Abstract:
The present invention is directed to apparatus for a winch assembly. The winch assembly may be secured to a towing trailer and arranged to assist in loading and unloading cargo from the trailer. The winch assembly may include mechanisms, systems, and features to make the winch assembly easy to assemble and use, increase the service life of the winch assembly, and improve the consistency of the performance of the winch assembly. Embodiments of a winch assembly disclosed include novel drive systems, novel ratchet and pawl systems, novel systems for guiding a winch strap, novel systems for securing the winch assembly to a towing trailer, and a novel frame member for a winch assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of prior U.S. patent application Ser. No. 12/558,252, filed on Sep. 11, 2009 now U.S. Pat. No. 7,967,278 which claims the benefit of U.S. Provisional Patent Application No. 61/191,682, entitled “Winch Assembly,” filed on Sep. 11, 2008, which are both hereby incorporated by reference in their entirety. 
    
    
     FIELD OF INVENTION 
     The present invention relates generally to winch assemblies for towing trailers, and more particularly, to apparatus for improving the functionality, ease of use, and ease of assembly and maintenance of winch assemblies. 
     BACKGROUND 
     Towing trailers are designed to secure and haul cargo. Trailers may be arranged to haul specific types of cargo such as boats, automobiles, consumer products, and the like. Many such cargo items are large, heavy and difficult to move or maneuver onto the bed or frame of a towing trailer. To assist in moving or maneuvering the cargo onto a towing trailer, such trailers are often equipped with a winch. The winch assembly may commonly be attached to the tongue of the trailer. The winch may be connected to a cargo item by, for example, a strap, cable, rope, chain or the like for pulling the cargo item onto the trailer. 
     The winch assembly typically uses a handle to rotate a drum to wind the strap or cable around the drum and thus pull the cargo item towards the winch. The winch assembly may also be used to unload a heavy item by rotating the drum in the opposite direction to unwind a strap or chain to allow the cargo item to be slid off the trailer. 
     SUMMARY OF THE PRESENT INVENTION 
     An apparatus for a winch assembly is provided. In one embodiment, a winch assembly may include a one-piece frame having at least one side. The one piece frame may include a first aperture having a winch drum shaft held therein, a second aperture having a drive gear shaft held therein, a pawl aperture having a pin assembly held therein, and a plurality of spokes arranged to suspend the first aperture. The winch assembly may further include a drive system located within the frame, the drive system may include a winch drum, and at least one drive gear capable of engagement with the winch drum. 
     Further in an alternative embodiment, a winch assembly may include a frame and a drive system located within the frame. The drive system may include a winch drum including at least one drum gear, a drive shaft, and at least one drive gear located on the drive shaft and capable of engagement with the at least one drum gear. The winch assembly may also include a pin located through the frame, where the pin is capable of engagement with a feature of the drive system other than the at least one drive gear, and where the engagement limits rotation of the drive system. 
     In yet another alternative embodiment, a winch assembly may include a frame and a drive system located within the frame. The drive system may include a winch drum including at least one drum gear, a drive shaft, and at least one drive gear located on the drive shaft and capable of engagement with the at least one drum gear. The winch assembly may also include a ratchet and pawl assembly connected to the frame. The ratchet and pawl assembly may include a pin, where the pin is movable to engage the drive system to limit rotation of the drive shaft, a biasing member engaging the pin, the biasing member capable of biasing the pin into engagement with the drive system, and a knob connected to the pin to adjust the pin between a first position to allow rotation of the drive shaft in a first direction, a second position to allow rotation of the drive shaft in a second direction opposite the first direction, and a third position to allow rotation of the drive shaft in either the first or second directions. 
     In yet another alternative embodiment, a winch assembly may include a frame having at least two sides and a front face positioned between the two sides and a drive system located within the frame. The drive system may include a winch drum including at least one drum gear, a drive shaft, and at least one drive gear located on the drive shaft and capable of engagement with the at least one drum gear. The winch assembly may further include a pin connected with the frame, wherein the pin is movable to engage the drive system to limit rotation of the drive shaft, and a handle connected to the drive shaft to facilitate manual rotation of the drive shaft, where the pin is located on the front face and approximately centered between the two sides of the frame. 
     In yet another alternative embodiment, a winch assembly may include a frame, a drive system located within the frame. The drive system may include a winch drum including at least one drum gear, a drive shaft, and at least one drive gear located on the drive shaft and capable of engagement with the at least one drum gear. The winch assembly may also include a handle connected to the drive shaft to facilitate rotation of the drive shaft, where the handle includes a plurality of attachment features positioned along its length for selective attachment of the handle to the drive shaft at any attachment feature position. 
     Finally in yet another alternative embodiment, a winch assembly may include a frame, a drive system located within the frame. The drive system may include a winch drum including at least one drum gear, where each of the at least one drum gear includes a plurality of teeth, a drive shaft, and at least one drive gear located on the drive shaft and capable of engagement with the at least one drum gear. The winch assembly may also include a strap connected to the winch drum and capable of being wound on itself about the winch drum, and a strap guide connected to the frame, the strap guide positioned to overlap the teeth of the at least one drum gear to prevent the strap from contacting the teeth. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Objects and advantages together with the operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations, wherein: 
         FIG. 1  is a perspective view of a winch assembly in an embodiment of the present invention. 
         FIG. 2  is a perspective view of internal mechanisms of the winch assembly of  FIG. 1 . 
         FIG. 3  is a perspective view of internal mechanisms of the winch assembly of  FIG. 1 . 
         FIG. 4  is a cross-sectional view of the winch assembly taken along line  4 - 4  of  FIG. 2 . 
         FIG. 5  is a cross-sectional view of the winch assembly taken along line  5 - 5  of  FIG. 3 . 
         FIG. 6  is an exploded view of a winch assembly in an embodiment of the present invention. 
         FIG. 7  is a perspective view of a winch assembly. 
         FIG. 8  is a perspective view of a frame for a winch assembly. 
         FIG. 9  is another exploded view of a winch assembly. 
         FIGS. 10A and 10B  are perspective views of a handle attached for the left side and right side of a winch assembly. 
         FIGS. 11A-11C  are perspective views of a handle attached to a winch assembly at varying positions. 
         FIGS. 12A-12C  are views of a ratchet system for a winch assembly. 
         FIGS. 13A and 13B  are perspective views of the bottom plate of a winch frame of a winch assembly. 
         FIGS. 14A and 14B  are perspective views of a handle for a winch assembly. 
         FIG. 15  is a front view of a partial winch assembly. 
         FIG. 16  is a rear view of a partial winch assembly. 
         FIG. 17  is a top view of a partial winch assembly. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the present invention. 
     A winch assembly  10  is illustrated in  FIG. 1 . The winch assembly  10  may include a handle or crank  12 , a grip  14 , and a winch housing or frame  16  that may house the internal components of the winch assembly  10 . The grip  14  may be secured to the handle  12  to facilitate the manual rotation of the handle  12 . As best seen in  FIG. 7 , the winch frame  16  may also include a base plate  26  that may be configured to facilitate the securing or attaching of the winch assembly  10  to a winch stand or directly to a towing trailer, for example. 
     Most trailer winches are manufactured from a formed steel stamping. This material and process severely limits the features and aesthetics that can be incorporated into the design. As best seen in  FIG. 8 , the winch frame  16  may be fabricated as a one-piece die cast aluminum component. Such an arrangement may incorporate many desirable features, allow for pleasant aesthetics, provide for a high strength construction, and may make manufacturing easier. Die casting allows for the grooves  66  and apertures  68  of the base plate  26  to be incorporated into the frame  16 , allows for precision control of dimensions of the frame  16 , and allows for forming thicker sections to strengthen the frame  16 . 
     As shown in  FIGS. 2 through 6 , the winch assembly  10  may also include a winch drum  18  and a ratchet and pawl system  20 . The winch drum  18  and ratchet and pawl system  20  may be located within the winch frame  16  for selectively driving and locking the winch drum  20 . The winch assembly  10  may be arranged to load and unload cargo onto a towing trailer by securing a strap (not show) to the cargo. 
     The strap may be attached to the drum  18  and pull cargo onto the trailer when the drum  18  is rotated in a first direction and allow cargo to slide off the trailer when the drum  18  is rotated in a second and opposite direction. The drum  18  may be located within the frame  16  and positioned on a shaft  46 , such as a pin, for example. The drum  18  may be driven by the manual rotation of the handle  12 . Disclosed herein is a novel drive system for driving the drum  18  to load and unload cargo. As will be described in detail, the winch drive system may be an adjustable floating winch system that may be driven by a hand operated adjustable crank handle  12 . 
     In an embodiment, the drive system may include a drive shaft  28 , a pair of outer bearings  30 , a pair of inner bearings  32 , and three drive gears  34 . The outer and inner bearings  30 ,  32  may be slip bearings and are positioned to hold the drive shaft  28  to form a floating drive system. The bearings  30 ,  32  may be slip bushings that hold the drive shaft assembly in place creating a floating hex drive system. The drive shaft  28  may be hexagonal in cross-sectional shape. The three drive gears  34  may be slip fit onto the hexagonal drive shaft  28 , and each drive gear  34  operates independent of the other two drive gears  34 . 
     The outer bushings  30  may have a generally square outer surface, a generally circular inner surface, and include a flange. The outer bushings  30  may slide into coaxial apertures  36  in the winch frame  16 . The frame apertures  36  may be arranged to match the generally square outer surface of the outer bushing  30  so that the outer bushing  30  will not rotate when located in the frame aperture  36 . In one embodiment, outer bushings  30  may be fabricated from a polymeric material such as nylon. 
     The inner bushings  32  may have a generally circular outer surface and include a flange. The inner bushings  32  may be positioned within the outer bushings  30 , where the circular inner surface of the outer bushings  30  matches the circular outer surfaces of the inner bushings  32 . The inner surface of the inner bushings  32  may have a hexagonal shape to accommodate the hexagonal shape of the drive shaft  28 . In an embodiment, the inner bushing  32  may be fabricated from an oil impregnated self-lubricating bronze material. Such an arrangement may provide for an extended service life. 
     As will be understood, the outer and inner bearings  30 ,  32  may support the drive shaft  28  within the winch frame  16 . The combination of the bearings  30 ,  32  functionally transforms the hexagonal outer surface of the drive shaft  28  to a circular outer surface to facilitate smooth and efficient rotation of the drive shaft  28  within the apertures  36  of the frame  16 . As will further described below, such an arrangement provides for a drive system that functions smoothly even when encountering irregularities in drum gears due to manufacturing and assembly processes such as stamping and welding. 
     The three drive gears  34  positioned on the drive shaft  28  may be arranged to drive the winch drum  18  and to facilitate the locking of the drum  18 . The drive gears  34  may be positioned within the frame  16  and between the left and right bushings  30 ,  32 . The two outer drive gears  34   a ,  34   c  may engage the drum  18  to drive the drum  18 . The drum  18  may be fabricated with an integral pair of drum gears  38 . The two outer drive gears  34   a ,  34   c  may engage the pair of drum gears  38  to drive the drum  18  with an even and balanced force. As will be further described below, the middle drive gear  34   b  may function as a ratchet type plunger engagement device to control the locking and release of forward and reverse rotational motion of the winch drum  18 . These gears  34  may be slip fit over the drive shaft  28  and function or operate independent of each other. 
     In an embodiment, the drive shaft  28  may be fabricated as a one-piece steel drive shaft with apertures drilled and tapped on each end. Retaining caps  40  may be engaged with each end of the drive shaft  28  to hold the drive shaft  28  within the frame  16 . Stainless steel washers  42 , such as shim washers, may also be used to prevent wear between bushing surfaces. As illustrated in  FIGS. 10A and 10B , the handle  12  may then be mounted on either end of the drive shaft  28  to permit right hand or left hand manual rotation of the handle  12  in a variety of possible length positions. The handle  12  and retaining cap  40  may be held in place by fasteners. 
     In addition, as illustrated in  FIGS. 11A-11C , the handle  12  may also include a number of adjustment apertures  44  located along the handle  12 . The handle  12  may thereby be positioned at a number of different positions via the adjustment apertures  44  to either shorten or lengthen the lever arm portion of the handle  12 . As will be understood, between the varying lengths and attaching the handle  12  on the left and right sides of the winch assembly  10 , the handle  12  may be assembled in a variety of positions depending on need and circumstances. Cap screws, washers, etc., as shown in the figures, may secure the handle  12  and retaining cap  42  to the winch assembly  10 . In an embodiment, all components are assembled with a toleranced slip fit and are universal right to left for assembly purposes. 
     Typical ratchet pawl systems are only located on one side or the other of a winch thereby limiting the access if the operator is on the opposite side. In addition, most ratchet pawl systems are made of several loose components that may be cumbersome to assemble and replace if needed. The ratchet and pawl system  20  of the present application is located in the middle of the winch  10  thereby making it easily accessible from either side. 
     The ratchet and pawl system  20  may be mounted in the center of a symmetrical winch frame  16  as a separate and self-contained one piece assembly, as shown in  FIGS. 12A-12C . Such positioning makes the ratchet and pawl system  20  accessible from either side of the assembly  10 . The winch frame  16  may be made such that the ratchet pawl assembly  20  fits into the frame  16  protecting it. This frame  16  enclosure also enables strength characteristics allowing the pin  50  to be captured as close to the gear  34   b  as possible. The knob  54  has a protrusion  58 , as best seen in  FIGS. 4 and 12A , that works with the mating insert bushing  56  that will seat the neutral position and if turned partially, will ramp down into the desired engaged or disengaged position, so that the knob  54  may self align itself into place easily from the neutral position or if only turned partially. 
     As best shown in  FIGS. 5 and 12B , the pin  50  may include a lip  48  located at one end. As will be understood, the lip  48  of the pin  50  may contact the middle drive gear or ratchet  34   b  and not the outer drive gears  34   a ,  34   c , thus, reducing wear by spreading the contact points over several gears. The pin  50  may be in contact with a spring  52  and a knob  54 . The pin  50  may pass through a bushing  56  such that the knob  54  is accessible from the outside of the housing  16 ; however, the pin  50  is located within the housing  16 . 
     The bushing  56  and knob  54  may be arranged such that features on the bushing  56  and knob  54  provide for the knob  54  to be selectively positioned to engage the pin  50  with the middle drive gear or ratchet  34   b  (as seen in  FIGS. 3 and 5 ) or be selectively positioned to disengage the pin  50  from the ratchet  34   b  (as seen in  FIGS. 2 and 4 ). In one embodiment, the spring  52  may bias the pin  50  into engagement with the ratchet  34   b . The system  20  may also be arranged to self align for easy placement of the pin  50  in contact with the middle drive gear or ratchet  34   b  when the knob  54  is only partially turned. 
     In one embodiment, for example, the ratchet and pawl system  20  may be positioned generally through the centerline of a symmetrical winch assembly  10  and is a separate, self-contained assembly. The winch frame  16  may be arranged such that the ratchet and pawl system  20  may be housed within the frame  16  to prevent unnecessary damage to components. Such positioning also allows for a shorter pin  50  because of its proximity to the ratchet  34   b . Such an arrangement places less bending forces on the pin  50  and increases the service life of the pin  50 . 
     Similar to the description above, the knob  54  may have a protrusion that mates with recesses in an insert component (such as a bushing) to seat the knob  54  in a neutral position, i.e., a position where the pin  50  is disengaged from the ratchet  34   b . However, a partial turn of the knob  54  would allow the spring  52  to bias the pawl  50  into contact and engagement with the ratchet  34   b.    
     As discussed above, the winch drum  18  may include a pair of drum gears  38  symmetrically positioned at the sides of the drum  18 . The drum  18  may be manufactured or fabricated so that the drum gears  38  are integrally formed with the drum  18 , i.e., the pair of drum gears  38  and the drum  18  are one singular, unitary component. Such fabrication eliminates the need for welding, riveting, or otherwise securing gears to a drum. The symmetric positioning of the drum gears  38  with respect to the drum  18 , along with the dual drive gears  34  of the drive system encourages even loading and balancing of forces when the drum  18  is wound and unwound. Such even loading reduces or eliminates side load conditions that may damage the drum  18 . Such balanced forces may increase the service life of the drum  18  and the drum gears  38 . 
     The drum  18 , along with the rear cover  22 , may guide the strap such that the strap experienced less wear and tear and is protected against grease from the gears and other contaminants. The drum  18  may include a sump  60  protruding from the inner side of each drum gear  38  (as best seen in  FIGS. 6 and 9 ). The sump  60  may extend from the inner surface of the drum gears  38  so as to encourage a retracting strap towards the center of the drum  18  and away from the teeth of the drum gears  38 . 
     Such an arrangement results in a reduction or elimination of instances when the strap engaging or becoming entangled with the drum gears  38 , which would cause damage and other wear, along with potentially contaminating the strap with grease. In addition, as will be described in detail below, the sumped sides  60  also encourage a strap guide to nest inside the rear cover  22  further protecting the strap from wear and or contamination. 
     The winch assembly  10  may also include a rear cover  22  with an opening  24  to accommodate the winding and unwinding of a strap or cable from the winch drum  20 . As best seen in cross-sectional views of  FIGS. 4 and 5  and in  FIG. 6 , the an opening  24  may allow movement of the strap into and out of the winch assembly  10 . The rear opening  24  may include material that wraps around the opening towards the drive gears  38  to form a strap guide  62 . 
     The strap guide  62  may extend into the housing  16  sufficiently to protect the strap against contact with the drum gears  38 , specifically protection against contact with the teeth of the drum gears  38 . Thus, further protecting the strap from damage, wear, grease and contaminants. As will be understood, the strap guide  62  may provide the strap with a smooth, clean port for entry and exit from the winch assembly  10 . The strap guide  62  may include protrusions  64  to protect the strap guide  62  from contacting the teeth of the drum gears  38 . The protrusions  64  run on the smooth portion of the drum gears  38  and avoid contact with the gear teeth. In addition, the strap guides  62  may enclose the potentially sharp edges of the winch frame  16 , further protecting the strap and uses of the winch assembly  10  from potential damage and injury. 
     The winch assembly  10  may be arranged so that it may be secured to a towing trailer or a winch stand without accessing the inside of the winch housing  16 . Such an arrangement provides for easy and quick installation of a winch assembly  10  without concern for opening or accessing the housing  16 , unwinding the strap, etc. A winch assembly  10  may be installed using fasteners such as bolts from the bottom of the winch assembly  10 . 
     As is best seen in  FIGS. 13A and 13B , the winch assembly  10  may include an easy install system. In a traditional mounting application, the fasteners have to be installed in through the inside of the winch. This is sometimes cumbersome due to several components on the inside of the winch. Making matters more difficult to access the mounting holes is when a winch line is fully wound onto the drum. With this limited inside access, being able to hold down the head of the bolts is sometimes a problem when trying to tighten the nuts from the bottom side. Sometimes parts of the winch may need to be disassembled to complete the installation. 
     In the present invention, an installer may insert bolts from the bottom of the winch  10 , place the winch assembly  10  onto a winch or mounting stand, and attach the nuts from the bottom side. The bottom plate  26  of the frame  16  may include a series of grooves  66  and apertures  68  that allow the bolts to be held in place until the nuts can be threaded onto the bolts. This is accomplished by the heads of bolts fitting through apertures  68  and allowing for the shaft of the bolt to slide along the grooves  66 . The grooves  66  along with the square necks of fasteners, such as carriage bolts, may prevent these bolts from spinning while tightening. Thus, simplifying installation and requiring less tools. 
     Although the preferred embodiment of the present invention has been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the preferred embodiment disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter.