Patent Publication Number: US-2022219297-A1

Title: Double overmolded display housing assembly

Description:
TECHNICAL FIELD OF THE INVENTION 
     The present invention relates generally to a display housing assembly for a tool. 
     BACKGROUND OF THE INVENTION 
     Display assemblies, such as, for example, LCD and LED displays, are often used in hand tools, such as motorized ratchet wrenches and drivers, that are commonly used in automotive, industrial, and household applications to tighten and untighten work pieces, such as threaded fasteners, and to apply a torque and/or angular displacement to a work piece, for example. Hand tools, such as power ratchets and drivers, generally include a motor contained in a cylindrically shaped housing, along with other components such as switches, printed circuit boards (PCBs), and a power source (e.g., battery), for example. Accordingly, housings of the hand tools require space to accommodate all the components needed to operate these tools, especially for hand tools that use brushless DC electric motors. Typically, display assemblies have separate buttons and flat displays. The tool housing thus must include space to accommodate additional structure for the buttons and have a shape to accommodate the flat display, which creates a bulkier housing for a user to operate in tight spaces. 
     SUMMARY OF THE INVENTION 
     The present invention relates broadly to a display housing assembly for a display unit, such as an LCD or LED. The display housing assembly includes a base, a lens, and buttons. The display unit, base, lens, and buttons are shaped to correspond with an external geometry of the tool housing, such as, for example, arcuate or cylindrically shaped. The display housing assembly is made by molding the lens, then molding the base over the lens, and then molding the buttons over the base. By molding the base over the lens, and molding the buttons over the base, the display housing assembly includes integrated buttons and is easier to manufacture and assemble, compared to current solutions. Also, by having the buttons integrated with the display housing assembly, less space to accommodate additional structure for the buttons is needed. The display housing assembly can further be shaped to correspond with an external geometry of the tool housing, such as, for example, curved, arcuate or cylindrically shaped, thereby resulting in a more compact tool housing. 
     In an embodiment, the present invention broadly comprises a tool housing for a tool. The tool housing including a display unit and a display housing assembly adapted to be coupled to the tool housing. The display housing assembly includes a lens and a base molded over the lens. 
     In another embodiment, the present invention broadly comprises a tool. The tool includes a tool housing portion, a display unit disposed in the tool housing portion, and a display housing assembly coupled to the tool housing portion. The display housing assembly includes a lens and a base molded over the lens. 
     In another embodiment, the present invention broadly comprises a display housing assembly. The display housing assembly housing includes a lens and a base molded over the lens. 
     In another embodiment, the present invention broadly comprises a method of making a display housing assembly. The method includes molding a lens, molding a base over the lens, and molding buttons over the base. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated. 
         FIG. 1  is a perspective view of an exemplar tool, such as a motorized ratchet tool, including a display housing assembly in accordance with an embodiment of the present invention. 
         FIG. 2  is a perspective view of an exemplar display housing assembly, according to an embodiment of the present invention. 
         FIG. 3  is a front view of a base of the display housing assembly of  FIG. 2 , according to an embodiment of the present invention. 
         FIG. 4  is a rear view of the base of  FIG. 3 . 
         FIG. 5  is a front view of exemplar buttons of the display housing assembly of  FIG. 2 , according to an embodiment of the present invention. 
         FIG. 6  is a rear view of the exemplar buttons of  FIG. 5 . 
         FIG. 7  is a bottom view of the exemplar buttons of  FIG. 5 . 
         FIG. 8  is a front view of a lens of the display housing assembly of  FIG. 2 , according to an embodiment of the present invention. 
         FIG. 9  is a bottom view of the lens of  FIG. 8 . 
         FIG. 10  is a flow diagram illustrating a method of manufacturing a display housing assembly, in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention is susceptible of embodiments in many different forms, there is shown in the drawings, and will herein be described in detail, embodiments of the invention, including a preferred embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the present invention and is not intended to limit the broad aspect of the invention to any one or more embodiments illustrated herein. As used herein, the term “present invention” is not intended to limit the scope of the claimed invention, but is instead used to discuss exemplary embodiments of the invention for explanatory purposes only. 
     The present invention broadly includes a display housing assembly for a display unit, such as an LCD or LED. In an embodiment, the display housing assembly is disposed in a motorized hand tool, such as, for example, a motorized ratchet tool. The display housing assembly includes a base, a lens, and buttons. The base, lens, and buttons are shaped to correspond with an external geometry of the tool housing, such as, for example, curved, arcuate or cylindrically shaped. The display housing assembly is made by molding the lens, molding the base over the lens, and molding the buttons over the base. 
     Referring to  FIGS. 1-9 , a tool  100 , such as, for example, a motorized ratchet tool, includes a tool housing portion  102  adapted to be held by a user and a driver portion  104  coupled to the tool housing portion  102 . The driver portion  104  is adapted to apply torque to a work piece and includes a drive lug  106  adapted to engage a tool (e.g., socket or bit) to drive the work piece, for example, in a well-known manner. The drive lug  106  is operatively coupled to and driven by a motor (not shown) via a ratcheting mechanism (not shown) of the driver portion  104  in a well-known manner. The driver portion  104  also includes a selector knob  108  adapted to select a rotational drive direction of the drive lug  106  (i.e., clockwise or counter-clockwise). In an embodiment, the driver portion  104  is a ratchet head of a ratchet tool. 
     The tool housing portion  102  operably houses one or more of the motor adapted to drive the drive lug  106 , a trigger  110  adapted to actuate the motor, a power source (not shown) adapted to provide electrical power for the motor, such as a battery, one or more PCBs for motor and/or display control, and a display assembly  112  (described in more detail below). In an embodiment, the housing portion  102  is assembled from first and second clamshell housing portions  114 ,  116  coupled together to cooperatively form the tool housing portion  102 . The housing portion  102  may also include a handle portion  118  that a user may grip or hold during operation of the tool  100 . 
     The first and second clamshell housing portions  114 ,  116  are configured to couple together and couple the driver assembly  104  to the tool  100 . When assembled, as shown in  FIG. 1 , for example, the first and second clamshell housing portions  114 ,  116  retain the display assembly  112  therein. In an embodiment, the first and second clamshell housing portions  114 ,  116  cooperatively form a display opening  120  when coupled together. The display opening  120  includes a peripheral lip  122  disposed at least partially around the perimeter of the display opening  120  to retain the display assembly  112  in the first and second clamshell housing portions  114 ,  116 . 
     The motor can be, for example, an electric motor electrically coupled to the power source via the trigger  110 . The power source can be external (e.g., an electrical wall outlet, generator, external battery, etc.) or internal (e.g., a removable and rechargeable battery). The trigger  110  can be adapted to cause the motor to be turned ON and OFF, or cause electric power/voltage to flow from the power source to the motor or cease flow from the power source to the motor. 
     The trigger  110  can be an actuation mechanism that employs a push button actuator or other type of actuator. For example, the user can depress the trigger  110  inwardly to selectively cause power to be supplied from the power source to cause the motor to operate and provide torque to the driver assembly  104  in a desired rotational direction. Any suitable trigger  110  or switch can be implemented without departing from the spirit and scope of the present invention. For example, the trigger  110  can be a toggle actuator, a touch sensitive actuator, a slide actuator, or other suitable actuator or device. In another example, the trigger  110  can be biased such that the trigger  110  is depressible inwardly, relative to the tool housing portion  102 , to cause the tool  100  to operate, and releasing the trigger  110  causes the trigger  110  to move outwardly, relative to the tool housing portion  102 , to cease operation of the tool  100  via the biased nature of the trigger  110 . The trigger  110  may also be a variable speed type mechanism. In this regard, relative actuation or depression of the trigger  110  causes the motor to operate at variable speeds, depending on the depression level of the trigger  110 . 
     The display assembly  112  includes a display housing assembly  124  that houses and protects a display unit (not shown). In an embodiment, the display housing assembly  124  includes a base  126 , a lens  128 , and buttons  130 . In an embodiment, the display assembly  124  may include touch-sensitive areas, so that separate buttons  130  are unnecessary. In such embodiment, selection of tool settings can be accomplished through the touch-sensitive display. In an embodiment, the display assembly  112  has a shape that substantially corresponds to an external geometry of the tool housing portion  102 . For example, each of the display unit, display housing assembly  124 , base  126 , lens  128 , and buttons  130  is curved, arcuate, or cylindrically shaped. 
     The base  126  is molded over the lens  128 . In an embodiment, the base  126  is a glass-filled polymer, such as, for example, black glass-filled nylon. However, the invention is not limited as such and any other suitable moldable material may be used. The base  126  includes a lens opening  132  adapted to retain the lens  128  therein to allow the display unit to be viewed by a user. In an embodiment, notches  134  are disposed around the lens opening  132  to allow the lens  128  to be held inside the mold as the base  126  is molded over the lens  128  by the molder. Although six notches  134  are illustrated, any suitable number of notches  134  can be used. The base  126  may further includes a button opening  136  to allow the buttons  130  to pass therethrough. In an embodiment, apertures  138  are disposed around the button opening  136 . The apertures  138  allow the material of the buttons  130  to passed therethrough when the buttons are molded over the base  126  to ensure the buttons  130  are mechanically coupled to the base  126 . Although six apertures  138  are illustrated, any suitable number of apertures  138  can be used. In another embodiment, a recess  140  is disposed at least partially around the lens opening  132 . 
     The lens  128  is a substantially clear lens and is made of a synthetic polymer, such as, for example, nylon. In an embodiment, the lens  128  includes first  142  and second  144  components or layers. For example, the first  142  and second  144  components or layers include one or more of light guide(s), substrate(s), polarizer(s), diffuser(s), reflector(s), etc. In an embodiment, the first component or layer  142  forms a peripheral lip  146  that substantially surrounds the second component or layer  144  and is shaped to substantially correspond to the recess  140 . 
     In an embodiment, the buttons  130  are molded around the base  126  and through the apertures  138  and button opening  136  of the base  126 , thereby maximizing contact area between these two components to ensure a good mechanical coupling therebetween. 
     Accordingly, the buttons  130  are relatively difficult to remove from the base  126  once assembled. The buttons  130  can be made of an elastomer material, such as, for example, rubber. Although three buttons are illustrated, any suitable number of buttons can be used. The buttons  130  are electrically coupled to the display unit via a PCB in a well-known manner and are adapted to receive a user input, such as, for example, selecting what is to be shown on the display unit, for selecting tool parameters, such as, for example, the driving direction of the drive lug  106 , and/or for otherwise manipulating the display unit to control the tool  100  and/or parameters of the tool  100 . 
     The display unit is adapted to indicate tool information to the user. In an embodiment, the display unit is an LCD or LED display unit. The tool information can include, for example, a tool status, such as, for example, a power level of the power source, a selected driving direction of the drive lug  106 , a power state of the motor, output torque of the tool  100 , etc. The display unit can further include a display driver adapted to generate signals with suitable voltage, current, timing and demultiplexing to cause the display unit to show the desired text or image in a well-known manner. 
     An embodiment of a method  200  of manufacturing a display housing assembly  100  is shown in  FIG. 10 . The method, at step  202 , includes molding the lens  128 . As stated above, the lens  128  can be made of a synthetic polymer, such as nylon or other suitable material, and is substantially clear. 
     The method, at step  204 , includes molding the base  126  over the lens  128 . As stated above, the base  126  can be made of a glass-filled polymer, such as black glass-filled nylon or other suitable material, and includes a lens opening  132 , a button opening  136 , and apertures  138 . 
     The method, at step  206 , includes molding the buttons  130  around the base  126 . As stated above, the buttons  130  are molded such that the material of the buttons passes through the apertures  138  and the button opening  136  to restrict removal of the buttons  130  from the base  126 . Further, as stated above, the buttons  130  are composed of an elastomer material, such as rubber or other suitable material. 
     As discussed above, the aspects of the present invention are described in terms of a motorized ratchet tool, as shown. However, it should be understood that aspects of the present invention could be implanted in other hand tools or implements. For example, and without limitation, the hand tool can be ratchet wrench, open wrench, screw driver, nut driver, drill, or any other tool capable of applying torque to a work piece. 
     As used herein, the term “coupled” can mean any physical, electrical, magnetic, or other connection, either direct or indirect, between two parties. The term “coupled” is not limited to a fixed direct coupling between two entities. 
     The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of the inventors&#39; contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.