Integrated dust extractor and power tool

Abstract

To provide dust extractor assemblies for use with power tools.SOLUTION: A handheld power tool includes: a housing; a tool receptacle disposed on a first end of the housing and configured to receive a tool accessory; and a motor positioned within the housing and operatively coupled to the tool receptacle to drive the tool accessory. A dust container is selectively coupled to the housing. A dust tube is coupled to the first end of the housing and in fluid communication with the dust container, where the dust tube is movable between an extended position and a retracted position. A fan is positioned within the housing and is operable to generate a suction air flow path through the dust tube and into the dust container, where the fan is rotatably driven by the motor.SELECTED DRAWING: Figure 22

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Patent Application No. 63 / 169,611, filed April 1, 2021, and U.S. Provisional Patent Application No. 63 / 211,856, filed June 17, 2021, the entire contents of each of which are incorporated by reference herein.

[0002] (Technical field) The present disclosure relates to power tools, and more particularly, to a dust collection assembly for use with a power tool. [Background technology]

[0003] Dust collection assemblies are commonly used in conjunction with hand-held drilling tools, such as rotary hammers, to collect dust and other debris during drilling operations and prevent the dust and other debris from accumulating at the work site. Such dust collection assemblies may be attached to the rotary hammer so as to position the suction inlet of the collection device in close proximity to a drill bit attached to the rotary hammer. Such dust collection assemblies may also include an on-board dust bin for accumulating dust and other debris. Such dust bins are often removable from the dust collection assembly to facilitate disposal of the accumulated dust and debris. Summary of the Invention [Means for solving the problem]

[0004] The present disclosure provides, in one aspect, a handheld power tool comprising a housing, a tool receptacle disposed on a first end of the housing and configured to receive a tool accessory, a drive assembly disposed within the housing and configured to drive the tool accessory, a motor disposed within the housing and operably coupled to the drive assembly for driving the drive assembly, a dust receptacle selectively coupled to the housing, a suction pipe coupled to the first end of the housing and in fluid communication with the dust receptacle, the suction pipe being movable between a first position and a second position, and a suction fan disposed within the housing and operable to generate an air flow path through the suction pipe into the dust receptacle.

[0005] The present disclosure provides a handheld power tool including a housing, a tool receptacle disposed on a first end of the housing and configured to receive a tool accessory, and a motor disposed within the housing and operably coupled to the tool receptacle for driving the tool accessory. A dust receptacle is selectively coupled to the housing. A dust tube is coupled to the first end of the housing and in fluid communication with the dust receptacle, the dust tube being movable between an extended position and a retracted position. A fan is disposed within the housing and operable to generate a suction air flow path through the dust tube and into the dust receptacle, the fan being rotatably driven by the motor.

[0006] The present disclosure also provides a handheld power tool comprising a housing, a tool receptacle disposed on a first end of the housing and configured to receive a tool accessory, a motor disposed within the housing and operably coupled to the tool receptacle for driving the tool accessory, a dust receptacle selectively coupled to the housing, an overbit dust tube coupled to the first end of the housing and in fluid communication with the dust receptacle, the overbit dust tube being movable between an extended position and a folded position, and a suction fan disposed within the housing and operable to generate an air flow path through the dust tube and into the dust receptacle.

[0007] Additionally, the present disclosure provides a handheld power tool comprising: a housing; a tool receptacle disposed on a first end of the housing and configured to receive a tool accessory, the tool accessory defining an actuation axis; a handle extending rearwardly from a second end of the housing; a motor disposed within the housing and operably coupled to the tool receptacle for driving the tool accessory; a dust receptacle selectively coupled to the housing; a dust tube coupled to the first end of the housing and in fluid communication with the dust receptacle, the dust tube being movable between an extended position and a retracted position; a dust transfer tube fluidly connecting the dust tube and the dust receptacle, the dust transfer tube extending through at least a portion of the housing; and a fan disposed within the housing and operable to generate a suction air flow path through the dust tube and into the dust receptacle.

[0008] In some embodiments, the dust receptacle is substantially received within the housing.

[0009] In some embodiments, the hand held power tool includes a filter that is at least partially disposed within the dust receptacle when the dust receptacle is coupled to the housing.

[0010] In some embodiments, the drive assembly, motor, suction fan, and filter are located within the top half of the housing.

[0011] In some embodiments, the central axis of the filter and the axis of rotation of the suction fan intersect at an obtuse angle.

[0012] In some embodiments, the dust receptacle is adapted not to be coupled to the housing when the filter is not disposed within the housing.

[0013] In some embodiments, the suction fan is driven by a motor. Further, in some embodiments, the suction fan is mounted on the motor output shaft so as to be driven by the motor.

[0014] In some embodiments, the hand held power tool includes a cooling fan driven by the motor and operable to generate a second air flow path across the motor for cooling the motor.

[0015] In some embodiments, the suction fan and the cooling fan are coaxial.

[0016] In some embodiments, the cooling fan generates a first air flow path, the first air flow path flowing from a cooling air intake located behind the motor to a cooling air exhaust located in front of the motor.

[0017] In some embodiments, the suction fan generates a second air flow path that flows from the end of the suction pipe to a suction air outlet located behind the motor.

[0018] In some embodiments, the hand-held power tool includes a transfer tube in fluid communication with the suction pipe and the dust receptacle for transferring dust from the suction pipe to the dust receptacle, the transfer tube including a bend of 0 degrees to 90 degrees.

[0019] In some embodiments, the dust receptacle is coupled to the transfer tube by a connection port.

[0020] In some embodiments, the hand-held power tool includes a filter cleaning mechanism, the filter cleaning mechanism being operable as an automatic filter cleaning mechanism, and further, in some embodiments, the filter cleaning mechanism being operable as a manual filter cleaning mechanism.

[0021] In some embodiments, the filter cleaning mechanism includes a striker movable between a first striker position and a second striker position, where the striker contacts the filter, a spring biasing the striker to the first striker position, and a solenoid, where activation of the solenoid moves the striker to the second striker position such that the striker impacts the filter.

[0022] In some embodiments, the filter cleaning mechanism further comprises an anvil disposed between the striker and the filter. The anvil is rotatable between a first anvil position in which the anvil is spaced from the filter and a second anvil position in which the anvil contacts the filter. A torsion spring biases the anvil to the first anvil position. Actuation of the solenoid rotates the anvil and moves the striker to the second striker position such that the anvil impacts the filter.

[0023] In some embodiments, the dust receptacle includes a latch disposed adjacent to a handle section of the housing, the latch being operable by a user while gripping the handle.

[0024] In some embodiments, the hand held power tool includes a depth stop disposed on the housing.

[0025] In some embodiments, the hand held power tool includes a collapsible overbit suction pipe.

[0026] In some embodiments, the hand held power tool includes a single fan for generating the motor cooling airflow and the suction airflow, the single fan being a bi-axial fan with radial exhaust ports.

[0027] Other features and aspects of the present disclosure will become apparent upon consideration of the following detailed description and accompanying drawings. [Brief description of the drawings]

[0028] [Figure 1] FIG. 1 is a front perspective view of a rotary hammer with an integrated dust collection assembly according to one embodiment. [Diagram 2] FIG. 1 is a rear perspective view of a rotary hammer with an integrated dust collection assembly according to one embodiment. [Figure 3A] FIG. 2 is a first cross-sectional view of the rotary hammer of FIG. 1. [Figure 3B] FIG. 2 is a second cross-sectional view of the rotary hammer of FIG. [Figure 4] FIG. 4 is an enlarged cross-sectional view of the rotary hammer of FIG. 3. [Diagram 5] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to another embodiment. [Figure 6] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 7] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 8] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 9] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 10] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 11] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 12] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 13] FIG. 13 is a schematic diagram of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 14] FIG. 13 is a cross-sectional view of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 15]FIG. 13 is a side view of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 16] FIG. 16 is a side view of the rotary hammer of FIG. 15 with the rotary portions hidden for clarity. [Figure 17] FIG. 16 is a detailed view of a portion of the rotary hammer of FIG. 15 showing the motor and fan. [Figure 18] FIG. 16 is a side view of the rotary hammer of FIG. 15 with portions of the rotary hammer hidden for clarity. [Figure 19] FIG. 13 is a first perspective view of a rotary hammer with an integrated dust collection assembly according to yet another embodiment. [Figure 20] FIG. 20 is a second perspective view of the rotary hammer shown in FIG. 19. [Figure 21] FIG. 21 is a cross-sectional view of the rotary hammer of FIG. 20. [Figure 22] FIG. 2 is a detailed view from a first side of the drive unit and dust collection assembly. [Figure 23] FIG. 11 is a detailed view from a second side of the drive unit and dust collection assembly. [Figure 24] FIG. [Diagram 25] FIG. 4 is a detailed view of a portion of the dust transport tube. [Figure 26] FIG. 13 is a detailed view of the connection between the dust tube and the nose of the rotary hammer. [Figure 27] FIG. 2 is a detailed view of a fan according to one embodiment. [Figure 28] FIG. 13 is a detailed view of a fan and filter cleaning mechanism according to one embodiment. [Figure 29] 1 illustrates an auxiliary handle according to one embodiment. [Diagram 30] FIG. 4 is a detailed view of a portion of the auxiliary handle. [Diagram 31] FIG. 4 is a detailed view of the connection between the auxiliary handle and the rotary hammer. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Before describing embodiments of the present disclosure in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0030] Power tools, such as rotary hammers, generate a large amount of dust and debris when the tool is operated. As such, dust collectors or dust collection systems have been implemented to attempt to capture the dust rather than allowing it to be exhausted into the air or inhaled by the user. Existing dust collection systems are generally completely separate tools that may be used in conjunction with the power tool. For example, some dust collection systems are housed in a separate tool housing and may be connected to the housing of the power tool. Other dust collection systems utilize a separate industrial vacuum cleaner and dust passageway to collect the dust. Current dust collection systems may be bulky, cumbersome, or heavy when connected to the power tool. Similarly, dust collection systems that utilize a separate industrial vacuum cleaner may limit the movement and maneuverability of the power tool due to the fact that it is restrained by the industrial vacuum cleaner. Additionally, because existing dust collection is generally implemented as a separate tool, the overall tool system may be more costly due to the fact that the power tool and the dust collection system may include duplicate parts. For example, the power tool and the dust collection system may each have their own batteries, motors, fans, controllers, housings, and the like.

[0031] The present disclosure addresses some of these challenges and also provides a series of other improvements that may be implemented in one or both of the power tool and / or the dust collection assembly. The present disclosure provides a power tool with an integrated dust collection assembly housed within the power tool. As used in this disclosure, the integration of the dust collection assembly is intended to mean that at least some parts of the dust collection assembly are not removable from the power tool and / or are integrated within the same housing as the power tool. Some parts of the dust collection assembly, such as the suction tube and / or dust receptacle, may be removably coupled to the power tool, while other parts, such as the fan and / or fan motor, are not intended to be removed from the power tool. Additionally, the integration of the dust collection assembly within the power tool results in at least some of the components being utilized in a manner that is shared between the power tool and the dust collection assembly. However, this does not require that all parts are shared. Some parts of the dust collection assembly may be separate from the power tool or may overlap with parts of the power tool.

[0032] The integration of the dust collection assembly into the power tool may provide several different advantages. For example, the integration of the dust collection assembly into the power tool may reduce the number of parts for the operation of the power tool and the dust collection assembly. This in turn may reduce the overall cost of the system. Additionally, in some embodiments, the reduction in parts may also reduce the overall weight and size of the system. Similarly, in some embodiments, the profile of the tool system is more compact, which may allow a user to more easily manipulate and hold the tool system.

[0033] As will be appreciated by those skilled in the art, although the present disclosure is described with respect to a rotary hammer, the features described herein may be applied to other hand-held power tools that generate dust during operation. For example, in some embodiments, the present disclosure may be applied to other types of power tools, such as drills, grinders, sanders, cutting tools, or other power tools that generate dust.

[0034] 1 and 2 show a power tool such as a rotary hammer 4 according to one embodiment. The illustrated rotary hammer 4 includes a dust collection assembly 8 integrated into the body of the tool. In other embodiments, one or more parts of the dust collection assembly 8 may be implemented as a separate element from the rotary hammer 4 or may be located outside the rotary hammer 4. As will be understood based on the present disclosure, the integration of the dust collection assembly 8 into the rotary hammer 4 may allow a reduction in the number of parts for the operation of the rotary hammer 4 and the dust collection assembly 8. For example, in some embodiments, the dust collection assembly 8 and the rotary hammer 4 may share certain parts. In some embodiments, this may reduce the overall cost of the system. Similarly, in some embodiments, this may reduce the overall weight and size of the system. Similarly, in some embodiments, the profile of the tool system is more compact, which may allow a user to operate and hold the tool system more easily. It should be understood that the various features and embodiments described in the present disclosure may be mixed together or interchanged into different combinations of features and embodiments. In other words, the particular combinations of features disclosed herein are not intended to be limiting, but are merely illustrative of example embodiments incorporating various features throughout the disclosure.

[0035] The rotary hammer 4 comprises a housing 12 having a body 16 and a handle 20 extending rearwardly of the body 16. The body 16 comprises a first end 24 to which a tool bit 32 may be coupled and a second end 28 from which the handle 20 extends. The tool bit 32 may be received within a chuck assembly 36 formed at the first end 24 of the body 16. Additionally, a suction pipe 40 is slidably engaged with the first end 24 of the body 16. As shown in FIGS. 3A and 3B, the housing 12 may be divided into quarters defined by an upper half, a lower half, a front half, and a rear half. In the illustrated embodiment, the upper half begins above the suction pipe 40 of the dust collection assembly 8. Additionally, in the illustrated embodiment, the front half begins at the first end 24 of the housing 12 and extends to a midpoint between the first end 24 of the body 16 and the rear end of the handle 20. This therefore results in an anterior upper quadrant (UFQ), a posterior upper quadrant (URQ), an anterior lower quadrant (LFQ), and a posterior lower quadrant (LRQ). However, in other embodiments, each quadrant may be defined by a different boundary.

[0036] A drive unit 44 is disposed within the body 16 of the housing 12. The drive unit 44 includes a motor 48 and a drive assembly 52 operatively coupled to the motor 48 for receiving torque from the motor 48. The motor 48 defines a motor axis A1 parallel to an operating axis A2 of the rotary hammer 4. The operating axis A2 of the rotary hammer 4 is defined as an axis passing through the tool bit 32 and the drive assembly 52. ​​Power to the motor 48 is provided by a battery 56, which may be received in a battery receptacle 60 at the bottom of the handle 20. However, in other embodiments, the battery receptacle 60 may be located in other portions of the housing 12.

[0037] A cooling fan 64 is operatively coupled to the motor 48 and shares a common axis of rotation with the motor axis A1. The motor 48 thereby drives both the drive assembly 52 and the cooling fan 64. In the illustrated embodiment, the cooling fan 64 is disposed between the chuck 36 and the motor 48 on the forward side of the motor 48. In another embodiment, the cooling fan 64 is operatively coupled to the motor 48 and disposed below the drive unit 44. As described in further detail herein, the cooling fan 64 draws air along an air flow path that extends across the motor 48 to cool the motor 48. More specifically, the cooling fan 64 draws air through a cooling air inlet 68 located on the housing 12 rearward of the motor 48 and exhausts the air through a cooling air outlet 72 located on the housing 12 forward of the motor 48.

[0038] In the illustrated embodiment, the drive unit 44 and the cooling fan 64 are disposed in the upper half of the housing 12. Thus, the drive unit 44 and the cooling fan 64 are disposed above the suction pipe 40. Furthermore, the drive unit 44 and the cooling fan 64 are disposed in the front half of the housing 12. The disposition of the drive unit 44 and the cooling fan 64 in the front upper quarter provides additional space for the dust collection assembly 8. For example, the drive unit 44 does not extend (or extends only minimally) into the rear upper quarter. Thus, there is space between the drive unit 44 and the second end 28 of the body 16. Similarly, the drive unit 44 does not extend (or extends only minimally) into the front lower quarter and the rear lower quarter, leaving sufficient space for the dust collection assembly 8.

[0039] The rotary hammer 4 also includes a dust collection assembly 8. In the illustrated embodiment, the dust collection assembly 8 is integrated into the body 16 of the rotary hammer 4. However, in other embodiments, one or more components of the dust collection assembly 8 may be disposed in the handle 20 of the rotary hammer 4 or may be disposed outside the housing 12. Referring to FIGS. 3A-3B, the dust collection assembly 8 includes a nozzle 76, a telescopic suction pipe 40, a dust container 84, a filter 88, and a suction fan 92. The nozzle 76 is disposed at a first end of the telescopic suction pipe 40 adjacent to the tool bit 32 of the rotary hammer 4 such that the tool bit 32 extends through the nozzle 76. The second end of the telescopic suction pipe 40 extends into the housing 12 such that the suction pipe 40 extends from and is retracted into the first end 24 of the body 16.

[0040] The dust container 84 is selectively coupled to the housing 12. The dust container 84 is removable from the housing 12 of the rotary hammer 4 and may be removed to allow an operator to empty the dust container 84 of dust and other debris. A latch 96 operable by a user to selectively disconnect the dust container 84 from the housing 12 is located on the housing 12 proximate the handle 20. In the embodiment of FIG. 2, the latch 96 is located near the bottom edge of the housing 12. In another embodiment, as shown in FIG. 14, the latch 96 may be located on the second end 28 of the housing 12 such that the latch 96 faces the handle 20 and is positioned to be operated by a user while the user is holding the handle 20. In the illustrated embodiment, the latch 96 is located opposite a trigger switch 98 that selectively operates the rotary hammer 4. In the illustrated embodiment, the dust container 84 is prevented from being secured to the housing 12 unless the filter 88 is in place. For example, the filter 88 serves as part of the connection between the dust container 84 and the housing 12. Thus, without the filter 88 in place, the dirt receptacle 84 is prevented from being coupled to the housing 12 .

[0041] When coupled to the rotary hammer 4, the dust receptacle 84 is substantially received within the body 16 of the housing 12 such that when coupled to the housing 12, the dust receptacle 84 does not extend (or extends only minimally) outside the housing 12. However, in other embodiments, the dust receptacle 84 may only be partially received within the housing 12 or may be attached to an exterior portion of the housing 12. In the illustrated embodiment, the dust receptacle 84 extends along the width of the bottom of the body 16. Additionally, the dust receptacle 84 extends into the rear upper quarter and into the space between the drive unit 44 and the second end 28 of the body 16.

[0042] The dust container 84 comprises an inlet 100 for a dust-containing air stream and an outlet 104 defined by the outlet end of the filter 88. More specifically, the dust container 84 comprises opposing side walls 108 and a bottom wall 112 extending between the side walls 108. The dust container 84 additionally comprises end walls 116 adjacent to each of the side walls 108 and the bottom wall 112. An opening 120 is defined in the first end wall 116 through which the filter 88 is received. The first end wall 116 further comprises the inlet 100 for the dust-containing air. A connection port 124 extends through the inlet 100 for directing the dust-containing air from the suction pipe 40 into the dust container 84. In some embodiments, the connection port 124 is a DEC26 connection. The dust bin 84 is operable to collect dust and other debris from the workpiece during drilling and / or hammering operations performed by the rotary hammer 4 to maintain a user's work area substantially free of dust and other debris.

[0043] As mentioned above, the dust bin 84 extends upwardly into the housing 12 of the rotary hammer 4 between the motor 48 and the handle 20. The filter 88 is disposed within the dust bin 84 in a section of the dust bin 84 that extends into the space between the motor 48 and the second end 28 of the body 16 (i.e., the upper rear quadrant). In other embodiments, the filter 88 may be disposed in other sections of the dust bin 84. In some embodiments, the filter 88 is a high efficiency particulate air ("HEPA") filter disposed between the dust bin 84 and the suction fan 92.

[0044] The suction fan 92 is disposed adjacent to the filter 88 behind the motor 48 to draw dust-laden air through the filter 88. The suction fan 92 is directly attached to the output shaft 94 of the motor 48 and shares a common axis of rotation with the motor axis A1. However, in some embodiments, the suction fan 92 is operatively coupled to the motor 48 via other mechanical means, such as a clutch, a belt, or a power take-off. As can be seen in FIG. 3, the motor 48, the suction fan 92, and the filter 88 are disposed within the top half of the housing 12. More specifically, the filter 88 is aligned with the suction fan 92, the motor 48, the cooling fan 64, and the drive unit 44. An axis A3 passing through the center of the filter 88 intersects the axis of rotation A1 of the suction fan 92 at an obtuse angle. In the illustrated embodiment, the axis A3 passing through the filter 88 is defined as extending perpendicularly from the surface of the filter 88 facing the suction fan 92. The angled orientation of the filter 88 reduces the overall length of the rotary hammer 4 as measured from the rearmost point of the handle 20 of the housing 12 to the forwardmost point of the nozzle 76 of the dust collection assembly 8. The obtuse angle of the filter 88 may improve the vertical upward movement of the rotary hammer 4. Additionally, the obtuse angle of the filter 88 may improve the sealing surface between the dirt receptacle 84 and the filter 88.

[0045] When rotated by the motor 48, the suction fan 92 creates an airflow that creates a vacuum in the suction pipe 40 to draw dust and other debris into the dust receptacle 84 and through the filter 88. After the dust is separated from the air through the filter 88, the clean air is exhausted through an exhaust port 128 formed in the housing 12 adjacent to the suction fan 92. As shown in FIG. 1, the exhaust port 128 is located behind the motor 48 and adjacent to the suction fan 92.

[0046] 3A-3B, the suction pipe 40 extends longitudinally within the housing of the rotary hammer 4 in a direction parallel to the working axis A2. The suction pipe 40 is configured to move along the same longitudinal axis, thereby adjusting the length of the suction pipe 40 and the position of the nozzle 76. When the tool bit 32 is inserted into the workpiece, the suction pipe 40 is retracted within the housing 12 in a telescopic manner. A depth of insertion adjuster 132 is provided within the rotary hammer housing 12, which limits the extent to which the suction pipe 40 can be retracted within the housing 12, and thus the extent to which the tool bit 32 can be inserted into the workpiece. The depth of insertion adjuster 132 is movable along the length of the suction pipe 40 and is selectively fixed to limit the extent to which the suction pipe 40 can be retracted within the housing 12. The housing 12 is also provided with an extension stop 136. The extension adjuster 136 limits the extent to which the suction pipe 40 may extend from the housing 12 by selectively securing the suction pipe 40 along its length. This feature may be used to adjust the extension length of the suction pipe 40 to correspond to the size of the tool bit 32 being used. For example, if a two inch tool bit is used, the extension length of the suction pipe 40 may be reduced to two inches to correspond to the length of the tool bit 32. If the length of the suction pipe 40 were not limited, the end of the suction pipe 40 may extend well beyond the end of the tool bit 32.

[0047] A transfer tube 140 is coupled to the suction pipe 40. The transfer tube 140 is fixed to the housing 12 and serves as a connection between the suction pipe 40 and the dust container 84. A first end of the transfer tube 140 proximate to the dust container 84 has a bend of 0 to 90 degrees. A connection port 124 is coupled to the first end of the transfer tube 140 to facilitate connection with the dust container 84. In some embodiments, the connection port 124 can be a DEC26 port. The bend in the transfer tube 140 and the connection port 124 can improve the sealing between the transfer tube 140 and the dust container 84. Additionally, the connection port 124 allows a user to remove the dust container 84 for the purpose of emptying the dust container 84 without being exposed to the dust in the dust container 84.

[0048] 3A and 4, the filter cleaning mechanism 148 is disposed within the housing 12 and is positioned adjacent to a forward-most edge of the filter 88. In other embodiments, the filter cleaning mechanism 148 may be positioned adjacent to any edge of the filter 88. The filter cleaning mechanism 148 includes an anvil 152 for impacting the filter 88, a striker 156 for striking the anvil 152, a solenoid 160 for causing the striker 156 to strike the anvil 152, and a biasing member 164 for biasing the striker 156. The anvil 152 is positioned adjacent to the filter 88 and is coupled to the housing 12 about an anvil axis A4. The anvil 152 rotates about the anvil axis A4 to move between a first anvil position spaced apart from the filter 88 and a second anvil position that contacts an impact position on the filter 88. The striker 156 has a longitudinal axis A5 parallel to the actuation axis A2 of the rotary hammer 4, along which the striker 156 moves between a first striker position and a second striker position. In the first striker position, the striker 156 contacts the anvil 152 in the first anvil position. In other embodiments, the striker 156 may be spaced apart from the anvil 152 while in the first striker position. In the second striker position, the striker 156 contacts the anvil 152 such that the anvil 152 rotates to the second anvil position and contacts the filter 88 in the impact position. In some embodiments, the filter cleaning mechanism 148 does not include the anvil 152. Rather, the striker 156 directly impacts the filter 88 when in the second striker position. A solenoid 160 is supported by the housing 12 and surrounds at least a portion of the striker 156. The biasing member 164 is disposed on the opposite side of the striker 156 and the solenoid 160 relative to the anvil 152 and the filter 88. In the illustrated embodiment, the biasing member 164 is a compression spring. The biasing member 164 biases the striker 156 toward the first striker position until the solenoid 160 is activated, at which point the solenoid 160 overcomes the biasing member 164 and moves the striker 156 to the second striker position.In the embodiment of FIG. 14, a second biasing member 166, illustrated as a torsion spring, is coupled to the anvil 152 for biasing the anvil 152 toward the first anvil position.

[0049] The filter cleaning mechanism 148 operates as follows. In one embodiment, the filter cleaning mechanism 148 is automatically activated when the suction fan 92 is deactivated. A controller (not shown) controls activation of the solenoid 160 to move the striker 156. Activation of the solenoid 160 may be based on detection of deactivation of the suction fan 92 or deactivation of the motor 48. As used herein, the suction fan 92 may be considered deactivated when it has stopped rotating, or the suction fan 92 may be considered deactivated when the suction fan 92 is rotating at a speed below a predetermined threshold when the airflow induced by the suction fan 92 has substantially stopped. Similarly, the motor 48 may be considered deactivated when it has stopped rotating or is operating below a predetermined threshold of rotational speed. In another embodiment, the filter cleaning mechanism 148 may be activated while the suction fan 92 or the motor 48 are operating. In the illustrated embodiment, an actuator, such as a push button 168, is located on the outside of the housing 12 to allow a user to manually initiate the filter cleaning mechanism 148 (FIG. 1). A push button 168 allows the operator to clean the filter 88 at will or between automatic cleaning operations.

[0050] In the rest state, the anvil 152 is in the first anvil position, the striker 156 is in the first striker position, and the solenoid 160 is not energized. To initiate the operating state, the solenoid 160 must be energized, either automatically or via a push button 168. When energized, the solenoid 160 overcomes the biasing member 164 to move the striker 156 from the first striker position to the second striker position. Once in the second striker position, the striker 156 strikes the anvil 152, causing the anvil 152 to move from the first anvil position to the second anvil position and impact the filter 88 at the impact position. The impact of the anvil 152 on the filter 88 dislodges dust and other debris from the filter 88. After the anvil 152 impacts the filter 88, the solenoid 160 is automatically deactivated, allowing the anvil 152 and striker 156 to return to their first anvil and striker positions, respectively.

[0051] The rotary hammer 4 of the embodiment of Figures 1-4 utilizes a single power source (e.g., battery 56) and a single electric motor 48 to operate the drive assembly 52 and the dust collection assembly 8. The integration of parts of the dust collection assembly 8 with the housing 12 allows for an improved component layout for vertical upward operation. Two distinct air flow paths are designated within the housing 12. The first air flow path is a dust collection flow path where dust-laden air enters through the suction air inlet at the nozzle 76, travels through the suction pipe 40 into the transfer tube 140, and deposits the dust in the dust container 84 with the aid of the filter 88. After passing through the dust container 84 and the filter 88, the now cleaned air exits the housing 12 through the suction air outlet 128. The air flow in the dust collection flow path is driven by the suction fan 92 and the motor 48. The second air flow path is characterized as a cooling air flow path. The cooling air flow path includes a cooling air inlet 68 on the housing 12 and a cooling air exhaust 72 spaced from the cooling air inlet 68 on the housing 12. Air in the cooling air flow path enters through the cooling air inlet 68, is directed over the motor 48 to cool the motor 48, and exits through the cooling air exhaust 72. The cooling air path is powered by a cooling fan 64 that is mounted coaxially with a suction fan 92 on the motor 48.

[0052] FIG. 5 shows another embodiment of a rotary hammer 4b with an integrated dust collection assembly 8b, where like parts are given like reference numerals with the addition of the letter "b", with the following differences being explained below. In the embodiment shown in FIG. 5, the motor axis A1b of this embodiment is perpendicular to the drive assembly 52b and the actuation axis A2b. The dust container 84b is selectively coupled to the housing 12b at a lower front portion below the drive assembly 52b. The geometry of this embodiment can improve vertical downward movement, resulting in a shorter length of the rotary hammer 4b.

[0053] FIG. 6 shows yet another embodiment of a rotary hammer 4c with an integrated dust collection assembly 8c, where like parts are given like reference numerals with the addition of the letter "c", with the following differences being explained below: The housing 12c has a lower housing part designed to connect with a dust container 84c. A single fan 172 driven by a motor 48c draws in the dust collection airflow and the cooling airflow. The rotary hammer 4c of this embodiment can improve horizontal drilling. Advantageously, this embodiment has only a single fan 172 to cool the motor and drive the dust collector.

[0054] FIG. 7 shows yet another embodiment of a rotary hammer 4d with an integrated dust collection assembly 8d, where like parts are given like reference numerals with the addition of the letter "d", with the following differences being explained below. A single fan 172d axially disposed within the housing 12d between the motor 48d and the drive assembly 52d draws in both the dust collection airflow and the cooling airflow. The arrangement of the components of the dust collection assembly 8d, namely the filter 88d, the dust container 84d, the transfer tube 140d, the suction pipe 40d, and the nozzle 76d, remains unchanged from the embodiment of FIGS. 1-4. This geometric arrangement results in a rotary hammer 4d with improved vertical upward movement.

[0055] FIG. 8 shows yet another embodiment of a rotary hammer 4e with an integrated dust collection assembly 8e, where like parts are given like reference numerals plus the letter "e", with the following differences explained below: A secondary transfer tube 176 is disposed between the filter 88e and the suction pipe 40e. Additionally, the filter axis A3e is oriented perpendicular to the motor axis A1e. This housing 12e geometry allows for a low tool height and a long tool length. The tool geometry of this embodiment may improve horizontal operation.

[0056] Figure 9 shows yet another embodiment of a rotary hammer 4f with an integrated dust collection assembly 8f, where like parts are given like reference numerals plus the letter "f", with the following differences explained below: The suction pipe 40f is located horizontally next to the drive assembly 52f. This results in a short tool height, optimized for horizontal drilling.

[0057] FIG. 10 shows yet another embodiment of a rotary hammer 4g with an integrated dust collection assembly 8g, where like parts are given like reference numerals plus the letter "g", with the following differences explained below: The suction fan 92g is located on a suction fan drive shaft 180, separate from the motor 48g. The suction fan drive shaft 180 is parallel to the motor axis A1g. A belt or chain 184 connects the suction fan drive shaft 180 to the motor 48g, enabling the motor 48g to drive the suction fan 92g. Advantageously, the suction drive of this embodiment allows the rotational speed of the motor 48g and the suction fan 92g to be different.

[0058] 11 illustrates yet another embodiment of a rotary hammer 4h with an integrated dust collection assembly 8h, where like parts are given like reference numerals plus the letter "h", with the following differences being explained below: A suction fan 92h is oriented perpendicular to the motor shaft A1h and is driven via a bevel gear train 188.

[0059] Figure 12 shows yet another embodiment of a rotary hammer 4i with an integrated dust collection assembly 8i, where like parts are given like reference numerals plus the letter "i", with the following differences being explained below: The dust collection assembly 8i is geometrically arranged similarly to the embodiment of Figure 6, but the suction fan 92i is oriented perpendicular to the motor shaft A1i and is driven via a bevel gear train 188i.

[0060] 13 shows yet another embodiment of a rotary hammer 4j with an integrated dust collection assembly 8j, where like parts are given like reference numerals plus the letter "j", with the following differences being explained below. A second motor 192 is disposed within the housing 12j for driving the suction fan 92j of the dust collection assembly 8j. Advantageously, this embodiment allows independent control of the speed of the dust collection assembly 8j and the speed of the drive assembly 52j. In this embodiment, the dust collection assembly 8j can operate even when the drive assembly 52j is not engaged.

[0061] 15-18 show yet another embodiment of a rotary hammer 4k with an integrated dust collection assembly 8k, where like parts are given like reference numerals with the addition of the letter "k", with the following differences being explained below. With reference to FIG. 15, the rotary hammer 4k comprises a housing 12k having a body 16k and a handle 20k extending rearwardly of the body 16k. With reference to FIG. 16, a motor 48k, a drive assembly 52k, and a fan 200 are disposed within the body 16k. Each of the drive assembly 52k and the fan 200 is operatively coupled to the motor 48k to receive torque from the motor 48k. The motor 48k is oriented within the body 16k such that it is not parallel to the working axis A2 of the rotary hammer 4k. In particular, the motor 48k is oriented such that the motor axis A1, defined as the rotation axis of the motor 48k, transverses the working axis A2 of the rotary hammer 4k. In some embodiments, the motor 48k may be oriented such that the motor axis A1 is oriented vertically and perpendicular to the actuation axis A2. The body 16k of the rotary hammer 4k supports the dust receptacle 84k in its lower half such that the motor 48k, the fan 200, and the dust receptacle 84k are aligned along the motor axis A1 and the fan 200 is disposed between the motor 48k and the dust receptacle 84k.

[0062] Referring to FIG. 17, the fan 200 is a two-axis fan. Torque from the motor 48k causes the fan 200 to rotate, which draws air towards the fan 200. In the illustrated embodiment, air enters the fan 200 from two opposite directions along the rotation axis A1 of the fan 200, as indicated by the arrows in FIG. 17. Specifically, a first air flow enters the fan 200 from the top side of the fan 200, and a second air flow enters the fan 200 from the bottom side of the fan 200. When the air reaches the fan 200, the air is directed radially outward from the fan 200 to be exhausted. In particular, the fan 200 draws cooling air to the rotary hammer 4K through an opening in the housing of the rotary hammer 4K. The cooling air flow is then drawn over the motor 48k to cool the motor 48K. The fan 200 may further draw cooling air to the controller 205 to cool the controller 205. After passing through motor 48K and / or controller 205, the cooling airflow enters fan 200 from the top side of fan 200.

[0063] The fan 200 also creates a suction airflow, where air is directed through the dust collection assembly 8k in the opposite direction to the cooling airflow towards the fan 200 and then radially out the exhaust port 204. The rotation of the fan 200 simultaneously creates a motor cooling airflow and a suction airflow. In some embodiments, the cooling airflow and the dust collection airflow may be two separate airstreams that are separated from each other until they merge within the fan 200 and are exhausted together as a combined airstream. In some embodiments, the cooling airflow is directed over other components of the rotary hammer 4k (e.g., circuit boards) to cool those components as well. As will be described in more detail below, the suction airflow draws dust and / or debris into a dust bin.

[0064] 15-18, the dust collection assembly 8k includes a collapsible suction pipe 208 instead of the telescopic suction pipe 40. The collapsible suction pipe 208 is selectively coupled to the housing 12k of the rotary hammer 4k and configured to surround the tool bit 32k. In other words, the dust collection assembly 8k utilizes an overbit suction pipe 208. In the illustrated embodiment, the collapsible suction pipe 208 is fixed to the housing 12k via a snap fit. However, it will be understood by those skilled in the art that other fastening methods, such as a threaded connection or a latch connection, perform the same function as the snap fit and may be used instead of the snap fit. With reference to FIG. 19, the collapsible suction pipe 208 includes a biasing member 212, illustrated as a spring, configured to bias the suction pipe 208 to an extended state. When the tool bit 32k is inserted into the workpiece, a front end 216 of the suction pipe 208 engages the workpiece. As the tool bit 32k is inserted further into the workpiece, the suction pipe 208 folds or collapses against the force of the spring 212 while the front end 216 remains in contact with the workpiece. When collapsed, the entire collapsible suction pipe 208 remains outside the housing 12k of the rotary hammer 4k, thereby making room for other components of the rotary hammer 4k within the housing 12k without increasing the overall size of the housing 12k.

[0065] In some embodiments, the collapsible suction pipe 208 further comprises a locking mechanism 220, illustrated as a hook, that selectively secures the collapsible suction pipe 208 in a collapsed state. When collapsed, the hook 220 engages a corresponding lock on the housing 12k to counter the force from the biasing spring 212. Securing the suction pipe 208 in a collapsed state allows for easy replacement of the tool bit 32k without removing the collapsible suction pipe 208 from the housing 12k.

[0066] When the collapsible suction pipe 208 is secured to the housing 12k, an uninterrupted flow path is formed between an opening at the front end 216 of the suction pipe 208 and the fan 200. The suction airflow therefore draws dust and / or debris created by the tool bit 32k through the collapsible suction pipe 208 and into the dust bin 84k before the air is combined with the motor cooling airflow and exhausted through the exhaust port 204.

[0067] 19-21 illustrate a power tool, such as a rotary hammer 1004, according to another embodiment of the present disclosure. The illustrated rotary hammer 1004 includes a dust collection assembly 1008 integrated into the body of the tool. In some embodiments, one or more portions of the dust collection assembly 1008 may be implemented as a separate element from the rotary hammer 1004 or may be located external to the rotary hammer 1004.

[0068] The rotary hammer 1004 comprises a housing 1012 having a body 1016 and a handle 1020 extending rearwardly of the body 1016. The body 1016 comprises a first end 1024 to which a tool accessory may be coupled and a second end 1028 from which the handle 1020 extends. The tool accessory may be, for example, a tool bit 1032, a sander, a grinder, a cutter, or any other accessory intended to operate on a work surface, so that dust can be expelled during a work operation of the rotary hammer 1004. The tool bit 1032 may be received within a chuck assembly 1036 formed in the first end 1024 of the body 1016. The tool bit 1032 defines an actuation axis A2 (FIG. 21) of the rotary hammer 1004. The handle 1020 comprises a trigger 1098 adapted to actuate the rotary hammer 1004. In the illustrated embodiment, the trigger 1098 is located on the handle 1020 in a position proximate to the actuation axis A2 of the rotary hammer 1004. In other words, the vertical position of the trigger 1098 along the handle 1020 (i.e., the vertical direction shown in the drawings) is close to or along the actuation axis A2 of the rotary hammer 1004. This causes the trigger 1098 to be generally aligned with the tool bit 1032 such that the user's fingers are also aligned with the tool bit 1032.

[0069] In some embodiments, the rotary hammer 1004 may be provided with an auxiliary handle 1300 selectively coupled to the rear of the handle 1020. The auxiliary handle 1300 may help the user control the rotary hammer 1004, especially when engaged in overhead drilling or when positioned at an awkward angle to the work surface. For example, the auxiliary handle 1300 acts as an extension arm, allowing the user to reach farther while still holding and supporting the rotary hammer 1004. Meanwhile, the auxiliary handle 1300 also allows the user to hold the rotary hammer 1004 closer to the user's body without the user having to extend their arm as much. Holding the rotary hammer 1004 closer to the user's body allows the rotary hammer 1004 to be supported more firmly and stably. Furthermore, like the trigger 1098, the auxiliary handle 1300 is generally aligned along the actuation axis A2 of the rotary hammer 1004. This configuration allows for better aiming and control of the working axis A2 anywhere from one end of the rotary hammer 1004 to the other. In other words, the user has greater control and stability over the orientation of the working axis A2 and can more easily adjust and / or maintain the angle of the working axis A2 relative to the work surface.

[0070] 29-31 provide detailed views of the auxiliary handle 1300. The auxiliary handle 1300 includes a curved grip 1330 that allows a user to grasp the grip 1330 with the palm of his / her hand and wrap his / her fingers toward the front of the grip. This style of grip allows a user to grasp the auxiliary handle 1300 directly from behind to help support the weight of the rotary hammer 1004 when engaged in overhead drilling. Additionally, because a user may grasp the curved grip 1330 directly from behind, it is also easier to operate the rotary hammer without twisting or torqueing the wrist. The illustrated auxiliary handle 1300 includes a telescoping body having a first shaft 1308 and a second shaft 1312 that is slidable within the first shaft 1308. The telescoping body thus allows the auxiliary handle 1300 to be extended to different lengths. For example, Figure 19 shows the auxiliary handle 1300 in a fully extended state, and Figure 20 shows the auxiliary handle 1300 in a retracted state. However, the auxiliary handle 1300 can be extended to a number of different lengths between the fully extended state and the retracted state. Specifically, the first shaft 1308 and the second shaft 1312 include a locking hole 1316 that, when aligned, allows a locking pin 1320 to lock the second shaft 1312 relative to the first shaft 1308. This helps maintain the auxiliary handle 1300 at a desired length.

[0071] Additionally, the auxiliary handle 1300 can be rotated to a stowed position when not in use. For example, the auxiliary handle 1300 can be rotated toward the top of the rotary hammer 1004 (counterclockwise in FIG. 19) and stowed along the top surface of the body 1016. Alternatively, the auxiliary handle can be rotated toward the rear end of the handle 1020 (clockwise in FIG. 19) and stowed along the length of the handle. This can be achieved by a rotation lock 1324, which selectively couples the auxiliary handle 1300 to the rotary hammer 1004 in various orientations. Specifically, the rotation lock 1324 releasably couples the auxiliary handle 1300 to the rear end of the rotary hammer 1004 while maintaining the auxiliary handle 1300 in different orientations relative to the rotary hammer 1004. The rotation lock 1324 can include a hinge that allows rotation of the auxiliary handle 1300 relative to the rotary hammer 1004. Additionally, the auxiliary handle 1300 may be completely removable from the rotary hammer 1004.

[0072] 21, the housing 1012 may be divided into quarters defined by an upper half, a lower half, a front half, and a rear half. In the illustrated embodiment, the upper half begins near the electric motor 1048. Additionally, in the illustrated embodiment, the front half begins at the first end 1024 of the housing 1012 and extends to a midpoint between the first end 1024 of the body 1016 and the rear end of the handle 1020. This therefore results in a front upper quarter (UFQ), a rear upper quarter (URQ), a front lower quarter (LFQ), and a rear lower quarter (LRQ). In the illustrated embodiment, the center of mass CM of the tool is located proximate to the intersection of the front upper quarter (UFQ), rear upper quarter (URQ), front lower quarter (LFQ), and rear lower quarter (LRQ).

[0073] 21-23, the drive unit 1044 is disposed within the body 1016 of the housing 1012. However, in other embodiments, one or more components of the drive unit 1044 may be disposed in the handle 1020. In the illustrated embodiment, the drive unit 1044 is disposed primarily within the top half of the housing 1012. The configuration of the drive unit 1044 provides additional space for the dust collection assembly 1008. The drive unit 1044 includes a motor 1048 and a drive assembly 1052 operably coupled to the motor 1048 to receive torque from the motor 1048. The motor 1048 defines a motor axis A1 that is angled relative to the actuation axis A2 of the rotary hammer 1004. For example, in some embodiments, the included angle between the motor axis A1 and the actuation axis A2 is between 80 degrees and 135 degrees. In some embodiments, the included angle between the motor axis A1 and the actuation axis A2 is between 90 degrees and 115 degrees. In some embodiments, the angle is 105 degrees. In yet other embodiments, the angle is 90 degrees such that the motor axis A1 extends perpendicular to the actuation axis A2. The actuation axis A2 of the rotary hammer 1004 is defined as the axis passing through the tool bit 1032 and the drive assembly 1052. In the illustrated embodiment, the motor 1048 is located proximate to the center of mass CM. In some embodiments, the motor 1048 is located in the front half near the centerline between the upper and lower housing halves 1012.

[0074] Power for the motor 1048 is provided by a battery 1056, which may be received in a battery receptacle 1060 at the bottom of the handle 1020. In other embodiments, the battery receptacle 1060 may be located in other portions of the housing 1012. In some embodiments, the battery 1056 may be a removable, rechargeable battery.

[0075] The operation of the rotary hammer 1004 is controlled by a single controller 1205. The illustrated controller 1205 controls both the motor 1048 and the dust collection assembly 1008. However, in other embodiments, two or more controllers may be included in the rotary hammer 1004 to separately control various components of the drive unit 1044 and the dust collection assembly 1008. The controller 1205 is located in the rear upper quadrant (URQ). In particular, the controller 1205 is located behind the drive assembly 1052 and above the motor 1048.

[0076] A fan 1200 is operatively coupled to the motor 1048 and shares a common axis of rotation with the motor axis A1. The motor 1048 thereby drives both the drive assembly 1052 and the fan 1200. In the illustrated embodiment, the fan 1200 is disposed below the motor 1048 and the drive assembly 1052. Thus, in the illustrated embodiment, the fan 1200 is disposed below the center of mass of the rotary hammer 1004. As described in more detail herein, the fan 1200 draws air along a cooling air passage that extends across the motor 1048 to cool the motor 1048. In some embodiments, the cooling air passage is directed over other components of the rotary hammer 1004 (e.g., the controller 1205, circuit boards) to also cool these components. At the same time, the fan 1200 draws air along a suction air passage to draw dust and / or debris into the dust collection assembly 1008. However, in other embodiments there may be two separate fans generating the cooling airflow and the dust collecting airflow.

[0077] The rotary hammer 1004 also includes a dust collection assembly 1008. In the illustrated embodiment, the dust collection assembly 1008 is integrated within the body 1016 of the rotary hammer 1004. However, in other embodiments, one or more components of the dust collection assembly 1008 may be located within the handle 1020 or may be located external to the housing 1012. The dust collection assembly 1008 includes a nozzle 1076, a dust tube 1040, a dust receptacle 1084, a filter 1088, and a fan 1200.

[0078] As shown in FIG. 24, the nozzle 1076 is disposed at a first end 1040a of the dust tube 1040. The nozzle 1076 and the dust tube 1040 surround at least a portion of the tool bit 1032 of the rotary hammer 1004. In other words, the dust collection assembly 1008 utilizes the overbit dust tube 1040. Additionally, in the illustrated embodiment, the dust tube 1040 is a collapsible suction tube. In other words, the dust tube 1040 is constructed of a compressible material that can accordion-like expand and contract. A spring, such as the spring 212, biases the dust tube 1040 toward the extended position. When the tool bit 1032 is inserted into the workpiece, the nozzle 1076 engages the workpiece. Further insertion of the tool bit 1032 into the workpiece causes the dirt tube 1040 to collapse or fold against the force of the spring 212 while the nozzle 1076 maintains contact with the workpiece.

[0079] In some embodiments, a depth adjuster 1130 is coupled to the dust tube 1040 to limit the extent to which the tool bit 1032 may be inserted into the workpiece. The depth adjuster 1130 includes a depth of insertion adjuster 1132 that limits the extent to which the dust tube 1040 may be retracted, and thus the extent to which the tool bit 1032 may be inserted into the workpiece. The depth of insertion adjuster 1132 is movable along the length of a ruler 1134 coupled to the dust tube 1040 and is selectively secured to limit the extent to which the dust tube 1040 may be retracted. Also included in the extension adjuster 1136. The extension adjuster 1136 limits the extent to which the dust tube 1040 may extend by selectively securing to the ruler 1134. This feature may be used to adjust the extension length of the dust tube 1040 to correspond to the size of the tool bit 1032 being used. Additionally, in some embodiments, the suction tube 1040 may not include a depth adjustment device 1130 at all, or may only include an insertion depth adjustment device 1132 or an extension adjustment device 1136 .

[0080] Further, in some embodiments, the dust tube 1040 may also be provided with a locking mechanism 220 to maintain the dust tube 1040 in a folded state, as shown in the previous embodiment. However, in other embodiments, the dust tube 1040 may be a sliding suction tube or a telescoping suction tube (e.g., as shown in FIGS. 3A and 3B ) rather than a collapsible suction tube. Additionally, in other embodiments, the dust tube 1040 may be positioned adjacent to the tool bit 1032 instead of being configured as an overbit dust tube 1040. For example, the dust tube 1040 may be positioned above, below, or to the side of the tool bit 1032, with only the nozzle 1076 extending above the tool bit 1032.

[0081] 24, a first end of the dust tube 1040 is coupled to the nozzle 1076 and a second end 1040b of the dust tube 1040 is coupled to the housing 1012 of the rotary hammer 1004. In the illustrated embodiment, the second end 1040b of the dust tube 1040 is coupled to the housing 1012 via an external transfer tube 1140. The dust tube 1040 is secured to the nozzle 1076 and the external transfer tube 1140 by tabs 1050 that serve to hold and support the dust tube 1040 at both ends. The external transfer tube 1140 is then removably coupled to the housing 1012 via a combination of snap fit and rotational connection.

[0082] As shown in FIG. 25, the external transfer tube 1140 is first snap-fitted to the first end 1024 of the housing 1012 and then rotated (e.g., clockwise in FIG. 25) to secure the external transfer tube 1140 to the housing 1012. Specifically, the first end 1140a of the external transfer tube 1140 is snap-fitted to the housing 1012 and the second end 1140b of the external transfer tube 1140 is rotated to a locked position. The first end 1140a of the external transfer tube 1140 forms a collar, which can be snap-fitted to the nose 1064 of the rotary hammer 1004 by a snap ring 1054. The snap-fit ​​is achieved by linearly moving the external transfer tube 1140 until the snap ring 1054 axially locks the first end 1140a of the external transfer tube 1140 to the housing 1012. When secured to the housing 1012, the first end 1140a (i.e., collar) of the external transfer tube 1140 surrounds the nose 1064 such that the chuck assembly 1036 and / or the tool bit 1032 extend through an opening in the first end 1140a of the external transfer tube 1140.

[0083] To rotationally lock the external transfer tube 1140, the external transfer tube 1140 is rotated until it reaches a locked position. To achieve this, the first end 1140a of the external transfer tube 1140 is provided with one or more annular projections 1068 formed in an opening in the collar, which are received in corresponding annular recesses 1070 in the nose 1064 of the rotary hammer 1004 to facilitate rotational engagement therebetween. The external transfer tube 1140 is rotated until the second end 1140b is received in an annular groove 1062 formed in the first end 1024 of the housing 1012. The annular groove 1062 prevents further rotation of the external transfer tube 1140 relative to the housing 1012. Furthermore, the annular groove 1062 serves to align the second end 1140b of the external transfer tube 1140 with an opening that matches the internal transfer tube 1141 of the housing 1012. The external transfer tube 1140 and the internal transfer tube 1141 together direct the dust-laden air from the dust tube 1040 into the dust container 1084. The second end 1140b of the external transfer tube 1140 is fluidly connected to the internal transfer tube 1141 to form an airtight connection. Those skilled in the art will appreciate that other fastening methods may alternatively be used, such as threaded or latched connections, which perform the same function as the snap-fit ​​and rotational connections.

[0084] As shown in FIG. 26 , the rotary hammer 1004 includes a brush seal 1224 disposed within the dust tube 1040 to prevent dust from entering the body 1016 through the chuck assembly 1036. In the illustrated embodiment, the brush seal 1224 is disposed proximate the second end 1040b of the dust tube 1040, where the dust tube 1040 connects to the housing 1012. However, in other embodiments, the brush seal 1224 may be disposed within a bit holding area of ​​the housing 1012 rather than within the dust tube 1040. In yet another embodiment, the brush seal 1224 may be disposed proximate the first end 1040a of the dust tube 1040. The illustrated brush seal 1224 surrounds and engages a portion of the tool bit 1032 to prevent dust and / or debris drawn into the dust tube 1040 from entering the housing 1012. The brush seal 1224 prevents dust transported via the dust collector airflow from entering through the tool nose 1064 and / or bit retaining assembly 1036. Rather, the air flows through the dust tube 1040, through the outer transfer tube 1140, through the inner transfer tube 1141, and into the dust receptacle 1084 without entering the chamber in the body 1016 that houses the drive unit 1044 and controller 1205.

[0085] 21-23, the external transfer tube 1140 extends from the dust tube 1040 to the housing 1012, and the internal transfer tube 1141 extends from the external transfer tube 1140 to the inlet 1100 of the dust container 1084. The external transfer tube 1140 and the internal transfer tube 1141 together form a dust transfer tube 1145. As discussed, the external transfer tube 1140 is selectively coupled to the dust tube 1040 and the nose 1064 of the rotary hammer 1004 to form a suction air flow path for the dust collector. The internal transfer tube 1141 extends from the top to the bottom along the first end 1024 of the body 1016 and is coupled at the bottom to the inlet 1100 of the dust container 1084.

[0086] The dust receptacle 1084 is selectively coupled to the housing 1012. The dust receptacle 1084 is removable from the housing 1012 of the rotary hammer 1004 and may be removed to allow an operator to empty the dust receptacle 1084 of dust or other debris. In the illustrated embodiment, the dust receptacle 1084 is prevented from being secured to the housing 1012 unless the filter 1088 is in place. For example, the filter 1088 serves as part of the connection between the dust receptacle 1084 and the housing 1012. Thus, unless the filter 1088 is in place, the dust receptacle 1084 is prevented from being coupled to the housing 1012. The filter 1088 is connected to the underside of the fan 1200. In particular, the filter 1088 is connected to a shroud 1072 of the fan 1200, which extends around the circumference of and below the fan 1200. Both the fan 1200 and the filter 1088 are located at the bottom of the body 1016 below the center of mass (CM).

[0087] The dust receptacle 1084 comprises an inlet 1100 for a dust-containing air stream and an outlet 1104 defined by the outlet end of the filter 1088. More specifically, the dust receptacle 1084 comprises opposing side walls 1108 and a bottom wall 1112 extending between the side walls 1108. The dust receptacle 1084 additionally comprises end walls 1116 adjacent each of the side walls 1108 and the bottom wall 1112. An opening 1120 is defined in the top wall 1118 through which the filter 1088 is received. The top wall 1118 further comprises the inlet 1100 for the dust-containing air. A connection port 1124 extends through the inlet 1100 for directing the dust-containing air from the dust tube 1040 to the dust receptacle 1084. In some embodiments, the connection port 1124 is a DEC26 connection. The dust bin 1084 is operable to collect dust and other debris from the workpiece during drilling and / or hammering operations performed by the rotary hammer 1004 to maintain a user's work area substantially free of dust and other debris.

[0088] As described above, the fan 1200 forms both the intake air flow path (AF1) and the cooling air flow path (AF2). The fan 1200 is a dual-axis radial exhaust fan located between the motor 1048 and the filter 1088. The fan 1200 is mounted on the output shaft of the motor 1048 such that torque from the motor 1048 drives the rotation of the fan 1200. The rotation axis of the fan 1200 is therefore coaxial with the motor axis A1. As best seen in FIG. 22, air enters the fan 1200 along the rotation axis A1 of the fan 1200 from two opposite directions. Specifically, the cooling air flow path (AF2) enters the fan 1200 from the top side of the fan 1200, and the intake air flow path (AF1) enters the fan 1200 from the bottom side of the fan 1200. When air from either air flow path reaches the fan 1200, the air is directed radially outward from the fan 1200 to be exhausted.

[0089] In particular, the fan 1200 draws cooling air into the rotary hammer 1004 through an inlet opening 1066 in the housing 1012 of the rotary hammer 1004. The cooling airflow (AF2) is then drawn over the motor 1048 to cool the motor 1048. In some embodiments, the inner surface of the housing 1012 includes ribs to guide the cooling airflow (AF2) into the motor 1048, thereby ensuring that the cooling airflow (AF2) passes over the motor 1048. The fan 1200 may further draw cooling air into the controller 1205 to cool the controller 1205. After passing through one or both of the motor 1048 and the controller 1205, the cooling airflow (AF2) enters the fan 1200 from the top side of the fan 1200 and exits radially through the outlet 1104 of the fan 1200. The cooling airflow (AF2) is then exhausted from the rotary hammer 1004 through an outlet opening 1074 ( FIG. 20 ) in the housing 1012 of the rotary hammer 1004. Specifically, the outlet 1104 is formed as a radial opening in the shroud 1072 of the fan 1200, which is aligned with the outlet opening 1074 to direct the air outside the rotary hammer 1004. In some embodiments, the outlet opening 1074 is provided on a single side of the housing 1012, and the outlet 1104 of the shroud 1072 is provided on a single side of the housing 1012.

[0090] The fan 1200 also forms an intake airflow (AF1), in which air is directed through the dust collection assembly 1008 in the opposite direction to the cooling airflow (AF2) toward the fan 1200, and then radially out the exhaust port 1204. In particular, the air is drawn into the nozzle 1076, through the dust tube 1040, through the dust transfer tube 1045 (i.e., the outer transfer tube 1140 and the inner transfer tube 1141), and into the dust container 1084 where the dust is captured. The clean air is sucked up through the filter 1088 into the fan 1200 and exhausted through the outlet 1104 and the opening 1074. After the dust is separated from the air through the filter 1088, the clean air is exhausted. In some embodiments, the filter 1088 is a high-efficiency air ("HEPA") filter.

[0091] Thus, the rotation of the fan 1200 simultaneously creates the suction airflow (AF1) and the cooling airflow (AF2). In the illustrated embodiment, the fan 1200 is a dual-fin fan with a first set of fan blades 1078 and a second set of fan blades 1080, as best shown in FIG. 27. The first set of fan blades 1078 is used to create the suction airflow (AF1), and the second set of fan blades 1080 is used to create the cooling airflow (AF2). However, other types of fans may be used to create one or both airflows. For example, in some embodiments, a fan with a single set of fan blades may create both the suction airflow (AF1) and the cooling airflow (AF2). In some embodiments, the cooling airflow (AF2) and the dust collection airflow (AF2) may be two separate airstreams that are separated from each other until they meet within the fan 1200 and are exhausted together as a combined airstream. In some embodiments, the cooling airflow is directed over other components of the rotary hammer 1004 (eg, circuit boards) to cool those components as well.

[0092] In some embodiments, the dust collection assembly 1008 may have additional features. For example, in the illustrated embodiment, a hole board for the motor 1048 is disposed between the motor 1048 and the fan 1200. Additionally, a bearing 1202 supporting the output shaft of the motor 1048 is also disposed between the motor 1048 and the fan 1200 such that the cooling airflow travels over the bearing 1202. This configuration allows air from the suction airflow to travel from the dust tube 1040 into the filter 1088 and through the fan 1200 without being guided around the bearing. Additionally, this configuration allows the cooling air that cools the motor 1048 and / or the fan to travel through the stator of the motor 1048 and be guided around the bearing support structure before reaching the fan 1200.

[0093] The dust collection assembly 1008 may further include a filter cleaning mechanism 1148 (FIG. 23) that removes dust from the filter 1088. In one embodiment, the filter cleaning mechanism 1148 includes a solenoid 1082 that is activated to extend a pin 1086. The pin 1086 then engages an anvil 1090 that rotates and strikes the filter 1088 to free the debris. As described above, the controller 1205 is adapted to operate the dust collection assembly 1008 and the drive unit 1044. This allows for coordination between the two assemblies. In one embodiment, the filter cleaning mechanism 1148 is automatically activated when the fan 1200 transitions from an active state to an inactive state. In another embodiment, the filter cleaning mechanism 1148 is automatically activated when the motor 1048 transitions from an active state to an inactive state. As used herein, the fan 1200 transitions from an active state to a non-active state when the fan 1200 stops rotating or when the fan 1200 slows down to a rotational speed below a predetermined threshold such that the airflow induced by the fan 1200 substantially stops. The controller 1205 may monitor an indicator of the rotational state of the fan 1200. In some embodiments, the controller 1205 may be configured to monitor the rotation of the fan 1200 by using a Hall effect sensor to directly detect the rotational speed of the fan 1200 (e.g., by using a magnet that rotates with the fan 1200). In another embodiment, the fan 1200 transitions from an active state to a non-active state when the motor 1048 no longer transmits rotational force to the fan 1200. Similarly, the motor 1048 may transition from an active state to a non-active state when the motor 1048 stops rotating or when the motor 1048 slows down to a predetermined rotational speed threshold. For example, the controller 1205 may monitor a sensor that detects the voltage or current applied to the motor 1048 to determine whether the motor 1048 has transitioned from an operating state (i.e., a state providing torque to the fan 1200) to a non-operating state.

[0094] FIG. 28 provides another embodiment of a filter cleaning mechanism 1448. In the illustrated embodiment, the filter cleaning mechanism 1448 comprises an actuator in the form of a clutch bearing 1464 (i.e., a one-way bearing) disposed between the shaft of the motor 1048 and a rotatable plate 1462 having a plurality of teeth 1466. In normal operation, the motor 1048 and the fan 1200 rotate in a first direction (i.e., counterclockwise in FIG. 28) about the axis of rotation A1. When rotating in the first direction, no torque from the motor 1048 is transferred to the plate 1462. However, when the fan 1200 transitions from an operating state to a non-operating state (i.e., slows down to a stop or slows down below a predetermined threshold speed), the motor 1048 is configured to pulse in a second or reverse direction (i.e., clockwise in FIG. 28). Due to the action of the clutch bearing 1464, torque is transferred to the plate 1462 when the motor 1048 pulses in the reverse direction. Teeth 1466 extending from the plate 1462 in turn engage a linkage 1468 which in turn impacts the filter 1088. In the illustrated embodiment, the linkage 1468 rotates about a pivot 1472.

[0095] The integration of the dust collection assembly 1008 into the rotary hammer 1004 may provide several different advantages. For example, the integration of the dust collection assembly 1008 into the rotary hammer 1004 may allow for a reduction in the number of parts for the operation of the rotary hammer 1004 and the dust collection assembly 1008. This in turn may reduce the overall cost of the system. Additionally, in some embodiments, the reduction in parts may also reduce the overall weight and size of the system. Similarly, in some embodiments, the profile of the tool system is more compact, which may allow a user to more easily manipulate and hold the tool system. It should be understood that the various features and embodiments described in this disclosure may be mixed together or interchanged into different combinations of features and embodiments.

[0096] For example, the disclosed rotary hammer 1004 utilizes a single power source (e.g., battery 1056) and a single electric motor 1048 to operate the drive assembly 1052 and the dust collection assembly 1008. Furthermore, the rotary hammer 1004 includes a single controller adapted to control the operation of the drive assembly 1052 and the dust collection assembly 1008. Additionally, a single fan 1200 can be used to generate two different air flow paths, including a suction air flow path and a cooling air flow path. The first air flow path is a dust collection flow path, where dust-laden air enters through the nozzle 1076, travels through the dust tube 1040 into the external and internal transfer tubes 1140, 1141, and deposits the dust in the dust container 1084 with the help of the filter 1088. The air flow in the dust collection flow path is driven by the fan 1200 and the motor 1048. The second flow path is characterized as a cooling flow path, which directs clean air over the motor 1048 and / or controller 1205, or other components of the drive assembly, to cool these components.

[0097] In some embodiments, the rotary hammer 1004 is ONE-KEY® compatible. In particular, the rotary hammer 1004 is capable of wireless communication (e.g., using Bluetooth or other short-range wireless communication protocols), allowing the rotary hammer 1004 to be monitored and / or controlled via a remote device (e.g., a smartphone). When wirelessly connected to a remote device, the remote device can track the position of the rotary hammer 1004, monitor the battery 1056, remotely lock the trigger 1098, and control other aspects of the rotary hammer 1004. For example, a user can control or adjust the rotational speed and / or torque output of the motor 1048. Similarly, a user can adjust other operational settings of the tool. In some embodiments, the ONE-KEY electronics are integrated into the controller 1205. However, in other embodiments, the ONE-KEY electronics may be provided via a separate controller PCB.

[0098] Although several embodiments of a rotary hammer have been described above, those skilled in the art will appreciate that various features and components of the described embodiments may be interchanged. Furthermore, while the present disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosed disclosure as described.

[0099] Various features of the disclosure are set forth in the following claims.

Claims

[Claim 1] Housing and a tool receptacle disposed on a first end of the housing and configured to receive a tool accessory; a motor disposed within the housing and operably coupled to the tool receptacle for driving the tool accessory; a dust receptacle selectively coupled to the housing; a dust tube coupled to the first end of the housing and in fluid communication with the dust receptacle, the dust tube being movable between an extended position and a retracted position; a fan disposed within the housing and operable to generate a suction air flow path through the dust tube and into the dust receptacle, the fan being rotatably driven by the motor; A hand-held power tool comprising:

Images