Abstract:
A right angle attachment for use with a power tool that includes a housing having a handle portion and a gear case attached to the handle portion and supporting first and second right angle gears wherein the first right angle gear is driven by an input shaft that is connected to the drill and the second right angle gear has an opening therein for receiving a hex bit directly therein. A floating magnet head can surround the hex bit to aid in fastener retention and can be movable out of proximity of the hex bit to facilitate easy removal of the hex bit for replacement. An additional magnet can be disposed within the gear case at the base of the hex bit in order to magnetize the hex bit and further enhance the retention of the fastener therein.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/570,918, filed on Dec. 15, 2011. The entire disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure relates to a right angle attachment for power tools and more particularly, to an accessory to be attached to a power tool to allow a fastener to be inserted or a hole to be drilled in tight spaces. 
       BACKGROUND 
       [0003]    Drills are widely used in the housing and other industries for drilling holes and for installing screws in various materials and in various locations. On occasion, it is necessary to drill a hole or to install a screw in a tight space that does not allow the drill to be accessed to the location for the drilling or inserting process. Accordingly, right angle accessories have been developed to help to facilitate the drilling of holes and the insertion of fasteners in these tight spaces. Although these angled accessories have been available, some of the designs are not as compact as needed to allow their use in very tight spaces. 
       SUMMARY 
       [0004]    Although similar angled drive accessories have been developed for use with power tools, it is desirable to provide an improved right angle attachment for use with power tools that can work with impact tools that has improved durability and life, has an even further reduced low profile so that it can reach into the tightest of spaces, has an ergonomic design for user comfort and has superior fastener retention to help facilitate the insertion of fasteners in these tight spaces. 
         [0005]    The present disclosure provides a right angle attachment for use with a power tool that includes a housing having a handle portion and a gear case attached to the handle portion and supporting first and second right angle gears wherein the first right angle gear is driven by an input shaft that is connected to the drill and the second right angle gear has an opening therein for receiving a hex bit directly therein. A floating magnet head can surround the hex bit to aid in fastener retention and can be movable out of proximity of the hex bit to facilitate easy removal of the hex bit for replacement. An additional magnet can be disposed within the gear case at the base of the hex bit in order to magnetize the hex bit and further enhance the retention of the fastener therein. With the hex bit being received within the second right angle gear, the drive unit can have a low profile so that it can reach into the tightest space. 
         [0006]    According to a further aspect of the present disclosure a right angle attachment for a power tool is provided including a housing including a handle and a gear case attached to the handle. An input shaft extends through the handle. A first right angle gear is rotatably mounted within the gear case and drivingly attached to the input shaft. A second right angle gear is rotatably mounted within the gear case and meshingly engaged with the first right angle gear. The second right angle gear includes a polygonal opening therein adapted for receiving a tool bit and a magnet is disposed in the gear case inward from the polygonal cavity in the second right angle gear. 
         [0007]    According to another aspect of the present disclosure a right angle attachment for a power tool includes a housing including a handle and a gear case attached to the handle. An input shaft extends through the handle. A first right angle gear is rotatably mounted within the gear case and drivingly attached to the input shaft. A second right angle gear is rotatably mounted within the gear case and meshingly engaged with the first right angle gear. The second right angle gear includes a polygonal opening therein adapted for receiving a tool bit and a bit release device is supported by the gear case and in communication with the polygonal opening in the second right angle gear. 
         [0008]    One or more of the following features can be implemented with each of the above embodiments. The magnet support can include at least one boss movably received in a guide opening in the gear case. 
         [0009]    The magnet support can include a pair of bosses movably received in a pair of guide openings in the gear case. 
         [0010]    The magnet support can include a pair of arms slidably engaged with the gear case. 
         [0011]    The magnet support can be pivotal relative to said gear case. 
         [0012]    A bit release device can be supported by the gear case and in communication with the polygonal opening in the second right angle gear. 
         [0013]    The gear case can include a Philips-shaped opening adjacent the bit release device. 
         [0014]    The input shaft can include a pointed end that engages a surface of the gear case. 
         [0015]    A magnet can be disposed in the gear case inward from the polygonal cavity in the second right angle gear. 
         [0016]    The first right angle gear can be rotatably supported in the gear case by a first bearing that is supported in the gear by a first c-clip. The second right angle gear can be rotatably supported in the gear case by a second bearing that is supported in the gear case by a second c-clip. 
         [0017]    The magnet support can be supported by a pair of shoulder screws engaged with the gear case. The pair of shoulder screws secure a first gear case portion to a second gear case portion. The second right angle gear can be secured in the gear case by a plate member that is secured to the gear case by the pair of shoulder screws. 
         [0018]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0019]    The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
           [0020]      FIG. 1  is a perspective view of the right angle attachment according to the principles of the present disclosure; 
           [0021]      FIG. 2  is a side-plan view of the right angle attachment shown in  FIG. 1 ; 
           [0022]      FIG. 3  is a front view of the attachment shown in  FIG. 1 ; 
           [0023]      FIG. 4  is a cross-sectional view taken along line  4 - 4  of  FIG. 3 ; 
           [0024]      FIG. 5  is a perspective view similar to  FIG. 1  showing the ring magnet head moved axially forward from the gear case; 
           [0025]      FIG. 6  is a perspective view similar to  FIGS. 1 and 5 , showing the ring magnet head pivoted partially out of the way of the gear case; 
           [0026]      FIG. 7  is a perspective view similar to  FIGS. 1 ,  5 , and  6  showing the ring magnet head pivoted fully out of the way of the gear case; 
           [0027]      FIG. 8  is a cross-sectional view similar to  FIG. 4 , showing the ring magnet head moved axially away from the gear case. 
           [0028]      FIG. 9  is a perspective view of a right angle attachment according to a second embodiment of the present disclosure; 
           [0029]      FIG. 10  is a cross-sectional view of the right angle attachment shown in  FIG. 9 ; 
           [0030]      FIG. 11  is a perspective view of a right angle attachment according to a third embodiment of the present disclosure; 
           [0031]      FIG. 12  is a side plan view of the right angle attachment shown in  FIG. 11 ; 
           [0032]      FIG. 13  is a rear plan view of the right angle attachment shown in  FIG. 11 ; 
           [0033]      FIG. 14  is a cross-sectional view of the right angle attachment shown in  FIG. 11 ; 
           [0034]      FIG. 15  is a perspective view of a right angle attachment according to a fourth embodiment of the present disclosure; 
           [0035]      FIG. 16  is a cross-sectional view of the right angle attachment shown in  FIG. 15 ; 
           [0036]      FIG. 17  is a cross-sectional view taken along line  17 - 17  of  FIG. 16 ; 
           [0037]      FIG. 18  is a front plan view of a right angle attachment according to a fifth embodiment of the present disclosure; 
           [0038]      FIG. 19  is a side plan view of the right angle attachment shown in  FIG. 18  with the floating magnet holder in a retracted position; 
           [0039]      FIG. 20  is a side plan view similar to  FIG. 19 , and showing the floating magnet holder in an extended position; and 
           [0040]      FIG. 21  is a cross-sectional view of the right angle attachment shown in  FIG. 18 . 
       
    
    
       [0041]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0042]    Example embodiments will now be described more fully with reference to the accompanying drawings. 
         [0043]    With reference to  FIGS. 1-8 , the right angle attachment  10  according to the principles of the present disclosure will now be described. The right angle attachment  10  includes a housing  12  including a gear case  14 , a handle  16  and a rear cap  18 . The gear case  14 , the handle  16  and the rear cap  18  can be connected together utilizing various techniques including threaded connection, heat staking, adhesives, fasteners and other known connecting techniques. The gear case  14 , handle  16  and rear cap  18  can also be made of various materials including metals and plastics. 
         [0044]    An input shaft  20  can be coupled to a chuck  22  of a power tool  24  each shown in phantom in  FIG. 3 . As best shown in  FIG. 4 , the input shaft  20  extends into the housing  12  where it is supported by a journal  25  and bearing  26  in the rear cap  18 . An internal sleeve  28  rotatably supports the journal  25  at a first end within the rear cap  18  and extends through the handle  16  and into the gear case  14 . The forward end of the internal sleeve  28  abuts against a bearing assembly  30  that rotatably supports a first right angle gear  32  on the end of the input shaft  20 . The internal sleeve  28  is retained in the gear case  14  by a snap ring  34  and a spring washer  35  that engage a shoulder of the internal sleeve  28  and the snap ring  34  is received in an internal groove in the gear case  14 . The spring washer  35  allows limited axial movement of the internal sleeve  28  and the first right angle gear  32 . 
         [0045]    The first right angle gear  32  is in meshing engagement with a second right angle gear  38  that rotates about an axis that is approximately 90° relative to the axis of the input shaft  20 . The second right angle gear  38  is supported by a bearing assembly  40  within the gear case  14 . The bearing assembly  40  is retained in the gear case  14  by a snap ring  42  received in an internal groove in the gear case  14 . The second right angle gear  38  includes a hexagonal aperture  46  extending there through for receiving a hex bit  48  such as a screwdriver bit or drill bit. The screwdriver bit  48  can have a straight, Phillips or other shaped drive head. A magnet  50  is disposed within the gear case  14  at the base of the hex bit  48 . The magnet  50  helps hold the bit  48  inside the gear  38  and it magnetizes the bit  48  so that it can better hold a screw. 
         [0046]    A floating ring magnet head  54  is movably mounted to the gear case  14  and supports a ring magnet  56  around the hex bit  48  to further enhance fastener retention. The ring magnet head  54  includes a pair of pivot arms  60  on opposite sides of the gear case  14  and include an ear that is received in a slot  64  in the sides of the gear case  14  to allow axial movement of the ring magnet head  54  relative to the gear case  14 . 
         [0047]    In one possible embodiment, as illustrated in  FIGS. 5 and 8 , the ring magnet head  54  may be moved in an axial direction along the slots  64  relative to the gear case as compared to  FIG. 1  wherein the ring magnet head  54  is in its retracted position. In the axial extended position illustrated in  FIGS. 5 and 8 , the ring magnet head  54  can help hold and magnetize the head of a screw or fastener for better retention for assembly in tight spaces. The ring magnet head  54  may include detents that engage corresponding recesses in the slots  64  to help retain the ring magnet head  54  in the axial extended position so that the right angle attachment can be operated with the head  54  in this position. 
         [0048]    In another possible embodiment, as illustrated in  FIGS. 6 and 7 , after the ring magnet head  54  is moved to its axially extended position as shown in  FIG. 5 , the ring magnet head  54  can be pivoted about its ears as illustrated in  FIGS. 6 and 7  wherein the ring magnet head  54  is moved out of the way of the hex bit  48 . The pivotal movement of the ring magnet head  54  allows for easier access for easily changing or removal of the hex bit  48  from the second right angle gear  38  especially if the bit breaks during operation. 
         [0049]      FIG. 8  is a cross-sectional view similar to  FIG. 4 , but showing the ring magnet head  54  in its axially extended position relative to the gear case  14 . In operation, the user inserts the input shaft  20  into the chuck  22  of a power tool  24  (best shown in  FIG. 3 ), and inserts a bit  48  into the opening  46  in the second right angle gear  38 . Driving the power tool  24  will cause the bit  48  to rotate at a right angle relative to the input shaft  20  to drive a screw or drill a hole in a very tight space. 
         [0050]    With reference to  FIGS. 9 and 10 , a right angle attachment  110  according to a second embodiment of the present disclosure will now be described. The right angle attachment  110  includes a housing  112  including a gear case  114  and a handle  116 . In the illustrated embodiment, the handle  116  is connected to the gear case  114  by a plurality of threaded fasteners, although various techniques including threaded connection, heat staking, adhesives and other known connecting techniques can be utilized. The gear case  114  and handle  116  can be made of various materials including metals and plastics. 
         [0051]    A hex-shaped input shaft  120  can be coupled to a chuck of a power tool. As best shown in  FIG. 10 , the input shaft  120  can be connected to an optional intermediate shaft  122  which extends into the housing  112  where it is supported by a rearward bearing  125  and a forward bearing  126  that are supported in the handle  116  and gear case  114 , respectively. The forward end of the intermediate shaft  122  is connected to a first right angle gear  132 . 
         [0052]    The first right angle gear  132  is in meshing engagement with a second right angle gear  138  that rotates about an axis that is approximately 90° relative to the axis of the intermediate shaft  122 . The second right angle gear  138  is rotatably supported by a bearing assembly  140  within the gear case  114 . The bearing assembly  140  is retained in the gear case by a snap ring  142  received in an internal groove in the gear case  114 . The second right angle gear  138  includes a hexagonal aperture  146  extending therethrough for receiving a hex bit  48  such as a screwdriver bit or drill bit. The screwdriver bit  48  can have a straight, Philips or other shaped drive head and a hexagonal or polygonal shaped shank. A magnet  150  is disposed within the gear case  114  at the base of the hex bit  48 . The magnet  150  holds both the bit  48  inside the gear  138  and it magnetizes the bit  48  so that it can better hold a screw. 
         [0053]    A floating ring magnet head  154  is movably mounted to the gear case  114  and supports a ring magnet  156  around the hex bit  48  to further enhance fastener retention. The floating ring magnet head  154  includes a boss  160  that is received in a guide opening  162  provided in the gear case  114  to allow axial movement of the floating ring magnet head  154  relative to the gear case  114 . The gear case  114  can be provided with a hole  164  on a back side of the gear case for receiving a bit release device  166  that can be depressed to eject the hex bit  148  from the hexagonal aperture  146  in the second right angle gear  138 . The bit release device  166  can include a narrow pin  168  that can extend through a hole in the magnet  150  in order to engage the hex bit  148 . 
         [0054]    With reference to  FIGS. 11-14 , a third embodiment of the right angle attachment  210  will now be described. The right angle attachment  210  includes a housing  212  including a gear case  214  and a handle  216 . The gear case  214  and the handle  216  can be connected together utilizing various techniques, while the particular embodiment shows threaded fasteners  218  connecting the handle  216  to the gear case  214 . 
         [0055]    An input shaft  220  extends into the housing  212  where it is supported at its first end by a journal  225  and bearing  226  at the rear end of the handle  216 . The forward end of the input shaft  220  has a center point  228  that engages a wall surface  229  of the gear case  214 . The hex-shaped input shaft  220  is received in a hexagonal opening  230  provided in a first right angle gear  232 . The first right angle gear  232  is rotatably supported by a bearing  234  that is retained within the gear case  214  by a snap ring  235 . 
         [0056]    The first right angle gear  232  is in meshing engagement with a second right angle gear  238  that rotates about an axis that is approximately 90° relative to the axis of the input shaft  220 . The second right angle gear  238  is supported by a bearing assembly  240  within the gear case  214 . The bearing assembly  240  is retained in the gear case  214  by a snap ring  242  received in an internal groove in the gear case  214 . The second right angle gear  238  includes a hexagonal aperture  246  extending therethrough for receiving a hex bit  48  such as a screwdriver bit or drill bit. The screwdriver bit  48  can have a straight, Philips or other shaped drive head. A magnet  250  is disposed within the gear case  214  at the base of the hex bit  48 . The magnet  250  helps hold the bit  48  inside the gear  238  and it magnetizes the bit  48  so that it can better hold a screw. 
         [0057]    A floating ring magnet head  154  is movably mounted to the gear case  214  and supports a ring magnet  156  around the hex bit  48  to further enhance fastener retention. The structure of the floating magnet holder  154  is described above with respect to the prior embodiment shown in  FIGS. 9 and 10  and further description will therefore not be provided with regard to floating ring magnet head  154 . 
         [0058]    A bit release device  266  is received in an opening  268  provided in gear case  214  on the back side of the hex bit  48 . The bit release device can include an elongated pin  272  that can extend through an opening in the magnet  250  in order to press the hex bit  48  out of the hexagonal aperture  246  of the second right angle gear  238 . The gear case  214  can be provided with a Philips-shaped access hole that allows the head of a Philips-shaped bit or a straight bit to be inserted therethrough to engage the bit release device  266  to aid in the release of the hex bit  48 . 
         [0059]    It is noted that the pointed tip feature  228  of the hex-shaped input shaft  220  aids in centering the shaft to prevent misalignment of the shaft  220  which can result in binding in the rotating gear elements  232 ,  238 . This improvement provides a simple, low cost solution to enable larger tolerances in production of the right angle attachment  210 . 
         [0060]    With reference to  FIGS. 15-18 , a right angle attachment  310  according to a fourth embodiment of the present disclosure will now be described. The right angle attachment  310  includes a housing  312  including a gear case  314  and a handle  316 . 
         [0061]    An input shaft  320  can be coupled to an intermediate shaft  322  as best illustrated in  FIG. 16 . The intermediate shaft  322  can be rotatably supported by a journal/bearing  325  disposed at the rearward end of the handle  316 , as best shown in  FIG. 16 . A first right angle gear  332  can be supported at the forward end of the intermediate shaft  322 . The first right angle gear  332  can be rotatably supported by a bearing assembly  330  that is received in the gear case  314 . The bearing assembly  330  can be supported within the gear case  314  by a snap ring received in an internal groove in the gear case  314 . 
         [0062]    The first right angle gear  332  is in meshing engagement with a second right angle gear  338  that rotates about an axis that is approximately 90° relative to an axis of the intermediate shaft  322 . The second right angle gear  338  is rotatably supported within the gear case  314  by a bearing assembly  340  that is retained in the gear case  314  by a snap ring  342  received in an internal groove in the gear case  314 . The second right angle gear  348  includes a hexagonal aperture  346  extending therethrough for receiving a hex bit  48  such as a screwdriver bit or drill bit. A magnet  350  can be disposed within the gear case  314  at the base of the hex bit  48 . The magnet  350  helps hold the bit  48  inside the second right angle gear  338  and it magnetizes the bit  48  so that it can better hold a screw. 
         [0063]    A floating ring magnet head  354  is movably mounted to the gear case  314  and supports a ring magnet  356  around the hex bit  48  further enhancing fastener retention. The floating ring magnet head  354  includes a pair of bosses  360  on opposite sides of the gear case  314  that are each received within a pair of guide channels  362  formed in the gear case  314 . The guide channels  362  and bosses  360  allow the magnet support head  354  to move axially by a limited amount to allow the ring magnet  356  to be moved in an axial direction relative to the gear case  314  to help hold and magnetize the head of a screw or a fastener for better retention for assembly in tight spaces. Each boss  360  can be provided with a head portion  364  that can engage a stop within the guide channels  362  to limit the axial movement therein. 
         [0064]    A quick release device  370  can be provided on the rear surface of the gear case  314  to allow the device to be pressed in order to assist in removing a hex bit  48  from the hexagonal aperture  346  in the second right angle gear  338 . The release device  370  can include an elongated pin  372  that extends through an opening in the magnet  350  as best shown in  FIGS. 16 and 17  in order to assist in removal of a hex bit  48 . 
         [0065]    With references to  FIGS. 18-21 , a right angle attachment  410  according to a fifth embodiment of the present disclosure will now be described. The right angle attachment  410  includes a housing  412  including a gear case  414  and a handle  416 . The gear case  414  and handle  416  can be connected together by entrapping the handle  416  between first and second gear case portions  414   a,    414   b  or by utilizing various alternative techniques including threaded connection, heat-staking, adhesives, fasteners, and other known connecting techniques. A hex-shaped input shaft  420  can be connected to an intermediate shaft  422  which is drivingly connected to a first right angle gear  432  as best illustrated in  FIG. 21 . 
         [0066]    The first right angle gear  432  can be supported within the gear case  414  by a bearing assembly  434  that can be retained within the gear case  414  by an end  436  of the handle  416 . The first right angle gear  432  is in meshing engagement with a second right angle gear  438  that rotates about an axis that is approximately 90° relative to the axis of the intermediate shaft  422 . The second right angle gear  438  is supported by a bearing assembly  440  within the gear case  414 . The bearing assembly  440  is retained in the gear case  414  by a plate  442 . 
         [0067]    The plate  442  is secured to the gear case  414  by a pair of shoulder screws  444 . The shoulder screws  444  include a shoulder portion that abuts against the plate  442  while the screws are threaded into a first gear case portion  414   a  for securing a second gear case portion  414   b  thereto. Thus, the shoulder screws  444  are provided for securing the gear case portions  414   a,    414   b  together while also securing the plate  442  against the bearing assembly  440  for securing the components within the gear case  414 . The shoulder screws  444  also support a floating magnet head  454  for movement relative to the gear case  414 . The floating ring magnet head  454  supports a ring magnet  456  around the hex bit  48  to further enhance fastener retention. The floating ring magnet head  454  slides along a smooth surface of the shoulder screws  444  and abut against a head at an end thereof that limits the axial movement of the floating ring magnet head  454 . A magnet  450  can be disposed within the gear case  414  at the base of the hex bit  48 . The magnet  450  can help hold the bit  48  inside the gear  438  and it magnetizes the bit  48  so that it can better hold a screw. 
         [0068]    This design utilizes two shoulder screws to tie the floating ring magnet support  454  and metal plate  442  and gear case  414  together. As the first and second gear case components  414   a,    414   b  are sandwiched around the handle  416 , the handle  416  becomes entrapped therein. This creates a unique package that is easy to assemble and disassemble for repair. 
         [0069]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.