Patent Publication Number: US-8118444-B2

Title: LED illuminated tool

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Priority is claimed on Provisional Patent Application Ser. No. 60/936,269, filed Jun. 19, 2007. Further, this is a Continuation-In-Part of application Ser. No. 12/006,516, filed Jan. 3, 2008, now U.S. Pat. No. 7,510,296 entitled: “Led Illuminated Screwdriver”. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     REFERENCE TO A “SEQUENCE LISTING”, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON COMPACT DISC 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to tools for driving fasteners such as screws or for illuminating hard to reach areas, and more particularly, to an illuminating tool having an LED situated in a bore extending through the shaft. 
     2. Description Of Prior Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
     Tools for driving fasteners such as screws are common. Conventional tools of this type include a solid handle, made of plastic, rubber, or wood, from which a rigid metal shaft extends. The screw-engaging end of the shaft is shaped to engage a correspondingly shaped recess in the screw head. For conventional screw heads, the shaft end is tapered to form a blade. 
     Screwdrivers sometimes must be used to drive screws in poorly lighted places. In such instances, a light source may be required to provide sufficient light to enable the user of the screwdriver to correctly align the screw-engaging end of the screwdriver with the recess in the screw head. A flashlight or other portable light source could be used if space permits. However, such light sources must be held by the user while using the screwdriver, forcing the user to manipulate the screwdriver and the screw with one hand, while holding the light source with the other. Manipulating the screwdriver and the screw with one hand is difficult. 
     In order to overcome this problem, screwdriver handles have been fashioned to include a battery and a standard incandescent flashlight-type bulb which shines light from the front of the handle along the exterior of the shaft, toward the screw-engaging end of the shaft. See, for example, Singleton, U.S. Pat. No. 4,107,765; Nalbandian U.S. Pat. No. 4,253,757; McKain U.S. Pat. No. 5,369,555; Berg, U.S. Pat. No. 4,936,171 and Barlet et al. U.S. Pat. No. 2,670,427. 
     However, the devices disclosed in the above mentioned patents have a disadvantage inherent in having such a bulb located in the handle, and thus far from the screw-engaging end of the shaft, which is the point where illumination is required. Because the light from the bulb spreads out as it travels along the shaft, and because of the limitations on the light output of a standard battery operated incandescent bulb, placing the bulb in the handle has proven to be less than adequate for illuminating the area immediately in front of the blade of the screw-engaging end of the shaft. 
     U.S. Pat. No. 1,603,985 to Rosenberg unsuccessfully attempted to overcome that problem by placing the bulb within a bore in the shaft. That arrangement required a very small bulb which provided inadequate light and, at the same time, required such a large bore to accommodate the bulb that the strength of the shaft is weakened substantially. 
     Another attempt to overcome the problem inherent in the above mentioned patents is disclosed by Jong-Pyng Jeng, in U.S. Pat. Nos. 5,124,893 and 5,211,468. Those patents teach a device in which bulbs are mounted in a member which slides along the shaft. That configuration allowed the bulbs to be situated close to the screw-engaging end of the shaft. However, the bulb-carrying member resulted in an extremely cumbersome tool in which the view of the screw-engaging end of the shaft is at least partially obstructed when the bulb-carrying member is situated close enough to the blade to provide adequate illumination Further, the device required exposed wires extending from the bulb-carrying member to the handle where the battery is located. 
     In my U.S. Pat. No. 5,826,969, a screwdriver is disclosed in which the handle has a cavity for retaining a battery and a standard incandescent bulb. The shaft, extending from one end of the handle, is provided with a bore or channel extending from the handle and through the screw-engaging end of the shaft. The blade at the end of the shaft is bifurcated, having blade sections one either side of the bore opening. The bore guided light from the bulb down the shaft and out the end of the shaft, to illuminate the area proximate the front of the blade. 
     That invention overcame the disadvantages of the above noted prior art structures by utilizing a light guiding bore extending within the interior of the shaft and a bifurcated blade at the screw-engaging end of the shaft. The bore directs the light down the shaft and through the bifurcated blade to illuminate the area proximate the front of the screw-engaging end of the shaft. However, the structure of U.S. Pat. No. 5,826,969 still does not provide an optimum result. 
     It has been suggested, for example in U.S. Pat. No. 4,302,797 to Cooper, that a fiber optic bundle be used in the bore of the shaft to convey light from bulb in the handle to the screw-engaging end of the shaft. However, even that approach has proven inadequate. 
     The present invention constitutes a further improvement over my patented device, and that proposed by Cooper. It utilizes a LED instead of an incandescent bulb as the light source. Further, the LED is situated within the bore of the shaft, at a location proximate the end of the screw-engaging end of the shaft, instead of in a remote position in the handle. 
     Since the LED is situated close to the end of the shaft, the light from the LED does not spread out to any significant extent and almost all of the light is focused on the point where illumination is required. Thus, the relatively high intensity light from the LED provides ample illumination, exactly where it is needed to illuminate the area in front of the screw-engaging end of the shaft. 
     Further, because the diameter of the LED is quite small, the inner diameter of the bore can be small relative to the outer diameter of the shaft. Hence, the bore does not significantly reduce the strength of the shaft. 
     The LED is connected to the battery power source in the handle by wires that extend through the bore, from the handle to the LED. A spring-loaded pushbutton switch is situated on the exterior of the handle to actuate the LED when depressed. 
     In addition, a very similar structure, with the screw-engaging end eliminated, makes an excellent tool for illuminating hard to reach areas or for focusing light in a small area. 
     It is therefore, a prime object of the present invention to provide a LED illuminated tool. 
     It is another object of the present invention to provide a LED illuminated tool in which adequate illumination of the area in front of the end of the shaft is provided by mounting the LED close to the end of the shaft. 
     It is another object of the present invention to provide a LED illuminated tool in which the LED is mounted within a bore extending though the shaft. 
     It is another object of the present invention to provide a LED illuminated tool in the form of a screwdriver in which the strength of the shaft is not weakened substantially by the bore in which the LED is situated. 
     It is another object of the present invention to provide a LED illuminated tool in which the inner diameter of the bore is relatively small as compared to the outer diameter of the shaft. 
     It is another object of the present invention to provide an LED illuminated screwdriver with interchangeable heads for use with multiple screw heads having various configurations. 
     It is another object of the present invention to provide a LED illuminated tool for illuminating hard to reach areas. 
     It is another object of the present invention to provide a a LED illuminated tool for focusing light in a small area. 
     BRIEF SUMMARY OF THE INVENTION 
     In general, those objects are achieved by the present invention which relates to a tool with a handle and a rigid shaft having an end. The shaft extends from the handle and has an internal bore. The bore extends through the shaft from the handle to the end of the shaft. A LED is situated in the bore, proximate the end of the shaft. The handle has a recess. A battery is situated within the recess. Means are provided for electrically connecting the LED and the battery to energize the LED to illuminate the area proximate the end of the shaft. 
     The connecting means includes wires extending within the bore, between the LED and the handle. The connecting means also includes a switch for operably connecting the wires and the battery to energize the LED. 
     The shaft preferably has an outer diameter of approximately one quarter inch. The bore preferably has an inner diameter of approximately one eight inch. 
     In the first preferred embodiment, the tool takes the form of a screwdriver with a screw-engaging end on the shaft. The screw-engaging end takes the form of a bifurcated blade. The blade includes spaced blade sections. The spaced blade sections are situated on either side of the bore opening so as not to block the light from the LED. 
     The screwdriver handle has an end with a cover member. The cover member is removable to permit access to the battery recess. 
     In a second preferred embodiment of the present invention, the tool takes the form of a screwdriver in which the screw-engaging end includes at least one removable head. 
     Preferably, a plurality of interchangeable heads designed to be mounted on the screw-engaging end of the shaft are provided for use with screws having different configurations. Each head is provided with a bore which aligns with the shaft bore such that light from the LED can travel through the head mounted on the screw-engaging end of the shaft. 
     In a third preferred embodiment of the invention, the tool takes the form of a device for illuminating hard to reach areas or for focusing light in a small area. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS 
       To these and to such other objects that may hereinafter appears, the present invention relates to a LED illuminated tool as described in detail in the following specification and recited in the annexed claims, taken together with the accompanying drawings, in which like numerals refer to like parts and in which: 
         FIG. 1  is a perspective view of a first preferred embodiment of the present invention; 
         FIG. 2  is a top plan view of the screwdriver of  FIG. 1 ; 
         FIG. 3  is a side cross-sectional view of the screwdriver of  FIG. 1 ; 
         FIG. 4  is a perspective, exploded view of the screw-engaging end of the shaft of a second preferred embodiment of the present invention along with a typical head; 
         FIG. 5  shows a side plan view and a front plan view of an interchangeable head for a Philips head screw; 
         FIG. 6  shows a side plan view and a front plan view of an interchangeable head for a hexagonal head screw; 
         FIG. 7  shows a side plan view and a front plan view of an interchangeable head for a Spanner head screw; and 
         FIG. 8  is a perspective view of a third preferred embodiment of the present invention, in which the tool takes the form of a device for illuminating hard to reach areas or focusing light in a small area. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As seen in  FIGS. 1-3 , the first preferred embodiment of the tool of the present invention takes the form of a screwdriver which includes a handle, generally designated  10 , from one end of which a shaft, generally designated  12 , extends. Handle  10  is preferably provided with circumferentially spaced outwardly protruding grip members  11  with recesses  13  to accommodate the fingers of the user. Shaft  12  is preferably made of hardened steel and preferably has a diameter of approximately one quarter of an inch. 
     Handle  10  may be made of any conventional material, such as plastic, rubber or wood. Handle  10  has a hollow cavity  14 . Within cavity  14  is situated an open ended battery receiving chamber  16 . Chamber  16  is defined by a substantially cylindrical wall formed of an electrically conductive outer wall layer  18  and an electrically non-conductive inner wall layer  20 . 
     The rear end of cavity  14  defines an internally threaded battery receiving opening  22 . Opening  22  is adapted to receive the body  23  of an externally threaded cover member  24 . Member  24  is removable from the handle by rotation to provide access to chamber  16  for insertion and replacement of batteries. 
     Body  23  of cover member  24  has an electrically conductive inner bottom surface  26 . An electrically conductive spring  28  extends inwardly from the center of surface  26  towards the interior of chamber  16 . Spring  28  has the double function of maintaining the batteries within chamber  16  in the proper position and providing a secure electrical connection between one pole of the batteries and conductive surface  26  of the cover member. When cover member  24  is in place within opening  22 , the electrically conductive inner surface  26  of cover  24  abuts and is in electrical connection with conductive wall layer  18 . 
     One or more flat batteries  30  are situated, front to back, within chamber  16 , in series electrical contact with each other, between spring  28  and a stationary contact pin  32 . Pin  32  is electrically connected to one input of a circuit board  34  situated adjacent to chamber  16 . The other input of circuit board  34  is connected to the other pole of batteries  30  via spring  28 , the electrically conductive inner surface  26  of cover  24  and electrically conductive outer wall layer  18 . 
     Circuit board  34  forms the base of a spring-loaded pushbutton  36  which extends through an opening in the handle wall and is externally accessible. Circuit board  34  is mounted on a “U” shaped support  35  and is connected to a LED  37  situated within the screw-engaging end of a bore  40  which extends the entire length of shaft  12 . Pin  32  is fixed within support  35 , in alignment with batteries  30 . 
     In this preferred embodiment, the screw-engaging end  42  of shaft  12  takes the form of a bifurcated blade  44 . Blade  44  is composed of spaced blade sections  46 ,  48 . Between blade sections  46 ,  48  is situated an opening  50 , which is the open end of bore  40 . LED  37  is lodged in the very end of bore  40 , proximate opening  50 . Wires  52  and  54 , which extend the entire length of bore  40 , connect LED  37  with the outputs of circuit board  34 . 
     In use, the application of inwardly directed force on pushbutton  36  causes circuit board  34  to complete the electrical circuit between batteries  30  and LED  37 . That causes the LED to be energized and to project light out opening  50  at the end of bore  40 , between blade sections  46 ,  48 , to illuminate the area proximate the screw-engaging end  42  of shaft  12 . 
       FIGS. 4 through 7  illustrate a second preferred embodiment of the present invention. As illustrated in  FIG. 4 , the second preferred embodiment of the present invention is the same as the first preferred embodiment except that the screw-engaging end of shaft  12  is designed to accept a removable head, more particularly, one of a plurality of interchangeable heads, generally designated  62 . In this embodiment, blade sections  46 ,  48  are eliminated, leaving a flat shaft end  56  surrounding opening  50  of bore  40 . Further, axially elongated protrusions  58 ,  60 , extending outwardly from the wall of shaft  12  in opposite directions, are provided. 
       FIGS. 5 ,  6  and  7  illustrate three possible interchangeable heads  62  that could be mounted on the screw-engaging end  56  of the shaft of the second preferred embodiment of the invention. In each case, the head  62  has a mounting section  63  with an internal axial bore  64  with an internal diameter slightly larger than the external diameter of the shaft end  56  such that the head can be mounted snuggly on the shaft end. 
     The bore  64  of each head  62  has oppositely oriented, axially extending slots  66 ,  68 . Slots  66 ,  68  are shaped and positioned to receive protrusions  58 ,  60 , respectively, when the head is mounted on the end of the shaft. Slots  66 ,  68  cooperate with protrusions  58 ,  60  to prevent relative rotation between the shaft and the head, permitting the transfer of torque from the screwdriver shaft to the head. 
     Each head  62  also has a screw-engaging portion  72  with an internal axial bore  70  adapted to align with opening  50  in bore  40  when the head is mounted on the shaft end. When the head is mounted, and the pushbutton is depressed, light from LED  37  travels from opening  50  through bore  70  to illuminate the area in front of the head. 
       FIG. 5  shows the side and front of a head designed for use with a Philips head screw. The screw-engaging portion  72  of the head illustrated therein has the configuration of a standard Philips head screwdriver, except for bore  70 . 
       FIG. 6  shows the side and front of a head designed for use with a hexagonal head screw. The screw-engaging portion  72  of the head illustrated therein has the configuration of a standard hexagonal head tool, except for bore  70 . 
       FIG. 7  shows the side and front of a head designed for use with a Spanner head screw. The screw-engaging portion  72  of the head illustrated therein has the configuration of a standard Spanner head screwdriver, except for bore  70 . 
     Interchangeable heads designed to drive screws with other configurations are possible, as well. 
     The third preferred embodiment of the present invention is illustrated in  FIG. 8 . The tool illustrated in  FIG. 8  is the same as that of the previous embodiments except that the screw-engaging end is eliminated such that the end  74  of shaft  12  is substantially planar and the end of bore  40  extends through the shaft end permitting light from LED  37  located proximate the end of bore  40  to exit the end of the shaft to illuminate hard to reach areas or focus light on a small area. 
     It will now be appreciated that the present invention relates to a tool with a handle and a rigid shaft that extends from the handle. When designed as a screwdriver, the shaft has an end formed to engage a screw. It also has a bore that extends through the shaft from the handle to the end of the shaft. An LED is situated in the bore, proximate the end of the shaft. The handle has a recess. A battery is situated within the recess. Means are provided for electrically connecting the LED and the battery. 
     The connecting means include a switch and wire means extending through the bore, between the LED and the battery in the handle. 
     In the first preferred embodiment, the tool takes the form of a screwdriver and the screw-engaging end of the shaft comprises a bifurcated blade. In the second preferred embodiment, the tool takes the form of a screwdriver with interchangeable heads designed for use with different types of screws are provided for mounting on the shaft. 
     In the third preferred embodiment, the tool takes the form of a device for illumination hard to reach areas or for focusing light in a small area. 
     While only a limited number of preferred embodiments of the present invention have been disclosed for purposes of illustration, it is obvious that many modifications and variations could be made thereto. It is intended to cover all of those modifications and variations which fall within the scope of the present invention, as defined by the following claims.