TECHNICAL FIELD
[0001] The present disclosure relates, generally, to angle impact tools and, more particularly,
to work attachment housings for such tools.
BACKGROUND
[0002] Many power tools that are used for tightening and loosening fasteners have difficulty
fitting in tight spaces. In particular, existing impact tools may not be able to reach
certain fasteners due to the size and/or orientation of the tool head and the output
drive. In contrast, many tools that do fit in tight spaces may not be able to accomplish
tightening and loosening of fasteners effectively and/or safely.
[0003] Various impact tools have been proposed in an attempt to address the foregoing concerns.
Impact tools generally include a motor coupled to an impact mechanism that converts
torque provided by the motor into a series of powerful rotary blows directed from
one or more hammers to an anvil that is integrally formed with (or otherwise drives
rotation of) an output drive of the impact tool. In angle impact tools, the output
drive typically rotates about an output axis that is non-parallel to a motor axis
about which an output shaft of the motor rotates.
[0004] The housing that supports the output drive, the impact mechanism, and other drive
train components of existing angle impact tools has typically had a "clamshell" construction,
in which the housing is partitioned into two sections along a parting plane that is
parallel to both the output axis and the motor axis of the tool (e.g., a parting plane
similar to the cross-section planes used in FIGS. 4, 7, and 10 of the present disclosure).
However, this "clamshell" construction of the housing can result in poor alignment
of the various drive train components, as well as difficultly in assembling and/or
servicing the angle impact tool.
SUMMARY
[0005] According to one aspect, an angle impact tool may comprise a handle assembly extending
along a first axis and supporting a motor, where the motor includes a shaft configured
to rotate about a first axis, and a work attachment coupled to the handle assembly.
The work attachment may comprise an impact mechanism including an anvil configured
to rotate about a second axis that is non-parallel to the first axis and a hammer
configured to rotate about the second axis to periodically deliver an impact load
to the anvil to cause rotation of the anvil about the second axis, a gear assembly
configured to transfer rotation from the shaft of the motor to the hammer of the impact
mechanism, and a housing supporting the impact mechanism and the gear assembly. The
housing may be partitioned along a first parting plane that is perpendicular to the
second axis such that the housing includes a first housing section and a second housing
section.
[0006] In some embodiments, the first axis may be parallel to the first parting plane. The
first axis may lie in the first parting plane. In other embodiments, the first axis
may be spaced apart from the first parting plane. The first axis may intersect the
second axis between (i) a position of the anvil along the second axis and (ii) a point
at which the second axis intersects the first parting plane. In other embodiments,
the first parting plane may intersect the second axis between (i) a position of the
anvil along the second axis and (ii) a point at which the second axis intersects the
first axis. The first and second housing sections may also be partitioned along a
second parting plane that is perpendicular to the first axis.
[0007] In some embodiments, the second housing section may be removably coupled to the first
housing section by a plurality of fasteners. Each of the plurality of fasteners may
extend through a corresponding aperture formed in the second housing section and may
be received in a corresponding bore formed in the first housing section. Each of the
corresponding apertures formed in the second housing section may be recessed from
an exterior profile of the second housing section such that each of the plurality
of fasteners that removably couples the second housing section to the first housing
section does not extend beyond the exterior profile of the second housing section.
The angle impact tool may further comprise a gasket positioned between the first and
second housing sections to provide a fluid seal when the second housing section is
removably coupled to the first housing section by the plurality of fasteners.
[0008] In some embodiments, the first housing section may be formed to include a first bore
extending along the first axis, a second bore extending along the second axis, and
a third bore extending along a third axis that is parallel to the second axis. The
third bore may be positioned between the first and second bores and overlap both the
first and second bores. The impact mechanism may be positioned in the second bore.
The gear assembly may be positioned at least partially within the first and third
bores. The second housing section may be formed to include a fourth bore extending
along the second axis and a fifth bore extending along the third axis.
[0009] In some embodiments, the work attachment may further comprise a plurality of pins
that each extend into a corresponding bore formed in the first housing section and
into a corresponding bore formed in the second housing section, such that the plurality
of pins align the fourth bore with the second bore and the fifth bore with the third
bore. The first housing section may be formed to include a shoulder that protrudes
toward the second housing section, and the second housing section may be formed to
include a lip that protrudes toward the first housing section. The lip may engage
the shoulder such that the fourth bore is aligned with the second bore and the fifth
bore is aligned with the third bore.
[0010] In some embodiments, the gear assembly may include a first bevel gear positioned
in the first bore of the first housing section and configured to rotate about the
first axis and a second bevel gear positioned in the third bore of the first housing
section and configured to rotate about the third axis, where the second bevel gear
meshes with the first bevel gear. The first bore may comprise adjacent first and second
bore sections. The second bore section may have a smaller diameter than the first
bore section and may be located closer to the third bore than the first bore section.
The first bore section may be bounded by a first internal surface of the first housing
section, and the second bore section may be bounded by a second internal surface of
the first housing section. The first bevel gear may include a shaft that extends along
the first axis and comprises adjacent first and second shaft sections. The second
shaft section may have a larger diameter than the first shaft section. The first shaft
section may be positioned within the first bore section, and the second shaft section
may be positioned within the second bore section. A bearing may support the first
bevel gear for rotation about the first axis and engages both the first shaft section
and the first internal surface. The bearing may abut both the second shaft section
and the second internal surface to align the first and second bevel gears.
[0011] In some embodiments, the work attachment may be removably coupled to the handle assembly
by a plurality of fasteners. Each of the plurality of fasteners may extend through
a corresponding aperture formed in the first housing section and may be received in
a corresponding bore formed in the handle assembly. Each corresponding bore extending
along an axis may be disposed at an acute angle to the first axis.
[0012] According to another aspect, a work attachment may comprise a housing body configured
to be coupled to a motorized tool including a rotatable output shaft, where the housing
body is formed to include (i) a first bore extending along a first axis, (ii) a second
bore extending along a second axis that is perpendicular to the first axis, and (iii)
a third bore extending along a third axis that is perpendicular to the first axis,
the third bore being positioned between the first and second bores and overlapping
both the first and second bores. The work attachment may further comprise an impact
mechanism received in the second bore of the housing body, the impact mechanism including
a hammer configured to rotate about the second axis to periodically deliver an impact
load to an anvil to cause rotation of the anvil about the second axis. The work attachment
may further comprise a gear assembly received at least partially in the first and
third bores of the housing body, where the gear assembly is configured to be coupled
to the rotatable output shaft of the motorized tool such that rotation of the output
shaft about the first axis drives rotation of the hammer about the second axis. The
work attachment may further comprise a housing cap removably coupled to the housing
body by a plurality of fasteners to enclose the second and third bores, where the
housing cap abuts the housing body along a first parting plane that is perpendicular
to the second and third axes.
[0013] In some embodiments, the housing cap may also abut the housing body along a second
parting plane that is perpendicular to the first axis. The second parting plane may
be located between the third axis and an end of the housing body configured to be
coupled to the motorized tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The concepts described in the present disclosure are illustrated by way of example
and not by way of limitation in the accompanying figures. For simplicity and clarity
of illustration, elements illustrated in the figures are not necessarily drawn to
scale. For example, the dimensions of some elements may be exaggerated relative to
other elements for clarity. Further, where considered appropriate, reference labels
have been repeated among the figures to indicate corresponding or analogous elements.
The detailed description particularly refers to the accompanying figures in which:
FIG. 1 is a perspective view of one illustrative embodiment of an angle impact tool;
FIG. 2 is an exploded view of the angle impact tool of FIG. 1;
FIG. 3 is an exploded view of a work attachment of the angle impact tool of FIG. 1;
FIG. 4 is a cross-sectional view of the work attachment of FIG. 3, taken along line
4-4 in FIG. 1;
FIGS. 5A-5J illustrate an impact cycle of the angle impact tool of FIGS. 1-4;
FIG. 6 is an exploded view of another illustrative embodiment of a work attachment
for an angle impact tool;
FIG. 7 is a cross-sectional view of the work attachment of FIG. 6, taken along line
7-7 in FIG. 6;
FIG. 8 is a side elevation view of yet another illustrative embodiment of an angle
impact tool including a work attachment;
FIG. 9 is an exploded view of the angle impact tool of FIG. 8;
FIG. 10 is a cross-sectional view of the work attachment of the angle impact tool
of FIG. 8, taken along a similar line to the cross-sectional views of FIGS. 4 and
7;
FIG. 11 is a perspective view of a housing body of the work attachment of the angle
impact tool of FIG. 8; and
FIG. 12 is a perspective view of a housing cap of the work attachment of the angle
impact tool of FIG. 8.
DETAILED DESCRIPTION OF THE DRAWINGS
[0015] While the concepts of the present disclosure are susceptible to various modifications
and alternative forms, specific exemplary embodiments thereof have been shown by way
of example in the drawings and will herein be described in detail. It should be understood,
however, that there is no intent to limit the concepts of the present disclosure to
the particular forms disclosed, but on the contrary, the intention is to cover all
modifications, equivalents, and alternatives falling within the spirit and scope of
the present disclosure. Unless otherwise specified, the terms "coupled," "mounted,"
"connected," "supported," and variations thereof are used broadly and encompass both
direct and indirect couplings, mountings, connections, and supports.
[0016] Referring now to FIGS. 1-4, one illustrative embodiment of an angle impact tool 10
that includes a handle assembly 12 and a work attachment 14 is shown. The illustrated
handle assembly 12 includes a motor 16, a motor housing 18, a motor bracket 20, a
handle housing section 22, a handle housing section 24, a trigger lever 26, and a
lock ring 28. The lock ring 28 and a plurality of fasteners 30 retain the two handle
housing sections 22, 24 together. The motor housing 18 is coupled to the handle housing
sections 22, 24 by a plurality of fasteners 32 and a U-shaped part 34. A switch 36
is included in the handle assembly 12 between the handle housing sections 22, 24.
The switch 36 is coupled (mechanically and/or electrically) to the trigger lever 26,
such that actuation of the trigger lever 26 causes actuation of the switch 36 and,
therefore, operation of the motor 16.
[0017] The motor bracket 20 is coupled to the motor 16 by a plurality of fasteners 38. The
motor 16 includes an output shaft, such as the illustrated rotor 40, that is rotatable
about a longitudinal handle axis 42. The illustrated motor 16 is an electric motor,
but any suitable prime mover (such as the pneumatic motor disclosed in
U.S. Patent No. 7,886,840, the entire disclosure of which is incorporated by reference herein) may be utilized.
Although not shown in FIGS. 1-4, a battery and a directional reverse switch may be
provided on the angle impact tool 10, in some embodiments.
[0018] The illustrated work attachment 14 includes a housing 46, 48 that is partitioned
into two sections, namely, a housing body 46 and a housing cap 48. As described in
greater detail below (with reference to the illustrative embodiment of FIGS. 8-12),
the housing 46, 48 is partitioned along a parting plane that is perpendicular to an
output axis 86 of the work attachment 14. A plurality of fasteners 50 removably couple
the housing cap 48 to the housing body 46. The motor housing 18 is coupled to the
housing body 46 with a plurality of fasteners 52. The motor bracket 20 is coupled
to the housing body 46 by a plurality of fasteners 54.
[0019] The housing 46, 48 of the illustrated work attachment 14 supports a gear assembly
58 and an impact mechanism 60. In the illustrative embodiment of FIGS. 1-4, the gear
assembly 58 includes a bevel gear set comprising a bevel gear 62 and a bevel gear
66. The bevel gear 62 is coupled to the rotor 40 for rotation with the rotor 40 about
the longitudinal handle axis 42. A bearing 64 is positioned between the bevel gear
62 and the motor bracket 20. The bevel gear 66 meshes with the bevel gear 62. The
bevel gear 66 is coupled to a shaft 68 for rotation with the shaft 68 about an axis
74 (FIG. 4). The shaft 68 is supported in the housing 46, 48 of the work attachment
14 by bearings 70a, 70b. The shaft 68 includes a splined portion 72 near bearing 70b.
The splined portion 72 functions as a spur gear and, in some embodiments, can be replaced
with a spur gear.
[0020] In the illustrative embodiment of FIGS. 1-4, the gear assembly 58 also includes a
spur gear set comprising the splined portion 72 of the shaft 68, an idler spur gear
76, and a drive spur gear 84. Rotation of the splined portion 72 of the shaft 68 causes
rotation of the idler spur gear 76 about an axis 78 (FIG. 4). The idler spur gear
76 is coupled to a shaft 80 for rotation with the shaft 80 about the axis 78. The
shaft 80 is supported in the housing 46, 48 of the work attachment 14 by bearings
82a, 82b.
[0021] The idler spur gear 76 meshes with a drive spur gear 84 to cause rotation of the
drive spur gear 84 about the axis 86 (FIG. 4). The drive spur gear 84 is coupled to
an output drive 88 through the impact mechanism 60 for selectively rotating the output
drive 88. The drive spur gear 84 and the output drive 88 are supported for rotation
within the housing 46, 48 by bearings 90a, 90b, 90c. The output drive 88 is illustratively
embodied as a square drive that may be connected to a socket or other fastener-driving
output element.
[0022] In the illustrative embodiment of FIGS. 1-4, the axes 74, 78, and 86 are all parallel
to each other and are all perpendicular to the axis 42. It is contemplated that, in
other embodiments, one or more of the axes 74, 78, and 86 may be oriented at another
angle that is non-parallel to the axis 42.
[0023] The impact mechanism 60 may be embodied as any type of impact mechanism. In the illustrative
embodiment of FIGS. 1-4, the impact mechanism 60 is a ball-and-cam-type impact mechanism.
The impact mechanism 60 includes a cam shaft 94 coupled to the drive spur gear 84
for rotation with the drive spur gear 84 about the axis 86. The illustrated cam shaft
94 includes opposite cam grooves 96a, 96b that define pathways for respective balls
98a, 98b. The illustrated impact mechanism 60 further includes a hammer 100 that includes
opposite cam grooves 102a, 102b that are substantially mirror-images of cam grooves
96a, 96b. The balls 98a, 98b are retained between the respective cam grooves 96a,
96b, 102a, 102b. The hammer 100 also includes hammer jaws 104a, 104b.
[0024] The motor 16 drives the gear assembly 58 and the impact mechanism 60 to drive rotation
of the output drive 88, as shown in the illustrated embodiment. The output drive 88
is rotated about the axis 86, which is non-parallel to the axis 42. In the illustrative
embodiment of FIGS. 1-4, the axis 86 is perpendicular to the axis 42. In other embodiments
(not shown), the axis 86 may be at any acute or obtuse angle to the axis 42.
[0025] In the illustrative embodiment of FIGS. 1-4, a cylindrical spring 106 is positioned
between the drive spur gear 84 and the hammer 100 to bias the hammer 100 away from
the drive spur gear 84. The spring 106 surrounds a portion of the cam shaft 94. In
the illustrated embodiment, the spring 106 rotates with the drive spur gear 84 and
the bearing 90c permits the hammer 100 to rotate with respect to the spring 106. Other
configurations are possible, and the illustrated configuration is given by way of
example only.
[0026] The illustrated output drive 88 is integrally formed with anvil jaws 108a, 108b to
create an anvil 110 of the impact mechanism 60. In other embodiments, the output drive
88 may be coupled to the anvil 110 (such that rotation of the anvil 110 drives rotation
of the output drive 88). The anvil 110 is supported for rotation within the housing
body 46 by the bearing 90a. The hammer jaws 104a, 104b impact the anvil jaws 108a,
108b to drive the output drive 88 in response to rotation of the drive spur gear 84.
In particular, the hammer jaws 104a, 104b rotate to periodically deliver an impact
load to the anvil jaws 108a, 108b and, thereby, cause intermittent rotation of the
output drive 88.
[0027] In the illustrative embodiment of FIGS. 1-4, the impact cycle of the impact mechanism
60 is illustrated in FIGS. 5A-5J. The spring 106 permits the hammer 100 to rebound
after impact, and balls 98a, 98b guide the hammer 100 to ride up around the cam shaft
94, such that hammer jaws 104a, 104b are spaced axially from the anvil jaws 108a,
108b. The hammer jaws 104a, 104b are permitted to rotate past the anvil jaws 108a,
108b after the rebound. In other words, as the hammer 100 rotates about the axis 86,
the hammer 100 also reciprocally translates along the axis 86 (due to the balls 98a,
98b and the spring 106). FIGS. 5A-5J illustrate one impact cycle of the impact mechanism
60 of FIGS. 1-4. It will be appreciated that the impact cycle illustrated in FIGS.
5A-5J is exemplary in nature and that, in other embodiments, impact mechanisms with
different impact cycles may be used.
[0028] FIGS. 6 and 7 illustrate another embodiment of a work attachment 214 for use with
an angle impact tool. The work attachment 214 may be coupled to a handle and a motor
216 having a rotor 240 (i.e., an output shaft). The motor 216 is supported by a motor
housing 218. The illustrated motor 216 is an electric motor, but any suitable prime
mover (such as the pneumatic motor disclosed in
U.S. Patent No. 7,886,840) may be utilized. Although not specifically illustrated, a battery and a directional
reverse switch may be provided on the angle impact tool, in some embodiments.
[0029] The work attachment 214 includes a housing 246, 248 that is partitioned into two
sections, namely, a housing body 246 and a housing cap 248. As described in greater
detail below (with reference to the illustrative embodiment of FIGS. 8-12), the housing
246, 248 is partitioned along a parting plane that is perpendicular to an output axis
286 of the work attachment 214. The housing body 246 and the housing cap 248 cooperate
to support a gear assembly 258 and an impact mechanism 260.
[0030] The rotor 240 of the motor 216 rotates about a longitudinal handle axis 242. In the
illustrative embodiment of FIGS. 6 and 7, the gear assembly 258 includes a bevel gear
set comprising a bevel gear 262 and a bevel gear 266. The bevel gear 262 is coupled
to the rotor 240 for rotation with the rotor 240 about the longitudinal handle axis
242. A bearing 264 is positioned between the bevel gear 262 and the motor housing
218. The bevel gear 266 meshes with the bevel gear 262. The bevel gear 266 is coupled
to a shaft 268 for rotation with the shaft 268. The shaft 268 is supported in the
housing 246, 248 of the work attachment 214 by bearings 270a, 270b. The shaft 268
includes a splined portion 272 near bearing 270b. The shaft 268 rotates about an axis
274. The splined portion 272 functions as a spur gear and, in some embodiments, can
be replaced with a spur gear.
[0031] In the illustrative embodiment of FIGS. 6 and 7, the gear assembly 258 also includes
a spur gear set comprising the splined portion 272 of shaft 268, an idler spur gear
276, and a drive spur gear 284. Rotation of the splined portion 272 of shaft 268 causes
rotation of the idler spur gear 276 about an axis 278. The idler spur gear 276 is
coupled to a shaft 280 for rotation with the shaft 280 about the axis 278. The shaft
280 is supported in the housing 246, 248 of the work attachment 214 by bearings 282a,
282b.
[0032] The idler spur gear 276 meshes with the drive spur gear 284 to cause rotation of
the drive spur gear 284 about an axis 286. The drive spur gear 284 is coupled to an
output drive 288 through the impact mechanism 260 for selectively rotating the output
drive 288. The drive spur gear 284 and the output drive 288 are supported for rotation
within the housing 246, 248 of the work attachment 214 by bushing 290a and bearings
290b, 290c. The output drive 288 is illustratively embodied as a square drive that
may be connected to a socket or other fastener-driving output element.
[0033] In the illustrative embodiment of FIGS. 6 and 7, the axes 274, 278, and 286 are all
parallel to each other and are all perpendicular to axis 242. It is contemplated that,
in other embodiments, one or more of the axes 274, 278, and 286 may be oriented at
another angle that is non-parallel to axis 242.
[0034] The impact mechanism 260 may be embodied as any type of impact mechanism. In the
illustrative embodiment of FIGS. 6 and 7, the impact mechanism 260 is a ball-and-cam-type
impact mechanism. The impact mechanism 260 includes a cam shaft 294 coupled to the
drive spur gear 284 for rotation with the drive spur gear 284 about the axis 286.
The illustrated cam shaft 294 includes opposite cam grooves 296a, 296b that define
pathways for respective balls 298a, 298b. The illustrated impact mechanism 260 further
includes a hammer 300 that includes opposite cam grooves 302a, 302b that are substantially
mirror-images of cam grooves 296a, 296b. The balls 298a, 298b are retained between
the respective cam grooves 296a, 296b, 302a, 302b. The hammer 300 also includes hammer
jaws 304a, 304b.
[0035] The motor 216 drives the gear assembly 258 and the impact mechanism 260 to drive
rotation of the output drive 288, as shown in the illustrated embodiment. The output
drive 288 is rotated about the axis 286, which is non-parallel to the axis 242. In
the illustrative embodiment of FIGS. 6 and 7, the axis 286 is perpendicular to the
axis 242. In other embodiments (not shown), the axis 286 may be at any acute or obtuse
angle to the axis 242.
[0036] In the illustrative embodiment of FIGS. 6 and 7, a cylindrical spring 306 is positioned
between the drive spur gear 284 and the hammer 300 to bias the hammer 300 away from
the drive spur gear 284. The spring 306 surrounds a portion of the cam shaft 294.
In the illustrated embodiment, the spring 306 rotates with the drive spur gear 284,
and the bearing 290c permits the hammer 300 to rotate with respect to the spring 306.
Other configurations are possible, and the illustrated configuration is given by way
of example only.
[0037] The illustrated output drive 288 is integrally formed with anvil jaws 308a, 308b
to create an anvil 310 of the impact mechanism 260. In other embodiments, the output
drive 288 may be coupled to the anvil 310 (such that rotation of the anvil 310 drives
rotation of the output drive 288). The anvil 310 is supported for rotation within
the housing body 246 by the bushing 290a. The hammer jaws 304a, 304b impact the anvil
jaws 308a, 308b to drive the output drive 288 in response to rotation of the drive
spur gear 284. In particular, the hammer jaws 304a, 304b rotate to periodically deliver
an impact load to the anvil jaws 308a, 308b and, thereby, cause intermittent rotation
of the output drive 288. The impact cycle of the impact mechanism 260 is similar to
the impact cycle illustrated in FIGS. 5A-5J. It will be appreciated that the impact
cycle illustrated in FIGS. 5A-5J is exemplary in nature and that, in other embodiments,
impact mechanisms with different impact cycles may be used.
[0038] FIG. 8 illustrates yet another illustrative embodiment of an angle impact tool 410.
The angle impact tool 410 includes a handle assembly 412 and a work attachment 414
coupled to the handle assembly 412. As described in more detail below, the handle
assembly 412 supports a motor 416, and the work attachment 414 supports a gear assembly
458, an impact mechanism 460, and an output drive 488. While the tool 410 is in use,
torque generated by the motor 416 is transferred via the gear assembly 458 to the
impact mechanism 460, which in turn delivers torque (via a series of powerful rotary
blows) to the output drive 488.
[0039] The handle assembly 412 extends along a longitudinal handle axis 442, as shown in
FIG. 8. The handle assembly 412 illustratively includes a handle housing section 422
and a handle housing section 424, as best seen in FIG. 9. A plurality of fasteners
(not shown) are used to secure the two handle housing sections 422, 424 together.
As shown in FIGS. 9 and 10, the handle assembly 412 supports the motor 416 such that
an output shaft 440 of the motor 416 (e.g., the illustrated rotor 440) is rotatable
about the axis 442. The illustrated motor 416 is an electric motor, but any suitable
prime mover (such as the pneumatic motor disclosed in
U.S. Patent No. 7,886,840) may be utilized.
[0040] As shown in FIGS. 8 and 10, the work attachment 414 supports the output drive 488
for rotation about an output axis 486. Torque generated by the motor 416 is transferred
via the gear assembly 458 to the impact mechanism 460 to cause the output drive 488
to rotate about the axis 486. In the illustrative embodiment of FIGS. 8-12, the axis
486 is perpendicular to the axis 442 such that the tool 410 is a right-angle impact
tool. In other embodiments (not shown), the axis 486 may be at any acute or obtuse
angle to the axis 442.
[0041] The work attachment 414 includes a housing 446, 448 that is partitioned into two
(or more) sections. In other words, the housing 446, 448 of the work attachment 414
includes a housing section 446 and a housing section 448 that are physically separable
from one another. In the illustrative embodiment of FIGS. 8-12, the housing 446, 448
is partitioned along a parting plane 423 into a housing body 446 and a housing cap
448. The parting plane 423 is defined by the line 423 shown in FIG. 8 and by a line
traveling directly into and out of the page of FIG. 8. In this illustrative embodiment,
the parting plane 423 that primarily separates the housing body 446 and the housing
cap 448 is perpendicular (i.e., orthogonal) to the output axis 486 of the work attachment
414. Furthermore, in this illustrative embodiment, the parting plane 423 is parallel
to the axis 442 and is spaced apart from the axis 442 away from the output drive 488.
In other words, as illustrated in FIG. 8, the axis 442 intersects the axis 486 between
the position of the output drive 488 along the axis 486 and a point 433 at which the
axis 486 intersects the parting plane 423.
[0042] As shown in the illustrative embodiment of FIG. 8, the housing body 446 and the housing
cap 448 are also partitioned along a parting plane 425 that is perpendicular (i.e.,
orthogonal) to the axis 442. The parting plane 425 is defined by the line 425 shown
in FIG. 8 and by a line traveling directly into and out of the page of FIG. 8. In
this illustrative embodiment, the parting plane 425 is parallel to the axis 486 and
is spaced apart from the axis 486 toward a rear end 520 of the work attachment 414
that is coupled to the handle assembly 412. As such, when the housing cap 448 is coupled
to the housing body 446, the housing cap 448 abuts the housing body 446 along a portion
of the parting plane 423 that extends from a front end 522 of the work attachment
414 (opposite the rear end 520 of the work attachment 414) to the parting plane 425.
Similarly, when the housing cap 448 is coupled to the housing body 446, the housing
cap 448 abuts the housing body 446 along a portion of the parting plane 425 that extends
from an exterior profile 455 of the housing cap 448 to the parting plane 423.
[0043] Although the housing 446, 448 of the work attachment 414 is illustrated in FIGS.
8-12 (and will be generally described herein) as being partitioned along the parting
planes 423, 425, it is contemplated that the housing 446, 448 may alternatively be
partitioned along different parting planes in other embodiments. For instance, in
one illustrative embodiment, the housing 446, 448 may be partitioned into two housing
sections along a parting plane 423'. This parting plane 423' is defined by the line
423' shown in FIG. 8 and by a line traveling directly into and out of the page of
FIG. 8. Like the parting plane 423, the parting plane 423' that primarily separates
the housing sections 446, 448 in this embodiment is perpendicular to the output axis
486 of the work attachment 414 and parallel to the axis 442. In contrast to the parting
plane 423, however, the parting plane 423' is spaced apart from the axis 442 toward
(rather than away) from the output drive 488. In other words, as illustrated in FIG.
8, the parting plane 423' intersects the axis 486 between the position of the output
drive 488 along the axis 486 and a point 435 at which the axis 486 intersects the
axis 442. In this illustrative embodiment, the two housing sections 446, 448 may also
be partitioned by the parting plane 425.
[0044] In another illustrative embodiment, the housing 446, 448 may be partitioned into
two housing sections along a parting plane 423". This parting plane 423" is defined
by the line 423" shown in FIG. 8 and by a line traveling directly into and out of
the page of FIG. 8. Like the parting plane 423 (and the parting plane 423'), the parting
plane 423" that primarily separates the housing sections 446, 448 in this embodiment
is perpendicular to the output axis 486 of the work attachment 414 and parallel to
the axis 442. In contrast to the parting plane 423 (and the parting plane 423'), however,
the axis 442 lies in the parting plane 423" (rather than the parting plane 423" being
spaced apart from the axis 442). In some embodiments, the two housing sections 446,
448 may also be partitioned along the entire parting plane 423" from the front end
522 to the rear end 520 of the work attachment 414.
[0045] Just as the housing 446, 448 may be partitioned by any number of parting planes that
are perpendicular to the axis 486 (i.e., other parting planes that are parallel to
the illustrated parting planes 423, 423', 423"), the housing 446, 448 may also be
partitioned by any number of parting planes that are perpendicular to the axis 442
(i.e., other parting planes that are parallel to the illustrated parting plane 425).
As noted above, it is also contemplated that the housing 446, 448 may be partitioned
solely along a parting plane that is perpendicular to the axis 486, without being
partitioned along a secondary parting plane that is perpendicular to the axis 442.
It will also be appreciated that, in embodiments where multiple parting planes are
used to partition the housing 446, 448, the multiple parting planes need not be perpendicular
to one another.
[0046] As shown in FIGS. 8 and 9, the housing cap 448 is removably coupled to the housing
body 446 using a plurality of fasteners 450. When the housing cap 448 is removably
coupled to the housing body 446, each of the fasteners 450 extends through one of
a plurality of apertures 451 formed in the housing cap 448 (FIG. 12) and is received
in one of a plurality of bores 453 formed in the housing body 446 (FIG. 11). In the
illustrative embodiment, the fasteners 450 are embodied as threaded fasteners (e.g.,
screws), while the bores 453 are formed to include internal threading that engages
the threaded fasteners 450. As shown in FIG. 8, the apertures 451 formed in the housing
cap 448 may be recessed from the exterior profile 455 of the housing cap 448. As such,
when the housing cap 448 is removably coupled to the housing body 446, each of the
fasteners 450 is received in one of the apertures 451 such that the fasteners 450
do not extend beyond the exterior profile 455 of the housing cap 448.
[0047] In the illustrative embodiment, the housing body 446 of the work attachment 414 is
removably coupled to the handle assembly 412 using a plurality of fasteners 497, as
shown in FIG. 8. Each of the plurality of fasteners 497 extends through one of a plurality
of apertures 499 formed in the housing body 446 (FIG. 11) and is received in one of
a plurality of bores (not shown) formed in the handle assembly 412. In the illustrative
embodiment, the fasteners 497 are embodied as threaded fasteners (e.g., screws), while
the bores formed in the handle assembly 412 include internal threading to engage the
threaded fasteners 497. As suggested in FIG. 8, each of the bores formed in the handle
assembly 412 extends along an axis 413. In the illustrative embodiment, each of the
axes 413 is disposed at an acute angle to the axis 442, such that the axes 413 are
non-parallel to the axis 442 and to one another. This configuration may increase the
serviceability of the angle impact tool 410 by allowing the fasteners 497 to be more
readily installed and removed from the bores formed in the handle assembly 412. For
instance, in one illustrative embodiment, each of the axes 413 intersects the axis
442 at an 11 degree angle.
[0048] FIG. 9 illustrates an exploded view of the angle impact tool 410, including the components
of both the handle assembly 412 and the work attachment 414. As discussed above, the
handle assembly 412 includes the handle housing sections 422, 424 that are coupled
together using a plurality of fasteners (not shown). The handle assembly 412 includes
a switch 436 that is coupled to a trigger 426 such that actuation of the trigger 426
causes actuation of the switch 436 and, therefore, operation of the motor 416 of the
tool 410. The handle assembly 412 also includes a directional control 427 that is
coupled to the switch 436 to control the rotational direction of the output shaft
440 of the motor 416 (i.e., counterclockwise or clockwise about the axis 442). The
trigger 426 and the directional control 427 are each supported by the handle housing
sections 422, 424 such that the trigger 426 and the directional control 427 are both
accessible from the exterior of the handle assembly 412, as shown in FIG. 8. The switch
436 is also coupled to a battery terminal 428 supported by the handle housing sections
422, 424 such that, when a battery is coupled to the tool 410, electrical power is
supplied to the switch 436 via the battery terminal 428.
[0049] The handle assembly 412 further includes a motor housing 418 configured to support
the motor 416 so that the output shaft 440 extends toward the work attachment 414
when the angle impact tool 410 is assembled as shown in FIG. 10. The motor 416 is
secured within the motor housing 418 via mounting screws 445. The handle assembly
412 also includes a number of o-rings 434 that are positioned between the motor 416
and the motor housing 418 to radially stabilize the motor 416.
[0050] In the illustrative embodiment shown in FIGS. 9 and 10, the gear assembly 458 of
the work attachment 414 includes a planetary gearset 570. The planetary gearset 570
includes a central or sun gear 572, a number of planet gears 574 arranged within a
ring gear 576 so that each planet gear 574 meshes with both the sun gear 572 and the
ring gear 576, and a planet carrier 578 coupled to each of the planet gears 574 and
supporting each of the planet gears 574 for rotation. The sun gear 572 includes a
shaft 430 that extends along the axis 442 and couples to the output shaft 440 of the
motor 416 for rotation therewith. It should be appreciated that, in other embodiments,
the planetary gearset 570 of the gear assembly 458 may have other configurations.
[0051] The gear assembly 458 further includes a bevel gear 462 having a shaft 489 that extends
along the axis 442 and is coupled to the planet carrier 578 of the planetary gearset
570 for rotation therewith, as shown in FIGS. 9 and 10. The bevel gear 462 is supported
for rotation about the axis 442 by a needle bearing 439 and a spindle bearing 495.
The work attachment 414 also includes a spacer 437 positioned between the bearing
495 and the ring gear 576 of the planetary gearset 570, as shown in FIGS. 9 and 10.
[0052] The gear assembly 458 also includes a bevel gear 466 that meshes with the bevel gear
462. The bevel gear 466 is mounted on a shaft 468 for rotation therewith about an
axis 463 that is perpendicular to the axis 442, as shown in FIG. 10. The shaft 468
is supported for rotation in the housing 446, 448 of the work attachment 414 by bearings
470a, 470b of the gear assembly 458. A spur gear 472 of the gear assembly 458 is mounted
on the shaft 468 for rotation therewith, as shown in FIGS. 9 and 10.
[0053] The gear assembly 458 further includes a drive spur gear 484 that meshes with the
spur gear 472, as shown in FIG. 10. The drive spur gear 484 is mounted on a camshaft
494 of the impact mechanism 460 for rotation therewith about the axis 486, and the
camshaft 494 is supported for rotation in the housing 446, 448 of the work attachment
414 by a bearing 490b. Rotation of the drive spur gear 484 is transferred to the impact
mechanism 460 to cause a hammer 400 of the impact mechanism 460 to rotate about the
axis 486 (within a sleeve 464 that is sized to receive the hammer 400). As described
above, this rotation of the hammer 400 results in periodic impacts between the hammer
400 and an anvil 411 of the impact mechanism 460, causing rotation of the anvil 411
(and, hence, the output drive 488) about the axis 486.
[0054] As shown in FIG. 9, the output drive 488 of the work attachment 414 is integrally
formed with anvil jaws to create the anvil 411 of the impact mechanism 460. In other
embodiments, the output drive 488 may be distinct from and coupled to the anvil 411
(such that rotation of the anvil 411 drives rotation of the output drive 488). In
the illustrative embodiment, the anvil 411 (including the output drive 488) is supported
for rotation relative to the housing body 446 by the bushing 490a. The output drive
488 may be configured to connect to a socket or other fastener-driving output element.
In the illustrative embodiment, a resilient retainer 511 is positioned near an end
of the output drive 488 opposite the anvil jaws, as shown in FIGS. 9 and 10. When
a socket is connected to the output drive 488, the resilient retainer 511 may engage
an internal surface or recess of the socket to maintain the socket in engagement with
the output drive 488.
[0055] The impact mechanism 460 of the work attachment 414 may be embodied as any suitable
type of impact mechanism. As shown in FIGS. 9 and 10, the impact mechanism 460 is
illustratively embodied as a ball-and-cam-type impact mechanism with similar construction
and operation to the impact mechanisms 60, 260 described above with reference to FIGS.
1-7 (except as noted below). For instance, the camshaft 494 and the hammer 400 of
the impact mechanism 460 each include cam grooves defined therein that receive respective
balls to couple the hammer 400 to the camshaft 494. The camshaft 494 is coupled to
the drive spur gear 484 for rotation therewith. As shown in FIGS. 9 and 10, a key
447 is disposed between the camshaft 494 and the drive spur gear 484, and a retaining
ring 449 is also used to maintain the position the drive spur gear 484 on the camshaft
494.
[0056] As illustrated in FIGS. 9 and 10, the work attachment 414 includes a conical spring
506 positioned between the drive spur gear 484 and the hammer 400 of the impact mechanism
460 (rather than a cylindrical spring, like the springs 106, 306 positioned between
the drive spur gears 84, 284 and the hammers 100, 300 of the impact mechanisms 60,
260). The conical spring 506 biases the hammer 400 away from the drive spur gear 484
(such that hammer jaws of the hammer 400 are moved into engagement with the anvil
jaws of the anvil 411). The conical spring 506 surrounds a portion of the camshaft
494.
[0057] As best seen in FIG. 10, the conical spring 506 has a generally conical (or frusto-conical)
cross-section. In other words, one end of the conical spring 506 is wider, or has
a larger diameter, than the opposite end of the conical spring 506. In the illustrative
embodiment, an end of the conical spring 506 that is coupled to the drive spur gear
484 has a smaller diameter than an opposite end of the conical spring 506 that is
coupled to the hammer 400. It is contemplated that, in other embodiments, the end
of the conical spring 506 that is coupled to the drive spur gear 484 may have a larger
smaller diameter than the opposite end of the conical spring 506 that is coupled to
the hammer 400.
[0058] In the illustrated embodiment, the conical spring 506 rotates with the drive spur
gear 484, and a washer 452 and a plurality of thrust balls 456 cooperate to form a
bearing 490c that permits the hammer 400 to rotate about the axis 486 with respect
to the conical spring 506. In other embodiments, the conical spring 506 may rotate
with the hammer 400 and a bearing may permit the drive spur gear 484 to rotate with
respect to the conical spring 506.
[0059] It is believed that the conical spring 506 may provide several advantages over the
cylindrical springs 106, 306. For instance, the conical spring 506 may have a longer
service life than the cylindrical springs 106, 306. The conical spring 506 may also
have a smaller solid height than the cylindrical springs 106, 306, while maintaining
similar performance. Decreasing the solid height of the conical spring 506 may allow
for a decrease in the overall height of the work attachment 414. In the illustrative
embodiment of FIG. 9, the smaller diameter of the end of the conical spring 506 coupled
to the drive spur gear 484 may also allow the drive spur gear 484 to have a smaller
diameter, further decreasing the dimensions of the work attachment 414.
[0060] As shown in FIG. 9 (and discussed in detail above), the housing 446, 448 of the work
attachment 414 is partitioned into the housing body 446 and the housing cap 448. When
the housing cap 448 is removably coupled to the housing body 446 using the fasteners
450, a gasket 457 is positioned between the housing body 446 and the housing cap 448
to provide a fluid seal for the housing 446, 448.
[0061] As shown in FIGS. 9-11, the housing body 446 is formed to include a bore 459 that
extends along the axis 442, a bore 461 that extends along the axis 486, and a bore
465 that extends along the axis 463. As discussed above, in the illustrative embodiment
of FIGS. 8-12, the axes 463, 486 are parallel to one another and each perpendicular
to the axis 442. The bore 465 is positioned between the bores 459 and 461, such that
the bore 465 overlaps each of the bore 459 and the bore 461. In other words, in the
illustrative embodiment, the bore 465 is in direct fluid communication with both the
bore 459 and the bore 461. When the work attachment 414 is assembled and the housing
cap 448 is removably coupled to the housing body 446 (as shown in FIG. 10), the impact
mechanism 460 is positioned in the bore 461 and the gear assembly 458 is positioned
primarily within the bores 459, 465 (though the drive spur gear 484 of the gear assembly
458 is also positioned in the bore 461).
[0062] As best seen in the cross-sectional view of FIG. 10, the bore 459 is formed in the
housing body 446 such that the bore 459 includes several bore sections having differing
diameters from one another. More specifically, the bore 459 includes a bore section
477, a bore section 479, a bore section 481, and a bore section 483, each of which
has a successively smaller diameter than the previous section (moving from the rear
end 520 of the work attachment 414 toward the front end 522 of the work attachment
414). Each of the bore sections of bore 459, and the components positioned therein
when the work attachment 414 is assembled (as shown in FIG. 10) are discussed in more
detail below.
[0063] The ring gear 576 of the planetary gearset 570 is positioned in the bore section
477 of the bore 459, as shown in FIG. 10. The bore section 477 is bounded by an internal
surface 485 of the housing body 446 that defines a diameter of the bore section 477.
The ring gear 576 is engaged with the internal surface 485 such that the ring gear
576 is fixed relative to the housing body 446. As shown in FIG. 10, the sun gear 572,
the planet gears 574, the planet carrier 578, and a section 508 of the shaft 489 of
the bevel gear 462 are also each at least partially positioned in the bore section
477.
[0064] The spacer 437 is positioned in the bore section 479 between the ring gear 576 and
the bearing 495. The bore section 479 is bounded by an internal surface 487 of the
housing body 446 that defines a diameter of the bore section 479. The diameter of
the bore section 479 is less than the diameter of the bore section 477. The spacer
437 is positioned in the bore section 479 such that the spacer 437 is engaged with
the internal surface 487. The section 508 of the shaft 489 of the bevel gear 462 extends
through the bore section 479 along the axis 442.
[0065] The bearing 495 is positioned in the bore section 481 between the spacer 437 and
the bearing 439. The bore section 481 is bounded by an internal surface 491 of the
housing body 446 that defines a diameter of the bore section 481. The diameter of
the bore section 481 is less than the diameter of the bore section 479. The section
508 of the shaft 489 of the bevel gear 462 also extends through the bore section 481
along the axis 442. The bearing 495 engages both the internal surface 491 and the
section 508 of the shaft 489 to support the bevel gear 462 for rotation about the
axis 442.
[0066] The bearing 439 is positioned in the bore section 483 between the bearing 495 and
the bore 465, as shown in FIG. 10. The bore section 483 is bounded by an internal
surface 510 of the housing body 446 that defines a diameter of the bore section 483.
The diameter of the bore section 483 is less than the diameter of the bore section
481. A section 512 of the shaft 489 of the bevel gear 462 extends through the bore
section 483 along the axis 442. A diameter of the section 512 of the shaft 489 is
greater than a diameter of the section 508 of the shaft 489 discussed above. The bearing
439 engages both the internal surface 510 and the section 512 of the shaft 489 to
support the bevel gear 462 for rotation about the axis 442. As shown in FIG. 10, the
bearing 495 (positioned in the bore section 481) abuts both the section 512 of the
shaft 489 and the internal surface 510 of the housing body 446, which serves to properly
align the bevel gears 462, 466.
[0067] During operation of the tool 410, rotation of the output shaft 440 of the motor 416
will be transferred to the sun gear 572 (via the shaft 430 of the sun gear 572). Rotation
of the sun gear 572 relative to the ring gear 576 will cause the planet gears 574
to travel about the sun gear 572. Travel of the planet gears 574 causes rotation of
the planet carrier 578 which is coupled to the bevel gear 462 such that rotation of
the planet carrier 578 drives rotation of the bevel gear 462.
[0068] The bevel gear 462 extends along the axis 442 into the bore 465 such that the bevel
gear 462 meshes with the bevel gear 466 positioned in the bore 465. The bevel gear
466 is coupled to an end 513 of the shaft 468 for rotation therewith about the axis
463. The end 513 of the shaft 468 is supported for rotation in the bore 465 by the
bearing 470b. The shaft 468 extends through the bore 465 along the axis 463 to an
end 515 opposite the end 513. The spur gear 472 is coupled to the end 515 of the shaft
468 for rotation therewith about the axis 463. The end 515 of the shaft 468 is supported
for rotation by the bearing 470a.
[0069] As best seen in FIG. 12, the housing cap 448 is formed to include a bore 516 that
extends along the axis 463 when the housing cap 448 is removably coupled to the housing
body 446. As such, when the housing cap 448 is removably coupled to the housing body
446 as shown in FIG. 10, the bore 465 is aligned with the bore 516 such that the bearing
470a and the spur gear 472 are received in the bore 516.
[0070] During operation of the tool 410, rotation of the bevel gear 462 about the axis 442
will drive rotation of the bevel gear 466 about the axis 463. Rotation of the bevel
gear 466 causes the shaft 468 to rotate about the axis 463, thereby causing the spur
gear 472 to rotate about the axis 463.
[0071] In the illustrative embodiment, the impact mechanism 460 is positioned in the bore
461 such that a portion of the anvil 411 including the output drive 488 extends along
the axis 486 through a bottom face 530 of the housing body 446 to a point outside
of the housing body 446. As discussed above, the anvil 411 (including the output drive
488) is supported for rotation about the axis 486 by the bushing 490a which is positioned
adjacent the bottom face 530 of the housing body 446, as shown in FIG. 10. The hammer
400 is coupled for rotation with the camshaft 494 about the axis 486, and the camshaft
494 is supported for rotation about the axis 496 by the bearing 490b.
[0072] As best seen in FIG. 12, the housing cap 448 is formed to include a bore 518 that
extends along the axis 486 when the housing cap 448 is removably coupled to the housing
body 446. As such, when the housing cap 448 is removably coupled to the housing body
446 as shown in FIG. 10, the bore 461 is aligned with the bore 518 such that the bearing
490b and the drive spur gear 484 are received in the bore 518.
[0073] During operation of the tool 410, rotation of the spur gear 472 about the axis 463
drives rotation of the drive spur gear 484 about the axis 486. Rotation of the drive
spur gear 484 causes the camshaft 494 to rotate about the axis 486, thereby causing
the hammer 400 to rotate about the axis 486. As discussed above, as the hammer 400
rotates about the axis 486, the hammer 400 also reciprocally translates along the
axis 486 to periodically deliver an impact load to the anvil 411. These impact blows
cause intermittent rotation of the anvil 411 and, hence, the output drive 488.
[0074] Referring now to FIG. 11, the housing body 446 is shown in a detailed perspective
view (without the remaining components of the work attachment 414). As mentioned above,
the housing body 446 includes a rear end 520 configured to couple to the handle assembly
412 and a front end 522 opposite the rear end 520. As shown in FIG. 11, and discussed
in greater detail below, the housing body 446 also includes a side 524, a side 526,
a top face 528, and the bottom face 530 as shown in FIG. 11.
[0075] The rear end 520 of the housing body 446 includes a receiving surface 532 defining
an exterior profile 533 and a coupling surface 534 that is recessed from the exterior
profile 533 such that the coupling surface 534 does not extend beyond the exterior
profile 533. The receiving surface 532 interconnects with the coupling surface 534,
as shown in FIG. 11. The rear end 520 is configured to couple to the handle assembly
412 such that the handle housing sections 422, 424 of the handle assembly 412 extend
past the receiving surface 532 to engage the coupling surface 534 to permit the housing
body 446 to be coupled to the handle assembly 412 using the plurality of fasteners
497. As shown in FIG. 11, the bore 459 is formed in the coupling surface 534 such
that the bore 459 extends along the axis 442.
[0076] The front end 522 of the housing body 446 is arranged in closer proximity to the
bore 461 than the rear end 520, as shown in FIG. 11. The bore 459 extends from the
rear end 520 along the axis 442 toward the front end 522 and overlaps the bore 465,
as shown in FIGS. 10 and 11. The sides 524, 526 of the housing body 446 are arranged
opposite one another and, in the illustrative embodiments, are mirror images of one
another. Each of the sides 524, 526 interconnects with each of the ends 520, 522.
[0077] The bottom face 530 of the housing body 446 is interconnected with each of the ends
520, 522 and each of the sides 524, 526. In the illustrative embodiment, the bore
461 extends through the bottom face 530 along the axis 486, while the bore 465 does
not extend through the bottom face 530. The top face 528 of the housing body 446 is
arranged opposite the bottom face 530. The top face 528 interconnects with each of
the ends 520, 522 and each of the sides 524, 526. The top face 528 includes a section
536 that interconnects with the rear end 520 and a section 538 that interconnects
with the front end 522. As shown in FIG. 11, the sections 536, 538 interconnect with
one another.
[0078] The section 536 of the top face 528 of the housing body 446 includes a surface 540
that extends from the rear end 520 toward the section 538. The section 536 also includes
a surface 542 that interconnects with the surface 540 and extends parallel to the
axes 463, 486 and perpendicular to the axis 442 (i.e., along the parting plane 425)
to connect with the section 538. The apertures 499 discussed above are formed in the
surface 540 such that the apertures 499 extend through the coupling surface 534 of
the rear end 520 of the housing body 446, as shown in FIG. 11. Similar to the bores
of the handle assembly 412 that receive the fasteners 497 when the handle assembly
412 is coupled to the housing body 446, each of the apertures 499 formed in the surface
540 extends at an acute angle relative to the axis 442. As such, a cutout section
544 is formed in the surface 540 adjacent to each of the apertures 499.
[0079] The section 538 of the top face 528 of the housing body 446 includes a surface 546
that is coupled to the surface 542 and extends perpendicular to the axes 463, 486
and parallel to the axis 442 (i.e., along the parting plane 423) toward the front
end 522. The surface 546 is positioned closer to the axis 442 than the surface 540,
as shown in FIG. 11. The bores 465, 461 extend through the surface 546 along the axes
463, 486, respectively. In the illustrative embodiment, four bores 453 formed in the
housing body 446 also extend through the surface 546. As discussed above, the bores
453 are configured to receive fasteners 450 that removably couple the housing cap
448 to the housing body 446.
[0080] In the illustrative embodiment shown in FIG. 11, the section 538 of the top face
528 of the housing body 446 also includes a shoulder 548 that protrudes from the surface
546 in a direction parallel to the axes 463, 486 and away from the axis 442. Likewise,
the section 536 of the top face 528 of the housing body 446 includes a shoulder 549
that protrudes from the surface 542 in a direction parallel to the axis 442 and toward
the axes 463, 486. In other words, the shoulders 548, 549 of the housing body 446
each protrude toward the housing cap 448 when the housing 446, 448 is assembled (see
FIG. 10).
[0081] Referring now to FIG. 12, the housing cap 448 is shown in a detailed perspective
view (without the remaining components of the work attachment 414). The housing cap
448 includes a rear end 550, an front end 552, a side 554, a side 556, a bottom face
558, and a top face 560. The rear end 550 of the housing cap 448 includes a surface
541 that is configured to engage the shoulder 549 of the housing body 446 when the
housing cap 448 is removably coupled to the housing body 446. The rear end 550 of
the housing cap 448 also includes a lip 568 that protrudes from the surface 541 in
a direction parallel to the axis 442 (when the housing cap 448 is removably coupled
to the housing body 446) and away from the axes 463, 486. The lip 568 is configured
to engage the surface 542 of the housing body 446 when the housing cap 448 is removably
coupled to the housing body 446. In particular, the lip 568 of the housing cap 448
abuts the surface 542 of the housing body 446 along the parting plane 425. The front
end 552 of the housing cap 448 is arranged opposite the rear end 550 such that the
front end 552 is aligned with the front end 522 of the housing body 446 when the housing
cap 448 is removably coupled to the housing body 446.
[0082] The bottom face 558 of the housing cap 448 is configured to abut the section 538
of the top face 528 of the housing body 446 when the housing cap 448 is removably
coupled to the housing body 446. The bottom face 558 of the housing cap 448 includes
a surface 562 that is coupled to the surface 541 and extends perpendicular to the
axes 463, 486. The surface 562 is configured to engage the shoulder 548 of the housing
body 446 when the housing cap 448 is removably coupled to the housing body 446. The
bottom face 558 of the housing cap 448 also includes a lip 566 that protrudes from
the surface 562 in a direction parallel to the axes 463, 486 and toward the axis 442
(when the housing cap 448 is removably coupled to the housing body 446). In other
words, the lip 566 (as well as the lip 568) of the housing cap 448 protrudes toward
the housing body 446 when the housing 446, 448 is assembled (see FIG. 10). The lip
566 is configured to engage the surface 546 of the housing body 446 when the housing
cap 448 is removably coupled to the housing body 446. In particular, the lip 566 of
the housing cap 448 abuts the surface 546 of the housing body 446 along the parting
plane 423.
[0083] The bottom face 558 is formed to include the bores 516, 518 described above. The
bore 516 includes a bore section 517 sized to receive the bearing 470a and a bore
section 519 sized to receive the spur gear 472. The bore 518 includes a bore section
521 sized to receive the bearing 490b and a bore section 523 sized to receive the
drive spur gear 484. When the housing 446, 448 is assembled, the lips 566, 568 engage
the corresponding shoulders 548, 549 such that the bores 461, 518 are aligned with
one another and the bores 465, 516 are aligned with one another. The apertures 451
(which receive the fasteners 450, as discussed above) are formed in the lip 566 such
that the plurality of apertures 451 extend from the bottom face 558 to the top face
560, as shown in FIG. 12.
[0084] In the illustrative embodiment, the work attachment 414 also includes a number of
alignment pins 473 (FIG. 9). As shown in FIG. 11, the housing body 446 includes a
corresponding number of non-threaded bores 454. Similarly, as shown in FIG. 12, the
housing cap 448 includes a corresponding number of non-threaded bores 564. When the
housing cap 448 is brought into engagement with the housing body 446, each of the
alignment pins 473 is received in a corresponding bore 454 of the housing body 446
and a corresponding bore 564 of the housing cap 448. In this embodiment, the pins
473 will align the bores 461, 518 and will align the bores 465, 516 while the housing
cap 448 is removably coupled to the housing cap 448.
[0085] Head height dimensions 114, 314, 614 of the work attachments 14, 214, 414 are illustrated
in FIGS. 4, 7, and 10, respectively. The head height dimension 114, 314, 614 is the
distance (measured parallel to the output axis 86, 286, 486) from the top of the housing
cap 48, 248, 448 to the bottom of the housing body 46, 246, 446. The motor housings
18, 218, 418 define analogous motor housing height dimensions 118, 318, 618, as shown
in FIGS. 4, 7, and 10. It may be desirable to reduce the head height dimensions 114,
314, 614 so that the work attachments 14, 214, 414 can fit into small spaces. As suggested
in the drawings, the illustrative embodiments of the present disclosure allow the
head height dimensions 114, 314, 614 to be equal to or smaller than the corresponding
motor housing height dimensions 118, 318, 618. Such configurations permit insertion
of the angle impact tools into smaller spaces than has previously been achievable,
without compromising torque.
The present disclosure also provides:
An angle impact tool comprising:
a handle assembly extending along a first axis and supporting a motor, the motor including
a shaft configured to rotate about the first axis;
a work attachment coupled to the handle assembly, the work attachment comprising:
an impact mechanism including an anvil configured to rotate about a second axis that
is non-parallel to the first axis and a hammer configured to rotate about the second
axis to periodically deliver an impact load to the anvil to cause rotation of the
anvil about the second axis;
a gear assembly configured to transfer rotation from the shaft of the motor to the
hammer of the impact mechanism; and
a housing supporting the impact mechanism and the gear assembly, wherein the housing
is partitioned along a first parting plane that is perpendicular to the second axis
such that the housing includes a first housing section and a second housing section.
In embodiments, the first axis is parallel to the first parting plane. For instance,
the first axis may lie in the first parting plane. In alternative embodiments of the
angle impact tool, the first axis is spaced apart from the first parting plane.
[0086] The first axis may for instance intersect the second axis between (i) a position
of the anvil along the second axis and (ii) a point at which the second axis intersects
the first parting plane.
[0087] In embodiments, the first parting plane intersects the second axis between (i) a
position of the anvil along the second axis and (ii) a point at which the second axis
intersects the first axis.
[0088] In embodiments, the first and second housing sections are also partitioned along
a second parting plane that is perpendicular to the first axis.
[0089] In the above embodiments of the angle impact tool, the second housing section may
be removably coupled to the first housing section by a plurality of fasteners, each
of the plurality of fasteners extending through a corresponding aperture formed in
the second housing section and being received in a corresponding bore formed in the
first housing section.
[0090] In embodiments, each of the corresponding apertures formed in the second housing
section is recessed from an exterior profile of the second housing section such that
each of the plurality of fasteners that removably couples the second housing section
to the first housing section does not extend beyond the exterior profile of the second
housing section.
[0091] The angle impact tool may further comprise a gasket positioned between the first
and second housing sections to provide a fluid seal when the second housing section
is removably coupled to the first housing section by the plurality of fasteners.
[0092] In embodiments of any of the above aspects and embodiments, the angle impact tool
is provided wherein:
the first housing section is formed to include a first bore extending along the first
axis, a second bore extending along the second axis, and a third bore extending along
a third axis that is parallel to the second axis, the third bore being positioned
between the first and second bores and overlapping both the first and second bores;
the impact mechanism is positioned in the second bore; and
the gear assembly is positioned at least partially within the first and third bores.
[0093] In embodiments, the second housing section is formed to include a fourth bore extending
along the second axis and a fifth bore extending along the third axis. In such embodiments,
the work attachment further comprises a plurality of pins that each extend into a
corresponding bore formed in the first housing section and into a corresponding bore
formed in the second housing section such that the plurality of pins align the fourth
bore with the second bore and the fifth bore with the third bore.
[0094] In embodiments, the angle impact tool is provided wherein:
the first housing section is formed to include a shoulder that protrudes toward the
second housing section; and
the second housing section is formed to include a lip that protrudes toward the first
housing section, the lip engaging the shoulder such that the fourth bore is aligned
with the second bore and the fifth bore is aligned with the third bore.
[0095] In the angle impact tool of embodiments above, the gear assembly may include (i)
a first bevel gear positioned in the first bore of the first housing section and configured
to rotate about the first axis and (ii) a second bevel gear positioned in the third
bore of the first housing section and configured to rotate about the third axis, wherein
the second bevel gear meshes with the first bevel gear.
[0096] In embodiments, the first bore comprises adjacent first and second bore sections,
the second bore section having a smaller diameter than the first bore section and
being located closer to the third bore than the first bore section, the first bore
section being bounded by a first internal surface of the first housing section, the
second bore section being bounded by a second internal surface of the first housing
section;
the first bevel gear includes a shaft that extends along the first axis and comprises
adjacent first and second shaft sections, the second shaft section having a larger
diameter than the first shaft section, the first shaft section being positioned within
the first bore section, the second shaft section being positioned within the second
bore section; and
a bearing that supports the first bevel gear for rotation about the first axis and
engages both the first shaft section and the first internal surface abuts both the
second shaft section and the second internal surface to align the first and second
bevel gears.
[0097] In any of the embodiments above, the angle impact tool may be provided wherein the
work attachment is removably coupled to the handle assembly by a plurality of fasteners,
each of the plurality of fasteners extending through a corresponding aperture formed
in the first housing section and being received in a corresponding bore formed in
the handle assembly, each corresponding bore extending along an axis that is disposed
at an acute angle to the first axis.
[0098] A work attachment of the present disclosure may comprise:
a housing body configured to be coupled to a motorized tool including a rotatable
output shaft, the housing body being formed to include (i) a first bore extending
along a first axis, (ii) a second bore extending along a second axis that is perpendicular
to the first axis, and (iii) a third bore extending along a third axis that is perpendicular
to the first axis, wherein the third bore is positioned between the first and second
bores and overlaps both the first and second bores;
an impact mechanism received in the second bore of the housing body, the impact mechanism
including a hammer configured to rotate about the second axis to periodically deliver
an impact load to an anvil to cause rotation of the anvil about the second axis;
a gear assembly received at least partially in the first and third bores of the housing
body, the gear assembly configured to be coupled to the rotatable output shaft of
the motorized tool such that rotation of the output shaft about the first axis drives
rotation of the hammer about the second axis; and
a housing cap removably coupled to the housing body by a plurality of fasteners to
enclose the second and third bores, the housing cap abutting the housing body along
a first parting plane that is perpendicular to the second and third axes.
[0099] In embodiments, the work attachment is provided wherein the housing cap also abuts
the housing body along a second parting plane that is perpendicular to the first axis.
In further embodiments, the second parting plane is located between the third axis
and an end of the housing body configured to be coupled to the motorized tool.
[0100] In an aspect of the invention is provided an angle impact tool comprising:
a handle assembly extending along a first axis and supporting a motor, the motor including
a shaft configured to rotate about the first axis;
a work attachment coupled to the handle assembly, the work attachment comprising:
a housing body formed to include (i) a first bore extending along the first axis,
(ii) a second bore extending along a second axis that is perpendicular to the first
axis, and (iii) a third bore extending along a third axis that is perpendicular to
the first axis, wherein the third bore is positioned between the first and second
bores and overlaps both the first and second bores;
an impact mechanism received in the second bore of the housing body, the impact mechanism
including a hammer configured to rotate about the second axis to periodically deliver
an impact load to an anvil to cause rotation of the anvil about the second axis;
a gear assembly received at least partially in the first and third bores of the housing
body, the gear assembly configured to transfer rotation from the shaft of the motor
to the hammer of the impact mechanism; and
a housing cap removably coupled to the housing body by a plurality of fasteners to
enclose the second and third bores, the housing cap abutting the housing body along
a first parting plane that is perpendicular to the second and third axes.
[0101] In embodiments, the first axis lies in the first parting plane.
[0102] In embodiments, the first axis is spaced apart from the first parting plane. For
instance, the first axis may intersect the second axis between (i) a position of the
anvil along the second axis and (ii) a point at which the second axis intersects the
first parting plane. In embodiments, the first parting plane intersects the second
axis between (i) a position of the anvil along the second axis and (ii) a point at
which the second axis intersects the first axis.
[0103] In the angle impact tool of aspects and embodiments of the invention disclosed herein,
the housing cap may also abut the housing body along a second parting plane that is
perpendicular to the first axis.
[0104] In embodiments of aspects and embodiments of the invention disclosed herein, each
of the plurality of fasteners that removably couples the housing cap to the housing
body extends through a corresponding aperture formed in the housing cap and is received
in a corresponding bore formed in the housing body. In embodiments, each of the corresponding
apertures formed in the housing cap is recessed from an exterior profile of the housing
cap such that each of the plurality of fasteners that removably couples the housing
cap to the housing body does not extend beyond the exterior profile of the housing
cap.
[0105] In embodiments of aspects and embodiments of the invention disclosed herein, the
angle impact tool further comprises a gasket positioned between the housing cap and
the housing body to provide a fluid seal when the housing cap is removably coupled
to the housing body by the plurality of fasteners.
[0106] In embodiments of aspects and embodiments of the invention disclosed herein, the
housing cap is formed to include a fourth bore extending along the second axis and
a fifth bore extending along the third axis. For instance, the work attachment may
further comprise a plurality of pins that each extend into a corresponding bore formed
in the housing body and into a corresponding bore formed in the housing cap such that
the plurality of pins align the fourth bore with the second bore and the fifth bore
with the third bore. In embodiments, the housing body is formed to include a shoulder
that protrudes toward the housing cap; and the housing cap is formed to include a
lip that protrudes toward the housing body, the lip engaging the shoulder such that
the fourth bore is aligned with the second bore and the fifth bore is aligned with
the third bore.
[0107] In embodiments of aspects and embodiments of the invention disclosed herein, the
angle impact tool of any preceding claim, wherein the gear assembly includes (i) a
first bevel gear positioned in the first bore of the housing body and configured to
rotate about the first axis and (ii) a second bevel gear positioned in the third bore
of the housing body and configured to rotate about the third axis, and wherein the
second bevel gear meshes with the first bevel gear.
[0108] In embodiments, the first bore comprises adjacent first and second bore sections,
the second bore section having a smaller diameter than the first bore section and
being located closer to the third bore than the first bore section, the first bore
section being bounded by a first internal surface of the housing body, the second
bore section being bounded by a second internal surface of the housing body; the first
bevel gear includes a shaft that extends along the first axis and comprises adjacent
first and second shaft sections, the second shaft section having a larger diameter
than the first shaft section, the first shaft section being positioned within the
first bore section, the second shaft section being positioned within the second bore
section; and a bearing that supports the first bevel gear for rotation about the first
axis and engages both the first shaft section and the first internal surface abuts
both the second shaft section and the second internal surface to align the first and
second bevel gears.
[0109] In embodiments of aspects and embodiments of the invention disclosed herein, the
work attachment is removably coupled to the handle assembly by a plurality of fasteners,
each of the plurality of fasteners extending through a corresponding aperture formed
in the housing body and being received in a corresponding bore formed in the handle
assembly, each corresponding bore extending along an axis that is disposed at an acute
angle to the first axis.
[0110] While certain illustrative embodiments have been described in detail in the figures
and the foregoing description, such an illustration and description is to be considered
as exemplary and not restrictive in character, it being understood that only illustrative
embodiments have been shown and described and that all changes and modifications that
come within the spirit of the disclosure are desired to be protected. There are a
plurality of advantages of the present disclosure arising from the various features
of the apparatus, systems, and methods described herein. It will be noted that alternative
embodiments of the apparatus, systems, and methods of the present disclosure may not
include all of the features described yet still benefit from at least some of the
advantages of such features. Those of ordinary skill in the art may readily devise
their own implementations of the apparatus, systems, and methods that incorporate
one or more of the features of the present disclosure.