Abstract:
An air blast tool having an air nozzle and integrated air powered electrical generator with electric lamp is disclosed. Compressed air supplied to the air blast tool is also supplied to the air powered generator within the tool to produce electricity. Light produced by the electric lamp is directed in the same direction as the air blast nozzle to enable the user to readily see machined surfaces and the like.

Description:
FIELD OF THE INVENTION 
     The present invention relates in general to pneumatically powered hand tools and more specifically to an air blast hand tool including an air powered generator that produces an electrical signal supplied to a source of illumination such as an incandescent bulb 
     BACKGROUND OF THE INVENTION 
     Lathes, mills, and other similar material removal machining devices are typically used to produce custom machined parts. Oftentimes, the machinist operating such machinery desires to remove the machined away metal chips from the work area to perform visual inspection of the machined surfaces. Removal of the machined chips by hand is dangerous due to the sharp edges of the chips. Common techniques for removing machined chips from the work piece include hand held brushes and air blast tools. For the machinist, an air blast tool is perhaps the most convenient and most commonly used tool for chip removal. After the chips are removed from the work piece the machinist typically desires to visually inspect the machined surfaces to evaluate the machining operation and its quality and progress. A hand held “drop light” or a flashlight are currently the best mechanisms for illuminating the work piece in its mounted position within the machining station. A combination air blast tool having a light integrated into the air blast tool would simplify the machinists work by providing a light source that illuminates the machined surfaces during and after chip removal. Further, since a source of pressurized air is.already present where an air blast tool is in use, a light producing device that derives its power from a miniature pneumatically driven electric generator within the air blast tool improves efficiency of motion for the machinist while eliminating the power cord necessary for supplying power to a hand held drop light. 
     SUMMARY OF THE INVENTION 
     An air blast tool having an integral light source, according to one aspect of the present invention, comprises a body having an inlet aperture, a first outlet aperture and a second outlet aperture and wherein said first outlet aperture and said second outlet aperture are in fluid communication with said inlet aperture, first valve means partially disposed within said first outlet aperture for controlling air flow therethrough, an air powered electrical generator having a rotor and a stator, said air powered generator being disposed within said second outlet aperture, said air powered electrical generator producing an electrical signal in response to pressurized air supplied from said inlet aperture to said second outlet aperture, an electric light attached to said body and receiving said electrical signal to illuminate said electrical light, and air nozzle means attached to said body and disposed over said first outlet aperture. 
     One object of the present invention is to provide an improved air blast hand tool for use with machining or woodworking operations. 
     Another object of the present invention is to provide an air blast tool with an integrated light that is powered by an air driven electrical generator incorporated into the air blast tool. 
     Yet another object of the present invention is to eliminate the need for electrical power cords and drop lights in the area of a machining operation, yet take advantage of the presence of an air blast tool necessary to remove metal chips or sawdust. 
     These and other objects of the present invention will become more apparent from the following description of the preferred embodiment. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an air gun with integral air powered light according to one aspect of the present invention. 
     FIG. 2 is a side elevational view of the air gun with integral air powered light of FIG.  1 . 
     FIG. 3 is a. cross-sectional view of the air gun with integral air powered light of FIG.  1 . 
     FIG. 4 is cross-sectional view of the air powered generator. 
     FIG. 5 is an exploded perspective view of the air powered generator. 
     FIG. 6 is a bottom view of the body portion. 
     FIG. 7 is a cross-sectional view of the body looking in the direction of the arrows labeled A—A in FIG.  6 . 
     FIG. 8 is a cross-sectional view of the body looking in the direction of the arrows labeled B—B in FIG.  6 . 
     FIG. 9 is a front elevational view of end plate  68 . 
     FIG. 10 is a cross-sectional view of end plate  68 . 
     FIG. 11 is a front elevational view of end plate  64 . 
     FIG. 12 is a cross-sectional view of end plate  64 . 
     FIG. 13 is a side elevational view of trigger valve body  42 . 
     FIG. 14 is a plan view of trigger valve body  42 . 
     FIG. 15 is a cross-sectional view of trigger valve body  42  looking in the direction of arrows A—A in FIG.  14 . 
     FIG. 16 is a cross-sectional view of trigger valve body  42  looking in the direction of-the arrows labeled A—A in FIG.  13 . 
     FIG. 17 is a partial cross-sectional view of body  12  depicting valve  60 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
     Referring now to FIGS. 1 and 2, a perspective view and a front elevational view of an air gun with integral air powered light  10 , according to the present invention, are shown. Air gun  10  includes a body  12  made from metal, plastic or other suitable material. Fitting  14  is rotatably inserted into a threaded aperture in body  12  and secured thereto. A source of compressed air (not shown) is attached to fitting  14 . A directional exhaust assembly  16  is rotationally inserted into a threaded aperture in body  12  (discussed in more detail below). Trigger  18  is movably mounted to body  12  and is depressable by the user to engage a valve (see FIG. 3) within body  12  to enable the internal flow of compressed air from fitting  14  to air nozzle  20  within body  12 . Valve  22 , attached to body  12 , is positionable to enable and disable the delivery of compressed air to an air powered electrical generator (shown in more detail below) within body  12 . A source of light, such as an incandescent bulb or suitable substitute, is disposed within light tube  24 . A lens  26  is mounted on the distal end of tube  24 . Lens  26  focuses light emanating from within tube  24  onto objects aligned with tube  24 . Hook portion  28  extends upwards and turns back towards body  12  to provide a convenient mechanism for removably hanging device  10  on a suitable mounting location in the users workplace. 
     Operationally speaking, compressed air is delivered to fitting  14  so that apertures (also referred to as fluid passages or cavities) within body  12  are filled with compressed air. Trigger  18  activates a valve (discussed below and shown in FIG. 3 ) within body  12  to deliver compressed air to air nozzle  20 . Valve  22  enables and disables the flow of compressed air to an air powered electric generator (see below) within body  12  that produces electricity for powering the lamp within tube  24 . 
     Referring now to FIG. 3, a partial cross-section of the air gun with integral air powered light  10  is shown. Body  12  includes apertures shown at  30  and  32 . Hollow compressed air fitting  14  includes a threaded portion  14   a  that mates with a threaded portion  12   a  of body  12 . Standard tapered threads are formed at  12   a  and  14   a  to provide an air tight seal. Directional exhaust  16  is comprised of a threaded fitting  34  having a fluid channel  36  therethrough enabling compressed air in aperture  30  to escape to the atmosphere through channel  36 . An exhaust deflector ring  38  is rotatably disposed over fitting  34 . Ring  38 , includes a slot  38   a  formed therein so that compressed air escaping aperture  30  via channel  36  may be redirected in any direction desired by the user of device  10  by rotating ring  38  about fitting  34 . Fitting  34  includes a threaded portion  34   a  that mates with corresponding threads  30   a  formed in aperture  30 . 
     Trigger  18  is attached to valve stem  40  via threaded portion  18   a  of trigger  18  and threaded portion  40   a  of valve stem  40 . Valve body  42  receives valve stem  40  therein. Trigger  18 , when depressed, forces valve stem  40  toward spring  44  and compresses spring  44 . When valve stem  40  is moved toward spring  44 , compressed air in apertures  32  and  56  passes over valve stem  40  and into the interior of valve body  42  when o-ring seal  46  is separated from contact with valve body  42 . Apertures  32  and  56  are in fluid communication with each other. An aperture in valve body  42  (see FIGS. 13-16) enables compressed air within valve body  42  to flow into aperture  48  and out through nozzle  20 . O-ring seals  50  prevent compressed air in aperture  32  from escaping past valve body  42  through trigger aperture  52 . Roll pin  54  is inserted into aperture  55  and through body  12  transverse to valve stem  40  through a cutout in valve body  42  to retain valve body  42  in position with respect to body  12 . Nozzle  20  is shown having a threaded portion  20   a  that mates with corresponding threads  48   a  formed within aperture  48 . 
     Aperture  32  is in fluid communication with apertures  56  and  58 . Compressed air travels through aperture  58  and encounters motor valve  60 . Motor valve  60  enables and disables the flow of compressed air in aperture  58  to aperture  62 . Aperture  62  provides a conduit through which compressed air is delivered to electrical generator  63 . Set screw or plug  81  provides an air seal of aperture  62 . To machine aperture  62 , a hole is drilled vertically downward into body  12  and aperture  62  is sealed by set screw  81 . Generator  63  is an air powered electricity generating device discussed in more detail below. See FIGS. 4-5 and the discussion below for more detail on the configuration and operation of motor valve  60 . Compressed air in aperture  62  travels through end plate  64  to engage rotor  66 . Compressed air flowing over rotor  66  exits through end plate  68  and travels though slot  112  in end plate  68  (see FIG. 9) into aperture  104  (see FIG. 7) and on to aperture  30 , the exhaust aperture, and out into the atmosphere. Bearings  70  and  71  support rotor  66  and enable rotor  66  to rotate freely. Rotor housing  65  surrounds rotor  66 . Magnet spacer  77  is mounted on rotor  66 . Magnet  72  is attached to one end of rotor  66  and rotates between stator poles  74 . Stator poles  74  are attached to bobbin  76  via staked or riveted stator core  75 . Bobbin  76  includes a multitude of wire windings  78  wrapped thereabout. Magnetic flux field deviations generated by the rotation of magnet  72  are routed through stator poles  74  to induce a current to flow in windings  78 . Windings  78  are electrically connected to rivet  82  Contact spring  84  is attached to rivet  82  and provides a path for electricity to travel to insulated conductor  86 . Conductor  86  is electrically connected to disk shaped metal contact  87  that physically contacts spring  84 . Metal spring  90  is attached to metal rivet  88  and conductor  86  is electrically attached to rivet  88 . Insulator  89  centers or fixes contact  87  in position and encourages physical contact between contact  87  and spring  84 . Incandescent bulb  80  receives an electrical signal from contact spring  90 , and metal tube  24  provides a return path for electricity to windings  78 . Insulator cap  92  is attached with adhesives or the like over stator poles  74 . Rivet  82  is attached to plastic insulator cap  92  via adhesives or molded integrally therewith. Rivet or contact lug  88  is supported in position and surrounded by insulator  94 . Threaded adapter  96  mates with threads in body  12  to secure insulator cap  92  and stator poles  74  in a fixed position within aperture  98 . Threaded adapter plug  100  mates with threads in body  12  and secures rotor  66  and magnet  72  in position as shown within aperture  98 . Also shown are lens  26  mounted to adapter  102  which matingly engages external threads  24   a  of tube  24 , groove pin  69  that attaches end plates  64  and  68  to one another, and hook  28  of body  12 . Various o-ring fluid seals  97  are also shown in FIG.  3 . 
     Referring now to FIGS. 4 and 5, an enlarged cross-sectional view of the air powered generator  63  and an exploded view of the generator  63  are shown. Rotor shaft  67  is inserted through bearing  70  and is press fit into a mating hole in rotor  66 . Bearing  70  is mounted in end plate  64  and bearing  71  is mounted in end plate  68 . Groove pin  69  is inserted through a hole in rotor housing  65  and pressed into apertures in end plates  64  and  68 . Air vanes  73  are fixedly attached into slots in rotor  66 . Spacer  77  is disposed on the rotor shaft  66   a  and provides a predetermined mounting location on shaft  66   a  for magnet  72 . Bobbin  76  and windings  78  are disposed between stator poles  74 . Stator core  75  is inserted through bobbin  76  and staked or riveted to stator poles  74 . Insulator cap  92  receives and is attached to stator poles  74  with adhesive or the like. Electrical contact rivet  82  is attached to insulator cap  92  and contact spring  84  attaches to rivet  82 . Windings  78  are electrically connected to contact rivet  82  and solder lug  79 . Solder lug  79  makes electrical contact with body  12  via stator poles  74  to provide a return path for electricity generated by motor*generator  63 . 
     Operationally, compressed air enters orifice  64   a  in end plate  64 , travels within rotor housing  65 , over vanes  73 , through orifice  65   a  in rotor housing  65  and along channel  68 a in end plate  68 . The force of the compressed air on vanes  73  causes rotor  66  to rotate. Magnet  72 , fixedly attached to rotor  66 , rotates accordingly. Magnet  72  varies in magnetic intensity rotationally around the lateral surface thereof so that rotation of magnet  72  causes a varying magnetic field to impinge upon stator poles  74 . A varying magnetic field impinging upon stator poles  74  induces a current to flow in coil or windings  78 . 
     Referring now to FIG. 6, a bottom view of the handle portion of body  12  is shown. From this view, it is more apparent that aperture  30  is in fluid communication with apertures or fluid channels  104  and  106 . Also shown in FIG. 6 is aperture or fluid channel  32 . Aperture  104  provides a fluid flow path for exhaust of pressurized air from generator  63 . Aperture  106  is a channel or fluid passage through which compressed air is delivered to air blast nozzle  20  from aperture  52 . A fluid path from compressed air supply aperture  32  to aperture  52  is established through valve body  42  when valve stem  40  is actuated toward spring  44  (see FIGS.  3  and  13 - 14 ). 
     Referring now to FIGS. 7 and 8, cross-sectional views of the body  12  are shown. FIG. 7 is a cross-sectional view looking in the direction of the arrows labeled A—A in FIG. 6, and FIG. 8 is a cross-sectional view looking in the direction of the arrows labeled B—B in FIG.  6 . Various fluid channels or apertures wherein compressed air flows within body  12  are shown in more detail in FIGS. 7 and 8. Compressed air is supplied to aperture  32  Which is in fluid communication with apertures  52  and  58 . Compressed air that encourages motor-generator  63  to rotate is supplied via apertures  58 ,  61  and  62  to aperture  98 . Fluid passage or aperture  104  provides a channel for compressed air to pass from aperture  98 , through aperture  52 , and on to exhaust aperture  30 . Similarly, aperture  106  provides a fluid passage for compressed air to flow between aperture  52  and aperture  48 . Valve body  42  (see FIG. 3) prevents compressed air flow between apertures  52  and  30  yet allows air to flow between aperture  30  and aperture  98  via aperture  104 . Also shown are roll pin slot or aperture  55  into which roll pin  54  is inserted and aperture or through hole  61  wherein motor valve  60  (see FIGS. 3 and 17) is received. 
     Body  12  is preferably cast from aluminum or other suitable metal and then machined on various- surfaces to establish desired dimensional tolerances with internal components and to form various threads therein. 
     Referring now to FIGS. 9 and 10, end plate  68  is shown in a front elevational view and a cross-sectional view. End plate  68  includes bore  108  for receiving bearing  71  (see FIG. 5) therein. Hole  110  receives pin  69  (FIG. 5) to maintain rotational alignment of end plate  68  with respect to end plate  64  (FIG. 5) and rotor housing  65  (FIG.  5 ). Slot  112  provides a channel for compressed air to flow past end plate  68  and into aperture  98  and on through aperture  104  to exhaust aperture  30  (see FIG.  7 ). 
     Referring now to FIGS. 11 and 12, a front elevational view and a cross-sectional view of end plate  64  are shown. Bore  114  receives bearing  70  (FIG. 5) therein. Compressed air from aperture  62  (FIGS. 7) flows through slot  116  and into the rotor housing  65  (FIG. 3) to engage vanes  73  of rotor  66  (see FIG. 5) and exits the rotor area via slot  112  in end plate  68  (FIG.  9 ). Hole  118  receives pin  69  (FIG.  5 ). It should be apparent that slot  116  and slot  112  are not in alignment due to the location of hole  110  (FIG. 9) and hole  118  so that an offset angle of about ninety degrees is established therebetween. The non-alignment of slot  116  and slot  112  establishes a non-direct path so that air must flow over rotor  66  (FIG. 5) and vanes  73  (FIG. 5) and thereby encourages rotor  66  to rotate. 
     Referring now to FIGS. 13-16, trigger valve body  42  is shown in detail. FIG. 13 is a front elevational view, FIG. 14 is a plan view, FIG. 15 is a cross-sectional view looking in the direction of the arrows labeled A—A of FIG. 14, and FIG. 16 is a cross-sectional view looking in the direction of the arrows labeled A—A in FIG.  13 . Slot  55  engages roll pin  54  (FIG. 3) to secure valve body  42  in position within aperture  52  (FIG.  7 ). When trigger  18  (FIG. 3) is depressed inward, compressed air in aperture  32  (FIG. 3) is supplied to the interior  120  of valve body  42 . Compressed air from interior aperture  120  flows out through aperture  122  through aperture  106  (FIG. 8) and into aperture  48  (FIG. 8) and from there through air nozzle  20  (FIG.  3 ). Cutout portion  124  establishes a fluid passage for exhaust air from aperture  98  (FIG. 8) to flow through aperture  104  (FIG.  8 ), past valve body  42  (FIG.  3 ), and into exhaust aperture  30  (FIG.  3 ). Annular groove  126  receives o-ring seal  50  (FIG.  3 ). 
     Referring now to FIG. 17, a partial cross-sectional view of body  12  is shown. In this view, the details of motor valve  6 . 0  are shown. Valve  60  is disposed in a through-hole  61  machined or formed in body  12 . Valve  60  has a very small clearance with hole  61 . Valve  60  includes three annular grooves  128 ,  129  and  130 . Grooves  128  and  129  receive o-ring seals  131  therein. Groove  130  provides a fluid passage around valve  60  so that compressed air will flow from aperture  58  to aperture  62  when valve  60  is repositioned horizontally so that groove  130  is aligned with apertures  58  and  62 . In the position shown, valve  60  prevents compressed air from passing between aperture  58  and aperture  62 . C-clip  134  is attached as shown in groove  136  formed in valve  60  to prevent removal of valve  60  from within aperture  61 . 
     While the invention has been illustrated and described in detail in the drawings and foregoing description of the preferred embodiment, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.