Housing with functional overmold

Abstract

A hand-held power tool having a housing, which has first and second shell members and an end cap, and a trigger. The first and second shell members define a handle portion that is configured to be engaged by a first hand of a user. The trigger is coupled to the handle portion and configured to be operated by the first hand of the user. The end cap is removably coupled to the first and second shell members and defines an auxiliary gripping structure that is remote from the handle portion and configured to be selectively engaged by a second hand of the user to aid in operating the power tool. The end cap has a structural portion and an overmold portion that is formed from a resilient material. The overmold portion is at least partially interposed between the structural portion and the second hand.

1 . A hand-held power tool having a housing and a trigger, the housing including first and second shell members and an end cap, the first and second shell members defining a handle portion that is configured to be engaged by a first hand of a user, the trigger being coupled to the handle portion and configured to be operated by the first hand to permit the user to control the operation of the power tool, the end cap being removably coupled to the first and second shell members and defining an auxiliary gripping structure that is remote from the handle portion the auxiliary gripping structure being generally convex in shape and configured to be selectively engaged by a second hand of the user to aid in operating the power tool, the end cap having a structural portion and an overmold portion, the overmold portion being formed from a resilient material and molded onto the structural portion, the overmold portion being at least partially interposed between the structural portion and the second hand.  
   
   
       2 . The power tool of  claim 1 , wherein the resilient material is a vibration damping material that is configured to attenuate vibrations that are transmitted between the structural portion and the second hand.  
   
   
       3 . The power tool of  claim 2 , further comprising a driveline having a motor and a transmission, and wherein the overmold portion also attenuates vibrations transmitted between the driveline and the structural portion.  
   
   
       4 . The power tool of  claim 1 , wherein the power tool is a rotary power tool.  
   
   
       5 . The power tool of  claim 4 , wherein the power tool is selected from a group comprising drill/drivers and hammer drills.  
   
   
       6 . The power tool of  claim 1 , wherein the overmold portion includes an isolator portion for contacting a structure within an interior portion of the power tool, the isolator portion attenuating vibrations transmitted between the structure and the structural portion.  
   
   
       7 . The power tool of  claim 1 , wherein the overmold portion includes a seal portion for contacting a structure within an interior portion of the power tool, the seal portion forming a seal between the structure and the structural portion.  
   
   
       8 . The power tool of  claim 1 , wherein each of the first and second shell members includes a shell structure and a shell overmold, the shell overmold being overmolded onto the shell structure and covering at least a portion of the handle portion.  
   
   
       9 . The power tool of  claim 8 , wherein the shell overmold of each of the first and second shell members abuts an exterior surface of the end cap.  
   
   
       10 . The power tool of  claim 1 , wherein the overmold portion is formed on a rearward facing portion of the power tool.  
   
   
       11 . The power tool of  claim 1 , wherein the resilient material is a thermoplastic.  
   
   
       12 . The power tool of  claim 11 , wherein the thermoplastic is a thermoplastic elastomer.  
   
   
       13 . A hand-held power tool having a housing and a trigger, the housing defining a handle portion, which is configured to be engaged by a first hand of a user, and an auxiliary gripping structure, the trigger being coupled to the handle portion and configured to be operated by the first hand to permit the user to control the operation of the power tool, the gripping structure being spaced apart from the handle portion and configured to be selectively engaged by a second hand of the user to aid in operating the power tool, wherein the auxiliary gripping structure includes an overmold that is discrete and separate from the handle portion.  
   
   
       14 . The hand-held power tool of  claim 13 , wherein the housing comprises first and second shell members that collectively define a chamber into which a motor is at least partially disposed.  
   
   
       15 . The hand-held power tool of  claim 14 , wherein the auxiliary gripping structure is an end cap that closes a portion of the chamber defined by the first and second shell members.  
   
   
       16 . The hand-held power tool of  claim 15 , wherein the auxiliary gripping structure is removable from the first and second shell members.  
   
   
       17 . The hand-held power tool of  claim 15 , wherein at least one vent is formed in the structural portion to vent an interior portion of the housing.  
   
   
       18 . The hand-held power tool of  claim 17 , wherein the overmold member does not extend about a perimeter of the vent.  
   
   
       19 . The hand-held power tool of  claim 13 , wherein the overmold member covers only a portion of an outer surface of the structural member.  
   
   
       20 . The hand-held power tool of  claim 19 , wherein the overmold member extends through a plurality of holes that are formed in the structural member.  
   
   
       21 . The hand-held power tool of  claim 20 , wherein the overmold forms a plurality of spaced-apart bumper members.  
   
   
       22 . The hand-held power tool of  claim 13 , wherein the auxiliary gripping structure includes a structural member onto which the overmold is coupled.  
   
   
       23 . The hand-held power tool of  claim 13 , wherein the overmold is located on a rearward facing portion of the power tool.  
   
   
       24 . The hand-held power tool of  claim 13 , wherein the resilient material is a thermoplastic.  
   
   
       25 . The hand-held power tool of  claim 24 , wherein the thermoplastic is a thermoplastic elastomer.  
   
   
       24 . A hand-held power tool comprising: 
 a housing having first and second housing shells and an end cap, each of the first and second housing shells including a shell structure and a shell overmold, the shell structure defining a handle portion, the shell overmold at least partially covering the handle portion, the end cap closing an end of a cavity formed by the first and second housing shells, the end cap including an end cap structure and a resilient end cap overmold, the end cap defining an auxiliary gripping structure having a generally convex shape;    a motor at least partially disposed in the cavity defined by the first and second housing shells;    a drill chuck coupled to the motor; and    a trigger coupled to the housing and configured to be actuated by a user when a first hand of the user is grasping the handle portions of the first and second housing shells, wherein the auxiliary gripping structure is adapted to be engaged by a palm of a second hand of the user.    
   
   
       25 . The hand-held power tool of  claim 24 , further comprising a battery pack that is coupled to the motor and the trigger.