Power tool and rotary tool

A power tool (1), such as an impact wrench (1), includes: a brushless motor (8); a motor housing (7), which houses the brushless motor (8); an anvil (4), which is rotationally driven by the brushless motor (8) and disposed forward of the brushless motor (8); a handle (3), which is disposed downward of the motor housing (7); a battery-mount part (5), which is disposed downward of the handle (3); a battery pack (6), which is mounted on the battery-mount part (5) by being slid relative to the battery-holding housing (5); and a controller (70) for controlling the brushless motor (8). A switch panel (73) having at least one manipulatable button (73c) and at least one display part is provided downward of the handle (3) and is tilted such that the switch panel (73) is higher in the front.

The present application claims priority to Japanese patent application serial number 2019-133947 filed on Jul. 19, 2019 and to Japanese patent application serial number 2019-195493 filed on Oct. 28, 2019, the contents of which are incorporated fully herein by reference.

TECHNICAL FIELD

The present invention relates to a power tool and a rotary tool, such as an impact wrench in which a battery pack serves as a power supply.

BACKGROUND ART

A power tool and a rotary tool, such as an impact driver, an impact wrench, and the like, are known in which a battery pack is used as a power supply. For example, Japanese Laid-open Publication 2018-183874 discloses a power tool having a battery-mount part (battery-holding housing), on which a battery pack is mounted, that is provided on a lower end of a grip part (handle) extending downward away from a main body that has been equipped with a motor and an output part. A terminal block (tool-side terminal), to which the battery pack is electrically connected, and a controller, to which an operating power supply is supplied via the terminal block, are each housed inside the battery-mount part. In addition, a switch panel, which comprises a manipulatable part, a display part, etc., is provided on the battery-mount part.

SUMMARY OF THE INVENTION

Because the upper surface of the battery-mount part of the above-described known power tool is provided in a tilted manner such that the upper surface is lower in the front, the switch panel also has a tilted attitude such that the switch panel is lower in the front. Thereby, from the viewpoint of the user, the switch panel is difficult to view and to manipulate while the user is holding the grip part.

In addition or in the alternative, because the tool-side terminal and the controller are disposed such that they are arranged side-by-side in the up-down direction inside the battery-holding housing, the height of the battery-holding housing in the up-down direction must be at least the combined thickness of the tool-side terminal and the controller. Therefore, such a design makes it difficult to reduce the thickness of the battery-holding housing in the up-down direction in order to reduce the height of the entire product in the up-down direction.

Accordingly, one non-limiting object of the present teachings is to provide a power tool and a rotary tool that provide improved visibility and ease of operation of the switch panel.

In addition or in the alternative, another non-limiting object of the present teachings is to provide a power tool and a rotary tool in which it is possible to make the entire product more compact, in particular in the up-down direction, by reducing the thickness of the battery-holding housing.

In one aspect of the present teachings, a power tool comprises:

a motor;

a motor housing, which houses the motor;

a battery-holding housing, which is connected to the motor housing;

a battery pack, which is mounted on the battery-holding housing by being slid thereon (relative thereto); and

a controller housed in the battery-holding housing and configured to control the motor;

wherein the battery pack and the controller overlap one another in a sliding direction of the battery pack.

In another aspect of the present teachings, a rotary tool comprises: a motor;

a tool-accessory retaining part, which is rotationally driven by the motor and is disposed forward of the motor;

a motor housing, which houses the motor;

a grip housing, which is disposed downward of the motor housing;

a battery-holding housing, which is disposed downward of the grip housing;

a battery pack, which is mounted on the battery-holding housing by being slid thereon (relative thereto) in a front-rear direction; and

a controller housed in the battery-holding housing and configured to control the motor;

an upper portion of the battery pack has an outer shape that is tilted such that it is higher in the front or inclines upwardly (toward the tool-accessory retaining part) in the front-rear direction; and

the controller is disposed with a tilt attitude that is higher in the front or inclines upwardly (toward the tool-accessory retaining part) in the front-rear direction.

The tilted upper portion of the battery pack may include a tab (upward projection) that is configured to latch with the battery-holding housing when the battery pack is mounted on the battery-holding housing. In such an embodiment, the controller and the tab overlap one another in a sliding direction of the battery pack, i.e. in the direction that the battery pack slides relative to the battery-holding housing when mounting the battery pack on the rotary tool.

In addition or in the alternative, the rotary tool may include:

a tool-side terminal (e.g., a terminal block), which is held on a lower side of the controller inside the battery-holding housing and is electrically connectable to the battery pack;

wherein the controller and the tool-side terminal each have a plate shape that is thin walled in the up-down direction, and the tool-side terminal extends in a direction that differs from the direction in which the controller extends. In other words, the controller extends in a first plane and the tool-side terminal extends in a second plane; the first and second plane intersect each other, i.e. they are oblique.

In addition or in the alternative, the rotary tool may include:

a tool-side terminal (e.g., a terminal block), which is held on a lower side of the controller inside the battery-holding housing and is electrically connectable to the battery pack;

wherein the tool-side terminal has a plate shape that is thin walled in the up-down direction, and the battery-holding housing extends in a direction that differs from the direction in which the tool-side terminal extends. In other words, the battery-holding housing (at least a portion thereof, such as a portion of an upper surface thereof) extends in a first plane and the tool-side terminal extends in a second plane; the first and second plane intersect each other, i.e. they are oblique.

In addition or in the alternate, the battery-holding housing may include a switch panel for manually inputting instructions and for displaying information, the switch panel being disposed at an attitude such that the switch panel (e.g., an upper surface thereof) is parallel to the controller.

In another aspect of the present teachings, a power tool comprises:

a motor;

a motor housing, which houses the motor;

a tool-accessory retaining part, which is rotationally driven by the motor and is disposed forward of the motor;

a grip housing, which is disposed downward of the motor housing;

a battery-holding housing, which is disposed downward of the grip housing;

a battery pack, which is attached to the battery-holding housing by being slid thereon (relative thereto);

a controller for controlling the motor; and

a switch panel for manually inputting instructions and for displaying information that is provided, downward of the grip housing, in a tilted manner such that the switch panel is higher in the front.

The switch panel may be provided on the battery-holding housing such that the switch panel is exposed at the upper surface of the battery-holding housing and the upper surface of the switch panel is tilted such that the switch panel is higher in the front.

The controller may be housed in the battery-holding housing, such that the switch panel is disposed on an upper side of the controller.

In addition or in the alternative, the controller is tilted such that it is parallel to the upper surface of the battery-holding housing and is higher in the front.

In addition or in the alternative, a light, which illuminates the space forward of the tool-accessory retaining part, is provided along a forward extension of the controller on a front surface of the battery-holding housing.

In some embodiments of the present teachings, the controller may be housed in the grip housing.

In some embodiments of the present teachings, the controller may be housed in the motor housing.

In some embodiments of the present teachings, the controller may be housed downward of the motor with an attitude that extends in a front-rear direction.

In some embodiments of the present teachings, the motor is disposed such that its rotary shaft is oriented in a front-rear direction, and the controller is housed rearward of the motor with an attitude that is orthogonal to the rotary shaft.

In any of the above-described aspects and embodiments, the controller may include a control circuit board on which at least one switching device (current switching device) is installed. A microprocessor also optionally may be provided on the control circuit board to control the at least one switching device, which may more preferably be a plurality of switching devices that selectively supply current to coils of the motor. The control circuit board preferably extends in a first plane that is oblique to a second plane that contains rails of the battery-holding housing, which rails define the sliding direction of the battery pack relative to the battery-holding housing. The upper surface of the switch panel preferably extends in a third plane that is parallel to the first plane.

In at least some aspects of the present teachings, visibility and ease of operation of the switch panel are more favorable than in known power tools.

In addition or in the alternate, some aspects of the present teachings make it possible to design the entire product in a more compact manner, in particular in the up-down direction of the power tool, by reducing the thickness (height) of the battery-holding housing in the up-down direction.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the present teachings are explained below, with reference to the drawings.

As was noted above,FIG.1is an oblique view of an impact wrench1, which is one exemplary example of a power tool and a rotary tool according to the present teachings;FIG.2is a side view thereof; andFIG.3is a center, longitudinal, cross-sectional view thereof.

The impact wrench1has a T shape in side view in which a handle3is formed downward from a main body2, which extends in a front-rear direction. An anvil4protrudes beyond a tip of the main body2. A battery pack6, which constitutes a power supply, is detachably mounted on a battery-mount part (battery-holding housing)5, which is provided on a lower end of the handle3.

A housing of the main body2comprises: a motor housing7, which houses a brushless motor8; and a hammer case9, which is assembled (joined) forward of the motor housing7and houses a spindle10and an impact mechanism11. The motor housing7is made of a rigid polymer (resin) and is integrally formed with the handle3by assembling (joining) a pair of left and right half housings12a,12busing a plurality of screws13. The hammer case9is a tubular body made of metal and comprises a tapered portion14. That is, the front portion of the hammer case9is tapered at the tapered portion14and extends to a front-tube part15, which has a smaller diameter than a rear end of the hammer case9. A rubber cover16is mounted on the frontward portion of the hammer case9so as to cover the outer circumferences of the tapered portion14and the front-tube part15.

A metal gear case17is disposed within the motor housing7and mates with the rear end of the hammer case9. A rib18is provided on an outer circumference of the gear case17such that the rib18protrudes therefrom. Rearward of the rib18, four rear bosses19are formed on an outer circumference of a front end of the motor housing7. Forward of the rib18, four front bosses20are formed on an outer circumference of a rear end of the hammer case9. Therefore, by inserting four bolts21respectively through the four rear bosses19and the rib18from the rear and screwing them into the front bosses20, it is possible to join the motor housing7, the gear case17, and the hammer case9together into one body. Thus, by screwing the bolts21into the hammer case9, which is made of metal, the motor housing7and the hammer case9are rigidly joined to one another, and durability is also improved.

The brushless motor8inside the main body2is an inner-rotor type that comprises a rotor23that is rotatably disposed within the stator22. The stator22comprises: a stator core24, which has a tube shape and is formed of a plurality of laminated steel sheets; front and rear insulators25, which are respectively provided on the front and rear end surfaces of the stator core24in the axial direction; and six coils26, which are wound on the front and rear insulators25and on the stator core24. On the rear-side insulator25are mounted: a sensor circuit board27on which three rotation-detection devices (not shown), which detect the positions of permanent magnets32provided on the rotor23and output rotation-detection signals, are installed; and a connecting (short-circuiting) member28, in which a plurality of sheet-metal members29are insert molded. The connecting member28electrically connects the coils26, in a three-phase configuration, by virtue of the sheet-metal members29being electrically connected to fusing terminals, which are respectively fused (electrically connected) to different portions of a winding wire that forms the coils26.

The rotor23comprises a rotary shaft30, which is located at the axial center of the rotor23; a rotor core31, which has a substantially circular-cylindrical shape that is disposed around the rotary shaft30and is formed by laminating a plurality of steel sheets; and four of the plate-shaped permanent magnets32, which are fixed in the interior of the rotor core31. A rear end of the rotary shaft30is axially supported by a first bearing33, which is held in a rear portion of the motor housing7. A front end of the rotary shaft30is axially supported by a second bearing35, which is held by a bearing-retaining part34formed on the gear case17. The front end of the rotary shaft30, on which a pinion36is formed, protrudes forward of the gear case17. A fan37is mounted on a portion of the rotary shaft30that is rearward of the second bearing35. Air-exhaust ports38are formed in left and right side surfaces of the motor housing7radially surrounding the fan37. Air-suction ports39are also formed in the side surfaces of the motor housing7rearward of the air-exhaust ports38.

A carrier40is formed integrally with (on) a rear portion of the spindle10. Support pins42project rearwardly from the carrier40and rotatably support four planet gears41A,41B. A through hole43is formed in (at) the axial center of a rear end of the spindle10, and the pinion36of the rotary shaft30, which is inserted into the through hole43from the rear with clearance, meshes with the planet gears41A. The diameter of each of the planet gears41B has two steps, wherein the front side is a large-diameter part and the rear side is a small-diameter part. The front-side, large-diameter parts of the planet gears41B mesh with the planet gears41A, and the rear-side, small-diameter parts of the planet gears41B mesh with an internal gear44, which is held inside the gear case17.

The carrier40has a front plate45and a rear plate46, which respectively support the front ends and rear ends of the support pins42. An outer-side support part47, whose diameter is larger than that of the outer circumference of the bearing-retaining part34of the gear case17, is provided such that it is rearward facing and protrudes from a rear surface of the rear plate46and such that it overlaps the bearing-retaining part34in the radial direction of the spindle10. A third bearing48is disposed between the outer-side support part47and the gear case17, and a rear end of the spindle10is axially supported from its outer side. In this state, the third bearing48is located radially outward of the second bearing35, such that the third bearing48overlaps the second bearing35in the radial direction.

The impact mechanism11comprises: a hammer50, which is externally mounted on (around) the front portion of the spindle10; balls51, which are provided between the hammer50and the spindle10; and a coil spring52, which biases the hammer50forward. The hammer50comprises a pair of tabs (not shown) on its front surface and is capable of engaging, in a rotational direction, with (or striking or impacting) a pair of arms53, provided on a rear end of the anvil4. The balls51span and are fitted between cam grooves54, which are defined by an outer-circumferential surface of the spindle10and an inner-circumferential surface of the hammer50, and cause the spindle10and the hammer50rotate integrally in the rotational direction. The coil spring52is externally mounted on (around) the spindle10and inserted into a ring groove55. A front end of of the ring groove55is provided (defined) on a rearward-facing surface within the hammer50. On the other side, a rear end of the coil spring52contacts a front surface of the front plate45of the part40. Therefore, the coil spring52applies a biasing force that urges the hammer50toward an advanced position at which the tabs respectively engage with the arms53in the rotational direction.

The anvil4is axially supported by a metal bearing (plain bearing)56held by the front-tube part15so as to extend coaxially with the spindle10. The anvil4is positioned in the forward direction by a restricting ring (positioning ring)57provided between the front-tube part15and the arms53. A small-diameter part58provided on (at) the front end of the spindle10is inserted into an insertion hole59, which is formed in the rear end of the anvil4at the axial center thereof and coaxially supports the spindle10.

In addition, a mounting part (square drive)60, which has a square shape in transverse cross section and on which a socket (not shown) is mountable (attachable), is formed on the tip of the anvil4.

Below the hammer case9, a switch61, which causes a trigger62to protrude forward, is provided on an upper portion of the handle3. In addition, a forward/reverse-changing button (reversing switch lever)63, which is slidable to change the rotational direction of the brushless motor8, is provided above the switch61. A light64, which comprises an LED that illuminates the space forward of the anvil4, is provided upward of the trigger62.

Furthermore, as shown also inFIG.4, the battery-mount part5is divided into two parts, namely, the left and right half portions5a,5b, which are formed separately from the handle3. The battery-mount part5is coupled to the handle3by first assembling (joining) the two half portions5a,5bto a coupling part65, which has a tube shape and is provided such that it protrudes from the lower end of the handle3, and by then fixing (securing) the half portions5a,5btogether using the screws13. The battery-mount part5protrudes forward beyond the lower end of the handle3in this state. Furthermore, an upper surface of the battery-mount part5includes a tilted upper surface portion5cthat is higher in the front (i.e. a portion of the upper surface5cis inclined upwardly in the direction from the rear to the front of the power tool1) such that the upper surface becomes higher as it goes forward from the lower end of the handle3. An elastic material66is interposed between the coupling part65and the battery-mount part5and is capable of absorbing impacts, vibration, or the like transmitted from the handle3to the battery-mount part5.

A plate-shaped controller70, which is thin in the up-down direction, is housed within the battery-mount part5, and comprises a control circuit board71housed inside a metal tray72. Six switching devices (current switching devices, such as power FETs), a microcontroller, etc. for controlling the brushless motor8are installed on the control circuit board71. A switch panel (switch plate)73for use in manually inputting instructions to the controller70and for displaying information is provided on an upper side of the control circuit board71. A board73ais electrically connected to the control circuit board71by lead wires and is a separate body that is supported parallel to the control circuit board71. The switch panel73is disposed above the board73aand comprises a plurality of switching buttons, which each comprise a depressible button73cdisposed above a pushbutton switch73b, and a plurality of lamps. For example, the switching buttons may include one or more of an impact-force setting button, an assist-mode setting button and/or a light ON/OFF button. The lamps may include a plurality of lamps (e.g., LEDs) for indicating the impact force that was set (manually input), one or more lamps for indicating the assist-mode that has been set (manually input), a light ON/OFF indicating lamp, and/or one or more battery charge remaining (battery level) lamps. The upper surface of the switch panel73, which includes the buttons73c, etc., is exposed at (on) the upper surface5cof the battery-mount part5.

The controller70is also supported by support ribs74provided such that they each protrude from inner surfaces of the half portions5a,5b, with a tilted attitude that is higher in the front to hold the controller70parallel to the tilted upper surface5cof the battery-mount part5. The switch panel73is parallel to both the controller70and the upper surface5c. At a lower portion of a front surface of the battery-mount part5, a second light75, which comprises an LED, is held upward facing along a forward extension of the controller70.

Two rails76(FIGS.1,2) for mounting the battery pack6by sliding the battery pack6from the front toward the rear are formed on the left and right sides, one on each side, of a lower portion of the battery-mount part5. A plate-shaped terminal block77, which is thin in the up-down direction, comprises terminal plates78that are configured to be electrically connected to corresponding terminals on the mounted battery pack6. The terminal block77is provided adjacent to the controller70in the up-down direction and between the rails76. Although the rails76and the terminal block77extend parallel to one another in the same orientation, it is noted that the rails76and the terminal block77may be formed (extend) in a direction that is tilted from the front-rear direction, which is the axial direction of the main body2(e.g., the rotational axis of the anvil4), such that they are slightly lower in the front, whereas the tilt direction of the upper surface5cof the battery-mount part5and of the controller70is the reverse thereof.

Forward of the terminal block77, a latching recess79is defined in and/or on the battery-mount part5. A retractable tab88(further described below) provided on the battery pack6is configured to releasably engage in the latching recess79in order to block or permit, respectively, demounting of the battery pack6from the battery-mount part5. The latching recess79is formed with a rear-side inner surface80that is tilted (inclined) in the upward direction such that the forward end of the surface80is higher than the rearward end of the surface80. The tilt angle of the surface80is preferably greater than the tilt angle of the controller70relative to the front-rear direction (i.e. a horizontal plane). Forward of the latching recess79, a guide surface81, which is tilted higher in the front at an angle greater than that of the tilt of the rear-side inner surface80, is formed on a front surface of the battery-mount part5.

In addition, the latching recess79protrudes upward until its upper end approaches (is proximal to) the bottom surface of the tray72at the front portion of the controller70and is configured such that the upper end of the latching recess79overlaps, in the front-rear direction, the rear portion of the controller70. That is, e.g., a horizontal plane extending in the front-rear direction intersects both the upper end of the latching recess79and the rear portion of the controller70.

Furthermore, at least a rearward portion of the terminal block77is disposed more rearward than the rearward edge of the controller70, as can be seen inFIGS.4and5. Therefore, lead wires82, which are respectively connected to terminals that extend through the terminal block77to an upper surface of the rear portion of the terminal block77, can be wired (routed), without interference by the controller70, into the interior of the handle3by routing (extending) the lead wires82directly (straight) upward or vertically.

As can be seen inFIG.4, the battery pack6includes a convex mating part86, which includes projections (not shown) on its right and left that mate between the rails76of the battery-mount part5. The convex mating part86protrudes upwardly from an upper surface of a case (housing)85, which houses a plurality of battery cells. When the battery pack6is mounted on the battery-mount part5, connection terminals (not shown), which are provided inside the mating convex part86, respectively electrically connect to the terminal plates78of the terminal block77, thereby electrically connecting the battery pack6to the controller70, etc. of the power tool1. Forward of the convex mating part86, a lock button87includes the above-mentioned tab88at its upper end and is provided such that the lock button87is biased (spring-loaded) so that the tab88protrudes above the case85. A rear surface89of the tab88is tilted such that it is higher in the front and at an angle the same as that of the tilt of the rear-side inner surface80of the latching recess79. As can be seen inFIGS.1and2, two stoppers90are configured to make contact with the front ends of the rails76of the battery-mount part5and are respectively provided on the upper portion of the case85on the left and right of the lock button87.

In the impact wrench1configured as described above, when the battery pack6is slid rearward from the front of the battery-mount part5, the projections of the convex mating part86are respectively mated between the rails76. In so doing, the rear surface89of the tab88makes contact with the guide surface81, thereby pushing the lock button87, against its bias, into the case85while being guided by the tilted surfaces. Subsequently, after the tab88has passed by a lower surface of the battery-mount part5, the tab88moves upwardly into the latching recess79owing to the spring force applied to it and thereby latches to (in) the latching recess79, and the stoppers90make contact with the front ends of the rails76, thereby stopping the sliding and completing the mount. Simultaneous with the sliding, the terminal plates78of the terminal block77advance into the convex mating part86and electrically connect to the respective connection terminals. In this state, the same as with the rear surface89of the tab88, as shown inFIG.5, the rear portion of the controller70, which is tilted forward and downward in the sliding direction (toward the rear side), and the tab88of the battery pack6overlap one another in the extension direction of the rails76and the terminal block77, which intersect in the up-down direction.

In this state, when the hand, which is grasping the handle3, manipulates the trigger62by pushing it in, the switch61turns ON, and the brushless motor8is driven by the current (power) supplied by the battery pack6. Thereafter, the microcontroller of the control circuit board71acquires the rotational state of the rotor23by obtaining the rotation-detection signals, which are output from the rotation-detection devices of the sensor circuit board27and indicate the positions of the permanent magnets32of the rotor23, controls the ON/OFF state of the switching devices in accordance with the acquired rotational state, and causes the rotor23to rotate by sequentially supplying (flowing) a three-phase current to the coils26of the stator22.

As a result, when the rotary shaft30rotates, the planet gears41A of the carrier part40move with planetary motion about the pinion36and thus the planet gears41B move with planetary motion inside the internal gear44, thereby reducing the rotational speed (while increasing the torque) in two stages. Because the spindle10rotates at a decelerated speed and the hammer50is caused to rotate owing to the balls51,51, the anvil4rotates owing to the engagement with the hammer50, whereby it is possible to fasten a bolt or the like using a socket attached to the anvil4. In addition, when the switch61is turned ON, the control circuit board71turns ON the light64, thereby illuminating the space forward of the socket, and also turns ON the second light75, thereby also illuminating the socket from below.

As the fastening proceeds and the torque on the anvil4increases, the hammer50begins to retract (disengage), against the bias of the coil spring52, while the balls51roll rearward along the cam grooves54. When the tabs of the hammer50separate from the arms53of the anvil4, the hammer50advances, owing to the bias of the coil spring52, while rotating. As a result, the tabs are caused to strike against (intermittently engage with) the arms53, such that a rotational-impact force (impacts) is generated by the anvil4and further tightening can be performed at a higher impact force (torque).

Thus, the impact wrench1according to the above-described embodiment comprises, e.g., the brushless motor8(motor) and the motor housing7, which houses the brushless motor8. In addition, the impact wrench1comprises: the anvil4(which preferably includes a tool-accessory retaining part), which is rotationally driven by the brushless motor8(e.g., via a hammer50) and disposed forward of the brushless motor8; the handle3(grip housing), which is disposed downward of the motor housing7; and the battery-mount part5(battery-holding housing), which is disposed downward of the handle3. In addition, the impact wrench1comprises the battery pack6, which is mounted on the battery-mount part5by being slid thereon; and the controller70for controlling the brushless motor8. Furthermore, the switch panel73is provided downward of the handle3and is tilted such that it is higher in the front. The switch panel73includes one or more manipulatable buttons or switches and one or more display parts.

Owing to this configuration, because the switch panel73is easy to view as well as to manipulate from the rear of the handle3, improved visibility and ease of operation are possible. In addition, because the front end of the switch panel73is the highest, external objects tend not to directly contact the switch panel73. This helps to protect the switch panel73and reduce the likelihood of inappropriate manipulation (e.g., pressing) of the buttons and/or switches on the switch panel73.

In particular, the switch panel73is provided on the battery-mount part5and has an upper surface that is tilted to be higher in the front; the switch panel73is exposed at (on) the upper surface of the battery-mount part5. In this arrangement, the front portion of the battery-mount part5serves to protect or shield the switch panel73.

In addition, the controller70is housed in the battery-mount part5, and the switch panel73is disposed on the upper side of the controller70. Thereby, the distance of the electrical connection(s) between the controller70and the switch panel73can be shorter.

In addition, the controller70is tilted such that it is parallel to the tilted upper surface5cof the battery-mount part5and is higher in the front. As a result, the terminal block77and the battery pack6can be moved upward more than in prior designs, in which the controller70was oriented perpendicular to an extension direction of the handle3(i.e. substantially parallel to the front-rear direction), thereby making it possible to reduce the thickness of the battery-mount part5and to make the entire product more compact in the up-down direction that is perpendicular to the front-rear direction.

In addition, the second light75(light), which illuminates the space forward of the anvil4, is provided along a forward extension of the controller70on the front surface of the battery-mount part5. Thereby, even though the second light75is provided, it can be disposed without it protruding upward beyond the upper surface5cof the battery-mount part5.

In addition, in another configuration, the battery pack6and the controller70overlap one another in the sliding direction of the battery pack6.

In addition, in another configuration, the upper portion of the battery pack6includes the tab88(the outer shape of which is tilted such that it is higher in the front), and the controller70is disposed with a tilted attitude that is higher in the front.

Owing to this configuration, the terminal block77and the battery pack6can be moved upward more than in prior designs, thereby making it possible to reduce the thickness (height) of the battery-mount part5in the up-down direction and to make the entire product more compact in the up-down direction.

In particular, an upper portion of the battery pack6, which is tilted such that it is higher in the front, serves as the tab88, which latches to (with) the battery-mount part5when the battery pack6is mounted on the battery-mount part5. In addition, the controller70and the tab88overlap one another in the sliding direction of the battery pack6(i.e. a line perpendicular to the front-rear direction intersects both the controller70and the tab88). Therefore, an overlap of the controller70and the tab88in the front-rear direction can be achieved easily owing to the tilt of the controller70.

In addition, the terminal block77(tool-side terminal) is held on the lower side of the controller70inside the battery-mount part5and is electrically connectable to the battery pack6. In addition, the controller70and the terminal block77each have a plate shape overall that is relatively thin in the up-down direction. Furthermore, the plate shape of the terminal block77extends in the front-rear direction, which differs from the oblique direction in which the controller70extends. Therefore, even though the controller70is tilted relative to the terminal block77, the battery pack6can be mounted with the same orientation as in the past, while reducing the up-down dimension (height) of the mounted battery pack6in the up-down direction.

Furthermore, the tilted portion of the upper surface5cof the battery-mount part5also extends in a direction that differs from (is oblique relative to) the plate shape direction (front-rear direction) of the terminal block77. Therefore, the battery pack6can still be mounted on the lower side of the battery-mount part5with the same orientation as in the past while ensuring sufficient space within the battery-mount part5for the tilted controller70.

It is noted that the configuration, the tilt angle, and the like of the controller is not limited to the above-mentioned embodiment and it may be, e.g., a standalone control circuit board without the tray. In addition, the controller may overlap with the battery pack at a location other than above the tab. The tool-side terminal also can be modified as needed.

The higher-in-the-front tilt of the battery-holding housing, which comprises the switch panel, is likewise not limited to the embodiment in which it is formed as a plane that is tilted such that it is higher in the front as in the above-mentioned embodiment. For example, it may be tilted such that it is higher in the front and formed as a curved surface that is recessed downward facing, or it may be tilted such that it is higher in the front by providing a stepped part.

In addition, the controller is not limited to being disposed in the battery-holding housing. For example, as shown inFIG.6, the controller70may be housed with a vertically oriented attitude inside the handle3. In this embodiment, the vertically oriented attitude may be parallel to the up, down, left, and right planes as shown inFIG.6, or the vertically oriented attitude may be parallel to the up, down, front, and rear planes.

In the alternative, as shown inFIG.7, the controller70may be disposed inside the motor housing7downward of the brushless motor8with an attitude such that it extends in the front-rear direction.

In another alternative, as shown inFIG.8, the controller70may be disposed inside the motor housing7rearward of the brushless motor8with an attitude such that it is orthogonal to the rotary shaft30.

If the controller70is provided outside of the battery-mount part5, e.g., according to any of the above-mentioned embodiments, then the dimension (height) of the battery-mount part5in the up-down direction can be reduced, which may lead to more compact design overall in the up-down direction.

Furthermore, the controller of the present teachings need not include all of the switching devices, the microcontroller, etc. that are installed on the control circuit board as in the above-described embodiments, as long as the controller includes at least the switching devices.

In addition or in the alternative, the motor does not have to be brushless. In addition or in the alternative, the present teachings are not limited to an impact wrench because the present teachings are also applicable to other types of power tools such as impact drivers, driver-drills, screwdrivers, circular saws, and the like. For example, the battery-holding housing may be directly connected to the motor housing without a handle or the like being interposed therebetween. In addition or in the alternative, if the battery-holding housing is provided on the rear end or the side end of the housing instead of the lower end thereof, the controller and the battery pack preferably still overlap one another in the sliding direction of the battery pack. In this case, it is still possible to achieve a compact design in the direction in which the controller and the tool-side terminal are adjacent to one another.

The inclination of the plate-shaped controller70relative to the sliding direction of the battery pack6is preferably in the range of 5-30°, more preferably 5-20°, even more preferably 8-15°, such as about 10°. The inclination of the upper surface5cof the battery-mount part5relative to the sliding direction of the battery pack6is preferably in the range of 5-30°, more preferably 5-20°, even more preferably 8-15°, such as about 10°. The sliding direction of the battery pack6may be defined, e.g., by the extension direction of the rails76. The inclination angle of the plate-shaped controller70may be determined based upon a plane defined by the control circuit board71, on which the switching devices, microprocessor, etc. are mounted. For example, the plane defined by the control circuit board71and a plane defined by the rails76preferably intersect rearward of the power tool1, i.e. on the side of the power tool1that is opposite of the tool-accessory mounting part60.

Additional aspects of the present teachings include, but are not limited to:

a motor (8);

a motor housing (7), which houses the motor (8);

a battery-holding housing (5), which is connected to the motor housing (7);

a battery pack (6), which is mounted on the battery-holding housing (5) by being slid relative to the battery-holding housing (5) in a sliding direction; and

a controller (70) for controlling the motor, the controller (70) being housed in the battery-holding housing (5);

wherein the battery pack (6) and the controller (70) overlap one another in the sliding direction of the battery pack (6).

a motor (8);

a tool-accessory retaining part (4), which is rotationally driven by the motor (8) and extends forward of the motor (8) in a front-rear direction of the rotary tool (1);

a motor housing (7), which houses the motor (8);

a grip housing (3), which is disposed downward of the motor housing (7);

a battery-holding housing (5), which is disposed downward of the grip housing (3);

a battery pack (6), which is mounted on the battery-holding housing (5) by being slid relative to the battery-holding housing (5) in the front-rear direction;

a controller (70) for controlling the motor (8), the controller (70) being housed in the battery-holding housing (5);

an upper portion (88) of the battery pack (6) has an outer shape that includes a first tilt angle relative to the front-rear direction such that the first tilt angle extends upwardly toward the front in the front-rear direction; and

the controller (70) is tilted relative to the front-rear direction at a second tilt angle such that a front side of the controller (70) in the front-rear direction is higher than a rear side of the controller (70) in the front-rear direction.

3. The rotary tool (1) according to the above embodiment2, wherein:

the upper portion (88) of the battery pack (6) includes a tab (88) configured to latch with the battery-holding housing (5) in the state in which the battery pack (6) is mounted on the battery-holding housing (5); and

the controller (70) and the tab (88) overlap one another in a sliding direction of the battery pack (6) relative to the battery-holding housing (5).

4. The rotary tool (1) according to the above embodiment2or3, further comprising:

a tool-side terminal (77), which is held on a lower side of the controller (70) inside the battery-holding housing (5) and is electrically connectable to the battery pack (6);

wherein the controller (70) and the tool-side terminal (77) each have a plate shape that is thinner in an up-down direction than in the front-rear direction; and

the plate shape of the tool-side terminal (77) is oblique to the plate shape of the controller (70).

5. The rotary tool (1) according to the above embodiment2or3, further comprising:

a tool-side terminal (77), which is held on a lower side of the controller (70) inside the battery-holding housing (5) and is electrically connectable to the battery pack (6);

wherein the tool-side terminal (77) has a plate shape that is thinner in the up-down direction than in the front-rear direction, and

at least a portion of an upper surface (5c) the battery-holding housing (5) is oblique to the plate shape of the tool-side terminal (77).

6. The rotary tool (1) according to any one of the above embodiments2-5, further comprising:

a switch panel (73) disposed on the battery-holding housing (5),

wherein the switch panel (73) includes one or more manipulatable buttons (73c) for manually inputting instructions to the controller (70); and

an upper surface of the switch panel (73) is parallel to the controller (70), in particular to the plate shape of the controller (70).

a motor (8);

a motor housing (7), which houses the motor (8);

a tool-accessory retaining part (4), which is rotationally driven by the motor (8) and extends forward of the motor (8) in a front-rear direction of the rotary tool (1);

a grip housing (3), which is disposed downward of the motor housing (7);

a battery-holding housing (5), which is disposed downward of the grip housing (3);

a battery pack (6), which is mounted on the battery-holding housing (5) by being slid relative to the battery-holding housing (5) in the front-rear direction;

a controller (70) for controlling the motor; and

a switch panel (73) disposed downward of the grip housing (3) in a tilted manner relative to the front-rear direction such that the switch panel (73) is higher in the front, wherein the switch panel (73) includes one or more manipulatable buttons (73c) for manually inputting instructions to the controller (70).

8. The power tool (1) according to the above embodiment7, wherein:

the switch panel (73) is provided on the battery-holding housing (5), and is exposed on an upper surface (5c) of the battery-holding housing (5); and

the upper surface (5c) of battery-holding housing (5) is tilted relative to the front-rear direction such that the upper surface (5c) is higher in the front.

9. The power tool (1) according to the above embodiment8, wherein the controller (70) is housed in the battery-holding housing (5), and the switch panel (73) is disposed on an upper side of the controller (70).

10. The power tool (1) according to the above embodiment9, wherein the controller (70) is tilted relative to the front-rear direction to be higher in the front such that the controller (70) is parallel to the upper surface (5c) of the battery-holding housing (5).

11. The power tool (1) according to the above embodiment9or10, further comprising a light (65) for illuminating the space forward of the tool-accessory retaining part (4), the light (65) being provided along a forward extension of the controller (70) on a front surface of the battery-holding housing (5).

12. The power tool (1) according to the above embodiment7or8, wherein the controller (70) is housed in the grip housing (3).

13. The power tool (1) according to the above embodiment7or8, wherein the controller (70) is housed in the motor housing (7).

14. The power tool (1) according to the above embodiment13, wherein the controller (70) is housed downward of the motor (8) with an attitude that extends in the front-rear direction.

15. The power tool (1) according to the above embodiment13, wherein the motor (8) is disposed such that its rotary shaft (30) is oriented in the front-rear direction, and the controller (70) is housed rearward of the motor (8) with an attitude that is orthogonal to the rotary shaft (30).

16. The power tool (1) according to any one of the above embodiments7-15, wherein the controller (70) includes a control circuit board (71) on which at least a switching device is installed.

17. The power tool (1) according to any preceding embodiment, wherein the controller (70) is plate-shaped and the plate shape of the controller (70) is inclined relative to the front-rear direction, and/or relative to the sliding direction of the battery pack (6) with respect to the battery-holding housing (5), by an angle of 5-30°, more preferably 5-20°, even more preferably 8-15°, such as about 10°.

EXPLANATION OF THE REFERENCE NUMBERS

71Control circuit board

80Rear-side inner surface