Power tool

Abstract

A power tool includes: a housing having a main housing and a secondary housing coupled with the main housing; a motor supported within the main housing; an output member driven by the motor and extending from the sub-housing; an illumination assembly coupled to the secondary housing, the illumination assembly including a light source configured to illuminate a workpiece; a circuit board assembly supported within the main housing; a passage at least partially formed by the sub-housing; a wire extending from the circuit board assembly through the passage to the lighting assembly; and a sleeve positioned in the passage and surrounding at least a portion of the electrical wire.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 515,027 filed on July 21, 2023 and U.S. Provisional Patent Application No. 63 / 489,932 filed on March 13, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to lighting assemblies, such as shadowless lighting assemblies, for power tools and, more particularly, to electrical wiring pathways for such lighting assemblies. Background Art

[0004] Some power tools may include a work light located on the front surface of the power tool that is configured to illuminate the working area of ​​the power tool. For example, an impact tool (e.g., a high-torque impact wrench) may include a single light emitting diode (LED) positioned near an output unit that is configured to transfer rotational energy from the high-torque impact wrench to a fastener. When a user operates the high-torque impact wrench, the LED may illuminate the fastener so that the user can see the fastener more easily. However, the use of a single LED may cause the output unit to cast a shadow, which may have a negative impact on the visibility of the fastener. To address this issue, the power tool may include a plurality of LEDs positioned radially around the output unit or end tool of the power tool. Arranging a plurality of LEDs around the output unit achieves uniform illumination of all sides of the output unit or end tool, which prevents shadows from being cast. This type of lighting may generally be referred to as shadowless lighting.

[0005] Although shadowless lighting helps improve fastener visibility, implementing shadowless lighting in a power tool (e.g., on the front surface of a housing) may cause other problems. For example, each LED mounted to the front surface of a power tool may require multiple wires to provide power and / or control signals to the LEDs. As more LEDs are included, more wires may be required. Therefore, power tools that implement shadowless lighting require an effective method to position these wires in the limited space provided within a handheld power tool. Utility Model Content

[0006] In some aspects, the technology described herein relates to a power tool comprising: a housing including a main housing and a sub-housing connected to the main housing; a motor supported within the main housing; an output member driven by the motor and extending from the sub-housing; a circuit board assembly supported within the main housing; a passage at least partially formed by the sub-housing; and a lighting assembly connected to the sub-housing, the lighting assembly comprising: a light source configured to illuminate a workpiece, an electrical wire extending from the circuit board assembly through the passage to the lighting assembly, and a sleeve positioned in the passage and surrounding at least a portion of the electrical wire.

[0007] In some aspects, the technology described herein relates to a power tool wherein a main housing includes a motor housing portion in which a motor is supported and a handle portion extending from the motor housing portion and wherein a circuit board assembly is supported within the handle portion.

[0008] In some aspects, the technology described herein relates to a power tool wherein a passage includes a first end, a second end opposite the first end, and a middle portion between the first end and the second end, and wherein a cross-sectional area of ​​the passage increases from the middle portion toward the first end.

[0009] In some aspects, the technology described herein relates to a power tool wherein a cross-sectional area of ​​a passage increases from a middle portion toward a second end such that the middle portion defines a minimum cross-sectional area of ​​the passage.

[0010] In some aspects, the technology described herein relates to a power tool, wherein the socket is a first socket received between the first end and the intermediate portion, and wherein the power tool further includes a second socket received between the second end and the intermediate portion.

[0011] In some aspects, the technology described herein relates to a power tool wherein the first and second sockets are plugs compressed within a passageway.

[0012] In some aspects, the technology described herein relates to a power tool wherein the secondary housing is molded using a mold assembly, and wherein a parting line of the mold assembly extends through the intermediate portion.

[0013] In some aspects, the technology described herein relates to a power tool, wherein the light source is a first light source, and wherein the lighting assembly further includes a second light source and a third light source.

[0014] In some aspects, the technology described herein relates to a power tool in which the first light source, the second light source, and the third light source are offset 120 degrees from each other.

[0015] In some aspects, the technology described herein relates to a power tool wherein the secondary housing includes a wall defining a recess, and wherein the power tool further includes a cover received within the recess.

[0016] In some aspects, the technology described herein relates to a power tool wherein a passageway is defined between a cover and a wall.

[0017] In some aspects, the technology described herein relates to a power tool wherein the wall and cover are generally U-shaped.

[0018] In some aspects, the technology described herein relates to a power tool wherein the secondary housing includes a cylindrical inner surface, and wherein the cover includes a top wall that is substantially flush with the cylindrical inner surface.

[0019] In some aspects, the technology described herein relates to a power tool wherein the secondary housing and the cover comprise different materials.

[0020] In some aspects, the technology described herein relates to a power tool wherein the socket is made of fiberglass.

[0021] In some aspects, the technology described herein relates to a power tool comprising: a housing including a main housing and a sub-housing connected to the main housing; a motor supported within the main housing; an output member driven by the motor and extending from the sub-housing; a circuit board assembly supported within the main housing; a passage defined between a wall extending along a bottom side of the sub-housing and a cover; and a lighting assembly connected to the sub-housing, the lighting assembly comprising: a light source configured to illuminate a workpiece, and an electrical wire extending from the circuit board assembly through the passage to the lighting assembly.

[0022] In some aspects, the technology described herein relates to a power tool wherein the output member is configured to rotate about an axis, and wherein the circuit board and the passageway both extend parallel to the axis.

[0023] In some aspects, the technology described herein relates to a power tool further comprising: a drive assembly having a camshaft driven by a motor; and a hammer head configured to reciprocate along the camshaft, and wherein the cover separates the wire from the hammer head.

[0024] In some aspects, the technology described herein relates to a power tool comprising: a housing including a main housing and a sub-housing connected to the main housing; a motor supported within the main housing; an output member driven by the motor around an axis and extending from the sub-housing; a circuit board assembly supported within the main housing; a passage defined by a hole extending through the sub-housing in a direction parallel to the axis; and a lighting assembly connected to the sub-housing, the lighting assembly comprising: a light source configured to illuminate a workpiece, an electrical wire extending from the circuit board assembly through the passage to the lighting assembly, and a sleeve positioned in the passage and surrounding at least a portion of the electrical wire.

[0025] In some aspects, the technology described herein relates to a power tool in which the sleeve is made of fiberglass.Other aspects of the disclosure 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 power tool according to an embodiment of the present disclosure.

[0027] Figure 2 yes Figure 1 Cross-sectional view of a power tool.

[0028] Figure 3 yes Figure 1 A partial perspective view of a power tool showing a lighting assembly of the power tool.

[0029] Figure 4 yes Figure 1 An exploded rear perspective view of a portion of a power tool further illustrating a lighting assembly.

[0030] Figure 5 yes Figure 1 A partially exploded perspective view of a power tool further illustrating the lighting assembly.

[0031] Figure 6 yes Figure 1 A partial cross-sectional view of a power tool.

[0032] Figure 7 yes Figure 1 A perspective view of a portion of a power tool in which some features are hidden or transparent to separate internal aspects of the power tool.

[0033] Figure 8 yes Figure 1 A front view of a housing component of a power tool.

[0034] Fig. 9 yes Figure 1 A partial cross-sectional view of a power tool.

[0035] Fig.10 yes Fig. 9 A magnified view of the callout box.

[0036] Fig.11 is a perspective view of a power tool according to another embodiment of the present disclosure.

[0037] Fig.12 yes Fig.11 Cross-sectional view of a power tool.

[0038] Fig.13 yes Fig.11 A partially exploded perspective view of a power tool.

[0039] Fig.14 It is shown Fig.11 An enlarged perspective view of a portion of a lighting assembly of a power tool.

[0040] Fig.15 yes Fig.11 A cross-sectional view of a portion of a power tool showing access to a lighting assembly to house electrical wiring.

[0041] Fig.16 yes Fig.11 A rear perspective view of the secondary housing of the power tool further illustrates the passage.

[0042] Fig.17 is a cross-sectional view of a power tool according to another embodiment of the present disclosure.

[0043] Before explaining any embodiments of the present disclosure in detail, it should be understood that the present disclosure is not limited in its application to the construction details and component arrangements set forth in the following description or shown in the following figures. The present disclosure can have other embodiments and can be practiced or performed in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered as limiting. DETAILED DESCRIPTION

[0044] Figure 1 An embodiment of a power tool 10 in the form of a rotary impact tool, more specifically an impact wrench, is shown, which includes a shadowless lighting system. The power tool 10 includes a main housing 14 having a motor housing portion 18. A secondary housing 22 (which may also be referred to as an impact box or hammer box) is coupled to the main housing 14. The main housing 14 shown includes a handle portion 26 extending downwardly from the motor housing portion 18. In the illustrated embodiment, the handle portion 26 and the motor housing portion 18 are defined by mating first and second clamshell halves or first and second housing portions 28a, 28b ( Figure 5). The secondary housing 22 may be integrally formed as a single piece and coupled to the primary housing 14 by a plurality of fasteners or other suitable means.

[0045] In the illustrated embodiment, the end cap 30 is coupled to the motor housing portion 18 opposite the secondary housing 22. The clamshell halves 28a, 28b may be coupled (e.g., fastened) together at an interface or seam 31. In the illustrated embodiment, the end cap 30 is continuous and may be pressed or assembled onto the rear ends of the clamshell halves 28a, 28b. In other words, the end cap 30 may not include two halves so that the end cap 30 may extend across the seam 31. The end cap 30 is coupled to the motor housing portion 18 by a plurality of fasteners. In yet other embodiments, the power tool 10 may not include a separate end cap such that the clamshell halves 28a, 28b instead define the rear ends of the motor housing portion 18.

[0046] refer to Figure 1 and Figure 2 , the power tool 10 includes a battery 34 that is removably coupled to a battery receptacle 38 that, in the illustrated embodiment, includes a cavity 40 that extends into the handle portion 26. When the battery 34 is coupled to the battery receptacle 38, a motor 42 is supported within the motor housing portion 18 and receives power from the battery 34 via connections, pads, and / or battery terminals in the battery receptacle 38. In the illustrated embodiment, the handle portion 26 of the clamshell halves 28a, 28b may be covered or surrounded by a grip portion 45 that may be overmolded onto the handle portion 26.

[0047] The battery 34 may be a power tool battery pack (e.g., a 12-volt rechargeable battery pack) commonly used to power power tools such as electric drills, electric saws, etc. The battery 34 may include lithium-ion (Li-ion) cells. The 12-volt nominal output voltage of the battery 34 provides an optimal balance between weight / size and power in the illustrated power tool 10; however, in other embodiments, batteries with other nominal voltages may be used.

[0048] Specific reference Figure 2 The motor 42 is a brushless DC ("BLDC") motor having a stator 46 and a rotor, and an output shaft 50 is rotatable about an axis 54 relative to the stator 46. A fan 58 is coupled to the output shaft 50 at the rear of the motor 42 to generate airflow to cool the motor 42 and / or other components of the power tool 10.

[0049] Continue to refer Figure 2, the power tool 10 includes a trigger 62 supported by the main housing 14, which may include an actuator and a trigger switch, which (e.g., via a suitable control circuit system disposed on one or more printed circuit boards (“PCBAs”)) selectively electrically connects the motor 42 to the battery 34 to provide DC power to the motor 42. In other embodiments, the power tool 10 may include a power cord for electrically connecting the trigger 62 and the motor 42 to an AC power source. As another alternative, the power tool 10 may be configured to operate using a different power source (e.g., a pneumatic or hydraulic power source, etc.).

[0050] In the illustrated embodiment, a first PCBA 63 is supported within the motor housing portion 18 of the main housing 14 adjacent to the front end of the stator 46. The illustrated first PCBA 63 extends perpendicular to the axis 54 and may include one or more Hall effect sensors for controlling feedback of the motor 42. A second PCBA 65 is supported within the main housing 14 (e.g., at the upper end of the handle portion 26 and / or the lower end of the motor housing portion 18) and extends generally parallel to the axis 54. The second PCBA 65 is in electrical communication with the motor 42, the switch elements of the trigger 62, and the terminals of the battery receptacle 38. In the illustrated embodiment, the second PCBA 65 includes a plurality of semiconductor switch elements (e.g., MOSFETs, IGBTs, etc.) that control and distribute power to the windings in the stator 46 so as to rotate the rotor and the output shaft 50. The second PCBA 65 may also include one or more microprocessors, machine-readable non-transitory memory elements, and other electrical or electronic elements for providing operational control to the power tool 10. In some embodiments, the first PCBA 63 may be omitted, and the motor 42 may be configured for sensorless control via the second PCBA 65. In some embodiments, the position of the first PCBA 63 and / or the second PCBA 65 within the main housing 14 may vary.

[0051] Still reference Figure 2 , the illustrated power tool 10 further includes a gear assembly 66 driven by the output shaft 50 and an impact mechanism 70 coupled to the output end of the gear assembly 66. The impact mechanism 70 may also be referred to herein as a drive assembly 70. The gear assembly 66 provides a speed reduction between the output shaft 50 and the input end of the drive assembly 70.

[0052] refer to Figure 2 The gear assembly 66 includes a pinion gear (not shown) coupled to the output shaft 50 of the motor 42, a plurality of planetary gears 86 meshing with the pinion gears, and a ring gear 90 meshing with the planetary gears 86 and rotatably fixed within the main housing 14. The rearwardly facing side of the ring gear 90 rests on the clamshell halves 28a, 28b ( Figure 5) formed on the partition wall 113. The illustrated ring gear 90 is directly supported by the clamshell halves 28a, 28b. In other embodiments, the ring gear 90 can be supported by a gear box, which in turn can be supported by the clamshell halves 28a, 28b.

[0053] The planetary gears 86 are coupled to the camshaft 94 of the drive assembly 70 so that the camshaft 94 serves as a planet carrier. Accordingly, the rotation of the output shaft 50 rotates the planetary gears 86, which then travel along the inner circumference of the ring gear 90, thereby rotating the camshaft 94. The drive assembly 70 also includes an anvil 126 extending from the secondary housing 22 to which a tool element (e.g., a socket, not shown) can be coupled to perform work on a workpiece (e.g., a fastener). The drive assembly 70 is configured to convert a constant rotational force or torque provided by the gear assembly 66 into an impact rotational force or torque intermittently applied to the anvil 126 when the reaction torque on the anvil 126 (e.g., due to the engagement between the tool element and the fastener being performed) exceeds a certain threshold. In the illustrated embodiment of the power tool 10, the drive assembly 70 includes a camshaft 94, a hammer head 130 supported on the camshaft 94 and axially slidable relative to the camshaft, and anvil 126. In other words, the hammer head 130 is configured to reciprocate axially along the cam shaft 94 and apply periodic rotational impacts to the anvil 126 in response to the rotation of the cam shaft 94 .

[0054] The hammer 130 includes a first hammer portion 131 and a second hammer portion 132. The first hammer portion 131 is disposed or extends behind the second hammer portion 132 in the axial direction of the power tool 10, and the second hammer portion 132 is larger (e.g., in diameter) than the first hammer portion 131. The drive assembly 70 further includes a spring 134 that biases the hammer 130 toward the front of the power tool 10. In other words, the spring 134 biases the hammer 130 toward the anvil 126 in the axial direction along the axis 54. The thrust bearing 138 is positioned between the spring 134 and the hammer 130. After each impact strike, when the hammer lug 146 ( Fig. 9 ) and the corresponding anvil lug 147 ( Fig. 9 ) engages and the rotation of the hammer 130 is temporarily stopped, the thrust bearing 138 allows the spring 134 and the camshaft 94 to continue to rotate relative to the hammer 130. In the illustrated embodiment, the anvil 126 is rotatably supported by the bushing 128, which in turn is supported in the nose portion of the front end of the secondary housing 22.

[0055] The cam shaft 94 includes cam grooves 150 in which corresponding cam balls 154 are received (although in Figure 2Only one cam ball is shown in the figure). The cam ball 154 is drivingly engaged with the hammer 130, and as the hammer lugs 146 and the anvil lugs engage and the cam shaft 94 continues to rotate, the movement of the cam slot 150 within the cam ball 154 allows the hammer 130 to move axially relative to the cam shaft 94. The axial movement of the hammer 130 compresses the spring 134, and then, once the hammer lugs 146 leave the anvil lugs, the spring releases its stored energy to propel the hammer 130 forward and rotate the hammer 130.

[0056] Still reference Figure 2 , the gear assembly 66 and the drive assembly 70 may be coated with a lubricant (such as grease or oil) that helps the power tool 10 operate smoothly by minimizing friction between the movable parts. Thus, the power tool 10 includes an intermediate box 156, one end of which is positioned adjacent to the secondary housing 22, and the other end of the intermediate box 156 is positioned adjacent to the interior portion of the main housing 14. In the illustrated embodiment, the intermediate box 156 is fixed between the secondary housing 22 and the main housing 14 by an interference fit, preventing lubricant from escaping from the gear assembly 66 and the drive assembly 70.

[0057] The power tool 10 further includes a lighting assembly 160 positioned at a front end or first end 164 of the power tool 10, which is generally opposite to a rear end or second end 168 (defined by the cap 30 in the illustrated embodiment). The illustrated lighting assembly 160 is directly coupled to the secondary housing 22. A passage 170 is defined by a hole extending through the secondary housing 22 in a direction generally parallel to the axis 54. As described in more detail below, electrical wires for providing power and / or operational control for the lighting assembly 160 extend through the passage 170, beyond the rear end of the secondary housing 22, and ultimately to the second PCBA 65.

[0058] One or both of the PCBAs 63, 65 may include one or more electronic components that can implement a control system for the power tool 10. For example, the PCBAs 63, 65 may include an electronic processor configured to receive power from a power source (e.g., battery 34) connected to the power tool 10. The electronic processor may be configured to control whether power is provided to the lighting assembly 160 and / or the motor 42. The PCBAs 63, 65 may also include switching elements (e.g., field effect transistors) that are controlled by the electronic processor to selectively provide power to the coil of the motor 42 to allow the motor to operate. In other embodiments, the PCBAs 63, 65 may include additional or alternative components. In some embodiments, the lighting assembly 160 may be activated in response to a user's operation of the trigger 62.

[0059] refer to Figures 2 to 5, the lighting assembly 160 includes a lamp housing 172. Figure 4 As shown, the lamp housing 172 shown includes a main body 173 and a cap 174 ( Figure 4 ). Cap 174 can be a resilient layer that is overmolded onto body 173 to provide protection and impact resistance (e.g., due to being dropped, etc.) to lighting assembly 160. In other embodiments, cap 174 can be coupled to body 173 via snap fit, adhesive, fasteners, etc., or cap 174 can be omitted. The illustrated lamp housing 172 is coupled to secondary housing 22 via retaining ring 175 (e.g., snap ring) that is disposed in complementary grooves on secondary housing 22 and lamp housing 172 ( Figure 2 In other embodiments, the lamp housing 172 may be coupled to the sub-housing 22 in other ways.

[0060] refer to Figure 3 to Figure 4 , the illustrated lighting assembly 160 includes a plurality of light emitting diode ("LED") assemblies 178a, 178b, 178c, which may each be supported on an inner surface 182 of a lamp housing 172. In other embodiments, the lighting assembly 160 may include a light source other than an LED. Power may be provided to each LED assembly 178a, 178b, 178c by wiring wires 186, 188 from the second PCBA 65 through the passage 170 of the secondary housing 22 to the first LED assembly 178a. Typically, each LED assembly 178a, 178b, 178c includes a board 180 and an LED 181.

[0061] like Figure 3As best shown, the first LED assembly 178a includes a separate LED PCBA 192 supported by the lamp housing 172. The LED PCBA 192 receives the initial wires 186, 188 from the main PCBA 65, and the remaining LED assemblies 178b, 178c are powered / controlled by the wires 186, 188 from the LED PCBA 192. In the illustrated embodiment, the wires 186, 188 ultimately provide power to the LED assemblies 178a, 178b, 178c from the battery 34. In some embodiments, the power source that provides power to the LED assemblies 178a, 178b, 178c via the wires 186, 188 is a second power source separate from the battery 34. For example, the second power source can be a button cell battery, etc. In some embodiments, the second power source can be configured to provide power to the LEDs, but not to the motor or other electrical components on the tool (e.g., one-key technology, safety features, etc.). In still other embodiments, the LED assemblies 178a, 178b, 178c can be replaced by a diffuser that is coupled to one or more light sources (e.g., LEDs) within the power tool 10 via a light pipe. In these embodiments, the diffuser emits light that is transmitted by the light pipe from a remote light source. In these embodiments, the light pipe can extend through the passage 170 (instead of the wires 186, 188).

[0062] The light housing 172 may include one or more lenses 196 to allow the LED 181 to emit light through the lighting assembly 160 to the front of the power tool 10 ( Figure 5 In some embodiments, the LED assemblies 178a, 178b, 178c may be arranged around a center point of the lighting assembly 160, and in some cases may be arranged around the axis 54 ( Figure 3 ). For example, the LED assemblies 178a, 178b, 178c can be evenly spaced circumferentially about the axis 54 in 120 degree increments. This allows the LED assemblies 178a, 178b, 178c to illuminate the workpiece without casting a shadow (e.g., a shadow from a tool tip). In other embodiments, the LED assemblies 178a, 178b, 178c can have other spacings and arrangements.

[0063] Reference now Figures 6 to 10, wires 186, 188 can be routed from the main PCBA 65 through the passage 170 and fall onto the LED PCBA 192. One end of the illustrated passage 170 extends from the interior of the main housing 14, and the other end extends to the interior of the lamp housing 172. The wires 186, 188 are surrounded by a sleeve 200 received in the passage 170. In the illustrated embodiment, the sleeve 200 is configured as a plug 200 that at least partially seals the passage 170. The plug 200 can be a stopper, a seal, etc. In some embodiments, the plug 200 is elastic (and therefore flexible). For example, the plug 200 can be made of rubber. The plug 200 can support the wires 186, 188 in the passage 170, and can also prevent debris (e.g., dust, lubricant, etc.) from penetrating through the passage 170 in either direction. More specifically, supporting the wires 186, 188 includes preventing friction and wear during use, which can extend the life of the power tool 10. In some embodiments, the plug 200 may also be oversized to prevent lubricant from escaping from the interference fit formed between the secondary housing 22 and the intermediate case 156 .

[0064] refer to Figure 7 , the wires 186, 188 can optionally be engaged via a connector 204 positioned in the main housing 14. Including the connector 204 allows fewer and / or easier steps during the manufacturing process. In an example method, the wires 186, 188 can be directly connected (e.g., crimped, soldered, etc.) to the main PCBA 65, and the first part of the connector 204a can be attached to the opposite ends of the wires 186, 188. Separately, the wires 186, 188 can be directly connected to the LED PCBA 192, and the second part of the connector 204b can be attached to the opposite ends of these wires 186, 188. Finally, the builder can more simply attach the first connector part and the second connector part 204a, 204b to complete the wiring, rather than having to include additional wire material to accommodate the final assembly. In some embodiments, the connector 204 can then be fixed in the main housing 14. In some cases, the main housing 14 can be formed with a designated space or recess for receiving the connector 204.

[0065] Brief reference Figure 8 , the plug 200 may include a recess 208 extending through the plug 200. The recess 208, which may be similar in shape or cross-section to a round wire, may be slightly smaller than the wires 186, 188 to provide a tight fit between the plug 200 and the wires 186, 188. Similarly, the plug 200 may be slightly larger than the passage 170 for the same purpose. In the illustrated embodiment, the plug 200 and the passage 170 are both polygonal. In other embodiments, the plug 200 and the passage 170 may have different shapes.

[0066] refer to Figure 6 In the illustrated embodiment, the secondary housing 22 is integrally formed as a single piece via a molding process. The molding process may be a molten metal molding process such as casting. In other embodiments, the molding process may be a powder metal molding process such as compaction and sintering. During the molding process, a passage 170 is formed in the secondary housing 22. In some embodiments, the secondary housing 22 may be molded via a two-piece mold, thereby having a parting line 197 extending perpendicular to the axis 54. In the illustrated embodiment, the parting line 197 extends through the center of the passage 170, but in other embodiments, the parting line 197 may be located elsewhere. The illustrated passage 170 tapers outwardly from the parting line 197 toward each end of the passage 170. Thus, the cross-sectional area of ​​the passage 170 decreases from the rear end of the passage 170 to the minimum cross-sectional area at the parting line 197, and then increases from the parting line 197 to the front end of the passage 170. Thus, the passage 170 has a draft angle, thereby allowing an insert of the mold to form the passage 170 during the molding process and then be released and extracted from the passage 170 after molding. Molding the secondary housing 22 including the passage 170 can provide lower manufacturing costs and / or higher manufacturing yields compared to forming the secondary housing 22 and then machining the passage 170. In addition, the draft angle of the passage 170 can provide a wedging effect to compress and secure the plug 200.

[0067] Finally, reference Fig. 9 and Fig.10 , the clamshell halves 28a, 28b can be joined together to form a partial barrier wall 212 between the secondary housing 22 and the handle portion 26. The clamshell halves 28a, 28b further provide an opening 216 just below one end of the passage 170 in the secondary housing 22. In some embodiments, the connector 204 can be stored just below the opening 216. In the illustrated embodiment, the opening 216 accommodates the passage of wires 186, 188 from the secondary housing 22 to the handle portion 26 and to the main PCBA 65, which can be positioned near the top of the handle portion 26 and oriented in an orientation generally parallel to the axis 54.

[0068] In operation of the power tool 10, the operator depresses the trigger 62 to start the motor 42, which continuously drives the gear assembly 66 and the cam shaft 94 via the output shaft 50. As the cam shaft 94 rotates, the cam ball 154 drives the hammer 130 to rotate with the cam shaft 94, and the driving surfaces of the hammer lugs 146 respectively engage the driven surfaces of the anvil lugs to provide impact and rotatably drive the anvil 126 and the tool element. After each impact, the hammer 130 moves or slides backward along the cam shaft 94 away from the anvil 126, so that the hammer lugs 146 are disengaged from the anvil lugs.

[0069] As the hammer 130 moves rearward, the cam ball 154 located in the corresponding cam groove 150 in the cam shaft 94 moves rearward in the cam groove 150. The spring 134 stores a portion of the rearward energy of the hammer 130, thereby providing a return mechanism for the hammer 130. After the hammer lug 146 is disengaged from the corresponding anvil lug, as the spring 134 releases its stored energy, the hammer 130 continues to rotate and move or slide forward toward the anvil 126 until the driving surface of the hammer lug 146 reengages the driven surface of the anvil lug to cause another impact.

[0070] When the operator operates the power tool 10, the lighting assembly 160 can illuminate (e.g., in response to the operator depressing the trigger 62) to illuminate the workpiece without casting a shadow. Power for the lighting assembly 160 is supplied by wires 186, 188 extending through the passage 170, which protects and guides the wires 186, 188 while providing compact and direct wiring between the lighting assembly 160 and the second PCBA 65.

[0071] Fig.11 A power tool 510 according to another embodiment is shown. The power tool 510 is similar in some respects to the power tool 510 described above with reference to FIG. Figures 1 to 10 The power tool 10 described herein is similar to the power tool 10 described herein, and features of the power tool 510 that correspond to features of the power tool 10 are indicated by corresponding reference numerals plus "500". The following description focuses primarily on the differences between the power tool 510 and the power tool 10, and it should be understood that, where applicable, the features of the power tool 510 and the alternatives described herein may be incorporated into the power tool 10, and vice versa. In addition to the differences described herein, the power tool 510 may additionally or alternatively include some or all of the features of the power tools 100, 800 described and illustrated in International Patent Application No. PCT / US2022 / 048534 of Milwaukee Electric Tool Company, the entire contents of which are incorporated herein by reference.

[0072] refer to Fig.11 , the power tool 510 includes a main housing 514 having a motor housing portion 518. A secondary housing 522 is coupled to the main housing 514. The illustrated main housing 514 includes a handle portion 526 that extends downwardly from the motor housing portion 518 and terminates in a battery receptacle 538. In the illustrated embodiment, the handle portion 526 and the motor housing portion 518 are defined by mating first and second clamshell halves or first and second housing portions 528a, 528b.

[0073] refer to Fig.12, a motor 542 is supported within the motor housing portion 518 and has a stator 546 with a plurality of coil windings and a rotor with an output shaft 550 that is rotatable relative to the stator 546 about an axis 554. A trigger 562 supported by the main housing 514 is operable to electrically connect the motor 542 (e.g., via appropriate control circuitry disposed on one or more printed circuit board assemblies (“PCBAs”)) to a battery (e.g., an 18 volt rechargeable battery pack; not shown) to provide DC power to the motor 542.

[0074] In the illustrated embodiment, a first PCBA 563 is supported within the motor housing portion 518 of the main housing 514. The illustrated first PCBA 563 extends perpendicular to the axis 554 and may include one or more Hall effect sensors that provide feedback for controlling the motor 542. A second PCBA 565 is supported within the main housing 14 (e.g., within the handle portion 526) and extends generally at an oblique angle relative to the axis 554. The second PCBA 565 is in electrical communication with the motor 542, the switch elements of the trigger 562, and the terminals of the battery receptacle 538. In the illustrated embodiment, the second PCBA 565 includes a plurality of semiconductor switch elements (e.g., MOSFETs, IGBTs, etc.) that control and distribute power to the windings in the stator 546 so as to rotate the rotor and the output shaft 550. The second PCBA 565 may also include one or more microprocessors, machine-readable non-transitory memory elements, and other electrical or electronic elements for providing operational control to the power tool 510. In some embodiments, the first PCBA 563 may be omitted, and the motor 542 may be configured for sensorless control via the second PCBA 565. In some embodiments, the position of the first PCBA 563 and / or the second PCBA 565 within the main housing 514 may vary.

[0075] Like the power tool 10, the illustrated power tool 510 includes a gear assembly 566 driven by an output shaft 550 and an impact mechanism or drive assembly 570 coupled to the output end of the gear assembly 566. The gear assembly 566 provides a speed reduction between the output shaft 550 and the input end of the drive assembly 570. The gear assembly 566 includes a pinion 572 integrally formed with the output shaft 550 in the illustrated embodiment, a plurality of planetary gears 586 meshing with the pinion 572, and a ring gear 590 meshing with the planetary gears 586 and rotatably fixed within the main housing 514. The rearwardly facing side of the ring gear 590 rests on a portion of the main housing 514 formed by the clamshell halves 528a, 528b ( Figure 5) is formed on the dividing wall 613. The illustrated ring gear 590 is directly supported by the clamshell halves 528a, 528b. In other embodiments, the ring gear 590 can be supported by a gear box, which in turn can be supported by the clamshell halves 528a, 528b.

[0076] The planetary gears 586 are coupled to the camshaft 594 of the drive assembly 570 so that the camshaft 594 serves as a planet carrier. Accordingly, the rotation of the output shaft 550 rotates the planetary gears 586, which then travel along the inner circumference of the ring gear 590, thereby rotating the camshaft 594. The drive assembly 570 also includes an anvil 626 extending from the secondary housing 522 to which a tool element (e.g., a socket, not shown) can be coupled to perform work on a workpiece (e.g., a fastener). The drive assembly 570 is configured to convert the constant rotational force or torque provided by the gear assembly 566 into an impact rotational force or a torque intermittently applied to the anvil 626 in a manner similar to the drive assembly 70 described above.

[0077] Still reference Fig.12 , the gear assembly 566 and the drive assembly 570 may be coated with a lubricant (such as grease or oil) that helps the power tool 510 operate smoothly by minimizing friction between the movable parts. Thus, the power tool 510 includes an intermediate box 656, one end of which is positioned adjacent to the secondary housing 522, and the other end of the intermediate box 656 is positioned adjacent to the ring gear 590. In the illustrated embodiment, the intermediate box 656 is fixed between the secondary housing 522 and the ring gear 590 by an interference fit, preventing the lubricant from escaping from the gear assembly 566 and the drive assembly 570.

[0078] The power tool 510 further includes a lighting assembly 660 directly coupled to the secondary housing 522. A passage 670 extends through the secondary housing 522 in a direction generally parallel to the axis 554. As described in more detail below, electrical wires for providing power and / or operational control for the lighting assembly 660 extend through the passage 670, beyond the rear end of the secondary housing 522, and ultimately to the second PCBA 565.

[0079] The lighting assembly 660 includes a lamp housing 672 having a body 673 and a cap 674. The cap 674 may be an elastic layer that is overmolded onto the body 673 to provide protection and impact resistance (e.g., due to being dropped, etc.) to the lighting assembly 660. In other embodiments, the cap 674 may be coupled to the body 673 via a snap fit, adhesive, fasteners, etc., or the cap 674 may be omitted. The illustrated lamp housing 672 is coupled to the secondary housing 522 by a retaining ring 675 (e.g., a snap ring) that is disposed in complementary grooves on the secondary housing 522 and the lamp housing 672 ( Fig.12In other embodiments, the lamp housing 672 may be coupled to the auxiliary housing 522 in other ways.

[0080] refer to Fig.13 , the illustrated lighting assembly 660 includes a plurality of light emitting diode ("LED") assemblies 678a, 678b, 678c, which may each be supported within a lamp housing 672. The LED assemblies 678a, 678b, 678c may be similar to the LED assemblies 178a, 178b, 178c and their alternatives described above. The wires 686, 688 ( Fig.12 ), can provide power to each LED assembly 678a, 678b, 678c. The passage 670 extends through the secondary housing 522 in a direction substantially parallel to the axis 554.

[0081] The illustrated passage 670 extends from the interior of the main housing 514 at one end and extends to the interior of the light housing 672 at the other end and retains a plug 700 that can partially seal the passage 670. The plug 700 can support the wires 686, 688 in the passage 670 and can also prevent debris (e.g., dust, lubricants, etc.) from penetrating in either direction through the passage 670. More specifically, supporting the wires 686, 688 includes preventing friction and wear during use, which can extend the life of the power tool 510.

[0082] refer to Figures 14 to 16 In the illustrated embodiment, the passage 670 is defined between a generally U-shaped wall 800 extending along the bottom side of the auxiliary housing 522 and a generally U-shaped cover 804 coupled to the wall 800. In the illustrated embodiment, the wall 800 protrudes from the bottom side of the auxiliary housing 522 and extends in a front-to-rear direction parallel to 554 ( Fig.12 ). The inner side of the wall 800 defines a recess for receiving the cover 804. The height of the cover 804 is approximately equal to the height of the recess, so that the top wall 808 of the cover 804 is substantially flush with the inner cylindrical wall 812 of the secondary housing 522. Thus, the cover 804 does not interfere with the movement or operation of the drive assembly 570. In some embodiments, the cover 804 is made of a first material (e.g., a plastic material) and the secondary housing 522 is made of a second material (e.g., a metal material). The cover 804 can be coupled to the wall 800 by a snap fit or interference fit within the recess, or in other embodiments via a sliding fit (e.g., having a mating feature such as a track to keep the cover 804 within the recess defined by the wall 800). During operation, the cover 804 protects the wires 686, 688 from the heat, lubricant, and movement of the drive assembly 570 within the interior of the secondary housing 522.

[0083] Fig.17A power tool 1010 according to another embodiment is shown. The power tool 1010 is similar in some respects to the power tool 1010 described above with reference to FIG. Figures 1 to 10 The following description focuses primarily on the differences between power tool 1010 and power tool 10, and it should be understood that, where applicable, the features of power tool 1010 and the alternatives described herein may be incorporated into power tool 10, and vice versa. In addition to the differences described herein, power tool 1010 may additionally or alternatively include some or all of the features of the power tools described and illustrated in International Patent Application No. PCT / US2022 / 048534 of Milwaukee Electric Tool Company, the entire contents of which are incorporated herein by reference.

[0084] The illustrated power tool 1010 includes a main housing 1014 having a motor housing portion 1018. A secondary housing 1022 is coupled to the main housing 1014. A motor 1042 is supported within the motor housing portion 1018 and has a stator 1046 with a plurality of coil windings and a rotor with an output shaft 1050 that is rotatable relative to the stator 1046 about an axis 1054. A first printed circuit board assembly ("PCBA") 1063 is supported within the motor housing portion 1018 of the main housing 1014. The illustrated first PCBA 1063 extends perpendicular to the axis 1054 and may include one or more Hall effect sensors that provide feedback for controlling the motor 1042. A second PCBA 1065 is supported within the main housing 1014 and extends generally parallel to the axis 1054. The second PCBA 1065 is in electrical communication with the motor 1042.

[0085] Like the power tool 10, the illustrated power tool 1010 includes a gear assembly 1066 driven by an output shaft 1050 and an impact mechanism or drive assembly 1070 coupled to the output end of the gear assembly 1066. The gear assembly 1066 provides speed reduction between the output shaft 1050 and the input end of the drive assembly 1070. The gear assembly 1066 includes a pinion 1072 integrally formed with the output shaft 1050 in the illustrated embodiment, a plurality of planetary gears 1086 meshing with the pinion 1072, and a ring gear 1090 meshing with the planetary gears 1086 and rotatably fixed within the main housing 1014. In the illustrated embodiment, the ring gear 1090 is directly supported by the main housing 1014. In other embodiments, the ring gear 1090 may be supported by a gear box, which in turn may be supported by the main housing 1014.

[0086] The planetary gears 1086 are coupled to the camshaft 1094 of the drive assembly 1070 so that the camshaft 1094 serves as a planet carrier. Accordingly, the rotation of the output shaft 1050 rotates the planetary gears 1086, which then travel along the inner circumference of the ring gear 1090, thereby rotating the camshaft 1094. The drive assembly 1070 also includes an anvil 1126 extending from the secondary housing 1022 to which a tool element (e.g., a socket, not shown) can be coupled to perform work on a workpiece (e.g., a fastener). The drive assembly 1070 is configured to convert the constant rotational force or torque provided by the gear assembly 1066 into an impact rotational force or a torque intermittently applied to the anvil 1126 in a manner similar to the drive assembly 70 described above.

[0087] The gear assembly 1066 and the drive assembly 1070 may be coated with a lubricant (such as grease or oil) that helps the power tool 1010 operate smoothly by minimizing friction between the movable parts. Thus, the power tool 1010 includes an intermediate box 1156, one end of which is positioned adjacent to the secondary housing 1022, and the other end of the intermediate box 1156 is positioned adjacent to the ring gear 1090. In the illustrated embodiment, the intermediate box 1156 is fixed between the secondary housing 1022 and the ring gear 1090 by an interference fit, preventing lubricant from escaping from the gear assembly 1066 and the drive assembly 1070.

[0088] The power tool 1010 further includes a lighting assembly 1160 directly coupled to the secondary housing 1022. A passage 1170 extends through the secondary housing 1022 in a direction generally parallel to the axis 1054. As described in more detail below, electrical wires for providing power and / or operational control for the lighting assembly 1160 extend through the passage 1170, beyond the rear end of the secondary housing 1022, and ultimately to the second PCBA 1065.

[0089] The lighting assembly 1160 includes a lamp housing 1172 having a cap 1174. The cap 1174 may be a resilient layer that is overmolded over the body of the lamp housing 1172 to provide protection and impact resistance (e.g., from being dropped, etc.) to the lighting assembly 1160. In other embodiments, the cap 1174 may be coupled to the body of the lamp housing 1172 via a snap fit, adhesive, fasteners, etc., or the cap 1174 may be omitted. The illustrated lamp housing 1172 is coupled to the secondary housing 1022 by a retaining ring 1175 (e.g., a snap ring) that is disposed in complementary grooves on the secondary housing 1022 and the lamp housing 1172. In other embodiments, the lamp housing 1172 may be coupled to the secondary housing 1022 by other means.

[0090] The illustrated lighting assembly 1160 includes a plurality of light emitting diode ("LED") assemblies that are similar to the LED assemblies 178a, 178b, 178c, but in a Fig.17 Only one LED assembly 1178 is shown. The LED assemblies 1178 can each be supported within the lamp housing 1172. The LED assemblies 1178 can be similar to those described above. Figure 3 LED assemblies 178a, 178b, 178c and their alternatives. Power can be provided to each LED assembly 1178 by wires 1188 routed through passages 1170 from the second PCBA 1065.

[0091] One end of the illustrated passage 1170 extends from the interior of the main housing 1014, and the other end extends to the interior of the light housing 1172. The sleeve 1200 surrounds and protects the wires 1188 within the passage 1170. In some embodiments, the entire portion of the wires 1188 extending through the passage 1170 is surrounded by the sleeve 1200 (i.e., the sleeve 1200 extends the entire length of the passage 1170). In some embodiments, the sleeve 1200 can extend beyond the end of the passage 1170. The sleeve 1200 can protect the wires 1188 from friction and wear during use of the power tool 1010.

[0092] In the illustrated embodiment, sleeve 1200 is made of fiberglass. Specifically, a single layer of fiberglass surrounds wire 1188. In some embodiments, multiple layers of fiberglass or other types of sleeves may surround wire 1188. In other embodiments, wire 1188 may be surrounded by multiple different sleeves (e.g., Figure 6 The plug 200 and Fig.17 The illustrated sleeve 1200) surrounds and / or supports.

[0093] Although the present disclosure has been described in detail with reference to certain exemplary embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the present disclosure as described. For example, the lighting assembly 160, 660 described and illustrated herein may be incorporated into other types of power tools such as drills, electric screwdrivers, ratchet tools, precision torque tools, and the like.

[0094] Various features of the present disclosure are set forth in the appended claims.

Claims

1. A power tool comprising: A housing, the housing comprising a main housing and a secondary housing connected to the main housing; a motor supported within the main housing; an output member driven by the motor and extending from the secondary housing; as well as a circuit board assembly supported within the main housing; Features: a passageway formed at least in part by the secondary housing; and A lighting assembly is coupled to the secondary housing, the lighting assembly comprising: a light source configured to illuminate the workpiece, an electrical wire extending from the circuit board assembly through the passage to the lighting assembly, and A sleeve is positioned in the passageway and surrounds at least a portion of the wire.

2. The power tool according to claim 1, wherein: The main housing includes a motor housing portion in which the motor is supported and a handle portion extending from the motor housing portion and wherein the circuit board assembly is supported within the handle portion.

3. The power tool according to claim 1, wherein: The passage includes a first end, a second end opposite the first end, and a middle portion between the first end and the second end, and wherein a cross-sectional area of ​​the passage increases from the middle portion toward the first end.

4. The power tool according to claim 3, wherein: The cross-sectional area of ​​the passage increases from the middle portion toward the second end such that the middle portion defines a minimum cross-sectional area of ​​the passage.

5. The power tool according to claim 4, wherein: The socket is a first socket received between the first end and the intermediate portion, and wherein the power tool further includes a second socket received between the second end and the intermediate portion.

6. The power tool according to claim 5, wherein: The first sleeve and the second sleeve are plugs compressed within the passageway.

7. The power tool according to claim 4, wherein: The secondary housing is molded using a mold assembly, and wherein a parting line of the mold assembly extends through the intermediate portion.

8. A power tool as claimed in any preceding claim, wherein: The light source is a first light source, and wherein the lighting assembly further comprises a second light source and a third light source.

9. The power tool according to claim 8, wherein: The first light source, the second light source, and the third light source are offset from each other by 120 degrees.

10. The power tool according to claim 1, wherein: The secondary housing includes a wall defining a recess, and wherein the power tool further includes a cover received within the recess.

11. The power tool according to claim 10, wherein: The passage is defined between the cover and the wall.

12. The power tool according to claim 10, wherein: The wall and the cover are generally U-shaped.

13. The power tool according to any one of claims 10 to 12, wherein: The secondary housing includes a cylindrical inner surface, and wherein the cover includes a top wall that is substantially flush with the cylindrical inner surface.

14. The power tool according to any one of claims 10 to 12, wherein: The secondary housing and the cover include different materials.

15. The power tool according to any one of claims 1 to 7, wherein: The sleeve is made of fiberglass.

16. A power tool comprising: A housing, the housing comprising a main housing and a secondary housing connected to the main housing; a motor supported within the main housing; an output member driven by the motor and extending from the secondary housing; as well as a circuit board assembly supported within the main housing; Features: a passage defined between a wall extending along a bottom side of the secondary housing and the cover; and A lighting assembly is coupled to the secondary housing, the lighting assembly comprising: a light source configured to illuminate the workpiece; and An electrical wire extends from the circuit board assembly through the passage to the lighting assembly.

17. The power tool according to claim 16, wherein: The output member is configured to rotate about an axis, and wherein the circuit board and the passageway both extend parallel to the axis.

18. The power tool according to claim 16 or 17, further comprising: a drive assembly having a camshaft driven by the motor; and a hammer head configured to reciprocate along the cam shaft, and wherein the cover separates the wire from the hammer head.

19. A power tool comprising: A housing, the housing comprising a main housing and a secondary housing connected to the main housing; a motor supported within the main housing; an output member driven by the motor about an axis and extending from the secondary housing; as well as a circuit board assembly supported within the main housing; Features: a passageway defined by a hole extending through the secondary housing in a direction parallel to the axis; and A lighting assembly is coupled to the secondary housing, the lighting assembly comprising: a light source configured to illuminate the workpiece, an electrical wire extending from the circuit board assembly through the passage to the lighting assembly, and A sleeve is positioned in the passageway and surrounds at least a portion of the wire.

20. The power tool according to claim 19, wherein: The sleeve is made of fiberglass.

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