away from the forward direction.

The power tool may further include a forward operation actuator and a reverse operation actuator.

The forward operation actuator may be actuated when the actuation collar is slid forward when in the forward operation position.

The reverse operation actuator may be actuated when the actuation collar is slid forward when in the reverse operation position.

The forward operation actuator and the reverse operation actuator may be microswitches.

The power tool may further include a nosepiece between the body and the output member.

The power tool may further include a circuit board disposed in the nosepiece.

The power tool may further include at least one actuator mounted on the circuit board.

The at least one actuator may further include a forward operation actuator and a reverse operation actuator

The forward operation actuator may be actuated when the actuation collar is slid forward when in the forward operation position.

The actuation collar may also be rotatable to a lock-off position.

According to another aspect, there is an exemplary embodiment of a power tool including a handle, a motor, a power source, and an output member selectively driven by the motor.

An actuation collar may be movable in a forward direction towards the output member to actuate the power tool.

The collar may be rotatable to at least three positions.

The at least three positions comprise a lock-off position, a forward operation position and a reverse operation position.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIG.1illustrates a side view of a non-limiting, exemplary embodiment of a screwdriver10. The screwdriver10includes a body portion20. The body portion may serve as a handle which a user can grasp so as to hold the screwdriver10. A motor80and a battery90are housed in the body portion20. The battery90may consist of a single battery cell or multiple battery cells and may charged by conventional means. The body portion20may also house other components, such as a printed circuit board (PCB) on which a controller such as a microprocessor may be mounted.

The screwdriver10further includes a collar30for actuating the screwdriver10, a nosepiece40and a bit holder50. The bit holder50may be a hexagonal bit holder configured to hold a hexagonal screwdriver bit. In other embodiments, the output may be something other than a hexagonal bit holder. For example, the output may be a chuck. In other embodiments, the tool may be something other than a screwdriver and the output may vary accordingly. For example, the collar30and other features may be applied to a rotary tool and the output member would then be a rotary tool chuck for holding rotary tool accessories. Similarly, the collar and other features of the exemplary embodiment may be applied to a wrench and the output member be modified accordingly.

The screwdriver10further includes a rotary dial60. The rotary dial60may be used to control the speed and/or a torque limit of the screwdriver10. The rotary dial60may have a variety of settings, such as six settings from a to f. Each of the six settings may represent a speed for the screwdriver10or a maximum torque. In some embodiments, the screwdriver10may be configured such that it has two modes—a first mode in which the rotary dial60sets a speed and a second mode in which the rotary dial sets a maximum torque. There may be more or fewer than six settings.

The collar30is biased in a rearward direction R, as shown inFIG.1. As shown inFIG.1, the rearward direction R is towards the handle20, motor80and battery90and away from the nosepiece40and output member50. The output member50is located at the front of the screwdriver10. The collar30is biased rearwardly by a biasing member such as a spring.

The collar30is operated by a user to actuate the screwdriver10. When the collar30is in the rearward position, the motor80is not activated, the output50does not rotate and the screwdriver10is off. The collar30is rotatable to three different positions. The collar30has a central, lock-off position in which the collar30is blocked from being slid forward. The collar30can be rotated counter-clockwise to a reverse position in which the collar30can be translated forward in order to actuate the screwdriver10and the screwdriver10will operate to drive the output member50in reverse, so as to, for example, unscrew a screw. The collar30is rotatable clockwise from the central, lock-off, position to a forward operation position. When the collar30is in the forward operation position, the collar30can be slid forward so that the screwdriver10will operate to drive the output member50in a forward direction, so as to, for example, drive a screw into a workpiece.

FIG.2illustrates a front view of the screwdriver10. As shown inFIG.2, there are four light emitting diodes (LEDs)71mounted on a printed circuit board (PCB)70. The LEDs71illuminate an area forward of the screwdriver10. The LEDs71may be covered by a lens. The lens72in the exemplary embodiment is transparent. The lens may be translucent, frosted, colored, curved, flat or other lens configurations.

FIG.3is an exploded view of selected components of the screwdriver10.FIG.4is a plan view of a rear face of the PCB70.FIG.3includes the body portion20, collar30, a spring38, a nosepiece40and the PCB70. As shown inFIG.3, and again inFIGS.11and12, the body portion20includes receiving projections21and22. The collar30is received on the receiving projections21and22. The collar30is radially outside of the receiving projections21and22and can translate along the receiving projections21,22to actuate the screwdriver.

The collar30includes a plurality of recessed gripping portions31on its outer surface. The collar30also includes a projection32. The projection32projects forward partially through the nosepiece40and selectively contacts microswitches75and76mounted on the PCB70. When the projection32actuates the microswitch75by depressing the microswitch75, the screwdriver10is configured to rotate in reverse. When the projection32actuates the microswitch76by depressing the microswitch76, the screwdriver10is configured to rotate in a forward direction, opposite the reverse direction. The exemplary embodiment uses microswitches. In other embodiments, there may be different types of actuators such as other types of switches. The PCB70may also include an electrical connector port77for connecting the PCB70to the battery90and any controller, such as the controller100shown inFIG.13. The various electrical components of the screwdriver10may be electrically connected by wires or other electrical connectors and the connector port77may be a wire harness connector. The PCB70is mounted in the nosepiece40.

As shown in, for example,FIG.4, the PCB70has a flat78. The flat78may help with placement of the PCB70in the nosepiece40to ensure that it is located at the correct rotational location. There may be one or more other flats or location portions that are configured to ensure that the PCB70is installed in the correct orientation. The PCB70also includes a central hole79that allows for transmission through to the output member.

FIG.5illustrates microswitch75. The microswitch75has a movable portion65that is moved to actuate the microswitch75. The microswitch76has the same configuration as the microswitch75shown inFIG.5.

FIG.6illustrates a front view of the collar30andFIG.7illustrates a side view of the collar30. As shown, the collar30includes the previously mentioned gripping portions31. These gripping portions31are recessed and assist a user in gripping and moving the collar30. There may be various friction increasing features on the gripping portions31. As shown inFIG.6, the collar30includes two alignment projections34,35. These alignment projections34and35guide the collar30as it slides and rotates. The alignment projection35may be aligned with the projection32or integrally formed with the projection32. The collar30further includes a ridge36for supporting a spring. The spring38(FIG.3) sits between the ridge36and a portion of the nosepiece40to bias the collar30rearward.

FIG.8is a front view of the nosepiece40,FIG.9is a side view of the nose piece40andFIG.10is a perspective view of the nosepiece40. The nosepiece40, includes a flat portion48that corresponds with the flat78of the PCB70and allows proper placement of the PCB70. The PCB70generally sits on a shoulder49of the nosepiece40near a forward end of the nosepiece40.

The nosepiece40also includes a blocking piece41. As shown inFIG.10, the blocking piece41is generally “T” shaped. The blocking piece41blocks advancement of the collar30. The blocking piece41includes three portions42,43and44, corresponding to the central, forward and reverse rotational positions of the collar30. In the central or lock-off position, the alignment portion34of the collar30(FIG.6) is aligned with the central blocking portion42. When the collar30is in the lock-off position, if a user tries to slide the collar30forward, the alignment portion34of the collar30contacts the central blocking portion42and the collar30is prevented from advancing forward.

The collar30can be rotated clockwise to a forward operation position. In the forward operation position, the alignment portion34of the collar30(FIG.6) is aligned with the forward blocking portion43. When the collar30is in the forward operation position, the user is able to slide the collar30forward sufficient that the projection32contacts the microswitch76and the screwdriver10is actuated so that the output member50rotates in the forward direction. The alignment portion34of the collar30contacts the forward blocking portion43. The forward blocking portion43is located to allow the collar30to advance sufficient for actuation of the microswitch76, but prevents the collar30from advancing too far, so as to avoid damage to the microswitch76or PCB70.

The collar30can be rotated counter-clockwise to a reverse operation position. In the reverse operation position, the alignment portion34of the collar30(FIG.6) is aligned with the reverse blocking portion44. When the collar30is in the reverse position, the user is able to slide the collar30forward sufficient that the projection32contacts the microswitch75and the screwdriver10is actuated so that the output member50rotates in the reverse direction. The alignment portion34of the collar30contacts the reverse blocking portion44. The reverse blocking portion44is located to allow the collar30to advance sufficient for actuation of the microswitch75, but prevents the collar30from advancing too far, so as to avoid damage to the microswitch75or PCB70.

FIG.11is a side view of the body portion20andFIG.12is a front view of the body portion20. As previously discussed, the collar30fits over the receiving projections21,22. As shown inFIGS.3and11, the receiving projections21,22may have grooves23and24. The collar30may have internal projections which selectively fit into the grooves23,24when the collar30is rotated to the lock-off, forward and reverse positions so that the collar30can be rotated to the appropriate position. That is, the collar30will be lightly secured in a lock-off position so that a user may easily rotate and keep it in the lock-off position. The grooves23,24and detents may be appropriately sized to allow a user to rotate the collar30so that the detents may move out of the grooves. Alignment projections34,35may contact ends of the projections21,22to limit rotational movement of the collar30relative to the body. That is, the collar30may rotate only as the alignment projection34rotates from contacting one radial end of projection21to contacting a facing radial end of projection22. The alignment projection35may operate similarly.

In other embodiments, the collar may have grooves and the body portion include detents. In other embodiments, the receiving projections21,22may have various different grooves, rails, detents or other features to allow for advancement and rotation of the collar30the collar30may have corresponding grooves, rails, detents and other features to facilitate the movement.

In some embodiments, the body portion20may also house a transmission connected to an output of the motor. Wires and various other electrical connectors as are known in the art may be used to connect the various components of the screwdriver10. The screwdriver10may also include additional circuit boards including one or more controller, memory, transmitter, receiver or other electrical components. As discussed above, although the exemplary embodiment has been described with respect to a screwdriver, exemplary embodiments of other power tools are also contemplated.

FIG.13is an explanatory circuit diagram for the screwdriver10. As shown, the motor80, battery90, rotary dial60and microswitches75and76may be connected to a controller100, which may be a microprocessor100. A current sensor65may also be connected to the microprocessor100. The current sensor65may include a resistor and may measure a motor current. Since motor current is proportional to torque, the measure of motor current by the current sensor65may be used to provide the torque limits mentioned above.

Although described by way of exemplary embodiments, it is understood that the words which have been used herein are words of description, rather than words of limitation. Although the description provided above provides detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the disclosure is not limited to the expressly disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims

It is to be understood that the present disclosure contemplates that, to the extent possible, one or more features of any embodiment can be combined or exchanged with one or more features of any other embodiment.