CA1235315A - Ratchet wrench - Google Patents

Abstract

ABSTRACT OF DISCLOSURE

In a preferred embodiment, a gear drive mechanism includes a non-driving interval in the reverse direction of rotation of the handle of a ratchet wrench. Within that interval handle engagement with a toggle-type switch can occur for reversing ratcheting direction. This handle engagement of the ratcheting mechanism being by way of handle twistable out of alignment with the mounting structure of the handle portion of the wrench.
In this arrangement non-circular circumscribing inside wall surfaces of the handle (as viewed in transverse cross-section) engages and wedges a roller against the rounded surface of the drive shaft. Thus, while the roller is wedged, reverse direction turning of the handle causes the drive shaft to turn to thereby flip the toggle-like switch mechanism, thereby reversing the ratcheting direction of the ratchet wrench.

Description

~'~353~.~

BACKGROUND OF THE INVENTION

This invention is directed to a ratchet wrench having an improved mechanism for driving a ratchet-reversing mechanism and for the mechanism achieving ratchet reversal.
Prior to the present invention and the cozen-ding parent application, U.S. Serial No. 083380, having issued March 9, 1982 as U.S. Patent 4,318,314, the no-vernal mechanisms for ratcheting of ratchet wrenches has always necessitated a separate and distinct fever-set switch apart from the normally-gripped handle of the ratchet wrench. The handle of the ratchet wrench revolved during a non-driving ratcheting stroke of the shaft and handle of the prior art ratchet wrenches. A
typical prior art patent illustrating the above noted turning (revolving) of the handle during the ratcheting stroke of oscillation is U.S. Patent 4,086,829 dated May 2, 1978 to Hugeness. Both that prior art patent and also U.S. Patent 3,372,781 dated March 12, 1968 to Fulton illustrates the use of separate switches for no-versing direction of ratcheting, the action being by force transmission by other than the normal drive shaft of the ratchet wrench. There has, therefore, been pro-sent the difficulty of properly retaining a tight grip on the handle when it rotates during ratcheting, loge-then with necessity of a two hand operation -- one to hold the wrench and the other to flip the separate but-ton or switch apart from normal handle gripping Also, as compared to the force-transmitting mechanism in the head of the ratchet wrench of the prior parent applique-lion above noted, transmitted through the paw itself, and likewise as compared to torque of the parent apply-cation handle mechanism through a spring structure, thus- - - I- - = - n I ,. 3 it 1 requiring a sturdy spring structure to endure against breakage of the spring when subjected to large forces, the invention of the present application deals with such disadvantages and difficulties.

SUMMARY OF THE INVENTION

Accordingly, the present invention has one or more objects such as obtaining an improved ratchet wrench overcoming one or more of the preceding problems and difficulties.
Another object, more specifically, is to obtain a ratchet wrench having a ratchet mechanism reversible by reverse twisting and turning the handle of the ratchet wrench.
Another object is to obtain the preceding objects together with greater strength and sturdiness of driving - mechanisms thereof.
Another object is to obtain a ratchet wrench having head gearing drive mechanism of improved strength and sturdiness.
Another object is to obtain a ratchet wrench with a novel mechanism for drive of the drive shaft rotatable, upon a rotating of the handle thereof.
Another object is to obtain the above noted objects, together with a female ratchet member of improved strength and sturdiness.
Other objects will become apparent from the preceding and following disclosure.
One or more objects of the invention are obtained ho the invention as disclosed herein, as diagrammatic gaily illustrated typically by the Figures.
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a ratchet wrench assembly ~3S3~

1 having selectable ra-tcheting action for causing rotation in alternate directions. The wrench assembly has a support structure and a drive stud means mounted on the support structure for rotation thereon. Also included 5 it a gear means mounted on the support structure and coupled to the drive stud means for driving it The wrench assembly also has a two position ratchet means coupled to the drive stud means for allowing i-t relative to the support structure freedom of rotation in one of two directions. This freedom of rotation can reverse its direction in response to a change in the position of the two-position ratchet means. The assembly includes a drive shaft means for drivel engaging the first gear means, and also includes a barrel means mounted about the drive shaft means or rotatable driving it. The wrench assembly also includes a coupling means coupled between the gear means and the two-position ratchet means for alternating the position of the latter in response to alternate rotation of the barrel means.
unidirectional rotation of the barrel means in a direction beyond that required to reverse the position of the ratchet means is thereafter operable to cause rotation of the drive stud means in the direction allowed by the freedom of rotation of the two position ratchet means.
The invention, in a preread embodiment, may be described as a novel ratchet wrench typically inclusive of a general and continuous support structure supporting the handle, drive shaft, gearing and driven socket stud and support structure thereof, one improvement being a mechanism such that concurrently the handle is free from revolving connection during a ratcheting stroke of the handle and shaft, while the ratchet reversal switch is actuatable by initial reverse -twisting and rotation of the handle of the ratchet wrench. Another improvement includes a toggle-switch mechanism actuatable by the 1 head gears upon the initial reverse twisting end revolving of the handle ox the ratchet wrench. Another improvement arises in the line of direct force transmittal by the stationary gears in their interconnection with the support structure of the socket stud of the ratchet wrench. Another improvement arises in a novel mechanism of force-transmittal from the handles inside irregularly shaped circumscribing surface (as viewed in transverse cross-section through the handle) through a wed gable roller by the wedging of the roller against the rounded shaft (of circular cross-section as viewed in transverse cross-section there through when the handle is twisted and revolved in a non-driving ratcheting direction of rotation. Another improvement is a novel drag mechanism for permitting the handle to be twisted off center alignment with the handle support structure, such that the wedging and gripping operation is thusly initiated and such that the handle drives through the wedged roller, the round drive shaft-Preferably the wedging structure includes paired adjacent oppositely slanted surfaces as surface portions of the inside, irregular shaped surface of the handle, as previously discussed above. A broad range for an angle formed between an imaginary line of extension of one of the slanted surfaces and an opposing converging imaginary tangent line that is orthogonal to a perpendicular taken through a center diameter of the roller in a wedged state, ranges between about 7 degrees to about 12.5 degrees. But for preferred non-slipping engagement, even if slightly soiled with oil or the like, a preferred range is from about 9 agrees to about 11 degrees.
Preferably the dragging composition and concurrently the composition that permits the handle to twist out of alignment with the handle support structure I

1 is rubber, and preferably in the form of an O-ring. By saying rubber is meant any suitable elastic material or composition. The drag serves as a braking compositor and this function facilitates the ability of the twisted and revolved handle in the non-driving reverse direction, to grab with its slanted surface the surface of the roller thusly effecting (achieving) the wedging operation ox the ball or roller between the slanted surface and the rounded shaft surface against which the roller is normally mounted. Accordingly, while the roller normally revolves when the rounded shaft revolves, the roller is not normally in wedging state of relationship with the handle except when the handle is reversely twisted and revolved. Once the wedged state has been achieved, continued reverse turning continues to cause the rounded shaft to revolve It is to ye naturally understood that what is termed the reverse direction of revolving is dependent upon at any given moment which opposite direction therefrom is the driving direction -- which depends on which currently is the ratchet state of ratcheting of the ratchet wrench. If it is in a clockwise driving state, then reverse direction is counterclockwise. On the other hand, if it is in the counterclockwise driving state, then the reverse direction is clockwise.
The invention may be better understood by making reference to the following Figures. It is particular pointed out that the drawings of the Figures are not to scale and are not engineering drawings, and are nut representative of necessarily exact size and position relationships, instead, the drawings are purely diagrammatical in nature, intended to illustrate mechanism, operation and general shape and function for improved understanding of the description of the invention. However, the elements illustrated are accurate and operative, this invention having been ] reduced to practice by actual construction prior to the filing of this application for patent.

BRIEF DESCRIPTION OF TEE DRAWINGS

Fig. 1 illustrates an embodiment of the novel ratchet wrench diagrammatically in a perspective view.
Fig. PA illustrates a head-end view of the assembly of Fig. 1, as taken along line AHAB of Fig. 1.
Fig. BAA illustrates diagrammatically a detailed and cross-sectional view of a portion of -the structure illustrated in Figs. PA and PA.
Fig. 2B illustrates diagrammatically a handle-end of the Fig. 1 embodiment, as taken along line AHAB of Fig. 1, in a side cross-sectional view at the 2B end of line AHAB.
Fig. PA illustrates diagrammatically a plan view for the Fig. 1 embodiment, transverse -to the stud axis, as viewed looking down upon the several plates arranged on owns on top of the other.
Fig. 3B illustrates diagrammatically a plan view of the Fig. 1 embodiment after removal of the top plate illustrated in Fig. PA, thus illustrating the upper toggle switch actuating plate that is rotatedly moved by a gear actuated by teeth on the driving plate of Fig.
PA.
Fig. 3C illustrates diagrammatically a plan view of the Fig o 1 embodiment after removal of the two upper plates of Figs. PA end 3B, thus illustrating the lower toggle-switch actuating plate that is rotatedly moved in response to a gear actuated my teeth on the driving plate of Fig. PA, and part of head support structure.
Fig. ED illustrates diagrammatically a top view of the head-end of the embodiment of Fig. 1 after removal of the top cover plate and after removal of the upper plates of Figs. PA, 3B and 3C, thus illustrating a ~35~

1 face of the socket stud support structure, the mounted gear, -the toggle-spring-mounting recess, a cross section of the plates-mounting shaft, the ratchet paw positioned in an arcuate cut-away section of the socket stud-support structure, the biasing spring that is biased against the paw, the female toothed ratchet surface o-E the head support structure and the like.
Fig. PA illustrates diagrammatically a transverse cross section of the embodiment ox Fig. 1 as taken along line 4-4 of Fig. 2B, illustrating the rounded drive shaft, the mounted roller and support structure thereof -- the barrel structure and the slanted surfaces of the irregularly shaped inside surface at the circumscribing surface of the handle as viewed transversely.
Fig. 4B illustrates diagrammatically the same matters illustrated in Fig. PA in detailed and cross-sactional view but in different positions causing a wedged state of being, such that a rotation of the handle rotates the drive shaft (and also illustrating the angle of the slanted surfaces).

DETAILED DESCRIPTION

Figs. 1, PA, BAA, 2B, PA, 3B, 3C, ED, PA and 4B
all illustrate a common embodiment of the invention and accordingly, identical and corresponding indicia are shown in more than one Figure where common elements are illustrated in differing views. Once an indicia in one view has been described, it normally is not repeated for other Figures.
The perspective view of Fig. 1 illustrates broadly the outward appearance of the novel ratchet wrench 5 having a head 6 and a handle end 7.
The Fig. PA cross-sectional view of the head 6 shows collectively the stack of consecutive plates 8 driven by, directly or indirectly, the shaft 9 and 3~l5 l portions pa and 9b thereon as illustrated in Figs. PA, 3B and 3C. Portion pa is squared and has plate 16 with its square hole 16b formed by hole plate edges aye, such that plate 16 revolves with the shaft 9. In contrast, each of plates 17 and 18 merely revolve around -the rounded portion 9b of the shaft 9. The shaft 9 is driven by the teeth 10 being acted upon by teeth 11 of gear element 12 that it driven by action on its beveled ; teeth 13 by bevel gear teeth aye of bevel gear 14 mounted fixedly upon drive shaft 15. The socket stud 20 is continuous and integral with stud support structure lo. The stud bearing surface 21 of annular shape serves to cushion torque forces of the stud support structure during use, substantially eliminating the po~siblility of stretching or rupture of support structure portion aye. 'rho head support structure portion 22b has the female ratchet teeth 27 on the inside face thereof, and at its upper portion seats the support head top 59.
Within the circularly-shaped stud support structure 19, having a substantially flat upper face, there is a recess space 23 in its upper face having spring 28 mounted therein, with its spaced apart upwardly extending spring ends aye and 28b. A scalloped cut-out space 36 has a coil spring 25 mounted at one end within a recess 24 of the scalloped inwardly located wall of the stud support structure 19 and the other end of the spring is mounted within the paw recess eye viably best in Fig ED of the paw 26. The paw 26 has, as presently positioned, the non-ratcheting toothed portion aye held in the position shown in Figs. PA, 3C
and ED ho the clamping surface aye of the actuating key 41 of plate 18 and the ratcheting toothed portion 26b.
The clamping surfaces aye and 41b, respectively, act on the paw heads 26c and 26d of Figs. PA, 3C and ED.
Figs. PA, 3B and 3C illustrate the aperture 30 having the spring end orb mounted therein. Spring end I

1 aye is minutely in the plate aperture 38, best seen in Fig. I Space 37 in plate 16 of Fig. PA merely provides space for movement of that plate about the spring end aye. Likewise, space 31 in Fig. 3C provides space for movement of plate 18 about spring end aye.
With reruns to principally Figs. PA, PA, 3B
and 3C, the plate 16 has cut-out slot 32 with male teeth aye engaging gear 35. Cut-out slot 33 is also viably in Fig. PA. The cutout slot 33 is in plate 17 through which slot 34 is also viably, the slot 33 having female teeth aye in Fig. 3B. Non-toothed, mere space-providing slot 34 provides space for plate 18 to move freely about the gear 35. The Fig. PA plate 16 has a cut out space 37 providing room for movement of the 15 plate 16 about the spring end aye. Thus, spring end aye can relatively move in the the cut-out space 37 in direction 45 when the plate 16 is driven in direction 42, and in direction 45 when plate 17 forces its movement by revolving in direction 43. The spring end 20 aye moving in direction 45 can cause plate 1~3 to move revoltingly in direction 44 which would cause the actuating key 41 to reverse the positron of the paw 26 by the clamping surface 41b pressing against heat Dow Fig. 3B shows space 29 for movement of spring end 28b~
Plate 16 has a downwardly (inwardly) extending, radially projecting, and peripherally located, flange-like key member 39 having opposite force-transmitting faces aye and 39b shown in Figs. PA, PA, 3B, BAA, 3C and ED for portions 8'. Key member 39 can respectively act on flange or ridge (rim) structure aye extending outwardly from the stud support structure and having force receiving (pressure receiving) face aye' and the spaced apart other flange or ridge structure 40b with its pressure receiving face 40b'.
Force is transmitted from the plate 16 through key member 39 to drive -the stud 20. Thus, initial reverse I

1 turning of the shaft pa causes the plate 16 through teeth aye to rotate gear 35 which gear 35 rotates plate 17 reversing the position of the spring end aye thereby causing the spring end 28b to also reverse to thusly move plate 18 in direction 44. This concurrently causes thereby the actuating key 41 to reverse the direction of the paw 26 to become spring biased and clamped in the opposite direction.
The Honda end 7 of the ratchet wrench, as shown in Figs. 2B and 4, illustrates the drive shaft 15 against which rollers aye, 47b and 47c rest within the guide space of barrel structure 48. The rollers during normal operation and positioning roll freely with the contacting drive shaft 15 and do not become wedged wedge :15 against the irregularly shaped surfaces aye of structure 50 that is tubular in shape and mounted integrally and fixedly with and on the surrounding circumscribing handle structure 60. Even when the handle is gripped and twisted by a person the rollers do not engage or wedge at the apex locations aye where angled surfaces converge and meet. However, the twisting of the handle and turning thereof in a non-driving direction of ratcheting causes the handle structure 60 and structure 50 to be twisted by virtue of yielding elastic 0-rings 51 and 52. Because the 0-rings yield when the handle is twisted, the handle structure 60 moves out of alignment with regard to structure 22d which is a part of the support structure and with regard to the barrel structure 48 whereby the rollers tone or more) become 30 wedged as shown in Fig. 4B by movement relatively) in direction 61 by the roller aye. This motion with regard to movement by handle structure 60 and/std~ecture 50 in direction 62 thereby drives the shaft 15 in the ratcheting direction 63 (drive shaft 15).
The abutment bearing member 55 of the handle portion 7 in Fig. 2B, of annular shape, serves to hold 53~5 1 members onto the drive shaft 15 being locked into position by the horse shoe clamp (pin) 57 on the drive shaft slot 56. The end plug member 58 merely fits snugly in a wedge fit as shown (a snap-fit).
For either ratchet position, the ratchet wrench is operated to forcefully and manually move the socket stud by the oscillating movement of the handle relative to the anchored head portion. The twist of the handle in a ratcheting direction causes the ratcheting driving -functions to reverse and a continued turning beyond the intermediate reversing phase results in driving in the reverse direction as the new alternate driving direction and what heretofore was the driving direction has thusly become the new alternate ratcheting direction.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

Claims (13)

WHAT IS CLAIMED IS:

1. A ratchet wrench assembly having selectable ratcheting action for causing rotation in alternate directions, comprising:
a support structure;
a drive stud means mounted on the support structure for rotation thereon;
a gear means mounted on the support structure and coupled to said drive stud means for driving it;
a two-position ratchet means coupled to said drive stud means for allowing it relative to said support structure freedom of rotation in one of two directions, said freedom of rotation reversing its direction in response to a change in the position of said two-position ratchet means; and a drive shaft means for drivably engaging said first gear means, characterized by:
a barrel means mounted about said drive shaft means for rotatably driving it;
coupling means coupled between said gear means and said two-position ratchet means for alternating the position of the latter in response to alternate rotation of said barrel means, unidirectional rotation of said barrel means in a direction beyond that required to reverse the position of said ratchet means being thereafter operable to cause rotation of said drive stud means in the direction allowed by the freedom of rotation of said two-position ratchet means.

2. A ratchet wrench assembly according to claim 1, further characterized by:
a clutch means for bi-directionally engaging and optionally driving said drive shaft means in either of opposite directions responsive to rotating said barrel means, said clutch means being operable to disengage said drive shaft means from said barrel means and to allow said drive stud means to rotate in the relative direction allowed by said freedom of rotation without rotating said barrel means, whereby rotation of said barrel means causes it to engage and thereby drive said drive shaft means, thus eventually causing said first gear means to drive said drive stud means.

3. A ratchet wrench assembly according to claim 2, characterized in that said clutch means includes:
at least one roller mounted in rolling-contact with said drive shaft means, said barrel means having a hollow with a plurality of internal facets, said roller being positioned within the hollow of said barrel means, at least one of said facets forming a converging passage with the circumference of said drive shaft means, said drive shaft means being sized to cause said roller to become wedged between said drive shaft means and barrel means when the latter is rotated about the drive shaft means.

4. A ratchet wrench assembly according to claim 3, in which said drive shaft means includes:
a drive shaft of substantially circular cross-sectional shape transversely thereof, said roller being in rolling-contact with said drive shaft, said hollow comprising a regular prism, upon being wedged against an adjacent one of said facets, said roller having a tangent line at its point of contact with said drive shaft which is at an acute angle between about 7 degrees and about 12.5 degrees with respect to said adjacent one of said facets.

5. A ratchet wrench assembly according to claim 4, in which said acute angle ranges between about 9 degrees and 11 degrees.

6. A ratchet wrench assembly according to claim 5, in which said clutch means includes a roller-mounting structure substantially free along a major portion thereof from contact with said drive shaft and revolvably mounted on said support structure.

7. A ratchet wrench assembly according to claim 6, in which said clutch means includes a drag means between and in contact with said roller-mounting structure and said support structure for applying drag on revolving tendencies of the roller-mounting structure with respect to the support structure.

8. A ratchet wrench assembly according to claim 7, including a handle structure affixed to said barrel means, and a braking-bearing surface-material between and in con-tact with said handle structure and said portion of the support structure such that there exists drag on revolving tendencies of the handle structure with respect to the portion of the support structure.

9. A ratchet wrench assembly according to claim 1, wherein said two-position ratchet means includes:
an engageable supporting ratchet member mounted on said support structure;
a dual action ratchet member having a first portion positioned and adapted to effect ratcheting action of said drive stud means in one direction relative to said supporting ratchet member, and a second portion positioned and adapted to effect ratcheting action in another direction relative to the supporting ratchet member;

a toggle-spring having one end thereof mounted on the drive stud means and having an opposite end thereof spring-biased against the dual-action ratchet member to alternately bias its first and second portions into engagement with said supporting ratchet member; and a reversible switch means coupled to said gear means for reversing the direction of said freedom of movement of the drive stud means, said reversible switch means including a spring-biased toggle switch having a spring element with spaced opposite first and second spring ends and with a central portion rotatably mounted on and movable with said drive stud means, said first spring end being coupled to and movable alternately in opposite directions by said gear means, said two-position ratchet means including a pivotal member having a portion thereof freely moveable alternately in opposite directions and fixedly mounting said second spring end, to move with the second spring end, and the pivotal member being alternately engageable with each of said first and second portions of said dual action ratchet member for alternate movement thereof into and away from engagement with the second ratchet member, whereby alternately reverse-rotatable-turning of said barrel means shifts said dual action ratchet member alternately between a first position of ratcheting by the first portion and non-ratcheting of the second portion, and a second position of ratcheting by the second portion and non-ratcheting of the first portion.

10. A ratchet wrench assembly according to claim 1, wherein said gear means includes a tooth member rotatably mounted alongside said gear means to be driven thereby, a portion of said toothed member having affixed thereto a driving member having a tab extending toward said drive stud means and, said drive stud means including at least one key structure, said tab being positioned to engage said key structure to restrict the amount of relative rotation permitted between said toothed member and said drive stud means.

11. A ratchet wrench assembly according to claim 3 or 11, including a handle structure revolvable around a portion of the support structure and affixed to said barrel structure, and a resilient braking-bearing O-ring between and in contact with said handle structure and said portion of the support structure and positioned such that the handle structure is twistable with respect to the support structure.

12. A ratchet wrench assembly according to claim 1, wherein said coupling is characterized by:
a toothed plate coaxially and rotatably mounted about said drive stud means, said toothed plate being driven by said gear means and coupled to said two-position ratchet means.

13. A ratchet wrench assembly according to claim 12, further characterized by:
an idler means rotatably and coaxially mounted on said drive stud means and coupled between said toothed plate and said gear means for driving the former by the latter; and a spring means coupled between said toothed plate and said two-position ratchet means for biasing it into one of two positions, the position being alterable by the motion of said toothed plate.