Locking flex-head ratchet wrench

<u>FIELD OF THE INVENTION</u>

0001The present invention relates generally to ratchet wrenches. More particularly, the present invention relates to a ratchet wrench including a locking flex-head having a ratcheting feature.

<u>BACKGROUND OF THE INVENTION</u>

0002Wrenches having heads that pivot with respect to the wrench's handle axis ("flex-head" wrenches) for adjusting fasteners in hard to reach locations are well known, see for example <patcit id="pcit0001" dnum="DE3023882C2"><text>DE3023882C2</text></patcit> and <patcit id="pcit0002" dnum="US5199335A"><text>US5199335A</text></patcit>. <patcit id="pcit0003" dnum="DE3023882C2"><text>DE 3023882 C2</text></patcit> discloses a locking flex head tool having the features of the preamble portion of claim 1. <patcit id="pcit0004" dnum="US5199335A"><text>US5199335 A</text></patcit> discloses a locking flex head tool in which the head pivots freely was not locked. Existing flex-head wrenches include a fastener-engaging head portion that is attached to a handle at a pivot joint so that a user may adjust the angular position of the head portion relative to the handle. As well, flex-head wrenches may include locking mechanisms for securing the head portion in the desired position relative to the handle during use. Often, these flex-head wrenches are not adequately suited for adjusting the angle of the head portion relative to the handle with only one hand. More specifically, when the locking mechanism is disengaged from the head portion to allow for adjustment, the head portion pivots freely about the handle. As such, a user must grasp the head portion with one hand for positioning while operating the locking mechanism with the remaining hand. Also, in flex-head wrenches that do not have locking mechanisms, it is not uncommon for the head portion to pivot unexpectedly relative to the handle when torque is applied to a fastener.

<u>SUMMARY OF THE INVENTION</u>

0003The present invention recognizes and addresses considerations of prior art constructions and methods. According to the present invention, there is provided a ratcheting tool comprising the features as defined by claim 1.

0004The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention.

<u>BRIEF DESCRIPTION OF THE DRAWINGS</u>

0005A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which: <ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">Fig. 1</figref> is a perspective view of a locking flex-head ratchet wrench in accordance with an embodiment of the present disclosure;</li><li><figref idref="f0002">Fig. 2</figref> is an exploded partial perspective view of the ratchet wrench shown in <figref idref="f0001">Fig. 1</figref>;</li><li><figref idref="f0001">Fig. 3</figref> is a perspective view of a locking spool of the ratchet wrench shown in <figref idref="f0001">Fig. 1</figref>;</li><li><figref idref="f0003">Figs. 4A and 4B</figref> are partial top views of the ratchet wrench shown in <figref idref="f0001">Fig. 1</figref> in the locked and unlocked positions, respectively;</li><li><figref idref="f0004">Figs. 5A and 5B</figref> are partial cut-away side views of the ratchet wrench shown in <figref idref="f0003">Figs. 4A and 4B</figref>, respectively, taken along lines 5A-5A and 5B-5B;</li><li><figref idref="f0005">Figs. 6</figref> is a partial perspective view of the ratchet wrench shown in <figref idref="f0001">Fig. 1</figref> with the tool head locked in a desired position; and</li><li><figref idref="f0005">Fig. 7</figref> is a partial perspective view of an embodiment of the present invention where the ratchet wrench includes a selectively reversible ratcheting mechanism.</li></ul>

0006Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention according to the disclosure.

<u>DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS</u>

0007Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention.

0008Referring to <figref idref="f0001">Figures 1</figref> and <figref idref="f0002">2</figref>, a locking flex-head wrench 100 in accordance with the present invention includes a tool head 110 pivotally mounted to a handle 130 such that the angle of tool head 110 relative to the axis of handle 130 may be selectively altered. Tool head 110 includes a rearwardly-facing annular hub 112 with a through-bore 114 formed therein and a plurality of transverse teeth 116 formed on the outer surface thereof. A ratchet ring 111 is rotatably received in tool head 110 and includes an inner engaging surface 113 for engaging variously shaped fasteners, tools, <i>etc.</i> A ratcheting mechanism (not shown) is disposed within tool head 110 and engages an outer surface of ratchet ring 111. Embodiments of such ratchet mechanisms are disclosed in <patcit id="pcit0005" dnum="US5636557A"><text>U.S. Patent No. 5,636,557, to Ma, issued June 10, 1997</text></patcit>.

0009A yoke 132 is formed by a pair of parallel legs extending from an end of handle 130. Yoke 132 forms a recessed portion 138 having a rear bearing surface 140. A through-bore 136 is formed through an outermost end of yoke 132 so that yoke through-bore 136 aligns with tool head through-bore 114 when annular hub 112 of tool head 110 is positioned between the legs of yoke 132. A pivot pin 120 is received in through-bores 114 and 136 to pivotally secure tool head 110 to handle 130. Pivot pin 120 includes a threaded end 121 that engages a threaded portion 137 of yoke through-bore 136 to secure the pivot pin therein. Preferably, wrench 100 includes a standard open wrench head 144 on the end of handle 130 opposite yoke 132. However, other embodiments can include a box wrench head, a ratcheting box wrench head, another locking flex-head, etc.

0010A locking spool 150 is carried within handle 130 aft of the pivot joint that connects tool head 110 to handle 130. Locking spool 150 may be rotated to a first position in which tool head 110 is locked in position with respect to handle 130 or to a second position in which tool head 110 may be pivoted relative to handle 130. As best seen in <figref idref="f0001">Figure 3</figref>, locking spool 150 includes a central portion having a locking surface 152 with a set of locking teeth 154, a ratcheting surface 156 with a set of ratcheting teeth 158, and a curved rear wall 160 (<figref idref="f0003">Figure 4A</figref>) with a blind bore 170 formed therein. Preferably, at least a first tooth 153 extends continuously along both locking surface 152 and ratcheting surface 156 and is common to both sets of locking teeth 154 and ratcheting teeth 158. In other embodiments, the first tooth may include two independent, yet axially aligned portions which extend along locking surface 152 and ratcheting surface 156, respectively. In the preferred embodiment shown, the set of locking teeth 154 further includes at least a second tooth 155 that is not shared in common with the set of ratcheting teeth 158. A spring 166 and a detent 168 are received in bore 170 so that detent 168 extends outwardly therefrom. The central portion of locking spool 150 extends between an upper flange 162 and a lower flange 164, each flange including a lever 172 and 174, respectively, for manipulating locking spool 150.

0011When assembled, locking spool 150 is carried in yoke 132 of handle 130 such that upper and lower flanges 162 and 164 abut opposing sides of handle 130. Upper and lower flanges 162 and 164 prevent motion of locking spool 150 in a direction transverse to the longitudinal axis of handle 130. As shown in <figref idref="f0003">Figures 4A and 4B</figref>, locking spool 150 is pivotal between a first position in which locking surface 152 is adjacent annular hub 112 and a second position in which ratcheting surface 156 is adjacent annular hub 112. In the first position, locking teeth 154 engage transverse teeth 116 and in the second position ratcheting teeth 158 engaged transverse teeth 116. In either position, detent 168 is urged rearwardly by spring 166 and continuously engages rear bearing surface 140 of yoke 132. Spring 166 imparts a biasing force through detent 168 which urges locking spool 150 forwardly and into constant contact with transverse teeth 116 of annular hub 112.

0012As shown in <figref idref="f0003">Figure 4A</figref>, the central portion of locking spool 150 is dimensioned such that when the spool is in the first position its fore and aft dimension relative to the longitudinal axis of handle 130 causes locking spool 150 to be "wedged" between rear bearing surface 140 and annular hub 112. As shown in <figref idref="f0003">Figure 4B</figref>, when locking spool 150 is in the second position the fore and aft dimension of the central portion is less than the distance between rear bearing surface 140 and the rear surface of annular hub 112. However, the previously noted biasing force provided by spring 166 through detent 168 urges locking spool 150 forward and into constant contact with annular hub 112 so that a gap 180 exists between rear bearing surface 140 of handle 130 and rear wall 160 of locking spool 150.

0013To adjust the angle of tool head 110 relative to handle 130, a user first repositions locking spool 150 from the first position shown in <figref idref="f0003">Figures 4A</figref> and <figref idref="f0004">5A</figref> to the second position shown in <figref idref="f0003">Figures 4B</figref> and <figref idref="f0004">5B</figref>. As best seen in <figref idref="f0004">Figure 5A</figref>, in the first position, locking teeth 154 engage transverse teeth 116 on annular hub 112 and a portion of curved rear wall 160 is in contact with rear bearing surface 140 of handle 130. Fore and aft motion of locking spool 150 along the longitudinal axis of handle 130 is prevented so that the engagement between locking teeth 154 and transverse teeth 116 prevents pivotal motion of tool head 110 relative to the axis of handle 130. To unlock tool head 110, the user rotates locking spool 150 with lever 172 (or lever 174) so that locking surface 152, and therefore locking teeth 154, are pivoted away from annular hub 112 and ratcheting surface 156 is pivoted toward annular hub 112 (<figref idref="f0003">Figures 4B</figref> and <figref idref="f0004">5B</figref>). When locking spool 150 is in the second position, ratcheting surface 156 is adjacent annular hub 112, and ratcheting teeth 158 engage transverse teeth 116. Biasing force provided by spring 166 through detent 168 insures that ratcheting teeth 158 are continuously biased toward engagement with transverse teeth 116, although locking spool 150 is now capable of fore and aft motion along handle 130 due to the dimensions of locking spool 150.

0014In the second position, a gap 180 exists between rear bearing surface 140 of handle 130 and rear wall 160 of locking spool 150. When repositioning locking spool 150 from the first position to the second position, or vice versa, the biasing force provided by spring 166 and detent 168 maintains locking spool 150 adjacent annular hub 112 so that either locking teeth 154 or ratcheting teeth 158 constantly engage transverse teeth 116. Therefore, tool head 110 remains in its initial angular position relative to handle 130 during manipulation of locking spool 150. As well, because at least first tooth 153 is common to both sets of locking and ratcheting teeth 154 and 158, respectively, at least first tooth 153 continuously engages transverse teeth 116 of annular hub, thereby preventing pivotal motion of tool head 110 relative to handle 130. The continual engagement of first tooth 153 with transverse teeth 116 insures that both locking teeth and ratcheting teeth 158 remain properly aligned with transverse teeth 116 when repositioning locking spool 150. As noted, other embodiments include a first tooth having two separate yet axially-aligned portions. Preferably, the gap between the two tooth portions is sized such that prior to one tooth portion disengaging transverse teeth 116, the second tooth portion engages the transverse teeth so that pivotal motion of tool head 110 relative to handle 130 is prevented.

0015To adjust the angular position of tool head 110 relative to handle 130 after locking spool 150 has been placed in the second position, the user exerts pivotal force on tool head 110 until the force exerted on ratcheting teeth 158 by transverse teeth 116 along the longitudinal axis of handle 130 is enough to overcome the forward biasing force provided by spring 166 and detent 168 on unlocking spool 150. As the rearward force exerted by transverse teeth 116 overcomes the forward biasing force, locking spool 150 is urged rearwardly so that spring 166 is compressed and detent 168 retracts inside bore 170. As locking spool 150 moves rearwardly, gap 180 narrows and transverse teeth 116 "override" ratcheting teeth 158. Upon reaching the desired angular position of tool head 110 relative to handle 130, a user ceases exerting pivotal force on tool head 110 and spring 166 and detent 168 urge locking spool 150 forwardly so that ratchet teeth 158 securely engage transverse teeth 116, thereby maintaining tool head 110 and the desired angular position.

0016To secure tool head 110 in the new position relative to handle 130 (<figref idref="f0005">Figure 6</figref>), a user returns locking spool 150 to the first position previously discussed with regard to <figref idref="f0003">Figures 4A</figref> and <figref idref="f0004">5A</figref>. As best seen in <figref idref="f0004">Figure 5A</figref>, in the preferred embodiment, the set of locking teeth 154 includes teeth 155 in addition to those teeth which may be common to both sets of locking and ratcheting teeth 154 and 158, respectively. These additional teeth 155 engage transverse teeth 116 for additional strength in the locked position.

0017As discussed, when manipulating locking spool 150 either the locking teeth 154 or ratcheting teeth 158, and at least first tooth 153 which is common to both, continuously engage transverse teeth 116 of annular hub 112. Therefore, when repositioning locking spool 150, it is not necessary for a user to hold tool head 110 to prevent tool head from pivoting freely relative to handle 130. Simply put, the entire operation of repositioning tool head 110 from a first angular position to a second angular position relative to handle 130 may be accomplished by one hand.

0018Referring now to <figref idref="f0005">Figure 7</figref>, an alternate embodiment of a flex-head wrench 100a is shown in accordance with the present invention. Tool head 110a is constructed similarly to tool head 110 shown in <figref idref="f0001">Figures 1</figref> and <figref idref="f0002">2</figref>, with the exception that the ratcheting mechanism (not shown) disposed within head portion 110a is selectively reversible by manipulating a ratchet lever 182. Manipulation of ratchet lever 182 allows the user to select the direction of rotation of wrench 100a that causes torque to be transmitted to a fastener. Embodiments of such ratchet mechanisms are disclosed in <patcit id="pcit0006" dnum="US6918323B"><text>U.S. Patent No. 6,918,323, to Arnold, et al., issued July 19, 2005</text></patcit>.

0019While one or more preferred embodiments of the invention are described above, it should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the appended claims. For example, the locking flex-head feature can be used with non-ratcheting wrenches. As well, the cross-sectional shapes and number of teeth formed on the locking spool and hub can vary. It is intended that the present invention cover such modifications and variations as come within the scope of the appended claims.