Patent ID: 12186864

DETAILED DESCRIPTION

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 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.1illustrates a power tool10selectively coupled to a tool bit15by an extension adapter20. The power tool10is operable to rotate the adapter20and the tool bit15about a rotational axis25(FIG.2). In the illustrated embodiment, the connection between the tool bit15and the adapter20and the connection between the adapter20and the power tool10is commonly referred to as a Special Direct System (SDS) plus connection. In other embodiments, the connection between the tool bit15and the adapter20and/or the connection between the adapter20and the power tool10can be a different type of SDS connection (e.g., SDS top connection, SDS max connection, etc.). In other embodiments, the tool bit15can be directly coupled to the power tool10by omitting the adapter20.

With reference toFIG.2, the adapter20includes a body30having a rear portion35separated from a front portion40by a flange45. The flange45extends radially from an outer surface50of the body30. The rear portion35of the body30includes two opposing cylindrical apertures55(only one cylindrical aperture55is illustrated inFIG.2). The cylindrical apertures55are spaced 180 degrees from each other and are in communication with a central bore65of the adapter20defined by an inner surface70of the body30. In the illustrated embodiment, the inner surface70defines a diameter72(FIGS.4-7) of about 0.394 inches (e.g., slightly larger than a shank of the tool bit15). In other embodiments, the diameter72can be greater than or less than about 0.394 inches. Each cylindrical aperture55is sized to receive a locking member (e.g., a ball bearing or locking sphere75) so that a portion of each locking sphere75extends beyond the inner surface70and into the central bore65(FIG.4). In other embodiments, a plug or protrusion can be received through each aperture55into the central bore65and fixed relative to the body30.

In addition, the body30includes two opposing protrusions80(e.g., anti-rotational rails) extending beyond the inner surface70of the central bore35radially toward the rotational axis25(FIG.4). The illustrated protrusions80also linearly extend from the rear portion35of the body30to the front portion40of the body30. In the illustrated embodiment, the protrusions80are formed integral with the body30as a single component. In other embodiments, the protrusions80can be inserts that are coupled to the body30(e.g., by a press fit engagement, by a brazing process, or the like). In further embodiments, the body30can include more than two protrusions80(e.g., four protrusions) with a pair of protrusions associated with the rear portion35of the body30and the other pair of protrusions associated with the front portion40of the body30.

Referring toFIGS.1and2, the body30of the adapter20is coupled to the power tool10by an extension shank or shaft85. The illustrated shaft85includes a first end portion90that is coupled to the body30and a second end portion95that is coupled to a chuck100of the power tool10. Both end portions90,95include two opposing channels105and two opposing grooves110, which collectively define a SDS plus interface. To connect the shaft85to the body30, the shaft85is positioned within the central bore65so that a portion of each protrusion80is received within one channel105of the first end portion90and each locking sphere75is received within one groove110of the first end portion90(FIG.4). Such a connection between the shaft85and the body30locks the shaft85to the body30and allows the shaft85to axially move along the rotational axis25, but inhibits the shaft85from rotating relative to the body30. In other embodiments, the shaft85can be fixed to the body30(e.g., inhibited from axial and rotational movement relative to the body30). Furthermore, the shaft85extends through a rear end cover115that is coupled to the rear portion35of the body30(e.g., by a threaded engagement between the rear portion35of the body30and the rear end cover115). The rear end cover115extends over the two cylindrical apertures55—and ultimately the two locking spheres75—to trap each locking sphere75within the respective cylindrical aperture55between the respective groove110and the rear end cover115(FIG.4). In addition, a gasket120is positioned within a slot122formed between the rear portion35and a portion of the rear end cover115. The gasket120inhibits dust and debris from entering the adapter20through the central bore65between the shaft85and the rear end cover115. The gasket120can be composed of an elastomeric or rubber material. The gasket120can be a wiper ring-type gasket, a quad ring gasket, an O-ring gasket, etc. In other embodiments, the gasket120can be omitted.

With continued reference toFIG.2, the front portion40includes one elongated aperture125(in a direction parallel to the rotational axis25) spaced 90 degrees relative to the protrusions80. As shown inFIG.3, the elongated aperture125includes a forward end130and a rearward end135with the rearward end135positioned closer to the rear portion35of the body30than the forward end130. The elongated aperture125is sized to receive a retaining member (e.g., a ball bearing or retaining sphere140). Specifically, the elongated aperture125includes an open floor145in which a portion of the retaining sphere140extends through to extend into the central bore65. In the illustrated embodiment, at least about 1.5 millimeters (mm) of the retaining sphere140extends into the central bore65(FIGS.4and6). In other embodiments, about 2 mm of the retaining sphere140extends into the central bore65. In further embodiments, about 1.5 mm to about 2 mm of the retaining sphere140extends into the central bore65. The illustrated retaining sphere140includes a major dimension (e.g., diameter150;FIG.2) of about 4.5 mm. In other embodiments, the diameter150of the retaining sphere140can be less than about 7 mm. In further embodiments, the diameter150of the retaining sphere140can be between about 4.5 mm and about 7 mm. In yet further embodiments, the diameter150of the retaining sphere140can be less than 4.5 mm.

As best shown inFIGS.2and3, a first biasing member (e.g., a first compression coil spring155) surrounds the front portion40of the body30with one side of the first spring155contacting the flange45and the other side of the first spring155having a radially inward extending protrusion160. The protrusion160is sized to be received within the elongated aperture125to engage the retaining sphere140and bias the retaining sphere140toward the forward end130of the elongated aperture125(e.g., away from the shaft85). The illustrated protrusion160is a U-shaped protrusion formed away from one end165of the first spring155. In another embodiment, the end165of the first spring155can form at least a portion of the protrusion160. In further embodiments, the protrusion160can be a loop or a V-shaped protrusion.

As best shown inFIGS.2and4, the adapter20also includes a collar170slidably coupled to the front portion40of the body30. The illustrated collar170includes an outer diameter175of about 0.827 inches, which is substantially the same as an outer diameter of the rear end cover115. As such, a ratio of the outer diameter175over the diameter72of the central bore65is about 2.1. In other embodiments, the outer diameter175is less than about 0.875 inches so that a ratio of the outer diameter175over the diameter72of the central bore65is less than about 2.1. In further embodiments, the outer diameter175is less than about 0.75 inches so that a ratio of the outer diameter175over the diameter72of the central bore65is less than about 1.9. Stated another way, a maximum width of the adapter20is less than about 0.875 inches or less than about 0.75 inches. In addition, a ratio of the maximum width of the adapter20(e.g., the outer diameter175) over the major dimension150of the retaining member140(both measured in inches) is about 4.7. In other embodiments, the ratio of the maximum width of the adapter20over the major dimension150of the retaining member140can be less than 4.7.

As shown inFIG.4, the illustrated collar170includes a step180extending around an inner surface of the collar170with the step180including an obliquely angled surface185(relative to the rotational axis25) and an inner surface188. The angled surface185generally faces toward the rear portion35of the body30. The illustrated first spring155is positioned between the flange45and the step180. In addition, a second biasing member (e.g., a second compression coil spring190) is positioned between the step180and a front end cover195. The front end cover195is coupled to the front portion40of the body30(e.g., by a threaded engagement between the front portion40of the body30and the front end cover195). The second spring190engages the step180to bias the collar170away from the front end cover195(e.g., toward the shaft85).

With continued reference toFIG.4, the adapter20includes a gasket200positioned within a slot204formed between the front portion40and a portion of the front end cover195. The gasket200inhibits dust and debris from entering the adapter20through the central bore65when the tool bit15is coupled to the adapter20(FIG.6). The gasket200can be composed of an elastomeric or rubber material. The gasket200can be a wiper ring-type gasket, a quad ring gasket, an O-ring gasket, etc. In other embodiments, the gasket200can be omitted.

In some embodiments, a dust cover or shield can be coupled to an outer surface of the front end cover195to divert dust and debris away from a front interface (e.g., a gap202) between the front end cover195and the collar170. As such, dust and debris are inhibited from entering into the adapter20through the gap202between the collar170and the front portion40of the body30. The dust cover can include an outer diameter that is equal to or smaller than the maximum outer diameter of the adapter20. In other embodiments, the front end cover195and the dust cover can be formed as a single integral component.

In the illustrated embodiment, the tool bit15is coupled to the adapter20without the use of a tool, and the tool bit15can be automatically locked to the adapter20without moving the collar170relative to the body30. With reference toFIG.4, to couple the tool bit15to the adapter20, the tool bit15is inserted into the central bore65through the front end cover195and the gasket200so that a portion of the protrusions80are received within channels of the tool bit15(similar to the channels105of the shaft85). With further movement of the tool bit15toward the shaft85, a rear surface205of the tool bit15contacts the retaining sphere140, and the tool bit15pushes the retaining sphere140off of the inner surface188of the step180toward the rearward end135of the elongated aperture125against the biasing force of the first spring155. In one embodiment, the retaining sphere140can then slide along the angled surface185of the step180toward the rearward end135. Once the tool bit15pushes the retaining sphere140into engagement with the rearward end135, the retaining sphere140then moves radially toward the collar170to provide enough clearance between the tool bit15and the retaining sphere140for the tool bit15to be fully inserted into the central bore65. For example, the tool bit15pushes the retaining sphere140radially outward so that no portion of the retaining sphere140extends into the central bore65, thereby allowing the tool bit15to be fully inserted into the central bore65. The first spring155then pushes the retaining sphere140against the angled surface185for the retaining sphere140to slide radially inward into the central bore65to be received into a groove of the tool bit15(similar to the groove110of the shaft85). Accordingly, the retaining sphere140retains the tool bit15within the adapter20(FIG.6), but allows for some axial movement of the tool bit15along the rotational axis25.

Once the tool bit15is coupled to the adapter20and the adapter20is coupled to the power tool10, the power tool10is operable to drive the tool bit15into a workpiece (e.g., concrete, brick, or the like) to form a hole. During the drill operation, the tool bit15and the adapter20can move into the hole being formed in the workpiece if the diameter of the tool bit15is greater than the maximum width of the adapter20(e.g., greater than 0.875 inches). Advantageously, a tool bit15having a diameter greater than the outer diameter175of the adapter20(e.g., 0.875 inches) can be used to bore holes in a workpiece to various lengths that are greater than the length of the tool bit15itself. For example, a 6 inch long tool bit15having a diameter of at least 0.875 inches can be used to bore a hole that is longer than 6 inches by using the adapter20.

After the drilling operation is completed and the tool bit15is removed from the workpiece, the tool bit15can be removed from the adapter20by moving the collar170toward the front end cover195(FIG.7). As a result, the step180moves in a position between the elongated aperture125and the front end cover195to allow the retaining sphere140to move radially out of the central bore65as the tool bit15slides out of the adapter20. By releasing the collar170, the second spring190automatically biases the collar170toward the shaft85to position the step180over the elongated aperture125as the retaining sphere140slides along the angled surface185into engagement with the inner surface188of the step180. In other embodiments, the collar170can move toward the rear end cover115to release the tool bit15from the adapter20.

FIGS.8-11illustrate an adapter320(FIG.8) according to another embodiment of the disclosure. The adapter320is similar to the adapter20; therefore, like components have been given like references numbers plus 300. At least some differences and/or at least some similarities between the adapters20,320will be discussed in detail below. In addition, components or features described with respect to the adapter320are equally applicable to the adapter20.

With reference toFIGS.8and9, the adapter320includes a body330having an inner surface370defining a central bore365having a diameter372. The body330also includes an outer surface350and a rear portion335separated from a front portion340by a flange345. The adapter320defines a rotational axis325. In the illustrated embodiment, the rear portion335is longer than the front portion340, and the front portion340includes a larger diameter than the flange345and the rear portion335. The rear portion335includes a first pair of opposing cylindrical apertures355a(only one cylindrical aperture355ais illustrated inFIG.9) and also includes a second pair of opposing cylindrical apertures355b(only one cylindrical aperture355bis illustrated inFIG.9). Each cylindrical aperture355ais sized to receive a locking member (e.g., a locking sphere375).

With continued reference toFIGS.8and9, the adapter320also includes an extension shank or shaft385. The illustrated shaft385includes a first end portion390coupled to the body330and a second end portion395coupled to the chuck100of the power tool10. Both end portions390,395include two opposing channels405and two opposing grooves410(e.g., a SDS plus interface). A rear end cover415is coupled to the rear portion335of the body330(e.g., by a retaining ring) to extend over the two cylindrical apertures355a. As such, each locking sphere375is trapped within the respective cylindrical aperture355abetween the respective groove410and the rear end cover415(FIG.10). Such a connection between the shaft385and the body330allows the shaft385to axially move along the rotational axis325, but inhibits the shaft385from rotating relative to the body330. In addition, a gasket420is positioned within a slot422formed between the rear portion335and a portion of the rear end cover415.

With reference toFIGS.9and10, each of the second cylindrical apertures355bis sized to receive a retaining member (e.g., a retaining sphere440). The illustrated retaining spheres440include a major dimension (e.g., a diameter450) of about 5 mm. In other embodiments, the diameter450of the retaining sphere440can be less than about 7 mm. In further embodiments, the diameter450of the retaining sphere440can be between about 5 mm and about 7 mm. In further embodiments, the diameter450can be less than 5 mm.

With continued reference toFIGS.9and10, the adapter320also includes a collar470slidably coupled to the rear portion335of the body330. The illustrated collar470includes an outer diameter475of about 0.905 inches, which defines the largest diameter or width of the adapter320. As such, a ratio of the outer diameter475over the diameter372of the central bore365is about 2.3. In other embodiments, the outer diameter475of the adapter320is less than about 1 inch so that a ratio of the outer diameter475over the diameter372of the central bore365is less than about 2.5. In addition, a ratio of the maximum width of the adapter320(e.g., the outer diameter475) over the major dimension450of the retaining member440(both measured in inches) is about 4.6. In other embodiments, the ratio of the maximum width of the adapter320over the major dimension450of the retaining member440can be less than 4.6.

The illustrated collar470includes a step480having an obliquely angled surface485and a recess510positioned adjacent a front end of the collar470. A biasing member (e.g., a compression coil spring455) is positioned between the rear end cover415and the step480to bias the collar470toward the flange345and a front end cover495. The front end cover495is fixed to the front portion340of the body330and includes substantially the same diameter as the collar470. In other embodiments, the diameter of the front portion340and the collar470can be different.

With reference toFIGS.9and10, the adapter320includes a first gasket500positioned within a slot504formed by the front portion340of the body330. The adapter320also includes a second gasket515(e.g., an O-ring, a quad-ring, etc.) coupled to the rear portion335of the body330and abutting the flange345. The second gasket515also inhibits dust and debris from entering into the adapter320via the gap502when the adapter320is in the locked position (FIG.11), discussed in more detail below.

FIG.10illustrates the adapter320in an unlocked position. In particular, the collar470is moved toward the rear end cover415against the biasing force of the spring455so that the step480misaligns with the pair of cylindrical apertures355b. As a result, the retaining spheres440are allowed to move radially away from the central bore365and toward an inner surface of the collar470(e.g., a portion of the retaining spheres440extend beyond the outer surface350of the body330). However, rearward movement of the collar470toward the rear end cover415is limited to prevent the retaining spheres440from falling out of the cylindrical apertures355b. For example, a gap between a front end of the collar470and the cylindrical apertures355bis smaller than the diameter of the retaining spheres440so that the retaining spheres440cannot fall out of the adapter320through the gap when the collar470is in the unlocked position. When the adapter320is in the unlocked position, the tool bit15can be slid into the central bore365for portions of the two protrusions80to be received within the channels of the tool bit15(similar to the channels405of the shaft385). With further movement of the tool bit15toward the shaft385, the retaining spheres440align with a corresponding groove of the tool bit15(similar to the groove410of the shaft385). Thereafter, the collar470is released for the spring455to move the collar470into a locked position (FIG.11) to lock the tool bit15to the adapter320. In particular, the angled surface485comes into contact with the retaining spheres440to push the retaining spheres440radially toward the central bore365within the cylindrical apertures355. Accordingly, a portion of the retaining spheres440extend beyond the inner surface370of the body330to inhibit removal of the tool bit15from the adapter320. In addition, the spring455moves the collar470into the second gasket515to compress the second gasket515between the flange345and the recess510to inhibit dust and debris from entering into the adapter320via the gap502.

During a drill operation, the adapter320is sized to be received within a hole being formed by the tool bit15. As such, for any tool bit15having a diameter greater than about 0.905 inches (e.g., the maximum diameter of the adapter320), the adapter320can be received within the hole formed by the tool bit15.

After the drilling operation, the tool bit15can be removed from the adapter320by moving the collar470toward the rear end cover415to move the adapter320from the locked position (FIG.11) to the unlocked position (FIG.10). As the tool bit15slides out of the central bore365, the tool bit15contacts the retaining spheres440to push the retaining spheres440radially toward the collar470to provide enough clearance for the tool bit15to be removed out of the adapter320.

Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described. Various features and advantages of the disclosure are set forth in the following claims.