Patent Description:
The present invention relates to power tools, and more specifically to jigsaws.

There are various power tools known in the art that consider ergonomics as a factor in the design process. These power tools can include many benefits for the user due to the increases comfort a user experiences while using these tools.

<CIT> discloses a power tool according to the preamble of claim <NUM>, and in particular describes a palm electric tool that includes a housing adapted for palm gripping, a base connected to the housing for contacting with a workpiece and supporting the palm electric tool, a motor with an output shaft arranged within the housing. The output shaft is substantially parallel to the base. A transmission mechanism is connected to the output shaft of the motor which includes a slide bar. The slide bar is capable of being moved in a direction perpendicular to the output of the motor, a blade is connected to the slide bar which is positioned substantially perpendicular to the output of the motor and the base. A battery pack for powering the motor is inserted into the housing. An inserting direction of the battery pack is substantially parallel to the output shaft of the motor. The battery pack is positioned between the motor and the base and partially overlapped with the motor in a direction perpendicular to the base.

Aspects of the present invention are defined by appended independent claim <NUM>.

According to the invention, there is provided a power tool including a drive system and a housing at least partially supporting the drive system. The housing includes a base configured to support the power tool relative to a workpiece on which the power tool operates. The power tool includes a handle coupled to the housing. The handle defines a longitudinal axis and includes a first portion positioned between the longitudinal axis and the base and a second portion opposite the first portion along the longitudinal axis. The power tool includes an activation switch coupled to a side surface of the housing. The activation switch is slidable in a direction parallel with a switch axis that intersects the longitudinal axis from a deactivated state, in which the drive system is non-operable, to an activated state, in which the drive system is operable. The activation switch is slidable toward the second portion of the handle from an intersection point between the switch axis and the longitudinal axis.

Also described herein, in another aspect, is a power tool including a housing and a handle coupled to the housing. The handle is configured to be gripped by an operator to manipulate the power tool. The power tool also includes a drive system supported in one of the housing or the handle. The drive system includes a frame, a motor at least supported by the frame, and a transmission driven by the motor. The transmission is at least power tool operates. The power tool includes a handle coupled to the housing. The handle defines a longitudinal axis and includes a first portion positioned between the longitudinal axis and the base and a second portion opposite the first portion along the longitudinal axis. The power tool includes an activation switch coupled to a side surface of the housing. The activation switch is slidable in a direction parallel with a switch axis that intersects the longitudinal axis from a deactivated state, in which the drive system is non-operable, to an activated state, in which the drive system is operable. The activation switch is slidable toward the second portion of the handle from an intersection point between the switch axis and the longitudinal axis. According to the invention, the activation switch is a first activation switch, and the power tool further comprises a second activation switch coupled to another side surface of the housing, wherein the second activation switch is slidable parallel to the switch axis between a deactivated state, in which the drive system is non-operable, and an activated state, in which the drive system is operable.

Terms of degree, such as "substantially," "about," "approximately," etc. are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments.

<FIG> illustrates a power tool, such as a jigsaw <NUM>, including a housing <NUM> having a handle <NUM>, a battery <NUM> removably coupled to the handle <NUM> at a rear portion of the housing <NUM>, a guide plate <NUM> pivotably coupled to the housing <NUM> and configured to contact a workpiece <NUM> (<FIG>) during a cutting operation, and a cutting blade <NUM> protruding from a front portion of the housing <NUM> and a lower surface of the guide plate or base <NUM>. The jigsaw <NUM> includes a drive system <NUM> (<FIG>) powered by the battery <NUM> and operable to impart reciprocating motion to the cutting blade <NUM> for cutting the workpiece <NUM>. The handle <NUM> defines a longitudinal axis <NUM> extending centrally through handle <NUM> with the longitudinal axis <NUM> oriented substantially parallel (e.g., within <NUM> degrees) to the workpiece <NUM> in which the guide plate <NUM> abuts. Moreover, the longitudinal axis <NUM> is substantially perpendicular to a blade axis <NUM>-the blade axis <NUM> being substantially parallel to a central (vertical) axis of the housing <NUM>-along which the cutting blade <NUM> generally reciprocates during a cutting operation. The handle <NUM> includes a first or lower portion <NUM> (<FIG>) positioned between the longitudinal axis <NUM> and the guide plate <NUM>, and a second or upper portion <NUM> (<FIG>) positioned opposite the lower portion <NUM> along the longitudinal axis <NUM>.

With reference to <FIG>, the jigsaw <NUM> also includes gripping surfaces 42a, 42b disposed on the housing <NUM> and the handle <NUM>, respectively, that are graspable by a user to operate and maneuver the jigsaw <NUM> relative to the workpiece <NUM>. The gripping surfaces 42a, 42b, in addition to the housing <NUM> and the handle <NUM>, are composed of a non-conductive material (e.g., plastic with or without an elastomeric overmold). Such a non-conductive material electrically insulates the user in the event that the user inadvertently cuts an electrical wire during a cutting operation, thus inhibiting, or at least mitigating, an electrical shock. The gripping surface 42b on the handle <NUM> further includes a pair of recessed gripping portions 46a, 46b (<FIG> and <FIG>) disposed on opposite sides of the longitudinal axis <NUM> and generally located proximate the intersection of the housing <NUM> and the handle <NUM>. Each recessed gripping portion 46a, 46b is defined by a raised lip <NUM> that extends substantially around the periphery of the recessed gripping portions 46a, 46b and includes a step <NUM>. The step <NUM> and the raised lip <NUM> define an indentation <NUM> that is formed into at least one of the housing <NUM> and the handle <NUM> with the indentations <NUM> sized to receive a thumb or a finger (e.g., the index finger or the middle finger) of a user to prevent the users' thumb/finger from inadvertently slipping out of the recessed gripping portions 46a, 46b.

With continued reference to <FIG>, the jigsaw <NUM> further includes a first activation switch <NUM> (<FIG>) and a second activation switch <NUM> (<FIG>) in electrical communication with the drive system <NUM> to selectively supply power to the drive system <NUM> via the battery <NUM>, discussed in more detail below. The first activation switch <NUM> is provided on a first lateral side <NUM> of the housing <NUM> adjacent the first recessed gripping portion 46a, and the second activation switch <NUM> is provided on a second lateral side <NUM>-opposite the first lateral side <NUM>-of the housing <NUM> adjacent the second recessed gripping portion 46b. In other words, the activation switches <NUM>, <NUM> are located on opposite sides of the longitudinal axis <NUM>. Both switches <NUM>, <NUM> are slidable parallel to a switch axis <NUM>, which is oriented at an acute angle A1 relative to the longitudinal axis <NUM> (e.g., the acute angle A1 is located entirely above the longitudinal axis <NUM>; <FIG>). Specifically, the switch axis <NUM> intersects the longitudinal axis <NUM> and at least extends through the housing <NUM> such that the switch axis <NUM> is positioned between the first and second activation switches <NUM>, <NUM>. In the illustrated embodiment, the angle A1 of the switch axis <NUM> is approximately <NUM> degrees relative to the longitudinal axis <NUM>, as illustrated in <FIG>. In other embodiments, the angle A1 of the switch axis <NUM> may be approximately <NUM> degrees ± <NUM> degrees relative to the longitudinal axis <NUM>. That is, the angle A1 of the switch axis <NUM> may range from approximately <NUM> degrees to approximately <NUM> degrees relative to the longitudinal axis <NUM>. In further embodiments, the angle A1 may range from approximately parallel to the longitudinal axis <NUM> to approximately <NUM> degrees relative to the longitudinal axis <NUM>.

With reference to <FIG>, in a side view of the jigsaw <NUM> as shown in <FIG>, the switch axis <NUM> is oriented at an oblique angle B1 relative to a linear central axis <NUM> that intersects the longitudinal axis <NUM> with which the recessed gripping portions 46a, 46b are aligned. In the illustrated embodiment the oblique angle B1 is less than <NUM> degrees (e.g., approximately <NUM> degrees), however, in other embodiments, the oblique angle B1 can be between about <NUM> degrees and about <NUM> degrees.

With reference to the blade axis <NUM>, the switch axis <NUM> of the illustrated embodiment is oriented at an acute angle C1 that is approximately <NUM> degrees from the blade axis <NUM>. In other embodiments, the acute angle C1 is between about <NUM> degrees and about <NUM> degrees.

The first and second activation switches <NUM>, <NUM> are independently slidable between an activated state, in which the battery <NUM> supplies power to the drive system <NUM>, and a non-activated state (i.e., a deactivated state), in which no power is supplied to the drive system <NUM>. The activated state of the first activation switch <NUM> is shown in broken lines in <FIG> and the non-activated state of the first activation switch <NUM> is shown in solid lines in <FIG>. The activated state of the first activation switch <NUM> is positioned further from the guide plate <NUM> and the workpiece <NUM> in an upward direction <NUM> along the switch axis <NUM> than the non-activated state. The upward direction <NUM> moves away from the guide plate <NUM>/workpiece <NUM> and above the longitudinal axis <NUM>. Stated another way, the first activation switch <NUM> is slidable in the direction <NUM> and toward the upper portion <NUM> of the handle <NUM> from an intersection point <NUM> between the switch axis <NUM> and the longitudinal axis <NUM>. Although only the two states of the first activation switch <NUM> are shown in <FIG>, the two states of the second activation switch <NUM> are arranged in a similar manner. In other embodiments, the activated state and non-activated state of the switches <NUM>, <NUM> can be switched such that the non-activated state of the activation switches <NUM>, <NUM> is positioned further from the guide plate <NUM> in the direction <NUM> along the switch axis <NUM> than the activated state. In the illustrated embodiment of the jigsaw <NUM>, the switches <NUM>, <NUM> are configured as momentary switches that are biased toward the non-activated state, and that return to the non-activated state in response to being released by the user (after having been switched to the activated state). In other embodiments, the switches <NUM>, <NUM> can be momentary switches that are independently moveable along an axis substantially transverse to the longitudinal axis <NUM> (e.g., moveable in a direction into the housing <NUM> in the reference frame of <FIG>).

With reference to <FIG>, the drive system <NUM> of the jigsaw <NUM> is disposed within the housing <NUM> and the handle <NUM> adjacent the respective gripping surfaces 42a, 42b. The drive system <NUM> includes a motor <NUM>, a transmission <NUM> driven by the motor <NUM> and having an output spindle <NUM> to which the cutting blade <NUM> is removably secured, and a frame <NUM> for mounting the motor <NUM> and the transmission <NUM> in the housing <NUM>. The frame <NUM> is fixedly coupled within the housing <NUM>. Like the gripping surfaces 42a, 42b, the housing <NUM>, and the handle <NUM>, the frame <NUM> is composed of a non-conductive material (e.g., plastic). Such a non-conductive material electrically insulates the user in the event that the user inadvertently cuts an electrical wire during a cutting operation, thus inhibiting, or at least mitigating, an electrical shock. The frame <NUM> includes two apertures <NUM>, <NUM> (<FIG>) that together support the motor <NUM> and the transmission <NUM>. The first aperture <NUM> receives and supports a drive shaft <NUM> of the motor <NUM> which, in turn, supports a helical drive gear <NUM>. Specifically, the drive shaft <NUM>-which is parallel to the longitudinal axis <NUM>-is rotatably supported by the frame <NUM> via a first rotational support member <NUM> (e.g., a bushing, a radial bearing, etc.). The aperture <NUM> receives and supports a driven shaft <NUM> of a helical driven gear <NUM> of the transmission <NUM>. Specifically, the driven shaft <NUM>-which is parallel to the drive shaft <NUM>-is rotatably supported by the frame <NUM> via a second rotational support member <NUM> (e.g., a bushing, a radial bearing, etc.). The helical drive gear <NUM> intermeshes and drives the helical driven gear <NUM> of the transmission <NUM>. The transmission <NUM> transfers the rotational motion of the helical driven gear <NUM> to a reciprocating motion of the spindle <NUM> to drive the cutting blade <NUM> in a reciprocating manner.

During operation, a user may grasp the gripping surfaces 42a, 42b of the housing <NUM> and the handle <NUM> to maneuver the jigsaw <NUM> relative to the workpiece <NUM>. The user may rest the jigsaw <NUM> on the workpiece <NUM> via the guide plate <NUM> and align the cutting blade <NUM> with the desired cut. The cutting blade <NUM> reciprocates along the blade axis <NUM> in response to the user sliding one of the first activation switch <NUM> or the second activation switch <NUM> into the activated state and then releasing the switch <NUM>, <NUM> from the activated state. Specifically, the user either slides the first activation switch <NUM> parallel to the switch axis <NUM> from the non-activated state to the activated state (e.g., moves the first activation switch <NUM> in the direction <NUM>) or slides the second activation switch <NUM> parallel to the switch axis <NUM> from the non-activated state to the activated state (e.g., moving the second activation switch <NUM> in the direction <NUM>), causing the motor <NUM> to drive the transmission <NUM> and reciprocate the cutting blade <NUM>. In other words, both activation switches <NUM>, <NUM> are not positioned in the activated state for the motor <NUM> and the transmission <NUM> to drive the cutting blade <NUM>. By holding one activation switch <NUM>, <NUM> in the activated state for a short period in time (e.g., <NUM> seconds, <NUM> seconds, etc.), continuous power from the battery <NUM> is supplied to the drive system <NUM> to cut the workpiece <NUM>. Thereafter, the activation switch <NUM>, <NUM> is released from the activated state to be biased into the non-activated state. Stated another way, power is supplied to the drive system <NUM> while the switches <NUM>, <NUM> are in the non-activated state after one of the switches <NUM>, <NUM> is moved into the activated state. However, to interrupt power being supplied to the drive system <NUM> to stop movement of the cutting blade <NUM>, one activation switch <NUM>, <NUM> is simply moved back into the activated state from the non-activated state and released from the activated state (e.g., both switches <NUM>, <NUM> are then positioned within the non-activated state and the jigsaw <NUM> is non-operable).

As the activation switches <NUM>, <NUM> are conveniently located on the side surfaces <NUM>, <NUM> of the housing <NUM> adjacent one of the recessed gripping portions 46a, 46b of the gripping surface 42b, the activation switches <NUM>, <NUM> are easily accessible within an arc path of the user's thumb. As such, a user may simply slide the activation switches <NUM>, <NUM> without altering or adjusting his or her grip of the jigsaw <NUM>. Moreover, a user is able to use the jigsaw <NUM> for an extended period of time without experiencing discomfort. This is due, in part, to the non-heat conductive and non-electrically conductive material implemented on the gripping surfaces 42a, 42b, the housing <NUM>, the handle <NUM>, and the frame <NUM>. As a result, the gripping surfaces 42a, 42b are maintained at a moderate temperature without overheating. Also, the user may experience additional comfort due to the ergonomic recessed gripping portion 46a, 46b and the raised lip <NUM> of the gripping surface 42b, as well as, the orientation of the activation switches <NUM>, <NUM> (e.g., angles A1, B1).

Claim 1:
A power tool (<NUM>) comprising;
a drive system (<NUM>);
a housing (<NUM>) at least partially supporting the drive system, the housing including a base (<NUM>) configured to support the power tool relative to a workpiece on which the power tool operates;
a handle (<NUM>) coupled to the housing, the handle defining a longitudinal axis (<NUM>) and including a first portion positioned between the longitudinal axis and the base and a second portion opposite the first portion along the longitudinal axis; and
an activation switch (<NUM>) coupled to a side surface of the housing, the activation switch slidable in a direction parallel with a switch axis (<NUM>) that intersects the longitudinal axis from a deactivated state, in which the drive system is non-operable, to an activated state, in which the drive system is operable,
wherein the activation switch is slidable toward the second portion of the handle from an intersection point (<NUM>) between the switch axis and the longitudinal axis,
wherein the activation switch is a first activation switch,
characterized in that
the power tool further comprises a second activation switch (<NUM>) coupled to another side surface of the housing, and
wherein the second activation switch is slidable parallel to the switch axis between a deactivated state, in which the drive system is non-operable, and an activated state, in which the drive system is operable.