US20110058356A1 - Power tool with light emitting assembly - Google Patents

Abstract

A power tool including an end effector rotatable with respect to the housing, a collar non-rotatably coupled to the housing, an annular printed circuit board (PCB) rotatably fixed with respect to the housing, and a light element operatively connected to the PCB and adjacent to the end effector and in a recess of the collar and located to illuminate a workpiece machined by the power tool.

Description

FIELD
• The present application relates generally to handheld power tools. More particularly, the present application relates to handheld power tools having a light configured to shine onto a workpiece machined by the power tool.
BACKGROUND
• This section provides background information related to the present disclosure which is not necessarily prior art. Power tools are often used in a variety of conditions ranging from well-lit indoor work spaces to outside construction sites or other areas that are not always well-lit. Accordingly, it is desirable to provide a method or apparatus that permits a power tool to have a lighting feature that will illuminate the workpiece being machined or worked on by the power tool. Such a lighting feature will assist a user to be able to adequately view the workpiece or work area that is being worked on or machined by the power tool even in substandard light conditions.
• Because power tools may be used in adverse environmental conditions, it is desirable to protect such a lighting feature from the adverse environmental conditions.
SUMMARY
• This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. In accordance with one embodiment of the present teachings, a power tool is provided. The power tool includes a housing, an end effector rotatable with respect to the housing, a collar non-rotatable with respect to the housing, a printed circuit board (PCB) fixed with respect to the housing using a heat stake process, and a lighting element operatively connected to the PCB. The lighting element is adjacent to the end effector and in a recess of a transparent housing and located to illuminate a workpiece machined by the power tool.
• In accordance with another embodiment of the present teachings, a power tool is provided. The power tool includes a rotatable end effector, a non-rotatable collar, and a circular printed circuit board (PCB). Surface mount lighting elements are operatively connected to the PCB and are adjacent to the end effector to illuminate a workpiece machined by the power tool. The collar has a transparent cover supporting the PCB and wires configured to provide power to the PCB for illuminating the lighting elements. The lighting elements are annularly arranged on the PCB about the end effector. A portion of the end effector extends through a hole defined by the transparent cover and PCB. The transparent cover defines a groove and the PCB is coupled in the groove using a heat staking process.
• There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
• In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
• As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
• Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
• The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
• FIGS. 1aand1brepresent side views of two embodiments of power tools according to the present teachings;
• FIG. 2 represents a nose-piece subassembly of the power tool shown inFIG. 1;
• FIG. 3 represents a cross-sectional view of a holder subassembly associated with the nosepiece shown inFIG. 2;
• FIG. 4 represents a perspective cross-sectional view of the holder subassembly shown inFIGS. 2 and 3;
• FIG. 5 represents a perspective view of a transparent cover-circuit board subassembly according to the present teachings;
• FIG. 6 represents a perspective cross-sectional view of the transparent circuit board subassembly shown inFIG. 5;
• FIG. 7 represents a front perspective view of the subassembly shown inFIG. 5;
• FIG. 8 represents a close-up view of the circuit board/transparent housing interface of the subassembly shown inFIG. 5;
• FIG. 9 represents a rear perspective view of an alternate holder subassembly according to the present teachings;
• FIG. 10 represents a perspective cross-sectional view of the holder subassembly shown inFIG. 9; and
• FIG. 11 represents a front view of the holder subassembly shown inFIGS. 9 and 10.
• Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
• Example embodiments will now be described more fully with reference to the accompanying drawings. According to some embodiments of the invention, light emitting elements, such as light emitting diodes (LEDs), are placed in an annular or ring shape around part of the end effector and are configured to shine forward to illuminate the tool or accessory held by the end effector and the workpiece being machined by the tool. The end effector may be a tool or accessory holder mounted to an output spindle of the tool as described in U.S. patent application Ser. no. 12/394426, entitled “Bit Retention Device” filed on Feb. 27, 2009, the contents being incorporated herein by reference in its entirety. Other examples of end effectors that may be used in accordance with the invention may be the 7000 Series chuck manufactured and marketed by the Jacobs Chuck Manufacturing Company of Clemson, S.C., and quick change chucks similar to that found on products such as a DC825KA Impact Driver and a DC815KA Impact Driver manufactured and marketed by the DeWalt Industrial Tool Company of Baltimore, Md.
• Several different types of lighting elements can be used in accordance with the invention, such as light bulbs (for example, xenon bulbs) or other lighting elements. While having specific advantage, the LED lights discussed herein are an example, and do not limit embodiments in accordance with the invention to tools using LEDs. The LED lights, or other lighting elements, and associated parts are locked to the housing of the tool and do not rotate when the power tool is operated. It is, however, envisioned that the light elements can be incorporated into a rotatable member such as a chuck tightening ring. The lights may be powered by the same power source that provides power to the power tool's motor. In the case of cordless power tools, a battery powers the power tool and in the case of corded tools AC current is provided from a source voltage through a cord. This AC current may be modified according to the needs of the lighting device being employed. In the case of LED lights, a rectifier may be employed to convert AC current to DC.
• A first embodiment in accordance with the present teachings is illustrated inFIG. 1a. Thepower tool50 has ahousing51 which can be of a clam shell type or any other suitable type housing. Thepower tool50 may have atransmission housing56 located at the front portion of thepower tool50 to encapsulate a portion of anend effector53. Ahandle57 projects downwardly from thehousing51 and is terminated with a battery. The transmission housing of the embodiment ofFIG. 1acontains a speed reduction transmission (e.g., a single-stage planetary transmission) and an impact mechanism that provides an intermittent rotary impact to the end effector (e.g., a Pott mechanism). The transmission housing of the embodiment ofFIG. 1bcontains a speed reduction transmission (e.g., a multi-stage planetary transmission) and at least a portion of a torque clutch that disengages when a predetermined torque is reached.
• Theend effector53 may be configured to hold an accessory or tool such as a drill bit or a driving type accessory such as a Philips or standard screwdriver. Other types of tools or accessories may be held and used in theend effector53 as can be appreciated by one skilled in the art. The movement of theend effector53 may be controlled by thetrigger55. Thetrigger55 may selectively provide power from the battery to the motor located within thehousing51. In some embodiments of the invention, the more the trigger or switch55 is depressed the more power may be applied to the motor which may cause theend effector53 to spin faster. The battery provides the power to energize the motor and controllably turn theend effector53.
• As shown inFIG. 1band as described in U.S. patent application Ser. No. 12/379,585, entitled “Light for a Power Tool and Method of Illuminating” filed on Feb. 25, 2009, the contents being incorporated herein by reference in its entirety, thepower tool50 may be equipped with a clutch collar. Although not shown, other embodiments in accordance with the teachings may not have a rotating clutch collar, but rather a different mechanism, such as a drill/hammer mode selector, a gear shifter, an on/off switch, a variable speed control, or other control mechanism. However, this specification will refer to a clutch collar as an example but does not limit embodiments in accordance with the invention to tools having clutch collars. The clutch collar may be rotated to adjust the torque setting at which the clutch disengages. A numbered scale may appear on the clutch collar in order to provide a user an indication of the setting of the clutch collar. In some embodiments the user may turn the clutch collar to a desired position by hand An example of a clutch and transmission that may work in accordance with the invention is shown in U.S. Pat. No. 7,066,691 which is incorporated by reference in its entirety. Of course, other types of clutch and transmission mechanisms may be used in accordance with the invention.
• Thepower tool50, for example, can be equipped with alight emitting holder52 at an end of thetransmission housing56. As described below, theholder52 functions to couple a lighting circuit to atool housing51. A transparent ortransparent cover54 is shown mounted in a recess defined in theholder52. Theholder52 is mounted to thetransmission housing56 which is, in turn, supported by thehousing51. Achin shroud62 is located on theholder52 and provides a housing for a portion of the wires64 (SeeFIG. 2). Thewires64 have aconnector66 at afirst end68 are coupled at asecond end70 to acircuit board82 disposed within theholder52.
• FIG. 2 represents a perspective view of theholder52transmission housing56 subassembly. Shown is theholder52 having the associatedtransparent cover54 fixably coupled to thehousing transmission housing56. An associated pigtail wire assembly71 with associatedconnector66 is positioned to allow the coupling to correspondingly connect on thehousing51. Thetransmission housing56 has an associatedcoupling mechanism55 which is used to mate thetransmission housing56 to the two-piece housing51.
• FIG. 3 represents a cross-sectional view of theholder52transmission housing56 subassembly. Theholder52 can be coupled to thetransmission housing56 using a plurality of snap features, orbayonet mechanisms74 which are configured to interface with a corresponding L-shapedchannel76 defined within thetransmission housing56. Disposed within achannel78 defined by theholder52 is thetransparent cover54. As described below, thetransparent cover54 itself defines atransparent cover channel80 which annularly supports an associatedcircuit board82 having a plurality of surface mounted light emitting diodes (LEDS)84. As described in detail below, thecircuit board82 is held into thetransparent channel80 using a lockingmember86 which is heat staked to thecircuit board82 to effect a solid non-rotatable fixation of the circuit board to thetransmission housing56.
• Theholder52 is coupled to a steppedportion88 of thetransmission housing56. The steppedportion88 has afirst surface90 which is generally parallel to thecenterline92 of thetool50. Generally perpendicular to this surface is asecond surface94 which acts as an abutment for theholder52. Thefirst surface90 of the steppedportion88 has a protrudingflange96 which functions as a locking feature to couple theholder52 into the steppedportion88. Theflange96 has a rampedsurface98 which facilitates the snapping of acorresponding holder52locking feature100 onto the steppedportion88. Defined within asecond portion102 thefirst surface90 comprises the locking groove orchannel76. The lockinggroove76 is annularly formed within thesecond portion102 or can be formed of a plurality of radially disposed intermittent coupling grooves. The lockingfeature74 comprises a chamferedflange member106 having a ramped interfacedsurface108 and opposedplanar bearing surface110. Theplanar bearing surface110 is configured to interface with a correspondingplanar bearing surface111 defined either on theflange96 or locking groove orchannel76 defined withinsecond portion102 of thefirst surface90.
• FIG. 4 represents a perspective view of theholder52 in subassembly form. Theholder52 contains a mountingmember108 which defines a plurality of radially disposedcoupling slots110. Theslots110 are configured to accept a corresponding set of transparent coversnap coupling members112. Thesnap coupling members112 are configured to bear against aninner surface114 of the mountingmember108. Protruding from theinner surface114 are three depending coupling flanges which are configured to couple theholder52 to thetransmission housing56.
• Theholder52 has a generally cylindricalexterior surface118. Theexterior surface118 functions to encapsulate thetransparent cover54, mountingmember108 andcircuit board82. The mountingmember108 has a dependingwire support member120 having a center flanged portion122 which defines a pair of generally elongatedwire bearing slots124. The slots are configured to accept the pair ofpower wires64 from the wire harnesspig tail assembly71. Thewire support member120 is generally disposed within thechin shroud62 and facilitates the protection of the light source power wires. The mountingmember108 defines an axial throughbore126. The throughbore126 has an inner surface128 with a plurality of associated stand offflanges130. The stand offflanges130 function to apply pressure onto thecircuit board82 when the mounting member is engaged with theholder52. Further defined within the inner surface128 is anotch132 configured to accept a wire harnessstrain relief member134. The wire harnessstrain relief member134 has a pair of curved internal surfaces which accept thebent wires64 in a manner to minimize the overall axial length of theholder52.
• FIG. 5 represents a rear perspective view of thetransparent cover54circuit board82 subassembly. As shown, thecircuit board82 is generally circular and is disposed within thetransparent cover channel80. Thecircuit board82 defines a plurality of radially disposednotches136 on the exterior radial periphery of the circuit board. Thenotches136 accept correspondingflanges86 which are defined radially within an inner bearing surface140 of thetransparent cover channel80. Defined within the transparent cover and adjacent to theflanges138 are correspondingnotches142 which have a depth generally corresponding to the locational position of thecircuit board82. After thecircuit board82 is placed within thechannel80, theflanges138 are melted, thereby fixably coupling thecircuit board82 within thetransparent cover54 using a heat staking process.
• The couplers or attachment mechanisms between thecircuit board82 and thetransparent cover54, theholder52 and thetransmission case56, or theholder52 and thetransparent cover54 can take the form of the heat stake joint, the bayonet joint, or the locking flange within a slot, exemplary embodiments of which are described above. The couplers or attachment mechanisms are configured to withstand the extreme cyclic torsional loading associated with hand held power tools. In this regard, the joints are configured to prevent vibrational noise or damage to these components, especially to the PCB.
• FIGS. 6 and 7 represent cross-sectional perspective views of the subassembly shown inFIG. 5. Shown is thetransparent cover channel80, acoupling flange138,relief member134 andsnap member112. Thechannel80 defines aninner ledge142 which axially supports thecircuit board82 in a position which axially locates theLED84 at the proper distance from thetransparent cover54. The distance allows for the proper focusing of the light from the LED on to a workpiece.
• FIG. 8 represents a front view of the transparent cover/circuit board subassembly shown inFIGS. 5 and 6. Shown is the positional position of theLEDs84 with respect to the various snap and coupling features. While surface mountedLEDs84 are shown and have their own particular advantages, it should be envisioned that non-surface mount LEDs could be used. Shown adjacent to theLEDs84 is a plurality of surface mountedresistors151 which are electrically coupled to theLEDs84.
• FIGS. 9-11 represent analternate holder52 having an alternate circuit board to transparent cover coupling mechanism. In this regard, theholder52 contains atransparent cover150 having an innertubular member152. The innertubular member152 defines a generally L-shapedcoupling channel154. The L-shapedcoupling channel154 defines a protrudinglocking feature156 which engages a corresponding locking bayonet feature on the transmission housing.
• Further defined on the innertubular member152 is a plurality ofcoupling notches158. Thenotches158 have a depth corresponding to the preferred locational position of thecircuit board82 within thetransparent cover channel80. Adjacent to thecoupling notches158 are correspondingcoupling flanges160 which are configured to be positioned within a corresponding set of notches162 defined within an inner surface164 of thecircuit board72. As described above, thecoupling flanges160 are configured to be melted in a heat staking process to rotationally and longitudinally fix thecircuit board82 within thechannel80. As best seen inFIG. 11, the holder can define discrete apertures to allow light to be emitted from the nose section of the tool onto the workpiece. Theholder52 has a elastomeric overmolding to prevent damage to the workpiece and to the tool if the tool inadvertently strikes the workpiece.
• The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
• Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
• The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
• When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
• Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
• Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Claims (20)

What is claimed is:

1. A power tool comprising:

a housing;

an end effector rotatable with respect to the housing;

an annular collar defining a channel therein, said collar being coupled to the housing;

an annular printed circuit board disposed within the channel;

an annular transparent cover disposed within the annular collar, said transparent cover being rotatably and axially fixed to the printed circuit board; and

a plurality of lighting elements operatively connected to the printed circuit board and radially disposed about the end effector to illuminate a workpiece.

2. The power tool ofclaim 1, wherein the lighting elements are a plurality of light emitting diodes radially disposed about the printed circuit board, and wherein a portion of the end effector extends through a hole defined by the transparent cover and printed circuit board.

3. The power tool ofclaim 1, wherein the transparent cover defines a groove and the printed circuit board is rotationally fixed within the groove.

4. The power tool ofclaim 3, further comprising a plurality of heat meltable features on the transparent cover configured to allow the printed circuit board to be fixed into the groove in the transparent cover.

5. The power tool ofclaim 1, further including a chin portion defined by the annular collar, the chin portion providing a protective case for wires operable coupled to the lighting elements.

6. The power tool ofclaim 5, further comprising a plug terminating the wires and wire holding structure on the chin portion for securing the wires in place.

7. The power tool ofclaim 1, further comprising collar fasteners defined on the annular collar configured to couple the annular collar to the housing.

8. The power tool ofclaim 1, further comprising alignment grooves on the printed circuit board and alignment tabs on the transparent cover, the alignment grooves on the printed circuit board and the alignment tabs on the transparent cover are dimensioned and located so that the alignment grooves on the printed circuit board rotatably fit into and are retained on the alignment tabs on the transparent cover to keep the printed circuit board and the transparent cover aligned.

9. The power tool ofclaim 1, further comprising engaging structure on the transparent cover configured to bear against corresponding engaging structure on a transmission housing to lock the transparent cover from rotating with respect to the transmission housing.

10. The power tool ofclaim 1, further comprising a coupling member covering the printed circuit board so that the lighting element and the printed circuit board are substantially entrapped by the coupling member and the transparent cover.

11. The power tool ofclaim 9, wherein the coupling member is axially retained by the annular holder and attached to a transmission housing.

12. The power tool ofclaim 11, further comprising a stepped portion on the transmission housing wherein the annular holder resides in the stepped portion.

13. The power tool ofclaim 14, wherein the annular collar is axially locked to the transmission housing at least in part by the annular holder.

14. A power tool comprising:

a rotatable end effector;

an annular collar;

an annular printed circuit board;

light elements operatively connected to the annular printed circuit board and being adjacent to the end effector to illuminate a workpiece machined by the power tool; and

an annular cover having a transparent region, said annular cover axially supporting the printed circuit board, wherein a portion of the end effector extends through a hole defined by the cover and printed circuit board and wherein the cover defines a groove and the printed circuit board is located in the groove.

15. The power tool ofclaim 14, further comprising a heat meltable flange on the transparent cover configured to allow the printed circuit board to be non-rotatably fixed into the groove in the transparent cover and held in place in the transparent cover.

16. A power tool comprising:

a motor housing;

a handle coupled to the motor housing;

a transmission case coupled to the motor housing;

an end effector extending from the transmission case;

a substantially annular collar;

a substantially annular circuit board having a plurality of light emitting elements;

a substantially annular cover defining a channel and having a transparent portion;

a first coupler disposed between the collar and the transmission case, said first coupler preventing axial displacement of the collar with respect to the transmission case;

a second coupler disposed between the circuit board and the cover, said second coupler preventing axial and rotational displacement of the circuit board with respect to the cover;

a third coupler disposed between the collar and the cover, said third coupler preventing axial displacement of the cover with respect to the collar; and

wherein at least a portion of the end effector extends through the collar, the circuit board, and the cover.

17. The power tool according toclaim 16, wherein at least one of the first coupler, the second coupler, and the third coupler comprises at least one of a heat stake joint, a bayonet joint, and an engaged flange.

18. The power tool according toclaim 16, wherein the cover defines an annular groove and the circuit board is disposed therein.

19. The power tool according toclaim 16, wherein at least a portion of the cover is disposed through the collar portion.

20. The power tool according toclaim 16, wherein the cover is transparent.

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