Power tool with multiple modes of operation and ergonomic handgrip

Abstract

A power tool includes a housing having a motor housing portion, a transmission housing portion, and a handle portion. The motor housing portion includes a top surface generally opposite a bottom surface. A motor is disposed in the motor housing portion. A transmission is disposed in the transmission housing portion. A power switch is disposed on the handle portion. An electronic mode select switch is disposed on a surface of the motor housing portion. A first gripping region is on a top portion of the motor housing portion, a second gripping region is on the handle portion, and a third gripping region is on a bottom portion of the motor housing portion. The first gripping region includes a first concave recess on a first side of the motor housing portion and a second concave recess on a second side of the motor housing portion.

What is claimed is: 
     
         1 . A power tool comprising:
 a housing including a motor housing portion, a transmission housing portion coupled to the motor housing portion, and a handle portion coupled to and extending transverse to a bottom surface of the motor housing portion, the motor housing portion including a top surface generally opposite the bottom surface;   a motor at least partially disposed in the motor housing portion;   a motor controller disposed in the housing and in electrical communication with the motor;   a transmission disposed at least partially in the transmission housing portion;   a tool accessory holder configured to be driven by the motor via the transmission and configured to receive a tool accessory for performing an operation on a workpiece;   a power switch actuatable from outside the housing and in electrical communication with the motor controller to control power delivery to the motor; and   an electronic mode select switch coupled to and actuatable from outside the motor housing portion, the electronic mode select switch in electrical communication with the motor controller,   wherein the power switch and the electronic mode select switch are configured to be simultaneously actuatable by a user with one hand while gripping the housing with the one hand in a position for actuating the power switch to control power delivery to the motor and actuating the electronic mode select switch to change a mode of operation of the power tool.   
     
     
         2 . The power tool of  claim 1 , wherein:
 the power switch is disposed on the handle portion; and   the electronic mode select switch is disposed on the top surface of the motor housing portion.   
     
     
         3 . The power tool of  claim 2 , wherein the power switch is disposed along at least half of the handle portion. 
     
     
         4 . The power tool of  claim 2 , wherein the handle portion includes a finger rest recess as a gripping location by a finger of the one hand of the user. 
     
     
         5 . The power tool of  claim 4 , wherein the finger rest recess is axially forward of the power switch on the bottom surface of the motor housing portion. 
     
     
         6 . The power tool of  claim 1 , wherein:
 the motor housing portion defines a first concave recess on a first side of the motor housing portion and a second concave recess on a second side of the motor housing portion, the second side of the motor housing portion opposite the first side of the motor housing portion;   the first concave recess provides a first grip area for a thumb of the one hand of the user; and   the second concave recess provides a second grip area for a forefinger of the one hand of the user.   
     
     
         7 . A power tool comprising:
 a housing defining a tool axis, the housing including a motor housing portion, a transmission housing portion coupled to the motor housing portion, and a handle portion coupled to and extending transverse to a bottom surface of the motor housing portion, the motor housing portion including a top surface generally opposite the bottom surface;   a motor at least partially disposed in the motor housing portion;   a motor controller disposed in the housing and in electrical communication with the motor;   a transmission disposed at least partially in the transmission housing portion;   a tool accessory holder configured to be rotatably driven by the motor via the transmission and configured to receive a tool accessory;   a power switch disposed on the handle portion and in electrical communication with the motor controller to control power delivery to the motor;   an electronic mode select switch disposed on a surface of the motor housing portion, the electronic mode select switch in electrical communication with the motor controller;   a first gripping region on a top portion of the motor housing portion;   a second gripping region on the handle portion; and   a third gripping region on a bottom portion of the motor housing portion,   wherein the first gripping region includes a first concave recess on a first side of the motor housing portion and a second concave recess on a second side of the motor housing portion, the second side of the motor housing portion opposite the first side of the motor housing portion.   
     
     
         8 . The power tool of  claim 7 , wherein the third gripping region includes a finger rest recess disposed axially forward of the power switch on the bottom surface of the motor housing portion. 
     
     
         9 . The power tool of  claim 7 , wherein the handle portion includes a rear concave recess. 
     
     
         10 . The power tool of  claim 7 , wherein the handle portion defines a handle axis, the handle axis at an obtuse angle α to the tool axis. 
     
     
         11 . The power tool of  claim 10 , wherein the obtuse angle α is approximately between 100 degrees and 115 degrees. 
     
     
         12 . The power tool of  claim 7 , wherein the second gripping region lies along a generally elliptical shape that is centered approximately at the power switch, the elliptical shape having a major axis generally perpendicular to the tool axis and extending from a top surface of the motor housing portion to a distal end of the handle portion, and a minor axis generally parallel to the tool axis extending from a rear surface of the handle portion. 
     
     
         13 . The power tool of  claim 12 , wherein the major axis has a length of approximately 142 mm to approximately 147 mm and the minor axis has a length of approximately 128 mm to approximately 132 mm. 
     
     
         14 . The power tool of  claim 7 , wherein the power switch is disposed along at least half of the handle portion. 
     
     
         15 . The power tool of  claim 7 , wherein the power tool is configured to be selectively grasped in a first grip position using the first gripping region, the second gripping region, and the third gripping region or a second grip position using only the second gripping region and the third gripping region, the first grip position being different than the second grip position; and
 wherein both the first grip position and the second grip position enable simultaneous actuation of the electronic mode select switch and the power switch.   
     
     
         16 . A power tool comprising:
 a housing defining a tool axis, the housing including a motor housing portion, a transmission housing portion coupled to the motor housing portion, and a handle portion coupled to and extending transverse to a bottom surface of the motor housing portion, the motor housing portion including a top surface generally opposite the bottom surface;   a motor at least partially disposed in the motor housing portion;   a motor controller disposed in the housing and in electrical communication with the motor;   a transmission disposed at least partially in the transmission housing portion;   a tool accessory holder configured to be rotatably driven by the motor via the transmission and configured to receive a tool accessory;   a battery receptacle coupled to a distal portion of the handle portion;   a power switch disposed on the handle portion and in electrical communication with the motor controller to control power delivery to the motor; and   an electronic mode select switch disposed on a surface of the motor housing portion, the electronic mode select switch in electrical communication with the motor controller,   wherein the handle portion includes a top portion adjacent the bottom surface of the motor housing portion, a bottom portion adjacent the battery receptacle, and an intermediate portion between the top portion and the bottom portion, the top portion having a first depth and a first width, the intermediate portion having a second depth and a second width, and the bottom portion having a third depth and a third width, the first depth greater than the second depth, the second depth greater than the third depth, the first width greater than the second width, and the second width greater than or equal to the third width.   
     
     
         17 . The power tool of  claim 16 , wherein the first width is approximately 37 mm to 42 mm, the second width is approximately 31 mm to 36 mm, and the third width is approximately 28 mm to 35 mm. 
     
     
         18 . The power tool of  claim 17 , wherein the first depth is approximately 45 mm to 55 mm, the second depth is approximately 40 mm to 50 mm, and the third depth is approximately 38 mm to 48 mm. 
     
     
         19 . The power tool of  claim 16 , wherein:
 the motor housing portion includes a first concave recess on a first side surface of the motor housing portion, a second concave recess on a second side surface of the motor housing portion opposite the first side surface of the motor housing portion, and a finger rest recess axially forward of the power switch on the bottom surface of the handle portion.   
     
     
         20 . The power tool of  claim 16 , wherein:
 the power tool is configured to be selectively grasped in a first grip position using the top portion, the intermediate portion, and the bottom portion of the handle portion or a second grip position using the motor housing portion, the top portion of the handle portion, and the intermediate portion of the handle portion, the first grip position different than the second grip position; and   wherein both the first grip position and the second grip position enable simultaneous actuation of the electronic mode select switch and the power switch.