Patent Publication Number: US-7896103-B2

Title: Power tool housing support structures

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to power tools, and more particularly, to tool housings for power tools. 
     Various power tools, including corded electric, cordless electric and pneumatic tools, are well-known. Examples of such tools include, but are not limited to, drills, drill drivers, impact wrenches, grease guns and the like. Many of these tools have a pistol style housing generally including a tool body defining a head portion with a handle depending therefrom. A trigger or the like is typically provided at the forward junction of the head portion and the handle. In an effort to make such tools lighter, the tool body is typically manufactured from plastic or the like formed in a clam shell manner in which opposed halves of the body are formed separately and then joined together. Such tools have been known to experience cracking, particularly when dropped. It is also desirable to protect internal components, e.g. the motor or the like, if the tool is subject to a significant impact. 
     It is desired to provide an improved pistol style and/or clam shell style tool housing and support structure. 
     SUMMARY OF THE INVENTION 
     The present invention provides in at least one aspect a pistol style tool housing. The tool housing includes a body defining a head portion with a handle portion depending therefrom to define a forward and/or a rear junction. A metal reinforcing member is configured to span along an inside surface of the body from the head portion to the handle portion such that the reinforcing member bridges either the forward or rear junction. In at least one embodiment, body includes opposed body halves, each having at least rear engaging perimeters which are configured to engage one another when the body halves are secured together and wherein the reinforcing member extends along at least a portion of the rear engaging perimeters. 
     In another aspect, the invention provides a tool assembly comprising a tool housing body, a motor positioned within the tool body housing, and a drive mechanism connected with the motor to define a unitary motor/drive mechanism assembly. At least one elastic isolating member extends about a portion of the motor/drive mechanism assembly such that the motor/drive mechanism assembly is elastically isolated relative to the housing body. In yet another aspect, the tool assembly further comprises a motor/drive interface configured to connect the motor with the drive mechanism and an interface isolating assembly extends about a portion of the motor/drive interface such that the motor/drive interface is elastically isolated relative to the housing body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of an illustrative impact wrench tool of the present invention. 
         FIG. 2  is an isometric view of an illustrative drill tool of the present invention. 
         FIG. 3  is a exploded, rear isometric view of the impact wrench tool of  FIG. 1 . 
         FIG. 4  is an elevation view illustrating the inside of one half of the clam shell housing. 
         FIG. 5  is an elevation view of the impact wrench tool of  FIG. 1  with one half of the clam shell housing removed. 
         FIG. 6  is an elevation view illustrating an embodiment of the reinforcing member in accordance with at least one aspect of the invention. 
         FIG. 7  is an isometric view of the reinforcing member of  FIG. 6 . 
         FIG. 8  is an isometric view illustrating an embodiment of a motor isolating member in accordance with at least one aspect of the invention. 
         FIG. 9  is a front elevation view of the isolating member of  FIG. 8 . 
         FIG. 10  is a cross-sectional view along the line  10 - 10  in  FIG. 9 . 
         FIG. 11  is an isometric view illustrating the motor/drive interface of the impact wrench tool of  FIG. 1 . 
         FIG. 12  is a front elevation view of the motor/drive interface of  FIG. 11 . 
         FIG. 13  is a side elevation view of the motor/drive interface of  FIG. 11 . 
         FIG. 14  is an isometric view illustrating an embodiment of a motor/drive isolating assembly in accordance with at least one aspect of the invention. 
         FIG. 15  is a front elevation view of the isolating assembly of  FIG. 14 . 
         FIG. 16  is a side elevation view of one of the isolating members of the isolating assembly of  FIG. 14 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. 
     Referring to  FIGS. 1-2 , various exemplary power tools  50  are illustrated. In  FIG. 1 , the illustrated tool  50  is a cordless impact wrench and in  FIG. 2 , the illustrated tool  50  is a cordless drill, however, the present invention is not limited to such tools. For example, but not limited to, the tool  50  may be cordless or corded, pneumatic, or otherwise powered. Furthermore, the invention is not limited to drills and impact wrenches, but includes other power tools. Each of these illustrated tools  50  includes a tool body  52  defining a head portion  53  and a handle  54  depending therefrom. In each of these illustrated tools  50 , a forward junction  55  and a rearward junction  57  is defined at the junction between the head portion  53  and the handle  54 . Referring to  FIG. 4 , an imaginary plane J extends along the junction between the head portion  53  and the handle  54 . In each of these illustrated tools  50 , a trigger  60  is provided at the forward junction  55 , however, such is not required. In each of these illustrated tools  50 , a forward/reverse slide switch  62  is also provided adjacent the forward junction  55 . Again, such is not required. Forward of the head portion  53  is a head cap  59 . As illustrated in  FIGS. 1-2 , the head cap  59  can have various configurations. Furthermore, as illustrated in  FIGS. 1-2 , the tool head  61  can also have various configurations forward the head cap  59 . 
     Referring to  FIGS. 3 and 4 , the tool housing body  52  generally includes first and second tool body halves  52 A and  52 B. In these illustrated embodiments, the head portion  53  of the body halves  52 A and  52 B defines a hollow area  46  to house the motor  100  and a portion of the drive mechanism  120 . Again, the drive mechanism  120  may have various configurations and configured for various functions. In the present embodiment, a drive opening  68  is defined at the forward end of the head portion  53 . 
     In each of these illustrated embodiments, the handle  54  defines a generally hollow area  56  with an opening  58  into the hollow area  56 . The opening  58  is configured to receive a battery pack (not shown). As set forth above, the present invention is not limited to cordless power tools. Furthermore, while the illustrated embodiments provide the hollow area  56  and the opening  58  within the handle  54  of the electric tool  50 , the invention is not limited to such. If a hollow area  56  is provided, it may be provided at any desired location within the tool  50  with the opening  58  correspondingly positioned to open into the hollow area  56 . 
     Upon assembly, the body halves  52 A and  52 B are joined together by screws  40 , bolts  41  or the like extending through various screw holes  80 ,  82 . Each body half  52 A,  52 B has a forward engaging perimeter FP and a rear engaging perimeter RP which engages the respective perimeter of the other body half  52 A,  52 B when they are joined. In the present embodiment, the forward engaging perimeter FP extends from the battery opening  58  to the trigger opening  78  while the rear engaging perimeter RP extends from the battery opening  58  to the drive opening  68 . 
     Referring to  FIGS. 3-7 , in the present embodiment, a reinforcing member  70  extends between the head portion  53  and the handle  54 , bridging the imaginary plane J at the junction between the head portion  53  and the handle  54 . The reinforcing member  70  is illustrated along the rear perimeter RP bridging the imaginary plane adjacent to the rearward junction  57 . The reinforcing member  70  may further configured to extend along all or a more substantial portion of the rear engaging perimeter RP. Furthermore, a reinforcing member may also be provided additionally, or alternatively, along the forward engaging perimeter FP. As illustrated in  FIG. 4 , a portion  77  of the perimeter RP may be recessed to accommodate the reinforcing member. 
     The reinforcing member  70  desirably has a configuration complementary to the configuration of the perimeter RP, FP over which extends. In the present embodiment, the reinforcing member  70  has an angled configuration complementing the configuration of the rear junction  57  between the head portion  53  and the handle  54 . In the present embodiment, the reinforcing member  70  has a narrow middle portion  72  with wider end portions  74 . The wider end portions  74  may provide a greater area for connection to the housing body. The reinforcing member  70  may have other configurations, for example, a consistent width along its length. As illustrated, the reinforcing member  70  has a plurality of holes  75 . Referring to  FIGS. 3-5 , the holes  75  are configured to align with screw holes  80 ,  82  or posts  81  formed on one of the body halves  52 A,  52 B. The opposite half  52 A,  52 B has a receiving opening  83  configured to receive the posts  81  when the halves  52 A,  52 B are joined. The reinforcing member  70  may be supported on the posts  81  and thereafter secured in position by housing screws  40  as the housing body  52  is assembled. Alternatively, separate screws or the like may secure the reinforcing member  70  to one of the body halves  52 A,  52 B prior to assembly. 
     The reinforcing member  70  is preferably manufactured from a metal, for example, steel, but may be manufactured from other materials having a higher tensile strength than the material of which the housing body  52  is manufactured, for example, composite materials or reinforced plastics. 
     Referring to  FIGS. 1-5 , a continuous reinforcing ring  98  is preferably provided about the tool housing  52  to maintain the halves  52 A and  52 B from splitting. Since the ring  98  is continuous, it is less susceptible to wear or loosening. In the illustrated embodiments, the ring  98  is provided adjacent to the opening  58 . As illustrated in  FIG. 4 , the housing  52  may be provided with a circumferential channel  96  configured to receive the ring  98 . As illustrated in  FIG. 8 , the ring  98  may include an internal channel  97  such that the ring  98  is snap fit over projections  99  extending from the housing  52  about the channel  96 . While the reinforcing ring  98  is illustrated about the opening  58 , it is not limited to such position. For example, the reinforcing ring may be positioned adjacent to the junction plane J, about the forward end of the head portion  53 , the rearward end of the head portion  53  or any other location where radial forces may make such desirable. Additionally, while a pistol style housing is illustrated, the reinforcing ring  98  may be used with tools having other configurations, for example, a linear tool body. 
     The reinforcing ring  98  is preferably manufactured from metal, but may be manufactured from other substantially rigid materials. The reinforcing ring  98  is preferably formed as a continuous member and snap fit or otherwise positioned about the housing  52 . Alternatively, the reinforcing ring  98  may be formed with open ends which are attached, for example, via welding, after the ring  98  is positioned about the housing  58 . 
     Referring to  FIGS. 3-5  and  8 - 16 , another aspect of one or more embodiments of the present invention is illustrated. As explained above, in the present embodiment, the head portion  53  defines a hollow area  46  to house the motor  100  and a portion of the drive mechanism  120 . With reference to  FIGS. 3 ,  5  and  11 - 13 , a motor/drive interface  140  is connected between the motor  100  and the drive mechanism  120 . The interface  140  includes a mounting surface  142  for the motor and a mounting surface  144  for the drive mechanism  120  with a transverse surface  146  extending therebetween. As such, the motor  100  and the drive mechanism  120  are interconnected in a substantially rigid, unitary assembly. The interface  140  is not limited to the specific configuration illustrated and described and may have other configurations. The transverse surface  146  has a pair of through bores  143  configured for passage of the assembly bolts  41 . Upon assembly, bolts  41  pass through the bores  143 , thereby substantially axially fixing the interface  140  relative to the housing body  52 . 
     To support these components relative to the housing and reduce the risk of impact damage, the motor  100  and drive mechanism interface  140  are supported by motor isolation members  130  and an isolation assembly  160 , respectively. While the motor isolation members  130  and the isolation assembly  160  are described with respect to a piston style housing, they are not limited to such and may be used with tools of various constructions. 
     Referring to  FIGS. 8-10 , each motor isolation member  130  is defined by a ring member  132  manufactured from an elastomeric material. The elastomeric material may be any material, whether natural, synthetic or a combination thereof, having a desired elasticity. The ring member  132  defines an inner passage  134  configured to frictionally fit the motor  100  therein. The ring member  132  preferably has a stepped cross-section with an inner step portion  135  and an outer step portion  137  which has a larger diameter than the inner step portion  135 . The stepped configuration provides multiple levels of elastic response. 
     Referring again to  FIGS. 3-5 , a motor isolation member  130  is positioned on each end of the motor  100 . Rear and forward support surfaces  42  and  44 , respectively, are defined within the housing body halves  52 A,  52 B and are configured to engage the inner and outer step portions  135 ,  137  of the ring member  132 . As such, the motor  100  is supported elastically isolated from the housing body  52 . 
     To provide impact absorption, the interface  140  is supported relative to the housing body  52  by the isolation assembly  160 . Referring to  FIGS. 14-16 , the isolation assembly  160  of the present embodiment includes a pair of interface isolation members  162 . Each interface isolation member  162  includes a body  164  manufactured from an elastomeric material. The elastomeric material may be any material, whether natural, synthetic or a combination thereof, having a desired elasticity. The body  164  includes a recess  163  configured to complement and receive a portion of the transverse surface  146  of the interface  140 . Each body  164  further includes an outward projection  166  with an internal slot  165 . Each internal slot  165  is configured to receive and surround a respective wing member  145  extending from the respective received portion of the transverse surface  146 . The received wing member  145  is preferably surrounded on its five extending surfaces such that it is elastically isolated in each direction. The interface isolation members  162  thereby support the interface  140  elastically isolated from the housing body  52 . To further isolate the interface  140  from the bolts  41  extending therethrough, each interface isolation member  162  includes a pair of through passages  167  configured to align with the through bores  143 . The through bores  143  are desirably sized to have a slight clearance with respect to the bolts  41  while the passages  167  have a tight fit about the bolts  41 . The interface  140  is thereby elastically isolated from the bolts  41  through their contact with the interface isolators  162 . With the motor  100  and the interface  140  both elastically isolated from the housing body  52 , the unitary motor/drive mechanism assembly is complete elastically supported relative to the housing body  52 . 
     While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.