CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to prior-filed, co-pending U.S. Provisional Patent Application No. 63/089,997, filed on October 9, 2020, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to tools, and more particularly to socket wrenches and rotary tools. Rotary tools (e.g., a powered drill driver or hand wrench) are typically utilized to provide a rotational force to a tool adapter or workpiece (e.g., a fastener) to either tighten or loosen the fastener. Various tool attachments or onboard strain gauges can be used to limit the amount of torque delivered from the wrench to the workpiece.

SUMMARY OF THE INVENTION

[0003] In one embodiment, the invention provides, among other things, a socket adapter for limiting torque delivered from a tool to a socket piece. The socket adapter includes a female receiver that is coupleable to and driven by the tool, and a male drive that is coupled to and driven by the female receiver for transferring torque to the socket piece. The socket adapter further includes a clutch mechanism having a first clutch surface, a second clutch surface that engages the first clutch surface, and an adjustment mechanism for adjusting a clamping force between the first clutch surface and the second clutch surface. The second clutch surface slides relative to the first clutch surface when a reaction torque exerted on the clutch mechanism exceeds a predetermined torque limit.

[0004] In another embodiment, the invention provides, among other things, a socket adapter for limiting torque delivered from a tool to a socket piece including a clutch mechanism that is removably coupled to the tool and disposed between an output member of the tool and an output member of the socket adapter. The clutch mechanism includes a first clutch surface, a second clutch surface that engages the first clutch surface, and an adjustment mechanism for adjusting a clamping force between the first clutch surface and the second clutch surface. The second clutch surface slides relative to the first clutch surface when a reaction torque exerted on the clutch mechanism exceeds a predetermined torque limit. The adjustment mechanism is only accessible for adjustment by removing the clutch mechanism from the tool.

[0005] In another embodiment, the invention provides, among other things, a method of limiting torque delivered from a tool to a socket piece including driving a female receiver and a male drive with an output member of the tool by rotating the tool around a longitudinal axis, slipping a clutch mechanism between the female receiver and the male drive when a reaction torque from the socket piece is greater than a predetermined torque limit, such that the female receiver rotates relative to the male drive, and adjusting the predetermined torque limit of the clutch mechanism by inserting an adjustment tool through the female receiver and rotating an adjustment mechanism along the longitudinal axis, resulting in increased or decreased frictional forces of the clutch mechanism that resist relative rotation between the female receiver and the male drive.

[0006] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a perspective view of a clutch socket adapter according to an embodiment of the invention, illustrating the clutch socket adapter receivable by a socket wrench.

[0008] FIG. 2 is an exploded view of the clutch socket adapter of FIG. 1.

[0009] FIG. 3 is an exploded cross-sectional view of the clutch socket adapter of FIG. 2, taken along line 3 — 3.

[0010] FIG. 4 is a cross-sectional view of the clutch socket adapter of FIG. 1, taken along line 4 — 4.

[0011] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. DETAILED DESCRIPTION

[0012] FIG. 1 illustrates a tool, such as ratchet wrench 10, for delivering torque to a workpiece (e.g., a nut, a screw, a socket adapter, etc.). In the illustrated embodiment, the tool is a hand tool. In other embodiments, the tool may be a power tool, such as a driver drill. The illustrated ratchet wrench 10 includes an elongated handle 14, a grip 18 disposed at a distal end 22 of the elongated handle 14, and a working end 26 coupled to the elongated handle 14 opposite the grip 18. The working end 26 includes a male drive 30 for engaging and driving a workpiece. The male drive 30 may be 1/4 inch square drive, 3/8 inch square drive, 1/2 inch square drive, or some other size drive. In the illustrated embodiment, the working end 26 also includes a ratchet mechanism 34 for selectively transmitting rotational force from the elongated handle 14 to the male drive 30.

[0013] FIG. 1 further illustrates a clutch socket adapter 50 that is coupleable to the ratchet wrench 10 for limiting the amount of torque delivered from the ratchet wrench 10 to a workpiece. The clutch socket adapter 50 includes a socket member 54 with a female receiver 58 (FIG. 2) for receiving the male drive 30 of the wrench 10. The clutch socket adapter 50 further includes a drive member 62 with a male drive 66 for receiving a socket that engages and drives a workpiece (e.g., a nut, a bolt head, etc.). The socket member 54 and the drive member 62 are coaxial along a longitudinal axis 64 of the clutch socket adapter 50. As shown in FIG. 2, the male drive 66 of the clutch socket adapter 50 includes an annular groove 70 that receives an O-ring 74 and a retaining ring 78. The O-ring 74 and the retaining ring 78 extend beyond the outer periphery of the male drive 66 and are compressible to retain a socket on the male drive 66.

[0014] With reference to FIGS. 1 and 2, the clutch socket adapter 50 further includes an intermediate member 82 that is disposed between the socket member 54 and the drive member 62. The intermediate member 82 includes an annular rim 86 that extends into an aperture 84 (FIG. 3) of the socket member 54. Specifically, the annular rim 86 includes a pair of flat regions 90 that mate with corresponding flat regions 94 (FIG. 3) on the socket member 54 to form a keyed relationship therebetween, inhibiting relative rotation between the socket member 54 and the intermediate member 82. In other embodiments, the annular rim 86 and the aperture 84 may have other configurations to form the keyed relationship (e.g., square, hexagonal, D-shaped, oblong, etc.). Furthermore, one or more spring pins 96 are receivable within bore holes 98a, 98b of the annular rim 86 and the socket member 54, inhibiting axial movement between the socket member 54 and the intermediate member 82. That said, the socket member 54 and the intermediate member 82 are axially and rotationally constrained together when the socket member 54 and the intermediate member 82 are coupled together. However, the socket member 54 and the intermediate member 82 are capable of being decoupled in order to replace the socket member 54 with a separate socket member 54’ having a different sized female receiver 58’ (FIG. 3).

[0015] With reference to FIGS. 2 and 3, the clutch socket adapter 50 further includes a clutch mechanism 100 that is provided via a first clutch surface 104 of the drive member 62, a second clutch surface 108 of the intermediate member 82, and an adjustment mechanism 112. The adjustment mechanism 112 couples the intermediate member 82 to the drive member 62. Specifically, the adjustment mechanism 112 is a clamping screw that includes a head 116 and a threaded region 124. The head 116 seats against a shoulder 120 of the intermediate member 82. The threaded region 124 threadably engages a corresponding threaded region 128 of the drive member 62. The threaded regions 124, 128 may be provided with a thread locking compound to inhibit the adjustment mechanism 112 from inadvertently adjusting. The threaded region 124, however, does not threadably engage the intermediate member 82. The illustrated head 116 is a hex head, which can be driven by a hex tool upon inserting the hex tool through the female receiver 58 of the socket member 54. In other embodiments, the head 116 may alternatively be a Phillips head, a slotted head, or other types of heads. In the illustrated embodiment, the first clutch surface 104 and the second clutch surface 108 are entirely flat, planar surfaces that extend along a direction perpendicular to the axis 64. The first clutch surface 104 and the second clutch surface 108 rely on friction forces to resist relative rotation between the drive member 62 and the intermediate member 82. Therefore, the friction force between the first clutch surface 104 and the second clutch surface 108 is increased when the adjustment mechanism 112 exerts an increased clamping force (i.e., is tightened) between the drive member 62 and the intermediate member 82. Similarly, the friction force between the first clutch surface 104 and the second clutch surface 108 is decreased when the adjustment mechanism 112 exerts a decreased clamping force (i.e., is loosened) between the drive member 62 and the intermediate member 82.

[0016] As explained in further detail below, the intermediate member 82 rotates (or slides) relative to the drive member 62 when a reaction torque exerted on the drive member 62 overcomes the friction force between the first clutch surface 104 and the second clutch surface 108.

[0017] In operation, the clutch socket adapter 50 may be coupled to the ratchet wrench 10 once the desired socket member 54, 54’ is coupled to the intermediate member 82, where the female receiver 58 receives the male drive 30 of the ratchet wrench 10. Subsequently, a hex tool may be inserted through the female receiver 58 to adjust a torque limit of the clutch mechanism 100. Specifically, the hex tool engages and rotates the head 116 of the adjustment mechanism 112 to adjust the clamping force between the intermediate member 82 and the drive member 62. By adjusting the clamping force, the torque limit of the clutch mechanism 100 is correspondingly adjusted. In some embodiments, the adjustment mechanism 112 is adjusted to a factory preset clamping force during a manufacturing process, where subsequent adjustment is inhibited.

[0018] For example, tightening (e.g., rotating in a first direction) the adjustment mechanism 112 increases the clamping force, thereby increasing the friction force between the first clutch surface 104 and the second clutch surface 108. The torque limit at which the intermediate member 82 rotates relative to the drive member 62 increases as a result of increased friction force. Similarly, loosening (e.g., rotating in a second direction opposite the first direction) the adjustment mechanism 112 decreases the clamping force, thereby decreasing the friction force between the first clutch surface 104 and the second clutch surface 108. The torque limit at which the intermediate member 82 rotates relative to the drive member 62 decreases as a result of decreased friction force. Although in some embodiments the first direction may be clockwise and the second direction may be counterclockwise, in other embodiments, the first direction may be counterclockwise and the second direction may be clockwise.

[0019] Once the clamping force — and therefore the torque limit — is set, the male drive 66 of the clutch socket adapter 50 may be coupled to a socket. At this point, a user may exert a torque on a workpiece via the socket to drive (e.g., rotate) the workpiece by applying a force F (FIG. 1) on the elongated handle 14. The workpiece is driven by the socket wrench 10 and the clutch socket adapter 50 until the reaction torque exerted on the clutch socket adapter 50 overcomes the torque limit. Specifically, the second clutch surface 108 rotates (or slides) in direction A (FIG. 4) relative to the first clutch surface 104 when the reaction torque exerted on the drive member 62 overcomes the torque limit. Any additional force F applied to the elongated handle 14 of the socket wrench 10 will result in rotation of the elongated handle 14, the socket member 54, and the intermediate member 82 relative to the drive member 62 and the workpiece.

[0020] Various features of the invention are set forth in the following claims.