The present invention relates to a snap-in chuck assembly and a snap-in tool or tool holder for use in the snap-in chuck assembly. More specifically, the present invention is directed to a snap-in chuck assembly having an axially movable or rotatable nose for initiating or releasing gripping of a tool or tool holder received in the chuck assembly and is directed to a tool having a shank, a drill bit, a screwdriver, a Phillips screwdriver or other tool or implement formation at an outer end and a spline formation at an inner end of the shank. The invention also relates to a tool drive system for use with the chuck comprising an insert received in the inner bore portion; structure for preventing rotation of the insert relative to the chuck; structure on the insert for engaging an inner end of a tool or tool holder; and a mechanism for holding the tool or tool holder against axial movement relative to the insert.

2. Description of the Prior Art.

Heretofore many tools for mounting in a chuck assembly have been proposed.

Examples of previously proposed analogous and non-analogous chuck assemblies and tools and tool holders are disclosed in the following analogous and non-analogous U. S. patents: U. S. Patent No. Patentee 2,728,365 Austin 2,807,473 Kiehne 3,945,653 Falche 4,188,041 Soderberg 4,199,160 Bent 4,209,182 Sheldon 4,692,073 Martindell 4,900,202 Wienhold 5,013,194 Wienhold 5,193,824 Salpaka 5,417,527 Wienhold 5,458,445 Barder et al.

5,464,229 Salpaka 5,465,983 Owens et al.

5,470,180 Jore 5,674,031 Bilz et al.

5,921,562 Robison 5,951,026 Harman, Jr. et al.

5,984,596 Fehrle et al.

5,975,815 Zierpka et al.

SUMMARY OF THE INVENTION According to the present invention there is provided a chuck assembly comprising: a chuck body having an outer end portion, an outer periphery and a central axial bore extending at least part way therethrough; said chuck body further having three, substantially equidistantly spaced, generally axially extending, jaw receiving slots which open onto said central bore; mounting means for mounting said chuck assembly onto the outer end of a shaft of a drive mechanism; three axially and radially movable jaws received in respective ones of said axially extending slots; moving means for moving said jaws against the shank of a tool or tool holder or other accessory received in said central bore; a nose collar mounted on the outer end portion of the chuck body; and structure in the central bore for engaging the shank and preventing rotation of the shank relative to the chuck body.

Preferably, the outer end portion of the chuck body has at least one radially extending bore therein which extends from the outer periphery of the chuck body inwardly to an opening which opens to the central bore and which has a diameter less than the diameter of the radial bore; at least one ball or detent in the at least one radial bore; urging mechanism for urging the ball or detent into the radial bore and part way through the opening; and releasing mechanism for allowing the ball or detent to move radially outwardly in the radial bore and away from the opening; Additionally according to the present invention there is provided a tool comprising a smooth shank, a tool or implement formation at an outer end of the shank and a spline formation at an inner end of the shank. In some embodiments the shank also has a polygonal, e. g., hexagonal, formation thereon and an annular groove in the shank which can be in the area of the polygonal formation.

Also, according to the present invention there is provided a chuck assembly

comprising: a chuck body having an outer end portion, an outer periphery and a central bore extending at least partially through said chuck body along a central axis.

The chuck body further has three, substantially equidistantly spaced, generally axially extending, jaw receiving slots which open onto the central bore and has mounting structure for mounting the chuck assembly onto the outer end of a shaft of a drive mechanism. Three axially and radially movable jaws are received in respective ones of the axially extending slots. A mechanism for moving the jaws against the shank of a tool or tool holder received in the central bore is provided. The chuck body has at least one inwardly extending passageway located in the chuck body between two of the axially extending slots and the passageway extends from the outer periphery of the chuck body inwardly to an opening which opens to the central bore. The opening has a diameter less than the diameter of the passageway and at least one detent is provided in the passageway. Structure for urging the at least one detent toward the central bore is provided together with a mechanism for releasing the engagement of the at least one detent against a shaft or shank received in the central bore. A nose collar is mounted on the outer end portion of the chuck body. Drive structure is provided in the central bore for engaging mating drive structure on the shank of a tool or tool holder received in the central bore of the chuck body, whereby the chuck assembly can impart a rotary drive to the tool or tool holder by reason of the mating engagement of the mating drive structures, and whereby axial movement of the shank of the tool or tool holder received in the central bore of the chuck body is inhibited, if not prevented, by the engagement of the jaws with the shank or by the engagement of the at least one detent with the shank received in the central bore or by both engagements.

In one embodiment, the nose collar is mounted for rotation and the urging structure comprises a cylindrical wall portion of a cylindrical cavity in the nose collar and the releasing mechanism comprises one or more cavities or pockets in the cylindrical wall portion which are constructed and arranged to be aligned with the at least one passageway containing the at least one detent so that, upon rotation of the nose collar, the at least one detent in the at least one passageway is allowed to move away from the opening and into one of the pockets.

In another embodiment, the nose collar is mounted for axial movement relative to the outer end portion of the chuck body and the urging structure comprises a first

cylindrical wall portion of a cylindrical cavity in the nose collar having a diameter approximately the same diameter as the outer periphery of the outer end portion of the chuck body and the releasing mechanism comprises a second cylindrical wall portion having a diameter greater than the diameter of the outer periphery of the outer end portion, whereby axial movement of the nose collar will position the second cylindrical wall portion in the area of the at least one passageway to allow the at least one detent therein to move laterally outwardly away from the opening of the at least one passageway and into the central bore.

Further according to the present invention, there is provided a tool drive system for use with a chuck having a throughbore including an outer bore portion for receiving a tool or tool holder and an inner bore portion constructed to receive and be mounted on an outer end of a motor shaft of a power tool. The system comprises: an insert received in the inner bore portion; structure for preventing rotation of the insert relative to the chuck; structure on the insert for engaging an inner end of a tool or tool holder; and a mechanism for inhibiting or holding the tool or tool holder or other accessory from axial movement relative to the insert.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a longitudinal side view with portions broken away of one embodiment of a chuck assembly constructed according to the teachings of the present invention.

FIG. 2 is a fragmentary side view of the chuck shown in FIG. 1 and is taken along line 2-2 of FIG. 1.

FIG. 3 is a longitudinal plan view of the chuck similar to the view shown in FIG.

1 but with an outer end portion or nose collar rotated 90°.

FIG. 4 is a sectional view of the nose collar shown in FIG. 3 and is taken along line 4-4 of FIG. 3.

FIG. 5 is a longitudinal plan view of one embodiment of a drill type tool constructed according to the teachings of the present invention.

FIG. 6 is a longitudinal plan view of another embodiment of a screwdriver type tool constructed according to the teachings of the present invention.

FIG. 7 is a longitudinal plan view of one embodiment of a tool holder constructed according to the teachings of the present invention.

FIG. 8 is a longitudinal sectional view through a modified chuck body of a

second embodiment of a chuck assembly constructed according to the teachings of the present invention, and of half of a nose collar of the chuck assembly, which is used to move a locking detent (ball) radially inwardly and outwardly of a central hex bore of the chuck assembly and shows the collar holding the detent/ball in an inwardly locking position.

FIG. 9 is a longitudinal sectional view of the chuck body shown in FIG. 9 and shows the nose collar moved axially outwardly for placing the detent/ball in a non- restrained position where the detent/ball can move radially outwardly from a central hex bore.

FIG. 10 is a longitudinal partially sectional view of a chuck body of a third embodiment of a chuck assembly constructed according to the teachings of the present invention and shows a detent/ball in a radially extending bore and an annular groove in the area of the radially extending bore and having a split collar spring based therein for biasing the detent/ball toward the central chuck bore.

FIG. 11 is a longitudinal side view of a chuck body for one of the embodiments of the chuck assembly disclosed herein with an inner or lower portion broken away to show a spline area of the central chuck bore and a threaded area of the chuck bore.

FIG. 12 is a longitudinal sectional view of a fourth embodiment of the chuck assembly of the present invention and shows a nose collar on a chuck body similar to the chuck body shown in FIG. 10 with lateral bores in the nose collar adapted to be aligned with radially extending bores in the chuck body.

FIG. 13 is an end view of the chuck body of each of the four embodiments and shows three jaws at three corners of the hex bore and three detents/balls at the other three corners of the hex bore between the jaws.

FIG. 14 is a plan view of a tool constructed according to the teachings of the present invention which has a smooth shank with a spline formation at an inner end thereof.

FIG. 15 is a plan view of a tool constructed according to the teachings of the present invention which has a smooth shank with an annular groove therein and a spline formation at an inner end thereof.

FIG. 16 is a plan view of another tool constructed according to the teachings of the present invention which has a shank with a hexagonal portion, an annular

groove in the shank in the area of the hexagonal portion and a spline formation at an inner end thereof.

FIG. 17 is a exploded perspective view of one embodiment of the tool drive system of the present invention associated with a chuck and including an insert, the chuck, a tool holder and a tool.

FIG. 18 is a bottom end view of the tool shown in FIG. 17 and is taken along line 18-18 of FIG. 17.

FIG. 19 is an outer end view of the tool holder shown in FIG. 17 and is taken along line 19-19 of FIG. 17.

FIG. 20 is an inner end view of the tool holder shown in FIG. 17 and is taken along line 20-20 of FIG. 17.

FIG. 21 is an inner end view of the chuck shown in FIG. 17 and is taken along line 21-21 of FIG. 17.

FIG. 22 is an exploded view of another embodiment of a tool drive system of the present invention and includes an insert, a chuck, a tool holder and a tool.

FIG. 23 is a bottom end view of the tool shown in FIG. 22 and is taken along line 23-23 of FIG. 22.

FIG. 24 is an outer end view of the tool holder shown in FIG. 22 and is taken along line 24-24 of FIG. 22.

FIG. 25 is an inner end view of the tool holder shown in FIG. 22 and is taken along line 25-25 of FIG. 22.

FIG. 26 is an inner end view of the chuck shown in FIG. 22 and is taken along line 26-26 of FIG. 22.

FIG. 27 is an upper end view of the insert shown in FIG. 22 and is taken along line 27-27 of FIG. 22.

FIG. 28 is an upper end view of the insert shown in FIG. 17 and is taken along line 28-28 of FIG. 17.

FIG. 29 is an outer end view of the chuck shown in FIG. 28 and shows no intermediate spline portion at the upper end of the inner bore portion.

FIG. 30 is an outer end view of the chuck shown in FIG's. 17 and 22 with a spline configuration at the upper end of the inner bore portion and is taken along line 30-30 of FIG's. 17 and 22.

FIG. 31 is an enlarged view of a chuck with portions broken away to show the

threaded inner bore portion and an intermediate spline portion at the upper end of the inner bore portion.

FIG. 32 is an exploded perspective view of another embodiment of the tool drive system of the present invention with a threaded insert.

FIG. 33 is a bottom end view of the tool shown in FIG. 32 and is taken along line 33-33 of FIG. 32.

FIG. 34 is an outer end view of the tool holder shown in FIG. 32 and is taken along line 34-34 of FIG. 32.

FIG. 35 is an inner end view of the tool holder shown in FIG. 32 and is taken along line 35-35 of FIG. 32.

FIG. 36 is an outer end view of the chuck shown in FIG. 32 without an intermediate spline portion and is taken along line 36-36 of FIG. 32.

FIG. 37 is an inner end view of the insert shown in FIG. 32 and is taken along line 37-37 of FIG. 32.

FIG. 38 is an outer end view of the insert shown in FIG. 32 and is taken along line 38-38 of FIG. 32.

FIG. 39 is an exploded view of another embodiment of the tool drive system of the present invention including an insert, a chuck, a tool holder and a tool.

FIG. 40 is a vertical sectional view through the insert shown in FIG. 39.

FIG. 41 is a inner end view of the tool stem shown in FIG. 39 and is taken along line 41-41 of FIG. 39.

FIG. 42 is an outer end view of the tool holder shown in FIG. 39 and is taken along line 42-42 of FIG. 39.

FIG. 43 is an inner end view of the tool holder shown in FIG. 39 and is taken along line 43-43 of FIG. 39.

FIG. 44 is an inner end view of the chuck shown in FIG. 39 and is taken along line 4-43 of FIG. 39.

FIG. 45 is an exploded view of a still further embodiment of the drive system of the present invention including an insert, a chuck, a tool holder and a tool of the present invention.

FIG. 46 is an outer end view of the tool holder shown in FIG. 45 and is taken along line 46-46 of FIG. 45.

FIG. 47 is an end view of a screw having an Allen head shown in FIG. 45 and

is taken along line 47-47 of FIG. 45.

FIG. 48 is an inner end view of the tool holder shown in FIG. 45 and is taken along line 48-48 of FIG. 45.

FIG. 49 is a lower end view of the insert shown in FIG. 45 and is taken along line 49-49 of FIG. 45.

FIG. 50 is an upper end view of the insert shown in FIG. 45 and is taken along line 50-50 of FIG. 45.

FIG. 51 is a lower end view of the chuck shown in FIG. 45 and is taken along line 51-51 of FIG. 45.

DESCRIPTION OF THE PREFERRED EMBODIMENT (S) Referring now to the drawings in greater detail, there is illustrated in FIG. 1 a longitudinal side view of one embodiment of the chuck assembly 10 constructed according to the teachings of the present invention. The chuck assembly 10 includes a chuck body 12 and at least three jaws 14, one of which is shown in FIG. 1, which are movable axially and radially relative to the chuck body 12 into and out of a central chuck hex bore 16. Mounted on the chuck body 12 is a sleeve 18 which is rotatable on the chuck body 12 for moving the jaws 14 in and out of the central bore 16.

The chuck body 12 includes an outer end portion 22 having at least one, and preferably three, transverse radial bores 24 therein which extend through the outer end portion 22 and opening onto the central bore 16 with a. ;-^, aller opening 26 than the diameter of the radial bore 24. A ball 28, similar to a ball bearing, is received in each radial bore 24 and bears against an inner wall 30 of a cylindrical cavity 32 in a nose collar 34. To achieve this function, the outer end portion 22 most likely will have a reduced outer diameter such that the length of the radial bores 24 is less than the diameter of the ball 28 or a second ball or other spacing element is provided in each bore 24.

The hex cross-section of the central bore 16 can be limited to the area of the radial bores 24, as shown.

As shown in FIGS. 1,2 and 4, the nose collar 34 has two spaced apart finger engaging concave pockets or dimples 36 to enable a user to grip the collar 34 and rotate it 90°.

The inner wall 30 of the cavity 32 in the nose collar 34, FIGS. 3 and 4, has three concave pockets 38 which are located rotationally 120° from each other and

one is located 90° from one of the outer pockets 36 or in line with one of the outer pockets 36.

The outer end portion 22 further has a C-ring 39 mounted on an outer periphery 40 thereof for axially engaging an inwardly extending flange 41 of the nose collar 34, thereby to hold the nose collar 34 to the chuck body 12.

In use, one inserts the stem or shaft of a conventional tool or a specially constructed tool 42 (FIG. 5) into the central bore 16 and rotates the sleeve 18 to move the jaws 14 into engagement with the stem of the tool 42.

Alternatively, and in accordance with the teachings of the present invention, one can insert the specially configured tool 42 (FIG. 5) into the bore 16. Then a stem 44 of the tool 42 has a hex cross-section for mating with the central hex bore 16. The tool 42 has a Phillips head 46 and an annular groove 48 which can be moved into alignment with the balls 28 when the nose collar 34 is in the position shown in FIG.

3 where each ball 28 is in line radially within one the radial bores 24 between the opening 26 to the central hex bore 16 and the pocket 38 in the wall 30.

This allows a tool, such as the tool 42, to be axially inserted into the central bore 16 past the balls 28 until the balls 28 are in radial alignment with the annular groove 48. At this point, a user can rotate the nose collar 34 to move the pockets 38 away from the balls 28, thereby to move the surface of the cylindrical wall 30 against the balls 28 urging them toward and into the opening 26 to the central bore 16.

Then, to remove the tool, such as a tool 42, from the central hex bore 16 of the chuck body 12, a user will grip the nose collar 34 with his/her finger and thumb received in the pockets 36 and rotate the nose collar 90° until the pockets 38 on the inner wall 30 of the cavity 32 are aligned with the radial bores 24 so that when one pulls on the tool 42 the balls 28 can move inwardly in the radial bores 28 and into the pockets 38 so that the tool 42 can be removed axially from the central chuck bore 16.

The tool 42 illustrated in FIG. 5 includes the hex in cross-section shank or stem 44, the Phillips head 46 and the annular groove 48 in the hex in cross-section shank or stem 44.

It will be understood that other types of tool heads, such as a drill tool head or a straight screwdriver tool head can be provided on the tool 42 in place of the Phillips screwdriver head 46.

In FIG. 6 is illustrated another tool 50 having a middle stem portion 52, a hex

in-cross-section inner end 54 with an annular groove 56 therein, and a special drill head or spade bit 58 for drilling larger holes than the diameter of the stem portion 52.

In FIG. 7 is illustrated a tool holder 60 which can be of the type disclosed in the Robison U. S. Patent No. 5,921,562. The tool holder 60 has a middle stem portion 62 which is different than the stem disclosed in U. S. Patent No. 5,921,562. In this respect, the stem portion 62 is modified to have a hex in-cross-section area 64 with an annular groove 68 in the hex in-cross-section area 64, whereby the tool holder 60 is adapted to be received in the central hex bore 16 and axially locked therein by balls 28 received in the annular groove 68 and fixed against rotation in the bore by the engagement of the hex in-cross-section area 64 with the hex cross-section central bore 16.

The tool holder 60 further has a mushroom head 70 with a cavity 72 for receiving a tool and a magnet 74 at the bottom of the cavity 72 for releasably holding a tool in the cavity 72. The tool holder 60 further includes an inner end 76 which has a spline configuration 78 for being received in a spline section 80 of the central bore 16. The spline section 80 of the central bore 16 can be of the type disclosed in the Salpaka U. S. Patent No. 5,193,824, the disclosure of which is incorporated herein by reference.

In FIGS. 8 and 9 there is illustrated a second embodiment of a chuck assembly 90 constructed according to the teachings of the present invention wherein the construction of the chuck body 92 is identical to the construction of the chuck body 12 shown in FIGS. 3 and 4 with an outer end portion 93. However, in this embodiment, a nose collar 94 is constructed for axial movement as opposed to rotation movement. In this respect, as shown in FIG. 8, the nose collar 94 has at least two dimple concave pockets or dimples 96 on the outer surface thereof to enable one to grip the nose collar 94 and pull it or push it to move the nose collar 94 axially of the chuck assembly 90. Then, the interior of the nose collar 94 has a stepped cavity 98 including a first cylindrical portion 100 which has a diameter which will fictionally engage the ball or balls 28 in the radial bores 24 for urging them into and partially through the opening 26 of each radial bore 24 that opens to the central chuck bore 16. Then, the cavity 98 has a steppe, larger cylindrical portion 102 located inwardly of the cylindrical wall portion 100.

In use, and as shown in FIG. 9, when one grips the nose collar 94 and pulls

it outwardly, the larger-in-diameter cylindrical wall portion 102 of the cavity 98 is radially aligned with the ball or balls 28 in each radial bore 24 so that they can move radially outwardly from the opening 26 that opens to the central bore 16, thereby to allow a tool to be inserted or removed from the hex in-cross-section central bore 16.

The nose collar 94 has a lower annular flange 106 for engaging a ring 108 mounted on the outer end portion 93 of the chuck body 92 for holding the nose collar on the outer end portion 93 and for limiting axial movement of the nose collar 94.

It is to be noted that the outer portion 93 of the chuck body 92 can have a reduced-in-diameter outer surface to provide a length of each radial bore 24 which is less than the diameter of the ball 28 so that a friction engagement between the balls 28 and the cylindrical wall portion 100 of the cavity 98 can be established.

In FIG. 10 there is illustrated a third embodiment of a portion of a chuck assembly 110 constructed according to the teachings of the present invention. In this embodiment, the outer end portion 112 of a chuck body 114 has an annular groove 116 therein in the area of the radial bores 24 so that a C or split ring or band 118 can be received in the annular groove 116 for engaging the radially outwardly facing side of each of the three detents or balls 28 for urging each of them into one of the openings 26 at the inner end of each of the radial bores 24. In this embodiment, the outer end portion 112 of the chuck body 114 does not have a reduced-in-diameter relative to the rest of the chuck body 114. Further, in this embodiment, when a tool is inserted into the hex bore 16, pressure must be applied to move the balls 28 radially outwardly against the pressure of the spring band 118 to enable the tool to be inserted into the central hex cross-section bore 16 of the chuck body 114.

Likewise, when removing the tool from the hex bore 16, one must exert a pulling force to force the balls 28 against the spring band 118 to effect removal of the tool from the hex bore 16.

The outer periphery 120 of a chuck body 122 is illustrated in FIG. 11 with the bottom portion cut away to show a spline section 124 of a central hex bore 126 and an inner threaded section 128 of the chuck bore 126 for enabling the chuck body 122 to be mounted on a threaded end of a power tool as disclosed in the Salpaka U. S.

Patent No. 5,193,824.

In FIG. 12 there is illustrated a fourth embodiment of a chuck assembly 140 constructed according to the teachings of the present invention. In this embodiment,

the outer end portion 142 of the chuck body 144 does not have a reduced-in-diameter relative to the remainder of the chuck body 144 and does not have any annular slot in the chuck body 144 in the area of the balls 28. Instead, a nose collar 146 is provided with three radial bores 148 which extend inwardly from and are equally spaced around a cylindrical wall 150 of a cavity 152 in the nose collar 146. Then, a spring 154 is inserted into each one of these three bores 148 and the nose collar 146 is moved axially over the outer end portion 142 of the chuck body 144 until the bores 148 with the springs 154 therein are in alignment with the bores 24 having the balls 28 therein, at which point the compressed springs 154 will move one of the bores 148 into the radial bores 24 to engage and bear against the back side of each one of or the back one of a pair of the balls 28 in each radial bore 24.

It will be understood that suitable alignment means, such as for example, matting axially extending slots in, and a key between, the outer end portion 142 of the chuck body 144 and the cylindrical wall 150 of the cavity 152 in the nose collar 146 is provided for ensuring proper alignment of the nose collar 146 with the chuck body 144 and locking of the nose collar 146 against rotation relative to the chuck body 144.

FIG. 13 is an end view of one of the nose collas, e. g. nose collar 34, shown in FIGS. 1,3,8,9 and 12 showing the hex in-cross-section central bore 16 with jaws 14 located at alternate ones of the hex corners of the bore 16 and with balls 28 at the adjacent alternate corners of the hex bore 16.

In FIG. 14 there is illustrated a tool 160 constructed according to the teachings of the present invention. The tool 160 is a simplified tool which has a smooth shank 162, a spline configuration 164 at an inner end thereof, a tool formation 166 such as a Phillips screwdriver formation at an outer end thereof. This tool 160 is adapted to be simply and quickly inserted into one of the chuck assemblies described above and is rotatably driven by the spline formation 124 engaging with the spline formation 164 at the inner end of the shank 162 while three spring biased balls 28 in one of the chuck assemblies bears against the smooth shank 162 and the friction between the balls 28 and the smooth shank 162 provides a holding force, although minimal, against axial movement of the tool 160 in one of the chuck assembles described above.

To provide a stronger restraining force against axil movement of a tool, a tool 170 can be provided, as shown in FIG. 15, which has a shank 172, a spline

formation 174 at an inner end of the shank 172, a tool formation 176 at an outer end thereof and an annular groove 178 for receiving one or more balls 28.

When it is desired to provide a strong rotary drive between a tool and one of the chuck assemblies described above and the tool, as well as an axial straining force against axial movement of the tool relative to one of the chuck assemblies described above, a tool 180, as shown in FIG. 16, is provided. As shown, the tool 180 includes a shank portion 182, a spline formation 184 at an inner end thereof and a tool formation 186 at an upper end thereof. In addition, formed on the shank is a polygonal, preferably hexagonal, formation 188 which engages a mating configuration, e. g. the hex bore 16 shown in FIGS. 1,10 and 12, and an annular groove 190 in the shank 182 in the area of the hexagonal formation 188.

It will be understood that the tool 160,170 or 180, as well as the tools 42 and 50 and the tool holder 60 can be used with any of the chuck assemblies described above and that each tool 160,170 and 180, as well as the tools 42 and 60 and the tool holder 60 have advantages therein as described above. In particular, the tool 160 provides a very simple tool which can be pushed either in or out of one of the chuck assemblies described above and minimally held therein against axial movement in the chuck assembly. If movement of the tool 160 is encountered, the user can simply rotate an outer sleeve of the chuck assembly to bring the jaws into engagement with the shank 162, in addition to engagement of the balls or detents 28 with the shank 162.

Alternatively, if a very strong retention against axial movement of the tool is desired or required, the tool 170 or 180 can be used which can be easily and simply inserted into the conventional chuck having the balls or detents 28 mounted therein, as described above, with engagement of the balls 28 in the annular groove 178 or 190 to prevent axial movement of the tool 170 180.

For a stronger rotary drive the tool 180 with polygonal, hexagonal formation 188 and the spline formation 184 can be used with one of the chuck assemblies described above.

Additionally, the chuck assembly 10 or 90 can be used with the rotatable nose collar 34 or the axially movable nose collar 94 for locking or unlocking one or more of the balls 28 against the shank 44,52,62,162,172, or 182.

Referring now to FIG. 17, there is illustrated therein a tool drive system 210

including a drive insert 212, a conventional chuck 214, a tool holder 216 (which can be a tool) and, where the tool holder is utilized, a tool 218 receivable in the tool holder 216. The insert 212 includes a base portion 220 and a projection 222 having structure, such as a spline configuration 224, forengaging mating structure 226 within a cavity 228 at the inner end 229 of a stem 230 of the tool holder 216 (or tool where a tool is inserted directly into the chuck 214 instead of a tool holder 216).

FIGS. 18,23,33 and 41 are bottom end views of the tool 218 which has a base or stem 232 with a hex configuration which is received in a hex shaped cavity 233 in an outer, mushroom shaped head or end portion 234 of the tool holder 216 shown, respectively, in FIG's 17,22,32,39 and 45.

FIGS. 19,24,34,42 and 46 are outer end views of the tool holder 216 shown in FIGS. 17,22,32,39 and 45.

FIGS. 20 and 35 are inner end views of the tool holder 216 shown, respectively, in FIGS. 17 and 32.

Returning now to FIG's. 17 and 28, it will be seen that the base 220 of the insert 212 has three splines or keys 236, which are adapted to be slidably received in key ways or slots 238 formed in an inner bore portion 240 of the chuck 214, as shown in FIG. 21.

A typical construction of the base 220 is shown in FIG. 28 where the three keys, or splines 236 on the outer periphery of the base 220, are illustrated.

In use of the tool drive system 210, shown in FIG. 17, the insert 212 is inserted into the inner bore portion 240 shown in FIG. 21 where the keys or splines 236 are received in the key ways or slots 238. Then, the chuck 214 is screw threaded on a motor shaft of a power tool (not shown). This can be achieved with a tool that is received overthe spline configuration 224 on the projection 222 of the insert 218 and then rotated.

Once the chuck 214 and insert 212 are mounted on a threaded outer end of a motor shaft of a power tool, the tool holder 216 can be inserted into an outer bore portion 242 in the chuck 214 with the cavity 228 at the inner end 229 of the stem 230 thereof received over the spline configuration 224 on the projection 222 of the insert 212 to provide a drive connection between the insert 212 and the tool holder 216.

In the embodiment shown in FIGS. 17-21, the tool holder 216 is held to the chuck by magnets 244 positioned on an underside 246 of the mushroom shaped

head 234 of the tool holder 216. The tool 218 is held within the head 234 by a magnet 246 located at the bottom of the hex-shaped cavity 233 in an outer side 250 of the head 234 of the tool holder 216, as shown.

With the tool drive system 210 shown in FIGS. 17-21, the three key ways or slots 238 need to be cut into the inner bore portion 240 of a conventional chuck 214.

Then, with this modification, the insert 212 can be inserted into the inner bore portion 240 in the chuck 214 and a threaded end of a motor shaft of a power tool is screwed into the inner bore portion 240, which is threaded, to mount the chuck 214, with the insert 212 therein, to a motor shaft of a power tool. See, for example, the chuck assemblies illustrated in the Salpaka U. S. Patents Nos. 5,193,824 and 5,464,229.

Then, in use, an operator can rotate a portion of the chuck 214 to bring jaws within the chuck 214 into engagement with the shaft or stem 230 of a tool or the tool holder 216 or simply can move a specially configured inner end 229 of a stem or shaft 230 of a tool or of the tool holder 216 into mating engagement with the projection 222 of the drive insert 212. The special configuration comprises a spline or polygonal shaped cavity 228. The tool or the tool holder 216 can be held to the chuck 212 by magnets associated therewith, such as the magnets 244, thereby to hold the tool or the tool holder 216 against axial movement while the mating spline or polygonal configurations of the projection 222 of the insert 212 and in the cavity 228 of the stem 230 of the tool or tool holder 216 provide a tool drive for driving the tool from the shaft of the power tool.

Referring now to FIG's. 22-26, there is illustrated another embodiment of a tool drive system 260 including a tool or the tool holder 216 with the tool 218, the tool holder 216 having a mushroom shaped head 234 with a cavity 233 and a stem, shaft or shank 230 extending from the head 234 to a lower, inner free end 262 which has a spline or polygonal shape 264, a chuck 214 and a drive insert 266. The drive insert 266 includes a base portion 268 with three keys or splines 270 on the outer periphery thereof and a cavity 272 therein which has a configuration 274 (FIG. 27) that mates with the spline or polygonal configuration 264 at the inner end 262 of the stem 230 of the tool holder 216. It will be understood that a tool with a lower inner end having a spline of polygonal configuration constructed to mate with the configuration 274 in cavity 272 of the drive insert 266 can be provided in place of the tool holder 216 and tool 218.

The inner bore portion 240 of the throughbore of the chuck 214 shown in FIG.

26 has the same configuration as shown in FIG. 21 and is adapted to receive the insert 266 shown in FIG. 22. In this way, a drive connection from the threaded end of a motor shaft to the chuck 214 and the drive insert 266 can be transmitted to the inner end 262 of the tool holder 216 or to the inner end of a tool which is configured and shaped for being received in the cavity 272 in the insert 266.

FIG. 27 is a top end view of the drive insert 266 shown in FIG. 22 and FIG. 28 is a top end view of the drive insert 212 shown in FIG. 17.

FIG. 29 is an end view of the lower end of the chuck 214 shown in FIG. 32 without an intermediate spline bore portion 280 and FIG. 30 is an end view of the outer end of the chuck 214 shown in FIG's. 17 and 22.

FIG. 31 is an enlarged view of a conventional chuck 214 showing a throughbore 276 through the chuck 214, a jaw 278 movable into the throughbore 276, a intermediate spline bore portion 280 of the throughbore 276 for receiving a special tool for mounting the chuck 214 on the threaded end of a motor shaft of a power tool and a threaded inner bore portion 240 of the throughbore 276. Also shown is a key way 38 formed in the threaded inner bore portion 240.

FIG. 32 is an exploded view of another embodiment of a tool drive system 290 of the present invention similar to the tool drive system 210 shown in FIG. 17. Here, the tool drive system 290 is shown to include a drive insert 292, a chuck 214, a tool holder 216 and a tool 218. The end views shown in FIG's. 33,34 and 35 correspond to the end views shown in FIGS. 18,19 and 20. In this tool drive system 290, no key ways are formed in the threaded inner bore portion 240, as shown in FIG's. 32 and 36 and in this embodiment, the drive insert 292 has a threaded cylindrical base portion 294 and a projection 296, corresponding to the projection 222 shown in FIG.

17.

In this embodiment of the tool drive system 290, the insert 292 is threaded into the inner threaded bore portion 240 until it bottoms out and is locked in place after which the chuck 214 is threadably mounted on a threaded motor shaft of a power tool, such as with a socket tool (not shown) which is inserted through the throughbore 276 of the chuck 214 for engaging the projection 296. Then, the tool holder 216 can be held to the chuck 214 by the magnets 244, shown in FIG. 35. The tool holder 216 is then rotatably driven by the engagement of the splined or polygonal shaped

projection 296 in the cavity 228 in the inner end 229 of the stem, shaft or shank 230 of the tool holder 214.

FIG. 39 is an exploded view of still another embodiment of a tool drive system 300 of the present invention. Here, a tool holder 216 is provided which has a square- in-cross-section cavity 302 in the inner end 304 of the shank 230 of the tool holder 216 for receiving a square-in-cross section projection 306 of a drive insert 308. The insert 308 is similar to the insert 212 shown in FIG. 17, except that the square-in- cross-section projection 306 has a spring biased detent 310 mounted in a transverse slot 312 in the projection 306 as shown in FIG. 40. The insert also has a base 312 having three splines or keys 314 for being received in mating key ways 316 formed in the inner bore portion 240 of the throughbore 276 in the chuck 214.

In this embodiment of the tool drive system 300, the spring biased detent 310 provides a mechanical mechanism for holding the tool holder 216, or a tool having a cavity at an inner end thereof, from moving axially relative to the chuck 214. The tool holder 216 or tool with a cavity at the inner end thereof has to be forcibly pulled away from the chuck 214 to insert another tool in the chuck 214.

In this embodiment, the spring biased detent 310 is used in place of magnets 244 for holding the tool holder 216 or a similarly configured tool from moving axially relative to the chuck 214.

FIG. 45 illustrates still another embodiment of a tool drive system 320 constructed according to the teachings of the present invention. This tool drive system 320 utilizes the tool holder 216 shown in FIG. 22. This tool holder 216 has magnets 244 on the underside 246 of the mushroom shaped head 234 and a stem or shaft 230 with an inner end 262 having a spline or polygonal configuration 264.

In this embodiment, a drive insert 322 is inserted into the throughbore 276 of the chuck 214 from the upper end of the chuck 214. The insert 322 has an upper base portion 324 with a splined or polygonal cavity 326 therein and a depending projection 328 which has a spline configuration that is received in the intermediate spline bore portion shown in FIG. 31 for establishing a drive connection from the chuck 214 to the insert 322 and then from the cavity 326 in the upper base portion 324 of the insert 322 to the splined or polygonal inner end 262 of the stem or shaft 230 of the tool holder 216.

It is to be understood that such drive can be from the cavity 326 to a specially

configured inner end of a tool adapted to be received in the cavity 326.

In this embodiment, a throughbore 328 is provided through the depending projection 328 and opens into the cavity 326 so that a retainer screw 330 having an Allen head 332, as shown in FIG. 47, can be inserted through the insert 322 and threaded into an axially threaded bore in the threaded end of the motor shaft of the power tool.

A preferred embodiment of the tool drive system of the present invention includes an insert, such as the insert 292 shown in FIG. 22, which is threadably received into the inner threaded bore portion 240 of the throughbore 276 in the chuck 214 so that the tool drive system does not require any modification to the chuck 214.

Furthermore, the chuck can be of the type shown in FIG. 31 with an intermediate spline bore portion 280 above the inner threaded bore portion 240 or a chuck without an intermediate spline bore portion 280. Furthermore, such insert can utilize the projection shown in FIGS. 39 and 40 having a spring biased detent 310 for being received in a similarly shaped cavity at the inner end of a tool or a tool holder 216 for snap-fittingly locking the tool or tool holder 216 against axial movement relative to the chuck without magnets 244, except when the tool or tool holder 216 is forcibly pulled outwardly from the chuck 214. The embodiment just described has a mechanical holding structure instead of a magnetic holding structure for holding the tool or tool holder to the projection of the insert received in the chuck.