Backpack style power-pack with flexible drive and quick connect power take-off for connection to a variety of powered tools

The present invention relates to portable powered devices or tools for residential, commercial, or industrial applications, in which the power source may be carried on the back of the individual user, power is transferred via a flexible drive shaft, and the powered devices or tools may be quickly connected to or disconnected from the power source via a quick-connect power take-off and power take-on to allow the user to quickly, safely and ergonomically accomplish a variety of tasks, each requiring a different device or tool. Among residential, commercial, or industrial applications, the invention relates to power sources which are light-weight internal combustion engines or AC or DC powered electric motors and to portable powered tools for landscaping, maintenance and repair; such as, without limitation, string-trimmers, edge-trimmers, hedge cutters, brush saws, blowers, drills, buffers, grinders, sanders, drainer cleaners, or sump pumps.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

Not applicable.

REFERENCE TO A “SEQUENCE LISTING”

Not applicable.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to portable powered devices or tools for residential, commercial, or industrial applications, which may be quickly connected to or disconnected from the power source to allow the user to safely and ergonomically accomplish a variety of tasks, each requiring a different device or tool. In residential applications, the invention relates to portable powered devices for landscaping and home maintenance or repair; such as, without limitation, string-trimmers, edge-trimmers, hedge cutters, blowers, or paint spraying. In commercial settings, the invention relates to portable powered tools for, without limitation, spraying, painting, buffing, sanding, or stripping. In the industrial arena, the invention relates to portable powered tools used for, without limitation, sawing, drilling, grinding, nailing, sanding, or pumping.

More specifically, this invention relates to the field of small internal combustion (“IC”) engine-driven and alternating current (“AC”) or direct current (“DC”) powered electric motor-driven power-packs which may be connected to a variety of power driven tools. The invention further relates to the field of small engine and motor driven power packs which are light enough to be mounted on a backpack frame, outfitted with suitable straps, which allows a user to comfortably carry the powered assembly on the back.

The invention still further relates to the field of small engine and motor driven power packs where the drive shaft of the engine or motor is connected firmly to a rotating flexible drive shaft which is housed within a non-rotating sleeve. The rotating flexible drive shaft is of suitable strength to match the rotational speed, power, and torque of the power unit. The length of the flexible drive shaft and outer sleeve are selected to allow the power from the backpack power unit to be transferred at about waist high and arm's length to the front of the user.

The invention further relates to those powered devices where the end of the rotating flexible drive shaft and outer sleeve opposite the engine or motor connection point terminates at a throttle control arm. The throttle control arm is a light weight tube of suitable material of construction which houses an inner rotating drive shaft.

The invention still further relates to those devices where an engine or motor throttle control arm has mounted on it; a handle, which may be set in a variety of angular positions relative to the line along the length of the control arm, and on-off switch and speed controls for the engine or motor.

The invention further relates to those powered devices where an inner rotating drive shaft extends slightly beyond the end of the tube housing the drive shaft. The outer tube and inner rotating drive shaft terminate at a quick-connect power take off of suitable strength to match the rotational speed, power, and torque of the power unit. The quick-connect power take off allows a user to quickly and safely connect or disconnect to the drive shaft, extending from the throttle control arm, any variety of power tools which have been previously outfitted with a mating quick-connect power take on.

This invention further relates to powered tools which may be outfitted with a quick-connect power take on designed to mate with the quick-connect power take off at the end of a throttle control arm. The powered tools are those tools which may be used for any number of residential, commercial, or industrial applications.

There is a need for a small engine or motor driven power pack; which may be worn on the back of a user, which is connected to a flexible drive shaft allowing the power of the engine or motor to be transferred to the front of the user, and which may be quickly and safely quick-connected to a variety of powered tools. The light weight of the power unit, combined with flexible drive, and quick-connection of power tools allows a user to safely, efficiently, and ergonomically accomplish a wide variety of tasks which require one or more power tools. The present invention satisfies these industry needs, among other demands.

Backpack engine-driven power units and power driven tools are common in the marketplace. Flexible drive shafts with a wide range of length, angular and lateral motion, and speed, power, and torque capability are also well-known. Quick-connect power take-offs have been in existence for many years. A preliminary search by applicants revealed that these individual units are described in a number of patents and patent applications (U.S. Pat. Nos. 4,490,910; 4,823,464; 4,860,451; 5,713,191; 5,979,064; 6,415,585; 6,862,958; 6,895,735; U.S. Pat. Appl. Nos. 20020007559; 20020104896; 20020116825; 20030140884; and 20030221400). However, none of these patents or applications, either alone or in any combination thereof, anticipate the present invention or its various embodiments, nor render the same obvious to one of ordinary skill in this field of endeavor.

Consequently, there is a need for a small engine or motor driven power pack which may be worn on the back of the user and which may be quickly and safely quick-connected to a variety of powered tools via a flexible drive. The light weight of the power unit, combined with a flexible drive shaft, and quick-connection of power tools allows the user to safely, efficiently, and ergonomically accomplish a wide variety of tasks which require one or more power tools. The present invention provides these features and other advancements compared to the prior art.

BRIEF SUMMARY OF THE INVENTION

The present invention is a small IC engine or AC or DC powered electric motor mounted on a backpack which may be worn on the back of an individual user. The engine or motor drive shaft is connected to a flexible drive shaft, housed within a non-rotating sleeve, long enough to be routed from behind to the front of the person wearing the backpack. The free end of the flexible drive shaft is further connected to a throttle control arm—a hollow tube of suitable material of construction which houses a rotating drive shaft.

The throttle control arm has attached to its outer surface an adjustable handle to facilitate the user's positioning of a connected power tool relative to a particular point in space, such as the ground, or an object of work. The outer surface of the throttle control arm has further attached to it an on-off switch and speed control for the engine or motor. The end of the throttle control bar is outfitted with a quick-connect power take off. The quick-connect power take off is designed to permit a variety of power tools, with matching quick-connect power take on, to be connected to the end of the throttle control bar.

The quick-connect power take off attached to the end of the throttle control bar consists of one or more strong connection points around its outer surface. These connection points are designed to mate with the same number of strong points around the outer surface of a quick-connect power take on attached to the end of the powered tool. The quick-connect power take off is designed so that the rotating drive shaft extends sufficiently to allow a power take on to connect with it. This is but one example of a quick-connect power take off and power take on. Other such devices for the quick connection and transfer of power are known to those skills in such arts and would fall within the description here and claims.

The IC engine may be fueled by any appropriate combustible fluid; including, without limitation, alcohol, diesel fuel, gasoline, natural gas, or propane. The engine may be of 2-cycle or 4-cycle design. The electric motor may be powered by a standard AC power cord of sufficient electrical power carrying capability to match the size of the motor. The motor may also be powered by a battery pack of suitable electrical capacity mounted on or adjacent to the backpack. The motor may also be powered by more exotic electrical power sources, including, and without limitation, a fuel-cell or solar panels.

Depending on the power driven tool selected to be used, the user quick-connects the power take on attached to the tool to the power take off on the end of the throttle control bar. After ensuring that the connection is securely fastened, the user adjusts the handle on the throttle control bar based on the type of connected tool and the position of the object of work. The user selects the on position on the on-off switch mounted on the throttle control bar. The user then starts the engine; the electric motor being energized by selecting on. The engine or motor may be outfitted with a centrifugal clutch, well known to those skills in such arts, which allows the engine or motor to run at an idle speed without transferring power to the flexible drive shaft before work is to begin.

When the user is ready to use the power tool for its intended purpose, he activates the engine or motor speed control, thereby increasing its rotational speed. The increasing rotational speed causes power to be transferred to the connected power tool, through the flexible drive shaft and the drive shafts within the throttle control arm and powered tool handle.

The various power tools which may be connected to the quick-connect power take off may comprise; without limitation, string-trimmer, edge-trimmer, branch cutter, brush cutter, wood, metal, or masonry power saw, drills of all diameters and sizes, power ratchet, nail gun, grinder, sander, liquid or powder sprayer, paint roller, pump, blower, floor machines for stripping, sanding, or buffing, or a plumbing snake.

Once the work is completed with the particular connected power tool, the engine or motor may be switched off. After the power unit is switched off, the user may disengage the quick-connect power take on from the quick-connect power take on on the tool. The user may then quick-connect another tool to the quick-connect power take on and begin work again with a different tool.

DETAILED DESCRIPTION OF THE INVENTION

Throughout the specification, certain terms and phrases are defined by the inventors.

“Power take off” means the quick-connect power connection point on the end of the throttle control arm.

“Power take on” means the quick-connect power connection mounted on the drive shaft of the power tool.

“Quick-connect” or “quick-connection” refers to the link between the power take off at the end of throttle control arm and the power take on attached to the power tool.

“Flex-drive backpack” refers to the preferred embodiment of the invention and any modifications thereof; specifically, a backpack style power pack with flexible drive and quick-connect power take off for connection to a variety of powered tools.

(1) Detailed Description of the Preferred Embodiment

The invention described here represents the preferred embodiment. Additional embodiments are also described which depict the invention with other combinations of power supply units and connected power tools.

The flex-drive backpack20shown inFIG. 1comprises, a gasoline-powered engine22mounted on backpack frame24, with straps26, carried on the back of user28, with flexible drive assembly30, throttle control arm32, with adjustable handle34, on-off switch48, and speed control36, connected to a string-trimmer head38, the powered tool in the preferred embodiment. On-off control and speed of engine22are controlled by on-off switch48and speed control36, respectively, through wire50.

Quick-connect power take off40is attached to the end of throttle control arm32. Quick-connect power take on42is attached to the end of shaft44, which transfers power from item42to string-trimmer head38. Quick-connect power take off40and power take on42are secured by knob46.

Referring toFIGS. 3 and 4, flexible drive assembly30comprises rotating flexible drive shaft52, which rotates inside flexible, but stationary, sleeve54. The construction of flexible drive assembly30is well known to those skilled in those arts.

Drive shaft assembly56of engine22comprises engine drive shaft58, which rotates inside housing60. Outer sleeve66of flexible drive assembly30is mounted permanently around the outer surface of housing60. Outer sleeve66is secured to housing60using a plurality of set screws68.

Engine drive shaft58is machined at position62to permit connection to end plug64of flexible drive shaft52to allow transfer of power from engine drive shaft58to end plug64without slippage.

The connection between flexible drive assembly30and throttle control arm32is depicted inFIG. 5. Flexible drive assembly30is connected to throttle control arm32via threaded coupling70. The end of flexible drive assembly30is connected to the end of threaded coupling70at point72. Throttle control arm32is connected to the opposite end of threaded coupling70at point74. End plug76is connected tightly to flexible drive shaft52. Item76is machined to fit inside the expanded end80of shaft78. Item76is secured to shaft78by a plurality of set screws68. The connection between flexible drive shaft52and shaft78is made to permit the transfer of rotational power from52to78without slippage. Shaft78rotates freely inside throttle control arm32.

The connection between throttle control arm32and shaft44of a typical power tool is show inFIG. 6. Quick-connect power take off40comprises shaft78with end bell82. Shaft78rotates within bearing90, which minimizes the radial movement of78while in operation.

Shaft78and end bell82are co-machined at position84so that82may be fitted tightly onto shaft78. Items78and82are secured by a plurality of set screws68which allow the rotational power of shaft78to be transmitted to end bell82without slippage. Item82and shaft88are also co-machined at position86so that shaft88may easily seek a proper fit in82while at the same time creating a connection at point86which transmits rotational power from82to88without slippage.

Shaft88rotates within bearing92, which minimizes radial movement of88during operation. Shaft88has a lateral movement stop94secured to by a plurality of set screws68. Item94prevents the lateral movement of shaft88away from end bell82. Item94is constructed of a material which can rotate with minimal friction against Item92.

Shaft88is expanded at point96to accept shaft98. Shaft98rotates within tube44and transmit rotational energy to the power tool. Shaft88is secured to shaft98by a plurality of set screws68so that rotational power of88may be transferred to98without slippage.

As depicted inFIG. 6, the outside diameter of throttle control arm32and tube44are approximately the same. Item32is fitted with collar100for a portion of its length. Collar100is joined to the outside surface of throttle control arm32at position106. Collar100extends beyond the end of throttle control arm32sufficiently to support tube44when it is inserted into collar100.

As further shown inFIG. 6, tube44and collar100are through drilled at position102. The inside of tube44is fitted with spring loaded positioner104. The assembly of throttle control arm32with attached collar100, and end bell82connected to shaft78forms quick-connect power take off40. Tube44, fitted with shaft88and spring loaded positioner104form quick-connect power take on42.

The quick-connection between quick-connect power take on40and quick-connect power take off42is formed by; first loosening knob46, then inserting tube44into position within collar100while allowing shaft88is properly fit into end bell82, then rotating44within100until spring loaded positioner104emerges through hole102, and finally hand tightening knob46to secure collar100around shaft44.

FIG. 7Ashows the preferred embodiment in preparation for removal of the string-trimmer powered tool. To remove the string-trimmer tool, knob46is loosened by turning counter-clockwise. This frees collar100.

FIG. 7Bshows the preferred embodiment shortly after knob46has been loosened and tube44has been removed from collar100.

Operation of the preferred and alternate embodiments may be envisioned by referring toFIG. 1. User28prepares flex-drive backpack20for operation by connecting power supply unit106to string trimmer powered tool108at power take off40and power take on42and securing106to108by tightening knob46. The position of handle34is adjusted using positioning assembly110to suit the user's ergonomic preferences and the object of work.

User28switches on-off switch48to the on position and starts engine22by any number of engine starting means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions string trimmer head38adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, power take on42, and tube44, to string trimmer head38.

Flex-drive assembly30allows the user28is move throttle control arm32and string trimmer head38to any desired position relative to the object of work independently of his own position. This feature permits user28to perform his desired task with optimal ergonomic position and least stress on the upper torso, back, and legs.

Referring toFIG. 1, once the work is done, user28switches off engine22by selecting the off position of switch48. User28then loosens straps26and removes backpack frame24.

Further referring toFIG. 7A, if work is intended using a different powered tool, user28loosens knob46by rotating it counter-clockwise. This loosens collar100which unclasps quick-connect power take off40from power take on42.

(2) Detailed Description of the First Alternative Embodiment

The First Alternative Embodiment is depicted inFIG. 8A. If user28desires to trim hedges, he takes hedge trimmer powered tool112in hand and engages quick-connect power take off40and hedge trimmer quick-connect power take on114by sliding tube116into collar100.

As viewed inFIG. 8B, Item112is secured to throttle control arm32by rotating knob46clockwise until collar100is snug against tube116. User28adjusts handle34to an appropriate position to suit operation of powered tool112using handle positioning assembly110.

Referring toFIGS. 1,8A, and8B, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions hedge trimmer cutting bar118adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, power take on114, and tube116, to hedge trimmer cutting bar118.

(3) Detailed Description of the Second Alternative Embodiment

The Second Alternative Embodiment is depicted inFIG. 9. If user28desires to edge trim, he connects edge trimmer powered tool120to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube122to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube122. User28adjusts handle34to an appropriate position to suit operation of powered tool120using handle positioning assembly110.

Referring toFIGS. 1 and 9, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions edge trimmer cutting head124adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube122, to hedge trimmer cutting head124.

(4) Detailed Description of the Third Alternative Embodiment

The Third Alternative Embodiment is depicted inFIG. 10. If user28desires to cut branches with a chain saw, she connects chain saw powered tool126to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube128to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube128. User28adjusts handle34to an appropriate position to suit operation of powered tool126using handle positioning assembly110.

Referring toFIGS. 1 and 10, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions chain saw cutting chain130adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube128, to chain saw cutting chain130.

(5) Detailed Description of the Fourth Alternative Embodiment

The Fourth Alternative Embodiment is depicted inFIG. 11. If user28desires to drill, he connects drill powered tool132to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube134to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube134. User28adjusts handle34to an appropriate position to suit operation of powered tool132using handle positioning assembly110.

Referring toFIGS. 1 and 11, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions drill bit136adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube134, to drill bit136.

(6) Detailed Description of the Fifth Alternative Embodiment

The Fifth Alternative Embodiment is depicted inFIG. 12. If user28desires to grind or sand and object, she connects grinder/sander powered tool138to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube140to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube140. User28adjusts handle34to an appropriate position to suit operation of powered tool138using handle positioning assembly110.

Referring toFIGS. 1 and 12, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions grinding/sanding head142adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube140, to grinding/sanding head142.

(7) Detailed Description of the Sixth Alternative Embodiment

The Sixth Alternative Embodiment is depicted inFIG. 13. If user28desires to unplug a drain pipe, he connects plumbing snake powered tool144to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube146to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube146. User28adjusts handle34to an appropriate position to suit operation of powered tool144using handle positioning assembly110.

Referring toFIGS. 1 and 13, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions plumbing snake coil148adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube146, to plumbing snake coil148.

(8) Detailed Description of the Seventh Alternative Embodiment

The Seventh Alternative Embodiment is depicted inFIG. 14. If user28desires to buff a floor, she connects floor buffer powered tool150to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube152to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube152. User28adjusts handle34to an appropriate position to suit operation of powered tool150using handle positioning assembly110.

Referring toFIGS. 1 and 14, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions buffer pad154adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube152, to buffer pad154.

(9) Detailed Description of the Eighth Alternative Embodiment

The Eighth Alternative Embodiment is depicted inFIG. 15. If user28desires to pump out a sump which contains a pumpable liquid, he connects sump pump powered tool156to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube158to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube158. User28adjusts handle34to an appropriate position to suit operation of powered tool156using handle positioning assembly110.

Referring toFIGS. 1 and 15, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions sump pump160into the liquid to be pumped. User28positions hose162to direct the pumped liquid to the desired location. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube158, to sump pump160.

(10) Detailed Description of the Ninth Alternative Embodiment

The Ninth Alternative Embodiment is depicted inFIG. 16. If user28desires to use the invention as a blower, she connects blower powered tool164to throttle control arm32by rotating knob46counterclockwise enough to loosen collar100to allow tube166to slip inside Item100. Once in position, knob46is rotated clockwise to tighten collar100around tube166. User28adjusts handle34to an appropriate position to suit operation of powered tool164using handle positioning assembly110.

Referring toFIGS. 1 and 16, user28switches on-off switch48to the on position and starts engine22by any number of means well known to those skilled in the art. User28places backpack24over the shoulders and adjusts straps26for comfort. User28grasps throttle control bar32and handle34and positions blower head168adjacent to the desired work area. User28then squeezes speed control36which causes the rotational speed of engine22to increase. The rotational power of item22is transferred through flex drive assembly30, throttle control arm32, power take off40, and tube166, to blower head168.

(11) Detailed Description of the Tenth Alternative Embodiment

The Tenth Alternative Embodiment is depicted inFIG. 2. In this embodiment, the flex-drive backpack20shown inFIGS. 1 and 2comprises, a electric motor170, with battery pack172, mounted on backpack frame24, with straps26, carried on the back of user28, with flexible drive assembly30, throttle control arm32, with adjustable handle34, on-off switch48, and speed control36, connected to a string-trimmer head38, the powered tool in the preferred embodiment. On-off control and speed of motor170are controlled by on-off switch48and speed control36, respectively, through wire50.

(12) The Invention is Not Limited to the Embodiments Described Above

It is to be understood that the flexible drive back pack may be utilized with any number of powered tools and power supply units other than those described above. Accordingly, while only the preferred embodiment of the invention and specific modifications thereto have been described herein in detail, the invention is not limited thereby, and other modifications can be made within the scope of the attached claims.