AU2006202783A1 - Wedge Clutch Assembly - Google Patents

Description

30/06 2006 13:36 FAX +61 2 94090101 HODGKINSON McINNES R003/039

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Actual Inventor: Address for Service: Invention Title: Details of Associated Parent Application: Brian K. BOSK Brian K. BOSK HODGKINSON McINNES PAPPAS Patent Trade Mark Attorneys Levels 3 and 4, 20 Alfred Street MILSONS POINT NSW 2061 (HMP Ref: P20290AU02) "Wedge Clutch Assembly" 2005200810 filed on 23 February 2005 by Brian K. BOSK The following statement is a full description of this invention, including the best method of performing it known to me: COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:37 FAX +61 2 94090101HOGIHN McNEia04/3 HODGKINSON McINNES 1a004/039 INO 2 O WEDGE CLUTCH ASSEMBLY

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BACKGROUND OF THE INVENTION 1. FIELD OF THE INVENTION The present invention relates generally to gear systems. More specifically, the invention is 00 a wedge clutch assembly for insertion in power hand tools and drilling apparatus to prevent O damage to a gear drive sys temn upon excessive stress 4 O 2. DESCRIPTION OF THE RELATED ART The related art of interest describes various clutch assemblies, but none of the cited to references discloses the present invention. There is a need to provide a mechanism to avoid gear failure in power band tools and even in well drilling apparatus. The relevant art will be discussed in the order of perceived relevance to the present invention.

Patent Application Publication No. 2002/0062967, published on May 30, 2002, describes an electrical handheld power tool with an electromagnetic safety clutch provided 1s between a pinion shaft and a rotor shaft. The pinion shaft is formed as a hollow shaft provided in its interior with an inner bearing which rotatably supports the pinion shaft.

The rotor shaft has its end received in the interior of the pinion shaft and supported against the inner bearing. The safety clutch is distinguishable for requiring an electromagnetic means.

w0 U.S. Patent No. 3,625,292, issued on December 7, 1971 to Michael T. Lay, describes an insulated slip clutch for a power cutting tool such as a lawn edger and grass trimmer. A slip clutch made of Beliville washer springs is held in place by a retaining nut which allows the D-shaped end of the drive shaft to continue to rotate, but to immobilize the drive pinion and any cutting motion. The slip clutch is housed between the cutting blade and a plastic casing in two insulating cups and a liner with a D-shaped hole. The clutch assembly is deemed distinguishable for requiring the driving shaft end to have a flattened 1)-shaped cross-section, Beliville washer springs and a two-cup insulating casing.

U.S. Patent No. 4,606,443, issued on August 19, 1986 to Misao Kimura, describes a planetary drive with an overload clutch release means for a telescopic antenna comprises COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:37 FAX +61 2 94090101 H006KINSON McINNES a005/039 3

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o an intermediate gear which meshes with a gear portion provided on an inner surface of a driven rotary member and a clutch gear which meshes with the intermediate gear to Scomprise the planetary gears. The clutch assembly is distinguishable for requiring a o planetary drive with an intermediate gear for raising and lowering a telescopic antenna.

U.S. Patent No. 3,752,278, issued on August 14, 1973 to Ronald F. States, describes an en improved power operated wrench or screwdriver having two dog clutches in series for the 00 00- transmission of the drive in which one is a torque sensitive dog clutch having ramped Sinterengaging driving surfaces adapted to be induced to become displaced against the c action of a spring when the torque applied by the tool exceeds a predetermined value. The S 10o other dog clutch is a non-torque sensitive clutch which is adapted to become disengaged by Cl displacement of the torque sensitive clutch. The dog clutches are distinguishable for requiring two having different torque sensitivities.

U.S. Patent No. 4,053,980, issued on October 18, 1977 to Arthur G. Poehlman, describes a chain saw featuring an over-torque releasing clutch mechanism comprising a drive member is driven by the drive shaft and a driven member for rotating the chain sprocket. One of the members is axially movable relative to the other between an engaged or driving position and a released position wherein they are disengaged from each other. The drive and driven members have intermeshing clutch teeth which co-act to produce an axial force in a direction tending to separate the members which are releasably held by a resilient member.

The clutch mechanism is distinguishable for requiring intermeshing clutch teeth.

U.S. Patent No. 4,066,136, issued on January 3, 1978 to Karl Wanner et al., describes a torque and impulse transmitting portable hammer drill having a safety overload clutch mechanism inserted in series between the rotary shaft of the motor and the tool to terminate the transmission of torque from the rotary shaft to the tool when resistance to rotation exceeds a predetermined value. An intermediate gear with smaller teeth is positioned between the crank gear and the coupling gear. The clutch is distinguishable for requiring a third gear.

U.S. Patent No. 4,809,572, issued on March 7, 1989 to Katsuhiko Sasaki, describes a power driven screwdriver having a claw clutch comprising a fixed clutch member with teeth on the end of a main gear on a support shaft. The spindle has a movable clutch member with teeth and an engaging ball in an inclined groove. A spring is located COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:*37 FAX -*61 2 94090101 HUKNO cNE 0/3 HODGKINSON McINNES IaOO6/039 4 o between the movable clutch member and the fixed clutch member, The claw clutch is distinguishable for requiring engaging teeth and an engaging ball, n U.S. Patent No. 4,883,130, issued on November 28, 1989 to Paul H. Dixon, describes a rotating dual speed transmission for a screw fastener driving tool of an automatic assembly machine which acts in conjunction with two torque-responsive clutches to tighten a en threaded fastener such as a screw or a nut during rotation of the spindle. A first torque- 00 responsive clutch automatically switches the drive from a fast speed to a slow speed when torque of a predetermined magnitude is imposed on the fastener, and a second torqueresponsive clutch automatically interrupts the drive to the fastener when torque cf a higher oio predetermined magnitude is imposed on the fastener. The first lower clutch has lugs which Ci lock with the lower cam segments supported with a coil spring around the spindle. The upper clutch has lugs which lock with the jaw members of the lower clutch, The clutches are distinguishable for requiring locking elements such as lugs and camn segments.

U.S. Patent No. 4,967,888, issued on November 6, 1990 to Wolfgang Lippacher et al., is describes a safety clutch for a motor-driven hammer drill which breaks the rotational drive train when a working tool becomes seized in a receiving material. A pair of coupling balls upon seizure leave their recesses in the power take-off spindle housing to permit the drive to continue to rotate. However, the motor must be stopped and restarted. The safety clutch assembly is distinguishable for requiring coupling balls- U.S. Patent No. 5,060,772, issued on October 29, 1991 to Heiniz-Oerhard Anders et al., describes a pneumatic power-operated screw driving tool which includes a switching clutch to transfer the torque from the drive shaft to an output shaft when the tool seizes.

The driver has a first clutch having clutch coupling jaws at its end which engages the coupling jaws of the second clutch. The clutch system is distinguishable for requiring two engaging clutches with jaws.

U.S. Patent No. 5,094,133, issued on March 10, 1992 to Wolfgang Schreiber, describes a power-operated screwdriver with a switch-off means for screw-in depth and screw-rn torque having three clutch elements. A first clutch element arranged between the drive and the tool drive shaft, and transferable by axial displacement of the tool drive shaft from a rest position to a working position, A second clutch element connected to the tool drive shaft- A third clutch element arranged between the first and second clutch elements forms COMS ID No: SBMI-04024440 Received by IP3 Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:.38 FAX +61 2 84080101 HOKNO cNE 0/3 HOOGKINSON McINNES IaOO7/038 o an entrainment clutch with the first clutch element and forms a release clutch with the second clutch element. The clutch system is distinguishable for requiring three connecting ;Z clutches.

0 U.S. Patent No. 5,134,909, issued on August 4, 1992 to Katsuhiko Sasaki, describes a power driven screwdriver including a driving or frictional clutch mechanism interposed between the drive motor and the spindle. A claw clutch mechanism is interposed between 00 the spindle and a second driving member which is separated from a first driving member.

The clutch system is distinguishable for requiring a frictional clutch and a claw clutch.

IND U.S. Patent No. 5,138,916, issued on August 18, 1992 to Yuichi Sato et at., describes a power operated screwdriver having two clutches, a compression spring between a support shaft and an intermediate clutch disc and urges the clutch disc toward the main spindle to disengage the first clutch. The clutch system is distinguishable for requiring two clutches.

U.S. Patent No. 5,350,026, issued on September 27, 1994 to Heule Markus et al., describes an electric power-driven screw-driver having a single friction coupling consisting of first is and second coupling elements that undoes the drive connection between a driving electric motor and the tool output shaft.

U.S. Patent No. 5,372,206, issued on December 13, 1994 to Katsuhiko Sasaki et al., describes a tightening tool including a drive member rotatably driven by a motor. An intermediate member is interposed between the drive member and a spindle, and rotatable with the drive member. A claw clutch is formed between the spindle and the drive member. The clutch system is distinguishable for requiring a claw clutch.

U.S. Patent No. 5,538,089. issued on July 23, 1996 to Christopher P. Sanford, describes a power tool clutch assembly having a first spindle configured to rotate in a gear case. A drive clutch element is fixed to the first spindle. A second spindle rotates independently of the first spindle. An output clutch element is fixed to the second spindle. A compression spring is provided between the intermediate and output clutch elements. The clutch housing and clutch components can be removed from a power tool gear casing for easy service. The clutch assembly is distinguishable for requiring two clutches.

U.S. Patent No. 5,566,458, issued on October 22, 1996 to Thomas R. Bednar, describes so two embodiments of a clutch mechanism for reciprocating saws having a wobble plate COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/08 2006 13:.38 FAX *61 2 84080101 HDKNO cNE 0/3 HODGKINSON McINNES IaOOB/039 6 o drive member including a spindle reciprocally supported by the housing, and a clutch drivingly connecting the motor to the shaft and providing slippage between the motor and the shaft if there is binding of the spindle. The clutch mechanisms are distinguish-able for requiring structurally different elements- U.S. Patent No, 5,573,091, issued on November 12, 1996 to ichael Hung, describes an M electrically powered or manually driven clutch and brake assembly for an~ electric winch 00 cooperating with a. transmission assembly. The clutch mechanism is provided with a thrust bearing on a clutch shaft, and a large clutch gear is inserted thereon. A lining plate is Ci attached to a clutch plate of the large gear, and a pinion gear is attached tightly to the lining

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plate. Another thrust bearing is placed behind the pinion gear and a compression spring is ci inserted on the clutch shaft. The large gear and the pinion gear are pushed tightly together or loosened as a function of the resiliency of the spring. A clutch hand wheel can be provided for manual operation. The clutch mechanism is distinguishable for requiring a large clutch gear, a lining place and two thrust bearings.

U.S. Patent No. 5,622,230, issued on April 22, 1997 to David A. Giardino et al., describes a rotary impact wrench clutch comprising a two-part, readily assembled and disassembled pin cage-coupler. One part is a cylindrical, longitudinally grooved cage contains a clutch mechanism and capped at one end by a lobed end plate coupler. The clutch device is distinguishable for requiring a pin-cage coupler.

U.S. Patent No. 5,778,989, issued on July 14, 1998 to Anton Neumaier, describes a manually operable screw driving tool having a drive pinion axially fixed with a housing. A spindle in the housing is axially displaceable relative to the drive pinion against the force of a first spring. A clutch element is located in a passageway in a collar on the drive pinion, and is radially displaceable by an actuating member for engaging the spindle to the zi drive pinion. In the engaged position the clutch element sits against a stop surface in the spindle. The actuation member is axially displaceable by stops located on the spindle, and can be axially fixed to the drive pinion by a retaining element and a snap-element. The clutch element is distinguishable for requiring an actuation member axially displaceable by stops on the spindle.

U.S. Patent No. 6,283,226 B 1, issued on September 4, 2001 to Kenneth Chen, describes a clutch-buffer assembly for a power wrench comprising a driven wheel having an outwardly COMB ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/08 2008 13:38 FAX +81 2 84080101 HD~ZNO cNE 0/3 HODGKINSON McINNES R009/039 7 o positioning tube disposed at a power-input end. A retaining spring, a retainIng disc, a driven gear, an anchor ring, and a reversible motor are collared onto the positioning tube ;Z sequentially. The retaining disc is limited to move back and forth along the positioning tube without rotation. A pair of protruding teeth and reception cavities in respective contact faces of the retaining disc and the driven gear, and the reversible motor is used to drive the driven gear. When the driven wheel rotates at a higher speed, the retining disc Mc can be detached from the driven gear for control of the power consumption to lessen the imposed load in order not to blow a fuse. The clutch-buffer assembly is distinguishable for o requiring a pair of protruding teeth and reception cavities in the respective contact faces of INCic the retaining disc and the driven gear.

Cl U.S. Patent No. 6,439,091 B1, issued on August 27, 2002 to John E. Dibbern et al., describes a clutch mechanism for a power tool having a hole and first and second clamps connected to the arbor to clamp the blade. One of the cutting tool and at least one of the first and second clamps and arbor have a first drive surface fbr contacting a second drive, surface on the other of the cutting tool, and at least one of the first and second clamps and arbor. The second drive surface is movable between a first position and a second position bypassing the first drive surface. T1he second drive surface is resiliently connected to the other of' the cutting tool and at least one of the first and second clamps and arbor. At least one metal strip connects the second drive surface to the other of the blade and at least one of the first and second clamps and arbor. The clutch mechanism is distinguishable for requiring two clamps for the blade and first and second drive surfaces., German Patent Publication No. 3,807,308, published on September 14, 1989, describes a radially acting safety friction clutch positioned inside a component of a power tool with an axial mode of action to obtain a shorter and more compact tool. The clutch has compression or cup springs. The clutch is distinguishable for requiring a radially acting safety friction clutch assembly.

German Patent Publication No. 4,101,705, published on March 26, 1992, describes a positive, frictionless clutch for a hedge trimmer which has a locking ring to disengage the main gear from a driven bushing by moving two drive rollers into a clear space. The clutch assembly comprises a main drive gear, the driven bushing and a locking ring mounted co-axially on a fixed central shaft. One end of the drive bushing has eccentrics COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30106 2008 13:39 FAX +61 2 94090101HOJISN& cNESi01/3 HOOGKINSON McINNES la 0 10/039 8 o which drive the trimmer blades. Roller located in apertures of the driven bushing transmit the drive through ledges on the inside diameter of the main drive gear. When the trimmer ;Z handle grips are released a atop pin enters a hole in the flange of the locking ring and o prevents rotation. The main drive gear and the driven bushing continue rotating, causing the rollers to enter a clear space between the two members and immediately disengaging the drive. A preloading coil spring connects the locking ring to the driven bushing, and together with friction brings the trimmer blades to rest. The clutch assembly is distinguishable for requiring an eccentric drive bushing containing two rollers.

French Patent Publication No. 2,799,113, published on April 6, 2001, describes a jointed dental hand drill as a continuously rotating instrument having a torque limiter in the form- Ci of a spring-loaded sliding gear clutch on the primary drive shaft and a fixed gear on the secondary drive shaft. In the event of a set torque being exceeded, the sliding gear moves along the primary shaft against the pressure of the spring and disengages the transmission.

The two geas have asymmetrical teeth to give different torque levels according to the direction of motion. The dental drill clutch system is distinguishable for requiring asymnmetrical gear teeth on two gears.

None of the above inventions and patents. taken either singly or in combination, is seen to describe the instant invention as claimed. Thus, a wedge clutch assembly solving the aforementioned problems is desired.

SUMMARY OF TILE INVENTION The present invention is directed to multiple embodiments of a wedge clutch assembly requiring a minimum of space for inclusion in any electric or pneumatic power tool and drilling rig to prevent damage to an electrically powered rotary or reciprocal hand drill, screwdriver, well drill, and the like tool or apparatus. The first embodiment utilizes the wedge clutch assembly on a pinion or drive shaft having a configuration sequentially as a first small diameter and a proximate threaded region, a second conical region increasing in diameter, a third increased diameter region, a fourth gear region, and a fifth decreased diameter region. A steel clutch wedge spring washer is positioned adjacent the pinion gear, and a retaining nut is threaded on the proximate threaded region for retaining the steel clutch wedge spring washer. A clutch cup is inserted on the conical enlarged region of the pinion shaft and inside the pinion gear.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:39 FAX +6l 2 94090101 HOJISO&McNEIj01/3 HOOGKINSON McINMES IR 0 11/039 9 o A thrust bearing may be disposed on the pinion or drive shaft, The thrust bearing may be disposed either between the spring washer and the pinion gear, or between the retaining nut ;Z and the spring washer. The thrust bearing helps to take pressure off of the retaining nut.

The second embodiment utilizes a pinion gear having a tbroughbore with inclined sides; a cylindrical pinion shaft having a conical enlarged region proximate to a first end thereof for supporting the pinion gear and a second end having a threaded region; and a bearing 00 spacer element, a bearing, a clutch wedge spring steel washer, and a retaining nut sequentially secured on the threaded region of the pinion shaft.

INO A third embodiment utilizes a driven cylindrical motor shaft; a clutch cup having a first enlarged region adapted with a keyway for passing said motor shaft therethrough; the clutch cup having a second conical reduced region and a third externally threaded neck region; a sprocket wheel frictionally fitted on the second conical reduced region of the clutch cup; a steel clutch wedge spring washer positioned adjacent the sprocket wheel; and a nut retaining the steel spring washer on the motor shaft. Further embodiments, including the addition of a housing in order to protect the wedge clutch assembly from environmental contamination, are further described.

Accordingly, it is a principal object of the invention to provide a wedge clutch assembly for hand tools and drilling rigs.

It is another object of the invention to provide a wedge clutch assembly incorporating a clutch wedge spring washer.

It is a further object of the invention to provide a wedge clutch assembly incorporating a clutch cup.

Still another object of the invention is to provide a wedge clutch assembly adaptable to several different pinion and drive shafts.

It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:39 FAX +61 2 94090101 HODGKINSON 6 McINNES l012/039

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o These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS 0 FIG. 1 is a schematic elevational view of a first embodiment of a wedge clutch assembly s for installation in a hand tool or a drilling rig according to the present invention.

00 FIG. 2 is an exploded elevational view of the FIG. 1 wedge clutch assembly according to 0 the present invention.

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o FIG. 3 is a schematic elevational view of a second embodiment of a wedge clutch 0 assembly for installation in a hand tool or a drilling rig according to the present invention.

0o FIG. 4 is an exploded elevational view of the FIG. 3 wedge clutch assembly according to the present invention.

FIG. 5 is a schematic elevational view of a third embodiment of a wedge clutch assembly for installation in a hand tool or a drilling rig according to the present invention.

FIG. 6 is a perspective view of the FIG. 5 wedge clutch cup according to the present is invention.

FIG. 7 is a schematic elevational view of a wedge clutch assembly according to the present invention similar to FIG, 1, but including a thrust bearing, FIG. 8 is an exploded view of the clutch assembly of FIG. 7.

TIG. 9 is an exploded view of a wedge clutch assembly similar to FIG. 8, but with the thrust bearing disposed between the spring washer and the jam nut.

Fig. 10 is a side view of a frustoconical section of an alternative embodiment of the wedge clutch assembly according to the present invention.

Fig. 11 is a top view of the frustoconical section of the wedge clutch assembly of Fig. Fig. 12 is a partial side cut-away view of another alternative embodiment of the wedge clutch assembly according to the present invention.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:39 FAX +61 2 34090101 HODOKINSON 81 McINNES la013/039 11 Fig. 13 is a top view of a frustoconical section of the wedge clutch assembly of Fig. 12.

Fig. 14 is a partial side cut-away view of yet another alternative embodiment of the wedge clutch assembly according to the present invention, illustrating the frustoconical section en housed within a protective housing.

Fig. 15 is a side attachment view of a frustoconical section and a corresponding sealing oc bolt according to yet another embodiment of the wedge clutch assembly according to the present invention.

Fig. 16 is an exploded partial side cut-away view of yet another alternative embodiment of the wedge clutch assembly according to the present invention.

In Similar reference characters denote corresponding features consistently throughout the attached drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is directed to three embodiments of a wedge clutch assembly that can be utilized in rotatable electrically or pneumatically driven machinery, such as hand i tools and drilling rigs, which would prevent expensive broken gear damage.

A first embodiment 10 of a wedge clutch assembly is illustrated in FIGS. I and 2. A pinion gear 12 has a through-bore 14 with inclined sides 16 to define a frustoconical configuration and a countersink 18 on its upper surface to frictionally accommodate a spring washer 46. A cylindrical pinion drive shaft 22 has in sequence from the top, a first small diameter neck 24 and a proximate threaded region 26, a second frustoconical region 28 increasing in diameter, a third increased diameter region 30, a fourth gear region 32, and a fifth decreased diameter region 34. The pinion gear 12 revolves with the pinion driven shaft 22 in order to drive a drill bit or other load. A fillet 36 is provided to support the frustoconical region 28 on one side and fillets 36 are also provided on both sides of the gear region 32.

The frustoconical bronze clutch cup 20 is 1/16 inch thick (shown also in FI. 6) and has a wide aperture 40 and a smaller aperture 42. The bronze clutch cup 20 is inserted inside the throughbore 14 of the pinion gear 12 and fits over the frustoconical region 28 of the pinion COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:.40 FAX +61 2 94090101 HOJISH&McNElj01/3 HODGKINSON McINNES [a 014/039 INO 12 o drive shaft 22 to prevent the pinion gear 12 and the pinion drive shaft 22 from gouging or otherwise damaging the clutch wedge spring washer 46 by shear forces. Tfhe spring ;Z washer 46 is shaped as a shallow cup with open ends. The clutch wedge spring washer 46 is rmade of spring steel and is placed inside the countersink 18 and over the smaller en aperture 42 of the clutch cup 20. A fastener, such as a retaining nut or jam nut 48, is placed on the externally threaded region 26. The jam nut 48 secures the spring washer 46 to the assembly and adjusts the sensitivity of the clutch wedge spring washer 46, or frictional force applied by the spring washer 46 to the pinion gear 12, in the countersink 18 o to a specific applied torque on the drive shaft 22 of the tool, which will energize the INO i0 clutching action to eliminate any damage to the mechanical drive system of the tool.

Cl Under normal load the spring washer 46 applies sufficient frictional force against the pinion gear 12 to cause the pinion gear 12 to rotate with shaft 22 to drive the load.

However, the clutch wedge spring washer 46 collapses and assumes a more flattened shape when excessive torque is applied to the main drive system by the load in order to permit the pinion gear 12 to stop and the pinion drive shaft 22 to spin freely under an excessive load. This prevents the gears from being stripped or damnage to the motor when the load requires more torque than the motor can supply. This principle applies to all of the embodiments described herein., As shown in FIGS. 7-9, a thrust bearing may be disposed between the pinion gear 12 and the jam nut 48 to relieve pressure on the jam nut 48 and to prevent premature wear of the spring washer 46. In FIGS. 7 and 8, the thrust bearing 45 is disposed between the pinion gear 12 and the spring washer 46. In this configuration, under normal load the spring washer 46 exerts sufficient tension against the thrust bering 45 to cause the bearing 45 to frictionally engage pinion gear 12, causing pinion gear 12 to rotate with shaft 22, thereby driving the load. When the load exerts excessive torque on pinion gear 12, spring washer 46 collapses and flattens, relieving the frictional force exerted by the spring was;her 46 on bearing 45, thereby permitting pinion gear 12 to stop while shaft 22 rotates freely.

Alternatively, the thrust bearing 45 may be disposed between the jam nut 48 and the spring washer 46, as shown in FIG. 9. In this configuration the spring washer 46 again directly exerts frictional force against the pinion gear 12 by contact with the wall of the pinion gear 12 in countersink 18 under normal load, but collapses and flattens under excessive torque COMB ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:40 FAX +61 2 84090101 HDKHO cNE 1/3 HODGKINSON McINNES IR 015/039 INO 13 0 o applied by the load to disengage pinion gear 12 from shaft 22 to allow free rotation of tbe shaft 22. Thrust bearing 45 relieves pressure against jam nut 48 and prevents excessive ;Z wear of spring washer 46en FIGS. 3 and 4 depict a second embodiment of a wedge clutch assembly 50 comprising a pinion gear 52 having a frustoconical throughbore 54 with inclined sides 56 for accepting a en bronze clutch cup 58. The pinion gear 52 has a reinforcement ring 59 on the smaller 00 opening of the throughbore 54. A cylindrical pinion shaft 60 has a fmustoconicaI enlarged o region 62 proximate to a first end 64 thereof for supporting the pinion gear 52 and a second end 66 having an externally threaded region 68. A bearing spacer element 70 with a shoulder 72 supports a bearing 74 with evenly spaced blind bores 76, a steel clutch wedge Ci spring washer 78 which is inverted, and a retaining j am. nut 80 sequentially secured on the threaded region 68 of the pinion shaft 60, whereby the pinion gear 52 revolves with a pinion gear of a driven shaft (not shown). Again, the sensitivity of the clutch wedge spring washer 78 is adjusted by the amount of pressure exerted by thle jam nut 8O. Upon excessive torque on the driven shaft due to sticking in a bore, the clutch wedge spring washer 78 will compress to disengage the pinion gear 52 from the driven gear to avoid damage to the driving system of the tool.

FIG. 5 shows a third embodiment 82 of a wedge clutch assembly for a sprocket drive wheel 84 having cogs 102 on a driven cylindrical motor shaft 86. A bronze clutch cup 88 is provided with a first enlarged region 90 adapted with a keyway 92 for passage of the motor shaft 86 therethrough. The clutch cup 88 has a second frusroconical reduced region 94 and a third externally threaded neck region 96. The driven sprocket wheel 84 is fictionally fitted on said second frustoconical reduced region 94 of the clutch cup 88- A steel clutch wedge spring washer 98 is positioned abutting the driven sprocket wheel 84, and its sensitivity is adjustably maintained by a jam nut 100 on the threaded neck region 96. Thus, the driven sprocket wheel 84 is protected fromn damage by the efficient operation of the steel clutch wedge spring washer 98 on the motor shaft 86.

FIG. 6 illustrates a bronze clutch cup 20 used in the first two embodiments having a wide lower aperture 40 and a narrow upper aperture 42 to define a frustoconical configuration.

The clutch cup preferably has a peripheral thickness between 1/16 of an inch and 3 inches.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:41 FAX +61 2 94090101 HDIISN&IcNE 1/3 HODGKINSON McINNES la 0 16/039 INO 14 o As noted above, clutch cup 20 is the only element in the wedge clutch assemblies made of bronze, the remaining elements being made of hardened steel.

It should be noted that it may be desirable, in the alternative, to remove clutch cup 20 from 0 the wedge clutch assembly. By forming frustoconical region 16 and frusroconical section 28 from relatively soft materials, clutch cup 20 may be removed from system 10 without Mn affecting operation of the clutch assembly. Such a configuration may be desirable in that 00 friction between the moving parts will be decreased, and the chances for misalignment between the frustoconical pieces are minimized.

INO In the alternative embodiments illustrated in Figs. 10, 11 and 12, the furstoconical section 28 and upper externally threaded neck 24 are formed as a unitary structure having a channel 100 formed axially therethrough. Channel 100 receives a central shaft 120, which drives rotation of the wedge clutch assembly, As best shown in the top view of Fig. 11, channel 100 is patterned to include a plurality of axially extending projections, forming an engaging inner wall surface 110. la Fig. 12, central shaft 120 has a substantially cylindrical contour, however, depending on the needs of the user, shaft 120 could be contoured to include corresponding axially extending projections, forming an engaging outer wall surface for inner wall surface 110 of Fig. 11. Engagement of the extending projections of inner wall surface 110 with those of the outer wall surface of the shaft 120 releasably locks shaft 120 to frustoconical section 28 and neck portion. 24. This releasable locking of shaft 120 aids in driving rotation of the frustoconical section 28 and wedge clutch assembly 10 when shaft 120 is driven by an external motive force.

Further, in the embodiment illustrated in Fig. 12, a housing 130 is provided for covering the upper externally threaded neck portion 24 and the frustoconical section 28. Clutch assemblies are typically used in combination with some sort of motor, engine or other rotary machine. Thus, clutch assemblies are often exposed to dirt and other contaminants and pollutants which can clog the moving parts of the clutch assembly. The embodiment illustrated in Fig- 12 is well adapted for usage with lawn mower blades and the like. Cover 130 is provided to prevent clogging and contamination of the rotary section of the clutch assembly 10, when used in combination with a rotary drive system. A removable lid 140 is provided to allow the user selective access to the interior of housing 130 for repair or COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-0&-30 30106 2006 13:41 FAX +61 2 94090101 HODGKINSON McINNES l017/039 Sreplacement of parts. Removable lid 140 is secured to housing 130 through a plurality of releasable securement elements, such as, for example, screws or bolts 150, as shown.

-a Additionally, a threaded bore hole 160 may be formed through ftustoconical section 28, 0 extending radially therethrough from the outer surface of frustoconical section 28 to channel 100, as best shown in the top cut-away view of Fig. 13. The user may insert a M threaded engaging member, such as a screw or a bolt, for selective locking engagement 0 0 with central shaft 120, thus securing shaft 120 to the frustoconical section 28 and upper o neck portion 24. This additional locking engagement may be used with a smooth or keyed

NO

shaft, such as that shown in Fig. 12, a patterned shaft as would be necessary for the o 10 embodiment of Fig. 11, or may be used with a shaft contoured dependent upon the needs Cl and the desires of the user. Additionally, as further shown in Fig. 12, housing 130 may be contoured to include threads or the like for securely receiving and holding the threads 26 of threaded neck portion 24.

In the alternative embodiment shown in Fig. 14, the upper portion (in the configuration as shown) of frustoconical section 28 is housed within a first housing 170. First housing 170 includes an open upper end and an open lower end. A gasket or o-ring 210 is received within the open upper end of first housing 170, preventing contamination from dirt and other contaminants where the remainder of cylindrical pinion shaft 22 projects outwardly therefrom. The embodiment of Fig. 14 is well adapted for usage with the drive lines of heavy duty vehicles and the like.

The open lower end of first housing 170 is in communication with a second housing 180, which receives the remainder of frustoconical section 28 and the threaded neck portion 24.

The lower end of second housing 180 is open and is covered with a releasable lid 190.

Similar to that shown in Fig. 12, lid 190 is releasably held to housing 180 by a plurality of securement elements 200, which may be bolts, screws or the like.

In the similar embodiment shown in Fig. 16, a single housing 240 is provided for receiving and covering frustoconical section 28 and threaded neck portion 24. The remainder of pinion shaft 22 projects downwardly and outwardly from the lower end of housing 240, and a gasket or o-ring 210 is provided for sealing the open lower end of housing 240 about the shaft. The embodiment of Fig. 16 is well adapted for use with marine-type vehicles and the like.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:41 FAX *61 2 94090101 HODGKINSON McINNES 1018/039 16 0 o The open upper end 250 is adapted, sized and contoured to receive thrust bearing 74, a pair of fasteners, such as nuts 280, a washer 290 sandwiched between the fasteners 280, and a ;locking fastener 300. Washer 290 may be a locking-type washer for preventing further omovement of jam nuts 280. Particularly, washer 290 may be a keyed locking-type washer.

s Additionally, at least one elastic element, such as a disc spring, 270, is provided, as shown, Though shown as a stack of three disc springs, it should be understood that the number of oc elastic elements and the type of elastic elements used is dependent upon the needs and 0 desires of the user.

Each of the fasteners 280 and 300 have threaded passages formed centrally therethrough, to for engaging threads 26 of neck portion 24. Additionally, a second gasket or o-ring 310 C'l may be provided within the passage formed through fastener 300, for forming a seal against contamination with neck portion 24. Additionally, a third gasket or o-ring 320 may be provided around the external surface of fastener 300 in order to form a seal with the inner wall of housing 240, which defines opening 250.

is Further, a vertical channel 260 may be forned in the external surface of threaded neck portion 24, as shown in Fig. 16. The user may engage vertical channel 260 with an engaging element, such as a bolt or a screw, in order to selectively and releasably lock threaded neck portion 24 to housing 240.

Additionally, under certain conditions, such as in environments where a great quantity of polJutants might enter the clutch assembly 10, it may be necessary to seal off the interior of frustoconical section 28. As shown in Fig. 15, frustoconical section 28 may have an internal bore passage 230 formed through the upper end thereof. A threaded sealing element, such as bolt 220, for example, is provided for selective and releasable engagement with passage 230, to seal the upper open portion of the frustoconical section 28 from contamination.

It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30

Claims (19)

1. A wedge clutch assembly, comprising: 0 eC< a pinion gear having a top surface and a bottom surface, said pinion gear defining a centrally disposed throughbore having a frustoconical configuration; 00 a bronze clutch cup having a frustoconical configuration and defining a an upper aperture and a lower aperture, wherein the lower aperture is substantially larger than the 0 upper aperture, said clutch cup being inserted within the throughbore of said pinion gear; cI o a cylindrical pinion shaft including: O Ci an upper externally threaded neck extending through the throughbore and protruding from the top surface of said pinion gear; a frustoconical section adjacent said threaded neck, said frustoconical section being dimensioned to fit within said clutch cup; an increased diameter section depending from said frustoconical section and extending below the bottom surface of said pinion gear, said increased diameter section having a diameter substantially greater than the diameter of said upper neck; a gear section adjacent said increased diameter section; and a decreased diameter section having a diameter substantially less than the diameter of said increased diameter section and said gear section; a wedge clutch spring washer centrally disposed above the top surface of said pinion gear; a fastener threaded on said upper neck above said wedge spring washer for adjusting an applied torque to a drive shaft of a tool; and a thrust bearing disposed between said fastener and said pinion gear.

2. The wedge clutch assembly according to claim 1, wherein said thrust bearing is disposed between said spring washer and said pinion gear. COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:42 FAX +61 2 94080101 HIGISN&hcNE 2/3 HOOGKINSON McINNES IA020/039 :18 o

3. The wedge clutch assembly according to claim 1, wherein said thrust bearing is Cl disposed between said fastener and said spring washer. ;Z en

4. The wedge clutch assembly according to claim 1, wherein the top surface of the pinion gear defines a centered countersink. 00 The wedge clutch assembly according to claim 1, wherein said wedge clutch o spring is made of steel.

Cl

6. The wedge clutch assembly according to clam 1, wherein said pinion gear and said pinion shaft are made of hardened steel.

7. The wedge clutch assembly according to claim 1, wherein said bronze clutch cup has a thickness of 1/ 16 inch.

8. The wedge clutch assembly according to claim 1, wherein said fastener is a jam nut.

9. The wedge clutch assembly according to claim 1, wherein the wedge spring washer collapses so that said pinion shaft is allowed to rotate freely and independent of said pinion gear when the drive shaft of the tool is subjected to excessive torque. The wedge clutch assembly according to claim 1, further comprising a central shaft, wherein each of said upper externally threaded neck and said frustoconical section have a channel formed therethrougb, said channel extending ang the axis of rotation, said central shaft being received within said channel.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:42 FAX +61 2 94090101 HODGKINSON McINNES @021/039 19 O o

11. The wedge clutch assembly according to claim 10, wherein an exterior surface of said central shaft has a plurality of first engaging members formed thereon and Sprojecting radially therefrom, wherein an inner wall of said frustoconical section and said o upper externally threaded neck defines said channel, said inner wall having a plurality of e c n second engaging members formed thereon for releasable locking engagement with said plurality of first engaging members. 00 O

12. The wedge clutch assembly according to claim 11, wherein said frustoconical C section has a threaded passage formed therethrough, said threaded passage extending in the 0 radial direction, said threaded passage extending between an exterior surface of said C frustoconical section and said inner wall, wherein a threaded securement element is received within said threaded passage for releasably locking said central shaft to said frustoconical section.

13. The wedge clutch assembly according to claim 1, further comprising: a housing, said housing having an upper opening and a lower opening, said lower opening receiving a lower portion of said cylindrical pinion shaft, said upper externally threaded neck and said frustoconical section being received within, and covered by, said housing; and, a lid releasably secured to said housing, said lid selectively and releasably covering said upper opening of said housing.

14. The wedge clutch assembly as recited in claim 13, wherein said upper opening is adapted to receive and hold said wedge clutch spring washer, said fastener and said thrust bearing. The wedge clutch assembly as recited in claim 14, further comprising a lower gasket received within said lower opening and mounted on said lower portion of said cylindrical pinion shaft.

COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:42 FAX +61 2 94090101 HODGKINSON McINNES @022/039 O o

16. The wedge clutch assembly as recited in claim 15, further comprising a first upper gasket received within a threaded passage formed through said fastener, said gasket Sbeing mounted on said upper externally threaded neck.

17. The wedge clutch assembly as recited in claim 16, further comprising a second upper gasket mounted on an external surface of said fastener, said second upper gasket and 00 0 said fastener being received within said upper opening of said housing. In

18. The wedge clutch assembly according to claim 14, further comprising at least 0 one disc spring received within, and held by, said upper opening of said housing.

19. A wedge clutch assembly, comprising: a pinion gear having a top surface and a bottom surface, said pinion gear defining a centrally disposed throughbore having a frustoconical configuration; a cylindrical pinion shaft including: an upper externally threaded neck extending through the throughbore and protruding from the top surface of said pinion gear; a frustoconical section adjacent said threaded neck, said frustoconical section being dimensioned to fit within said throughbore; an increased diameter section depending from said frustoconical section and extending below the bottom surface of said pinion gear, said increased diameter section having a diameter substantially greater than the diameter of said upper neck; a gear section adjacent said increased diameter section; and, a decreased diameter section having a diameter substantially less than the diameter of said increased diameter section and said gear section; a wedge clutch spring washer centrally disposed above the top surface of said pinion gear; a fastener threaded on said upper neck above said wedge spring washer for adjusting an applied torque to a drive shaft of a tool; and COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30 30/06 2006 13:43 FAX +61 2 94090101 HODGKINSON McINNES l 023/039 21 a thrust bearing disposed between said fastener and said pinion gear. A wedge clutch assembly, substantially as herein described with reference to the drawings. Dated 30 June 2006 By: Brian K. Bosk HODGKINSON MCINNES PAPPAS Patent Trade Mark Attorneys COMS ID No: SBMI-04024440 Received by IP Australia: Time 12:49 Date 2006-06-30