Patent Publication Number: US-11638842-B2

Title: Portable electric rescue tool

Description:
TECHNICAL FIELD OF THE INVENTION 
     The present invention relates generally to portable rescue tools, and more particularly, to emergency portable spreader and cutter tools powered by a battery pack. 
     BACKGROUND OF THE INVENTION 
     Emergency rescue type tools are generally used by various rescue personnel such as police, fire fighting, and paramedic personnel to spread, open, or cut through metal layers of a vehicle, building, or other enclosure to extract trapped or injured persons. Pushing and pulling forces of 7,000 to 15,000 pounds at the tips of these tools are considered normal for the proper operation of such tools. To achieve such forces, these rescue tools typically are powered by hydraulics or combustion type engines. Such tools are costly, heavy, and have limited portability as they must be powered by nearby power supply devices (e.g., a hydraulic pump). 
     Recently, some rescue tools have been developed that are powered by electric power, such as described in U.S. Pat. No. 5,520,064, titled Portable Rescue Tool. This patent describes a rescue tool having a DC motor that operates on electric power and includes clutch, gear, and actuator mechanisms for providing high torque spreading and/or cutting motion. However, the electric rescue tool requires connection to an external DC power source, which limits the portability of the tool. 
     SUMMARY OF THE INVENTION 
     The present invention relates broadly to a portable electric emergency rescue tool, such as a spreader and cutter tool, that operates on a DC power source, which may be an external power source and/or an onboard battery, such as a rechargeable battery. For example, the tool includes a battery cradle or battery attachment portion adapted to receive a rechargeable battery pack and electrically couple the battery pack to the tool. The tool also includes a power adapter adapted to be removably coupled to the battery attachment portion instead of the battery pack, which allows the tool to be electrically coupled to an external DC power source, such as a 12V DC vehicle battery or other DC power source. 
     In other aspects, the tool may include a remote control removably or wirelessly couplable to the tool to allow the tool to be operated remotely instead of manually. Thus, an operator can operate the tool manually or remotely as the situation requires. For example, certain situations can be dangerous and unstable, and may require the operator to be in an unsafe location in order to manually operate the tool. The remote operation allows an operator to remain in a safe location, away from danger. 
     In an embodiment, the present invention broadly comprises a portable rescue tool having first and second operable jaws. The tool includes a housing, a battery adapted to removably couple to the housing and provide power, and a motor is disposed in the housing. In an embodiment, the motor is adapted to run on DC power via the battery, and provide output torque. A gear assembly is disposed in the housing and is operably coupled to the motor. The gear assembly is adapted to receive the output torque from the motor. An actuator assembly is also operably coupled to the gear assembly and adapted to receive output torque from the gear assembly, and to operate the jaws. 
     In another embodiment, the present invention broadly comprises a portable rescue tool with first and second jaws. The tool includes a housing, a battery adapted to removably couple to the housing, a power adapter adapted to removably couple to the housing when the battery is removed from the housing and electrically couple to an external power source. A motor is disposed in the housing, and the motor is adapted to receive power and provide output torque. In an embodiment, the power is 12V DC. A gear assembly is disposed in the housing and operably coupled to the motor. The gear assembly is adapted to receive the output torque from the motor. An actuator assembly is also operably coupled to the gear assembly and adapted to receive output torque from the gear assembly, and operate the jaws. 
     In another embodiment, the present invention relates to a portable rescue tool with first and second jaws. The tool includes a housing, a battery adapted to removably couple to the housing and provide power, and a motor disposed in the housing. The motor is adapted to receive power via the battery, and provide output torque. A gear assembly is disposed in the housing and operably coupled to the motor. The gear assembly is adapted to receive the output torque from the motor. An actuator assembly is operably coupled to the gear assembly and adapted to receive output torque from the gear assembly, and to operate the jaws. In this embodiment, the tool also includes a remote control connection port disposed on the housing and adapted to operably couple to a remote control adapted to operate the tool remotely. The remote control can be coupled wirelessly or via a communication wire. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of facilitating an understanding of the subject matter sought to be protected, there is illustrated in the accompanying drawing 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 a tool, according to an embodiment of the present invention. 
         FIG.  2    is a side view of the tool of  FIG.  1   , according to an embodiment of the present invention. 
         FIG.  3    is a side view of the tool of  FIG.  1    with the housing removed, according to an embodiment of the present invention. 
         FIG.  4    is a perspective view of a controller assembly of the tool of  FIG.  1   , according to an embodiment of the present invention. 
         FIG.  5    is a perspective view of a battery attachment portion of the tool of  FIG.  1    and an exemplary battery, according to an embodiment of the present invention. 
         FIG.  6    is a side view of the battery attachment portion of the tool of  FIG.  1    and the exemplary battery, according to an embodiment of the present invention. 
         FIG.  7    is a perspective view of the exemplary battery disposed in the battery attachment portion, according to an embodiment of the present invention. 
         FIG.  8    is a perspective view of a battery attachment portion of the tool of  FIG.  1    and an exemplary power adapter, according to an embodiment of the present invention. 
         FIG.  9    is a side view of the battery attachment portion of the tool of  FIG.  1    and the exemplary power adapter, according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings, and will herein be described in detail, a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated. As used herein, the term “present invention” is not intended to limit the scope of the claimed invention and is instead a term used to discuss exemplary embodiments of the invention for explanatory purposes only. 
     The present invention relates broadly to a portable electric rescue tool, such as spreader and cutter tool, that operates on a power source, which may be an external power source and/or an onboard rechargeable battery. In an embodiment, the tool operates on DC power. For example, the tool includes a battery cradle or battery attachment portion adapted to removably receive a rechargeable battery pack and electrically couple the battery pack to the tool. The tool also includes a power adapter that is adapted to be removably coupled to the battery attachment portion instead of the battery pack, and allows the tool to be electrically connected to an external power source, such as a vehicle battery or other power source. 
     In other aspects, the tool may include a remote control removably coupleable to the tool to allow the tool to be operated remotely instead of manually. The remote control can be operably coupled to the tool wireless or with a communication wire. Thus, an operator can operate the tool manually or remotely as the situation requires. For example, certain situations can be dangerous and unstable, and may require the operator to be in an unsafe location in order to manually operate the tool. Remote operation allows an operator to remain in a safe location, away from danger. 
     Referring to  FIGS.  1 - 3   , a tool  100 , such as a spreader and cutter rescue tool, is illustrated. The tool  100  includes a tool housing  102 , a motor  104  disposed in the tool housing  102 , a battery attachment portion  106  adapted to receive a battery and/or a power adapter, a gear assembly  108  disposed in the tool housing  102  and operably coupled to the motor  104 , an actuator assembly  110  operably coupled to the gear assembly  108 , and first and second jaws  112 ,  114 , such as spreader and cutter type jaws, operably coupled to the actuator assembly  110 . The tool housing  102  may include a first portion  116  adapted to at least partially cover a bottom portion of the tool  100 , a second portion  118  adapted to at least partially cover a middle section or sides of the tool  100 , and a third portion  120 , which may include the battery attachment portion  106 , and that is adapted to at least partially cover a top portion of the tool  100 . 
     The tool housing  100  may also include a first (upper) plate  122  and a second (lower) plate  124  that are disposed substantially parallel to each other and extend longitudinally along the tool  100 . One or both of the first and second plates  122 ,  124  include one or more cutouts adapted to receive and mate with the motor  104 , gear assembly  108 , and actuator assembly  110  to couple the motor  104 , gear assembly  108 , and actuator assembly  110  to the tool housing  102 . The first and second plates  122 ,  124  may also be coupled together via one or more spacers to provide strength and rigidity to the tool  100 . The first portion  116  of the tool housing  102  may also be coupled to the second plate  124 , the second portion  118  may be coupled to one or both of the first and second plates  122 ,  124 , and the third portion  120  (including the battery attachment portion  106 ) may be coupled to the first plate  122 . 
     The motor  104  disposed in the tool housing  102 , is an electric DC motor. For example, the motor  104  may be any type of DC electric motor, such as a brushed or brushless type DC motor. In an example, the motor  104  is a self-contained electric motor having an output sprocket and rotor shaft  126 . The motor  104  receives input power directly or indirectly (via a controller assembly  140 , as described in further detail below) from a battery pack or power adapter coupled to an external power source. In an embodiment, the motor  104  operates on 12V DC power. In another embodiment, the motor  104  operates on 14.4V DC power. In further embodiments, the motor  104  may operate on any voltage DC power. For example, the motor  104  may operate on any voltage, such as 6V to 60V, including 12V, 15V, 18V, 28V, 48V, 60V, etc. 
     The gear assembly  108  and actuator assembly  110  may be similar to those described in U.S. Pat. No. 5,520,064, titled Portable Rescue Tool, which is incorporated herein by reference in its entirety. For example, the gear assembly  110  may include input and output sprockets  128 ,  130 . The input sprocket  128  is adapted to receive output speed and torque from the motor  104  via a first belt or chain  132  operably coupling the output sprocket and rotor shaft  126  of the motor  104  to the input sprocket  128  of the gear assembly  108 . The output sprocket  130  is adapted to provide output speed and torque from the gear assembly  108  to the actuator assembly  110  via a second belt or chain  134  operably coupling the output sprocket  130  of the gear assembly  108  to an input sprocket  136  of the actuator assembly  110 . The gear assembly  108  is adapted to decrease speed and increase torque of the motor output. 
     The gear assembly  108  may also include a brake assembly  138 , which may be a fail-safe, electrically-off brake connected in parallel across the terminals of the motor  104 . Thus, when the motor  104  is not provided with DC power, the brake assembly  138  is engaged, and when the motor  104  is provided with DC power, the brake assembly  138  is disengaged. 
     The actuator assembly  110  includes the input sprocket  136 , and a second gear assembly adapted to decrease speed and increase torque output from the gear assembly  108 . As described above, the second chain  134  operatively couples the output sprocket  130  of the gear assembly  108  and the input sprocket  136  of the actuator assembly  110 . Similar to the gear assembly described in U.S. Pat. No. 5,520,064, the second gear assembly includes a shaft onto which the input sprocket  136  is mounted, a sun gear spline coupled to the splined shaft, planet gears operably coupled to the sun gear, planet shafts respectively corresponding to and associated with the planet gears, a splined gear carrier operatively engaged with the planet shafts, a sun gear operably coupled to the splined gear carrier, spindle gears operably coupled to the sun gear, first and second (upper and lower) fixed ring gears  142 ,  144  operably coupled to the spindle gears and having fixed ring gear lugs formed as a part thereof, and a movable ring gear  146  operably coupled to the spindle gears and having movable ring gear lugs formed as a part thereof. The first and second jaws  112 ,  114  (such as spreading and/or cutting arms) are coupled to the movable ring gear lugs of the ring gear  146  and the fixed ring gear lugs of the ring gears  142 ,  144  to perform rescue tool functions (e.g., cutting or spreading). In an example, the total gear reduction from the output of the motor  104  to the output of the actuator assembly  110  (i.e. the opening or the closing motion of the spreading and/or cutting arms) is typically 6000:1, thus providing significant force or power for the rescue tool functions. 
     The actuator assembly  110  may be rotatably coupled to the first and second plates  122 ,  124  with a snap ring or retaining rings, respectively. A clutch mechanism  147  may be utilized to selectively orient and mount the actuator assembly  110  in any one of multiple positions on the first and second plates  122 ,  124 . The clutch mechanism may be similar to that described in U.S. Pat. No. 5,520,064, titled Portable Rescue Tool, or U.S. Pat. No. 10,307,621, titled Portable Rescue Tool, which are both incorporated herein by reference in their entirety. For example, such a clutch mechanism  147  may include a clutch housing  148  (as shown in  FIG.  2   ) and a clutch handle  150  (as shown in  FIG.  3   ). The clutch housing  148  is coupled to the first plate  122 , and a first friction disk may be coupled to the clutch housing  148 . A second friction disk can be disposed directly beneath the first friction disk, and may be keyed to the actuator assembly  110  through the first fixed ring gear  142 . A third friction disk can be disposed beneath the second friction disk and rests upon a spacer. The spacer may be biased upwardly against the third friction disk by a bias device, such as a spring, which is supported by a threaded shaft. The threaded shaft passes through a center of the clutch housing  148  and engages the clutch handle  150 . Thus, the second friction disk, and hence the first fixed ring gear  142 , and the entire actuator assembly  110 , may be fixed in a desired position by tightening the second friction disk between the first and second friction disks and by tightening the clutch handle  150  down along the threaded shaft. 
     The actuator assembly  110  may also be repositioned, with respect to the first and second plates  122 ,  124 , by loosening the clutch handle  150  up along the threaded shaft, thereby relieving the frictional interactions between all of the friction disks and allowing the actuator assembly  110  to be rotated between the first and second plates  122 ,  124 . 
     Referring to  FIGS.  3  and  4   , the tool  100  may also include a controller assembly  140 , including one or more printed circuit boards (PCBs)  152 . The controller assembly  140  may be disposed in the tool housing  102  and coupled to one or both of the first and second plates  122 ,  124 . The controller assembly  140  (such as one or more of the PCBs  152 ) may be electrically coupled to electrical contacts exposed in the battery attachment portion  106 . This provides for electrical coupling of a power source, such as a battery or power adapter disposed in the battery attachment portion  106 , to the controller assembly  140 . The controller assembly  140  (such as one or more of the PCBs  152 ) may also be electrically coupled to the motor  104  and the brake assembly  138 . The controller assembly  140  (such as one or more of the PCBs  152 ) may also be operably coupled to a switch mechanism  154  of the tool  100 . This allows the controller assembly  140  to control the supply of power to the motor  104 , operation of the motor  104 , supply of power to the brake assembly  138 , and operation of the brake assembly  138 . 
     Referring again to  FIGS.  1 - 3   , the switch mechanism  154  is coupled to the tool housing  102 , and operably coupled to the controller assembly  140 . The switch mechanism  154  is adapted to be used to select a mode of operation of the tool  100 , such as, for example, opening or closing of the jaws  112 ,  114 . The switch mechanism  154  operates by causing (or not causing) power to be supplied to the motor  104 . Depending on the position of the switch mechanism  154 , power is allowed to be supplied to the motor  104  and provide a high speed, low torque output selectively in one of two rotational directions. The switch mechanism  154  may be a three-position switch with a first position being a clockwise (CW) direction position, a second position being a counter-clockwise (CCW) direction position, and a third position being a neutral or off position. 
     The battery attachment portion  106  may be part of the tool housing  102 , and be coupled to the first plate  122 . The battery attachment portion  106  may include electrical contact terminals or an opening that exposes the electrical contact terminals. The electrical terminals are adapted to electrically couple to a power source, such as a battery pack or power adapter, disposed in the battery attachment portion  106 . 
     Referring to  FIGS.  5 - 7   , the battery attachment portion  106  includes a base portion  156  with side walls  158 . A groove  160  may be formed in one side of the battery attachment portion  106 , and a latch  162  may be disposed on an opposite side. The latch  162  may include a protrusion  164  that projects inwardly into the battery attachment portion  106 , and a handle  166  operably coupled to the protrusion  164 . In an example, depression of the handle  166  causes the protrusion to move outwardly and away from the battery attachment portion  106  to allow removal of a battery pack or power adapter from the battery attachment portion  106 . 
     The tool  100  may include a battery pack, such as battery pack  168  with electrical contacts adapted to electrically couple to the electrical contacts exposed in the battery attachment portion  106 . As illustrated, the battery pack  168  may include a first projection  170  extending from a first end of the battery pack  168 , and a second projection  172  extending from a second opposing end of the battery pack  168 . The battery pack may be disposed or installed in the battery attachment portion  106  by inserting the first projection  170  into the groove  160  and pushing the battery pack  168  downwards into the battery attachment portion  106  causing the second projection  172  to be disposed underneath the protrusion  164  of the latch  162 , as shown in  FIG.  7   . When the battery pack  168  is disposed in the battery attachment portion  106 , the electrical contacts of the battery pack  168  electrically couple to the electrical contacts exposed in the battery attachment portion  106 . In an embodiment, the battery pack  168  may be a 12V DC rechargeable type of battery pack and include one or more battery cells. In other embodiments, the battery pack  168  may provide any desired voltage. For example, the battery pack  168  may provide any voltage, such as 6V to 60V, including 12V, 14.4V, 15V, 18V, 28V, 48V, 60V, etc. The battery pack  168  may also be any type of battery pack, including a lead-acid, zinc-air, nickel-cadmium (NiCd), nickel-metal hydride (NiMH), lithium-ion (Li-ion), Lithium Iron Phosphate (LiFePO4), and/or lithium-ion polymer (Li-ion polymer) type battery pack. 
     When the battery pack  168  is removed from the battery attachment portion  106 , a power adapter  174  may be disposed in the battery attachment portion  106 . The power adapter  174  includes similar features as the battery pack  164  to allow the power adapter  174  to be disposed in and coupled to the battery attachment portion  106 . For example, the power adapter  174  may include electrical contacts adapted to electrically couple to the electrical contacts exposed in the battery attachment portion  106 . The power adapter  174  also includes a first projection  176  extending from a first end of the power adapter  174 , and a second projection  178  extending from a second opposing end of the power adapter  174 . The power adapter  174  may be disposed or installed in the battery attachment portion  106  by inserting the first projection  176  into the groove  160  and pushing the power adapter  174  downwards into the battery attachment portion  106  causing the second projection  178  to be disposed underneath the protrusion  164  of the latch  162 . When the power adapter  174  is disposed in the battery attachment portion  106 , the electrical contacts of the power adapter  174  electrically couple to the electrical contacts exposed in the battery attachment portion  106 . 
     The power adapter  174  may also include power connection terminals  180  adapted to receive a power cord that is attachable to an external power source, such as an external battery or other power source. In an example, the external power source may be a 12V battery, such as a vehicle battery. In an embodiment, since the tool  100  can be configured for 12V DC, the tool  100  to be used anywhere a 12V DC power source is located, which is generally part of most vehicles. In other embodiments, the tool  100  can be configured for any desired voltage. For example, the tool  100  may operate on any voltage, such as 6V to 60V, including 12V, 14.4V, 15V, 18V, 28V, 48V, 60V, etc. Thus, the external power source may be any voltage capable of operating the tool, such as 6V to 60V, including 12V, 14.4V, 15V, 18V, 28V, 48V, 60V, etc. 
     Referring back to  FIG.  1   , the tool  100  may also include a remote control connection port  182 . The remote connection port  182  may be operably coupled to the controller assembly  140  (such as one or more of the PCBs  152 ). A remote control with a cord  184  may be operably coupled to the remote connection port  182  to allow the tool  100  to be operated remotely instead of manually with the switch mechanism  154 . For example, the remote control coupled to the controller assembly  140  via the remote connection port  182  may be used instead of or in combination with the switch mechanism  154  to cause (or not allow) power to be supplied to the motor  104 . In an embodiment, the tool  100  can include a transponder or transceiver to wirelessly communicate with a remote control. Like the switch mechanism  154 , the remote control may provide a remote three-position switch with a first position being a clockwise (CW) direction position, a second position being a counter-clockwise (CCW) direction position, and a third position being a neutral or off position. 
     Referring again to  FIG.  1   , the tool may also include first and second handles  186 ,  188  coupled to the tool housing  102  to allow for manual operation of the tool  100 . During manual operation, a user may hold or grasp the tool  100  via the first and second handles  186 ,  188 , and control operation of the tool  100  via the switch mechanism  154 . Alternately, or in addition to manual operation, the tool  100  may be operated remotely. During remote operation, the remote control may be operably coupled to the remote connection port  182 , and a user may control operation of the tool  100  via the remote control. For example, certain situations can be dangerous and unstable, and may require the user/operator to be in an unsafe location in order to manually operate the tool. This remote operation allows an operator to remain in a safe location, away from danger. 
     As used herein, the term “coupled” and its functional equivalents are not intended to necessarily be limited to direct, mechanical coupling of two or more components. Instead, the term “coupled” and its functional equivalents are intended to mean any direct or indirect mechanical, electrical, or chemical connection between two or more objects, features, work pieces, and/or environmental matter. “Coupled” is also intended to mean, in some examples, one object being integral with another object. As used herein, the term “a” or “one” may include one or more items unless specifically stated otherwise. 
     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.