Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 13/081,163 filed Apr. 6, 2011, now U.S. Pat. No. 8,517,715 which claims priority under 35 U.S.C.§119(e) to Provisional Patent Application No. 61/321,404 filed on Apr. 6, 2010. The content of each are hereby incorporated by reference in their entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to pipe and tubing expansion tools and methods. More particularly, the present invention relates to PEX (cross-linked polyethylene) expansion tools that utilize a multi-segment expansion head, and an auto-rotation feature. 
         [0003]    Polymer tubing is gaining popularity in residential home and commercial building construction due to the rising cost of copper pipe. One of the more common types of polymer tubing is made from cross-linked polyethylene, commonly known as PEX. Polymer tubing is connected to a joint by expanding the mouth of the tubing, thus allowing the tubing to slip over the joint. The tubing is then secured to the joint by crimping the expanded part of the tubing. A typical building will have many joints; hence installation of the tubing involves expanding the mouths of numerous tubes. 
       SUMMARY 
       [0004]    In one embodiment the invention provides a tool operable to expand an end of a pipe. The tool includes a plurality of jaws movable between a closed position and an expanded position and rotatable about a longitudinal axis and a rotation collar rotationally coupled to each of the plurality of jaws. A shuttle is selectively engageable with the rotation collar and is rotatable between a first orientation and a second orientation and a spindle is movable between a first position in which the shuttle is in the first orientation and is disengaged from the rotation collar, a second position in which the shuttle is in the first orientation and is engaged with the rotation collar, and a third position in which the shuttle and the rotation collar are rotated together to the second orientation. The rotation of the rotation collar produces a corresponding rotation of the plurality of jaws while the plurality of jaws is in the closed position. Movement of the spindle to a fourth position moves the plurality of jaws to the expanded position and maintains the engagement of the shuttle and the rotation collar in the second orientation. 
         [0005]    In another embodiment the invention provides a tool operable to expand an end of a pipe. The tool includes a plurality of jaws movable between a closed position and an expanded position and rotatable about a longitudinal axis and a shuttle that is selectively engageable with the plurality of jaws and rotatable between a first orientation and a second orientation. A spindle is selectively coupled to the shuttle such that the spindle and the shuttle move between a first position and a second position in unison. The shuttle is in the first orientation and is disengaged from the plurality of jaws when the spindle is in the first position and the shuttle is in the first orientation and is engaged with the plurality of jaws when the spindle is in the second position. Further movement of the spindle from the second position toward a third position in which the spindle engages the plurality of jaws to move the jaws to an expanded position produces rotation of the shuttle to the second orientation. A sleeve is coupled to the shuttle and includes a cam surface. The cam surface is engagable with the shuttle as the spindle moves from the second position to the first position to rotate the shuttle to the first orientation. 
         [0006]    In yet another embodiment the invention provides a method of rotating a plurality of jaws, the plurality of jaws being movable between a closed position and an expanded position. The method includes positioning a spindle in a first position wherein the spindle is spaced apart from the plurality of jaws and the plurality of jaws are in the closed position, coupling a shuttle to the spindle, the shuttle movable between a first orientation and a second orientation, and moving the spindle and the shuttle in unison along a longitudinal axis to a second position. The method also includes coupling the shuttle and the plurality of jaws when the spindle is in the second position, moving the spindle to a third position in which the spindle is spaced apart from the plurality of jaws and the plurality of jaws are in the closed position, and rotating the spindle and the plurality of jaws to the second orientation in response to movement of the spindle from the second position to the third position. The method further includes moving the spindle to a fourth position while maintaining the spindle and the plurality of jaws in the second orientation, moving the jaws to the expanded position in response to movement of the spindle to the fourth position, and returning the spindle to the first position from the fourth position. The method also includes disengaging the shuttle and the plurality of jaws as the spindle moves from the second position toward the first position, engaging the shuttle and a cam surface after the shuttle disengages from the plurality of jaws, and rotating the shuttle from the second orientation to the first orientation in response to the cooperation of movement of the spindle to the first position and the engagement of the shuttle and the cam surface. 
         [0007]    In another construction, the invention provides a tool operable to expand an end of a pipe that includes a plurality of jaws movable between a closed position and an expanded position and rotatable about a longitudinal axis and a shuttle movable along the longitudinal axis between a disengaged position and engaged position wherein the shuttle and the plurality of jaws are engaged and rotatable about the longitudinal axis between a first orientation and a second orientation. A spindle is movable between a first position in which the shuttle is in the first orientation and is disengaged from the plurality of jaws, a second position in which the shuttle is in the first orientation and is engaged with the plurality of jaws, and a third position in which the shuttle and the plurality of jaws are rotated together to the second orientation while the plurality of jaws is in the closed position. Movement of the spindle to a fourth position moves the plurality of jaws to the expanded position and maintains the shuttle and the plurality of jaws in the second orientation and in the engaged position. 
         [0008]    In another construction, the invention provides a tool operable to expand an end of a pipe. The tool includes a plurality of jaws movable between a closed position and an expanded position and rotatable about a longitudinal axis, a shuttle selectively engageable with the plurality of jaws and rotatable about the longitudinal axis between a first orientation and a second orientation, and a pin positioned normal to the longitudinal axis and rotationally coupled to the shuttle for rotation about the longitudinal axis. A housing includes a recess positioned to receive the pin and a spindle includes an opening positioned to receive the pin. The opening and the recess are arranged to guide the pin between a first arrangement in which the pin is in a first position within the opening, a first position within the recess and the shuttle and the plurality of jaws are disengaged, a second arrangement in which the pin is in the first position within the opening, a second position within the recess and the shuttle and the plurality of jaws are engaged in a non-rotated position, and a third arrangement in which the pin is in a second position within the opening, a third position within the recess and the shuttle and the plurality of jaws are engaged and in a rotated position. 
         [0009]    In still another construction, the invention provides a method of automatically rotating a plurality of jaws about a longitudinal axis to expand an end of a pipe. The method includes coupling a pin to a shuttle, the pin extending along an axis normal to the longitudinal axis and rotatable in unison with the shuttle about the longitudinal axis, and positioning a portion of the pin within a recess that is fixed with respect to the shuttle. The method also includes positioning a portion of the pin within an opening formed as part of a spindle to movably couple the spindle to the shuttle, biasing the shuttle and the spindle toward a first arrangement in which the shuttle is in a non-rotated position and is disconnected from the plurality of jaws, the plurality of jaws being in a retracted position, and moving the spindle along the longitudinal axis to a second arrangement in which the shuttle is in a non-rotated position and is coupled for rotation to the plurality of jaws, the plurality of jaws being in the retracted position. The method further includes moving the spindle further along the longitudinal axis to a third arrangement in which the shuttle is coupled for rotation to the plurality of jaws and both are in a rotated position, the plurality of jaws being in the retracted position, moving the spindle further along the longitudinal axis to a fourth arrangement in which the shuttle is coupled for rotation to the plurality of jaws and both are in a rotated position and the plurality of jaws are in the expanded position, and returning to the first arrangement, wherein the shuttle returns to the non-rotated position and the plurality of jaws remain in the rotated position. 
         [0010]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a cutaway top view an expanding tool. 
           [0012]      FIG. 2  is a top view of the spindle portion and jaws of the tool of  FIG. 1 , showing the tool in a home position. 
           [0013]      FIG. 3  is a top view of the spindle portion and jaws of the tool of  FIG. 1 , showing the spindle portion in a second position. 
           [0014]      FIG. 4  is a top view of the spindle portion and jaws of the tool of  FIG. 1 , showing the spindle portion in a third position. 
           [0015]      FIG. 5  is a top view of the spindle portion and jaws of the tool of  FIG. 1 , showing the spindle portion in a fourth position with the jaws in a partially expanded state. 
           [0016]      FIG. 6  is a top view of a plurality of jaws. 
           [0017]      FIG. 7  is a perspective view of a rotation collar. 
           [0018]      FIG. 8  is a perspective view of a spindle collar. 
           [0019]      FIG. 9  is a perspective view of a sleeve. 
           [0020]      FIG. 10  is a perspective view of a hand tool including the expanding tool of  FIG. 1 . 
           [0021]      FIG. 11  is a side view of another hand tool including the expanding tool of  FIG. 1 . 
           [0022]      FIG. 12  is a top view of the hand tool and the expanding tool of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention 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 invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
         [0024]    Referring now to the drawings, an expanding tool  3  includes a housing  2 , and disposed inside the housing  2  a cam  4  which is rotatably attached to the housing  2 . A buffer  6  is disposed inside the housing  2  and is in contact with the cam  4 , such that as the cam  4  rotates the buffer  6  moves inside the housing  2 . A spindle  8  is disposed inside the housing  2  and is in contact with the buffer  6 , such that the spindle  8  moves in conjunction with the buffer  6 . A spring  10  is disposed on the exterior of the spindle  8  and is in contact with the spindle  8 . The spindle  8  is partially disposed within a sleeve  12  that has a first end and a second end. The sleeve  12  is partially disposed within and connected to the housing  2 . The spindle  8  includes a portion disposed in the interior of a shuttle  14 , and a pin  16  connects the sleeve  12 , the shuttle  14 , and the spindle  8 . In one embodiment, a rotation collar  18 , having a first end and a second end, is disposed on the exterior of the spindle  8 , and the rotation collar  18  is able to engage the shuttle  14 . A cap  20  is disposed on the second end of the sleeve  12 . A wedge  22  is connected to the spindle  8 . A plurality of jaws  24  are connected to the cap  20  and engage with the rotation collar  18  and the wedge  22 . 
         [0025]      FIGS. 1 and 2  show the expanding tool in a home position, that is, the position the tool remains in when it is not being operated. In one embodiment, the cam  4  is connected to an electric motor (not shown) that is selectively operable by a user. In another embodiment the operator rotates the cam  4  via a lever (not shown) and gears (not shown). The cam  4  is connected to the housing  2  such that the cam  4  is able to rotate about an axis. 
         [0026]    As illustrated in  FIG. 6 , a first end of one of the jaws  24  includes an interface portion  26  including a slot  28  adapted to engage the rotation collar  18  as will be discussed with regard to  FIGS. 2-5 . A second end of the jaw includes a frustoconical end  30  that extends from a small diameter cylindrical portion  32 . A collar portion  34  is disposed adjacent the first end of the jaw  24 . The collar  34  includes a large diameter portion  36 . In the illustrated construction, a plurality of ribs  40  is formed in the frustoconical end  30 . However, other constructions may omit the ribs  40 . In the illustrated construction, two or more jaws  24  are used to define a complete  360  degree jaw section that fits within a tube to be expanded. Of course, other constructions could employ three or more jaws  24  to complete the jaw section of the tool. 
         [0027]    The rotation collar  18 , illustrated in  FIG. 7  includes a substantially hollow cylindrical body  44  that includes a first end having a radially extending boss  46  and a series of teeth  48  extending axially. In another embodiment the teeth  48  are shaped to allow the shuttle  14  to slip with respect to the rotation collar  18  when a certain opposing force is present on the rotation collar  18 . A second end of the rotation collar  18  has a series of extensions  50  sized and shaped to engage the slots  28  of the interface portion  26  of the jaws  24 . The extensions  50  extend axially in a direction opposite the teeth  48  on the first end. The extensions  50  extend in an axial direction and are configured such that each extension  50  engages one of the jaws  24  such that the rotation collar  18  and the jaws  24  are coupled for rotation about a central axis but are free to move separately along that axis if required. The shape and number of the extensions  50  is a function of the number of jaws  24  and the shape or arrangement of the interface portion  26  of the jaws  24 . Thus, other configurations of the extensions as well as the interface portion  26  are possible and are contemplated. 
         [0028]    The shuttle  14 , shown in  FIG. 8  includes a shoulder  54  (shown in  FIG. 2 ) positioned at the inner most diameter on a first end. The shuttle includes a hollow cylindrical body  56  having a series of teeth  58  extending in a second axial direction. In another embodiment the teeth  58  are shaped to allow the shuttle  14  to slip with respect to the rotation collar  18  when a certain opposing force is present on the rotation collar  18 . The teeth  58  are arranged to substantially match and engage the teeth  48  of the rotation collar  18  to couple the rotation collar  18  and the shuttle  14  for rotation as will be discussed with regard to  FIGS. 2-5 . A pair of apertures  60  are formed along a diameter of the shuttle  14  such that the central axis of the apertures intersects and is normal to the axis of the tool. As will be discussed in greater detail with regard to  FIGS. 2-5  the shoulder  54  operates to guide a spring  10  and maintain the spring  10  in a desired operating position. 
         [0029]    The sleeve  12 , shown in  FIG. 9  includes a pair of triangular shaped recesses  64 . The sleeve  12  includes a hollow cylindrical body  66  sized to substantially match and engage the interior of the housing  2 . A first end of the sleeve  12  includes a plurality of projections  68  having space therebetween and a shoulder  70  positioned on the exterior of the sleeve  12 . A second end of the sleeve includes a shoulder  72  disposed on the interior of the sleeve (as seen in  FIG. 2 ). Threads  74  are disposed on the exterior of the second end of the sleeve. 
         [0030]    As can be seen in  FIG. 2 , the spindle  8  is substantially cylindrical and is hollow. A pair of L-shaped apertures  78  are formed by the cylindrical wall  80  of the spindle  8 . A long portion of the L-shaped aperture  78  extends along an axis that is substantially parallel to the center axis of the spindle  8 . A flange  82  is disposed on a first end of the spindle  8 . The flange  82  receives and guides the spring  10  to maintain the spring  10  in a desired operating position. 
         [0031]    The wedge  22  attaches to the spindle  8  and is disposed within a space defined by the jaws  24 . The second end of the wedge  22  has a shape which is designed to substantially match and engage the interior of the jaws  24 . 
         [0032]    The spring  10  provides a force which keeps the spindle in contact with the buffer  6 , and the buffer  6  in contact with the cam  4 . In the home position the shuttle  14  and rotation collar  18  are separated. 
         [0033]    With reference to  FIG. 1 , the jaws  24  are arranged to extend  360  degrees around when in the home position. Thus, the collar portion  34  cooperates to define a complete disk-shaped collar that fits within a recess  86  formed as part of the cap  20 . The recess  86  restrains axial movement of the jaws  24  while allowing substantially free radial movement of the jaws  24 . A biasing member  88 , such as a spring, is positioned within the recess  86  and biases the jaws  24  in a closed position when the jaws  24  are not being expanded by the wedge  22 . 
         [0034]    The sleeve  12  is substantially disposed in the interior of the housing  2 . The second end of the sleeve  12  is partially disposed outside of the housing  2  and the cap  20  attaches to the second end of the sleeve  12 . The rotation collar  18  is positioned adjacent the second end of the jaws  24  such that the extensions  50  can engage the slots  28  of the interface portion  26  of the jaws  24 . The extensions  50  positively engage the slots  28  of the interface portion  26  of the jaws  24 . Thus the extensions  50  and the slots  28  of the interface portion  26  of the jaws  24  can be coupled together to ensure that the jaws  24  rotate when the rotation collar  18  rotates. The rotation collar  18  is supported for free rotation about the axis of the tool and is free to move axially if required until the boss  46  of the rotation collar  18  contacts the shoulder  72  of the sleeve  12 . 
         [0035]    A spring  90  may be disposed between the rotation collar  18  and the shuttle  14  in order to bias the rotation collar  18  and the shuttle  14  apart. The spring  90 , if employed provides less resistance to an axial force than the spring  10 , such that when the spring  10  is being compressed by the spindle  8  the spring  90  compresses before the spring  10  compresses. The spindle  8  is partially disposed on the interior of the rotation collar  18  and shuttle  14  and is free to move axially. The pin  16  is disposed in the L-shaped aperture  78  of the spindle  8 , the holes of the shuttle  60 , and the triangular recesses  64  of the sleeve  12  thus connecting the spindle  8 , shuttle  14  and sleeve  12 . 
         [0036]      FIG. 3  shows the spindle  8  during one point of its movement towards the jaws  24 . The cam  4  (not shown) is partially rotated, thus pushing the buffer  6  and the spindle  8  towards the jaws  24 . The spring  10  is in contact with a base of the spindle  8  and the shuttle  14 . As the spindle  8  moves towards the jaws  22 , the spring  10  is moved towards the jaws, thus causing the shuttle  14  to engage with the rotation collar  18 . The pin  16  is able to move with the spindle  8  for a set distance, due to the triangular recesses  64  of the sleeve  12 . At this point of the cam&#39;s  4  movement, the jaws  24  have not begun to expand. 
         [0037]      FIG. 4  shows the spindle  8  during a further point of its movements towards the jaws  24 . When the shuttle  14  is engaged with the rotation collar  18 , the shuttle  14  is unable to move towards the jaws  24 . At this point, the force on the spindle causes the pin  16  to move within the triangular shaped recesses  64 . The triangular shaped recesses  64  are positioned such that as the spindle  8  applies a force towards the jaws  24  on the pin  16 , the pin  16  moves along a side of the triangular recesses  64  that is at an angle to the center axis of the spindle  8 . The movement of the pin  16  in the triangular shaped recesses  64  allows continued axial movement of the spindle  8 . The shape of the triangular shaped recesses  64  thus forces the pin  16  to rotate in the short end of the L-shaped aperture  78 . The shuttle  14  being connected to the pin  16 , and the rotation collar  18  being engaged with the shuttle  14 , rotate with the pin  16 . As the rotation collar  18  rotates the jaws  24  rotate as well. At this point the jaws  24  have not begun to expand. 
         [0038]      FIG. 5  shows the jaws  24  in a partially expanded state. At this point the spindle  8  has been moved further towards the jaws  24 , further compressing the spring  10 . As the spindle  8  moves closer to the jaws  24 , the L-shaped aperture  78  moves in relation to the pin  16  such that the pin  16  moves along the long portion of the L-shaped aperture  78 , the buffer  6  thus being closer to the pin  16 . As the spindle  8  moves towards the jaws  24 , the wedge  22  moves towards the jaws  24 . The wedge  22  then pushes the jaws  24  radially outward, expanding the jaws  24 . The spindle  8  and wedge  22  will continue to move as the cam  4  rotates. When the cam  4  reaches a point in its rotation, the buffer  6 , spindle  8 , and wedge  22  no longer move towards the jaws  24 . 
         [0039]    When the cam  4  has reached the fully expanded position of the jaws  24 , the cam  4  continues to rotate and the buffer  6 , spindle  8 , and wedge  22  move away from the jaws  24  due to the force of the spring  10  on the base of the spindle  8 . If used, the spring  90  disposed between the rotation collar  18  and the shuttle  14 , forces the rotation collar  18  and the shuttle  14  to separate. The pin  16  engages the recess in the sleeve  12  thus forcing the pin  16  and the shuttle  14  to rotate back to the home position. As the shuttle  14  is no longer engaged with the rotation collar  18 , the rotation collar  18  and the jaws  24  do not rotate back to their original position. The biasing member  88  forces the jaws  24  to move radially inward to return to the home position. 
         [0040]    In operation, the spindle  8  begins in a first position illustrated in  FIG. 2 . In this position, the shuttle  14  is not engaged with the rotation collar  18  and the pin  16  is in a home position  100  in the triangular opening  64  of the sleeve  12  as illustrated in  FIG. 9 . The pin  16  is also in the short portion of the L-shaped opening  78  as illustrated in  FIG. 2 . As the spindle  8  moves to the right (in  FIG. 2 ), the spindle  8  reaches a second position illustrated in  FIG. 3 . During this movement, the pin  16  remains in the small portion of the L-shaped opening  78  such that the pin  16  and the shuttle  14  move with the spindle  8  until the shuttle  14  engages the rotation collar  18 . As the pin  16  moves, it moves from the home position  100  in the triangular opening  64  to an engaged position  105  within the triangular opening  64  (see  FIG. 3  and  FIG. 9 ). At this point, the wedge  22  has not yet engaged the jaws  24 . Further movement of the spindle  8  forces the pin  16  to move from the small portion of the L-shaped opening  78  to the large portion of the L-shaped opening  78  as the shuttle  14  and spindle  8  cannot move further toward the rotation collar  18  once the shuttle  14  and rotation collar  18  are engaged. Movement of the pin  16  in the L-shaped opening  78  forces the pin  16  to move to a rotated position  110  within the triangular opening  64  of the sleeve  12 . This movement of the pin  16  causes a rotation of the shuttle  14 , the rotational collar  18 , and the jaws  24  prior to the wedge  22  forcing the jaws  24  outward. Additional movement of the spindle  8  toward the rotation collar  18  produces expansion of the jaws  24  with no additional rotation. 
         [0041]    Once the expansion stroke is complete, the spindle begins to retract. As the spindle  8  retracts, the large portion of the L-shaped opening  78  moves along the pin  16  until the pin  16  reaches the end of the L-shaped opening  78 . At this point, the shuttle  14  is pulled out of engagement with the rotation collar  18 . The pin  16  then moves along the angled surface  115  of the triangular opening  64  to return the pin  16  to the home position  100  and to return the shuttle  14  to the non-rotated position. 
         [0042]    The expanding tool  3  is configured so that it rotates a set amount each time, the set amount being the amount of rotation needed to move the jaws  24  from a tube mouth portion that is stretched to a tube mouth portion that is unstretched. More specifically, the rotation of the jaws  24  is at least partially determined by the number of jaws  24  and is selected to allow for multiple rotations without repeating the position of the jaws  24 . For example, in one construction six jaws  24  are employed with each jaw  24  covering an arc length of  60  degrees. The tool is configured to rotate the jaws  24   25  degrees with each rotation such that twelve rotations are required before a jaw position is repeated. 
         [0043]    Thus, the invention provides, among other things, a polymer tubing expander tool including an auto-rotate function. Various features and advantages of the invention are set forth in the following claims.

Technology Category: 7