Ratchet load binder with removable lever

A ratchet assembly for a load binder includes a pawl bearing assembly biased between a surface of the pawl and a biased movable element whose movement is actuated by the insertion or withdrawal of the lever. In one position of the movable element, the bearing assembly is urged against the pawl to lock it. In the other position of the movable element, the bearing assembly is allowed to reduce its pressure on the pawl.

FIELD OF THE INVENTION

This invention relates to load binder ratchet systems. In particular, this invention relates to load binder ratchet systems with removable levers.

BACKGROUND OF THE INVENTION

A load binder is typically associated with a ratchet system for tightening the binding on the load. Where large loads are involved and the ratchet is operated manually, a lever is often used. It is known to provide removable levers that allow the remaining ratchet system to keep a lower profile to the load than if the lever were still attached. An example of a removable lever is disclosed in U.S. Pat. No. 4,510,651 to Prete Jr. et al. A number of ratchet systems with removable levers are available in the marketplace.

The load binders for large, tightly bound loads can be dangerous. Should the tension on the load binder be suddenly released, the backlash can easily injure or kill an operator or a person attempting to steal the load. Such a risk is minimized using a sleeve the interior of which is threaded in opposite senses at each end of the sleeve as exemplified in U.S. Pat. No. 2,673,632 to Stiranka, U.S. Pat. No. 7,552,913 to Amoss et al. and U.S. Pat. No. 7,055,804 to Scott. Turning the sleeve either draws or extends the threaded eyelets at each end towards or away from each other. Such a threaded sleeve can effectively not be turned accidentally.

When a load has been tightened and the lever is to be removed, the pawl is usually left in its last position wherein the tension on the lines and on the gear will hold the pawl in place, thereby providing a slight locking effect on the pawl. However such effect is fairly small and can be sometimes be overcome by manipulation of the pawl into the neutral or release positions. As a result, the load binder or even the load may be subject to theft. In some cases, operators install a padlock on the ratchet system to prevent tampering with the load binder as can be seen in U.S. Pat. No. 7,055,804 to Scott. As might be appreciated, the use of a padlock can be cumbersome.

It is an object of this invention to provide a ratchet system for accommodating a removable lever that is easy to use, provides a locking effect on the pawl and avoids the need to use a padlock.

Those and other objects of the invention will be better understood by reference to the detailed description of the preferred embodiment which follows.

SUMMARY OF THE INVENTION

According to the invention, the ratchet includes a pawl locking assembly that is engaged by the removal of lever from the ratchet.

More specifically, the pawl locking assembly comprises a pawl bearing assembly biased between a surface of the pawl and a biased movable element whose movement is actuated by the insertion or withdrawal of the lever. In one position of the movable element, the bearing assembly is urged against the pawl. In another position of the movable element, the bearing assembly is allowed to reduce its pressure on the pawl.

The movable element may comprise a varying shape along its contact surface with the bearing assembly such that the pressure exerted on the bearing assembly, and therefore on the pawl, varies according to the position of the movable element.

According to the preferred embodiment, the movable element is elongated and translates axially along a bore and against a spring bias when the lever is inserted onto the ratchet. In its fully inserted position, the movable element urges the bearing assembly against the pawl. In its extended position, the movable element allows the bearing assembly to reduce its pressure on the pawl.

The foregoing embodiment admits of a movable element whose end presses axially on the bearing assembly with more or less force depending on the axial position of the element. However, in the preferred embodiment, the movable element moves axially but the bearing assembly abuts the side of the movable element. According to that embodiment, one portion of the movable element (a contact surface that abuts the bearing assembly) is radially farther from the longitudinal axis of the movable element than another portion of the contact surface, with a section between the two portions having a graduating radial distance. Movement of the element axially thereby exerts greater or less pressure on the radially-abutting bearing assembly, which in turn exerts greater or less pressure on the pawl.

Preferably the bearing assembly is biased (for example by means of a spring) to extend components of the bearing assembly away from one another to release pressure on the pawl in the extended configuration. In the compressed configuration (caused by abutment with the relatively larger contact surface of the movable element), the bearing assembly will exert relatively more force against the pawl.

Preferably, the movable element is biased (for example by means of a spring) to an extended position in which the pressure on the bearing assembly is maximized.

One aspect of the invention comprises a ratchet assembly. The assembly has a housing, a gear, teeth on the gear and a pawl rotatably mounted for reciprocating engagement between the teeth. A lever is adapted for selective connection to or removal from the housing. A pawl bearing assembly extends between a surface of the pawl and a biased movable element whose movement is actuated by the connection or removal of the lever from the housing.

In a more particular aspect of the invention, the pawl bearing assembly is biased toward exerting a bearing pressure on the surface of the pawl.

In a further aspect, the movable element has an extended position in which a portion thereof extends outside the housing and an inserted position in which the portion is in the housing. The bearing pressure of the bearing assembly on the surface of the pawl is greater when the movable element is in the extended position than when it is in the inserted position.

In a further aspect of the invention, the housing is provided with a shaped portion for removably receiving the lever. The movable element has an extended position in which a portion thereof extends outside the housing and an inserted position in which the portion is in the housing. The connection of the lever to the shaped portion causes the insertion of the otherwise protruding portion of the movable element into the housing.

In a further aspect, the movable element has at least two positions in relation to the housing and a contact surface in engagement with the bearing assembly. The contact surface varies axially along a length of the movable element such that a pressure exerted by the movable element on the bearing assembly, and therefore on the pawl, varies according to the position of the movable element.

In yet another aspect, the invention comprises a ratchet assembly in which the movable element is elongated and has a contact surface in engagement with the bearing assembly. The contact surface varies axially along a length of the movable element such that a pressure exerted by the movable element on the bearing assembly, and therefore on the pawl, varies according to whether the movable element is in an extended or in an inserted position. The movable element is translated axially along a bore in the housing to the inserted position when the lever is connected to the housing.

In the extended position of the movable element, a first portion of the contact surface abuts the bearing assembly. In the inserted position, a second portion of the contact surface abuts the bearing assembly. The second portion of the contact surface is closer to a longitudinal axis of the movable element than the first portion.

Preferably, the bearing assembly comprises two components that are spring biased to extend away from one another.

In yet another aspect, the invention comprises a ratchet assembly comprising a housing, a gear, gear teeth and a pawl rotatably mounted for reciprocating engagement between the gear teeth. A pawl bearing assembly extends between a surface of the pawl and a biased movable element whose movement is actuated by the connection or removal of a lever from the housing. The pawl bearing assembly is biased toward exerting a bearing pressure on the surface of the pawl. The movable element has a first position in relation to the housing in which a contact surface of the movable element abuts the pawl bearing assembly at a first radial distance from a longitudinal axis of the movable element, and a second position in relation to the housing in which the contact surface abuts the pawl bearing assembly at a second radial distance from the longitudinal axis whereby to exert less pressure against the bearing assembly than in the first position. The first position of the movable element is actuated by removal of the lever from the housing thereby causing greater bearing pressure on the bearing assembly and thus on the pawl thereby restraining it against movement. The second position of the movable element is actuated by connection of the lever to the housing thereby causing a reduction in bearing pressure on the bearing assembly and thereby releasing the pawl for reciprocation and movement about the gear teeth.

The foregoing was intended as a summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiments. Moreover, this summary should be read as though the claims were incorporated herein as it is the intention that the claims also inform and be part of the present description.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring first toFIGS. 1,2,3and4, the ratchet assembly according to the preferred embodiment of the invention is generally designated by the numeral10. The principal components of the ratchet are the gear12, the gear teeth14, the pawl16and the housing18. A removable lever20is used to engage the ratchet assembly10and to crank the gear. Lever20may selectively be connected to or removed from housing18as will be described below.

Gear12is secured around a sleeve22. As seen inFIG. 2, the interior of sleeve22is threaded in opposite senses at each end of sleeve22. Threaded eyelets24(FIG. 3) are sized to thread into each end of the sleeve22. As is well known, turning sleeve22in one direction will draw the two eyelets24toward one another thereby tightening a chain or strap attached to the eyelets and around a load, while turning it in the opposite direction will have the opposite effect.

Housing18houses gear12and includes opposed apertures28(only one being visible inFIG. 7) that are co-axial with gear12. Apertures28accommodate the fitting of the housing18about sleeve22.

Referring now toFIGS. 1 and 4, pawl16is retained in housing18about a pawl shaft35mounted into opposed side walls34,36of the housing. Pawl16is rotatable about shaft35. Pawl16has two catches38,40at opposed ends of the engagement surface42of the pawl to engage the gaps44between the gear teeth14. As is well known, in normal operation of the ratchet, pawl16reciprocates about shaft35such that one of the two catches38,40intermittently engages between the gear teeth14.

An abutment surface41of the pawl16, generally opposed to engagement surface42, comprises a central detent48used to set the pawl in a neutral position in relation to gear12when detent48is aligned with shaft35and gear axis49, gear axis49being indicated inFIG. 6. At either side of detent48, surface41comprises opposed surfaces43,45. When either of opposed surfaces43or45is aligned with shaft35and gear axis49, the pawl is configured for a particular rotative direction of the gear12. InFIG. 4, surface43is aligned with shaft35and gear axis49allowing gear12to turn in the clockwise direction for the view ofFIG. 4. As it turns, catch38of pawl16rides up the advancing tooth. As it does, pawl16seeks to rotate about shaft35constrained only by the bias provided by spring80in pawl bearing assembly56(seeFIG. 14for a better view of spring80). The pawl bearing assembly56is configured such that the spring80that forms a part of the assembly has a correct amount of bias to allow the assembly to yield to the rotation of the pawl16when the latter rides over a tooth, and to bias the pawl to rotate back into the next adjacent tooth gap44when the catch of the pawl has passed over the advancing tooth. It will be appreciated that when the pawl is in a selected rotative position, the angle of the catch in relation to the teeth14and the gaps44is such as to not allow the gear teeth14to ride over the catch in the opposite direction, as is generally understood in the art.

As generally seen inFIGS. 1,5,7and13, housing18includes a laterally extending square shaped stub50sized to be received into a square socket52at the end of lever20. A bore54extends axially of the stub50through the housing18. Bore54is offset from the pawl16in the housing18to allow for the interposition of a bearing assembly56between the bore54and the pawl16. A cap58closes the end60of bore54that is distal from the stub50as seen inFIG. 13.

Still referring toFIG. 13, an elongated binder pin62extends along bore54for axial movement along bore54and terminates at a spring64that is stopped against cap58. The spring64biases pin62to an extended position at which one end66of pin62protrudes out from stub50.

Referring toFIGS. 10 and 13, pin62comprises a contact surface65that abuts the bearing assembly56. Contact surface65has a first portion68that is radially closer to the longitudinal axis67of the pin62than second portion70. Portions68and70are separated by a beveled intersection72. Pin62is effectively wider at portion70than at portion68.

Bearing assembly56is housed in a bore74(FIG. 6) extending radially from bore54and from pin62housed therein. Referring toFIG. 14, bearing assembly56comprises a first element76and a second element78, each having cavities opening toward the other element. A spring80biases elements76and78away from one another. Such a bias urges the bearing assembly (via element76) to exert a bearing pressure against the abutment surface41of the pawl when the bearing assembly is otherwise constrained on its pin side.

When lever20is not installed over stub50as shown inFIG. 11, pin62is at rest with end66extending out of housing18due to the bias provided by spring64. The length of pin62is selected such that in this position, the wider section70of pin62is aligned with the bearing assembly56thereby compressing assembly56which in turn bears against surface41of pawl16. The bias provided by spring is80in conjunction with the overall dimensions of the bearing assembly56are selected such that the pressure from the bearing assembly56bearing on the surface41of pawl16effectively locks pawl16against displacement when the pin62is in this extended position.

When lever20is secured over stub50as inFIG. 12, end66of pin62is pressed inward and translates pin62axially against the bias of spring64to an inserted position in relation to the housing18. The displacement of pin62moves the wider portion70of pin62away from bearing assembly56which then abuts the narrower portion68of pin62. This position provides room for the extension of elements76and78(elements of the bearing assembly56) away from one another, relieving the bias of spring80and reducing the bearing pressure of bearing assembly56on pawl16. This allows pawl16to assume a normal mode of operation wherein the pawl can reciprocate over the gear teeth14and can be adjusted to various operational positions. In this inserted position of pin62, bearing assembly56still exerts sufficient pressure on surface41to retain the pawl16in either rotative direction or in the neutral position, depending on whether the bearing assembly abuts surfaces43or45or detent48of the abutment surface41of the pawl16.

It will be appreciated that the invention provides for a ratchet load binder that automatically locks the pawl when a reversible lever is removed. The same mechanism operates as a pawl mode setting mechanism (either rotative direction or neutral) during normal operation of the ratchet.

In the foregoing specification, the invention has been described with reference to specific embodiments thereof. However, the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. The is specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.