Abstract:
A ratcheting tool has a head and a handle attached to the head. The head rotatably receives a gear ring and receives a pawl that is in operative engagement with the gear ring. A housing disposed in the head receives a spring that is in operative engagement with the pawl so that rotation of a lever causes the pawl to move between a first position and a second position.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    The present application claims the benefit of U.S. Provisional Patent Application No. 60/404,971, filed Aug. 20, 2002, the entire disclosure of which is incorporated by reference herein. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    Ratcheting tools, for example ratchets and wrenches, often include a circular ratchet gear and a pawl that controls the gear&#39;s ratcheting direction so that the gear may rotate in one direction but is prevented from rotation in the other. It is known to dispose the pawl so that it engages teeth either on the gear&#39;s inner or outer diameter. Examples of ratcheting tools having a sliding pawl engaging the outer diameter of a ratchet gear are provided in U.S. Pat. Nos. 6,230,591 and 5,636,557, the entire disclosure of each of which is incorporated by reference herein.  
         SUMMARY OF THE INVENTION  
         [0003]    The present invention recognizes and addresses considerations of prior art constructions and methods.  
           [0004]    In an embodiment of the present invention, a ratcheting tool has a body defining a head and handle attached to the head. The head defines a first compartment and a second compartment that opens into the first compartment. A gear ring is rotatably disposed in the first compartment and defines a plurality of teeth on an outer circumference thereof. The edges of the teeth extend between opposite axial ends of the gear and may be straight or define a curve extending inward from the opposite axial ends so that an outer surface of the gear is concave at a center area. A pawl disposed in the second compartment defines a plurality of teeth that extend between a top and bottom of the pawl. The teeth may be straight or define curves extending away from the opposite sides so that the pawl face is convex at a center area. A housing disposed in the head receives a spring in operative engagement with the pawl so that rotation of the lever causes the pawl to move between a first position and a second position.  
           [0005]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]    A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which:  
         [0007]    [0007]FIG. 1 is a perspective view of an embodiment of a ratcheting tool in accordance with the present invention;  
         [0008]    [0008]FIG. 2 is an exploded view of the ratcheting tool as in FIG. 1;  
         [0009]    [0009]FIG. 3A is a top view of a gear ring for use in the ratcheting tool shown in FIG. 1;  
         [0010]    [0010]FIG. 3B is a side view of the gear ring shown in FIG. 3A;  
         [0011]    [0011]FIG. 4 is a partial sectional view of the ratcheting tool shown in FIG. 1 including a socket;  
         [0012]    [0012]FIG. 5A is a top plan view of the ratcheting tool of FIG. 1, partly in section, with the reversing lever moved to a first predetermined position;  
         [0013]    [0013]FIG. 5B is a top plan view of the ratchet tool of FIG. 1, partly in section, with the reversing lever rotated in the clockwise direction from its position shown in FIG. 5A;  
         [0014]    [0014]FIG. 5C is a top plan view of the ratcheting tool of FIG. 1, partly in section, with the reversing lever moved to a second predetermined position;  
         [0015]    [0015]FIG. 6 is a perspective view of a pawl for use in the ratcheting tool shown in FIG. 1;  
         [0016]    [0016]FIG. 7 is a perspective view of a lever housing for use in the ratcheting tool shown in FIG. 1;  
         [0017]    [0017]FIG. 8A is a perspective view of a lever for use in the ratcheting tool shown in FIG. 1;  
         [0018]    [0018]FIG. 8B is a bottom perspective view of the lever shown in FIG. 8A;  
         [0019]    FIGS.  9 A- 9 B are perspective views of rotary tools for use with the ratcheting tool shown in FIG. 1;  
         [0020]    FIGS.  10 A- 10 E provide details of the rotary tool shown in FIG. 9B;  
         [0021]    FIGS.  11 A- 11 D are perspective views of an embodiment of a ratcheting tool in accordance with an embodiment of the present invention;  
         [0022]    FIGS.  12 A- 12 B are top and side views of a gear ring for use in the ratcheting tool shown in FIGS.  11 A- 11 D;  
         [0023]    FIGS.  13 A- 13 D are perspective views of an embodiment of a ratcheting tool in accordance with an embodiment of the present invention; and  
         [0024]    FIGS.  14 A- 14 B are top and side views of a gear ring for use in the ratcheting tool shown in FIGS.  13 A- 13 D  
     
    
       [0025]    Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.  
       DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0026]    Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope and spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.  
         [0027]    Referring to FIGS.  1 - 10 , and in particular to FIGS.  1 - 4 , a ratcheting tool  10  includes an elongated arm that may be formed as a handle  12 . Handle  12  may be a solid piece or may include snap-in polymer inserts  142 , one of which is shown in FIGS. 1 and 2. A head  14  extends from the handle  12 , and the head and handle may be integrally formed from the same material. The head has three openings formed therein (FIG. 2). The first is a substantially cylindrical opening  16  distal from handle  12 . A second opening  18  opens into cylindrical opening  16  and is intermediate the first opening and a third opening  26  located in a web  20 . Compartment  18  is closed above and below by top and bottom faces  22  and  24  of web  20  (FIG. 4). Third opening  26 , located proximate to handle  12 , is substantially cylindrical, extends through face  22  into web  20  at a hole  28  and opens into second opening  18 .  
         [0028]    [0028]FIGS. 2, 3A and  3 B disclose an annular gear ring  30  having a plurality of equi-spaced teeth  54  that are formed about the gear ring&#39;s outer circumference. The teeth curve inward at their center so that the gear ring&#39;s outer surface defines a concave shape. The gear ring is received in cylindrical opening  16  and includes an inner surface  32  that is concentric with an inner surface  34  of head  14 . A bottom side of gear ring  30  defines an extension portion  35  surrounded by a flat annular shoulder  36 . Extension portion  35  fits through a ledge  38  extending radially inward from inner surface  34  of head  14  so that shoulder  36  sits on ledge  38  (FIG. 4), thereby retaining gear ring  30  in the lower axial direction. Extension portion  35  fits through ledge  38  with sufficient clearance so that the ledge secures the gear ring in the radial direction yet permits the gear ring to rotate with respect to head  14 .  
         [0029]    Gear ring  30  defines an annular groove  40  (FIG. 3B) about its outer surface proximate its upper end. Referring to FIG. 4, groove  40  receives a C-ring  46  wherein an outer surface of the C-ring normally extends slightly outward of the groove. As gear ring  30  is inserted into compartment  16 , C-ring  46  compresses into groove  40  until groove  40  aligns with an annular groove  42  extending into the upper edge of the tool head&#39;s inner surface  34 . C-ring  46  then expands into groove  42 , thereby securing gear ring  30  in the upper axial direction.  
         [0030]    Referring again to FIGS. 3A and 3B, inner surface  32  of gear ring  30  defines six vertically-aligned keys  48  spaced equiangularly about inner surface  32 . Keys  48  extend radially into compartment  16  (FIGS.  5 A- 5 C) and have surfaces that are arcuate in cross-section. The arcuate surfaces are defined by circles intersecting what would otherwise be the circular boundary of surface  32 . Inner surface  32  defines a groove  50  extending entirely about surface  32  approximately half way between the top and bottom sides of gear ring  30 . While the mid-point of surface  32  is preferred, groove  50  may be defined at any suitable position. Referring again to FIG. 4, groove  50  receives a C-ring  52 , and an inner surface of C-ring  52  normally extends radially inward of the inner diameter of surface  32 . Thus, a portion of C-ring  52  extends into compartment  16  between keys  48 . Additionally, a portion of the top and bottom surface of gear ring  30  is beveled between inner surface  32  and a top and bottom flat surface  56  and  58 .  
         [0031]    As shown in FIGS. 2 and 4, compartment  18  receives a generally wedge-shaped pawl  60  so that the top and bottom surfaces of compartment  18  retain the pawl from above and below. Sufficient clearance is provided between those surfaces and the pawl, however, so that the pawl may easily slide from side to side. Pawl  60  defines a plurality of vertically-aligned teeth  62  aligned in an arc across the pawl&#39;s front face that matches the arc of the outer perimeter of gear ring  30 . In the vertical direction, teeth  62  are convex shaped to correspond to the concave outer surface of gear ring  30 . Consequently, when the pawl engages the gear ring, as shown in FIGS. 5A and 5C, all of teeth  62  engage opposing teeth  54  on the gear ring.  
         [0032]    Referring to FIG. 6, a notch  64  extends downward into the back end of pawl  60  from a top surface  66 . Notch  64  defines symmetric sides  68  and  70  that extend outward from front to back at an acute angle with respect to the pawl&#39;s center line. Notch  64  sits atop a ridge  72  extending from the back of the pawl. Ridge  72  is defined by a pair of grooves  74  and  76  on either side of the ridge that extend into the pawl&#39;s otherwise convex back surface.  
         [0033]    Referring to FIGS. 2 and 7, compartment  26  receives a wedge-shaped housing  78  having a generally arcuate back surface that matches the surface of compartment  26 . The back end of housing  78  defines an outwardly-extending notch  80  that fits into a corresponding groove (not shown) in the back of compartment  26  to retain the housing in position. An arcuate groove  82 , and two cylindrical bores  84  and  86 , extend downward into the housing from the housing&#39;s top surface. Groove  82  and bores  84  and  86  are blind; they do not extend entirely through the housing. Each of bores  84  and  86  receive a spring  88  and a ball  90 .  
         [0034]    A bore  92  extends entirely through housing  78  from back to front and receives a cylindrical pin  94 . An axial bore  96  extends from the back of pin  94  to proximate the pin&#39;s curved front end  98 . A spring  100  received in bore  96  engages the back end of compartment  26  and biases the pin forward (FIGS.  5 A- 5 C).  
         [0035]    Referring to FIGS. 2, 8A and  8 B, a switch lever  102  includes a handle portion  104  and a cylindrical bottom portion  106  extending below the handle portion. A pair of pins  108  and  110  extend downward from extension  106 . The outer surface of extension  106  defines an annular groove  112  that receives a C-ring  114  that normally extends slightly outward of groove  112 .  
         [0036]    Referring again to FIGS. 2 and 4, hole  28  defined in top surface  22  of web  20  receives extension  106 . The outer diameter of extension  106  is approximately equal to the inner diameter of hole  28 , although sufficient clearance is provided so that switch lever  102  rotates easily in the hole. Upon insertion of extension  106  into hole  28 , C-ring  114  is initially pushed radially inward into groove  112 . When groove  112  aligns with an annular groove  116  defined about the inner circumference of hole  28 , an outer portion of C-ring  114  extends into groove  116 , thereby axially securing switch lever  102  in web  20 .  
         [0037]    When switch lever  102  is inserted into hole  28 , pin  110  extends into notch  64  of pawl  60 , and pin  108  extends into arcuate groove  82  of housing  78 . Springs  88  bias their respective balls  90  upward against the bottom surface of extension  106  of switch lever  102 , thereby pushing the switch up against C-ring  114 . This prevents the switch lever from sitting loosely in hole  28  and facilitates the switch lever&#39;s smooth rotation.  
         [0038]    [0038]FIGS. 9A and 9B show two work tools  118  for use with ratcheting tool  10 . The work tool generally includes a post portion  122  and may include a socket portion  120  (FIG. 9B) or any desired tool end, for example a screwdriver head or an extension post  128  (FIG. 9A). Referring specifically to FIGS.  10 A- 10 E, a socket  118  includes a socket portion  120  and a post portion  122 . Socket portion  120  may define an inner surface  124  of any suitable socket shape, for example TORX, hex, or double hex configuration, as should be well understood. The socket&#39;s inner bore may extend in a countersunk manner entirely through the socket, as shown in FIGS. 10A and 10D at  126 , or may end in a blind surface at post section  122 . Thus, while a socket  118  is discussed herein, it should be understood that this is for purposes of example only and that the present invention may be employed with any suitable tool head that an operator desires to rotationally drive in ratcheting tool  10 . For purposes of the present discussion, such a tool head may be referred to as a “rotary tool.” 
         [0039]    Post  122  is beveled at an upper surface  130  to facilitate its insertion into the center hole of gear ring  30 . Referring also to FIGS. 2 and 4, the post&#39;s sides define six equiangularly spaced keyways  132  shaped correspondingly to keys  48  of gear ring  30  so that keys  48  secure socket  118  from rotating with respect to the gear ring.  
         [0040]    The outer surface of post  122  defines an annular groove  134  that aligns with groove  50  when the post is inserted into the gear ring so that C-ring  52  extends into groove  134 , thereby securing socket  118  axially in the gear ring. As shown in FIG. 10C, groove  134  has a pair of frustoconical sides  136  and  138  that meet in an apex at the back of the groove. Lower surface  136  defines an angle α (FIG. 10E) with respect to a plane  140  that bisects post  122  through aligned grooves  134  and  50 . Upper side  138  defines an angle β (FIG. 10E) that is larger than angle α. The smaller angle α restricts the ability to push socket  118  upward over C-ring  52 , while the larger angle β facilitates the socket&#39;s removal in the lower direction by a force that may be readily applied by hand. In one preferred embodiment, angle α is 30° and angle β is 60°, although it should be understood that groove  134  may have any suitable configuration.  
         [0041]    In operation, ratcheting tool  10  may be used as a ratcheting socket wrench upon the insertion of socket  118  as described above. Alternatively, the inner circumference of gear ring  30  may be sized so that tool  10  may also be used as a ratcheting wrench. In this case, keys  48  may, for example, be used to abut the flat sides of a hexagonal nut or other work piece the operator desires to drive. Thus, it should be understood that tool  10  may be used in either manner and that the tool&#39;s operation described below applies equally well to either situation.  
         [0042]    When the pawl engages the gear ring on either side of compartment  18 , pin  110  extends into notch  64  without engaging either of sides  68  or  70  (FIG. 6). Pin  108  extends into groove  82  in the housing. Groove  82  guides the rotation of switch  102 , and its ends provides stops that limit the lever&#39;s rotation. Thus, when switch lever  102  is rotated to either of its limits so that pawl  60  is on one of the two lateral sides of compartment  18 , pin  108  engages a corresponding side of groove  82 , and pin  110  sits in notch  64  between sides  68  and  70 .  
         [0043]    Referring once again to FIGS.  5 A- 5 C, and as indicated above, pawl  60  may slide to either side of compartment  18 . In the position shown in FIG. 5A, pawl  60  is wedged between gear ring  30  and the lower surface of compartment  18 . The front curved end  98  of pin  94  is pushed forward by spring  100  (FIG. 2) so that pin  94  engages curved groove  76  in the pawl&#39;s back side, thereby biasing the pawl into the wedged position. If torque is applied to handle  12  in the counterclockwise direction, the sides of compartment  18  push teeth  62  of pawl  60  upward against the sides of teeth  54  of gear ring  30 . If gear ring  30  is secured to a work piece, the reaction force applied to pawl  60  pushes the pawl against the side of compartment  18 . That is, the pawl remains wedged between the gear ring and the compartment&#39;s bottom edge, and the force applied from the operator&#39;s hand to the pawl through the bottom side of compartment  18  is therefore applied in the counterclockwise direction to the work piece through gear ring  30 .  
         [0044]    If an operator applies torque to the handle in the clockwise direction, teeth  54  of gear ring  30  apply a counterclockwise reaction force to pawl  60 . If gear ring  30  and/or socket  118  remains rotationally fixed to a work piece, teeth  54  hold the pawl in position so that the pawl moves back and up into compartment  18 , causing the curved side of groove  76  to push against the rounded tip of pin  94 . This pushes pin  94  against the force of spring  100 , and pawl teeth  62  eventually ride over gear teeth  54 . Spring  100  then pushes pin  94  forward against the sloped surface of groove  76 , forcing pawl  60  back down toward the bottom face of compartment  18  and into the next set of gear ring teeth. This ratcheting process repeats as the operator continues to rotate handle  12 .  
         [0045]    To change the operative direction of ratcheting tool  10 , the operator rotates switch  102  in the clockwise direction (as shown in FIG. 5B). Referring also to FIGS. 2, 4 and  6 , extension  106  rotates in hole  28 , and pin  108  moves through arcuate groove  82 , thereby bringing pin  110  into contact with side  70  of notch  64 . Continued rotation of switch  102  applies a counterclockwise force to the pawl so that pawl teeth  62  ride up and back into compartment  18  on gear teeth  54 . Gear ring  30  may also rotate slightly. This pushes pin  94  back against the force of spring  100 . As the operator continues to rotate switch  102  toward the position shown in FIG. 5C, ridge  72  passes over the end of pin  94 . Pin  94  then pushes forward against the curved surface of the following groove  74  in the back of the pawl. This assists the desired movement of the pawl, which then moves upward in compartment  18  and wedges between the gear ring and the compartment&#39;s upper edge, as shown in FIG. 5C. When the pawl has moved over to this wedged position, the configuration and operation of the gear, pawl and switch mirrors that described above. Thus, the tool ratchets, and applies torque to a work piece, in the same manner but in opposite directions.  
         [0046]    It should also be understood that various configurations of the components described herein may be employed. For example, while six keys  48  are illustrated in the embodiment shown in FIGS. 2 and 5, it should be understood that the gear ring and socket may define any suitable number of keys  48  and corresponding keyways  132  (FIG. 10A). For example, the embodiments shown in FIGS.  11 A- 12 B and FIGS.  13 A- 14 B (other components of the tool have been eliminated for purposes of clarity) illustrate single and dual key/keyway combinations, respectively.  
         [0047]    While one or more preferred embodiments of the invention have been described above, it should be understood that any and all equivalent realizations of the present invention are included within the scope and spirit thereof. The embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, it should be understood by those of ordinary skill in this art that the present invention is not limited to these embodiments since modifications can be made. Therefore, it is contemplated that any and all such embodiments are included in the present invention as may fall within the scope and spirit thereof.