Hybrid impact tool with two-speed transmission
A power tool that includes a housing, a motor, a planetary transmission, a first bearing and a second bearing. The motor is disposed in the housing and includes an output shaft. The planetary transmission has a sun gear, a plurality of first planet gears, a first ring gear and a carrier. The sun gear is driven by the output shaft. The first planet gears are driven by the sun gear and have teeth that are meshingly engaged to teeth of the first ring gear. The carrier includes a rear carrier plate and a front carrier plate between which the first and second planet gears are received. The rear carrier plate includes a first bearing aperture. The first bearing is received in the first bearing aperture and is configured to support the output shaft. The second bearing is received onto the rear carrier plate to support the carrier relative to the housing.
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This application claims the benefit of U.S. Provisional Patent Application No. 61/289,780 filed Dec. 23, 2009 and U.S. Provisional Patent Application No. 61/290,759 filed Dec. 29, 2009. The disclosures of each of these applications are incorporated by reference as if fully set forth in detail herein.
Notice: This is a reissue application of U.S. Pat. No. 8,460,153.
INTRODUCTIONThe present invention generally relates to a hybrid impact tool with a two-speed transmission.
Rotary impact tools are known to be capable of producing relatively high output torque and as such, can be suited in some instances for driving screws and other threaded fasteners. One drawback associated with conventional rotary impact tools concerns their relatively slow fastening speed when a threaded fastener is subject to a prevailing torque (i.e., a not insubstantial amount of torque is required to drive the fastener into a workpiece before the head of the fastener is abutted against the workpiece). Examples of such applications include driving large screws, such as lag screws, into a wood workpiece. In such applications, it is not uncommon for a rotary impact tool to begin impacting shortly after the tip of the lag screw is driven into the workpiece. As lag screws can be relatively long, a significant amount of time can be expended in driving lag screws into workpieces.
Hybrid impact tools permit a user to operate the tool in a rotary impact mode or a drill mode that provides continuous rotation of an output spindle. The ability to change between a rotary impacting mode and a non-impacting mode is highly advantageous as the non-impacting mode is much better suited for most types of drilling, particularly when relatively small diameter drill bits are employed. While several of the known hybrid impact tools are generally suited for their intended purpose, it will be appreciated that hybrid impact tools are susceptible to improvement. Such improvements can be made for example, to the transmission that transmits rotary power from a motor to an input spindle of the impact mechanism.
SUMMARYThis section provides a general summary of some aspects of the present disclosure and is not a comprehensive listing or detailing of either the full scope of the disclosure or all of the features described therein.
In one form, the present teachings provide a power tool that includes a housing, a motor, a planetary transmission, a first bearing and a second bearing. The motor is disposed in the housing and includes an output shaft. The planetary transmission has a sun gear, a plurality of first planet gears, a first ring gear and a carrier. The sun gear is driven by the output shaft. The first planet gears are driven by the sun gear and have teeth that are meshingly engaged to teeth of the first ring gear. The carrier includes a rear carrier plate and a front carrier plate between which the first and second planet gears are received. The rear carrier plate includes a first bearing aperture. The first bearing is received in the first bearing aperture and is configured to support the output shaft. The second bearing is received onto the rear carrier plate to support the carrier relative to the housing.
In another form, the present teachings provide a power tool that includes a housing, a motor, an output member, a power transmitting mechanism, and a shift mechanism. The motor is coupled to the housing and has an output shaft. The power transmitting mechanism drivingly couples the output shaft to the output member and includes a transmission having dual planetary stage with a sun gear, a first planet gear, a second planet gear, a planet carrier, a first ring gear and a second ring gear. The first and second planet gears are rotatably mounted on the planet carrier. The first planet gear is disposed between the motor and the second planet gear and has a pitch diameter that is smaller that a pitch diameter of the second planet gear. The first ring gear is meshingly engaged with the first planet gear and the second ring gear is meshingly engaged with the second planet gear. The shift mechanism has a collar that is non-rotatably but axially slidably coupled to the housing for movement between a first position and a second position. The collar includes an annular collar body, a first set of external splines and a second set of external splines. The collar body is received about the first ring gear. The first set of external splines extend radially inwardly from the collar body and engage a third set of external splines formed about the first ring gear when the collar is in the first position to inhibit rotation of the first ring gear relative to the housing. The second set of external splines is coupled to an end of the collar body that faces opposite the motor. The second set of external splines engages a fourth set of external splines formed on the second ring gear when the collar is in the second position to inhibit rotation of the second ring gear relative to the housing.
In still another form, the present teachings provide a power tool that includes a housing, a motor, an output member, a power transmitting mechanism and a shift mechanism. The motor is coupled to the housing and has an output shaft. The power transmitting mechanism drivingly couples the output shaft to the output member and includes a transmission having dual planetary stage with a sun gear, a compound planet gear, a planet carrier, a first ring gear and a second ring gear. The compound planet gear is rotatably mounted on the planet carrier and has first and second planet gears that are fixedly coupled to one another. The first planet gear is disposed between the motor and the second planet gear and has a pitch diameter that is smaller that a pitch diameter of the second planet gear. The first ring gear is meshingly engaged with the first planet gear, and the second ring gear being meshingly engaged with the second planet gear. The first planet gear has a first quantity (Q1) of teeth, the second planet gear has second quantity of teeth (Q2) and the quotient of the quantity of teeth on the second planet gear divided by the quantity of teeth on the first planet (Q2/Q1) gear is not an integer. The shift mechanism has a collar that is non-rotatably but axially slidably coupled to the housing for movement between a first position and a second position. The collar non-rotatably couples the first ring gear to the housing in the first position and non-rotatably couples the second ring gear to the housing in the second position.
Further areas of applicability will become apparent from the description provided herein. It should be understood that 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, its application and/or uses in any way.
The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. The drawings are illustrative of selected teachings of the present disclosure and do not illustrate all possible implementations. Similar or identical elements are given consistent identifying numerals throughout the various figures.
With reference to
The housing 10 can include a pair of mating housing shells 30 and a gear case 32 that can be removably coupled to the housing shells 30. The housing shells 30 can cooperate to define a handle portion 36 and a body portion 38. The handle portion 36 can include a battery pack mount 40, to which the battery pack 26 may be removably mounted, and a switch mount 42 (
With reference to
The motor assembly 12 can include a motor 70 that can include an output shaft 72 having a rear end 74 and a forward end 76. The rear end 74 can be supported for rotation relative to the housing by a bearing 78 that can be received in the rear mount 60. The motor 70 can be electrically coupled to the trigger assembly 24 and the battery pack 26 (
With reference to
The reduction gearset 100 can include an input sun gear 110, a first set of input planet gears 112, a second set of input planet gears 114, an input carrier 116, a first input ring gear 118 and a second input ring gear 120. The input sun gear 110 can be coupled for rotation with the output shaft 72 of the motor 70. The first set of input planet gears 112 can comprise a plurality of first planet gears having a first quantity of teeth that can be arranged about a first pitch diameter, while the second set of input planet gears 114 can comprise a plurality of second planet gears having a second quantity of teeth that can be arranged about a second pitch diameter. The first input ring gear 118 can be an annular structure having a plurality of internal teeth 126 disposed proximate a forward axial face and a plurality of external splines or teeth 128 that can extend radially outwardly from a portion of the first input ring gear 118 proximate a rear axial face. The plurality of internal teeth 126 can be meshingly engaged with the teeth of the first planet gears of the first set of planet gears 112. The second input ring gear 120 can include a plurality of internal teeth 130, which can be meshingly engaged with the teeth of the second planet gears of the second set of planet gears 114, and a plurality of external splines or teeth 132 (
With specific reference to
In the particular example provided, the planet gears of the first set of planet gears 112 are axially offset from the motor 70 by a distance that is smaller than the amount by which the planet gears of the second set of planet gears 114 are axially offset from the motor 70 (i.e., the planet gears of the first set of planet gears 112 are closer to the motor 70 than the planet gears of the second set of planet gears 114); the second quantity of teeth is greater than the first quantity of teeth; the second pitch diameter is larger than the first pitch diameter; each of the planet gears of the first set of planet gears 112 is coupled for rotation with a corresponding one of the planet gears of the second set of planet gears 114 (e.g., the planet gears of the first and second sets of planet gears 112 and 114 can be integrally formed); and only the planet gears of the second set of input planet gears 114 are meshingly engaged with the input sun gear 110 (
In
The switch 210 can include a plate structure 230, a switch member 232, a pair of second detent members (not specifically shown) and a bushing 236. The plate structure 230 can be received in a pair of slots (not specifically shown) formed into the housing shells 30 (
Each of the housing shells 30 (
The rail 220 can include a generally cylindrical rail body 250 and a head portion 252 that can be relatively large in diameter than the rail body 250. The rail 220 can be received through the bushing aperture in the bushing 236 such that the bushing 236 is slidably mounted on the rail body 250.
With additional reference to
The first biasing spring 224 can be mounted on the rail body 250 between the head portion 252 and the first end face 244 of the bushing 236. The second biasing spring 226 can be mounted on the rail body 250 between the second end face 246 of the bushing 236 and the collar 222.
With reference to
In the first position, which is illustrated in
In the second position, which is illustrated in
Configuration of the reduction gearset 100 and collar 222 in the manner provides several advantages. For example, the above-described configuration permits the collar 222 to be shifted into a neutral position when being moved between the first and second positions (i.e., the collar 222 will fully disengage the first input ring gear 118 before initiating engagement with the second input ring gear 120 and vice versa) as is shown in
As another example, the above-described configuration utilizes splines or teeth on the rear and front faces of the second input ring gear 120 and the collar 222, respectively, to reduce the overall diameter of the reduction gearset 100 as compared with an arrangement that places the mating splines or teeth on the second input ring gear 120 and the collar 222 in a radial orientation (as with the first input ring gear 118 and the collar 222). It will be apparent to those of skill in the art that as the planet gears of the first set of planet gears 112 are disposed about a smaller pitch diameter in the example provided, the first input ring gear 118 can be relatively smaller in diameter than the second input ring gear 120 and consequently, the use of mating splines or teeth disposed in a radial direction do not have a similar impact on the overall diameter of the reduction gearset 100.
It will be appreciated that the first and second biasing springs 224 and 226 are configured to resiliently couple the collar 222 to the switch 210 in a manner that provides for a modicum of compliance. In instances where the switch 210 is to be moved from the first switch position to the second switch position but the internal splines or teeth 264 formed on the collar 222 are not aligned to the external splines or teeth 132 formed on the second input ring gear 120, the switch 210 can be translated into the second switch position without fully moving the collar 222 by an accompanying amount. In such situations, the second biasing spring 226 is compressed between the second end face 246 of the bushing 236 and the mount 260 of the collar 222. Rotation of the second input ring gear 120 relative to the collar 222 can permit the external splines or teeth 132 formed on the second input ring gear 120 to align to the internal splines or teeth 264 formed on the collar 222 and once aligned, the second biasing spring 226 can urge the collar 222 forwardly into engagement with the second input ring gear 120.
In instances where the switch 210 is to be moved from the second switch position to the first switch position but the internal splines or teeth 262 formed about the inside surface of the collar 222 are not aligned to the external splines or teeth 128 of the first input ring gear 118, the switch 210 can be translated into the first switch position without fully moving the collar 222 by an accompanying amount. In such situations, the first biasing spring 224 is compressed between the head portion 252 of the rail 220 and the first end face 244 of the bushing 236. Rotation of the first input ring gear 118 relative to the collar 222 can permit the external splines or teeth 128 to align to the internal splines or teeth 262 formed about the collar 222 and once aligned, the first biasing spring 224 can urge the collar 222 rearwardly into engagement with the first input ring gear 118.
It will be appreciated that the motor bearing 166 may be positioned somewhat differently from that which is described above as is shown in
With reference to
With reference to
While the speed selector 102 (
The example of
The example of
With reference to
With regard to the upper half of
With regard to the lower half of
With reference to
With reference to
Pivoting movement of the shift cam 5010-1 also causes corresponding sliding motion of the plate structure 230-1 on the rail 220-1 to compress the biasing spring 224-1 against one of the bushings 236-1 and 236-2 depending on the direction in which the shift cam 5010-1 is moved. As the rail 220-1 is fixedly coupled to the collar 222, it will be appreciated that pivoting movement of the shift cam 5010-1 will effect a change in the gear ratio of the reduction gearset 100. It will further be appreciated that the biasing spring 224-1 permits the plate structure 230-1 to be moved without a corresponding movement of the collar 222 in situations where the collar 222 is not aligned to either the first ring gear 118 or the second ring gear 120.
It will be appreciated that the above description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. While specific examples have been described in the specification and illustrated in the drawings, it will be understood by those of ordinary skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure as defined in the claims. Furthermore, the mixing and matching of features, elements and/or functions between various examples is expressly contemplated herein, even if not specifically shown or described, so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise, above. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular examples illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of the present disclosure, but that the scope of the present disclosure will include any embodiments falling within the foregoing description and the appended claims.
Claims
1. A power tool comprising:
- a housing;
- a motor coupled to the housing, the motor having an output shaft;
- an output member;
- a power transmitting mechanism drivingly coupling the output shaft to the output member, the mechanism comprising a transmission having dual planetary stage with a sun gear, a first planet gear, a second planet gear, a planet carrier, a first ring gear and a second ring gear, the first and second planet gears being rotatably mounted on the planet carrier, the first planet gear being disposed between the motor and the second planet gear and having a pitch diameter that is smaller than a pitch diameter of the second planet gear, the first ring gear being meshingly engaged with the first planet gear, and the second ring gear being meshingly engaged with the second planet gear; and
- a shift mechanism having a collar that is non-rotatably but axially slidably coupled to the housing for movement between a first position and a second position, wherein the collar comprises an annular collar body, a first set of external splines and a second set of external splines, the collar body being received about the first ring gear, the first set of external splines extending radially inwardly from the collar body and engaging a third set of external splines formed about the first ring gear when the collar is in the first position to thereby inhibit rotation of the first ring gear relative to the housing, the second set of external splines being coupled to an end of the collar body that faces opposite the motor, the second set of external splines engaging a fourth set of external splines formed on the second ring gear when the collar is in the second position to thereby inhibit rotation of the second ring gear relative to the housing.
2. The power tool of claim 1, wherein the power transmitting mechanism comprises a rotary impact mechanism having an input spindle and an anvil, the input spindle being coupled for rotation with an output of the transmission, the output member being coupled for rotation with the anvil.
3. The power tool of claim 1, wherein the shift mechanism further comprises a switch member and a pair of springs, the springs cooperating to bias the collar into a neutral position relative to the switch member.
4. The power tool of claim 3, wherein the shift mechanism further comprises a rod that is fixedly coupled to the collar, the switch member being movably mounted on the rod.
5. The power tool of claim 4, wherein the springs are mounted on the rod on opposite sides of the switch member.
6. The power tool of claim 1, wherein the first and second planet gears are unitarily formed.
7. The power tool of claim 6, wherein the first planet gear has a first quantity (Q1) of teeth, the second planet gear has second quantity of teeth (Q2) and wherein the quotient of the quantity of teeth on the second planet gear divided by the quantity of teeth on the first planet (Q2/Q1) gear is not an integer.
8. The power tool of claim 7, wherein a timing aperture is formed in at least one of the first and second planet gears, the timing aperture being indexed at a predetermined angle relative to a timing tooth on one of the first and second planet gears.
9. A power tool comprising:
- a housing;
- a motor coupled to the housing, the motor having an output shaft;
- an output member;
- a power transmitting mechanism drivingly coupling the output shaft to the output member, the mechanism comprising a transmission having dual planetary stage with a sun gear, a compound planet gear, a planet carrier, a first ring gear and a second ring gear, the compound planet gear being rotatably mounted on the planet carrier and having first and second planet gears that are fixedly coupled to and integrally formed with one another, the first planet gear being disposed between the motor and the second planet gear and having a pitch diameter that is smaller than a pitch diameter of the second planet gear, the first ring gear being meshingly engaged with the first planet gear, and the second ring gear being meshingly engaged with the second planet gear, wherein the first planet gear has a first quantity (Q1) of teeth, the second planet gear has second quantity of teeth (Q2) and wherein the quotient of the quantity of teeth on the second planet gear divided by the quantity of teeth on the first planet (Q2/Q1) gear is not an integer; and
- a shift mechanism with a collar that is non-rotatably but axially slidably coupled to the housing for movement between a first position and a second position, wherein the collar non-rotatably couples the first ring gear to the housing in the first position and non-rotatably couples the second ring gear to the housing in the second position.
10. The power tool of claim 9, wherein a timing aperture is formed in at least one of the first and second planet gears, the timing aperture being indexed at a predetermined angle relative to a timing tooth on one of the first and second planet gears.
11. A power tool comprising:
- a housing;
- a motor in the housing, the motor including an output shaft;
- a planetary transmission having a sun gear, a plurality of first planet gears, a first ring gear and a carrier, the sun gear being driven by the output shaft, the first planet gears being driven by the sun gear and having teeth that are meshingly engaged to teeth of the first ring gear, the carrier including a rear carrier plate and a front carrier plate between which the first planet gears are received, the rear carrier plate including a first bearing aperture;
- a first bearing received in the first bearing aperture and being configured to support the output shaft; and
- a second bearing received onto the rear carrier plate to support the carrier relative to the housing.
12. The power tool of claim 11, wherein the planetary transmission includes a plurality of second planet gears.
13. The power tool of claim 12, wherein each of the first planet gears is coupled for rotation with a corresponding one of the second planet gears.
14. The power tool of claim 13, wherein each of the first planet gears has a first pitch diameter and each of the second planet gears has a second pitch diameter that is larger than the first pitch diameter.
15. The power tool of claim 13, wherein the first ring gear includes a plurality of external teeth that are axially spaced apart from the teeth that are meshingly engaged by the teeth of the first planet gears.
16. The power tool of claim 15, wherein the external teeth are positioned at least partly vertically in-line with at least one of the first and second bearings.
17. The power tool of claim 15, further comprising an axially slidable collar that is movable between a first position, in which the collar is engaged to the external teeth of the first ring gear, and a second position in which the collar is engaged to a second ring gear that is meshingly engaged to the second planet gears.
18. The power tool of claim 17, wherein the collar is non-rotatably coupled to the housing.
19. The power tool of claim 18, further comprising a switch member, a first spring (224) and a second spring, the first spring (224) being compressed when the switch member is moved from a first switch position to a second switch position without a corresponding movement of the collar from the first position to the second position, the second spring being compressed when the switch member is moved from the second switch position to the first switch position without a corresponding movement of the collar from the second position to the first position.
20. The power tool of claim 11, wherein the second bearing is engaged to a bearing support plate that is received in the housing.
21. The power tool of claim 11, wherein the second bearing is substantially axially aligned with the first bearing.
22. The power tool of claim 11, wherein the rear carrier plate comprises an annular structure with a first portion and a second portion, the first portion having a larger diameter than the second portion.
23. The power tool of claim 22, wherein the first portion abuts against a rear surface of the first planet gears.
24. The power tool of claim 22, wherein the second portion receives the first bearing therein.
25. The power tool of claim 24, wherein the second bearing is received onto the second portion.
26. The power tool of claim 11, wherein the output shaft has a front end portion supported axially forward of the motor by the first bearing and a rear end portion supported axially rearward of the motor by a third bearing received in a rear mount of the housing.
27. The power tool of claim 11, further comprising an output spindle configured to be rotationally driven by rotation of the carrier.
28. The power tool of claim 27, further comprising an impact mechanism disposed between the carrier and the output spindle, wherein the carrier rotationally drives the output spindle via the impact mechanism.
29. The power tool of claim 28, wherein the impact mechanism has an input spindle that is coupled for rotation with the front carrier plate.
30. The power tool of claim 27, further comprising a chuck coupled for rotation with the output spindle.
31. The power tool of claim 11, wherein the sun gear is coupled for rotation with the output shaft axially forward of the first bearing.
32. The power tool of claim 11, further comprising a controller configured to control distribution of electrical power to the motor.
33. The power tool of claim 32, wherein the controller is configured to select between at least a first control scheme and a second control scheme based on a user input, wherein, in the first control scheme, the controller causes rotation of the motor at a first rotational speed, and in the second control scheme, the controller causes rotation of the motor at a second rotational speed that is lower than the first rotational speed.
34. The power tool of claim 33, wherein the housing is instrumented to receive the user input of a selection between the first control scheme and the second control scheme.
35. The power tool of claim 33, wherein, in the first control scheme, electrical power is provided to the motor by a pulse-width-modulation signal having a relatively large ratio of on-time relative to the total time of the duty cycle, and, in the second control scheme, electrical power is provided to the motor by a pulse-width-modulation signal having a relatively smaller ratio of on-time relative to the total time of the duty cycle.
36. A power tool comprising:
- a housing;
- a motor in the housing, the motor including an output shaft having a forward end portion and a rear end portion;
- a planetary transmission having a sun gear, a plurality of planet gears, a ring gear and a planet gear carrier, the sun gear being driven in rotation by the output shaft, the plurality of planet gears being driven in rotation by the sun gear and having teeth that are meshingly engaged to teeth of the ring gear, and the carrier being driven in rotation by motion of the planet gears, the carrier defining a first bearing aperture;
- an impact mechanism having an input shaft that is fixedly coupled for rotation with the carrier and an output spindle;
- a first bearing received in the first bearing aperture and being configured to support the forward end of the output shaft; and
- a second bearing received onto the carrier to support the carrier relative to the housing.
37. The power tool of claim 36, wherein the carrier comprises a rear carrier plate axially rearward of the planet gears and a front carrier plate axially forward of the planet gears.
38. The power tool of claim 37, wherein the first bearing aperture is defined in the rear carrier plate axially rearward of the planet gears.
39. The power tool of claim 36, wherein the second bearing is engaged to a bearing support plate that is received in the housing.
40. The power tool of claim 36, wherein the second bearing is substantially axially aligned with the first bearing.
41. The power tool of claim 36, wherein the rear end portion of the motor shaft is supported axially rearward of the motor by a third bearing received in a rear mount of the housing.
42. The power tool of claim 36, further comprising a controller configured to control distribution of electrical power to the motor.
43. The power tool of claim 42, wherein the controller is configured to select between at least a first control scheme and a second control scheme based on a user input, wherein, in the first control scheme, the controller causes rotation of the motor at a first rotational speed, and in the second control scheme, the controller causes rotation of the motor at a second rotational speed that is lower than the first rotational speed.
44. The power tool of claim 43, wherein the housing is instrumented to receive the user input of a selection between the first control scheme and the second control scheme.
45. The power tool of claim 43, wherein, in the first control scheme, electrical power is provided to the motor by a pulse-width-modulation signal having a relatively large ratio of on-time relative to the total time of the duty cycle, and, in the second control scheme, electrical power is provided to the motor by a pulse-width-modulation signal having a relatively smaller ratio of on-time relative to the total time of the duty cycle.
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Type: Grant
Filed: Jun 5, 2015
Date of Patent: May 8, 2018
Assignee: Black & Decker Inc. (New Britian, CT)
Inventors: Scott Rudolph (Aberdeen, MD), Sankarshan Murthy (Mountain View, CA), Daniel Puzio (Baltimore, MD), Qiang Zhang (Lutherville, MD), Aris Cleanthous (Baltimore, MD), Mehdi Abolhassani (Houston, TX), Ren H. Wang (Perry Hall, MD), David Tomayko (Ellicott City, MD)
Primary Examiner: Jeffrey L Gellner
Application Number: 14/732,133
International Classification: F16H 3/44 (20060101); F16H 57/08 (20060101); B25B 21/02 (20060101); B25F 5/00 (20060101);