Abstract:
A screwdriver style pry bar comprising a handle member, a pry bar shank, and an impact cap. The impact cap is positioned on an end of the handle opposite the pry bar shank. The impact cap allows the pry bar to withstand impact blows without damaging the handle.

Description:
TECHNICAL FIELD  
       [0001]     The present invention relates to a pry bars. Specifically, this invention relates to a metal striking cap or anvil positioned on the end of a screwdriver style pry bar handle that is able to transfer impact shock loads directly to the shank of a pry bar.  
       BACKGROUND OF THE INVENTION  
       [0002]     Screwdriver style pry bars resemble a giant screwdriver and typically consist of an elongated metal bar with a handle opposite a working end typically in the form of a flat head screwdriver. The working end may be straight or slightly curved to help provide a fulcrum for the prying action of the tool. The pry bars are made in different lengths varying typically from 12 to 42 inches.  
         [0003]     A major problem with prior art screwdriver style pry bars is that the user will often strike the end of the handle with a hammer or mallet to force the working end into a desired position. The handle is typically made of cellulose acetate or some other plastic material which can be broken by the hammer impact.  
         [0004]     Accordingly, there is a need for a screwdriver style pry bar that can withstand repeated impact blows to the non-working end of the pry bar without damaging the plastic handle.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention overcomes at least one disadvantage of prior art screwdriver style pry bars by providing a screwdriver style pry bar comprising a handle member having a first end, a second end, and an aperture through the longitudinal axis thereof; an elongated metal shank member having a first end positioned within the aperture of the handle member, the shank member extending from the first end of the handle member; and a metal impact cap having a first end positioned within the aperture of the handle member, and a second end extending from the second end of the handle member.  
         [0006]     The present invention also provides a method for making a pry bar comprising the steps of providing a cylindrical metal impact cap; molding a handle having a longitudinal aperture around the cylindrical metal impact cap such that an end of the impact cap protrudes from a first end of the handle; and inserting a metal pry bar shank into the end of the longitudinal aperture in the handle. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]      FIG. 1  is an exploded perspective view of the pry bar of the present invention;  
         [0008]      FIG. 2  is a perspective view of the nesting impact cap of the present invention as shown in  FIG. 1 ;  
         [0009]      FIG. 3  is an exploded view of the pry bar shank and the nesting impact cap shown in  FIG. 1 ;  
         [0010]      FIG. 4  is a perspective view of the pry bar shank nested in the impact cap; and  
         [0011]      FIG. 5  is a perspective view of the assembled pry bar of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0012]     Referring to  FIG. 1 , a first embodiment of the pry bar assembly  10  is shown in an exploded perspective view. The pry bar assembly  10  comprises an elongated pry bar shank  20 , a handle  30 , and an anvil or impact cap  40 . The pry bar shank  20  has a first end  22 , and a second end  24  in the form of a flat head screwdriver. The shank  20  is made of metal and typically has a square cross-section in a ⅜″, ½″, or ⅝″ size. Although not shown, the second end  24  may also be slightly curved as is known in the art. The handle  30  has a first end  32 , a second end  34 , and an aperture  36  formed through the longitudinal axis  38  of the handle  30 . The handle  30  is typically manufactured of a plastic material and is generally cylindrical, however, the present invention is not limited to a particular shape of handle and may include styles such as ergonomically shaped handles.  
         [0013]     The impact cap  40  is best shown in  FIG. 2  and has a first end  42 , a second end  44 , and a closed aperture  46  formed in the second end  44 . The impact cap  40  may be cylindrical. In one embodiment, the impact cap  40  may include a means  48  for securing the impact cap to handle  30 . While means  48  is shown as a pair of grooves in  FIG. 2 , it is also contemplated that knurling, radially extending flanges, or other surface features may help attach the impact cap  40  to the handle  30  as the plastic handle  30  is molded about the impact cap  40  during manufacturing.  
         [0014]     The impact cap  40  will help protect the end of the handle  30  from impacts from a hammer. However, if the impact cap  40  is solely supported by the handle  30 , the plastic handle  30  may still be damaged by the transfer of the impact force through the impact cap  40  and directly into the handle body  30 . In a second embodiment, it is contemplated that the first end  22  of the shank  20  is inserted into the handle  30  until the first end  22  is abutted adjacent to and in contact with impact cap  40 . In this manner, impact forces will be transmitted through the impact cap  40  directly to the shank  20 . However, a user still may be able to damage the handle  30  with an off-center strike or impact that is oblique to the impact cap  40 . These forces may still be transmitted, at least partially, to the handle and, if severe enough, cause damage to the handle.  
         [0015]     In another embodiment of the present invention, as best shown in  FIGS. 3 and 4 , the first end  42  of the impact cap  40  comprises a closed aperture  46  which allows a nesting connection with the first end  22  of the shank  20 . The nesting connection, shown in phantom in  FIG. 4 , of the impact cap  40  and the shank  20  allows oblique blows to the impact cap  40  to be directly transmitted to the shank without the risk of damage to the handle  30 .  
         [0016]     With prior art screwdriver style pry bars, the handle is typically molded with a closed end aperture that provides an interference fit with a metal shank inserted into the aperture. One prior art design uses a handle with a square aperture and interference dimples that help retain the shank within the handle once the shank is inserted. The present invention is manufactured as follows. An impact cap is formed similar to that of a metal socket. The closed end of the metal impact cap may be machined to be rounded, and grooves or other gripping surfaces are cut into the exterior of the cap. The handle is molded with the impact cap in place along with a central longitudinal aperture. The plastic handle material conforms to the exterior of the cap and the grooves which help retain the cap in position in the end of the handle such that an end of the impact cap protrudes from the second end of the handle. The pry bar shank is then inserted into the molded handle.  
         [0017]     In one embodiment, appropriate tooling is produced such that the pry bar shank is inserted into the handle until the shank contacts the impact cap but does not push the impact cap out of the handle. In using an impact cap with an aperture, the shank is inserted into the handle until the shank contacts the bottom of the aperture. The shank is held in place due to an interference fit with the handle as is known in the art.  
         [0018]     It is also contemplated that the handle may be molded over top of the shank with the impact cap nested on the end of the shank. The impact cap may need to be held against the shank by glue or the like to prevent a gap from forming between the shank and the cap.  
         [0019]     Although the principles, embodiments, and operation of the present invention have been described in detail herein, this is not to be construed as being limited to the particular illustrative forms disclosed. They will thus become apparent to those skilled in the art that various modifications of the embodiments herein can be made without departing from the spirit or scope of the invention. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims