Tool accessory and manufacturing method thereof

Abstract

A tool attachment includes a drive portion configured to be engaged by an output shaft of a tool. The driving portion has a first hardness. The tool attachment further includes a tip configured to engage a workpiece. The tip has a second hardness different from the first hardness. The tool attachment further includes a handle interconnecting the drive portion and the tip. The shank has a third hardness different from the first hardness and different from the second hardness. The third hardness is between the first hardness and the second hardness, and the drive portion, the handle, and the tip are formed from a common material as a unitary body.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 459,384 filed on April 14, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to tool accessories. More particularly, the present disclosure relates to drill bit sockets and similar accessories (e.g., tool bits, drill bits, plug-in drill bits, or the like) for use with driver tools, such as power tools (e.g., impact drivers, drills, etc.) or hand-held tools (e.g., socket wrenches, socket wrench screwdrivers, etc.). Background Art

[0004] Drill sleeves and other tool accessories often must meet two competing requirements. First, the drill bit engagement surface must have sufficient wear resistance and hardness to allow a strong engagement over a reasonable life of the drill sleeve. Second, the tool shank engagement surface must have sufficient toughness and impact resistance to resist failure due to cyclic stresses (e.g., use with an impact driver). Generally speaking, high wear resistance requires high material hardness, which in turn results in lower toughness and impact resistance. Summary of the invention

[0005] In some aspects, the technology described herein relates to a tool accessory comprising: a drive portion configured to be engaged by an output shaft of a tool, the drive portion having a first hardness; a tip configured to engage a workpiece, the tip having a second hardness different from the first hardness; and a handle interconnecting the drive portion and the tip, the handle having a third hardness different from the first hardness and different from the second hardness, wherein the third hardness is between the first hardness and the second hardness, and wherein the drive portion, the handle, and the tip are formed as a single body from a common material.

[0006] In some aspects, the technology described herein relates to a tool accessory wherein the drive portion has a first toughness, wherein the tip has a second toughness different from the first toughness, wherein the handle has a third toughness different from the first toughness and different from the second toughness, and wherein the third toughness is between the first toughness and the second toughness.

[0007] In some aspects, the technology described herein relates to a tool accessory wherein the drive portion, the tip, and the shank are initially subjected to a first heat treatment to temporarily unify the hardness and toughness of the tool accessory, and wherein one of the drive portion and the tip is subsequently subjected to a second heat treatment different from the first heat treatment.

[0008] In some aspects, the technology described herein relates to a tool attachment wherein the drive portion, rather than the tip, is subjected to the second heat treatment, and wherein the amount of the shank subjected to the second heat treatment decreases from the drive portion to the tip.

[0009] In some aspects, the technology described herein relates to a tool attachment wherein the tip is subjected to the second heat treatment rather than the drive portion, and wherein the amount of the shank subjected to the second heat treatment decreases from the tip to the drive portion.

[0010] In some aspects, the technology described herein relates to a tool accessory wherein the drive portion includes a sleeve for receiving the output shaft of the tool, and wherein the sleeve has a substantially polygonal cross-section.

[0011] In some aspects, the technology described herein relates to a tool accessory wherein one of the output shaft and the drive portion includes a detent ball and the other of the output shaft and the drive portion includes a recess for receiving the detent ball, and wherein the sleeve has a substantially square cross-section.

[0012] In some aspects, the technology described herein relates to a tool attachment wherein the second heat treatment comprises induction tempering.

[0013] In some aspects, the technology described herein relates to a tool attachment wherein the first hardness is approximately 44 to 52 HRC, wherein the second hardness is approximately 57 to 62 HRC, and wherein the third hardness is approximately 46 to 62 HRC.

[0014] In some aspects, the technology described herein relates to a tool attachment wherein the first hardness is approximately 48 HRC, and wherein the second hardness is approximately 60 HRC.

[0015] In some aspects, the technology described herein relates to a tool attachment comprising: a unitary body comprising a first end, a second end opposite the first end, and an intermediate portion extending axially between the first end and the second end, the first end, the second end, and the intermediate portion being formed of a common material. The tool attachment further comprises: a first zone extending between the first end and a first side of the intermediate portion, the first zone having a first hardness; a second zone extending between the second end and a second side of the intermediate portion, the second zone having a second hardness different from the first hardness; and a transition zone between the first zone and the second zone, at least a portion of the transition zone having a hardness gradient between the first hardness and the second hardness, wherein the first side has undergone a first material treatment configured to provide the first hardness, and wherein the second side has undergone a second material treatment different from the first material treatment and configured to provide the second hardness.

[0016] In some aspects, the technology described herein relates to a tool attachment wherein the second side has undergone the first material processing and the second material processing in sequence.

[0017] In some aspects, the technology described herein relates to a tool attachment wherein the entire unitary body has been subjected to the first material treatment, and wherein only a portion of the second side and the middle portion have been subjected to the second material treatment.

[0018] In some aspects, the technology described herein relates to a tool accessory further comprising: a drive portion formed at the first end, the drive portion being configured to be engaged by an output shaft of a tool; and a tip formed at the second end, the tip being configured to engage a workpiece, wherein a desired hardness of the drive portion is different from a desired hardness of the tip.

[0019] In some aspects, the technology described herein relates to a tool accessory wherein the cross-section of the unitary body at the drive portion is different from the cross-section at the tip, such that the cross-section of the intermediate portion varies between the drive portion and the tip, and wherein the hardness gradient varies by different amounts at the center of the cross-section and at the periphery of the cross-section.

[0020] In some aspects, the technology described herein relates to a tool attachment wherein at least a portion of the profile of the hardness gradient is substantially parabolic.

[0021] In some aspects, the technology described herein relates to a tool attachment wherein the first material processing comprises heat treatment and the second material processing comprises induction tempering.

[0022] In some aspects, the technology described herein relates to a tool attachment wherein the first hardness is approximately 44 to 52 HRC, wherein the second hardness is approximately 57 to 62 HRC, and wherein the hardness of the hardness gradient varies between approximately 46 HRC and approximately 62 HRC.

[0023] In some aspects, the technology described herein relates to a method of manufacturing a tool attachment configured to be turned by a tool, the method comprising: forming a unitary body as a single piece from a common raw material; and heat treating the entire unitary body with a first heat treatment, the first heat treatment providing a first hardness that approximates the entire tool attachment. The method further comprises heat treating a portion of the unitary body with a second heat treatment that is different from the first heat treatment, the second heat treatment providing a second hardness that is less than approximate the entire tool attachment, wherein the second hardness is different from the first hardness.

[0024] In some aspects, the technology described herein relates to a manufacturing method, wherein the single body includes a first end, a second end opposite to the first end, and an intermediate portion extending axially between the first end and the second end, the method further comprising: providing the second heat treatment once the first heat treatment has been applied to the entire single body; defining a desired hardness zone in an axial direction from the second end toward the first end; and applying the second heat treatment to the second end until the second hardness in the desired hardness zone is approximately equal to the desired hardness.

[0025] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a perspective view of a tool attachment known in the art.

[0027] Figure 2 is a perspective view of a tool attachment according to one embodiment of the present disclosure.

[0028] Figure 3 yes Figure 2 A cross-sectional view of a tool attachment including profiles corresponding to the hardness and toughness of the tool attachment along the length of the tool attachment.

[0029] Figure 4A is the first step in the manufacturing process according to one embodiment of the present disclosure Figure 1 A perspective view of a tool attachment.

[0030] Figure 4B is another step in the manufacturing process Figure 1A perspective view of a tool attachment.

[0031] Figure 4C It is another step in the manufacturing process Figure 1 A perspective view of a tool attachment.

[0032] Figure 4D It is another step in the manufacturing process Figure 1 A perspective view of a tool attachment.

[0033] Figure 5 According to one embodiment of the present disclosure, Figure 1 Process diagram of the tool attachment method.

[0034] Before explaining any embodiment of the invention in detail, it should be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or shown in the following drawings. The invention is capable of other embodiments and can be practiced or carried out in various ways. DETAILED DESCRIPTION

[0035] See also Figure 1 , a known drill sleeve assembly 1 is shown having a base sleeve 2 and a separate drill tip 3 pressed into the base sleeve 2. The drill sleeve assembly 1 can therefore be referred to as a two-piece drill sleeve assembly. Typically, the base sleeve 2 and the drill tip 3 are formed of different materials and are processed separately based on their applications. For example, the base sleeve 2 may be formed and processed for applications requiring high toughness, while the drill tip 3 may be formed and processed for applications requiring high hardness. The base sleeve 2 and the drill tip 3 are often formed and processed separately before they are pressed together.

[0036] View now Figure 2 , a tool accessory 10 according to one embodiment of the present disclosure includes a body 14 having a unitary (e.g., single, monolithic, etc.) construction. The body 14 includes a tip 18, a drive portion 22, and a shank 26 that defines an intermediate portion 28 of the body 14 to interconnect the tip 18 and the drive portion 22. In the illustrated embodiment, the drive portion 22 defines a first end 20 of the tool accessory 10, and the tip 18 defines a second end 24 of the tool accessory 10. In other embodiments, the tip may define the first end 20, and the drive portion 22 may define the second end 24. In the illustrated embodiment, the tool accessory 10 is a socket-type drill bit, but may also be another type of tool accessory (e.g., a tool head, a drill bit, a plug-in drill bit, and / or the like). The tool accessory 10 may be selectively and / or interchangeably used with a driver tool, such as a power tool (e.g., an impact driver, a drill, etc.), a handheld tool (e.g., a socket wrench, a socket wrench screwdriver, etc.), or the like.

[0037] like Figure 2 and 3 , the tip 18, the drive portion 22, and the shank 26 are disposed along an axis 30 of the tool attachment 10; the axis extending centrally through the first end 20 and the second end 24. The drive portion 22 of the tool attachment 10 includes a sleeve 34 disposed along the axis 30 adjacent to the first end 20. The sleeve 34 may have a cross-section 38 that is substantially polygonal and sized to receive a standard drive or shaft (e.g., 1 / 4, 3 / 8, or 1 / 2 inch). In the illustrated embodiment, the cross-section 38 is substantially square. In other embodiments, the sleeve may have other cross-sectional profiles (e.g., hexagonal, rack, or the like) and sizes.

[0038] Typically, the drive portion 22 is sized and shaped to be engaged by a shaft or output member 40 of the driver tool. The tool attachment 10 may further include a recess 42 within the sleeve 34, and the output member 40 of the driver tool may include a detent ball biased toward the recess 42 in a direction substantially perpendicular to the axis 30. In other embodiments, the recess and detent ball may be disposed on alternative portions of the tool attachment 10 and the output member.

[0039] Continue to refer Figure 2 and 3 , the tip 18 is configured to engage a workpiece (e.g., a fastener, a drill bit, an extension, etc.). In one example configuration, the tip 18 may include a screwdriver-type tip (e.g., hexagonal, slotted, square, cross, star, etc.). Figure 3 , the tip 18 may alternatively or additionally include an accessory drive portion having a substantially square cross-section 62. The accessory drive portion (e.g., tip 18) may be configured and sized (e.g., 1 / 4, 3 / 8, or 1 / 2 inch) to be received by a drive socket of an additional accessory. The drive portion may include a catch ball arrangement similar to the recess and ball catch previously discussed. In other example configurations, the tip 18 may include a receiver, driver, or adapter based on the desired application.

[0040] Still refer to Figure 2 and 3 , the complete tool attachment 10 can be formed from high speed steel (HSS), other wear resistant metal alloys, impact resistant steel alloys (e.g., SAE 6150 low alloy steel), or materials composed of wear resistant and impact resistant alloys. In the illustrated embodiment, the complete tool attachment 10 is composed of S2 tool steel (e.g., UNS T41902), which represents a shock resistant steel designed to have high impact resistance (e.g., toughness) as well as strength and hardness. In other words, the tip 18, the drive portion 22, and the shank 26 are unitarily formed as a single piece from a single material.

[0041] In order to provide a combination of impact resistance and wear resistance, portions of the tool attachment 10 may be locally treated (e.g., hardened, tempered, etc.). More specifically, as described in more detail below, the entire body 14 may initially be subjected to a first heat treatment or a first material treatment to achieve a first hardness that approximates the entire body 14 to temporarily unify the hardness and toughness of the tool attachment 10. Next, a portion of the body 14 may then be subjected to an induction tempering treatment or a second material treatment to achieve a second, lower hardness of a specific portion of the body 14. For example, the entire body 14 may be treated so that the entire tool attachment 10 has the high hardness required for the tip 18 to increase wear resistance. Next, a portion of the tool attachment 10 may be induction tempered so that the drive portion 22 has the lower hardness and high toughness required to increase impact resistance. Therefore, the amount of the shank 26 subjected to the second material treatment may decrease from the drive portion 22 to the tip 18. Alternatively, the amount of the shank 26 subjected to the second material treatment may decrease from the tip 18 to the drive portion 22.

[0042] Specific references Figure 3 , in a first region 66 extending between the first end 20 and the first side 70 of the middle portion 28, the tool attachment 10 has a first hardness. In a second region 74 extending between the second end 24 and the second side 78 of the middle portion 28, the tool attachment 10 has a second hardness. The middle portion 28 may also serve as a hardness transition region 82 that provides a hardness gradient (e.g., increase or decrease, slope, etc.) between the first hardness region 66 and the second hardness region 74. In some embodiments, the hardness gradient may have a generally parabolic profile 86. In some embodiments, the profile 86 may be another shape. It should be understood that while the profile of a first cross-section through the body 14 is shown, as shown in FIG. Figure 3 1. Although shown vertically in FIG. 1, the profile of a second cross-section through the body 14 that is generally perpendicular to the first cross-section is substantially similar.

[0043] More specifically, the hardness of the body 14 at the central portion of the profile 86 (e.g., near the axis 30) can be lower than the hardness of the body at one end of the profile 86 (e.g., near the periphery of the body 14 / cross-section). Figure 2 , the corners 90 of the intermediate portion 28 of the tool attachment 10 may have a higher toughness that decreases toward the axis 30 along the curved portion of the profile 86 .

[0044] Still refer to Figure 3, the hardness of the tool attachment 10 may be measured or defined at various points between the first end 20 and the second end 24. The first point 94 may be located in the first zone 66, and the second point 98 may be located in the first zone 66 between the first point 94 and the second end 24. The third point 102 may be located in the transition zone 82, and the fourth point 106 may be located in the transition zone 82 between the third point 102 and the second end 24. The fifth point 110, the sixth point 114, the seventh point 118, and the eighth point 122 may be located successively in the second zone 74.

[0045] The hardness of the tool attachment 10 at the first point 94 and the second point 98 can be hardened to between approximately 44 Rockwell C hardness ("HRC") and approximately 52 HRC for high impact resistance. Specifically, the hardness of the tool attachment 10 at the first point 94 and the second point 98 can be hardened to approximately 48 HRC for high impact resistance. The hardness of the tool attachment 10 at the third point 102 and the fourth point 106 can be between approximately 46 HRC and approximately 62 HRC, so that the transition zone 82 provides a hardness gradient between the first zone 66 and the second zone 74. The transition zone 82 (e.g., the third point 102 and the fourth point 106) can also act as a heat sink between the first zone 66 and the second zone 74. The hardness of the tool attachment 10 at the fifth point 110, the sixth point 114, the seventh point 118, and the eighth point 122 can be hardened to between approximately 57 HRC and approximately 62 HRC for high wear resistance. Specifically, the hardness of the tool attachment 10 at the fifth point 110, the sixth point 114, the seventh point 118, and the eighth point 122 can be hardened to approximately 60 for high wear resistance. In the illustrated embodiment, the middle portion 28 in the transition zone 82 is not locally heat treated (e.g., induction tempered) compared to the first end 20 in the first zone 66. In some embodiments, the overall hardness difference between the first end 20 and the second end 24 is between approximately 4 HRC and approximately 20 HRC.

[0046] Reference Figures 4A to 5 According to one embodiment, a method 200 of manufacturing a tool attachment 10 includes forming the body 14 as a single piece ( Figure 4A ). Next, the body 14 may be cold headed, after which the sleeve 34 including edge chamfering and groove turning may be formed. In some embodiments, the sleeve 34 may be formed with a depth of approximately 8 millimeters ("mm") to approximately 13 mm, and the drive portion 22 may have a width of approximately 1 / 4 inch. In other embodiments, the sleeve 34 may be formed with a depth of approximately 10 mm to approximately 15 mm, and the drive portion 22 may have a width of approximately 3 / 8 inch. In one example configuration, the depth of the first zone 66 is approximately the same as the depth of the sleeve 34. In other example configurations, the depth of the first zone 66 and the transition zone 82 are similar to or greater than the depth of the sleeve 34.

[0047] Next, the body 14 may undergo vibration grinding. After vibration grinding, in one embodiment, the tip 18 and / or other portions of the body 14 may be turned, machined, and / or the like. Figure 4B ). Next, the entire body 14 may undergo a first material treatment to achieve a first hardness that approximates the entire body 14. The body 14 may then be first sandblasted or otherwise cleaned, after which a first portion of the body 14, such as the drive portion 22 or the tip 18, may undergo a second material treatment to achieve a second, lower hardness (i.e., higher toughness). In the illustrated embodiment, the drive portion 22 undergoes a second material treatment to increase its impact resistance. In other contemplated configurations, after the first material treatment, the tip 18 may be partially induction hardened ( Figure 4C ) to increase wear resistance. Next, the body 14 can be sandblasted or otherwise cleaned a second time, after which the body 14 can be laser etched and surface treated ( Figure 4D In one example configuration, the body 14 undergoes a manganese zinc surface treatment (eg, electroplating, electrocoating, or the like).

[0048] Thus, the present disclosure provides, among other things, a one-piece tool attachment having improved impact and wear resistance. Various features and advantages of the present disclosure are set forth in the appended claims.

Claims

1. A tool accessory, comprising: a drive portion configured to be engaged by an output shaft of a tool, the drive portion having a first hardness; a tip configured to engage a workpiece, the tip having a second hardness different from the first hardness; as well as a shank interconnecting the drive portion and the tip, the shank having a third hardness different from the first hardness and different from the second hardness, wherein the third hardness is between the first hardness and the second hardness, and Wherein the drive portion, the shank and the tip are formed as a single body from a common material.

2. The tool attachment according to claim 1, wherein the driving portion has a first toughness, wherein the tip has a second toughness different from the first toughness, wherein the handle has a third toughness different from the first toughness and different from the second toughness, and Wherein the third toughness is between the first toughness and the second toughness.

3. The tool attachment according to claim 2, wherein the drive portion, the tip and the shank are initially subjected to a first heat treatment to temporarily unify the hardness and toughness of the tool attachment, and wherein one of the drive portion and the tip is subsequently subjected to a second heat treatment different from the first heat treatment.

4. The tool attachment of claim 3, wherein the drive portion, rather than the tip, is subjected to the second heat treatment, and wherein an amount of the shank subjected to the second heat treatment decreases from the drive portion to the tip.

5. The tool attachment of claim 3, wherein the tip is subjected to the second heat treatment instead of the drive portion, and wherein an amount of the shank subjected to the second heat treatment decreases from the tip to the drive portion.

6. The tool attachment of claim 1, wherein the drive portion includes a sleeve for receiving the output shaft of the tool, and wherein the sleeve has a substantially polygonal cross-section.

7. The tool attachment of claim 6, wherein one of the output shaft and the drive portion includes a detent ball and the other of the output shaft and the drive portion includes a recess for receiving the detent ball, and wherein the sleeve has a substantially square cross-section.

8. The tool attachment of claim 3, wherein the second heat treatment comprises induction tempering.

9. The tool attachment according to claim 3, wherein said first hardness is approximately 44 to 52 HRC, wherein the second hardness is approximately 57 to 62 HRC, and Wherein the third hardness is approximately 46 to 62 HRC.

10. The tool attachment according to claim 3, wherein the first hardness is approximately 48HRC, and Wherein the second hardness is approximately 60HRC.

11. A tool attachment, comprising: a unitary body comprising a first end, a second end opposite the first end, and a middle portion extending axially between the first end and the second end, the first end, the second end, and the middle portion being formed of a common material; a first region extending between the first end and a first side of the mid-portion, the first region having a first hardness; a second region extending between the second end and the middle portion of the second side, the second region having a second hardness different from the first hardness; as well as a transition zone between the first zone and the second zone, at least a portion of the transition zone having a hardness gradient between the first hardness and the second hardness, wherein the first side has undergone a first material treatment configured to provide the first hardness, and Wherein the second side has undergone a second material treatment different from the first material treatment and configured to provide the second hardness.

12. The tool attachment of claim 11, wherein the second side has undergone the first material treatment and the second material treatment in sequence.

13. The tool attachment of claim 11, wherein the entire unitary body has been subjected to the first material treatment, and wherein only a portion of the second side and the middle portion have been subjected to the second material treatment.

14. The tool attachment of claim 11, further comprising: a drive portion formed at the first end, the drive portion being configured to be engaged by an output shaft of a tool; as well as a tip formed at the second end, the tip being configured to engage a workpiece, The desired hardness of the drive portion is different from the desired hardness of the tip.

15. A tool accessory according to claim 14, wherein the cross-section of the single body at the drive portion is different from the cross-section at the tip, so that the cross-section of the intermediate portion varies between the drive portion and the tip, and wherein the hardness gradient varies by different amounts at the center of the cross-section and at the periphery of the cross-section.

16. The tool attachment of claim 15, wherein at least a portion of the profile of the hardness gradient is generally parabolic.

17. The tool attachment of claim 11, wherein the first material treatment comprises heat treatment and the second material treatment comprises induction tempering.

18. The tool attachment according to claim 11, wherein said first hardness is approximately 44 to 52 HRC, wherein the second hardness is approximately 57 to 62 HRC, and The hardness of the hardness gradient varies between approximately 46 HRC and approximately 62 HRC.

19. A method of manufacturing a tool attachment, the tool attachment being configured to be rotated by a tool, the method comprising: A unitary body is formed as a single piece from common raw materials; heat treating the entire unitary body with a first heat treatment, the first heat treatment providing a first hardness approximately throughout the tool attachment; and A portion of the unitary body is heat treated with a second heat treatment different from the first heat treatment, the second heat treatment providing a second hardness less than approximately the entirety of the tool attachment, wherein the second hardness is different from the first hardness.

20. The method of claim 19, wherein the unitary body comprises a first end, a second end opposite the first end, and an intermediate portion extending axially between the first end and the second end, the method further comprising: providing the second heat treatment once the first heat treatment has been applied to the entirety of the unitary body; defining a desired hardness zone in an axial direction from the second end toward the first end; as well as The second heat treatment is applied to the second end until the second hardness in the desired hardness zone is approximately equal to the desired hardness.

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