Chuck key clip and method for manufacturing

Abstract: A chuck key clip 11 has a pair of spaced parallel sidewalls 17, 19 connected by a web 21. A cord receiving channel 23 and a key handle receiving channel 61 are formed by the sidewalls 17, 19 and web 21. The key channel may have an inwardly converging handle clamp 67 and an inwardly converging key shank clamp 71 to securely and detachably retain the key 13 in the clip. For comfort and ease of use, thumb depressions 107, 109 may be formed in the outer surface of sidewalls 17, 19. Web 21 may contain openings 99, 101 opposite to a cord clamping means 27 formed in the cord channel 23. Openings 99, 101 result from the method for molding the clip in a mold movable only in a single direction (i.e. without side movement). The formation of inwardly converging clamps 27, 67 in the parallel cord and key channels 23, 61 in a mold 131 without side movement simplifies the manufacturing process and contributes to the low cost of clip 11.

Description: The present invention relates to a holder for a chuck key and a method for making the holder. The key preferably has a pinion gear for tightening a chuck or alternatively may have a hexagonal cross-sectional configuration. BACKGROUND OF THE INVENTION Chuck keys are used to open and close the jaws of a chuck on a bit for various portable power tools. The key commonly has a pinion gear which fits into a gear of the chuck. Rotation of the key opens and closes the jaws of the chuck and thereby facilitates changing of a bit clamped in the jaws. Numerous means have been used to retain the chuck key associated with the tool. For example, the key may be mounted in a recess in the tool. This has been found to be disadvantageous because of the cost of forming the tool with the recess and because the key may be lost when removed from the recess for use. Secondly, the chuck key may be attached to the power cord of the tool with a strap. Such straps have been found to be disadvantageous because the key may swing freely and interfere with the workpiece or, otherwise, get in the way. Various rigid holders for attaching the key to the power cord are also known. Examples of such holders are shown, for example, in U.S. Patent Nos. 2,257,559, 2,941,426 and 4,274,772. Such holders have been found to be generally disadvantageous for reasons such as complexity in attachment to the cord, inconvenience, high cost and the lack of a suitable retainer which minimizes loss of the key. Accordingly, an important object of this invention is to provide a low cost chuck key holder which is convenient and comfortable to use, which securely retains the key but allows detached use of the key if desired, and which may be manufactured by a simple low cost method. A clip for a chuck key is described in US-A-2 941 426 having a handle and a shank, the clip comprising: a pair of spaced resilient sidewalls; a resilient web connecting the sidewalls; a cord channel for receiving an electric cord, a cord channel extending along a first axis and defined by the sidewalls and the web; and a key channel for receiving the key handle, said key channel extending along a second axis generally parallel to the first axis and formed by the sidewalls and the web; the key channel having a handle clamp for receiving the key handle, and the handle clamp converging inwardly in a plane transverse to said second axis; According to the present invention, we provide a clip for a chuck key having a handle and a shank, the clip comprising: a pair of spaced resilient sidewalls; a resilient web connecting the sidewalls; a cord channel for receiving an electric cord, said cord channel extending along a first axis and defined by the sidewalls and the web; and a key channel for receiving the key handle, said key channel extending along a second axis generally parallel to the first axis and formed by the sidewalls and the web; the key channel having a handle clamp for receiving the key handle, and the handle clamp converging inwardly in a plane transverse to said second axis; characterised in that the key channel has a shank clamp for receiving the key shank, and in that the shank clamp comprises two spaced pairs of jaws, each pair having one jaw on each sidewall and converging inwardly in a plane generally parallel to the second axis. The cord channel may have cord clamping means extending from the sidewalls for gripping the electric cord. Each sidewall may have an inner and outer surface for comfort and ease of use; a thumb depression may be provided in the outer surface of at least one sidewall. Said clamping means may comprise at least one barb extending from at least one sidewall, and preferably the barb has a sharp edge. In one preferred embodiment there is at least one pair of said barbs, a first barb extending from one sidewall and a second barb extending from the other sidewall towards the first barb. The or each barb preferably comprises a wall extending generally perpendicular from the surface of the sidewall. A clip according to the invention may further comprise an opening in the web opposite to said clamping means in a direction generally transverse to the first and second axes. In the clip of the invention, the web and sidewalls are generally "H"-shaped in section. The invention thus provides an apparatus comprising: a chuck key comprising; a handle; a shank fixed at one end to and extending generally transverse from the handle; a pinion formed at the distal end of the shank; and a clip as claimed hereinbefore. The present invention also provides a method for moulding a chuck key clip having a pair of sidewalls connected by a web, first and second parallel channels defined, respectively, by the sidewalls and opposed sides of the web and extending in a first direction, said method being characterised in that it comprises the steps of: a. moulding the clip in a mould having a cavity segment and a core segment, said segments being relatively movable back and forth in a second direction between an open position and a closed position, the second direction being generally transverse to the first direction; b. forming a first clamp having barbs projecting from the inner side of the sidewalls of the first channel and converging inwardly in a third direction generally perpendicular to the first and second directions, by means of a core bar extending through the second channel, through an opening in the web and into the first channel; and c. forming, on the inner sides of the sidewalls of the second channel, a second clamp inwardly converging in the third direction, by means of a core ejector extending parallel to the second direction. Preferably, the method of the invention further comprises the steps of: d. opening the mould by a relative movement of the cavity segment and core segment in the second direction to separate the cavity segment from the clip and core segment; and e. ejecting the clip from a base portion of the core segment by relative movement of the ejector and base portion in the second direction. The method of the invention may further comprise the steps of: f/1. separating the clip from the ejector by moving an ejector pin relative to the ejector in the second direction to eject the clip from the ejector, and/or f/2. removing the core bar from the first clamp in the first channel simultaneously with step e, and/or f/3. removing the core bar from the first clamp in the first channel subsequent to step e. In order that the invention be better understood, a number of embodiments will now be described in greater detail by way of example and with reference to the accompanying drawings in which: Figure 1 is a perspective view of a clip, in accordance with the present invention, containing a chuck key and attached to a power cord; Figure 2 is a cross-sectional view of the clip in Figure 1 exposing the cord and chuck key; Figure 3 is a cross-sectional view taken along line 3-3 of FIG. 2. FIG. 4 is a side-elevational view of the clip of the present invention taken along lines 4-4 of FIG. 5. FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4. FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 4. FIG. 7 is a side-elevational view taken along line 7-7 of FIG. 5. FIG. 8A and 8B are fragmentary cross-sectional views of alternate embodiments of cord clamps for a clip in accordance with the present invention. The cross-sections are taken along a plane transverse to the clip channels. FIG. 9 is an elevational view illustrating the manner of use of the clip and chuck key of the present invention. FIG. 10A-10B depict schematically, in sequence, the preferred embodiment of a method for molding a chuck key in accordance with another aspect of the present invention. FIG. 10B is a cross-sectional diagram taken along lines 10B-10B of FIG. 10A illustrating a clip in the mold for practicing the method of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred embodiment of a chuck key clip 11 for attaching a chuck key 13 to an electric power cord 15 is shown in FIGS. 1-7. FIGS. 1-3 show clip 11 with key 13 mounted in clip 11 and attached to power cord 15 with clip 11. FIG. 3-7 depict clip 11 with key 13 and cord 15 removed. FIG. 8A, 8B show alternate embodiments of cord clamps for clip 11. FIG. 9 depicts the preferred method for holding clip 11 and key 13 to tighten a drill chuck (not shown). FIGS. 10A-10E depict, in sequence, the preferred embodiment of a method for molding clip 11 in accordance with another aspect of the invention herein. In accordance with the invention, as depicted in FIGS. 1-7, key 11 comprises a pair of spaced resilient sidewalls 17, 19 and a resilient web 21 connecting sidewalls 17, 19 to form, as shown in FIG. 3, 5, a generally "H"-shaped body. Preferably sidewalls 17, 19 and web 21 are molded in one piece of type 6 nylon. A cord channel 23 for receiving electric cord 15 extends along a first axis 25, is defined by web 21 and sidewalls 17, 19, and has a cord clamp means 27 extending from sidewalls 17, 19 for gripping cord 15. Channel 23 is more specifically defined by one (wall 29) of the opposed walls 29, 31 of web 21 and the adjacent inner walls 33, 35 of sidewalls 17, 19. As embodied herein, cord clamp means 27 is preferably 2constituted by two pairs of barbs 37, 38; 39, 40 (FIGS. 2, 4, 6). In one pair, barb 37 extends from sidewall 17 and barb 38 extends from sidewall 19 toward the first barb 37. Similarly, in the second pair, barb 39 extends from sidewall 17 and barb 40 extends from sidewall 19 toward barb 39. As shown in FIG. 5, barb 37 comprises a wall 45 extending generally perpendicular from the surface of inner wall 33, an inwardly inclined wall 47 and a sharp edge 49 formed by the intersection of walls 45, 47. The construction of each of the remaining barbs 38-40 is identical to barb 37. Barbs 37-40 provide a secure, generally permanent gripping action on cord 15. Through the resilience of web 21 and inwardly inclined walls 47, cord 15 may be pushed into channel 23 by resiliently flexing sidewalls 17, 19 apart to allow the cord 15 to pass between barbs 37-40. However, due to the generally perpendicularly extending walls 45 and sharp edges 49, barbs 37-40 bite into the periphery of cord 15 and make selective removal of cord 15 from channel 23 difficult. Alternatively, if removal of cord 15 from channel 23 is desired, each pair of barbs 37-40 may be formed as shown in FIG. 8A by an inwardly inclined wall 51 and an outwardly inclined wall 53. With this construction, sidewalls 17, 19 will separate sufficiently for insertion and selective removal of cord 15 from channel 23 by resiliently flexing web 21. Alternatively, as shown in FIG. 8B, cord clamp means 27 may be constituted by a single barb 55 extending from one sidewalls 17, 19 toward the other sidewall 19 which has a smooth inner wall 57. Barb 55 may be constructed as depicted in either FIGS. 5 or 8A and sized to have a length sufficient to provide either a substantially permanent or releasable gripping action on cord 15 in channel 23. One or more barbs 55 spaced along a sidewall may be used. Alternatively, cord clamp means 27 may be constituted by a single pair of barbs 37, 38. Other variations will be apparent to those skilled in the art. In accordance with the invention, a key channel 61 for resiliently clamping a key handle 65 extends along a second axis 63 generally parallel to the first direction 25, is defined by the sidewalls 17, 19 and web 21, has a handle clamp 67 for receiving handle 65, and has a shank clamp 71 for receiving a key shank 73. Handle clamp 67 has a pair of jaws 75, 77 inwardly converging in a direction transverse to the second axis 63. As best shown in FIGS. 4, 6, jaw 75 preferably includes a pair of jaw segments 79, 80 extending from sidewall 17. Similarly, jaw 77 preferably comprises a pair of spaced jaw segments 81, 82 extending from sidewall 19 in a mutually opposed relationship respectively with jaw segments 79, 80. As shown in FIG. 5, jaw segment 79 comprises an inwardly inclined wall 87, an arcuate wall 89 and a flat wall 91 extending between walls 87, 89. Jaw segments 80-82 are preferably configured identically to jaw segment 79. As so configured, handle clamp 67 provides a resilient snap fit clamping action on key handle 65 and a resilient release of jaws 75, 77 by flexing web 21 when removal of key 13 is desired. Alternatively, handle clamp 67 may be constituted by a single pair of jaw segments 79, 80. As best seen in FIG. 4, shank clamp 71 has two spaced pairs of jaws 93, 94; 95, 96 which inwardly converge in a plane parallel to the second axis 63. Jaws 93, 95 extend from sidewall 17 in a mutually opposed relationship to jaws 94, 96 extending from sidewall 19. Jaws 93-96 are sized and spaced to engage the periphery of key shank 73 to retain shank 73 within clamp 71 thereby preventing handle 69 from sliding longitudinally along axis 63 in channel 61. As a result, key 11 is firmly retained in handle clamp 67 and shank clamp 71 thereby reducing significantly the risk of losing key 13. The clip 11 may further comprise a pair of openings 99, 101 in web 21, opposite cord clamp means 27 in a direction 103 transverse to first and second axes 25, 63. As will be explained more fully below, openings 99, 101 result from the method for molding clip 11 in a mold having a cavity segment and a core segment movable only in a single direction (i.e., without side movement). As a result, the molding process is greatly simplified and reduced in cost thereby reducing the cost of production of clip 11. As explained above, cord clamp 27 may utilize one or two pairs of barbs 37, 38; 39, 40. If one jaw pair is utilized, then only a single opening 101, 103 in web 21 opposite to barbs 37, 38 in a direction transverse to axes 25, 63 is required. As best shown in FIG. 1, 4 , 5, clip 11 may further comprise a thumb depression 107 formed in the outer surface of one sidewall 17 for ease of use and operator comfort. Preferably a second thumb depression 109 is formed in the outer surface of the second sidewall 19. The provision of depressions 107, 109 in each sidewall 17, 19 allows convenient use of key 13 with the left or right hand and permits the ends 110, 112 of clip 11 to be interchangeably located on cord 15 regardless of whether right handed or left handed use is anticipated. As shown in FIGS. 1, 2 and 7, clip 11 is intended for use with key 13 comprising (1) handle 69, (2) shank 73 fixed at one end to and extending generally transverse from handle 69 and (3) a pinion 111 formed on the distal end of shank 73. Key handle 69 is received in channel 61 and has a distal end 113 extending from key channel 61 and forming a finger gripping portion. Key shank 73 is received in shank clamp 71 of key channel 61 and has a distal end 115 extending from key channel 61 generally transverse to the axis 63. As depicted in FIG. 9, an operator may grip clip 11 and key 13 by placing a thumb in the thumb depression 107 and one or two fingers encircling end 113 of handle 69 and cord 13. In this manner, clip 11 and key 13 are easily gripped and a high level of torque may be comfortably applied to clip 11 and key 13. The high torque level is further enhanced by the relatively long lever arm formed between shank 73 and the distal end 113 of handle 69. The second aspect of the invention provides a method for making clip 11 in a plastic injection mold 131 which does not require side action or side pulls is another important aspect of the invention. The method will be explained in connection with the method for making the preferred embodiment of clip 11 as depicted in FIGS. 1-7. As shown in FIGS. 10A, 10B, mold 131 comprises cavity and core segments 133, 135 which are opened and closed along direction 137. Core segment 135 has (1) a pair of core barbs 139, 141 for forming clamp 27 in cord channel 23, (2) a core projection 142 for forming shank clamp 71 in key channel 61, (3) a pair of slidable ejectors 143, 145 for forming handle clamp 67 in key channel 61, (4) ejector pins 147, 149 slidable in ejectors 143, 145, respectively, and (5) a central slidable ejector pin 148. Pins 147-149 eject the part 11 from ejectors 143, 145. Ejectors 143, 145 and pins 147-149 are slidable relative a base portion 151 of core segment 131 which (base portion) includes barbs 139, 141 and projection 142. The sequence of operation of mold 131 is shown schematically in FIGS. 10A-10E. In brief, mold 131 operates as follows. Initially in FIGS. 10A, 10B, mold 131 is closed. Liquid plastic is injected into the part cavity formed by the cavity segment 133 and core segment 135 of mold 131. After cooling, in FIG. 10C mold 131 is opened by moving core segment 135 and molded clip 11 away from cavity segment 133 along direction 137. Next, in FIG. 10D, ejectors 143, 145 and ejector pins 147-149 are slid simultaneously together relative to base portion 151, which includes core bars 139, 141 and core projection 142 to thereby eject part 11 from base portion 151. Finally, in FIG. 10E, ejector pins 147-149 are slid simultaneously relative to base portion 151 and ejectors 143, 145 to eject part 11 from ejectors 143, 145. In accordance with this aspect of the invention, a method is provided for molding key 11 which comprises three primary steps. The first step is to mold clip 11 in mold 131 having cavity segment 133 and core segment 135 which are relatively movable back and forth between an open position and a closed position in a direction 137 transverse to axes 25, 63 in which channels 23, 61 extend. Except as indicated herein, mold 131 may be constructed in accordance with conventional techniques for plastic injection molds for materials such as nylon. Preferably, cavity segment 133 and core segment 135 are relatively movable back and forth along direction 137 between a closed position (FIG. 10A) and open position (FIG. 10C) by conventional means (not shown). The second step is to form clamp 27 inwardly converging in a direction transverse to direction 137 in the first channel 23 on core bars 139, 141. Bars 139, 141 extend parallel to direction 137, through the second channel 61, through openings 99, 101 in web 21 and into channel 23. As set forth above, clamp 27 may be constituted by either one or two sets of barbs 37-40. If one pair of barbs 37-40 is utilized, then only a single core bar 139, 141 is utilized to form clamp 27. The third step is to form in clamp 67 inwardly converging in a direction transverse to direction 137 in channel 61 on core ejectors 143, 145 which extend parallel to direction 137. As noted above, handle clamp 67 may be constituted by one or two pairs of jaw segments 79, 81; 83, 85. If handle clamp 67 is constituted by a single pair of jaw segments 79-82 then only a single core ejector 143, 145 is utilized. In accordance with an alternate embodiment of the method for forming clamps 27, 67 in channels 23, 61, when clamp 27 is constituted by barbs having outwardly inclined walls 53 as depicted in FIG. 8A, clamp 27 may be formed on core ejectors 143, 145 and handle clamp 67 may be formed on core bars 139, 141. As shown in FIG. 10C, for ejection of clip 11 from mold 131, mold 131 is opened by a relative movement of cavity segment 133 and core segment 135 in direction 137 to separate cavity segment 133 from clip 11 and core segment 135. Preferably as shown in FIG. 10C, core segment 135 and clip 11 are moved and cavity segment 133 remains stationary. As shown in FIG. 10D, clip 11 is ejected from the base portion 151 of core segment 135 by relative movement of core ejectors 143, 145 and base portion 151 in direction 137. Clip 11 remains supported on ejectors 143, 145. As shown in FIG. 10D preferably, base portion 151 remains stationary, and ejectors 143, 145 and pins 147-149 are moved in direction 137 to separate clip 11 from base portion 151. Preferably core bars 139, 141 are removed from clamp 27 simultaneously with the ejection of clip 11 from base portion 151. Alternatively, core bars 139, 141 may be removed from cord clamp 27 in channel 23 subsequent to the ejection of clip 11 from base portion 151. Lastly, as shown in FIG. 10E, clip 11 is separated from ejectors 141, 143 by moving ejector pins 147-149 relative to ejectors 143, 145 to eject clip 11 from ejectors 143, 145. Alternatively, core bars 139, 141 could move with ejectors 143, 145 to separate clip 11 from base portion 151. In this case, then ejector pins 147-149 serve to simultaneously remove ejectors 143, 145 from key channel 61 and ejector bars 139, 141 from core channel 23. The method for making clip 11 in a mold without "side movement" or "side pulls" (i.e., the requirement to have mold components which move laterally to the direction 137 for opening and closing the mold) simplifies the manufacturing process, reduces mold equipment cost and should result in a more durable mold. As a result the key clip may be produced at a significantly reduced per unit cost. It will be appreciated that this method can be applied to other objects besides chuck key clips where such objects comprise sidewalls and in interconnecting web and having inwardly directed flanges on the sidewalls. Obviously, it must not matter in such objects that holes will be formed in the application of the method in the web and indeed that the flanges will not extend along the entire length of the sidewalls. As will be appreciated, clip 11 also has significant advantages. By the use of handle clamp 67 and shank clamp 71 to retain key 13 in clip 11 significantly reduces the risk of losing key 13 due to the key sliding longitudinally out of channel 61 along axis 63. In addition, key 13, if desired, may be simply removed from clip 11 for use. However, as depicted in FIG. 9, clip 11 and key 13 are conveniently and comfortably used with clip 11 attached to cord 15. Thumb depressions 107, 109 and the alignment of key handle 69 with cord 15 contribute to the simplicity of use and enable a relatively high torque to be comfortably applied to key 13 by an operator. Because key 13 may be simply and comfortably used without detachment from cord 15, key 13 may be stored permanently in a convenient location and the risk of losing key 13 is minimized. A key clip and a method for making the clip in accordance with the invention have been explained in connection with a preferred embodiment and various modifications. Other modifications and variations can be made in the method and key clip of the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention covers these modifications and variations provided they come within the scope of the appended claims and their equivalents.

Claims: A clip for a chuck key having a handle and a shank, the clip comprising: a pair of spaced resilient sidewalls (17,19); a resilient web (21) connecting the sidewalls; a cord channel (23) for receiving an electric cord (13), said cord channel extending along a first axis (25) and defined by the sidewalls and the web; and a key channel (61) for receiving the key handle (113), said key channel extending along a second axis (63) generally parallel to the first axis and formed by the sidewalls and the web; the key channel (61) having a handle clamp (67) for receiving the key handle, and the handle clamp converging inwardly in a plane transverse to said second axis; characterised in that the key channel (61) has a shank clamp (71) for receiving the key shank (73), and in that the shank clamp (71) comprises two spaced pairs of jaws (93-96), each pair having one jaw on each sidewall and converging inwardly in a plane generally parallel to the second axis. A clip according to Claim 1, wherein said cord channel has cord clamping means (27) extending from the sidewalls for gripping the electric cord. A clip according Claim 1 or 2, wherein each sidewall has an inner and outer surface and a thumb depression (107) is formed in the outer surface of at least one sidewall. A clip according to Claim 2 or to Claim 3 dependent on Claim 2, wherein said cord clamping means comprises at least one barb (37,38;39,40) extending from at least one sidewall. A clip according to Claim 4, wherein the barb has a sharp edge (49). A clip according to Claim 4 or 5, wherein there is at least one pair (37,38; 39,40) of said barbs, a first barb (37,39) extending from one sidewall and a second barb (38,40) extending from the other sidewall towards the first barb. A clip according to Claim 4, 5 or 6, in which the or each barb comprises a wall (45) extending generally perpendicular from the surface of the sidewall. A clip according to Claim 2 or to any one of Claims 3 to 7 when dependent on Claim 2, which further comprises an opening (99,101) in the web opposite to said clamping means in a direction generally transverse tot he first and second axes. A clip as claimed in any one of the preceding claims wherein the web and sidewalls are generally "H"-shaped in section. An apparatus comprising: a chuck key (69) comprising; a handle (113); a shank (873) fixed at one end to and extending generally transverse from the handle; a pinion (111) formed at the distal end of the shank; and a clip as claimed in Claim 3 or in any of Claims 4 to 9 when dependent on Claim 3. A method for moulding a chuck key clip having a pair of sidewalls (17,19) connected by a web (21), first and second parallel channels (23,61) defined, respectively, by the sidewalls and opposed sides of the web and extending in a first direction, said method being characterised in that it comprises the steps of: a. moulding the clip in a mould (131) having a cavity segment (133) and a core segment (135), said segments being relatively movable back and forth in a second direction (137) between an open position and a closed position, the second direction being generally transverse to the first direction; b. forming a first clamp (27) having barbs (37,38;39,40) projecting from the inner side of the sidewalls of the first channel (23) and converging inwardly in a third direction generally perpendicular to the first and second directions, by means of a core bar (139,141) extending through the second channel, through an opening (99,101) in the web and into the first channel (23); and c. forming, on the inner sides of the sidewalls of the second channel (61), a second clamp (67) inwardly converging in the third direction, by means of a core ejector (143,145) extending parallel to the second direction. A method according to Claim 11 which further comprises the steps of: d. opening the mould by a relative movement of the cavity segment and core segment in the second direction to separate the cavity segment from the clip and core segment; and e. ejecting the clip from a base portion (151) of the core segment by relative movement of the ejector and base portion in the second direction. A method according to Claim 12 which further comprises the steps of: f. separating the clip from the ejector by moving an ejector pin (147,149) relative to the ejector in the second direction to eject the clip from the ejector. A method according to Claim 12 which further comprises the step of: f. removing the core bar from the first clamp in the first channel simultaneously with step e. A method according to Claim 12 which further comprises the step of: f. removing the core bar from the first clamp in the first channel subsequent to step e.

Inventors: DIETZEN WILLIAM H, MOORES JR ROBERT G, SOMERS ROBERT I, DIETZEN, WILLIAM H., MOORES, JR. ROBERT G., SOMERS, ROBERT I.
Applicants: BLACK & DECKER INC, BLACK & DECKER INC.
Application year: 1991
Main classification: B23B45
IPC codes: B23B45