Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation Application claiming priority benefit from U.S. patent application Ser. No. 12/802,727 entitled “Modular Long Handled Tool Component System” filed Jun. 11, 2010, now U.S. Pat. No. 8,322,764 issued Dec. 4, 2012. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to industrial long handled tools. In particular, the invention relates to interchangeable long handled tool component systems with interchangeable parts and capable of use in demanding environments. 
     BACKGROUND OF THE INVENTION 
     Many industrial tasks such as construction, road building and fire fighting require use of long handled tools for sweeping, digging, and raking. Such tasks typically have been accomplished by separate long handled brooms, shovels of various kinds, axes and rakes. The tasks are often rigorous and take place in caustic environments. Prior art long handle tools typically suffer from design weakness at the point where the handle connects to the tool head, often resulting in premature failure. If one part of the tool fails, the entire tool requires replacement. Replacement results in waste of the parts of the tool that are still operable. Also, industrial tasks are often completed under circumstances that require transport and storage of the tools. For example, in fire fighting applications, all tools must be transported to and from a fire and often carried by hand to remote locations. In other situations, caustic environments cause premature aging and failure of the tools. For example, spreading lime, asphalt and concrete creates a particularly demanding environment for tools due to chemical corrosion and rust. 
     Various methods have been tried in the prior art to address these problems. None have been entirely successful. 
     U.S. Pat. No. 4,162,132 to Kress, et al. discloses a set of garden or household implements comprising different heads which can be attached to a handle by a coupling. The coupling comprises a sleeve inserted into the handle, a hexagonally shaped handle on each head, an annular retaining ring and a threaded pin abutting the handle and forcing the handle into the sleeve. The coupling limits the extent to which the handle can be inserted therefore limiting the integrity of the connection. Further, the coupling and the annular ring allow for movement from impact vibrations increasing wear and tear to the coupling thereby reducing the useful life of the tool. 
     U.S. Pat. No. 4,606,089 to King discloses a ground working implement having a handle and a plurality of nested implement heads. Each implement head includes a tang adapted to be received by a socket assembly on the handle. A retaining pin secures the tang to the socket assembly. The socket assembly is permanently integrated into the handle and therefore is not interchangeable. The retaining pin and tang are subject to movement during use which lessens the strength of the coupling and leads to premature wear. 
     U.S. Pat. No. 4,786,095 to Dumont discloses a gardening hand tool fitted with interchangeable heads secured by a toggle. A tool head receives the handle and includes a toggle catch. The toggle is permanently attached to one end of the handle and includes a spring loop for engagement with the catch. The tool is not modular and the toggle does not provide a vibration free attachment nor is it designed for rigorous use. 
     U.S. Pat. No. 5,185,992 to Garcia discloses a garden tool assembly comprising a first connection and a second connection. The first connection is mounted to the handle of a traditional tool. The second connection receives an alternate tool head. The system requires manipulation of two tool heads. The connections are not secure but allow for translated vibration and movement leading to premature tool failure. 
     Therefore, there is a need for a long handled tool system made up of interchangeable parts that, when assembled, provide high strength and rigidity suited for industrial use. It is desirable to provide a long handled tool system that reduces storage space required for multiple tools and extends the useful life of each tool by providing for replacement of only damaged parts. It is also desirable that the assembled tool be more durable than prior art long handle tools and be resistant to caustic and abrasive work environments. It is further desirable to provide a coupling that reduces or eliminates vibrations between its parts during use thereby extending the useful life of the tool. 
     SUMMARY OF INVENTION 
     Accordingly, an embodiment of the tool system includes a collection of interchangeable tool heads, connectors, handles, and hand grips. Each tool head includes a receiver. The receiver includes an outer reinforcing collar and a concentrically aligned locking bar having a polygonal cross section. The receiver is removably coupled to a connector. The connector includes an axially aligned locking bar hole having a polygon shaped cross section for receiving the locking bar. An outer diameter is provided that nests within the outer reinforcing collar. A shoulder abuts the reinforcing collar. A plastic sleeve is positioned between the locking bar hole and the locking bar to reduce vibrations and provide electrical isolation. A flexible gasket is positioned between the shoulder and the receiving collar. The connector is removably coupled to the handle. A grip is also removably attached to the handle. The handle is of composite construction including an inner steel tube surrounded by an outer plastic tube. The handle may be filled with a shock absorbing polystyrene foam. 
     An alternate embodiment includes a tool head integrally formed with a receiver where the receiver is removably coupled to an alternate connector. The receiver has a polygonal cross section adapted to fit the alternate connector. The alternate connector includes a polygonal shaped cross section receiver hole. An angled extension may also be removably incorporated between the receiver and the connector to provide a variable angle of attack. 
     Those skilled in the art will appreciate the above-mentioned features and advantages of the invention together with other important aspects upon reading the detailed description that follows in conjunction with the drawings provided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the detailed description of the preferred embodiments presented below, reference is made to the accompanying drawings. 
         FIG. 1  is an exploded isometric view of a preferred embodiment of the modular tool component system. 
         FIG. 2A  is an isometric view of a preferred embodiment of a shovel head. 
         FIG. 2B  is an isometric view of a preferred embodiment of a hammer head. 
         FIG. 2C  is an isometric view of a preferred embodiment of a pick-axe head. 
         FIG. 2D  is an isometric view of a preferred embodiment of a axe head. 
         FIG. 2E  is an isometric view of a preferred embodiment of a rake head. 
         FIG. 2F  is an isometric view of a preferred embodiment of a hoe head. 
         FIG. 2G  is an isometric view of a preferred embodiment of a broom head. 
         FIG. 3  is a cross-sectional plan view of a preferred embodiment of a receiver. 
         FIG. 4  is an exploded isometric view of a preferred embodiment of a receiver and a connector. 
         FIG. 5  is an exploded cross-sectional plan view of a preferred embodiment of a connector. 
         FIG. 6A  is an isometric view of an alternate preferred embodiment of a rake head. 
         FIG. 6B  is an isometric view of an alternate preferred embodiment of a hoe head. 
         FIG. 6C  is an isometric view of an alternate preferred embodiment of a broom head. 
         FIG. 7  is an exploded cross-sectional plan view of an alternate preferred embodiment of a connector. 
         FIG. 8  is a cross-sectional plan view of a preferred embodiment of an extension. 
         FIG. 9  is a cross-sectional plan view of a preferred embodiment of a handle. 
         FIGS. 10A ,  10 B and  10 C are isometric views of a preferred embodiment of the grip. 
         FIG. 11  is an isometric view of a preferred embodiment of the modular tool component system assembled. 
         FIG. 12  is a cross-sectional plan view of a preferred embodiment of an assembled receiver, connector, and handle. 
         FIG. 13  is an isometric view of a preferred embodiment of the modular tool component system assembled. 
         FIG. 14  is a cross-sectional plan view of an alternate preferred embodiment of an assembled receiver, connector, and handle. 
         FIG. 15  is an exploded isometric view of a preferred embodiment of the modular tool component system. 
         FIG. 16  is an isometric view of a preferred embodiment of the modular tool component system assembled. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the descriptions that follow, like parts are marked throughout the specification and drawings with the same numerals, respectively. The drawing figures are not necessarily drawn to scale and certain figures may be shown in exaggerated or generalized form in the interest of clarity and conciseness. 
     A preferred embodiment of tool component system  100  is shown in  FIG. 1 . Generally, tool component system  100  comprises tool head  102  axially aligned with and removably coupled to connector  200 . Connector  200  is axially aligned with and removably coupled to handle  300 . Handle  300  is axially aligned with and removably coupled to grip  400 . 
     The preferred embodiment includes several tool heads adapted to be removably and securely attached to the connector. Examples are shovel type implements, pick axe type implements, axe type implements, hammer type implements, rake type implements, hoe type implements, and broom type implements. 
       FIGS. 2A-2G  show examples of such implements including shovel head  106 , pick-axe head  108 , axe head  105 , hammer head  107 , rake head  101 , hoe head  103 , and broom head  104 . The shovel head  106  may include any number of different shovel head types including but not limited to a flat head, a round head, a spade shovel, or a sand shovel. Additionally, the other tool head shapes are not limited to the shapes and dimensions shown, but can be any type of hammer, rake/cultivator, hoe, or broom shape as is common in the art. Weldment  109  permanently secures each tool head to its receiver  110 . 
     Referring to  FIGS. 3 and 4 , receiver  110  is generally cylindrical. In the preferred embodiment, the receiver is formed of steel, a steel alloy or a stainless steel. Receiver  110  includes receiver body  112  including a fixed, perpendicularly oriented supporting disk  116 . Opening  111  in receiver  110  is attached to tool head  102  by welding or epoxy adhesive. Locking bar  118  is rigidly affixed to disk  116  and is concentrically aligned with receiving body  112 . In the preferred embodiment, internal weldment  113  and external weldment  115  rigidly attach locking bar  118  to disk  116 . Other methods of rigid attachment as known in the art may be employed. As shown, locking bar  118  has a square cross section. Other polygonal shaped cross sections may be employed. Locking bar  118  is of a length that terminates flush with outer reinforcing collar  119 . Other lengths of the locking bar function with varying degrees of success. Adjacent to and surrounding locking bar  118  is outer reinforcing collar  119 . Locking bar  118  in the preferred embodiment is hollow to reduce weight. In other embodiments locking bar  118  may be solid. Between locking bar  118  and outer reinforcing collar  119  is opening  117 . Reinforcing collar  119  further includes through hole  114 . Threaded hole  120  is located on one side of locking bar  118  and is axially aligned with through hole  114 . 
     Referring to  FIGS. 4 and 5 , connector  201  will be described. Connector  201  is generally cylindrical. In a preferred embodiment, connector  201  is made of an aluminum alloy or a magnesium alloy. Rigid polymers may be employed such as Teflon or Dacron. Composites such as wound carbon fiber in resin may be employed with some success. In extremely light duty applications polyvinyl chloride may be employed. Connector  201  includes two sections, connector insert  202  and connector body  204  separated by outer shoulder  212  and inner shoulder  226 . The outer diameter of the connector body is generally the same as the outer diameter of the receiver body. The outer diameter of connector insert  202  is sized to nest within the inner diameter of reinforcing collar  119  and opening  117 . O-ring  224  is seated against outer shoulder  212  and surrounds the perimeter of connector insert  202 . O-ring  224  is preferably rubber or neoprene gasket material. Connector insert  202  is hollowed by locking bar hole  206 . Locking bar hole  206  in the preferred embodiment has a square cross-section. In general, locking bar hole  206  has the same cross-section shape as the locking bar. Connector  201  further includes sleeve  230  seated in locking bar hole  206 . Sleeve  230  is made of a polyvinyl chloride plastic or other semi-rigid plastic. Sleeve  230  is shaped to fit within locking bar hole  206  and includes a square shaped sleeve hole  232 . Sleeve hole  232  is sized to accommodate locking bar  118 . Sleeve  230  includes an integrally formed sleeve flange  238 . Connector body  204  includes through hole  220  and an axially aligned threaded hole  222 . Sleeve  230  further includes through hole  234  and  236 . Connector insert  202  also includes through hole  208  and retaining hole  210 . Locking screw  216  includes washer  217  and is sized to engage the threads of retaining hole  210  and threaded hole  120 . Locking screw  216  is sized to pass through through holes  208 ,  234 , and  114 . A first attachment means is shown as retaining pin  218  and washer  221 . The head of retaining pin  218  is sized for through hole  220 . The threads of retaining pin  218  are sized to engage threaded hole  222 . An alternate suitable attachment means is comprised of a hitch pin and latch (See  FIG. 7  for reference). An additional alternate attachment means is comprised of a cotter pin. (See  FIG. 8  for reference). An additional alternate attachment means is comprised of a hollow bolt having a threaded interior coupled with a screw to engage the interior threads of the bolt (See  FIG. 10A  for reference). 
       FIGS. 6A and 6B  show two additional examples of the tool head, rake head  156  and hoe head  158 . Rake head  156  and hoe head  158  may be any number of working shapes and include any number of working features that are common in the art for rakes and hoes and thus are not limited to the specific shape and features shown here. Integrally formed with each alternate tool head is receiver  168 . Receiver  168  includes a polygonal cross section having dimensions equal to locking bar  118 . In a preferred embodiment, the cross section of the receiver is square. Receiver  168  includes mounting hole  258 . 
     Referring to  FIG. 6C , another example of the tool head is shown as broom head  160 . Broom head  160  is comprised of body  162  from which bristles extend and to which bracket  164  is attached. It is understood that bracket  164  is capable of mounting to any number of broom head designs that are common in the art and therefore the embodiment is not limited to the specific broom head features and dimensions depicted here. Bracket  164  is integrally formed with receiver  166 . Receiver  166  extends from bracket  164  at an angle of approximately 30 degrees. Receiver  166  has a polygonal cross section having a shape and dimensions equal to locking bar  118  and receiver  168 . Receiver  166  is generally hollow with mounting hole  167  passing entirely through two opposing sides. Bracket  164  is attached to the broom body by retaining bolt  165  or a suitable epoxy. 
     An alternate embodiment of the connector is shown in  FIG. 7  as connector  250 . Rake head  156 , hoe head  158 , or broom head  160  is removably coupled to handle  300  by connector  250 . Connector  250  is generally cylindrical and in a preferred embodiment is made of an aluminum alloy or a magnesium alloy. Shoulder  276  resides on the internal surface of the connector between receiver end  252  and connector body  254 . Connector body  254  has a handle cavity  275 . Receiver end  252  includes receiver hole  256 . Receiver hole  256  in the preferred embodiment has a square shaped cross section but may assume other polygonal cross sections. Connector  250  includes through holes  259  and  260  which are in axial alignment with each other on opposite sides of connector  250 . Through holes  259  and  260  pass through to receiver hole  256 . Connector  250  further includes sleeve  280  seated in receiver hole  256 . Sleeve  280  is generally constructed of a polyvinyl chloride plastic and is sized to match the shape of receiver hole  256 . The sleeve includes square sleeve hole  282 . Sleeve  280  includes a disk shaped cap shown as sleeve head  288 . Sleeve  280  further includes through holes  284  and  286  in general axial alignment. Hitch pin  266  is sized to fit through through holes  259  and  260 . Latch  267  extends from the head of hitch pin  266  to engage the end of hitch pin  266 . Retaining pin  268  includes washer  271 . The head of retaining pin  268  is sized to fit in through hole  270 . The threads of retaining pin  268  are sized to engage threaded hole  272 . Accordingly, when sleeve  280  is seated in connector  250 , sleeve head  288  is adjacent shoulder  276  while through holes  259 ,  260 ,  284 , and  286  are all axially aligned. The inner dimensions of sleeve hole  282  are minimally larger than the outer dimensions of receivers  166  and  168  which allow receivers  166  and  168  to be inserted into sleeve hole  282 . 
     Referring to  FIG. 8 , extension  290  is shown. Extension  290  is preferably a solid steel rod comprising a central bend of approximately 30 degrees. Integrally formed with extension  290  is head  296  and receiver  292 . Head  296  includes a polygonal cross section. In the preferred embodiment the cross section is square. Head  296  includes square hole  298 . The inner dimensions of square hole  298  are larger than the outer dimensions of receivers  166  and  168  sufficient to allow receivers  166  and  168  to be inserted into square hole  298 . Head  296  includes mounting holes  299 . Mounting holes  299  on opposite sides of head  296  are axially aligned with each other. Cotter pin  291  is attached to extension  290  by tether  293 . Cotter pin  291  is sized to pass through mounting holes  299 ,  258 , and  167 . Receiver  292  is generally solid with a cross section having dimensions equal to locking bar  118  and receivers  166  and  168 . Receiver  292  further includes through hole  294  passing entirely through two opposing sides. 
       FIG. 9  shows composite handle  300 . Handle  300  includes inner tube  302  surrounded by outer tube  304 . In the preferred embodiment, inner tube  302  is formed of steel but an aluminum alloy, magnesium or titanium could also suffice. In the preferred embodiment, outer tube  304  is formed from fiberglass. Carbon fiber or Kevlar would also suffice Inner tube  302  and outer tube  304  are bonded by a suitable adhesive. In another embodiment, the handle is filled with an extruded polystyrene foam  305  to reduce translation of impact vibration through the handle. The outer diameter of outer tube  304  is slightly less than the inner diameter of handle cavity  219  and connector body  254  as previously described. Proximate one end of handle  300  is through hole  306 . Through hole  306  is sized to receive retaining pins  218  or  268 . Proximate the opposite end of handle  300  is through hole  308 . Through hole  308  is oriented generally perpendicularly to through hole  306 . 
       FIGS. 10A ,  10 B, and  10 C show multiple examples of the grip, specifically, D-grip  402 , cap grip  404 , and plug  406 . In a preferred embodiment, D-grip  402  is formed from a vinyl plastic but vulcanized rubber will also suffice. Other grip material such as neoprene will suffice. D-grip  402  has a “D” shaped handle  412  integrally formed with body  414 . Body  414  is tubular in shape and hollow. Body  414  is sized to fit over one end of handle  300 . Near the end of body  414  is through hole  420 . Through hole  420  passes through both sides of body  414 . The body of pin  416  is sized to fit through through hole  420  and is hollow. The end of pin  416  opposite its head is open and threaded on the interior to receive screw  418 . In a preferred embodiment, cap grip  404  is generally formed of rubber or durable synthetic rubber foam. Cap grip  404  is generally tubular in shape. Cap grip  404  is sized to accommodate handle  300  and is held in place with friction or a suitable adhesive. In a preferred embodiment, plug  406  is formed of plastic but could also be rubber. Plug  406  includes a tubular body and head  432 . Head  432  extends just beyond the perimeter of body  430 . Body  430  is sized to slip inside one end of handle  300  and is held in place with friction or suitable adhesive. 
       FIG. 11  shows an assembled shovel type tool. Shovel head  106  and receiver  110  are removably coupled to connector  201 . Connector  201  is removably secured to handle  300  and D-grip  402  is removably attached to handle  300 . A pick-axe type tool, an axe type tool, a hammer type tool, a rake type tool, a hoe type tool, and a broom type tool are assembled in an identical fashion using pick-axe head  108 , axe head  105 , hammer head  107 , rake head  101 , hoe head  103 , and broom head  104  respectively. 
       FIG. 12  shows a cross section view of the assembled components. Shovel head  106  and receiver  110  are coupled to connector  201 . Connector  201  is secured to handle  300 . 
     In use, sleeve  230  is inserted in locking bar hole  206  until sleeve flange  238  is adjacent inner shoulder  226 . In turn, connector insert  202  is inserted into opening  117  moving locking bar  118  into sleeve hole  232 . When through hole  208  is aligned with through hole  114  and threaded hole  120 , locking screw  216  is inserted through through holes  114  and  208  and threaded into threaded hole  120  thereby securing connector insert  202  within opening  117  and locking bar  118  within sleeve hole  232 . Outer reinforcing collar  119  sandwiches O-ring  224  against outer shoulder  212  thereby deforming O-ring  224  and resiliently biasing the receiver and connector to prevent unwanted rotation of the locking screw during use and so serves to lock the locking screw in place. The bias also serves to reduce the transmission of impact vibrations to and from the handle thus reducing fatigue stress and wear on all components. O-ring  224  further functions to seal against liquid penetration thereby providing an air tight seal between the outside environment and the interior of locking bar  118 . Similarly, washers  217  and  221  provide a seal between the environment and the interior of the openings and the interior of the locking bar and the handle. 
     In practice the sleeve also reduces transmission of impact loading and vibrations between the parts and so also serves to extend the useful life of the tool. Further, the sleeve serves to electrically insulate the connector from the tool head thereby preventing electron migration and chemical welding of the parts during use, further serving to increase the life of the tool. 
     When not in use, locking screw  216  may be threaded into retaining hole  210  to prevent loss during transport or storage. 
     When assembled, the connector provides excellent resistance to axial loads, torsional loading about the longitudinal tool axis (twisting) and bending moments about any radial axis. For example, axial loads are distributed by locking bar  118  and disk  116  to the complete internal circumference of the receiver and by outer shoulder  212  to the complete outer circumference of the connector. Torsional loading is resisted by the various surfaces of the locking bar in cooperation with disk  116 , locking screw  216  and retaining pin  218 . Bending moments are likewise resisted by the overlap and engagement of the reinforcing collar with the connector insert and the overlap and engagement of the locking bar with the locking bar hole. 
       FIG. 12  further shows handle  300  engaged with connector  201 . Handle  300  is inserted into handle cavity  219 . Once through holes  220  and  306  and threaded hole  222  are axially aligned, retaining pin  218  passes through through holes  220  and  306  and the threads of retaining pin  218  engage threaded hole  222 . Retaining pin  218  is tightened resulting in connector  201  and handle  300  securely yet removably engaged. The plastic outer tube serves dual purposes. First, it provides structural resiliency to the metallic inner tube thereby preventing “crimping” failure of the inner tube. Second, the plastic outer tube provides the advantage of being an insulating material slowing or preventing transmission of electricity and heat to the hands of the user thereby increasing safety and comfort during use. The metallic inner tube increases the toughness of the plastic outer tube thereby increasing the resistance of the tool to splintering and cracking failure caused by repeated impact loading. 
       FIG. 13  shows an assembled rake type tool. Rake head  156  is integrally formed to be one piece with receiver  168 . Receiver  168  is removably coupled to connector  250 . Connector  250  is removably secured to handle  300  and cap grip  404  is removably attached to handle  300 . A hoe type tool and a broom type tool are assembled in an identical fashion using hoe head  158  and broom head  160 . 
       FIG. 14  shows a view of the connections of the components from the tool head to the handle. Receiver  168  of rake head  156  is coupled to connector  250  and connector  250  is secured to handle  300 . 
     Receiver  168  is inserted into sleeve  280  until mounting hole  258  is aligned with through holes  259  and  260 . When the holes are aligned, hitch pin  266  is inserted through through holes  259  and  260  and mounting hole  258  until hitch pin  266  emerges on the opposite side of receiver end  252 . Once latch  267  is extended over the end of hitch pin  266 , rake head  156  and connector  250  are securely yet removably secured. When connector  250  is not attached to a tool head, hitch pin  266  can be securely stored in through hole  260  by latch  267 . 
       FIG. 14  further shows handle  300  securely connected with connector  250 . Handle  300  is inserted into the open end of connector body  254 . Once through holes  270  and  306  are axially aligned, retaining pin  268  is inserted through through holes  270  and  306  and the threads of retaining pin  268  engage threaded hole  272 . Retaining pin  218  is tightened resulting in connector  250  and handle  300  securely yet removably engaged. Washer  271  provides a seal between the environment and the interior of the opening and the interior the handle. The alternate attachment means previously shown and described may also be used without detracting from the broad inventive concept thereof. 
     An alternate embodiment of an assembled broom type tool incorporating extension  290  is shown in  FIGS. 15 and 16 . The connections are identical to what was previously described for a broom type tool except for the addition of extension  290 . Extension  290  allows for the user of the tool to achieve a variable working angle for the head of the tool. 
     Receiver  166  is inserted in to square hole  298 . Once mounting holes  299  and  167  are aligned, cotter pin  291  is inserted through mounting holes  299  and  167  to securely and removably couple extension  290  to broom head  160 . Receiver  292  is inserted in to sleeve  280  until through holes  259 ,  260  and  294  are aligned. When the holes are aligned, an attachment means is used to securely couple extension  290  to connector  250 . Handle  300  is attached to connector  250  and the desired grip is also attached as previously described. 
     It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims

Technology Category: b