Tool with ratchet mechanism

Abstract

Various designs for ratchet mechanisms and tools incorporating ratchet mechanisms are provided. One embodiment relates to a ratchet in which each layer of the gear set includes teeth that are rotationally offset from each other, thereby increasing the number of circumferentially spaced gear tooth surfaces available for engagement with the pawl teeth. Another embodiment relates to a ratchet having a plurality of pawls arranged in series, such that the pawls are circumferentially spaced around the gear.

Description

Technical Field

[0001] This invention generally relates to the field of tools. [Related Applications] This application relates to U.S. Provisional Application No. 63 / 388,027, filed July 11, 2022; U.S. Provisional Application No. 63 / 288,972, filed December 13, 2021; and the non-provisional application No. 63 / 243,294, filed September 13, 2021, the disclosures of which are incorporated herein by reference in their entirety. Prior Technology

[0002] This invention generally relates to the field of tools. Specifically, it relates to a tool with a ratchet mechanism, such as a ratchet, a combination wrench with a ratchet mechanism, a socket wrench with a ratchet mechanism, a screwdriver with a ratchet mechanism, etc. The ratchet mechanism is used for the torsional or rotational movements of various tools, typically for driving fastener components (e.g., nuts, bolts, screws, etc.), and allows the tool or tool handle to rotate relative to the fastening component to reset the handle position without driving the fastening assembly or disengaging the tool from the fastening assembly. Summary of the Invention

[0003] One embodiment of the present invention relates to a driving tool. The driving tool includes a body with a bore, a workpiece engagement surface coupled to the body, and a ratchet mechanism supported by the body within the bore and coupled to the workpiece engagement surface. The ratchet mechanism includes a gear coupled to the workpiece engagement surface and including gear teeth. The ratchet mechanism also includes a pawl structure. The pawl structure includes a first pawl having first pawl teeth and a first radially outward surface. The pawl structure also includes a second pawl having second pawl teeth and a second radially outward surface. The second pawl is arranged in series with the first pawl such that the first and second pawls are circumferentially spaced around the gear and configured to engage the gear. The ratchet mechanism includes a biasing component coupled to the first and second pawls. The first pawl includes a central protrusion located on a surface facing the second pawl. The central protrusion extends toward the second pawl and acts as a central fulcrum. The first pawl also includes a side protrusion located on the first radially outward surface. The side protrusion extends toward the inner surface of the hole and acts as a lateral fulcrum, such that when a force is applied to the first pawl, the load is evenly distributed across the entire first pawl tooth.

[0004] Another embodiment of the present invention relates to a driving tool. The driving tool includes a body including a bore, a workpiece engagement surface coupled to the body, and a ratchet mechanism supported by the body within the bore and coupled to the workpiece engagement surface. The ratchet mechanism includes a gear structure coupled to the workpiece engagement surface and including gear teeth. The ratchet mechanism also includes a pawl structure. The pawl structure includes a first pawl having first pawl teeth and a first radially outward surface. The pawl structure includes a second pawl having second pawl teeth and a second radially outward surface. The second pawl is arranged in series with the first pawl such that the first and second pawls are circumferentially spaced around the gear structure and configured to engage the gear teeth. The ratchet mechanism includes a biasing component coupled to the first and second pawls. The first pawl includes a central protrusion located on a surface facing the second pawl. The central protrusion extends toward the second pawl and acts as a central fulcrum. The first pawl also includes a side protrusion having an engagement surface disposed on the first radially outward surface. The side protrusion extends toward the inner surface of the bore and acts as a lateral fulcrum, such that when the first pawl engages the inner surface of the bore, the engagement surface of the side protrusion contacts the inner surface of the bore.

[0005] Another embodiment of the present invention relates to a driving tool. The driving tool includes a body including a bore, a workpiece engagement surface coupled to the body, and a ratchet mechanism supported by the body within the bore and coupled to the workpiece engagement surface. The ratchet mechanism includes a gear structure coupled to the workpiece engagement surface and including gear teeth. The ratchet mechanism also includes a pawl structure. The pawl structure includes a first pawl having first pawl teeth and a first radially outward surface. The pawl structure includes a second pawl having second pawl teeth and a second radially outward surface. The second pawl is arranged in series with the first pawl such that the first pawl and the second pawl are circumferentially spaced around the gear structure and configured to engage the gear teeth. The ratchet mechanism includes a biasing component coupled to the first pawl and the second pawl. The first pawl includes a side protrusion having an engagement surface disposed on the first radially outward surface. The side protrusion extends toward the inner surface of the hole and serves as a lateral fulcrum, such that when the first pawl engages the inner surface of the hole, the engaging surface of the side protrusion contacts the inner surface of the hole.

[0006] Another embodiment of the present invention relates to a driving tool. The driving tool includes a body including a bore, a workpiece engagement surface coupled to the body, and a ratchet mechanism supported within the bore and coupled to the workpiece engagement surface. The ratchet mechanism includes a gear structure coupled to the workpiece engagement surface and including gear teeth. The ratchet mechanism also includes a pawl structure. The pawl structure includes a first pawl having first pawl teeth and a first radially outward surface. The pawl structure includes a second pawl having second pawl teeth and a second radially outward surface. The second pawl is arranged in series with the first pawl such that the first and second pawls are circumferentially spaced around the gear structure and configured to engage the gear teeth. The ratchet mechanism includes a biasing component coupled to the first and second pawls. The first pawl includes an intermediate protrusion disposed together with the engagement surface, which is disposed on a surface facing the second pawl. The intermediate protrusion extends toward the second pawl and acts as a central fulcrum, such that when the second pawl engages the first pawl, the engaging surface of the intermediate protrusion contacts the second radially outward surface.

[0007] Another embodiment of the present invention relates to a driving tool. The driving tool includes a body, a workpiece meshing surface coupled to the body, and a ratchet mechanism supported by the body and coupled to the workpiece meshing surface. The ratchet mechanism includes a gear structure coupled to the workpiece meshing surface. The gear structure includes a top having gear teeth and a bottom having gear teeth. A circumferential distance between adjacent gear teeth defines the gear tooth spacing. The ratchet mechanism also includes a pawl structure. The pawl structure includes a first pawl having a first pawl tooth and a second pawl having a second pawl tooth. The second pawl is connected in series with the first pawl such that the first and second pawls are circumferentially spaced around the gear structure and configured to engage the top of the gear structure. The pawl structure also includes a third pawl having a third pawl tooth and a fourth pawl having a fourth pawl tooth. The fourth pawl is arranged in series with the third pawl, such that the third and fourth pawls are circumferentially spaced around the gear structure and internally configured to engage the bottom of the gear structure. A circumferential distance between adjacent pawl teeth defines the pawl tooth pitch. The ratchet mechanism includes a biasing component coupled to the first, second, third, and fourth pawls. The bottom gear tooth is rotatably biased relative to the top gear tooth by 1 / 2 of the gear tooth pitch. The first pawl tooth is rotatably biased relative to the second pawl tooth by 1 / 4 of the pawl tooth pitch. The third pawl tooth is rotatably biased relative to the fourth pawl by 1 / 4 of the pawl tooth pitch.

[0008] Another embodiment of the present invention relates to a driving tool. The driving tool includes a body, a workpiece meshing surface coupled to the body, and a ratchet mechanism supported by the body within a bore and coupled to the workpiece meshing surface. The ratchet mechanism includes a gear coupled to the workpiece meshing surface, the gear having gear teeth. The ratchet mechanism also includes a pawl structure. The pawl structure includes a first pawl having first pawl teeth and a first radially outward surface. A plurality of tooth root surfaces are disposed between the first pawl teeth. Each tooth root surface is disposed between a counterclockwise facing surface of the first pawl tooth and a leading surface of an adjacent first pawl tooth. The pawl structure also includes a second pawl having second pawl teeth and a second radially outward surface. The second pawl is arranged in series with the first pawl such that the first and second pawls are circumferentially spaced around the gear and configured to mesh with the gear. A plurality of tooth root surfaces are disposed between the second pawl teeth. Each tooth root surface is disposed between the counter-clockwise facing surface of the second pawl tooth and the leading surface of an adjacent second pawl tooth. The ratchet mechanism includes a biasing component coupled to the first pawl and the second pawl. The first pawl tooth angle is defined between a first plane bisecting the tooth root surface and the leading surface of the adjacent first pawl tooth. The second pawl tooth angle is defined between a second plane bisecting the tooth root surface and the leading surface of the adjacent second pawl tooth.

[0009] Another embodiment of the present invention relates to a driving tool. The driving tool includes a body, a workpiece meshing surface coupled to the body, and a ratchet mechanism supported by the body and coupled to the workpiece meshing surface. The ratchet mechanism includes a gear structure coupled to the workpiece meshing surface. The gear structure includes a top having gear teeth and a bottom having gear teeth. A circumferential distance between adjacent gear teeth defines the gear tooth spacing. The ratchet mechanism also includes a pawl structure. The pawl structure includes a first pawl having first pawl teeth and a second pawl having second pawl teeth. The second pawl is arranged in series with the first pawl such that the first and second pawls are circumferentially spaced around the gear structure and configured to engage the top of the gear structure. The pawl structure also includes a third pawl having third pawl teeth and a fourth pawl having fourth pawl teeth. The fourth pawl is arranged in series with the third pawl, such that the third and fourth pawls are circumferentially spaced around the gear structure and configured to engage the bottom of the gear structure. The circumferential distance between adjacent pawl teeth defines the pawl tooth pitch. The ratchet mechanism includes a biasing component coupled to the first, second, third, and fourth pawls. The bottom gear teeth are rotatably biased relative to the top gear teeth by 1 / 4 of the gear tooth pitch. The first pawl tooth is rotatably biased relative to the second pawl tooth by 1 / 2 of the pawl tooth pitch. The third pawl tooth is rotatably biased relative to the fourth pawl by 1 / 2 of the pawl tooth pitch.

[0010] Another embodiment of the invention relates to a tool. The tool includes a tool body comprising a workpiece engagement surface and a ratchet mechanism coupled to the workpiece engagement structure. The ratchet mechanism includes a gear structure having a plurality of gear teeth and a first pawl and a second pawl arranged in series. The first pawl and the second pawl are circumferentially spaced around the gear. In this embodiment, each pawl includes teeth that are rotatably offset from each other. In a particular embodiment, the ratchet mechanism further includes third and fourth pawls forming a pawl layer stacked beneath the first and second pawls, wherein these pawls are also either in series or circumferentially spaced around the gear. In another particular embodiment, the deflector of the ratchet mechanism may be a single integral material piece, such that all four pawls are spring-loaded by a single deflector.

[0011] In a particular embodiment, the ratchet mechanism includes a gear or sprocket and a pawl with two sets of teeth. When the pawl is loaded toward the center, a central set of pawl teeth engages, while when the ratchet mechanism is flipped and engaged toward the side, a second set of side teeth engages. The central and side teeth are biased to increase the number of circumferentially spaced gear teeth available for engagement with the pawl teeth.

[0012] In one embodiment, the ratchet mechanism includes a pawl that remains stationary when the gear or sprocket floats within the tool head under the loading of the eccentric member. In another embodiment, the pawl is a pair of stationary pawls stacked together to engage the eccentric gear.

[0013] In a particular embodiment, the ratchet mechanism includes a first or front pawl and a second or central pawl arranged in series. The front pawl includes a side fulcrum that engages with a bore in the tool body and an intermediate fulcrum that engages with the central pawl. The positions of the intermediate fulcrum and the side fulcrum are configured to allow for a uniform load distribution on the pawl teeth. In another particular embodiment, the pawl includes steeper pawl teeth, which are constructed to allow for a greater pawl load capacity.

[0014] Additional features and advantages will be set forth in the detailed description below, and in part will be readily apparent from the description or to those skilled in the art through practice of the embodiments described in the written description and claims and the accompanying drawings. It should be understood that the foregoing general description and the following detailed description are exemplary.

[0015] The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain the principles and operation of the various embodiments. Simple Explanation of the Diagram

[0016] This application will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, wherein the same element symbols represent the same elements, wherein:

[0017] [Figure 1] is a perspective view of a tool including a ratchet mechanism according to an exemplary embodiment.

[0018] [Figure 2] is a perspective view of the ratchet mechanism of the tool according to the exemplary embodiment of Figure 1.

[0019] [Figure 3] is an exploded view of the ratchet mechanism according to an exemplary embodiment of Figure 2.

[0020] [Figure 4] is a cross-sectional view of the ratchet tool of Figure 1 according to an exemplary embodiment, showing that the ratchet mechanism of Figure 2 is installed in the tool body.

[0021] [Figure 5] is a top view showing a ratchet mechanism installed in the tool body according to another exemplary embodiment.

[0022] [Figure 6] is a cross-sectional view of the ratchet tool of Figure 1, showing a ratchet mechanism installed in the tool body according to another exemplary embodiment.

[0023] [Figure 7] is a perspective view of the ratchet mechanism of Figure 6 according to an exemplary embodiment.

[0024] [Figure 8] is a detailed plan view showing the lower part of the ratchet mechanism of Figure 6 according to an exemplary embodiment.

[0025] [Figure 9] is a detailed plan view showing the upper part of the ratchet mechanism of Figure 6 according to an exemplary embodiment.

[0026] [Figure 10] is a perspective view of the ratchet tool of Figure 1, showing a ratchet mechanism installed in the tool body according to another exemplary embodiment.

[0027] [Figure 11] is a detailed plan view showing the ratchet mechanism of Figure 10 according to an exemplary embodiment.

[0028] [Figure 12] is a detailed plan view showing the upper part of the reversible ratchet mechanism according to an exemplary embodiment.

[0029] [Figure 13] is a detailed plan view showing the lower part of the reversible ratchet mechanism of Figure 12 according to an exemplary embodiment.

[0030] [Figure 14] is a top view showing a reversible ratchet mechanism according to another exemplary embodiment.

[0031] [Figure 15] is a top view showing a tool including a ratchet mechanism according to another exemplary embodiment.

[0032] [Figure 16] is a cross-sectional view showing the engagement between the gear and the pawl of the ratchet mechanism of Figure 15 according to an exemplary embodiment.

[0033] [Figure 17] is a plan view of the gear of the ratchet mechanism according to the exemplary embodiment of Figure 6.

[0034] [Figure 18] is a perspective view of a ratchet mechanism according to another exemplary embodiment.

[0035] [Figure 19] is a plan view of the gear of the ratchet mechanism of Figure 18 according to an exemplary embodiment.

[0036] [Figure 20] is a perspective view of a ratchet mechanism according to another exemplary embodiment.

[0037] [Figure 21] is an exploded view of the ratchet mechanism of Figure 20 according to an exemplary embodiment.

[0038] [Figure 22] is a cross-sectional view of a ratchet tool, showing that the ratchet mechanism of Figure 20 according to an exemplary embodiment is mounted in the tool body.

[0039] [Figure 23] is a detailed plan view showing the ratchet mechanism of Figure 20 according to an exemplary embodiment in a first loading state.

[0040] [Figure 24] is a detailed plan view showing the ratchet mechanism of Figure 20 according to an exemplary embodiment in a second loading state.

[0041] [Figure 25] is a detailed plan view showing a first pawl with a side pivot position according to an exemplary embodiment.

[0042] [Figure 26] is a detailed plan view showing a first pawl with a side pivot position according to another exemplary embodiment.

[0043] [Figure 27] is a graph showing the maximum torque of the first pawl at various side pivot positions of the present disclosure, plotted according to an exemplary embodiment with respect to the angular deflection of the first pawl.

[0044] [Figure 28] is a detailed plan view showing the tooth angle of the pawl according to an exemplary embodiment.

[0045] [Figure 29] is a graph showing the maximum torque of the pawl for various tooth angle embodiments of this disclosure, plotted relative to the pawl angle deflection according to an exemplary embodiment.

[0046] [Figure 30] is a perspective view of a reversible ratchet mechanism according to another exemplary embodiment.

[0047] [Figure 31] is an exploded view of the ratchet mechanism of Figure 30 according to an exemplary embodiment.

[0048] [Figure 32] is a detailed perspective view showing the upper part of the reversible ratchet mechanism of Figure 30 according to an exemplary embodiment in the engaged position.

[0049] [Figure 33] is a detailed perspective view showing the upper part of the reversible ratchet mechanism of Figure 30 according to an exemplary embodiment in the disengaged position. Implementation

[0050] Referring generally to the drawings, various embodiments of ratchet mechanisms for tools are shown and described. Ratchet mechanisms are typically used in various tools to transmit torque to workpieces (e.g., components of fasteners, such as nuts, bolts, screws, etc.). In various embodiments, the ratchet mechanisms discussed herein provide a high level of engagement between the components of the ratchet mechanism during driven rotation (e.g., during restricted rotation during which the ratchet mechanism transmits torque from the tool body / tool ​​handle to the workpiece), such that forces are distributed across multiple engagement surfaces during use. Furthermore, the components of the various embodiments of the ratchet mechanism are configured relative to the tool body such that the tool body provides a high level of support for the components of the ratchet mechanism during drive. Both tool body support and the high level of engagement of the ratchet components are considered to provide a high level of durability for the ratchet mechanism.

[0051] In an exemplary embodiment, the ratchet mechanism includes a gear or sprocket formed by multiple layers of similarly shaped annular structures stacked on top of each other. The ratchet mechanism also includes multiple layers of pawls stacked on top of each other. In such an embodiment, each layer of the gear stack includes teeth that are rotatably biased towards each other. This rotatability increases the number of circumferentially spaced gear tooth surfaces available for engagement with the pawl teeth, which in turn reduces the amount of backlash.

[0052] In another exemplary embodiment, the ratchet mechanism includes a gear or sprocket having a plurality of pawls arranged in series. The pawls are circumferentially spaced around the gear. In such an embodiment, each pawl includes teeth that are rotationally offset from each other. This rotational offset increases the number of circumferentially spaced pawl surfaces available for engagement with the gear teeth, which in turn reduces backlash.

[0053] In one particular embodiment, the ratchet mechanism includes gears or sprockets formed from multiple layers of similarly shaped annular structures stacked on top of each other. The ratchet mechanism also includes layers of pawls stacked on top of each other, wherein the pawls are either tandem or circumferentially spaced around the gears. In such embodiments, in addition to the pawls being rotationally biased relative to each other, each layer of the gear set includes teeth that are rotationally biased relative to each other. This combination of rotational biases increases the number of circumferentially spaced gear tooth surfaces available for engagement with the pawl teeth, which in turn reduces backlash. In one particular embodiment, the actuating element of the ratchet mechanism can be a single, monolithic material (e.g., a metal piece) such that all four pawls are spring-loaded by a single actuating element. A single actuating element improves tooling efficiency and ease of assembly.

[0054] In another specific embodiment, the ratchet mechanism includes a gear or sprocket formed by multiple layers of similarly shaped annular structures stacked on top of each other. The ratchet mechanism also includes multiple layers of pawls stacked on top of each other, wherein the pawls are also connected in series or circumferentially spaced around the gears. The ratchet mechanism includes a switching mechanism such that the ratchet mechanism is reversible, allowing tightening in both clockwise and counterclockwise directions.

[0055] In an exemplary embodiment, the ratchet mechanism includes a gear or sprocket and a pawl with two sets of teeth. When the pawl is loaded toward the center, one set of pawl teeth engages, while when the ratchet mechanism is flipped and engaged toward the side, a second set of teeth engages. The center and side teeth are biased to increase the number of circumferentially spaced gear teeth available for engagement with the pawl teeth, while maintaining a small arcuate oscillation.

[0056] In an exemplary embodiment, the ratchet mechanism includes a pawl or a stacked pawl that remains stationary while the gear or sprocket floats within the tool head under the loading of the eccentric member.

[0057] Referring to FIG1, a tool (e.g., wrench 10) according to an exemplary embodiment is shown. In the illustrated embodiment, wrench 10 is a combination wrench comprising a tool body 12, an open-end wrench end 14, and a ratchet head or end 16. The ratchet head 16 is formed by a generally annular portion 18 of the tool body 12, which surrounds and supports the wrench engagement surface 20. It will be understood that, in use, the wrench engagement surface 20 engages a component of a workpiece (e.g., a fastener, bolt, nut, etc.), and the tool body 12 serves as a handle and lever to apply torque to the component. Wrench 10 includes a ratchet mechanism 22 supported within the tool body 12, and the ratchet mechanism 22 provides ratcheting action to the wrench engagement surface 20.

[0058] Typically, the ratchet mechanism 22 is a mechanical structure that allows the tool body 12 to rotate freely or unrestricted about the engagement surface 20 in a first direction (as indicated by arrow 24) and allows restricted or driven rotation of the tool body 12 about the engagement surface 20 in a second direction 26. Typically, during rotation in the unrestricted direction 24, the ratchet mechanism 22 allows the tool body 12 to rotate about the engagement surface 20 (and about the fastening member located within the engagement surface 20) without transmitting torque to the engagement surface 20, and during rotation in the restricted direction 26, the ratchet mechanism 22 prevents the tool body 12 from rotating freely about the engagement surface 20 (and about the fastening member located within the engagement surface 20), such that the torque applied to the tool body 12 is transmitted to the engagement surface 20 and applied to the fastening member located within the engagement surface 20. In some embodiments, as described below, the tool 10 includes a reversible ratchet mechanism with a switching element that allows the user to switch or select which rotation direction is the driven direction and which rotation direction is the unrestricted direction.

[0059] Referring to Figure 2-4, the components of the ratchet mechanism 22 are shown in detail. In the orientation of Figure 2-4, the ratchet mechanism 22 includes a sprocket or gear 30. The gear 30 is a generally annular or ring-shaped structure, including an inner surface defining an opening in which a meshing surface 20 is located. The outer surface of the gear 30 includes an upper or first portion 34, which is stacked on a lower or second portion 36. The upper portion 34 and the lower portion 36 of the gear 30 each include a plurality of teeth 32 extending radially outward from the gear 30. The teeth 32 of the upper portion 34 are offset relative to the teeth 32 of the lower portion 36.

[0060] The ratchet mechanism 22 includes an engagement structure, shown as an upper pawl 38 or a first pawl 38, and a lower pawl 40 stacked below the upper pawl 38. The upper pawl 38 and the lower pawl 40 each include an upper radially outward surface 39 and a lower radially outward surface 41, respectively. The upper and lower radially outward surfaces 39, 41 extend in a generally circumferential direction. Each of the upper pawl 38 and the lower pawl 40 includes a plurality of teeth 42, 44 opposite to the upper and lower radially outward surfaces 39, 41. The upper pawl 38 and the lower pawl 40 also include clockwise facing surfaces 46, 48 having recesses 50, 52 for receiving a biasing element (shown as springs 54, 56). The springs 54, 56 are received within the recesses 50, 52 and bias and / or move the upper pawl 38 and the lower pawl 40 to engage them, providing the required biasing and flexibility to provide the ratchet motion described herein.

[0061] Referring to Figure 4, details of the ratchet mechanism 22 relative to the tool body 12 are shown. The tool body 12 defines a longitudinal axis or median axis 60. Typically, the upper pawl 38 and the lower pawl 40 are positioned on one side of the median axis 60. The tool body 12 includes a recess 58, which is shaped to receive the upper pawl 38 and the lower pawl 40. The upper and lower radially outward surfaces 39, 41 face and engage with the inner surface 59 of the recess 58.

[0062] When the tool body 12 is rotated in the direction of arrow 24, the teeth 42 of the upper pawl 38 and the teeth 44 of the lower pawl 40 engage with the gear teeth 32 of the upper 34 and lower 36, respectively. The spacing and shape of the pawl teeth 42, 44 relative to the gear teeth 32 cause the upper pawl 38 and the lower pawl 40 to deflect after engagement between the pawl teeth 42, 44 and the gear teeth 32. Springs 54, 56 deflect the upper pawl teeth 42 and the lower pawl teeth 44 into the space before the next gear tooth 32 of the upper 34 and lower 36 of the gear 30. Multiple sets of pawl teeth 42, 44 allow for a better / more uniform load distribution on the surfaces of these pawl teeth during drive engagement (i.e., when the tool is rotated in the direction of arrow 26).

[0063] As rotation continues in direction 24, pawl teeth 42 and 44 respectively engage with and slide on adjacent gear teeth 32 of the upper part 34 or lower part 36 of gear 30. Due to the spacing and relative shape of pawl teeth 42, 44 and gear teeth 32, springs 54, 56 bend or deflect during rotation in direction 24 when pawl teeth 42, 44 and gear teeth 32 are engaged. As pawl teeth 42, 44 pass over clockwise adjacent gear teeth, the elasticity / spring action of springs 54, 56 deflects pawl teeth 42, 44 into the space preceding the next gear tooth 32 as rotation in direction 24 continues.

[0064] When the rotation stops in direction 24 and the tool body begins to rotate in the direction of arrow 26, the workpiece can be engaged and driven. In various embodiments, the pawl teeth 42, 44 have a relative spacing to each other such that the maximum backlash distance is reduced (i.e., the maximum distance the leading pawl tooth must travel before engaging gear tooth 32 during the drive rotation, e.g., in the direction of arrow 26). In a particular embodiment, the lower pawl 40 is spaced apart from the upper pawl 38 to engage gear tooth 32 in increments of 1 / 4 to 3 / 4 of the tooth arc length / width, particularly 3 / 8 to 5 / 8 of the tooth arc, and more specifically 1 / 2 of the tooth arc length / width. In a particular embodiment, the angular spacing between the teeth of the lower pawl 40 and the upper pawl 38 is between 1 degree and 4 degrees, specifically between 2 degrees and 3 degrees, and more specifically 2.5 degrees. The offset of the teeth 42 of the upper pawl 38 and the teeth 44 of the lower pawl 40 allows for a reduction in rotational distance and time before engagement occurs.

[0065] Referring to Figure 5, another embodiment including a ratchet mechanism 122, which can be used with the wrench 10, is shown. As shown in Figure 5, the ratchet mechanism 122 includes a sprocket or gear 130. The gear 130 is a generally annular or ring-shaped structure that includes an inner surface that defines an opening within which the meshing surface 120 is located. In a particular embodiment, the gear 130 includes a single layer of teeth, which is schematically shown as gear teeth 132 extending radially outward from the gear 130.

[0066] The ratchet mechanism 122 includes an engagement structure, shown as a first pawl 138 and a second pawl 140 arranged in series with the first pawl 138 (i.e., circumferentially spaced apart rather than stacked around the gear 130). The first pawl 138 has a radially outward surface 139 whose geometry matches the inner surface 159 of a recess 158 for receiving the first and second pawls 138 and 140. The first pawl 138 also includes an intermediate engagement surface 162, which is positioned near the central axis 160 of the wrench 10. The intermediate engagement surface 162 is adjacent to the engagement surface 164 of the second pawl 140. This configuration wedges the first pawl 138 between the gear 130 and the inner surface 159, similar to a standard ratchet mechanism. The second pawl 140 wedges between the first pawl 138 and the gear 130, positioned against the inner surface 159.

[0067] The first pawl 138 and the second pawl 140 each include a plurality of teeth 142 and 144 opposite to the radially outward surfaces of the pawls 138 and 140. The radially outward surface 139 of the first pawl 138 receives a biasing member shown as a spring 154. The second pawl 140 also includes a clockwise surface 148 that receives a biasing member (shown as a spring 156). The springs 154 and 156 bias the first pawl 138 and the second pawl 140 into engagement, providing the necessary biasing and flexibility to provide the ratcheting motion discussed herein.

[0068] The ratchet mechanism 122 is similar to the ratchet mechanism 22 in that, during unrestricted rotation in direction 24, the ratchet mechanism 122 allows the tool body 12 to rotate about the engagement surface 120 (and about the fastening member located within the engagement surface 120) without transmitting torque to the engagement surface 120. During restricted rotation in direction 26, the ratchet mechanism 122 prevents the tool body 12 from rotating freely about the engagement surface 120 (and about the fastening member located within the engagement surface 120), such that the torque applied to the tool body 12 is transmitted to the engagement surface 120 and to the fastening member located within the engagement surface 120. In a particular embodiment, the first pawl 138 and the second pawl 140 are spaced apart to engage the gear teeth 132 with incremental tooth arc length / widths of 1 / 4 to 3 / 4, particularly 3 / 8 to 5 / 8, and more specifically, 1 / 2, tooth arc length / width. The first pawl 138 and the second pawl 140 engage the gear 130 with a half-tooth increment to produce a 144-pawl / gear engagement.

[0069] Referring to Figures 6-9, another embodiment including a ratchet mechanism 222, which can be used with a wrench 10, is shown. Generally, the ratchet mechanism 222 is substantially the same as the ratchet mechanism 122, except for the differences discussed herein. The ratchet mechanism 222 includes a sprocket or gear 230. The gear 230 is a generally annular or ring-shaped structure including an inner surface that defines an opening within which an engagement surface 220 is located. In one specific embodiment, the gear 230 includes a stack of teeth 232 extending radially outward from the gear 130. The outer surface of the gear 230 includes an upper or first portion 234 stacked on a lower or second portion 236. The teeth 232 of the upper portion 234 and the teeth 232 of the lower portion 236 are offset from each other.

[0070] The ratchet mechanism 222 includes an engagement structure, shown as an upper pawl or first pawl 238 and a lower pawl or second pawl 240 stacked below the upper pawl 238. The first pawl 238 and the second pawl 240 each include an upper radially outward surface 239 and a lower radially outward surface 241, respectively. The upper and lower radially outward surfaces 239 and 241 extend in a generally circumferential direction. Each of the first pawl 238 and the second pawl 240 includes a plurality of teeth 242 and 265 opposite to the upper and lower radially outward surfaces 239 and 241. Each of the first and second pawls 238 and 240 also includes deflecting surfaces 246 and 248, respectively, defining a receiving hole 250 for deflecting elements (shown as springs 254 and 256).

[0071] The ratchet mechanism 222 includes a third pawl 235 and a fourth pawl 237, respectively, arranged in series with the first pawl 238 and the second pawl 240 (i.e., circumferentially spaced rather than stacked around the gear 230). The third and fourth pawls 235 and 237 each include a second upper radially outward surface 262 and a second lower radially outward surface 264. Each of the second upper radially outward surface 262 and the second lower radially outward surface 264 includes a hole 252 for receiving a biasing element (shown as springs 255 and 257). Each of the third and fourth pawls 235 and 237 includes a plurality of teeth 244 and 266 opposite to the second upper and second lower radially outward surfaces 262 and 264.

[0072] The surfaces 239 and 241 of the first and second pawls 238 and 240 have a geometry that matches the inner surface 259 of the groove 258 accommodating the first, second, third, and fourth pawls 138, 240, 235, and 237. The first pawl 238 also includes an intermediate engagement surface 268, which is positioned close to the central axis 260 of the wrench 10. The intermediate engagement surface 268 is designed to receive and fully engage the curved engagement surface 270 of the third pawl 235 (i.e., the intermediate engagement surface 268 has a corresponding shape to match the curved engagement surface 270 and engage along the entire surface). The second pawl 240 also includes an intermediate engagement surface 269 positioned close to the central axis 260 of the wrench 10. The intermediate engagement surface 269 is designed to receive and fully engage the curved engagement surface 271 of the fourth pawl 237. In one particular embodiment, the engagement increment between the pawl teeth and the gear teeth is between 1 / 16 and 1 / 2 of the tooth arc length / width, specifically between 1 / 8 and 3 / 8 of the tooth arc length / width, and more specifically 1 / 4 of the tooth arc length / width. In one particular embodiment, this construction, which includes a combination of stacking and the use of wedges in the ratchet mechanism 122, produces a quarter-tooth engagement increment, resulting in 288 pawl / gear engagement positions.

[0073] Referring to Figures 10-11, another embodiment of a ratchet mechanism 322 that can be used with wrench 10 is shown. Generally, ratchet mechanism 322 is substantially the same as ratchet mechanism 222, except for the differences discussed herein. Ratchet mechanism 322 includes a deflector 350, which is configured to deflect all four pawls 338, 340, 335, and 337. The deflector 350 is a single, integral piece of material (e.g., metal). In a particular embodiment, the deflector 350 may be formed by stamping. As shown in Figure 10, all four pawls 338, 340, 335, and 337 are spring-loaded by a single deflector 350. This single deflector improves tool efficiency and ease of assembly.

[0074] The biasing member 350 includes a body 352, four arms 354, 356, and a bent end 360. A first pair of biasing arms 354 engages with first and second pawls 338 and 340 along first and second biasing surfaces 346 and 348. A second pair of biasing arms 356 engages with third and fourth pawls 335 and 357 along third and fourth biasing surfaces 362 and 364. The bent end 360 of the biasing member 350 extends from the body 352 into a radially outward curve that engages with the inner surface 359 of the bore 358.

[0075] Referring to Figures 12-13, another embodiment including a ratchet mechanism 422, which can be used with the wrench 10, is shown. Generally, the ratchet mechanism 422 is substantially the same as the ratchet mechanism 222, except for the differences discussed herein. Figure 12 shows the upper portion of the ratchet mechanism 422, while Figure 13 shows the lower portion configuration of the ratchet mechanism 422. In another embodiment, the pawl configuration can be switched such that the lower portion of the ratchet mechanism is configured as shown in Figure 12 and the upper portion as shown in Figure 13. The ratchet mechanism 422 also includes a switching element, schematically shown as element 474. When the user pushes the switching element 474 into the reverse position, the bottom of the ratchet mechanism 422 becomes internally engaged.

[0076] In this opposite configuration, the second pawl 440 becomes the portion wedged into abutting the inner surface 459 opposite to the first pawl 438, wherein the fourth pawl 437 acts as a wedge, engaging with the intermediate engagement surface 482 of the second pawl 440 via an intermediate engagement surface 480. In a particular embodiment, the engagement increment between the pawl teeth and the gear teeth is between 1 / 4 and 3 / 4 of the tooth arc length / width, specifically between 3 / 8 and 5 / 8 of the tooth arc length / width, more specifically 1 / 2 of the tooth arc length / width. In a particular embodiment, this configuration, which includes stacked and tandem wedges combined with switching elements used in the ratchet mechanism 222, forms a reversible mechanism including half-tooth engagement increments, resulting in 144 pawl / gear engagement positions.

[0077] Referring to Figure 14, another embodiment including a ratchet mechanism 522, which can be used with the wrench 10, is shown. The ratchet mechanism 522 can be used with both reversible and irreversible ratchet mechanisms. Figure 14 shows a switching mechanism 550 in which the lever 552 is in the reverse position. The ratchet mechanism 522 includes a first pawl 538 having a central plurality of teeth 542 and a lateral plurality of teeth 543. A second pawl 540 similarly includes a central plurality of teeth 544 and a lateral plurality of teeth 545. When the central teeth 544 of the second pawl 540 engage with gear teeth 532 (gear schematically shown as 530), the lateral teeth 543 of the first pawl 538 are also engaged. Similarly, when the central teeth 542 of the first pawl 538 engage with gear teeth 532, the lateral teeth 545 of the second pawl 540 also engage with gear teeth 532.

[0078] The first and second pawls 538, 540 include a first radially outward surface 539 and a second radially outward surface 541. The first and second radially outward surfaces 539, 541 extend in a generally circumferential direction. Each of the first pawl 538 and the second pawl 540 includes a plurality of central teeth 542, 544 opposite to the first and second radially outward surfaces 539, 541. Each of the first and second pawls 538, 540 also includes deflecting surfaces 546 and 548, which define holes for receiving deflecting elements (shown as springs 554 and 556). In a particular embodiment, the central and side teeth of the first and second pawls 538, 540 engage gear teeth 532 with incremental tooth arc length / widths between 1 / 2 and 6 / 2, particularly between 1 / 2 and 3 / 2, and even more particularly 1 tooth arc length / width. In one particular embodiment, the central tooth and the side tooth are offset by one tooth to obtain 144 pawl / gear engagement positions while maintaining a 2.5° arc swing.

[0079] Referring to Figures 15-16, another embodiment including a ratchet mechanism 622 for use with the wrench 10 is shown. The ratchet mechanism 622 includes a gear 630 that floats within the ratchet head 16 of the wrench 10 and is spring-loaded by a biasing element 654 (e.g., a leaf spring or diving board), such that the gear 630 applies a load back in the direction of the pawl 638 to engage the pawl 638. The ratchet head 16 includes an inner surface 650 surrounding the gear 630.

[0080] The pawl 638 is stationary and centered on the central axis 660 of the tool body 12. The ratchet head 16 includes a bore 658 for receiving the pawl 638. The bore 658 includes an inner surface 659 that interacts with a first side surface 639 and an opposing side surface 641 of the pawl 638. The pawl 638 includes two protrusions 640 opposite to the pawl teeth 642, which distribute the load from the gear 630. In a particular embodiment, the tooth angle is less than 90° to prevent slippage between the gear 630 and the pawl 638. The tooth profile of the gear 630 is defined as D1. The slot or space between the gear 630 and the tool body 12 is defined as D2. D2 is greater than D1, such that the gear 630 can be deflected by the deflecting element 654 to engage with the pawl 638.

[0081] In one embodiment, gear 630 includes a single layer and pawl 638 includes a single layer of pawl teeth 642. In another embodiment, gear 630 may include a top having a plurality of teeth 632 and a bottom having a plurality of teeth 632 to engage top and bottom pawls.

[0082] Referring to FIG16, a cross-sectional view showing the meshing between gear teeth 632 and pawl teeth 644 according to an exemplary embodiment is shown. The meshing of pawl teeth 644 with gear teeth 632 is a top-and-bottom type meshing.

[0083] Referring to Figures 17-19, detailed views of the gear tooth pitch, or GTS, according to an exemplary embodiment are shown. When used herein, GTS is the circumferential or angular distance between adjacent gear teeth, as shown, for example, in Figures 17 and 19. The ratchet mechanism discussed herein includes a pitch designed to reduce the distance the pawl teeth must travel to engage with the gear teeth as the tool body rotates in the drive direction, thus reducing backlash. Furthermore, the applicant has achieved four different tooth pitches using only three uniquely shaped components, in contrast to many ratchet mechanisms with a standard ratchet consisting of four pawls offset by 1 / 4 from each other and a row of five uniquely shaped components. This design with a reduced number of uniquely shaped components reduces manufacturing costs and allows for more efficient production compared to conventional ratchet mechanisms with more uniquely shaped components.

[0084] Referring to FIG17, a detailed plan view of a portion of the ratchet mechanism 222 according to an exemplary embodiment is shown. As described above, the gear 230 includes an upper portion 234 and a lower portion 236, wherein a plurality of teeth 232 of the upper portion 234 and a plurality of teeth 232 of the lower portion 236 are offset from each other. In a particular embodiment, the offset pitch or circumferential distance between the teeth 232 of the upper portion 234 and the teeth 232 of the lower portion 236 is between 2 / 5 GTS and 3 / 5 GTS, more specifically approximately 1 / 2 GTS.

[0085] Table 1 below describes specific embodiments of gear tooth spacing and pawl tooth spacing for a ratchet mechanism (e.g., ratchet mechanism 222) including a gear comprising upper and lower parts stacked together and four pawls stacked and connected in series. To further reduce backlash, the pawl tooth spacing, circumferential distance, or angular distance between adjacent pawl teeth is also selected. As shown in Figure 7, the first pawl 238 and the third pawl 235 are arranged in series. Similarly, the second pawl 240 and the fourth pawl 237 are arranged in series.

[0086] In this embodiment, the pawl tooth spacing between the first pawl 238 and the third pawl 235 is between 1 / 8 and 3 / 8, more specifically about 1 / 4. Similarly, the pawl tooth spacing between the second pawl 240 and the fourth pawl 237 is between 1 / 8 and 3 / 8, more specifically about 1 / 4. The distance from the front surface of one of the pawl teeth to the nearest adjacent meshing surface of one of the gear teeth is approximately 1 / 4. As can be seen from Table 1, the combination of GTS and pawl tooth spacing produces a ratchet mechanism with an effective tooth pitch, which the applicant believes reduces backlash.

[0087] Referring to Figures 18-19, another embodiment including a ratchet mechanism 722, which can be used with the wrench 10, is shown. The ratchet mechanism 722 includes a sprocket or gear 730. The gear 730 is a generally annular or ring-shaped structure including an inner surface that defines an opening within which an engagement surface 720 is located. The outer surface of the gear 730 includes an upper or first portion 734 that stacks on a lower or second portion 736. The teeth 732 of the upper portion 734 are offset relative to the teeth 233 of the lower portion 736. In a particular embodiment, the offset pitch or circumferential distance between the teeth 732 of the upper portion 734 and the teeth 233 of the lower portion 736 is between 1 / 5 GTS and 2 / 5 GTS, more specifically, approximately 1 / 4 GTS.

[0088] The ratchet mechanism 722 includes a first pawl 738 and a second pawl 740, which are arranged in series (i.e., circumferentially spaced rather than stacked around the gear 730) and engage with the upper portion 734 of the gear 730. A third pawl 735 is stacked below the first pawl 738 and engages with the lower portion 736 of the gear 730. A fourth pawl 737 is stacked below the second pawl 740 and also engages with the lower portion 736 of the gear 730.

[0089] Table 2 below describes specific embodiments of gear tooth spacing and pawl tooth spacing for a ratchet mechanism (e.g., ratchet mechanism 722) having a gear comprising upper and lower parts stacked together and four pawls stacked and connected in series. To further reduce backlash, the pawl tooth spacing, circumferential distance, or angular distance between adjacent pawl teeth is also selected. As shown in Figure 18, the first pawl 738 and the second pawl 740 are arranged in series. Similarly, the third pawl 735 and the fourth pawl 737 are arranged in series.

[0090] In this embodiment, the pawl tooth spacing between the first pawl 738 and the second pawl 740 is between 2 / 5 and 3 / 5, more specifically, about 1 / 2. Similarly, the pawl tooth spacing between the third pawl 735 and the fourth pawl 737 is between 2 / 5 and 3 / 5, more specifically, about 1 / 2. As can be seen from Table 2, the combination of the pawl tooth spacing of the GTS and the ratchet mechanism 722 produces a ratchet mechanism with an effective tooth spacing, which the applicant believes reduces backlash.

[0091] Referring to Figures 20-23, an additional embodiment of a ratchet mechanism (shown as ratchet mechanism 822) for use with a tool (e.g., wrench 10) is shown. The applicant believes that, compared to conventional ratchet mechanisms with full engagement (see, for example, Figures 8-9, where the intermediate engagement surface has a shape corresponding to the engagement surfaces of the tandem pawls), the pawl device discussed herein with limited engagement (i.e., engagement at specific points and / or fulcrums) between tandem pawls provides improved performance for ratchet mechanisms. Specifically, the applicant believes that the limited engagement and arrangement of the intermediate and lateral fulcrums on the pawls allows for a uniform load distribution on the pawl teeth. The applicant believes that this uniform load distribution allows for reduced wear and / or damage on the pawl teeth, while also increasing the peak load capacity of the pawl (i.e., the pawl can withstand greater loads). In another specific embodiment, the applicant believes that using a steeper pawl tooth angle (i.e., a reduced angle) allows for an increase in the load capacity of the pawl.

[0092] The ratchet mechanism 822 includes a sprocket or gear 830. The gear 830 is a generally annular or ring-shaped structure including an inner surface that defines an opening within which an engagement surface 820 is located. In a particular embodiment, the gear 830 comprises a single layer (i.e., not stacked) including a plurality of teeth 832 extending radially outward from the gear 830. The ratchet mechanism 822 includes an engagement structure shown as a first pawl or front pawl 838 and a second or central pawl 840, which is arranged in series with the first pawl 838 (i.e., circumferentially spaced rather than stacked around the gear 830) and centered relative to the first pawl 838.

[0093] The first pawl 838 includes a first radially outward surface 839. The second pawl 840 includes a second radially outward surface 841. The first and second radially outward surfaces 839 and 841 extend in a generally circumferential direction. The first pawl 838 and the second pawl 840 each include a plurality of teeth 842 and 844 on the surfaces opposite to the first radially outward surface 839 and the second radially outward surface 841, respectively. As shown in Figures 21-23, each pawl 838 and 840 also includes counterclockwise deflecting surfaces 846 and 848, respectively, which define holes 850 and 852 for receiving deflecting elements (shown as springs 854 and 856).

[0094] The engagement structure of the ratchet mechanism 822 also includes a biasing assembly 860. The biasing assembly 860 includes a body 862 having a bent end 864. One end of the body 862 opposite the bent end 864 includes a first arm 866 extending from the body 862 away from it in a generally radial direction toward a first pawl 838. A second arm 868 extends inwardly from the body 862 toward a second pawl 840. Each spring 854, 856 includes a first end configured to couple and / or engage with holes 850 and 852 respectively, and a second end configured to couple and / or engage the first arm 866 and the second arm 868 of the biasing assembly 860.

[0095] The applicant believes that the use of the biasing assembly 860 provides a reduction in the reverse ratchet torque. Compared to a one-piece single-leaf spring biasing element (which can become stiff in smaller sizes, resulting in a large spring load that prevents the ratchet mechanism from smoothing), the use of a one-piece body 862 combined with springs 854 and 856 provides improved performance.

[0096] Referring to Figure 22, details of the ratchet mechanism 822 relative to the tool body 12 are shown. The tool body 12 defines a longitudinal axis, center axis, or intermediate axis 870, which extends longitudinally through the center of the tool body 12 between opposite ends of the tool. Typically, a first pawl 838 is positioned on one side of the intermediate axis 870, while a second pawl 840 extends across the intermediate axis 870. The tool body 12 includes a recess or hole 858 shaped to receive the first pawl 838 and the second pawl 840. A first radially outward surface 839 faces and engages with the inner surface 859 of the hole 858. A curved end 864 of the biasing assembly 860 extends from the body 862 into a radially outward curve that engages with the inner surface 859 of the hole 858.

[0097] Typically, the ratchet mechanism 822 is a mechanical structure that allows the tool body 12 to rotate freely or unrestricted about the engagement surface 820 in a clockwise direction (as indicated by arrow 824), and allows restricted or driven rotation of the tool body 12 about the engagement surface 820 in a counterclockwise direction 826. Typically, during rotation in the unrestricted direction 824, the ratchet mechanism 822 allows the tool body 12 to rotate about the engagement surface 820 (and about the fastening member located within the engagement surface 820) without transmitting torque to the engagement surface 820, and during rotation in the restricted direction 826, the ratchet mechanism 822 prevents the tool body 12 from rotating freely about the engagement surface 820 (and about the fastening member located within the engagement surface 820), such that the torque applied to the tool body 12 is transmitted to the engagement surface 820 and the fastening member located within the engagement surface 820.

[0098] Referring to Figure 23, the ratchet mechanism 822 is shown in a first loaded state. In the first loaded state (central loaded state), when the pawl tooth 844 of the second pawl 840 engages with the gear tooth 832, the second pawl 840 engages with the first pawl 838 (i.e., interacts and / or abuts against each other). In the first loaded state, only the second pawl 840 is fully engaged with the gear tooth 832 and the second pawl 840 is loaded against the first pawl 838. In the first loaded state, the load is guided by and / or applied by the second radially outward surface 841 of the second pawl 840 to the intermediate or inner protrusion 872, which serves as a fulcrum. The intermediate protrusion 872 is provided on the inward surface 873 of the first pawl 838 (i.e., facing the second pawl 840 and / or gear 830) and extends toward the second pawl 840. In one particular embodiment, the intermediate protrusion 872 has a concave engagement surface such that the engagement between the first pawl 838 and the second pawl 840 is located at the concave engagement surface of the intermediate protrusion 872 (i.e., limited engagement compared to a conventional pawl with full-surface engagement). The intermediate protrusion 872 is an integral protrusion that defines the contact position and contact area between the first pawl 838 and the second pawl 840. Compared to the previously described ratchet mechanism (see, for example, Figures 6-11), the contact area between the first pawl 838 and the second pawl 840 is reduced due to the limited engagement.

[0099] The inward-facing surface 873 includes a shovel-shaped notch or recessed portion with a central protrusion 872 (i.e., recessed relative to the remainder of the inward-facing surface 873) and an engagement surface extending from the shovel-shaped notch. The inward-facing surface 873 also includes a substantially horizontal portion (i.e., 180 degrees ± 10 degrees) below the central protrusion 872 before transitioning to the end portion. The end of the inward-facing surface 873 connects to the first radially outward-facing surface 839. The substantially horizontal portion lies between the central protrusion 872 and the end.

[0100] The concave engagement surface of the intermediate protrusion 872 provides limited engagement or contact between the intermediate protrusion 872 and the first pawl 838. As previously stated, the applicant believes that the limited engagement and positioning of the intermediate and side protrusions on the pawl allow the load to be evenly distributed on the pawl teeth, which reduces wear and / or damage to the pawl teeth, while also increasing the peak load capacity of the pawl (i.e., the pawl can withstand greater loads).

[0101] Referring to Figure 24, the ratchet mechanism 822 is shown in a second loaded state. In the second loaded state, the front pawl 838 engages with the gear 830 (i.e., the pawl teeth 842 interact with and / or abut against each other). During the second loaded state, the first pawl 838 carries and / or receives a larger portion and / or all of the load driven by the gear 830 when the second pawl 840 is in clearance (see, for example, the second pawl 840 in Figure 22). As the peak load on the ratchet increases, the clearance and / or space between the second pawl 840 and the first pawl 838 decreases and eventually disappears, causing the second pawl 840 to also carry and / or receive a portion of the load. When in the second loaded state, the load is directed and / or applied to the side protrusions or outer protrusions 874 of the first pawl 838 located on the first radially outward surface 839 and extends toward the bore 858. The side protrusion 874 acts as a fulcrum (i.e., pivot point) between the first pawl 838 and the inner surface 859 of the hole 858.

[0102] In one particular embodiment, the side protrusion 874 has a laterally concave engagement surface such that the engagement between the first pawl 838 and the inner surface 859 of the bore 858 is located at the laterally concave engagement surface of the side protrusion 874 (i.e., limited engagement, compared to a conventional pawl with full surface engagement). Specifically, the first radially outward surface 839 does not have full or complete surface engagement with the inner surface 859 of the bore 858.

[0103] The side protrusions extend toward the inner surface 859 of the hole 858 and act as lateral fulcrums, such that when the first pawl 838 engages the inner surface 859 of the hole 858, the engaging surface of the side protrusions 874 contacts the inner surface 859 of the hole 858. In various embodiments, both the intermediate protrusion 872 and the side protrusions 874 have a concave shape (i.e., extending outward) relative to the corresponding surface of the first pawl 838.

[0104] The applicant believes that the pawl configuration with limited engagement (i.e., engagement at specific points and / or fulcrums) between the first pawl 838 and the second pawl 840 shown in Figures 23-24 provides improved performance compared to a conventional ratchet mechanism 822 with full engagement (see, for example, Figures 8-9, where the intermediate engagement surface has a shape corresponding to the engagement surfaces of the tandem pawls). Specifically, the applicant believes that the limited engagement and arrangement of the intermediate protrusion and side protrusions 872, 874 on the first pawl 838, which acts as the fulcrum, allows for a uniform load distribution on the pawl teeth. The applicant believes that this uniform load distribution allows for reduced wear and / or damage to the pawl teeth, increases the pawl's ability to withstand greater loads (i.e., peak load capacity or maximum torque), and reduces ratchet mechanism jamming and / or slippage.

[0105] Multiple root surfaces 878 are disposed between multiple pawl teeth 844 of the second pawl 840. Root surfaces 878 are the lower surface and / or innermost surface of a groove located between adjacent pawl teeth. Each root surface 878 is disposed between a counter-clockwise facing surface 880 of a pawl tooth 844 and a leading surface 882 of the following adjacent pawl tooth 844. When there is an even number of pawl teeth 844, there is an odd number of root surfaces 878 (i.e., 5 root surfaces 878 when there are 6 pawl teeth 844). Intermediate or central root surfaces 884 are defined as having an equal number of root surfaces 878 on each side of the central root surface 884. In a particular embodiment, there are 6 pawl teeth and 5 root surfaces. In other embodiments, there may be different numbers of pawl teeth and root surfaces (i.e., 8 pawl teeth, 7 root surfaces, etc.).

[0106] Referring to Figure 23, when the second radially outward surface 841 of the second pawl 840 engages with the inward surface 873 of the first pawl 838, the resultant load, indicated by arrow 876, is applied to the intermediate protrusion 872 of the first pawl 838. The second radially outward surface 841 of the second pawl 840 and the inward surface 873 of the first pawl 838 have complete face-to-face contact, such that the load is distributed across the entire protrusion 872. The applicant believes that when the directional load 876 is set as shown in Figure 23, the position of the intermediate protrusion 872 provides a uniform load distribution on the pawl teeth 844. The load 876 is set along a plane 886 that extends along the leading surface 882 of the pawl teeth 844, which follows the central root surface 884. The plane 886 intersects the intermediate protrusion 872 of the first pawl 838. In one particular embodiment, the plane 886 and the leading surface 882 of the ratchet tooth 844, which follows the central root surface 884, are set at an angle.

[0107] Referring to Figures 25-26, details of the location and / or position of the side protrusions 874 of the first pawl 838 according to an exemplary embodiment are shown. A plurality of root surfaces 888 are disposed between a plurality of pawl teeth 842 of the first pawl 838. Each root surface 888 is disposed between a counter-clockwise facing surface 890 of a pawl tooth 842 and a leading surface 892 following the adjacent pawl tooth 842. When the number of pawl teeth 842 is even, the number of root surfaces 888 is odd (i.e., when there are 6 pawl teeth 842, there are 5 root surfaces 888). An intermediate or central root surface 894 is defined as having an equal number of root surfaces 888 on each side of the central root surface 894. In a particular embodiment, there are 6 pawl teeth and 5 root surfaces. In other embodiments, there may be different numbers of pawl teeth and root surfaces (i.e., 8 pawl teeth, 7 root surfaces, etc.).

[0108] As shown in Figure 25, when the first radially outward surface 839 of the current pawl 838 engages with the inner surface 859 of the hole 858, the resultant force load, indicated by arrow 896, occurs along the leading surface 892 of the pawl tooth 842 following the central root surface 894. During loading, the meshing surface area is confined to the side protrusion 874. The applicant believes that when the load 896 is set as shown in Figure 25, the position of the side protrusion 874 provides improved performance in terms of uniform load distribution on the pawl tooth 842.

[0109] The resultant load 896 is disposed along a plane 898, which extends along the leading surface 892 of the pawl tooth 842 that follows the central root surface 894. The plane 898 intersects the inner surface 859 of the hole 858 at an intersection point 900. In a particular embodiment, the side protrusion 874 is located between 12 and 18 degrees below the plane 898 and / or the intersection point 900, more specifically, between 13 and 17 degrees below the plane 898 and / or the intersection point 900. In this embodiment, the side protrusion 874 is disposed approximately 15 degrees (i.e., 15 degrees ± 3 degrees) below the plane 898 and the resultant load 896.

[0110] As shown in Figure 26, in another embodiment, when the first radially outward surface 839 of the current pawl 838 engages with the inner surface 859 of the hole 858, the resultant load indicated by arrow 906 occurs along the leading surface 892 of the pawl tooth 842 following the central root surface 894. The applicant believes that when the resultant load 906 is set as shown in Figure 26, the position of the side protrusion 874 provides improved performance in terms of uniform load distribution on the pawl tooth 842. As previously stated, the applicant believes that uniform load distribution allows for reduced wear and / or damage to the pawl teeth, increased peak load capacity, and reduced likelihood of ratchet mechanism jamming and / or slippage.

[0111] The resultant load 906 is positioned along a plane 908, which extends along the leading surface 892 of the pawl tooth 842 that follows the central root surface 894. The plane 908 intersects the inner surface 859 of the hole 858 at point 910. In a particular embodiment, a side protrusion 874 is positioned between 4 and 10 degrees below the plane 908 and / or the intersection point 910, more specifically between 5 and 9 degrees below the plane 908 and / or the intersection point 910. In this embodiment, the side protrusion 874 is positioned approximately 7 degrees (i.e., 7 degrees ± 3 degrees) below the plane 908 and the resultant load 906.

[0112] Referring to Figure 27, a test data graph is plotted, showing the maximum torque of the first pawl relative to the first pawl at various side pawl positions for use in this disclosure according to the exemplary embodiments shown in Figures 25-26. Furthermore, the maximum torque of the angular deflection relative to an alternative exemplary embodiment is also shown. This alternative exemplary embodiment has a side pawl position at a lower 15-degree angle.

[0113] In one particular embodiment, when the side protrusion 874 is positioned approximately 7 degrees (i.e., 7 degrees ± 3 degrees) below the plane 908 and the resultant load 906, the maximum torque is increased. Specifically, the peak load capacity is increased by approximately 2-3% (i.e., 2% ± 1%). In another particular embodiment, when the side protrusion 874 is positioned approximately 15 degrees (i.e., 15 degrees ± 3 degrees) below the plane 898 and the resultant load 896, the maximum torque is increased.

[0114] Referring to Figure 28, a detailed plan view of the tooth angle of the pawl according to an exemplary embodiment is shown. As will be discussed in more detail below, the applicant believes that a steeper pawl tooth angle allows for increased load capacity or maximum torque of the pawl.

[0115] A portion of a ratchet mechanism 922 according to an exemplary embodiment is shown. The ratchet mechanism 922 has a pawl 938 comprising a plurality of pawl teeth 940. A plurality of root surfaces 941 are disposed between the plurality of pawl teeth 940 of the pawl 938. Each root surface 941 is disposed between a counter-clockwise facing surface 942 of a pawl tooth 940 and a leading surface 944 of the adjacent pawl tooth 940. A tooth angle is defined between a plane 946 that bisects the root surface 941 and the counter-clockwise facing surface 942 of the pawl tooth 940 adjacent to the root plane 941.

[0116] In one particular embodiment, the tooth angle is between 32 degrees and 42 degrees. In another particular embodiment, the tooth angle is approximately 42 degrees (i.e., 42 degrees ± 2 degrees). In yet another particular embodiment, the tooth angle is approximately 32 degrees (i.e., 32 degrees ± 2 degrees). In yet another particular embodiment, the tooth angle is approximately 37 degrees (i.e., 37 degrees ± 2 degrees).

[0117] Referring to Figure 29, a test data graph is plotted, showing the maximum torque of the pawl relative to the angular deflection of various tooth angles for use in this disclosure according to the exemplary embodiment shown in Figure 28. Furthermore, the maximum torque relative to the angular deflection of an alternative exemplary embodiment, which has a shallower tooth angle than the previously described tooth angle, is shown.

[0118] The applicant believes that a shallower tooth angle provides improved arc wobble (reduced arc wobble) for use in more confined working environments.

[0119] Referring to Figures 30-33, another embodiment including a ratchet mechanism 1022 is shown for use with the wrench 10. Generally, the ratchet mechanism 1022 is substantially the same as the previous ratchet mechanism, except for the differences discussed herein. Figure 30 shows a gear 1030 having stacked layers, the stack comprising an upper or first portion 1034 stacked on a lower or second portion 1036. Both the upper portion 1034 and the lower portion 1036 of the gear 1030 include a plurality of teeth 1032 extending radially outward from the gear 1030. The teeth 1032 of the upper portion 1034 and the teeth 1032 of the lower portion 1036 are offset from each other.

[0120] The ratchet mechanism 1022 includes an engagement structure shown as a first pawl or front pawl 1038 and a second or center pawl 1040, which is arranged in series with the first pawl 1038 (i.e., circumferentially spaced rather than stacked around the gear 1030) and centered relative to the first pawl 1038 (i.e., not configured to engage with the inner surface of the tool, see Figures 32-33). The ratchet mechanism 1022 also includes a third pawl 1042 and a fourth pawl 1044, which are substantially the same as the first pawl 1038 and the second pawl 1040 but in the opposite direction (i.e., the third pawl engages with the tool body). The third pawl 1042 and the fourth pawl 1044 are stacked below the first pawl 1038 and the second pawl 1040 and are configured to engage the lower portion 1036 of the gear 1030. The upper part of the ratchet mechanism 1022, especially the first and second pawls 1038 and 1040, is configured to drive in a counter-clockwise direction. The lower part of the ratchet mechanism 1022, especially the third and fourth pawls 1042 and 1044, is configured to drive in a clockwise direction.

[0121] Referring to Figure 31, an exploded view of a ratchet mechanism 1022 according to an exemplary embodiment is shown. First and second pawls 1038, 1040 engage with a camber assembly 1046, while third and fourth pawls 1042, 1044 similarly engage with camber assembly 1048. Camber assemblies 1046 and 1048 are substantially identical to camber assembly 860 and engage with a camber element, shown as a spring 1050 (see, for example, Figure 32). The ratchet mechanism 1022 also includes a front switch 1052 configured to engage or disengage the first and second pawls 1038, 1040 according to a desired drive direction. Similarly, a rear switch 1054 is configured to engage or disengage the third and fourth pawls 1042, 1044 according to a desired drive direction.

[0122] Referring to Figures 32-33, detailed perspective views are shown of the upper portion of the ratchet mechanism 1022 according to an exemplary embodiment in a first engaged position and a second disengaged position. In Figure 32, the front switch 1052 is in the disengaged position, meaning that the first and second pawls 1038, 1040 are engaged with the gear 1030. In Figure 33, the front switch 1052 has been actuated or reversed. When the front switch 1052 is reversed, the front switch engages and / or abuts against the first deflecting surface 1060 on the first pawl 1038 and the second deflecting surface 1062 on the second pawl 1040 to push and / or move the first and second pawls 1038, 1040 so that they are not in contact with the gear 1030 (i.e., the pawls are now spaced apart from the gear).

[0123] It should be understood that these figures illustrate exemplary embodiments in detail, and that this application is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology is used for descriptive purposes only and should not be considered limiting.

[0124] Given this description, those skilled in the art will understand further modifications and alternative embodiments of the invention. Therefore, this description is to be interpreted only as illustrative. The constructions and arrangements shown in the various exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, many modifications are possible without substantially departing from the novel teachings and advantages described herein (e.g., variations in the size, shape, and proportions of various elements, parameter values, mounting configurations, use of materials, color, orientation, etc.). Some elements shown as integrally formed may be composed of multiple parts or elements, the positions of elements may be reversed or otherwise altered, and the nature, number, or position of separate elements may be changed or modified. The order or sequence of any processing, logical algorithm, or method steps may be changed or reordered according to alternative embodiments. Other substitutions, modifications, alterations, and omissions may be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of the invention.

[0125] Unless otherwise expressly stated, none of the methods articulated herein shall be construed as requiring their steps to be performed in a particular order. Thus, it in no way means that any particular order can be inferred if the method request does not actually state the order in which its steps follow, or if there is no other specific statement in the request or description that the steps will be restricted to a particular order. Furthermore, as used herein, the article “a” is intended to include one or more components or elements and is not intended to be construed to denote only one. When used herein, “rigidly coupled” means that two members are coupled in such a way that the members move together in a fixed positional relationship when they are acted upon by a force.

[0126] Various embodiments of the disclosures involve any combination of any feature, and any such combination of features may be requested in this application or in a future application. Any feature, element or member of any exemplary embodiment discussed above may be used alone or in combination with any feature, element or component of any other embodiment discussed above.

[0127] For the purposes of this disclosure, the term “coupling” refers to connecting two members directly or indirectly to one another. This connection can be immovable in nature or movable in nature. Such a connection may be achieved by forming two members and any additional intermediate members into one another as a single whole, or by attaching two members or two members and any additional members to one another. This connection can be permanent, or it can be removable or releasable.

[0128] Although the present application describes specific combinations of features in the scope of the appended patent application, various embodiments of the invention relate to any combination of any of the features described herein, whether or not such combinations are currently claimed for protection, any combination of such features may be claimed in this application or in future applications. Any feature, element or member of any exemplary embodiment discussed above may be used alone or in combination with any feature, element or member of any other embodiment discussed above.

[0129] In various exemplary embodiments, relative dimensions including angle, length, and radius as shown are drawn to scale. The actual measurements of the accompanying drawings will disclose the relative dimensions, angles, and scales of various exemplary embodiments. Various exemplary embodiments are extended to various ranges in the vicinity of absolute and relative dimensions, angles, and scales that can be determined from the figure. Various exemplary embodiments include any combination of one or more relative dimensions or angles that can be determined from the diagram. In addition, actual dimensions not expressly stated in this specification may be determined by the proportion of the dimensions measured in the accompanying drawings in conjunction with those expressly stated in this specification.

[0130] 10: Wrench 12: Tool Body 14: End of open-end wrench 16: Ratchet head 18: Circular section 20: Wrench engagement surface 22: Ratchet Mechanism 24: First direction (unrestricted direction) 26: Second direction (restricted direction) 30: Gear 32: Teeth 34: Upper part or first part 36: Lower part or second part 38: Upper pawl or first pawl 40: Lower pawl or second pawl 39: Surface facing outwards in the upper radial direction 41: Surface facing outwards in the lower radial direction 42: Razor claw teeth 44: Razor claw teeth 46: Surface facing clockwise 48: Surface facing clockwise 50: concave part 52: concave part 54: Spring 56: Spring 58: concave part 60: Longitudinal axis or intermediate axis 59: Inner surface 122: Ratchet Mechanism 130: Sprockets or gears 132: Gear teeth 138: First Claw 140: Second pawl 139: Radial outward-facing surface 159: Inner surface 158: concave part 160: Central axis 162: Intermediate meshing surface 142: Ratchet teeth 144: Ratchet teeth 154: Spring 156: Spring 222: Ratchet Mechanism 220: Meshing surface 230: Sprockets or gears 232: Gear teeth 234: Upper part 236:lower part 238: First Claw 240: Second pawl 239: Surface facing outwards in the upper radial direction 241: Surface facing outwards in the lower radial direction 242: Ratchet teeth 265: Ratchet teeth 246: Eccentric Surface 248: Eccentric Surface 250: Hole 254: Spring 256: Spring 235: Third Claw 237: Fourth Claw 262: Second radially outward-facing surface 264: Second radially outward-facing surface 262: Ratchet teeth 264: Ratchet teeth 268: Intermediate meshing surface 270: Bending meshing surface 244: Ratchet teeth 266: Ratchet teeth 269: Intermediate meshing surface 271: Bending meshing surface 322: Ratchet Mechanism 350: eccentric component 338: First Claw 340: Second pawl 335: Third Claw 357: Fourth Claw 352:Ontology 354: Oscillating Arm 356: Oscillating Arm 360: Bending end 346: First eccentric surface 348: Second offset surface 362: Third offset surface 364: Fourth Eccentric Surface 358: Kong 359: Inner surface 422: Ratchet Mechanism 474: Switching component 438: First Claw 437: Fourth Claw 459: Inner surface 480: Intermediate meshing surface 482: Intermediate meshing surface 522: Ratchet Mechanism 550: Switching mechanism 552: Leverage 542: Center tooth 545: Side teeth 544: Center tooth 543: Side teeth 538: First Claw 540: Second pawl 532: Gear teeth 539: First radially outward-facing surface 541: Second radially outward surface 546: First eccentric surface 548: Second Eccentric Surface 554: Spring 556: Spring 622: Ratchet Mechanism 630: Gear 654: Shaking element 638: Thorn Claw 660: Central axis 658: Kong 659: Inner surface 639: First side surface 641: Opposite side surface 640: Protrusion 642: Ratchet teeth 632: Gear teeth 644: Ratchet teeth GTS: Gear tooth pitch 720: Meshing surface 722: Ratchet Mechanism 730: Sprockets or gears 734: Upper part or first part 736: Lower or Second Part 732: Gear teeth 738: First Claw 740: Second pawl 734: Upper part or first part 736: Lower or Second Part 735: Third Claw 737: Fourth Claw 822: Ratchet Mechanism 830: Sprockets or gears 832: Gear teeth 838: First pawl or front pawl 840: Second pawl or central pawl 839: First radially outward-facing surface 841: Second radially outward surface 842: Ratchet teeth 844: Ratchet teeth 846: Deflecting surface facing counterclockwise 848: Deflecting surface facing counterclockwise 850: Hole 852: Kong 854: Spring 856: Spring 860: Shake assembly 862:Ontology 864: Bending end 866: First Arm 868: Second Arm 870: Central axis 859: Inner surface 824: Unrestricted direction 826: Restricted Direction 820: Meshing surface 872: Middle or inner protrusion 873: Inward-facing surface 874: Lateral or external protrusion 858: Kong 878: Tooth root surface 880: Surface facing counterclockwise 882: Leading surface 884: Center tooth root surface 876: Resultant Load 886: Plane 888: Tooth root surface 890: Surface facing counterclockwise 892: Leading surface 894: Center tooth root surface 896: Resultant load 898: Plane 906: Resultant Load 908: Plane 910: Intersection 922: Ratchet Mechanism 938: Thorn Claw 940: Ratchet teeth 941: Tooth root surface 942: Surface facing counterclockwise 944: Leading surface 946: Plane 1022: Ratchet Mechanism 1030: Gear 1032: Gear teeth 1034: Upper part or first part 1036: Lower part or second part 1038: First pawl or front pawl 1040: Second pawl or central pawl 1042: Third Claw 1044: Fourth Claw 1046: Shaking component 1048: Bias Component 1050: Spring 1052: Front Switching Unit 1054: Rear Switch 1060: First eccentric surface 1062: Second eccentric surface

Claims

1. A driving tool, comprising: a body including a bore; a workpiece engaging surface coupled to the body; a ratchet mechanism supported by the body within the bore and coupled to the workpiece engaging surface, the ratchet mechanism including: a gear coupled to the workpiece engaging surface, the gear including gear teeth; a pawl structure including: a first pawl including first pawl teeth and a first radially outward surface; a second pawl including second pawl teeth and a second radially outward surface, the second pawl being arranged in series with the first pawl such that the first pawl and the second pawl are circumferentially spaced around the gear and configured to engage the gear; and a biasing assembly coupled to the first pawl and the second pawl, the biasing assembly including: a biasing body including: a first end; and a... A second end opposite to the first end; a first arm disposed at the first end and extending toward the first pawl; and a second arm extending from the body toward the second pawl; a first spring extending between and engaging with the first pawl teeth; and a second spring extending between and engaging with the second pawl teeth; wherein the first pawl includes a central protrusion disposed on a surface facing the second pawl, the central protrusion extending toward the second pawl and acting as a central fulcrum, and wherein the first pawl includes a side protrusion disposed on the first radially outward surface of the first pawl, the side protrusion extending toward the inner surface of the hole and acting as a side fulcrum, such that when a force is applied to the first pawl, the load is evenly distributed across the entire first pawl teeth.

2. The drive tool of claim 1, wherein the eccentric assembly is configured such that the first pawl and the second pawl move away from the gear teeth such that the first pawl teeth and the second pawl teeth can rotate beyond the gear teeth in a first rotational direction and wherein the first pawl teeth and the second pawl teeth mesh with the gear teeth such that the first pawl teeth and the second pawl teeth are rotatably fixed relative to the gear teeth in a second rotational direction.

3. The driving tool as claimed in claim 1, wherein the eccentric body is formed from a single monolithic material.

4. The drive tool of claim 1, wherein the intermediate protrusion has a concave engagement surface such that the engagement between the second pawl tooth and the first pawl tooth is located at the concave engagement surface of the intermediate protrusion.

5. The drive tool of claim 1, wherein the side protrusion has a laterally convex engagement surface such that engagement between the first pawl and the inner surface of the bore is located at the laterally convex engagement surface of the side protrusion.

6. The drive tool of claim 1, wherein when the ratchet mechanism is in a first loaded state, the second pawl tooth engages with the gear tooth and the second radially outward surface applies a load to the intermediate protrusion of the first pawl.

7. The drive tool of claim 1, wherein when the ratchet mechanism is in a second loaded state, the first pawl tooth engages with the gear tooth and the first radially outward surface of the first pawl abuts against the inner surface of the hole, such that a load is applied to the side protrusion of the first pawl.

8. A driving tool, comprising: a body including a bore; a workpiece engaging surface coupled to the body; and a ratchet mechanism supported by the body within the bore and coupled to the workpiece engaging surface, the ratchet mechanism comprising: a gear structure coupled to the workpiece engaging surface, the gear structure including gear teeth; a pawl structure comprising: a first pawl including first pawl teeth and a first radially outward surface; a second pawl including second pawl teeth and a second radially outward surface, the second pawl being arranged in series with the first pawl such that the first pawl and the second pawl are circumferentially spaced around the gear structure and configured to engage the gear teeth; and a biasing assembly coupled to the first pawl and the second pawl, the biasing assembly comprising: a biasing body including: a first end; and a biasing component connected to the first end. The first pawl has the following components: a second end; a first arm disposed at the first end and extending toward the first pawl; a second arm extending from the body toward the second pawl; a first spring extending between and engaging with the first pawl teeth and the first arm; and a second spring extending between and engaging with the second pawl teeth and the second arm; wherein the first pawl includes a central protrusion disposed on a surface facing the second pawl, the central protrusion extending toward the second pawl and acting as a central fulcrum; and wherein the first pawl includes a side protrusion having a meshing surface disposed on the first radially outward surface of the first pawl, the side protrusion extending toward the inner surface of the hole and acting as a side fulcrum, such that when the first pawl engages the inner surface of the hole, the meshing surface of the side protrusion abuts against the inner surface of the hole.

9. The driving tool of claim 8 further includes a plurality of root surfaces disposed between the first pawl teeth, each root surface being disposed between a counterclockwise facing surface of the first pawl tooth and a leading surface of an adjacent first pawl tooth.

10. The driving tool of claim 9, wherein the first pawl includes an even number of first pawl teeth and wherein a central tooth root surface includes an equal number of tooth root surfaces on both sides thereof.

11. The drive tool of claim 10, wherein a plane is provided along the leading surface of the first pawl tooth following the root surface of the central tooth, and wherein the plane intersects with the inner surface of the hole, defining an intersection point.

12. The drive tool of claim 11, wherein the side protrusion of the first pawl is positioned between 12 and 18 degrees below the plane.

13. The drive tool of claim 11, wherein the side protrusion of the first pawl is positioned 15 degrees below the plane.

14. A driving tool, comprising: a body including a bore; a workpiece engaging surface coupled to the body; and a ratchet mechanism supported by the body within the bore and coupled to the workpiece engaging surface, the ratchet mechanism comprising: a gear structure coupled to the workpiece engaging surface, the gear structure including gear teeth; a pawl structure comprising: a first pawl including first pawl teeth and a first radially outward surface; and a second pawl including second pawl teeth and a second radially outward surface, the second pawl being arranged in series with the first pawl such that the first pawl and the second pawl are circumferentially spaced around the gear structure and configured to engage the gear teeth; and a biasing component coupled to the first pawl and the second pawl. The biasing assembly includes: a biasing body comprising: a first end; a second end opposite to the first end; a first arm disposed at the first end and extending toward the first pawl; and a second arm extending from the body toward the second pawl; a first spring extending between and engaging with the first pawl teeth; and a second spring extending between and engaging with the second pawl teeth; wherein the first pawl includes a side protrusion having an engaging surface disposed on the first radially outward surface of the first pawl, the side protrusion extending toward the inner surface of the bore and acting as a lateral fulcrum, such that when the first pawl engages the inner surface of the bore, the engaging surface of the side protrusion abuts against the inner surface of the bore.

15. The driving tool of claim 14 further includes a plurality of root surfaces disposed between the first pawl teeth, each root surface being disposed between a counterclockwise facing surface of the first pawl tooth and a leading surface of an adjacent first pawl tooth.

16. The drive tool of claim 15, wherein the first pawl includes an even number of first pawl teeth and wherein a central tooth root surface includes an equal number of tooth root surfaces on both sides thereof.

17. The drive tool of claim 16, wherein a plane is provided along the leading surface of the first ratchet tooth following the root surface of the central tooth, and wherein the plane intersects with the inner surface of the hole, defining an intersection point.

18. The drive tool of claim 17, wherein the side protrusion of the first pawl is positioned between 4 and 10 degrees below the plane.

19. The drive tool of claim 17, wherein the side protrusion of the first pawl is positioned 7 degrees below the plane.

20. A driving tool, comprising: a body including a bore; a workpiece engaging surface coupled to the body; and a ratchet mechanism supported by the body within the bore and coupled to the workpiece engaging surface, the ratchet mechanism comprising: a gear structure coupled to the workpiece engaging surface, the gear structure including gear teeth; a pawl structure comprising: a first pawl including first pawl teeth and a first radially outward surface; and a second pawl including second pawl teeth and a second radially outward surface, the second pawl being arranged in series with the first pawl such that the first pawl and the second pawl are circumferentially spaced around the gear structure and configured to engage the gear teeth; and a biasing component coupled to the first pawl and the second pawl. The biasing assembly includes: a biasing body comprising: a first end; a second end opposite to the first end; a first arm disposed at the first end and extending toward the first pawl; and a second arm extending from the body toward the second pawl; a first spring extending between and engaging with the first pawl teeth; and a second spring extending between and engaging with the second pawl teeth; wherein the first pawl includes a central protrusion configured to have an engagement surface disposed on a surface facing the second pawl, the central protrusion extending toward the second pawl and acting as a central fulcrum, such that when the second pawl engages the first pawl, the engagement surface of the central protrusion abuts against the second radially outward surface.

21. The driving tool of claim 20 further includes a plurality of root surfaces disposed between the second pawl teeth, each root surface being disposed between a counterclockwise facing surface of the second pawl tooth and a leading surface of an adjacent second pawl tooth.

22. The driving tool of claim 21, wherein the second pawl includes an even number of second pawl teeth and wherein a central tooth root surface includes an equal number of tooth root surfaces on both sides thereof.

23. The drive tool of claim 22, wherein a plane is provided along the leading surface of the second pawl tooth following the root surface of the central tooth, and wherein the plane intersects with the intermediate protrusion of the first pawl.

24. The drive tool of claim 20, wherein the surface facing the second pawl further comprises: a recessed portion from which the engagement surface of the intermediate protrusion extends; a substantially horizontal portion; and an end portion connected to the first radially outward surface, wherein the substantially horizontal portion is disposed between the end portion and the engagement surface of the intermediate protrusion.

25. A driving tool comprising: a body; a workpiece engaging surface coupled to the body; and a ratchet mechanism supported by the body within a hole and coupled to the workpiece engaging surface, the ratchet mechanism comprising: a gear coupled to the workpiece engaging surface, the gear including gear teeth; A pawl structure comprising: a first pawl, which includes a first pawl tooth and a first radially outward surface; a plurality of tooth root surfaces disposed between the first pawl tooth, each tooth root surface being disposed between a counterclockwise facing surface of the first pawl tooth and a leading surface of an adjacent first pawl tooth. A second pawl, comprising a second pawl tooth and a second radially outward surface, is connected in series with the first pawl such that the first and second pawls are circumferentially spaced around the gear and configured to mesh with the gear; a plurality of tooth root surfaces disposed between the second pawl teeth, each tooth root surface being disposed between a counter-clockwise facing surface of a second pawl tooth and a leading surface of an adjacent second pawl tooth; and a biasing assembly coupled to the first and second pawls, the biasing assembly comprising: a biasing body comprising: a first end; and a second end opposite to the first end. The body comprises: an end; a first arm disposed at the first end and extending toward the first pawl; and a second arm extending from the body toward the second pawl; a first spring extending between and engaging with the first pawl tooth and the first arm; and a second spring extending between and engaging with the second pawl tooth and the second arm; wherein a first pawl tooth angle is defined between a first plane bisecting the root surface of the tooth and the leading surface of the adjacent first pawl tooth, and wherein a second pawl tooth angle is defined between a second plane bisecting the root surface of the tooth and the leading surface of the adjacent second pawl tooth.

26. The drive tool of claim 25, wherein the angle of the first ratchet tooth is between 32 degrees and 42 degrees.

27. The drive tool of claim 25, wherein the angle of the second pawl tooth is between 32 degrees and 42 degrees.

28. The drive tool of claim 25, wherein the angle of the first pawl tooth is between 32 degrees and 42 degrees and wherein the angle of the second pawl tooth is between 32 degrees and 42 degrees.

Images