Field of the Invention This invention relates to ratchet wrenches, in general, and relates specifically to a predominately plastic, lightweight ratchet wrench that may be employed as a ratchet wrench for removing/securing a nut to a bolt or to a shoe cleat replacement tool, or more specifically to a golf shoe cleat replacement tool.

Background of the Invention This invention is an improvement in applicant's prior invention described in U. S. Patent No. 5,284,072. In this patent, a golf cleat removal/install tool is disclosed employing a ratchet at one end of an offset handle extending therefrom. A cleat receiving tool, having a concave surface mating with the upper surface of a golf cleat, is positioned within the ratchet mechanism. A spike receiving recess is provided in the curved surface so that the spike can nest in the tool during the removal or installation process. A pair of prong members extend from the concave surface of the cleat removal tool and serve to engage the cleat during the removal or installation. This tool, and other prior art cleat removal tools, are manufactured from metal, making the tool heavy to carry and expensive to produce.

In the present invention, the tool construction is predominately plastic

to substantially reduce the tool weight while retaining the advantageous features of prior art ratchet tools.

Accordingly, it is an object of the present invention to provide an improved ratchet tool that is light in weight and strong in durability.

Another object of the present invention is to provide a lightweight ratchet tool that may be adapted for use as a nut/bolt application or as a cleat removal/installation tool.

An additional object of the present invention is to provide a ratchet tool formed of substantially all plastic.

A further object of the present invention is to provide a novel ratchet mechanism for a ratchet wherein the spring force for the ratchet pawl is provided by a plastics leaf spring.

Summary of the Invention According to the present invention, the foregoing and additional objects are attained by providing a lightweight plastic ratchet tool having an open body portion and a hollow handle integral therewith. A ratchet mechanism is provided in the open body portion and includes a rotatable disk having a first end surface and a second end surface and including a plurality of circumferentially disposed teeth substantially intermediate the first and second end surfaces to form a toothed wheel serving as a ratchet wheel. In the preferred embodiment of the present invention, the second end surface of the toothed ratchet wheel is provided with a concave face and an opening through the central axis thereof to mate with and receive a golf cleat therein. A pair of diametrically opposed cleat removal pins are embedded within and extend from the second end surface of the toothed ratchet wheel. The cleat removal pins are positioned to be aligned with cleats to allow for insertion and removal of cleats, such as are used in golf shoes. In another embodiment of the present invention the toothed ratchet wheel is provided with an opening

through the central axis thereof of the desired dimensions to engage a nut, bolt, a cleat used in other sports, or a member of a socket wrench set to permit use of the tool as a conventional ratchet wrench. The ratchet direction of the rotatable disk is controlled by a pawl that is accessed from the exterior of the top, or sides, of the open body portion of the tool. The pawl is, in turn, maintained in the desired direction through use of a curved plastic spring.

Brief Description of the Drawinqs A more complete appreciation of the invention and many of the attendant advantages thereof will be more readily apparent as the same becomes better understood in reference to the accompanying drawings wherein: FIG 1 is a cutaway, part section, schematic side view of the hollow plastic ratchet wrench tool of the present invention ; FIG 2 is a cutaway, part section, schematic top view of the ratchet wrench tool shown in FIG 1 with the top closure for the ratchet wrench body being removed; FIG 3 is a schematic top view of the closure panel for the ratchet wrench body shown in FIGS 1 and 2; FIG 4 is a schematic end view of the inside of the closure cap for the open handle of the ratchet wrench tool shown in FIGS 1 and 2; Fig 5 is a schematic, part section, view of the toothed ratchet wheel having cleat removal pins embedded therein ; FIG 6 is a schematic view of the toothed ratchet wheel shown in FIG 5 and looking in the direction of arrow VI, or the area thereof supporting the embedded cleat removal pins ; FIG 7 is a schematic top plan view of the pawl mechanism of the present invention ; and FIG 8 is a schematic section view of an alternate embodiment of the

toothed ratchet wheel of the present invention configured for use with a socket wrench set.

Detailed Description Referring now to the drawings, and more particularly to FIGS 1 and 2, the plastic ratchet tool of the present invention is shown and designated generally by reference numeral 10. Ratchet tool 10 includes a one piece molded hollow handle 12 and an open ratchet housing panel or body 13.

Hollow handle 12 is of a frusto-conical configuration, having the smaller end thereof integral with ratchet housing panel 13 and the larger end thereof open to provide access to the handle interior 14. The open handle end is provided with an internally threaded lip 16. A semi-spherical closure cap 18, having an externally threaded cap flange 20, is employed to threadingly close the opening in handle 12. Closure cap 18 is provided with internal support structure 21, as will be further explained hereinafter. Hollow handle 12 provides a convenient storage area for extra tees, cleats, a cleat cleaning tool, and the like.

In the preferred embodiment illustrated, tool 10 is provided with a vertical angle offset between the open ratchet housing panel 13 and hollow handle 12. This angular offset"A"is normally within the range of 20-40 degrees, and preferably 35 degrees. It is also considered within the scope of the invention to eliminate the angular offset and place the handle on the same plane as the ratchet panel housing.

Ratchet tool 10 is designed to provide standard ratchet action however, since essentially all parts are manufactured of plastics, the weight reduction over that of metal tools is substantial. A closure lid 25 (FIGS 1 and 3) serves to close open ratchet housing panel 13, to confine the ratchet mechanism therein, and as will be further explained hereinafter. The ratchet mechanism of the present invention includes a rotating disk 30 having a first end surface

31 extending through an opening in closure lid 25, a second end surface 31 a extending through an opening provided in open ratchet housing panel 13 and a geared row of circumferentially disposed teeth 32 intermediate the first and second end surfaces thereof. Rotating disk 30 is free to move rotationally but is held in the same rotational plane due to the first and second end surfaces thereof protruding respectively, through closure lid 25 and the bottom surface of ratchet housing panel 13.

The direction of rotation of rotating disk 30 is controlled by pawl 34, as shown in FIG 2. Pawl 34 is manually accessed through pawl lever 44 to control the direction of the locking action of pawl 34.

The top of closure lid 25 for ratchet body housing 13 is shown in FIG 3. As shown therein, pawl lever 44 protrudes through the curved lever receiving opening 45 provided in closure lid 25 for accessibility by the user.

As shown more clearly in FIG 7, pawl 34 is essentially a modified triangular shaped body and is provided with end flanges 47,47a to interact with teeth 32 of rotating disk 30. Pawl 34 is prevented from sliding within the ratchet housing 13 by a rivet or other pin structure 48 securing pawl 34 therein such that only rotative pawl movement is permitted.

The position of pawl 34, as illustrated in FIG 2, is maintained by a curved leaf spring 36. Spring 36 is formed of an arcuate or curved plastic material having an inherent memory built therein such that it will return to the curved condition after any straightening force exerted thereon is removed.

Spring 36 is prevented from excessive movement within the interior of ratchet housing 13 by a pair of wedge detents 38,38a integrally formed therein.

The arc of spring 36 must be sufficient to maintain the pawl 34 in the desired position but not so great as to prevent manual switching of pawl 34, via pawl lever 44, from the clockwise position to the counterclockwise position.

As pawl 34 is switched from clockwise to counterclockwise, the spring 36 is compressed, returning to its arched position once the pawl 34 is in place by built-in memory. Spring 36 may also be designed using a flat shape to fit

within its location so as to be arched upon installation. Pawl 34 rotates around pivot pin 48 and is prevented from excessive rotation by the wedge detents 38,38a controlling the limit of straightening movement of spring 36.

Rotating disk 30 is shown in greater detail in FIGS 5 and 6 illustrating the alignment of the pair of cleat removal pins 50 and 51. The cleat removal pins 50,51 are embedded within the rotating disk 30 and are dimensioned and spaced to interact with conventional golf shoe cleats. Second end surface 31 a, of rotating disk 30 having pins 50,51 extending therefrom, is provided with a concave face and a spike receiving recess 33 provided in the central axis thereof to mate with a golf cleat. The top, or first end surface 31 of rotating disk 30, extends through closure lid 25 to permit application of thumb pressure thereon during a cleat removal/install procedure.

Paired optional nibs 35,35a (or other suitable indicia) are provided on first surface 31 in alignment with, and to indicate the location of, cleat removal pins 50,51 when looking at surface 31 of tool 10.

Since the cleat removal pins 50,51 take a substantial amount of the pressure during a cleat removal process, pins 50,51 must be formed of a high strength material. In the preferred embodiment of the present invention, removal pins 50,51 are formed of stainless steel pins. Other high strength materials such as a high strength aluminum alloy, or high strength composites, having sufficient strength to prevent pin breakage, during operation, may also be employed for constructing pins 50,51.

The preferred embodiment of the interior supports 21 for semi-spherical closure cap 18 for enlarged end of handle 12 are further illustrated in FIG 4.

As shown therein, four reinforcing supports 21, serving to substantially divide the interior of cap 18 into quarters. Reinforcing supports 21 extend interiorly, from external flange 20 to the top of cap 18. When employing a composite plastic for tool construction, it is preferable to limit the wall thickness of the components to limit ripple effects in the wall surfaces. Thus, the need for reinforcers in cap 18 is obvious and other designs, such as the use of six or

eight supports, for this reinforcement may be employed within the scope of the present invention.

Referring to FIG 8, an alternate embodiment for the rotating disk is shown and designated by reference numeral 60. Rotating disk 60 is provided with a row of gear teeth 62 and an internal opening 63. Opening 63 is in the form of a square or hexagonal configuration and adapted to mate with the ends of sockets in a socket wrench set or for a specific nut configuration.

Rotating disk 60 is also formed of a lightweight plastics or composite material.

In the preferred embodiments of the present invention, the unitary tool housing and handle, as well as all of the interior tool components, save the cleat removal pins and the curved spring, are molded from a fiberglass/nylon composite material. One composite of this type is 10-50% fiberglass filled nylon commercial available under the tradename ZYTEL, a du Pont product.

In the preferred embodiment of the present invention, a 15% glass filled nylon is employed. Other plastic materials suitable for construction of the tool housing and components include the plastic materials polycarbonate, polyvinlychloride, and other reinforced composites.

Curved leaf spring 36 is a plastic material, preferably made from formed or molded acetal. Acetal suitable for producing spring 36 is available under the tradename CEYLON from Hoechst Celanese Corporation, 90 Morris Avenue, Summit, NJ 07901-3914.

Spring 36 may also be formed of molded nylon. In the preferred embodiment, spring 36 has a curved length of 0.6 inch, a width of 0.25 inch, and a thickness of 0.05 inch.

The use of curved leaf spring 36 permits the tool handle offset to be large (20-40 degrees) without the plane of the wrench body being required to be extended in length.

As discussed hereinbefore, cleat removal pins are preferably formed of stainless steel and are inserted and embedded within rotating disk 30 as it is molded. Alternatively, the pins 50,51 may be adhesively secured within

preformed openings formed in rotating disk 30 when it is molded.

From the foregoing it is apparent that the present invention provides a new plastics ratchet tool having advantageous and unobvious features not known or appreciated in the prior art. The use of a leaf spring for a ratchet drive is not limited to the specific embodiments of the invention described herein but is considered applicable for use in any ratcheting mechanism. Also, the ratchet wrench of the present invention may be used on soft spikes, regular golf spikes, football, soccer, or any other kind of cleat removal/installation procedure.

Thus, although the invention has been described relative to specific embodiments thereof, it is not so limited and there are numerous variations and modifications thereof that will be readily apparent to those skilled in the art in light of the above teachings. For example, the toothed ratchet wheel, or rotating disk 60, may be provided with an opening through the central axis thereof, or other structure of the desired dimensions, to engage a nut, bolt, a cleat for other sports, or for any engagement structure, to permit use of the tool as a conventional ratchet wrench.

Also, the construction of the component parts is not limited to the specific example plastics and composites described and other plastics and composites having the strength and other physical property characteristics required may be employed. Further, the hollow handle described may be replace with a solid handle, if so desired without departing from the spirit and scope of the invention. In some instances, it may also be desirable to replace the plastic pawl and spring with lightweight metal construction. In addition, the pawl lever access need not be confined to an opening in the top of the open body portion but could be from the sides thereof.

These, and other modifications and changes, varied to fit particular operating requirements and environments, will be apparent to those skilled in the art. The specific examples described herein are, therefor, to be considered exemplary only and are not to be deemed as exhaustive. It is therefor to be

understood that the invention may be practiced other than as specifically described herein.

What is claimed as new and desired to be secured by Letters Patent of the United States is: