Patent Publication Number: US-7587962-B2

Title: Ratcheting handle for a tool

Description:
FIELD OF THE INVENTION 
   The present invention relates generally to a ratcheting driver tool. More precisely, the present invention relates to a ratcheting handle with a direction selector for receiving a socket tool. 
   BACKGROUND OF THE INVENTION 
   When using a conventional wrench, it is often inconvenient or impossible to torque and rotate a bolt, screw, nut, or other fastener without the user having to periodically reposition his or her hand on the tool handle and/or reposition the tool on the fastener. Ratcheting handles on rotating hand tools have been developed to allow the user to rotate the fastener through any number of rotations without having to reposition his hand on the handle or reposition the tool on the fastener. Ratcheting handles, such as those on conventional socket wrenches, have been developed with a direction selector or lever which the user can manipulate to change the ratcheting direction of the handle. The selector allows the ratcheting handle to apply torque to the fastener either clockwise to advance the fastener into the work piece or counterclockwise to withdraw the fastener out of the work piece. 
   Conventional socket wenches typically have a handle that extends at a ninety degree angle from the rotational axis of the fastener. The long handle and its rotational travel make such wrenches unsuitable for work in tight spaces, such as in an engine bay of an automobile. An extension can be inserted between the socket and the wrench to remove the wrench from the tight space. Of course, this solution requires the user to carry an extra component in his tool set, namely, the extension, and sometimes the extension on hand is still not long enough to completely locate the wrench into open space. Conventional socket wrenches also have a drive block that holds a socket in place, but typically lack additional support for the socket and a mechanism of guiding sockets on the drive block to facilitate rapid attachment/detachment of the socket. 
   Screwdriver-type ratcheting handles have also been developed with a rotating collar for selecting the ratcheting direction of the handle. Typical screwdriver-type ratcheting handles have narrow, tubular handles, similar to conventional screwdriver handles, which are suitable for low torque applications. However, such narrow, tubular handles do not provide sufficient mechanical leverage to develop the torque necessary for jobs that normally require use of a wrench. Also, a user of such narrow, tubular handles usually must grasp the handle in such a way that his palm rests on one side of the handle causing his wrist to be located off to another side of the handle. When a handle must be grasped in this way, it may be difficult for the user to apply sufficient axial force to keep the tool pressed on the fastener while simultaneously applying a large amount of torque to the fastener. 
   Persons skilled in the art have recognized a need for a ratcheting handle that can be used in tight spaces and which provides increased mechanical leverage. There is also a need for a ratcheting handle that allows a user to quickly change ratcheting direction without having to remove or disengage the tool from the fastener. A need also exists for a ratcheting handle that allows for rapid attachment of tools to the handle and that provides stability to the attached tool. The present invention in various embodiments satisfies many of these and other needs. 
   SUMMARY OF THE INVENTION 
   Briefly and in general terms, the present invention is directed to a ratcheting handle with a direction selector for receiving a socket tool. In various embodiments, the ratcheting handle includes a ratchet device including a means for ratcheting, a lock mechanism, a forward portion, and a rear portion, the ratchet device configured such that the rear portion is rotatable relative to the forward portion, the lock mechanism movable between a first orientation in which the rear portion is prevented from rotating in a first direction relative to the forward portion and a second orientation in which the rear portion is prevented from rotating in a second direction relative to the forward portion. The handle includes a grip attached to the rear portion of the ratchet device. The handle accepts a socket tool or like device including a forward segment, a recess formed in the forward segment, an adjusting mechanism disposed within the recess, and a rear segment attached to the forward portion of the ratchet device, the recess sized to receive at least a portion of the fastener, the adjusting mechanism moving in accordance with the predetermined size of the fastener when the socket device is pushed onto the fastener. The handle further includes a selector coupled to the lock mechanism, the selector including a forward end, an inward facing surface, an outward facing surface, and a forward aperture formed at the forward end and sized to receive the socket device, the inward facing surface surrounding the rear segment of the socket device, the outward facing surface positioned to be manipulated by a user of the tool to move the lock mechanism from the first orientation to the second orientation and from the second orientation to the first orientation. 
   In one embodiment, the adjusting mechanism includes a plurality movable pins extending axially within the recess of the socket device, the pins moving axially and independently of each other between a forward position and a rear position, and the pins are attached to the socket device such that when the socket device is pushed onto the fastener, a first number of the pins move from the forward position to the rear position and a second number of the pins remain at the forward position, and when torque is applied to the grip by a user, the applied torque is transferred to the fastener by the second number of the pins. 
   The ratcheting handle has an axis of rotation and the grip may include triangular shaped grip portions with peaks located away from the axis of rotation, improving the lever arm and mechanical advantage when the user applies torque to the grip. Also, the grip may include a curved, convex shaped rearward facing surface to allow axial pressure to be applied to the tool by the user to assist in advancing the fastener into the work piece. 
   The features and advantages of the invention will be more readily understood from the following detailed description which should be read in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a ratcheting handle showing a grip, a selector in front of the grip, and a tool adapter disposed within a recess of the selector. 
       FIG. 2  is an exploded, perspective view from the front of the ratcheting handle of  FIG. 1  showing a ratchet device having a forward end attached to the tool adapter, a lock mechanism coupled to the selector by means of a pin, and a rear portion having ribs that mate with grooves in a grip cavity formed in the grip. 
       FIG. 3  is an exploded, perspective view from the rear of the ratcheting handle of  FIG. 1  showing a drive block attached to the forward portion of the ratchet device and sized to fit into a square aperture formed in a tool, a rear aperture formed in the selector and sized to receive the forward portion of the ratchet device, and a forward flange on the grip. 
       FIG. 4  is cross-sectional view of an assembled ratcheting socket tool showing a socket at the front end of the tool, a selector surrounding a rear segment of the socket, a drive block securing the socket, a grip having a forward facing surfacing abutting a rear end of the selector, and a ratchet device having a forward end attached to the drive block. 
       FIG. 5  is a perspective view of the ratcheting socket tool of  FIG. 4  showing the middle finger, ring finger, and little finger of a user wrapped around a first forward facing surface of a first gripping portion of the grip, the index finger and thumb of the user wrapped around a second gripping portion of the grip, and the palm of the user pushing a rearward facing surface of the grip. 
       FIG. 6  is a perspective view of a self-adjusting, universal socket tool showing a cavity formed in the socket, a plurality of movable pins disposed within the cavity and biased outward, and a spacer pin centrally disposed among the movable pins. 
       FIG. 7  is an exploded, perspective view of the self-adjusting socket tool of  FIG. 5  showing a biasing device comprising a perforated frame retained within notches formed in the cavity of the socket and a plurality of springs coiled around the plurality of movable pins. 
       FIG. 8  is an exploded, perspective view of a preferred embodiment pawl and gear ratcheting device. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now in more detail to the exemplary drawings for purposes of illustrating embodiments of the present invention, wherein like reference numerals designate corresponding or like elements among the several views, there is shown in  FIG. 1  a ratcheting handle  10  adapted for use with a driving tool, which may be removably or permanently attached to the handle  10 . When the tool is attached to the handle  10 , a user can rotate the tool in a selected direction by grasping and rotating the handle in the selected direction. In this way, a fastener to be driven by the tool may also be rotated in the selected direction. The handle  10  has a ratcheting function, which allows the user to rotate the handle in a direction opposite the selected direction without rotating the tool. In this way, the user can rotate the tool and the fastener through an unlimited number of rotations in the selected direction without him letting go of the handle  10  and without removing or disengaging the tool from the fastener. This arrangement enables the user to quickly, efficiently, and with low effort to drive a fastener into or withdraw a fastener from a work piece. 
   In the preferred embodiment of  FIG. 1 , the handle  10  includes an ergonomically shaped grip  12  having an asymmetrical triangular shape with a long, curved bottom, a forward curving back, and a projection at the top. A barrel-like direction selector  14  is located in front of the grip  12 . A tool adapter  16  for securing a tool is centrally located within the selector  14  and is accessible through a forward facing aperture formed in the selector  14 . In use, a tool is inserted into the forward facing aperture and pushed into engagement with the tool adapter  16 . Preferably, the selector  14  rotates with the tool adapter  16  and the attached tool as the user rotates the handle  10  in that same direction. Advantageously, because the selector  14  rotates with the tool, tool rotation cannot inadvertently shift or change the ratcheting direction of the handle  10 . 
   As shown in  FIG. 2 , the handle  10  includes a ratchet device  18 , which is normally enclosed within the grip  12  and selector  14 . The ratchet device  18  has a forward portion  20  transitioning to the tool adapter  16 , a lock mechanism  22 , and a rear portion  24  engaging the grip  12 . The ratchet mechanism uses a conventional pawl biased into a gearwheel or rack (not shown), or a double pawl and gearwheel or rack arrangement could be used for selective forward and reverse ratcheting capability (described in more detail below). The rear portion  24  is rotatable relative to the forward portion  20  about a rotational axis  25  of the ratchet device  18 . The lock mechanism  22  is movable between a first orientation and a second orientation. In the first orientation, the rear portion  24  is locked against, or otherwise prevented from, rotating in a first direction  26  relative to the forward portion  20 . In the second orientation, the rear portion  24  is prevented from rotating in a second direction  28  relative to the forward direction. 
     FIG. 8  is a preferred embodiment of the ratchet device  18 . The ratchet device  18  has a shaft made from a front barrel  104  receiving a rear barrel  108  therein, which receives a switch rod  110  therethrough. The shaft has the tool adapter  16  at the front end and a slot  106  at the back end to receive the switch rod  110 , wherein a spring-loaded, square shaped pawl  112  slides within the slot  106 . A snap ring  114  holds the shaft assembly components together. A radial lock pin  38  passes through the selector switch opening or recess  42  to hold the switch rod  110  inside the shaft. The grip  12  fits over the retainer  100 . Rotating the grip  12  rotates the retainer  100 , which has ribs  36  on its opening or recess  42  to hold the switch rod  110  inside the shaft. The grip  12  fits over the retainer  100 . Rotating the grip  12  rotates the retainer  100 , which has ribs  36  on its outside circumference that transmit torque between it and the grip. The retainer  100  overlies the rear portion  24  of the shaft where the edges of the square-shaped pawl  112  selective engage the internal teeth  102  of the retainer  100 . The selector  14  overlies the recess  42 , wherein the radial lock pin  38  engages the selector  14 , thereby linking the selector  14  to the pawl  112  via the switch rod  110 . Rotating the selector  14  in the first or second directions  26 ,  28  of  FIG. 2  slides the pawl  112  into engagement or disengagement with the internal teeth  102  at one side of the retainer  100  or the other. This enables torque transmission while rotating in one direction while ratcheting freely in the opposite direction. More details of the ratchet mechanism can be found in, for example, U.S. Pat. No. 5,038,452 (Beugelsdyk et al.), or U.S. Pat. No. 5,582,081 (Lin), the contents of which are hereby incorporated by reference. 
   The grip  12  has a forward facing aperture  30  leading to a grip cavity  32  formed into the grip. Preferably, axially extending grooves  34  are formed at the interior walls of the grip cavity  32  and axially extending ribs  36  are formed on the rear portion  24  of the ratchet device  18 . When assembled, the grooves  34  and ribs  36  interlock to ensure that the rear portion  24  and grip  12  rotate together. The grooves  34  and ribs  36  may be replaced with a friction fit, adhesive bond, a radially extending roll pin, a single groove and tooth, etc., to interlock the rear portion  24  to the grip  12 . 
   In  FIG. 2 , the selector  14  is coupled to the lock mechanism  22  by a radial lock pin  38 , which extends through a side-facing aperture  40  formed through the selector and extending into a recess  42  formed in the ratchet device  18 . Preferably, the selector  14  is somewhat barrel-shaped and includes a cylindrical wall  44  which helps support or retain a tool therein. The cylindrical wall  44  extends axially in a direction parallel to the rotational axis  25  of the ratchet device  18 . The cylindrical wall  44  defines a central axis  46  of the selector  14  and has an outward facing surface  48  that faces away from the central axis and an inward facing surface  50  that faces toward the central axis. The central axis  46  is preferably coaxial and coincides with the rotational axis  25  of the ratchet device  18 . 
   The inward facing surface  50  of the selector  14  defines a tool recess  51  having an inner diameter  52  sized to accommodate a portion of the tool that is to be attached to the tool adapter  16 . This inner diameter  52  is preferably 1.030±0.002 inch so that it readily accepts standard socket tools having an outside diameter of one inch or less, so there is a gap of about 0.030±0.002 inch between the tool  57  O.D. and the selector  14  I.D. Through empirical observations, these dimensions create a preferred fitment that provides sufficient axial support and guidance of the tool  57  by the selector barrel for installation and use, yet preserves adequate clearance so that the tool  57  can be easily detached from the selector  14 . The tool recess  51  extends from a forward aperture  53  circumscribed by an optional chamfer, formed at the forward end  55  of the selector  14  and is sized to receive a socket tool  57 . When assembled, the inward facing surface  50  surrounds the tool adapter  16 . Also, the inward facing surface  50  is spaced a radial distance  47  ( FIG. 1 ) apart from the tool adapter and located to be adjacent to an exterior of a portion of the tool attached to the tool adapter  16  ( FIG. 4 ). The inward facing surface  50  can be used to physically guide the tool into engagement with the tool adapter  16 , and provides further lateral support for the tool during use. As such, the inward facing surface  50  facilitates rapid attachment of the tool to the handle  10  and provides stability to the attached tool when the handle is rotated by the user. 
   The outward facing surface  48  of the selector  14  may be manipulated by the user to move the lock mechanism  22  of the ratchet device  18  from the first orientation and the second orientation. Preferably, the selector  14  is wider toward the rear of the handle  10  in that the outward facing surface  48  has a forward area  54  with a forward outer diameter  56  and a rear area  58  with a rear outer diameter  60  that is greater than the forward outer diameter  56 , creating a slight taper or step. Preferably, one or more grooves  49  may be formed to allow the user to more easily grasp and manipulate the selector  14 . The grooved surface may be replaced by or supplemented by a knurled surface, a checkered surface, a fluted surface, a knobbed surface, or any anti-slip surface finish or treatment. In the embodiment shown, the grooves  49  are formed in the rear area  58  corresponding to outer diameter  60  so that they are adjacent the grip  12  when the handle  10  is assembled. Thus arranged, the grooves  49  and the change in diameter of the selector  14  provide tactile feedback to the user, thereby allowing the user to readily locate the selector on the handle  10  even though the tool and handle are not within eyesight. Furthermore, by pressing against the grooves  49  with an extended index finger, the user can conveniently rotate the selector  14  into either the first orientation or the second orientation without having to release the handhold on the grip  12 . 
   In  FIG. 3 , a socket-type tool  57  is shown detached from the tool adapter  16  of the disassembled handle  10  of  FIG. 2 . A rear aperture  59  is formed at the rear end  61  of the selector  14  and is sized to receive the forward portion  20  of the ratchet device  18  so that the tool adapter  16  is disposed within the tool recess  51  when assembled. The tool adapter  16  includes preferably a square-shaped drive block  62  having four side surfaces  64  and a key, detent, or pushing surface  66  protruding from one of the side surfaces. The drive block  62  is sized to mate with a standard socket tool square aperture  68  formed in the tool  57 , such that the side surfaces  64  engage and rotate the tool  57  when the grip  12  is rotated by the user. 
     FIG. 4  is a cross-sectional view of the handle  10  taken along its axis of rotation, and shows a ratcheting socket tool assembly  69 . A socket  57  is shown engaged with a drive block  62  of a tool adapter  16 . The socket  57  has a forward segment  70  and a forward recess  72  formed in the forward segment  70 . The forward recess  72  is sized to receive and engage a fastener, such as a nut or the head of a bolt, having a predetermined size. The forward recess  72  may have a polygonal shape that accommodates a common hexagonal nut or the hex head of the bolt. The socket  57  also has a rear segment  74  attached to the drive block  62  of the tool adapter  16 . The drive block  62  may be a standard size for conventional sockets. The side surfaces  64  of the drive block  62  contact the inner surface  75  of the socket  57  while the key or pushing surface  66  of the drive block extends into a retaining recess  76  formed in the inner surface  75  of the socket. Preferably, the tool adapter  16  further includes a biasing device  78 , such as a spring, coupled to the pushing surface  66 . The biasing device  78  urges the pushing surface  66  into the retaining recess  76  while allowing the pushing surface to move out of the retaining recess when a predetermined amount of force is used to pull apart the socket  57  and the tool adapter  16 . Accordingly, in one embodiment, the socket  57  may be attached and disconnected from the handle  10  and replaced with another socket having a different size. 
   The drive block  62  has a forward tip  79  that is preferably disposed within the tool recess  51  and to the rear of the forward end  55  of the selector  14 . As seen in  FIG. 4 , the drive block  62  is connected to a stem  80  located at the rear end of the tool adapter  16 . The stem  80  is fixedly attached to the forward portion  20  of the ratchet device  18 . Preferably, the stem  80  includes retainer features, such as grooves and/or ribs, which fixedly engage with corresponding features formed on the forward portion  20  of the ratchet device  18 . In other embodiments the tool adapter  16  is integrally formed on the forward portion  20  of the ratchet device  18 . In yet other alternative embodiments, the socket  57  is permanently attached directly to the forward portion  20  of the ratchet device  18 . 
   Still referring to  FIG. 4 , the grip  12  preferably has an asymmetrical cross-section on a plane extending through the rotational axis  25  of the ratchet device  18 . In the preferred embodiment the grip  12  has a first gripping portion  82  and a second gripping portion  84  smaller than the first gripping portion  82 . The first gripping portion  82  has a first forward facing surface  86  defining a first angle  88  extending entirely beneath the rotational axis  25  in  FIG. 4 . The second gripping portion  84  has a second forward facing surface  90  that defines a second angle  92  extending entirely above the rotational axis  25  in  FIG. 4 . In the embodiment shown, the second angle  92  is greater than the first angle  88 . In other embodiments, the relationship between the first and second angles  88 ,  92  is reversed or the angles  88 ,  92  are the same. In various embodiments, the first angle  88  preferably falls within a range of about 20-40 degrees inclusive and more preferably about 33-35 degrees inclusive, and the second angle  92  preferably falls into a range of about 35-80 degrees inclusive and more preferably about 37-40 degrees inclusive. Empirical observations suggest that these angles provide improved leverage and gripping ergonomics for the user. The grip  12  also has a curved, preferably convex, rearward facing surface  94  that extends from the first gripping portion  82  to the second gripping portion  84 . Preferably, at least a portion of the grip  12  is overmolded with a slip-resistant elastomeric material, such as rubber. 
   Referring to  FIGS. 2-4 , the forward end  95  of the grip  12  includes a cylindrical outer surface  96  adjacent the first and second, triangular-shaped grip portions  82 ,  84 . As seen in the cross-section of  FIG. 4 , the outer surface  96  slightly tapers inward and then flares outward to form a forward flange  98  at the forward end  95  of the grip  12 . At the forward end  95  of the grip  12 , the outer surface  96  has an outer diameter  99  ( FIG. 3 ) that is substantially matched to the rear outer diameter  60  of the selector  14 . The forward flange  98  provides tactile feedback as well as a finger rest for the user, which enables the user to quickly distinguish by touch only the region just rear of the selector  14  from the cylindrical outer surface  96  of the grip  12 . Also, the forward flange  98  helps to shield the selector  14  from inadvertent manipulation by the user during use. 
   When assembled, the forward flange  98  may abut the rear end  61  of the selector  14 . The forward flange  98  defines a substantially flat, forward facing support surface  100  that may support the rear end  61  of the selector  14 . Preferably, the support surface  100  does not rotationally engage the rear end  61  of the selector  14  so that rotation of the grip  12  does cause the selector to also rotate and inadvertently shift the orientation of the lock mechanism  22  of the ratchet device  18 . For example, a small diameter thrust washer or built-in conical face (not shown) may rest between rear end  61  and forward flange  98  to minimize a frictional torque connection between the respective parts. 
   In  FIG. 5 , the ratcheting socket tool assembly  69  of  FIG. 4  is shown in use. The first and second gripping portions  82 ,  84  extend outwardly in opposite directions from the rotational axis  25  to make it easier for a user grasping the grip  12  to apply greater torque to the handle  10  than would otherwise be possible with a narrow, tubular handle. The second gripping portion  84  is shaped to fit between the user&#39;s thumb and index finger. The first gripping portion  82  is shaped to allow the user&#39;s other fingers to wrap around the first forward facing surface  86  of the first gripping portion  82 . 
   Furthermore, the peaks or vertices of the triangular shaped first and second gripping portions  82 ,  84  increase the lever arm by locating a gripping point far away from the axis of rotation, as compared to a straight-barrel handle in a conventional screw driver for example. This lever arm translates to increased leverage and greater achievable torque transmitted to the socket tool. 
   The rearward facing surface  94  of the grip  12  is curved so that it rests comfortably in the palm of the user. In this way, the rearward facing surface  94  provides a large surface for the user&#39;s palm to push the handle  10  axially forward so that the socket remains engaged with a fastener. The rearward facing surface  94  of the grip  12  is located at an axial distance  101  from the rear area of the selector  14 . In one embodiment, the axial distance  101  is about 10 centimeters (about 4 inches). Preferably, the axial distance  101  is selected such that the user can place his or her index finger on the rear area  58  of the selector  14  while the rest of his hand is wrapped around the grip  12 . This allows the user to quickly and optionally change the ratcheting direction of the handle without having to remove the tool from the fastener or reposition his hand on the grip  12 . 
     FIGS. 6 and 7  show a self-adjusting, universal socket tool  57  that may be temporarily or permanently attached to the handles shown in  FIGS. 1-5 . The self-adjusting socket tool  75  has an adjusting mechanism  102  that adjusts for the size of the bolt head or nut in a variety of fasteners. The self-adjusting socket tool  57  may be of the type disclosed in U.S. Pat. Nos. 5,622,090, 5,791,209, and 6,928,906 to Marks, the entire contents of which are hereby incorporated by reference. As shown in the exemplary embodiments of  FIGS. 6 and 7 , the adjusting mechanism  102  includes a plurality of elongate pins  104  disposed within the forward recess  72  of the socket tool  57 . The elongate pins  104  extend axially within the forward recess  72  and are able to move independently of each other in an axial direction. The elongate pins  104  are attached to the body  105  of the self-adjusting socket tool  57  by a perforated plate or frame  106  which is retained by notches  108  formed in the inner surface  75  of the body  105 . Each elongate pin  104  is biased by a spring  114  away from the frame  106  and out of the body  105 . The perforations  110  in the frame  106  are arranged so that the elongate pins  104  are generally parallel to each other and act as a bundled. An optional, movable spacer pin  112  may be located at the center of the bundle of elongate pins  104 , which reduces total number of elongate pins required to fill the forward recess  72  and helps guide the socket tool  57  on to a bolt head. 
   Preferably, a coiled spring  114  is disposed around the shaft of each of the elongate pins  104 , with one end of the spring pushing against a shoulder  116  formed on the elongate pin and the opposite end of the spring pushing against the frame  106 . The springs  114  bias the elongate pins  104  to move toward the forward position (shown in  FIG. 6 ) when the socket tool is pulled away from a fastener, and bring compliance into the adjusting mechanism  102 . Of course, other types of springs and biasing devices may be used. When in the forward position, the elongate pins  104  are preferably located entirely within the forward recess  72  of the inner surface  75 . The elongate pins  104  may extend outside of the forward recess  72  in other embodiments. When the self-adjusting socket tool  57  is pushed onto a fastener having a given size and shape, the compliance in the adjusting mechanism  102  adapts the elongate pins  104 —allowing some to be pushed into the body  105 —to the given size and shape of the fastener. The remaining pins  104  are bundled and surround the fastener, ready to transmit torque to the fastener. Still other types of socket tools may of course be used with the handle  10  described earlier. 
   While several particular forms of the invention have been illustrated and described, it will also be apparent that various modifications can be made without departing from the scope of the invention. Other types of socket tools or tool bits may be attached to the handle. Examples of other types of tools include, without limitation, screwdriver bits and Torx bits. Further, the handle and its socket tool or tool bit can be used to apply torque to fasteners such as screws, bolts, rivets, nuts, cap nuts, wing nuts, or gas or water line valve stems, spigots, drain plugs, stripped nuts, etc. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.