Patent Publication Number: US-2023152055-A1

Title: Extendable baton with damage resistant locking mechanism

Description:
FIELD OF THE INVENTION 
     The field of the invention relates to telescopically extending and locking batons. More particularly, the field of the invention relates to extendable and lockable/releasable police or military batons with improved durability and reliability. 
     BACKGROUND 
     Batons for use by the police and military are well known. Such batons can be of great value in close quarters or where non-lethal force is necessary or warranted. In many cases, batons used by the police or military are compact to carry and easy to deploy. Such batons may be constructed of one or more telescoping sections including a handle and more or more sections that slide into the handle. 
     A three-section telescoping baton with locking clutches and a button release is disclosed, for example, in U.S. Pat. No. 9,677,843, which is incorporated by reference. These batons are advantageous because they may be deployed to an extended and locked position and unlocked and stowed with one hand. Referring to  FIG.  5   , in such designs, an inner baton section  1  includes a locking clutch comprising two opposing semi-circular clutch plates  3  that fit into slots which have been cut into opposing sides of one end of the inner baton section  1 . When collapsed, the clutch plates are kept retracted by clutch alignment rod. As each inner baton section is extended, the clutch alignment rod is withdrawn from the clutch plates, which are then biased outward by springs. When the baton section is fully extended, the clutch plates extend outwardly from the slots and into recesses in the next outer section to lock the two sections together. To collapse an extended and locked baton, a user pushes a button which extends the clutch alignment rod through apertures in the clutch plate coaxially with the baton section, which thereby aligns the clutch plates and withdraws them from the recess of the next outer baton section, allowing the baton to be collapsed while pushing on the ends of the baton. 
     While very convenient to deploy and stow, there are some disadvantages with such locking clutch designs. The ends of the baton sections where the locking clutches are located may be weakened by the slots for the clutch plates. Referring to  FIG.  6   , after cutting the slots  5 , the remaining section portions  7  are relatively thin. Also, the clutch plates nest against each other where the alignment rod goes through, requiring those annular portions  9  of the locking plates to be at half thickness relative to the semi-circular portions, creating another potential area of weakness. Such weak spots may result in failure. When a baton is used to strike an object, forces from the most extended section of the baton may be propagated through one or more intermediate extended sections to the handle. Due to the forces, the extended sections may deflect within the next larger section. When this happens, the relatively thin section portions  7  and/or annular portions  9  of the locking plates  3  may fail, breaking the locking clutch. Accordingly, a need exists for more durable extendable extended sections. 
     Another issue with known designs is that elastomeric O-rings are used to reduce play between sections. Such elastomeric O-rings must be treated with oil or other lubricant to provide a low friction interface. However, the oil or lubricant may attract dirt and contamination, or be wiped off the mating surfaces completely. If left unserviced, the oil or lubricant may dry up, seizing the baton sections against each other, rendering the baton inoperable, to the detriment of the user. 
     SUMMARY 
     An extendable baton is provided, having a base section, at least one extendable section and a control rod connected to a release button. The base section may be tubular and have a lengthwise axis, a first annular recess on an inner surface of a distal end and a release button on a proximal end, the first annular recess having a width. The extendable section may also be tubular and be dimensioned to nest inside the base section coaxially with the longitudinal axis. The extendable section includes a locking clutch on a proximate end, the locking clutch including a single slot disposed on the proximate end of the extendable section, a clutch plate disposed at least partially within the slot, the clutch plate including a locking portion having an arc that fits within the slot and a thickness that fits within the width of the first annular recess, and a control aperture portion having a control aperture, a guide cap disposed on the proximate end of the extendable section including a guide aperture, and at least one spring disposed to bias the clutch plate outwardly from the slot of the extendable section. The control rod is insertable through the guide and control apertures to retract the clutch plate toward the slot of the extendable section when the release button is depressed. When the extendable section is extended from the base section, the control rod is withdrawn from the aperture, the spring biases the clutch plate outwardly from the slot of the extendable section, and the locking portion of the clutch plate engages the annular recess. 
     It has been found that reducing the number of semi-circular clutch plates from two to one provides several advantages relating to the durability of the baton and to the cost the of manufacture, while still providing sufficient locking performance. The single slot section end has better resistance to damage from shock loading. The base section may comprise a handle of the baton. 
     The extendable baton may have a plurality of extendable sections having locking clutches. For example, the at least one extendable section may comprise a first extendable section having a second annular recess on an inner surface of a distal end of the first extendable section, and the extendable baton may further comprise a second extendable section. The second extendable section may be a smaller version of the first extendable section and may be tubular and dimensioned to nest inside the first extendable section coaxially with the longitudinal axis. The second extendable section also includes a second locking clutch on a proximate end, the second locking clutch being controlled by the same control rod and being dimensioned to engage the second annular recess when the second extendable section is extended. 
     The clutch plate disposed at least partially within the slot may consist of a single clutch plate. The locking portion of the clutch plate may have a radius that substantially matches the proximal end of the extendable section. The aperture may be located at a center of the radius. The control aperture portion of the clutch plate may have a thickness that is substantially the same as the locking portion of the clutch plate. 
     The slot may have an arc which is less than half the circumference of the proximal end of the extendable section. When the control rod is inserted through the aperture to retract the clutch plate, the clutch plate may be retracted completely within the slot. 
     The extendable baton may further include a plastic ring disposed in the distal end of the base section to provide a low friction bearing surface for the extendable section. 
     In one example, the guide cap is formed from a high impact thermoplastic and at least one spring seat is a molded into the guide cap. In another example, the guide cap is formed from metal for additional impact damage resistance. In another example, a portion of the section end opposite the clutch plate is reinforced for additional impact damage resistance. 
     In one particular example, an extendable baton is provided. The extendable baton has a handle section, first and second extendable sections and a control rod connected to a release button. The handle section may be tubular and have a lengthwise axis, a first annular recess on an inner surface of a distal end and a release button on a proximal end, the first annular recess having a width. The first extendable section may also be tubular and be dimensioned to nest inside the handle section coaxially with the longitudinal axis. The first extendable section includes a first locking clutch on a proximate end and a second annular recess on a distal end, the first locking clutch including a single slot disposed on the proximate end of the first extendable section, a clutch plate disposed at least partially within the slot, the clutch plate including a locking portion having an arc that fits within the slot and a thickness that fits within the width of the first annular recess, and a control aperture portion having a control aperture, a first guide cap disposed on the proximate end of the first extendable section including a guide aperture, and at least one spring disposed to bias the clutch plate outwardly from the slot of the extendable section. The second extendable section may also be tubular and be dimensioned to nest inside the first extendable section coaxially with the longitudinal axis. The second extendable section includes a second locking clutch on a proximate end, the second locking clutch including a single slot disposed on the proximate end of the first extendable section, a clutch plate disposed at least partially within the slot, the clutch plate including a locking portion having an arc that fits within the slot and a thickness that fits within the width of the second annular recess, and a control aperture portion having a control aperture, a second guide cap disposed on the proximate end of the second extendable section including a guide aperture, and at least one spring disposed to bias the clutch plate outwardly from the slot of the extendable section. 
     The control rod is insertable through the guide apertures and control apertures to retract the clutch plates toward their respective slots of the extendable sections when the release button is depressed. When the extendable sections are extended from the handle section, the control rod is withdrawn from the apertures, the springs bias the clutch plates outwardly from the slots of the extendable sections, and the locking portions of the clutch plates engage their respective annular recesses. This may happen sequentially or simultaneously. 
     In one example, the first guide cap is formed from a high impact thermoplastic and at least one spring seat is a molded into the guide cap, the second guide cap is formed from metal, and in the second extendable section, a portion of the section end opposite the clutch plate is reinforced for additional impact damage resistance. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS.  1 A-B  illustrates an example of an extendable baton in both stowed and deployed positions. 
         FIG.  2    shows a cut-away view of a baton having an improved locking clutch according to the present invention. 
         FIG.  3    is an exploded view of a locking clutch according to one aspect of the present invention. 
         FIGS.  4 A and  4 B  show components of a locking clutch of the embodiment in 
         FIG.  3   . 
         FIG.  5    illustrates a section end and guide cap according to another aspect of the invention. 
         FIG.  6    is an exploded view of prior art locking clutch components. 
     
    
    
     DETAILED DESCRIPTION OF AN ILLUSTRATED EMBODIMENT 
     While embodiments can take many different forms, specific embodiments thereof are shown in the drawings and will be described herein in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles hereof, as well as the best mode of practicing same. No limitation to the specific embodiment illustrated is intended. 
       FIGS.  1 A-B  is a side view of a police or military baton  10  shown generally in accordance with an illustrated embodiment.  FIG.  1 A  shows the baton  10  in a retracted or stowed position and  FIG.  1 B  shows the baton  10  in an extended position ready for use against an adversary. 
     In general, the baton is constructed of one or more tubular sections. The outermost section may comprise a base section, such as a handle section  12 . In a stowed position ( FIG.  1 A ), the inner section  16  and intermediate section  14  are coaxial and nested within the handle section  12 , and may partly extend from a distal end of handle section  12  and any intermediate sections. A baton tip  16   a  may be threaded on to a distal end of inner section  16 . As used herein, proximate and distal are used with respect to a user holding the baton ready for use. 
     In a deployed state ( FIG.  1 B ), the inner sections  14 ,  16  remain in a coaxial relationship with the handle section  12  and are extended along the predominant axis  18  of the sections  12 ,  14 ,  16 . The baton  10  may be deployed conventionally by grasping the handle section  12  with the heel of the user&#39;s hand near a proximate end  20  and flicking the distal end  22  with the baton tip  16   a  outwards away from the user via a quick rotation of the user&#39;s wrist. 
     Once deployed, a respective spring-loaded locking clutch (discussed below) locks each extended section  14 ,  16  to the directly adjacent next larger section. In this regard, the locking clutch locks the inner section  16  to the intermediate section  14  (or to the handle section  12  if no intermediate section is used). 
     The baton  10  may include a release button  24  on the proximate end of the handle section  12 . The release button  24  operates a control rod  34 . The control rod  34  extends between the release button  24  and each of the locking clutches. As the baton  10  is deployed and each section locks to the next section, the release button  24  may pop out of the handle section  12  as the control rod is disengaged from the locking clutches. To stow the baton, a user simply activates the button (pushing it back into the handle) to cause the control rod  34  to retract the locking clutches and then pushes the inner section  16  (and any intermediate sections) back into the handle section  12  thereby returning the baton  10  to the stowed position or state. 
       FIG.  2    is a cut-away view of the baton  10 . As shown in  FIG.  2   , the intermediate section  14  and inner section  16  each include a respective locking clutch  26 ,  28 . As the sections of the baton are extended to the fully deployed position, the locking clutches  26 ,  28  each engage and lock into a respective recess  30 ,  32 . In the illustrated example, recess  32  is an annulus cut into the inner surface of the distal end of intermediate section  14 , and recess  30  is an annulus cut into a collar  56  that is threaded onto handle section  12 . Each recess may be more deeply cut than in opposing clutch plate designs. 
       FIG.  3    is an exploded view of the distal end of the intermediate section  14  showing components of the locking clutch  26 .  FIGS.  4 A and  4 B  are exploded views of locking clutch  26  components including a top view and a side view. With reference to these figures, a locking clutch may comprise a slot  35 , semicircular clutch plate  38 , and springs  42 ,  44 . In the illustrated example, a single slot and clutch plate is included for each locking clutch. The slot  35  has an arc of just less than half the circumference of section end on which it is situated. However, the slot  35  may be larger than illustrated, including larger than half the circumference of the section end, so long as sufficient strength is maintained in the section end to avoid breakage. 
     The clutch plate  38  may include a locking portion  38   a  and a control aperture portion  38   b . The locking portion may comprise an outer edge defined by an arc (partial circumference of a circle) and a radius that is substantially the same as the distal end of intermediate section  14 . The length of the arc is such that the clutch plate substantially matches the slot  35 . The control aperture portion may have an aperture  36  at a center of the radius of the arc. The control aperture portion may be the same or substantially the same thickness as the locking portion. While the term “semicircular” may be used to describe the shape of clutch plate  38 , the arc need not comprise an exact half circle. The arc of a clutch plate may be less than half a circumference of the section end in which it is located. 
     The single slot  35  is cut into the distal end of the intermediate section  14  to receive a single clutch plate  38  of the locking clutch  26 . Once inserted into the slot  35 , an aperture  36  may be engaged by the control rod  34  to secure the clutch plate  38  within the slot  35 . 
     Also, because only one slot  35  is provided, a side of the section  14 ,  16  opposite slot  35  may be reinforced to provide even more resistance against damage from shock loading. 
     In the illustrated example, the locking clutch  26  further comprises a guide cap  64 . Guide cap  64  may be formed from a thermoplastic, such as polyoxymethylene (sold under the brand name Delrin). In some embodiments, the thermoplastic comprises high impact polypropylene for additional impact damage resistance. Guide cap  64  includes an aperture  65  to guide the control rod  34  and recessed seats  48  for springs  42 ,  44 . The guide cap  64  provides the advantages of reducing machining required for spring seats and improving the retraction action of the baton by guiding the control rod to the aperture of the clutch plate. In some embodiments, the guide cap  64  is retained in place by the springs  43 , 44 , and clutch plate  38 . In other embodiments, the guide cap is held in place by adhesive or a friction fit. 
     Included within the clutch plate  38  are a set of spring seats  46  that receive the other ends of the springs  42 ,  44 . Because there is only one clutch plate  38 , the control aperture portion of clutch plate  38  may be made at the full thickness of the locking portion of the clutch plate which engages the recess  30 , thereby improving resistance to damage from shock loading. 
     The inner section  16  has a similar single slot and locking clutch  28 , including clutch plate  40  and guide cap  66  sized appropriately to a diameter of inner section  16  and recess  32 . The configuration and operation of the components of locking clutch  28  may be the same as or similar to locking clutch  26 , and for purposes of brevity are not separately illustrated in exploded view. 
     In some embodiments, as illustrated in  FIG.  5   , the portion  35   a  of the section end  14   a  opposite a clutch plate is reinforced against impact damage with metal and seats for springs drilled into the section end. For example, in some embodiments, one or both of the guide caps  64 ,  66  may comprise a metal component attached to the proximal end of a baton section. The metal may comprise, for example, stainless steel. Examples of attaching the metal guide cap included threaded engagement, epoxy attachment, friction (interference) fit, and a combination of threaded engagement with epoxy or a thread-locking compound. In one embodiment, epoxy is applied to a top surface of the section end and/or inside surface of the guide cap and the components assembled together. 
     In some embodiments, a combination of metal and thermoplastic guide caps are used within the same baton. For example, guide cap  66  on inner section  16  may be fabricated as a metal component, and guide cap  64  on intermediate section  14  may be fabricated as a thermoplastic component. Such an arrangement optimizes strength at the striking end of the baton and reduced cost in the middle of the baton. 
     Compression rings  60 ,  62  ( FIG.  2   ) may be included in the handle section  12  and intermediate section  14 . Compression rings  60 ,  62  may be formed of a thermoplastic, such as acetal (polyoxymethylene) or other high-impact polymer. A split is provided in the compression rings to allow for expansion/compression during installation and compression/expansion when fit on a groove or annular recess on a section end. Compression ring  60  fits into an annular recess on the distal end of handle  12  and reduces play between intermediate section  14  and handle section  12 , while providing a low-friction bearing surface for intermediate section  14  to extend from handle section  12 . The low-friction surface is achieved without requiring oil or other lubricant as are required with prior known elastomeric O-rings, which may attract dirt and/or require periodic replacement. Compression ring  62  likewise reduces play between inner section  16  and intermediate section  14  while providing a low friction bearing surface. While low friction compression rings  60 ,  62  are considered advantageous, the locking clutches  26 ,  28  of the present invention may also be used in combination with elastomeric O-rings to reduce play. 
     During use, the control rod  34  extends through apertures  36  thereby holding the apertures  36  in coaxial alignment with the baton sections  14 ,  16 . The springs  42 ,  44  of each locking clutch  26 ,  28  are held in compression. So long as the control rod  34  extends through the apertures  36 , an outer edge of the locking clutch  26 ,  28  is held even with (or slightly within) an outer circumference (outside annular edge) of the respective sections  14 ,  16 . When the control rod  34  is withdrawn from the apertures, the springs bias the clutch plates  38 ,  40  outwards towards an inner surface of the next outer section, and eventually into the recesses  30 ,  32  when fully extended, thereby locking each inside section of the baton to the next closest outer section that is directly adjacent the inside section. In some embodiments, the surface of control rod  34  is textured or knurled. This provides a degree of control over a level of friction between the control rod  34  and the apertures  36  of the clutch plates  38 ,  40  to avoid inadvertent deployment. This may be advantageously combined with the low friction compression rings  60 ,  62  to achieve a baton that deploys reliably with reduced maintenance, yet does not inadvertently deploy if held tip down. 
     As the clutch plates  38 ,  40  move radially outwards, the apertures  36  are no longer in axial alignment with the sections  14 ,  16 . However, even with the clutch plates  38 ,  40  extended, the predominant axis  18  of the baton sections still passes through the apertures  36 , albeit off center. This allows a tapered end  54  of the control rod  34  to later re-engage and retract the clutch plates  38 ,  40 . 
     In order to deploy the baton  10 , a user may grasp the handle section  12  on one end and the baton tip  16   a  on the distal end of the inner section  16  and pull outwards. The outwards force may first cause the inner section  16  to begin sliding outwards relative to the intermediate section  14  and handle section  12 . Since the control rod  34  is attached to the handle section  12 , the outward movement of the inner section  16  causes the control rod  34  to begin to withdraw from the aperture  36  of the locking clutch  28 . Immediately before the locking clutch  28  reaches the recess  32 , the control rod  34  exits the aperture  36  of the locking clutch  28 . This allows the springs to push the semicircular plate  38  outwards into the recess  32 , thereby locking the first end of the inner section  16  to the second end of the intermediate section  14 . 
     If the user continues to pull, the inner section  16 , locked to intermediate section  14 , causes the intermediate section  14  to begin moving outwards away from the handle section  12 . As the intermediate section  14  moves outwards, the control rod  34  begins to withdraw from the locking clutch  26  of the intermediate section  14 . Immediately before the locking clutch  26  reaches the recess  30 , the control rod  34  exits the aperture  36  of the retainer of the intermediate section. This allows the springs of the locking clutch  26  to push the semicircular plates into the recess  30 , thereby, locking the intermediate section to the handle section  12 . 
     As the intermediate section locks to the handle section  12 , the release button  24  may pop out of the end of the handle section  12 . In one example, as the control rod  34  exits the locking clutches, a control rod  34  spring  52  ( FIG.  2   ) pushes the button  24  outwards at the same instant as the baton locks in the fully deployed state. In another example, the button is biased outward by the spring  52  even when the baton  10  is in a stowed configuration, and does not pop further out when the baton  10  is deployed. 
     In order to stow the baton  10 , the user may first depress or otherwise activate the release button and then push the baton tip  16   a  towards the handle section  12 . Depressing the release button  24  causes the control rod  34  to re-enter and align the aperture  36  of the locking clutch  26 , thereby retracting the locking clutch plate  38  from recess  30 . More specifically, a tapered distal end of the control rod  34  enters the aperture  36  contacting the aperture along one edge. As the tapered end enters the aperture, the sliding contact on the taper pushes the aperture into alignment by forcing the semicircular clutch plate inwards thereby realigning the aperture  36  with the control rod  34  and predominant axis  18  of the sections  14 ,  16  thereby retracting the clutch plates  38  and releasing the locking clutch  26 . This allows the intermediate section  14  to be nested within handle section  12 . As intermediate section  14  is fully retracted, if the user continues to depress button  24 , the tapered end of the control rod  34  with push into alignment clutch plate  40  of locking clutch  28 , retracting clutch plate  40  from recess  32 . This allows the inner section  16  to be nested within intermediate section  14 . 
     The locking clutches of the present invention offer significant advantages over prior batons. For example, the section ends incorporating the locking clutches are stronger than opposing locking plate designs due to only one slot  35  being cut into the section end. The portion of the section end opposite slot  35  may also be reinforced for additional strength and damage resistance. Additionally, the individual locking clutch plates  26 ,  28  are stronger than dual opposing locking plate designs because the full thickness of the plate may be maintained throughout the entire locking clutch plate. Thus, reliability and resistance to failure during use in the field is greatly improved. Additional benefits of the present invention include reduced cost of manufacture because there are fewer components to make or purchase, and reduced labor for assembly. 
     From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope hereof. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.