Ratchet Wrenches

Abstract

A ratchet wrench (1) is designed such that a clutch ring (500) forms the mid part of an extremely strong laminate like structure. Under torque conditions the compression forces applied to the clutch ring (500) are substantially dissipated around its circumference (507) and inner surface (508), this inward force clamping upon the inherently strong drive outer surface (405). The resultant pseudo laminate like construction of the drive element (400), clutch (500) and housing (201, 202) enables a proportionately stronger ratchet wrench 1 of much reduced depth. The drive element (400) may be used with interchangeable inserts (408).

Claims

1. A ratchet wrench comprising: a wrench head comprising a housing having a through-hole defined by a sidewall provided with a plurality of housing ramps; a clutch ring disposed in said through-hole, said clutch ring having first and second ends each having an actuator face, an outer circumferential surface provided with a plurality of clutch transmission ramps to engage with said housing ramps and inner circumferential surface, at least a portion of said inner circumferential surface being provided with a plurality of clutch teeth; a handle having a first end received in said wrench head, said first end being provided with an actuator disposed in said through-hole between said actuator faces and at least one protrusion engageable with a biaser disposed in said wrench head; and a drive element biasing disposed in said clutch ring, said drive element having an outer surface comprising a plurality of drive teeth to engage said clutch teeth and a drive aperture configured to engage a workpiece to be driven by the ratchet wrench.

2. A ratchet wrench as claimed in claim 1, wherein said inner circumferential surface of said clutch ring has a plurality of said clutch teeth at said first end and a smooth surface portion between said clutch teeth and said second end.

3. A ratchet wrench as claimed in claim 1, wherein said actuator has a first position and a second position, in said first position a first said biaser engages a first said biasing protrusion to cause said actuator to act on said actuator face of said first end of said clutch ring to pre-bias said transmission ramps against said housing ramps so that the wrench head is configured to apply a drive torque to said workpiece in a clockwise direction and to permit reverse rotation of said housing relative to said drive element in an anticlockwise direction, and in said second position a second said biaser engages a second said biasing protrusion to cause said actuator to act on said actuator face of said second end of said clutch ring to pre-bias said transmission ramps against said housing ramps so that said wrench head is configured to apply a drive torque to said workpiece in an anticlockwise direction and permit reverse rotation of said housing relative to said drive element in a clockwise direction.

4. A ratchet wrench as claimed in claim 3, wherein in said drive torque applying directions said clutch teeth initially engage said drive teeth thereby causing said clutch transmission ramps to move up along said housing ramps to cause consistent compression of said clutch ring against said drive element.

5. A ratchet wrench as claimed in claim 5, wherein said clutch transmission ramps move down along said housing ramps to allow said clutch to expand, thereby causing said clutch teeth to disengage said drive to permit said reverse rotation.

6. A ratchet wrench as claimed in claim 3, wherein said wrench at least one biaser comprises a ball and a spring acting on said ball.

7. A ratchet wrench as claimed in claim 3, wherein said first and second biasers and the first and second biasing protrusions are configured to selectively retain said actuator in said first and second positions.

8. A ratchet wrench as claimed in claim 1, wherein said housing ramps are disposed parallel to respective facing said clutch transmission ramps for complementary engagement by relative sliding movement.

9. A ratchet wrench as claimed in claim 1, wherein said housing is comprises a top housing portion and a bottom housing portion and each of said top and bottom housing portions has housing closure protrusions and housing closure holes which interlock when said top and bottom housing portions are assembled.

10. A ratchet wrench as claimed in any claim 1, wherein said housing is provided with a seal channel and at least one seal situated within said seal channel.

11. A ratchet wrench as claimed in claim 1, wherein said housing ramps have a length in a circumferential direction of said drive element, said clutch transmission ramps have a length in said circumferential direction and said housing ramps and said clutch transmission ramps have a common ramp angle in said circumferential direction that is in the range eight to thirty degrees.

12. A ratchet wrench as claimed in claim 1, having at least 40 drive teeth.

13. A ratchet wrench as claimed in claim 1, having at least 120 drive teeth.

14. A ratchet wrench as claimed in claim 1, having a inch square drive and said housing having a depth of less than 8 mm.

15. A ratchet wrench as claimed in claim 1, having a inch square drive and said housing having a depth of less than 9 mm.

16. A ratchet wrench as claimed in claim 1, having a inch square drive and said housing having a depth of less than 12 mm.

17. A ratchet wrench comprising: a handle having opposing ends, a first said end connected with a housing, said housing having a switch recess and an inner surface defining a housing aperture, said inner surface having a plurality of housing ramps; a clutch ring having a first and second ends each having an actuator face, said clutch ring having an outer surface and an inner surface that defines an aperture, said outer surface having a plurality of transmission ramps, at least a portion of said inner surface having a plurality of clutch teeth, and at least a portion of said inner surface being smooth; a switch situated within said switch recess, said switch having an actuator situated between said actuation faces of said clutch ring, and at least one biasing protrusion; a drive element having an outer surface and an inner surface defining a drive aperture, said outer surface comprising a plurality of drive teeth, said inner surface comprising a drive engaging member, said drive element being situated within said clutch ring, and said clutch ring being situated within said housing aperture.

18. A ratchet wrench comprising: a handle having opposing ends, said first end connected with a housing, said housing having a switch recess and an inner surface defining a housing aperture, said inner surface having a plurality of housing ramps; a clutch ring having a first end and second end each having an actuator face, said clutch ring having an outer surface and an inner surface defining an aperture, said outer surface having a plurality of transmission ramps, and at least a portion of said inner surface being smooth; a switch situated within said switch recess, said switch having an actuator situated between said actuation faces of said clutch ring, and at least one biasing protrusion; a drive element having an outer surface and an inner surface that defines a drive aperture, said inner surface comprising a drive engaging member, said drive element being situated within said clutch ring, and said clutch ring being situated within said housing aperture.

19. A ratchet wrench as claimed in claim 18, wherein said drive aperture is configured directly engage fasteners.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order that the invention may be well understood, some embodiments, which are given by way of example only, will now be described with reference to the drawings, in which:

[0040] FIG. 1 is a perspective view of the compact ratchet wrench;

[0041] FIG. 2 is a perspective view of the ratchet wrench with a switch;

[0042] FIG. 3 is an exploded perspective view of the ratchet wrench of FIG. 1;

[0043] FIG. 4 is an exploded perspective view of the ratchet wrench of FIG. 2;

[0044] FIG. 5 is a top view of the ratchet wrench of FIG. 1

[0045] FIG. 6 is an enlargement of the circle portion in FIG. 5;

[0046] FIG. 7 is an enlargement of the ratchet wrench of FIG. 1 with a handle end engaging a clutch ring;

[0047] FIG. 8 is a top view of the ratchet wrench of FIG. 2;

[0048] FIG. 9 is an enlargement of the circled portion in FIG. 8;

[0049] FIG. 10 is a perspective view of a drive element for the ratchet wrench of FIG. 1;

[0050] FIG. 11 is a perspective view of a drive element for the ratchet wrench of FIG. 2;

[0051] FIG. 12 is a perspective view of a clutch ring of the ratchet wrenches of FIGS. 1 and 2;

[0052] FIG. 13 is a top view of a portion of another ratchet wrench;

[0053] FIG. 14 is a top view of yet another ratchet wrench;

[0054] FIG. 15 is a part sectioned enlargement of a switch of the ratchet wrench of FIG. 14;

[0055] FIG. 16 is an enlargement of the ratchet wrenches showing a clutch ring engaging a drive element; and

[0056] FIG. 17 is a perspective view of the ratchet wrench of FIG. 1 fitted with a drive insert shown engaging a fastener.

DETAILED DESCRIPTION

[0057] The drawings are not necessarily to scale and, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as being limiting, but merely as a basis for the claims.

[0058] FIG. 1 illustrates an embodiment of a pass through ratchet wrench 1, denoting a handle 30 at one end and a housing 200 with a drive element 400 with its drive aperture 406 at the other end. A drive insert 408 with its engaging means 409 and fastener engaging means 410 shown separate from the ratchet wrench 1, the ratchet wrench 1 is at rest.

[0059] FIG. 2 illustrates a further embodiment of a said pass through ratchet wrench 1 wherein the drive direction D is effected by a switch 70, denoting the said handle 30 at one end and the housing 200 with a said central drive element 400 at the other end. The ratchet wrench 1 is shown is at rest.

[0060] FIG. 3 is a perspective view of the pass through ratchet wrench 1, the parts shown dismantled for display purposes. The top housing 201, bottom housing 202, housing aperture 203, spring and ball channel 204, dust seal channel 205, housing inner surface 208, pivot pin recess 209, housing closure protrusion 210, housing closure holes 211, housing closure holes 211, housing fixing holes 213, housing dust seals 214, housing outer surface 219, housing opening 220 and housing countersunk holes 221. The said handle 30, handle pivot pin 31, handle pivot bore 32, biasing protrusion 33, actuator 34 and levered end 35. The drive element 400, drive teeth 401, drive engaging member 411 and drive inner surface 412. Clutch ring 500, clutch toothed portion 501, clutch smooth portion 504 and clutch aperture 511. The spring 60, ball 61, screw fixings 91 and alternative rivet fixing 92 with their centre holes 93 are further shown.

[0061] FIG. 4 illustrates a further embodiment of a said pass through ratchet wrench 1 wherein the drive direction D is effected by a said switch 70. The said bottom housing 202 is directly attached to the said handle 30, the said top housing 201 being secured by a retaining clip 90 within the drive retaining clip channel 404, the parts are shown dismantled for display purposes. The said drive 400 having a retaining flange 407, said teeth 401, drive axle 403 and said engaging member 411. The said clutch ring 500, said toothed portion 501, said smooth portion 504, outer surface 507 and clutch aperture 511. The said top and bottom housing 201, 202 having a drive flange recess 215. The said top housing 201 having a further switch axle bore 217 and the said bottom housing 202 having an adjoining housing switch axle recess 216. The said switch 70 having switch axles 72, biasing protrusions 73, actuator 74 and finger grip 71. In use the switch 70 is operated in the required direction, the said biasing protrusions 73 acting with the said springs and balls 60, 61 to resiliently urge the switch actuator 74 against the corresponding clutch actuation face 509.

[0062] FIG. 5 illustrates the pass through ratchet wrench 1 operated in the drive direction D, the said top housing 201 (not shown) removed showing the said bottom housing 202 inner face 222. The handle 30 swivelled in the required said drive direction D around the said pivot pin 31, the resilient action of the said spring and balls 60, 61 upon the said biasing protrusions 33 urging the said actuator 34 against the said clutch actuation face 509. The said drive element 400 is shown within the said clutch ring 500 and a said drive insert 408 within the said drive element 400. The closure of the said top and bottom 201,202 housings is attained by the illustrated rivet upstands 212.

[0063] FIG. 6 is a close up view of the said pass through ratchet wrench 1 clutch toothed portion 501 teeth 510 engaged within corresponding drive teeth 401, the said drive teeth 401 having flat tops 402. The said clutch rings 500 engagement with the said drive element 400 robustly enhanced by the inward projection of the said clutch ring 500 as the clutch transmission ramps 502 and abutment angles 505 abutting the housing ramps 206 and contact angles 207 are driven upwards against one another as the said ratchet 1 is operated in the drive direction D.

[0064] FIG. 7 is a close up view of the said pass through ratchet mechanism 1 said housing 200, the said top housing 201 removed (not shown). The handle levered end 35 and said head portion 200 rotating as required around the said handle pivot pin 31, operated in the reverse or reposition direction R, the said handle protrusions 33 causing the said springs and balls 60,61 to be resiliently propelled back up the said spring and ball channel 204 thereby causing the said actuator 34 to reduce or release its pressure against the said clutch actuation face 509, the said clutch transmission ramps 502 no longer abutting the corresponding said housing ramps 206 thereby disengaging the clutch teeth 510 from the drive outer surface 405 and allowing the said head portion 200 to rotate relative to the said drive element 400, said drive insert 408 and its operated fastener 80.

[0065] FIG. 8 is a top view of a switch 70 version of the said ratchet wrench 1, the top housing 201 removed. The said housing 200 is directly attached to the said handle 30, the said clutch ring 500 and said drive element 400 are also shown.

[0066] FIG. 9 is a close up view of the switch 70 version of the said pass through ratchet wrench 1 denoting the said switch 70 with its said biasing protrusions 73 and its actuators 74 interaction with the clutch actuation faces 509. The spring and balls 60, 61 providing the biasing of the clutch ring 500 in the required drive direction D. The biasing spring 60 resilient force being transmitted via the switch biasing protrusion 73 then said actuator 74 to the said clutch actuation face 509 within the tail portion 506.

[0067] FIG. 10 is the drive element 400 showing the drive teeth 401 within the drive outer surface 413, drive axles 403 and said drive engaging member 411.

[0068] FIG. 11 is a further iteration of the said drive element 400 complete with a retaining flange 407, comprising said drive teeth 401, said drive axle 403, said retaining clip channel 404, drive outer surface 405, said drive aperture 406 and said drive engaging member 411.

[0069] FIG. 12 is the said clutch ring 500 comprising, a said toothed portion 501, said transmission ramps 502, aperture 503, said smooth portion 504, said abutment angle 505, tail portion 506, said outer surface 507, inner surface 508 and said actuation faces 509.

[0070] FIG. 13 is a top view of the said pass through ratchet wrench 1, said housing 200, the said top housing 201 removed (not shown). The handle 30 and said head portion 200 rotating as required around the said handle pivot pin 31, operated in the said drive direction D, the said springs and balls 60,61 resiliently acting on the said handle protrusions 33 causing the said actuator 34 to resiliently act against the said clutch actuation face 509 thereby urging the said clutch toothed portion 501 in best practice affixed the said clutch tail portion 506 to engage the said corresponding drive element teeth 401. This initial grip further allows the said clutch ramp abutment angle 505 to act upon the said housing ramps contact angle 207 forcefully constricting the said clutch ring 500 said toothed 501 and smooth portions 504 upon the said drive element 400. The compression and locking force increasing according to the torque applied to the said handle 30. It can be observed from the illustration that during use in the said drive direction D that the housing inner surface 208 is in equal force contact with most of the said clutch outer surface 507 and the said clutch inner surface 508 is in equal force contact upon the majority of the drive outer surface 413 thereby substantially distributing the inward and outward forces evident within the said housing 200 within the circumference of the aforementioned parts. The said drive insert 408, said drive engaging means 409 and said fastener engaging means 410 are further shown.

[0071] FIGS. 14 and 15 (in section) shows an alternative switched 75 version of the pass through ratchet wrench 1, the said top housing 201 removed (not shown), the said bottom housing 202 affixed the said handle 30. The alternative switch 75 having a spring bore 76 retaining the said spring 60 and balls 61. The said balls 61 acting against the alternate biasing profile 218 in order to impose the required resilient pressure in the desired drive direction D from the said switch actuator 74 to the said clutch actuation face 509 in order to resiliently initially engage the said clutch ring 500 upon the said drive element 400.

[0072] FIG. 16 is a close up view of the pass through ratchet wrench 1 said bottom inner housing face 223. Said clutch ring 500 said inner smooth portion 504 gripping upon the said drive teeth 401 said flat tops 402. The said clutch ramp abutment angles 505 and said housing ramps contact angles 207 are shown engaged as they would be in the said drive direction D providing the desired locking pressure between the housing inner surface 208, said clutch ring 500 and the said drive element 400.

[0073] FIG. 17 illustrates the said ratchet wrench 1, the handle 30, housing 200 with a drive insert 408 within the drive element 400. A further appropriately sized fastener 80 is shown, the fastener drive surfaces 81 engaged by the said drive insert engaging means 409. The housing outer surface 219 is shown secured by said rivet fixings 92.

[0074] FIGS. 1 to 17 illustrate various examples of the ratchet wrench 1 wherein the levered end 35 of the handle 30 has, in one iteration, biasing protrusions 33 for interaction with at least one spring 60 and ball detents 61, the sprung detent 60, 61 acting to provide a direction bias and the initial grip in the required said drive direction D of the clutch ring 500 upon the central drive 400. In the ratchet wrenches rest position, the partially compressed springs 60 transmit their resilient force via the said detent balls 61 and the actuator 34 to the clutch ring 500 in order to provide the necessary initial clamping of the clutch ring 500 and to obviate any slack or play inherent in normal ratchets.

[0075] The clutch portion 500 having a said generally smooth inner surface 504 with in best practice a said toothed 501 tail portion 506 and a said outer surface 507 with said ramp like protrusions 502 corresponding to said like ramps 206 within the said inner surface of the housing 208. When the said handle or drive shaft 30 is further operated in the said drive or locking direction D the said partially toothed 501 and smooth 504 inner surface 508 of the said clutch 500 having initially resiliently clamped the corresponding said toothed 401 profile of the said circumferential surface 405 of the said driven member 400 in order that when additional torque is applied in the said drive direction D to the said handle 30 or drive shaft (not shown) the said clutch portion 500 is further urged inwards as the said clutch ramp protrusions 502 usefully engage the corresponding said inner housing ramps 206, further propelling the said inner surface 508 of the said clutch ring 500 inwards upon the said outer surface 405 of the said central drive portion 400 and if required its said drive insert 408 enabling the said engaged fastener 80 to be robustly driven. In order to optimise the said clutch 500 initial said inner surface 508 grip upon the corresponding said drive portion 400 said outer circumference 405 the said toothed portion 501 of the said clutch 500 has said teeth 510 which interlock with the similar pitch and profile of the said drive teeth 401.

[0076] Operating the handle 30 in said reverse or reposition direction R the said actuator 34 releases its initial or direction biasing force clamping the said clutch inner surface 508 upon the said drive element circumference 405 provided by the said detent resilient portion 60,61 acting to free the said clutch ring 500 from the said drive portion outer circumference 405. The action of the said drive portion 400 being rotated against the clamping friction of the said clutch ring 500 further rotates the said clutch outer ramps 502 away from the said corresponding housing ramps 206 allowing the said clutch ring 500 to expand negating the grip of the said clutch ring 500 upon the said driven member drive surface 405 usefully allowing the said drive portion 400 to be said reversed or repositioned R. The magnitude of the clutch 500 engaging spring force is directionally proportionate to that of the detent resilient portion 60, to that end the clutch ring 500 generally requires to be thin in section and made from resilient material like high grade spring steel. The ratchet wrench 1 is designed such that the said clutch ring 500 forms the mid part of an extremely strong laminate like structure, under torque conditions the resultant compression forces applied to the said clutch ring 500 are substantially dissipated around its said circumference 507. The resultant pseudo laminate like construction of the said drive 400, clutch 500 and housing 201, 202 enables a proportionately far stronger or alternately a thinner lighter device.

[0077] The invention expressly comprises a pass thru ratchet wrench 1 wherein the said drive element 400 can have further drive inserts 408 fitted. In one example the said drive inner surface 412 could engage and operate say a 19 mm fastener, by the advantageous use of further said drive inserts 408 many said further fastener head sizes 410 and types can be operated utilising the same said ratchet wrench 1 whilst usefully retaining a low said housing 200 profile.