Pilotless Knockout Tool

Abstract

A knockout tool for forming a hole in a material, such as a sheet of metal, is provided. The knockout tool includes a body, a die mounted on a first end of the body, and a punch mounted on the second end of the body. A die plug is coupled to the first end of the body by a drive component, and a thrust bearing is positioned between the die and die plug such that at least a portion of the thrust bearing can rotate between the die and die plug. When the drive component is rotated in a first direction, the die plug and thrust bearing convert rotational movement of the drive component into linear movement and move the die into engagement with the punch.

What is claimed is: 
     
         1 . A knockout tool, comprising:
 a longitudinal axis;   a body, comprising:
 a first end centered on the longitudinal axis; and 
 a second end opposite the first end and aligned with the first end along the longitudinal axis; 
   a die plug coupled to the first end of the body;   a die coupled to the die plug;   a thrust bearing positioned between the die plug and the die, wherein at least a portion of the thrust bearing can rotate between the die and die plug with respect to the longitudinal axis;   a punch coupled to the second end of the body, the punch comprising a cutting end configured to be received in the die; and   a drive component extending through the first end of the body and received in the die plug, the drive component configured to rotate with respect to the longitudinal axis; and   wherein when the drive component is rotated in a first direction, the die plug and thrust bearing convert rotational movement of the drive component into linear movement and move the die into engagement with the punch along the longitudinal axis.   
     
     
         2 . The knockout tool of  claim 1 , wherein the die is removably coupled to the first end of the body. 
     
     
         3 . The knockout tool of  claim 1 , wherein the punch is removably coupled to the second end of the body. 
     
     
         4 . The knockout tool of  claim 1 , further comprising a retainer coupled to the punch opposite the cutting end, wherein the retainer is configured to retain the punch on the second end of the body. 
     
     
         5 . The knockout tool of  claim 4 , wherein the second end of the body comprises a bore extending through the second end and centered on the longitudinal axis, wherein the retainer is positioned within the bore. 
     
     
         6 . The knockout tool of  claim 4 , wherein the retainer comprises a mounting end coupled to the punch, and a distal end opposite the mounting end, wherein the retainer has a tapered shape such that an outer dimension of punch retainer decreases along its length from the distal end to the mounting end such that the mounting end has a smaller radius than the distal end. 
     
     
         7 . The knockout tool of  claim 4 , wherein the punch comprises a mounting channel with an threaded inner surface, and a mounting end of the retainer comprises threaded outer surface, wherein the punch and the retainer are coupled together through threaded engagement of the threaded inner surface and the threaded outer surface. 
     
     
         8 . A hole forming tool, comprising:
 a longitudinal axis;   a body, comprising:
 a first end centered on the longitudinal axis; and 
 a second end opposite the first end and aligned with the first end along the longitudinal axis; 
   a punch coupled to the second end of the body;   a die coupled to the first end of the body and centered on the longitudinal axis, the die comprising:
 a first side facing away from the first end of the body and configured to receive the punch; and 
 a second side opposite the first side along the longitudinal axis; 
   a die plug coupled to the first end of the body;   a thrust bearing positioned between the die plug and the second side of the die, wherein at least a portion of the thrust bearing can rotate between the die and die plug with respect to the longitudinal axis;   a drive component extending through the first end of the body and received in the die plug, the drive component configured to rotate with respect to the longitudinal axis; and   wherein, when the drive component is rotated in a first direction, the die plug and thrust bearing convert rotational movement of the drive component into linear movement such that the drive component moves axially along the longitudinal axis and moves the die into engagement with the punch.   
     
     
         9 . The hole forming tool of  claim 8 , wherein the die further comprises an opening formed in the first side of the die, wherein the punch is aligned with opening such that the punch is received in the opening when the die is moved into engagement with the punch. 
     
     
         10 . The hole forming tool of  claim 9 , wherein the opening has a first width greater than or equal to a second width of the punch. 
     
     
         11 . The hole forming tool of  claim 8 , wherein the punch comprises a cutting end and at least one cutting tip extends away from the cutting end of the punch towards the die along the longitudinal axis. 
     
     
         12 . The hole forming tool of  claim 8 , wherein the die plug comprises a projection positioned along the die plug adjacent to thrust bearing, wherein the projection extends through the thrust bearing and into the second side of the die. 
     
     
         13 . The hole forming tool of  claim 12 , wherein the die plug further comprises a recess positioned along the die plug opposite from the projection, wherein the recess is configured to receive and retain the drive component to couple the die to the first end of the body. 
     
     
         14 . The hole forming tool of  claim 8 , wherein the drive component comprises a drive shaft centered on and extending along the longitudinal axis and a drive receiver, wherein the drive receiver is configured to engage a driving tool. 
     
     
         15 . A tool, comprising:
 a body, comprising:
 a first end centered on a longitudinal axis; and 
 a second end opposite the first end and aligned with the first end along the longitudinal axis; 
   a die plug positioned adjacent to the first end of the body;   a die coupled to the die plug such that the die plug is positioned between the die and the first end of the body along the longitudinal axis;   a thrust bearing positioned between the die plug and the die, wherein at least a portion of the thrust bearing can rotate between the die and die plug with respect to the longitudinal axis;   a drive component extending through the first end of the body and received in the die plug such that the die plug is coupled to the first end of the body, the drive component configured to rotate with respect to the longitudinal axis; and   a punch coupled to the second end of the body, the punch comprising a cutting end configured to be received in the die; and   wherein, when the drive component is rotated in a first direction, the die plug and thrust bearing convert rotational movement of the drive component into linear movement such that the drive component moves the die plug, thrust bearing, and die axially along the longitudinal axis towards the punch.   
     
     
         16 . The tool of  claim 15 , wherein the body further comprises a center portion located between the first end and the second end, wherein the center portion is spaced from and substantially parallel to the longitudinal axis. 
     
     
         17 . The tool of  claim 16 , wherein the first end, the center portion, and the second end define a throat configured to receive a workpiece, wherein the throat has a depth measured between the center portion and the longitudinal axis. 
     
     
         18 . The tool of  claim 17 , wherein depth is at most 3 inches. 
     
     
         19 . The tool of  claim 17 , wherein the depth is between 1 inch and 3 inches. 
     
     
         20 . The tool of  claim 15 , wherein the die is removably coupled to the first end of the body, and wherein the punch is removably coupled to the second end of the body.