Locking pliers

[0002] This application claims the benefit of U.S. Provisional Application Ser. No. 60/047,688, entitled “Locking Pliers,” filed May 27, 1997 by the same inventors, which is incorporated herein by reference in its entirety.

[0003] 1. Field of the Invention

[0004] The invention relates generally to locking pliers, and more particularly, to locking pliers having an improved locking and release mechanism.

[0005] 2. Description of Related Art

[0006] Pliers having locking mechanisms to maintain the pliers jaws in a fixed position are well known. Such pliers typically include an adjustment mechanism that sets the pliers jaws at roughly a desired distance apart, and a toggle mechanism locks the pliers about a workpiece when the pliers handles are squeezed together. In known locking pliers, the action of squeezing the handles together drives the toggle mechanism beyond a “dead center point,” to lock the jaws onto the workpiece.

[0007] Known locking pliers typically include a fixed handle and jaw with a movable jaw coupled thereto. The movable jaw is operated by a movable lever that has one end coupled to the movable jaw. The opposite end of the movable lever defines a movable handle. A link member connects the fixed handle to a forward section of the movable lever intermediate the movable handle and the movable jaw. The combination of the link member and the forward section of the movable lever constitute the toggle mechanism for locking and releasing the pliers. An adjustment mechanism, such as an adjustment screw, laterally moves the end of the link member connected to the fixed handle to adjust the separation of the fixed and movable jaws. A spring may be employed, for example, between the movable jaw and the fixed handle, to normally bias the jaws apart.

[0008] The above described arrangement of the link member and forward section of the movable lever define three pivot points around which the locking mechanism of typical prior art locking pliers operates. The first pivot point is the point at which the movable lever connects to the movable jaw. The second pivot point is located where the link member connects to the forward section of the movable lever, and the third pivot point occurs at the opposite end of the lever member, where the link member connects to the fixed handle.

[0009] When the locking pliers handles are apart (jaws apart, or open), the toggle mechanism (the forward section of the movable lever and the link member) forms an obtuse angle. As the handles are brought together, the jaws close towards each other, and the angle formed by the toggle mechanism approaches a straight line. The “dead center point” occurs when toggle member forms a straight line; in other words, when the three pivot points are in a line. As the handles continue to move together, the second pivot point passes the dead center point, and movement of the movable handle is halted, usually by the one or both of the forward section of the movable lever or the link member contacting a stop or the fixed handle. The jaws will maintain their closed position until the second pivot point is forced back across the dead center point by actuation of a release lever or other actuator provided on the fixed handle.

[0010] Unfortunately, there are several shortcomings associated with known locking pliers, such as those described above using a “dead center point” locking operation. First, the action of releasing the locked pliers jaws by pushing the middle pivot point back across the dead center point often requires two hands. The user has one hand gripping the handles of the pliers, and the user's other hand is required to activate the release. This two-hand requirement is simply unacceptable for many tasks requiring the use of a pair of pliers.

[0011] Further, the jaws of prior art locking pliers will lock any time the handles are manipulated such that the middle pivot point crosses the dead center point. Often, it is desirable to operate a locking pliers as a spring loaded pliers, for example, to achieve a “ratcheting” action when turning a nut or bolt. However, with known locking pliers, the jaws lock each time the handles are squeezed together, and the release mechanism must be actuated to unlock the pliers. This necessitates repeatedly locking and unlocking the pliers whenever repeated opening and closing of the jaws is required.

[0012] Moreover, the release lever of many prior art locking pliers may cause an uncontrolled or unintentional unlocking of the pliers. The release mechanisms of typical prior art locking pliers perform the unlocking function by pushing the center pivot point back across the dead center point. Once the center pivot point passes the dead center point from the locked position, the jaws are not maintained in their closed position. Further, since most known locking pliers are spring biased to an open position (jaws apart), as soon as the center pivot point passes the dead center point, the pliers will “spring” open. This can create several difficulties.

[0013] For example, if the locking pliers are being used in a clamping operation, the pliers will completely release if the release lever is inadvertently activated. During operations requiring locking and unlocking of the pliers, the user often does not have a free hand available to activate the release lever. Hence, the user may be required to release his grip from the handles, at least partially, to activate the release. If the user does not maintain control of the handles when the release is activated, the pliers may spring out of the user's hands, or possibly spring open and strike the user's hand.

[0014] Still further, many prior art locking pliers designs have a toggle mechanism including the link member described above, extending between the fixed handle and the movable lever. The combination of the handles and the link member produce various “pinch points.” These pinch points are locations where material, such as a user's clothes or a finger, may be caught and pinched as the handles are moved relative to each other.

[0015] Thus, a need exists for locking pliers that address these, and other, shortcomings of the prior art.

[0016] In one aspect of the present invention, a pair of locking pliers includes a first assembly defining a first handle and a first jaw, and a second handle. A second jaw is rotatably coupled to the first assembly and the second handle, such that the second handle is movable relative to the first handle to move the second jaw relative to the first jaw. A locking mechanism interconnects the first assembly and the second handle. A release mechanism is rotatably coupled to the second handle. The release member interacts with the locking mechanism to fix the second jaw in a fixed position relative to the first jaw.

[0017] In another aspect of the present invention, a pair of locking pliers includes a first assembly defining a first handle and a first jaw, a second handle, and a second jaw rotatably coupled to the first assembly and the second handle. The second handle is movable relative to the first handle to move the second jaw relative to the first jaw. A release mechanism has a first setting wherein the second jaw is freely movable relative to the first jaw, a second setting wherein the second jaw locks at a preset distance from the first jaw when the second handle is moved toward the first handle, and a third setting wherein the second jaw unlocks when the second handle is moved toward the first handle.

[0018] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:

[0019] FIG. 1 is a perspective view illustrating an exemplary pair of locking pliers in accordance with an embodiment of the present invention;

[0020] FIG. 2 is a side view of the exemplary pair of locking pliers illustrated in FIG. 1, illustrating several interior components in dashed lines;

[0021] FIGS. 3A-3C illustrate a side view and bottom views of the main components of an upper handle assembly in accordance with an embodiment of the present invention;

[0022] FIG. 4 is a side view of an upper handle spacer in accordance with an embodiment of the present invention;

[0023] FIG. 5 is a side view of a pivot release member of a release mechanism in accordance with an embodiment of the present invention;

[0024] FIG. 6 is a side view of a release slide of a release mechanism in accordance with an embodiment of the present invention;

[0025] FIG. 7 is a side view of a release button of a release mechanism in accordance with an embodiment of the present invention;

[0026] FIG. 8 is a side view of a middle release spacer of a release mechanism in accordance with an embodiment of the present invention;

[0027] FIG. 9 is a side view of an outer release spacer of a release mechanism in accordance with an embodiment of the present invention;

[0028] FIG. 10 is a side view of a pivot release member in accordance with an alternate embodiment of the present invention;

[0029] FIG. 11 is a side view of a rotation pin in accordance with an embodiment of the present invention;

[0030] FIG. 12 is a side view of a lower jaw support in accordance with an embodiment of the present invention;

[0031] FIG. 13 is a bottom view of right and left side lower jaw supports as assembled in an embodiment of the present invention;

[0032] FIG. 14 is a side view of a lower jaw component in accordance with an embodiment of the present invention;

[0033] FIGS. 15A and 15B are side and bottom views of a right side lower handle in accordance with an embodiment of the present invention;

[0034] FIGS. 16A and 16B are side and bottom views of a left side lower handle in accordance with an embodiment of the present invention;

[0035] FIG. 17 is a partial bottom view illustrating the lower handle assembly of an embodiment of the present invention;

[0036] FIG. 18 illustrates an adjustment nut as it is fixed in place by the components of the lower handle assembly in an embodiment of the present invention;

[0037] FIG. 19 is a side view illustrating a locking arm in accordance with an embodiment of the present invention;

[0038] FIGS. 20A and 20B illustrate side and front views of an adjustment bracket in accordance with an embodiment of the present invention;

[0039] FIG. 21 is a side view illustrating an exemplary adjustment screw in accordance with an embodiment of the present invention;

[0040] FIG. 22 is a side view illustrating an upper jaw component in accordance with an embodiment of the present invention;

[0041] FIG. 23 is a bottom view illustrating an example of the laminate stack formed by various components of an embodiment of the present invention;

[0042] FIGS. 24A and 24B are front and side views of a pivot washer in accordance with an embodiment of the present invention;

[0043] FIG. 25 is a side view illustrating an anti-impingement pin in accordance with an embodiment of the present invention;

[0044] FIGS. 26A-26C are partial side views illustrating the operation of the release mechanism in an embodiment of the present invention;

[0045] FIG. 27A is a side view, and FIG. 27B is a conceptual diagram, illustrating the operation of the anti-past center stop of an embodiment of the present invention;

[0046] FIG. 28 is a partial side view illustrating an alternative embodiment of the present invention, in which the main biasing spring comprises an extension spring;

[0047] FIG. 29 is a side view illustrating an exemplary lower jaw support suitable for use with the embodiment of the present invention illustrated in FIG. 28;

[0048] FIGS. 30A and 30B are side views illustrating exemplary components of an upper jaw element suitable for use with the embodiment of the present invention illustrated in FIG. 28;

[0049] FIGS. 31A and 31B are side and bottom views of an exemplary leaf spring suitable for use in the lower handle assembly of an embodiment of the present invention;

[0050] FIG. 32 is a side view illustrating an alternate embodiment of a release actuator in accordance with the present invention; and

[0051] FIG. 33 is a side view illustrating a locking pliers in accordance with an alternate embodiment of the present invention, including wire strippers and a wire cutter.

[0052] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

[0053] Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0054] Turning to the drawings and, in particular, to FIG. 1, a perspective view of a pair of locking pliers 10 in accordance with an embodiment of the present invention is provided. In general, the pair of locking pliers 10 includes an upper handle assembly 12, a lower handle assembly 14, and a lower jaw assembly 16. The upper handle assembly 12 defines an upper handle 18 that extends from one end of the pliers 10. The upper handle assembly 12 is rotatably coupled to the lower jaw assembly 16 by a pin 20 (not visible in FIG. 1). An actuator 210 of a release mechanism 21 (not illustrated in FIG. 1) extends from the upper handle assembly 12.

[0055] The lower handle assembly 14 defines a lower handle 22 that extends in the same general direction as the upper handle 18. The lower handle assembly 14 also defines a head portion 24. An upper jaw member 26 is positioned within the head portion 24, and a lower jaw member 27 is positioned within lower jaw assembly 16. A pivot pin 28 passes through the lower handle assembly 14 and the lower jaw assembly 16, rotatably coupling the lower jaw assembly 16 to the lower handle assembly 14. The knurled end of an adjustment screw 30 extends from one end of the lower handle 22.

[0056] In the embodiment of FIG. 1, upper and lower grips 32aand 32b,formed of vinyl or other suitable material, are positioned about the upper and lower handles 18 and 22.

[0057] In operation, the user of the pair of locking pliers 10 may, through adjustment of the adjustment screw 30, preset the distance that will exist between the upper jaw member 26 and lower jaw member 27 in lower jaw assembly 16 when the pliers 10 are in their closed and locked position. Once the adjustment screw 30 is set, the pliers 10 may be placed in their closed and locked position by bringing the lower handle 22 towards the upper handle 18 (or vice versa) until the pliers 10 reach a locked and closed position. Once the pair of pliers 10 is placed in its closed and locked position, it may be released from that position through activation of the release actuator 210.

[0058] FIG. 2 shows a side view of the pliers 10 of FIG. 1, with many of the interior elements of the pliers 10 illustrated using dashed lines. The upper and lower grips 32a,32bare not illustrated in FIG. 2. Referring to FIGS. 2 through 4, the upper handle assembly 12 comprises three major components: a right side upper handle portion 34a(looking down—the topmost upper handle portion in FIG. 2); a left side upper handle portion 34b(looking down—the bottom upper handle portion, not visible in FIG. 2); and an upper handle spacer 36 (not visible in FIG. 2). In general, the right and left side upper handle portions 34aand 34band the upper handle spacer 36 are coupled together to form the upper handle 18 and an upper handle cavity within which is positioned the release mechanism 21.

[0059] In the embodiment of FIG. 2, both the right and left side upper handle portions 34aand 34bare constructed (blanked) from 1070 steel that has been cut through use of a progressive stamping die and has been heat treated and blackened via a black oxide coating. Other coatings, such as zinc chromate, would also be suitable. Still further embodiments using materials other than steel are envisioned. Both the right and left upper handle portions 34aand 34bmay be constructed (blanked) from a piece of material of the form of the component designated 34 illustrated in FIG. 3A.

[0060] Referring FIG. 3A, the illustrated component 34 has a first extension that defines a handle portion 40 and a main body portion 42. Pin-receiving bores 44a,44b,44care constructed (blanked and countersunk) in the handle portion 40 and three pin-receiving bores 46a,46b,46care formed in the main body portion 42. The embodiment of the component 34 illustrated in FIG. 3A further defines a pin-receiving bore 47 that is smaller than the pin-receiving bores 46a,46b,46c.The main body portion 42 also defines an extension member 48 that extends from the main body portion 42 back towards the handle portion 40. The main body portion 42 further defines a cut-out section 50 that is generally opposite the extension member 48.

[0061] The right and left upper handle portions 34aand 34bthat form the upper handle assembly 12 are generally identical with the exception of the handling of the extension member 48. To form the right side upper handle portion 34athe extension member 48 is bent in the direction illustrated in FIG. 3B by a pre-defined amount. In the illustrated example, the pre-defined amount is about 90 degrees. To form the left side upper handle portion 34b,the extension member 48 is bent in the direction opposite that illustrated in FIG. 3B. The bend used to form the left side upper handle portion 34bis generally illustrated in FIG. 3C. In the illustrated embodiment, the bend used to form the left side upper handle portion 34bis also about 90 degrees. In an alternative embodiment, the extension member 48 of both the right and left side upper handle portions 34a,34bis bent about 30 degrees.

[0062] FIG. 4 provides an illustrative example of the upper handle spacer 36. In the illustrative example, the upper handle spacer 36 is formed of injection molded Delrin plastic. In general, the upper handle spacer 36 follows the general profile of the handle portions 40 of the right and left upper handle portions 34aand 34b.The upper handle spacer 36 defines two pin-receiving bores 52aand 52bthat are arranged, constructed (blanked and countersunk), and sized in a manner similar to bores 44a,44bof component 34. The upper handle spacer 36 also defines an elongated channel 54.

[0063] Referring back to FIG. 2, the release mechanism 21 will be discussed in greater detail. In general, the release mechanism 21 includes a pivot release member 212 that may be formed from 1070 heat-treated steel that has been appropriately cut through use of a stamping die. An exemplary pivot release member 212 is illustrated in FIG. 5. The steel used to form the pivot release member 212 may be blackened in a manner similar to that used to construct component 34, although in one embodiment no blackening is used such that the pivot release member 212 has an appearance different from that of the right and left upper handle portions 34aand 34b.

[0064] Because the pivot release member 212 experiences movement during the use of the pliers 10, it may be coated with an appropriate protective coating, such as 0.001 inch of zinc chromate. In general, the thickness of the material used to form the pivot release member 212 will be greater than that used to form the right and left upper handle portions 34aand 34b.For example, if steel having a thickness of 0.090 inches is used to form the right and left upper handle portions 34aand 34b,steel having a thickness of 0.170 inch may be used to form the pivot release member 212. A pin-receiving bore 60 passes through the pivot release member 212 and first and second extension surfaces 62aand 62bform a locking ledge 64. The pivot release member 212 further defines a slot 58.

[0065] The release mechanism 21 further includes a release slide 214. An embodiment of the release slide 214 is illustrated in FIG. 6. The release slide 214 includes an actuator portion 210, which, as illustrated in FIG. 1 and FIG. 2, protrudes above the upper handle assembly 12. The release slide 214 further defines a cavity 216 that is adapted to receive a release button 218. An embodiment of the release button 218 is illustrated in FIG. 7. The embodiment of the release button 218 defines a bore 220 extending therethrough, generally transverse to the main axis of the release button 218. A release pin 222 is seated in the bore 220, such that a portion of the release pin 222 extends from either side of the release button 218. A release spring 224 is received within the cavity 216, and the release button 218, with the release pin 222 seated in the bore 220, is also situated within the cavity 216 such that the release spring 224 biases the release button 218 in an upwards direction.

[0066] First and second outer release spacers 230 are situated between the right and left upper handle portions 34aand 34bin the upper handle assembly cavity, and a middle release spacer 232 is sandwiched between the first and second outer release spacers 230. The first and second outer release spacers 230 are identical in shape, and are illustrated in FIG. 8. The middle release spacer 232 is illustrated in FIG. 9. The outer release spacers 230, and the middle release spacer 232 each define a channel 234 therein and a notch 236 that is adapted to receive the portions of the release pin 222 extending from either side of the release button 218. Each of the outer release spacers 230 defines two pin receiving bores 240a,240bextending therethrough, and the middle release spacer 232 defines two corresponding pin-receiving bores 242a,242b.

[0067] The manner in which the right and left upper handle portions 34aand 34b,the upper handle spacer 36, and the release mechanism 21 are coupled together to form the upper handle assembly 12 is generally illustrated in FIG. 2. Referring to FIG. 2, the upper handle assembly 12 may be formed by sandwiching the upper handle spacer 36, the pivot release member 212, and the remaining components of the release mechanism 21 between the right and left upper handle portions 34a,34b,with the actuator 210 of the release mechanism 21 extending from the right and left upper handle portions 34a,34b.

[0068] A rotation pin 66, which passes through the bore 60 of the pivot release member 212 and bores 46aof the right and left upper handle portions 34a,34b,serves to keep the pivot release member 212 in proper alignment with respect to the right and left upper handle portions 34aand 34b.One suitable rotation pin 66 is illustrated in FIG. 11. In general, the rotation pin 66 has an intermediate portion 67 of a first diameter and two projecting portions 65 of a lesser diameter. The projecting portions 68 are sized to be received by the corresponding bores 46ain the right and left upper handle portions 34aand 34b.The rotation pin 66 may be of standard construction and may be formed from either hot or cold rolled steel. In one embodiment, the rotation pin 66 is not fully hardened, but is only toughened to approximately 44-48 on the Rockwell C scale.

[0069] The upper handle assembly 12 may be held together by three upper handle rivet pins 67a,67b,67cthat are positioned through the pin-receiving bores 44a,44b,44cof the right and left upper handle portions 34aand 34b,the pin-receiving bores 52a,52bof upper handle spacer 36, the pin-receiving bores 240aof the outer release spacers 230, and the pin-receiving bore 242aof the middle release spacer 232. Additionally, a pin 67dextends through the pin receiving bores 240bof the outer release spacers 230 and the pin-receiving bore 242bof the middle release spacer 232, further keeping the middle release spacer 232 properly sandwiched between the outer release spacers 230. The use of pins 67a-67dis exemplary only; other suitable fasteners may be employed.

[0070] In the illustrative embodiment of FIG. 2, the channel 54 defined by the upper handle spacer 36, together with the right and left upper handle portions 36a,36b,form a cavity within which a pivot release spring 68 is situated. The pivot release spring 68 functions to bias the pivot release member 212 towards the head portion 24 of the upper handle assembly 12, and against the lower portion 238 of the release slide 214. The right and left upper handle portions 34a,34b,along with the channel 234 defined by the outer and middle release spacers 230, 232 forms another cavity within which a release slide spring 69 is situated, pushing the pivot release member 212 opposite the pivot release spring 68.

[0071] An alternative embodiment of the release mechanism is illustrated in FIG. 10. In the illustrated embodiment, the release mechanism generally comprises a single pivot release member 213, that may be formed in a manner similar to the pivot release member 213 of the release mechanism 21 disclosed herein in conjunction with FIGS. 5-9. An upper extension surface 56 of the pivot release member 213 protrudes from the upper handle assembly 12. This upper extension surface 56 may be depressed by the user of pliers 10 to disengage the pair of pliers from its closed and locked position. Because the human user of the pliers 10 will apply pressure to the pivot release member 213 to release the pliers 10 from their closed and locked position, the pivot release member 213 may be tumbled to smooth its surface. The lower portion of the pivot release member 213 is formed in a manner similar to the pivot release member 212 of the embodiment illustrated in FIG. 5. The operation of the release mechanism 21 is described further herein below.

[0072] As illustrated in FIG. 2, the upper handle assembly 12 is coupled to the lower jaw assembly 16 by a pin 20. The pin 20 may be formed in a manner similar to the rotation pin 66 illustrated in FIG. 11. FIGS. 12-15 illustrate the lower jaw assembly 16 in greater detail. In general, the lower jaw assembly 16 is formed from two substantially-identical components 70aand 70band a lower jaw member 27. FIG. 12 provides an illustrative example of the component 70a.In general, the component 70amay be formed of hardened, blackened 1070 steel. The component 70adefines a large bore 72 for receiving the pivot pin 28, and a first small bore 74 sized to receive the pin 20 for coupling the lower jaw assembly 16 to the upper handle assembly 12. Component 70aalso defines one or more small bores 76. In the embodiment illustrated, there are three small bores 76. The component 70ais bent-out at region 80 in a manner illustrated more clearly in FIG. 13. Component 70bis substantially identical to component 70a,except that the bend at region 80 in component 70bis opposite to that of component 70a.

[0073] Components 70aand 70bmay be brought together to form a lower jaw cradle in the manner illustrated in FIG. 13. The lower jaw member 27, which is illustrated in FIG. 14, may be placed in the lower jaw cradle to form the lower jaw assembly 16. As illustrated in FIG. 14, the lower jaw member 27 defines a toothed jaw surface 82 and a lower extension surface 84. In one embodiment the lower jaw element 27 is formed of powdered metal that has been formed in an appropriate mold and that has been manufactured to have a hardness of approximately 52 on the Rockwell C scale. Alternatively, the lower jaw member 27 may be of a laminated construction of similar material as the components 70aand 70bof the lower jaw assembly 16.

[0074] In the illustrated embodiment, the width of the toothed jaw surface 82 is greater than the width “d” of the lower jaw cradle and the width of the lower extension surface 84 is less than the width “d” of the lower jaw cradle (illustrated in FIG. 13). As such, the lower jaw element 27 may be placed in the lower jaw cradle such that the components 70aand 70bsupport the toothed jaw surface 82 of the lower jaw element 27. Rivet pins 85 may be positioned through the bores 76 in components 70aand 70band corresponding bores 77 in the lower jaw element 27. The rivet pins 85 may be of a standard construction, 1008 SAIP.

[0075] Referring to FIG. 2 and FIGS. 15-18, an embodiment of the lower handle assembly 14 will next be described. In general, the lower handle assembly 14 is formed from a right side lower handle portion 86a(looking down—the topmost lower handle portion in FIG. 2) and a left side lower handle portion 86b(looking down—the bottom lower handle portion, not shown in FIG. 2). The right and left side lower handle portions 86aand 86bare coupled together and define a cavity therebetween. As discussed in more detail below, an adjustment mechanism, comprising the adjustment screw 30, an adjustment nut 108, and a connecting arm 110, is positioned within the cavity defined by the lower handle assembly 14.

[0076] The right and left lower handle portions 86a,86bmay be formed from the same materials of and in the same manner of the right and left upper handle portions 34a,34b.Unlike the right and left upper handle portions 34a,34b,however, the right and left lower handle portions 86a,86bare not identical. FIGS. 15A and 16A show side views of the right and left side lower handle portion 86a,86b,respectively. The right and left side lower handle portions 86a,86beach define a handle portion 90 and an offset head portion 92. The handle portions 90 each define a nut-receiving slot 94. In the embodiment illustrated, the nut receiving slot 94 of the lower left side handle portion 86bhas a width that is less than the corresponding width of the nut-receiving slot 94 of the right side lower handle portion 86a.Located proximate to the nut-receiving slots 94 are a plurality of downwardly extending, generally L-shaped locking tabs 96. Each of the right and left side lower handle portions 86a,86bdefine a pin receiving slot 98 formed at a position adjacent the nut-receiving slot 94. Two bores 100, 102 are formed in the offset head portion 92 of the right side lower handle portions 86a,86b.

[0077] FIG. 17 is a partial bottom view, illustrating the right and left side lower handle portions 86a,86bin their assembled configuration. When placed in their respective, opposing positions, the locking tabs 96 on the right side lower handle portion 86aare mirror images of the locking tabs 96 on the left side lower handle portion 86b.The locking tabs 96 are simply interlocked to couple the right and left side lower handle portions 86a,86btogether.

[0078] Referring to FIG. 2, it may be noted that the novel configuration of the right and left lower handle portions 86a,86band, in particular, the configuration of the nut-receiving slots 94 and the L-shaped locking tabs 96, allow for economical and efficient assembly of the pair of pliers 10. Specifically, to assemble the pliers 10, an adjustment nut 108 is placed in the slot 94 of the left side lower handle potion 86b.The adjustment screw 30 is then threaded through the adjustment nut 108. Alternatively, the adjustment screw 30 may be threaded through the adjustment nut 108 prior to the nut 108 being positioned within the slot 94.

[0079] Once the adjustment nut 108 and the adjustment screw 30 are positioned within the slot 94 of the left side lower handle portion 86b,the right side lower handle portion 86ais positioned such that its slot 94 surrounds the adjustment nut 108. The right side lower handle portion 86ais then “snapped” into place such that its L-shaped locking tabs 96 engage the locking tabs 96 of the left side lower handle portion 86b.FIG. 18 generally illustrates the manner in which the adjustment nut 108 is held in place by the inter-locked nature of the right and left side lower handle portions 86a,86b.The use of the inter-locking locking tabs 96 in the illustrated embodiment of the present invention allows for efficient construction of the locking pliers 10 without time-consuming and costly brazing or welding techniques.

[0080] Referring back to FIG. 2, the adjustment screw 30 and the adjustment nut 108 are positioned and held in the cavity formed by the lower handle assembly 22 in the manner discussed above. The adjustment screw 30 is coupled to a connecting arm 110 by an adjustment bracket 112. Exemplary embodiments connecting arm 110, the adjustment bracket 112, and the adjustment screw 30 are illustrated in greater detail in FIGS. 19-21, respectively.

[0081] In general, the adjustment bracket 112 is coupled to the adjustment screw 30 via a slot 113 formed in the adjustment bracket 112 and a pin 115 formed in the adjustment screw 30. As illustrated in FIG. 21, the adjustment screw 30 defines a pin member 115 that may be received in the slot 113 of the adjustment bracket 112. The exemplary adjustment screw 30 also defines a knurled end 117 that projects from the lower handle 22 for use in adjusting the locked and closed position of the locking pliers 10. In one embodiment, only the end of adjustment screw 30 near the pin 115 is hardened.

[0082] Referring back to FIG. 2, the adjustment bracket 112 may be coupled to the connection arm 110 via a rivet pin 111. The rivet pin 111 may extend through the adjustment bracket 112 and into the slots 98 of the right and left lower handle portions 86aand 86b.Referring to FIG. 19, the connection arm 110 has a first end that defines a first bore 114 for receiving the rivet pin 111 for coupling the connection arm 110 to the adjustment bracket 112. The connection arm 110 also has a second end defining a second bore 116 for receiving a rivet pin 115 for connecting the connection arm 110 to the upper handle assembly 12. The second end of the connection arm 110 also defines a locking extension 118 that is shaped to be received by the locking ledge 64 of the pivot release lever 212 of the release mechanism 21. The second end of the connection arm 110 is coupled to the upper handle assembly 12 by the pin 115 that passes through the bore 116 of the connection arm 110 and the bores 46bof the right and left upper handle portions 34aand 34b.

[0083] As illustrated in FIG. 2, the lower handle assembly 14 defines a head portion 24 within which is positioned the upper jaw element 26. In general, the right and left side lower handle portions 86aand 86bform an upper jaw cradle that receives the upper jaw element 26 in a manner similar to the manner in which the lower jaw cradle receives the lower jaw element 27. Specifically, as illustrated in FIG. 22, the upper jaw element 26 includes a toothed jaw surface 122 and an upper extension portion 124. In the illustrated embodiment, upper extension portion 124 is sized to fit within the upper jaw cradle, and the toothed jaw surface 122 is of a width that is greater than the width of the upper jaw cradle, such that the upper extension surface 124 may be placed within the upper jaw cradle with the projecting head portions 92 of the right and left lower handle portions 86a,86bsupporting the upper jaw element 26. The upper jaw element 26 may be formed in the same manner previously described in connection with the lower jaw element 27.

[0084] When the pair of pliers 10 is assembled, the upper and lower handle assemblies 12 and 14 are positioned with respect to one another such that a laminate stack is formed. The general nature of the laminate stack formed when the pair of pliers is assembled is illustrated in FIG. 23. In the example of FIG. 23, a stainless steel pivot washer 135 is provided at each end of the laminate stack. An exemplary construction for such pivot washers is provided in FIGS. 24A and 24B.

[0085] The laminate stack is held together, in general, by a novel anti-impingement pin 28. In general, the anti-impingement pin 28 defines two extension members 172 that extend out from the laminate stack. To assemble the pliers, the laminate stack is formed and the extension members 172 are peened over. A detailed illustration of an exemplary anti-impingement pin 28 is provided in FIG. 25. The anti-impingement pin 28 comprises a pin having a center portion 170 and an outer portions 171. The center portion 170 has a width W1, and the center portion 170 together with outer portions 171 have a second width W2. Further, center portion 170 further has a first diameter, and outer portions 171 each have a diameter less than the diameter of center portion 170, whereby a shoulder 173 is formed on either end of the center portion 170. The width W1 is selected such that the width W1 is slightly greater than the width of the laminate stack formed by the upper handle assembly 12 and the lower jaw assembly 16. Because of this precise machining of with W1, the anti-impingement pin 28 will ensure some clearance between the laminate stack including the upper handle assembly 12 (right and left upper handle portions 86aand 86b) and lower jaw assembly 16. As such, the anti-impingement pin 28 ensures efficient and proper assembly of the pair of pliers 10. Further, the anti-impingement pin 28 of the invention simplifies the riveting process, eliminating the need to stretch the rivet for clearance. It also enhances tool durability, eliminating unpredictable wear.

[0086] In the embodiment illustrated in FIG. 2, a biasing spring 150 is situated between the upper and lower handle assemblies 12, 14 to bias the handles 18, 22 of the pliers 10 apart. A middle portion of the biasing spring 150 is coiled around a pin 152 that extends through the pin-receiving bores 47 through the right and left side upper handle portions 34a,34b.As shown in FIG. 2, a first outer portion of the biasing spring 150 is seated against the locking tabs 96 of the right and left side lower handle portions 86a,86b,and a second portion of the biasing spring is seated against the upper handle spacer 36 of the upper handle assembly 12.

[0087] The general operation of the novel locking pliers 10 of the present invention will now be described. The user selects a preferred distance between the upper and lower jaws 26, 27 and presets the jaws 26, 27 through proper adjustment of the adjustment screw 30. The release slide spring 69 is heavier than the pivot release spring 68, and the release pin 222 functions as a securing member. Therefore, if the release slide 214 is not positioned such that the release pin 222 is engaged in the notch 236 (as illustrated in FIG. 2), the release slide spring 69 biases the release slide 214 to a first setting, back (towards the handles 18, 22), and against the pivot release member 212. This prevents the locking extension 118 of the connecting arm 110 from engaging and “locking” into the locking ledge 64 of the pivot release member 212. Therefore, the jaws 26, 27 will not lock during use; in other words, the lower jaw 27 is freely movable relative to the upper jaw 27. Thus, the pliers 10 operates as a spring loaded pliers. This is particularly useful, for example, if the user desires to repeatedly open and close the jaws 26, 27 to “ratchet” the pliers 10 about a work piece.

[0088] FIGS. 26A-26C show partial side views of the pliers 10, illustrating the positions of the various components of the release mechanism 21 when the pliers 10 is in locked and unlocked positions. To lock the jaws 26, 27 about a work piece, the user first slides the actuator 210 of the release slide 214 forward (towards the jaws 26, 27) to a second setting, compressing the release slide spring 69. When the release pin 222 extending from the release button 218 reaches the notch 236, the release spring 224 will push the release button 218 up, and the release pin 222 will engage the notch 236, as shown in FIG. 26A. This locks the release mechanism in the second setting, preventing the release slide 214 from moving laterally within the cavity formed by the upper handle portions 34a,34band the outer and middle release spacers 230, 232. Hence, when the release pin 222 is engaged in the notch 236, the release slide 214 cannot engage the pivot release member 212.

[0089] The user then brings the upper and lower handles 18, 22 together until the locking extension 118 of the connecting arm 110 is received in and “locks” into the locking ledge 64 of the pivot release member 212. Now, the lower jaw 27 is locked at the distance preset by operation of the adjusting screw 30. Referring to FIG. 23A, once the locking extension 118 is received in the locking ledge 64, a gap 246 is formed between the lower portion 238 of the pivot release member 212 and the release slide 214, and the pivot release spring 68 biases the pivot release member 212 so as to prevent the locking ledge 64 from disengaging the locking extension 118 of the connecting arm. Thus, the pliers 10 will remain in their closed and locked position even as the user manipulates the handles 18,22.

[0090] Referring now to FIGS. 26B and 26C, the actions required to release the pliers 10 from the closed and locked position will be described. First, the user pushes the release button 218 to disengage the release pin 222 from the notch 236. As noted above, the release slide spring 69 is heavier than the pivot release spring 68, so the release slide spring 69 pushes the release slide 214 back (towards the handles 18, 22) to a third setting. This movement of the release slide closes the gap 246 between the lower portion 238 of the release slide 214 and the pivot release member 212, and slightly compresses the pivot release spring 68.

[0091] To release the jaws 26, 27, the user then squeezes the handles 18, 22 together, thereby disengaging the locking ledge 64 from the locking extension 118. As illustrated in FIG. 26C, the release slide spring 69 fully extends, pushing the pivot release member 212 against the pivot release spring 68 and, in turn, pushing the locking ledge 64 away from the locking extension 118 to prevent the pliers 10 from unintentionally locking. Since the release slide spring 69 is heavier than the pivot release spring 68, the release slide 214 remains biased back (towards the handles 18, 22) to the first setting. For this reason, the pliers 10 will not lock, until the release slide 214 is moved to the forward position.

[0092] The present invention is not limited to the specific embodiments of the release mechanism described above. For example, it would be a routine undertaking for one skilled in the art having the benefit of this disclosure to vary the configuration of the release button 218 such that it locks the release slide at a setting other than the second setting, wherein the jaws 26, 27 will lock. Further the biasing springs 68, 69 could be reconfigured to normally bias the release mechanism to a setting other than the first setting described above, wherein the jaws 26, 27 will not lock.

[0093] As may be noted from the preceding, the connection arm 110 of the pliers 10 of the present invention remains, during the operation of the pliers, essentially within the cavity defined by the lower handle assembly 14. Moreover, there are no projections from the connection arm 110 that extend out from the cavity defined by the lower handle assembly 14. This is in contrast to prior art locking pliers that typically include a link member that extends across the handles or that had an “extension bump” that would be contacted by another member to unlock the pliers. In the illustrated embodiment of the present invention, the connection arm 110 does not require such an “extension bump” since the locking and unlocking of the pliers is accomplished through the use of the release lever mechanism 21, which has its locking elements positioned within the cavity defined by both the upper and lower handle assemblies 12, 14. This aspect of the present invention is beneficial, among other things, because it reduces the chance that “pinch points” (points where material may be “pinched” between components of the pliers) will be formed.

[0094] A further feature of the pliers 10 of the present invention concerns the inclusion of an anti-past center stop 48 that prevents the positioning of the pliers in an inappropriate position. FIG. 27A generally reproduces FIG. 2 without certain labels. As illustrated in FIG. 17A, the bent portions 48 of the right and left upper handle portions 34aand 34bform a stop member 48. This stop member prevents undesirable centering of the pivot points marked A, B and C in FIG. 17A.

[0095] From FIG. 27A it will be apparent that, as the adjustment screw 30 is adjusted, the pivot points A, B and C will move with respect to one another. Specifically, as the adjustment screw 30 is adjusted to move the locking portion of the connection arm 110 towards the knurled end 117 of the adjustment screw 30, the pivot release member 212 will tend to move towards the knurled end 117 of the adjustment screw 30 and the pivot pin B will tend to move towards alignment with pivot points A and C. This relative movement is generally illustrated by FIG. 27B. Also, opening and closing the pliers 10 may tend to bring the pivot points A, B and C into alignment.

[0096] As those of ordinary skill in the art will appreciate, if the pivot points A, B and C become aligned, (i.e., if B becomes centered with respect to A and C) there is a possibility that, upon the application of force, the pivot point B will not return to its original and desired position—above A and C in the example, but will tend to move towards an undesirable position (e.g., below A and C in the example). To avoid this undesirable possibility, the present invention provides the anti-past center stop 48 that serves as a “stop” to prevent adjustment or movement of the pliers to the point where pivot point B is centered with respect to pivot points A and C. Specifically, the anti-past center stop 48 will contact the pivot release member 212 and prevent the release arm from moving to a position where B is centered with respect to A and C.

[0097] The laminate stack configuration of the pliers 10 allows for a novel “stack” manufacturing process, which provides a simple assembly process requiring minimal tools and sub-assembly processes. The components are essentially stacked one upon another to assemble the locking pliers 10. An example of the stack assembly process for the locking pliers 10 as is illustrated in FIG. 2 follows below.

[0098] Beginning with the left side lower handle 86b,one of the outer portions 171 of the anti-impingement pin 28 extends through the bore 100 such that the shoulder 173 seats against the left side lower handle 86b.Extension members 172 extend through the bore 100 and extend out from the left side lower handle 86b.The pivot washer 135 fits over the extension member 172, which is peened over to lock the anti-impingement pin 28 in place.

[0099] The left side upper handle 34bis stacked on the left side lower handle 86bsuch that the cut-out section 50 seats against the anti-impingement pin 28. The lower jaw assembly 16 is stacked on top of the left side upper handle 34bsuch that component 70blies adjacent the left side lower handle 86b.Further, the anti-impingement pin 28 center portion 170 extends through the large bore 72 in the lower jaw assembly 16. The upper jaw member 26 is positioned on the head portion 24 of the left side lower handle 86b.

[0100] The components of the release mechanism 21 are assembled as described above, and along with the pivot release member 212, are also stacked on the left side upper handle 34b.The rotation pin 66 extends through the bore 60 of the pivot release member 212 and the bore 46aof the left side upper handle 34bso that one end of a pin 66 terminates in the bore 46aand the pivot release member 212 pivots about the pin 66. The combination of the adjustment screw 30 coupled to the connecting arm 110 by the adjustment bracket 112 is stacked onto the left side upper handle 34b,and the rivet pin 111 extends through the adjustment bracket 112 and into the slot 98 in the left side upper handle 34b.The adjustment nut 108 is placed about the adjustment screw 30 and received by the slot 94.

[0101] The upper handle spacer 36 is stacked on the handle portion 40 of the left upper handle 34b.The pivot release spring 68 and the release slide spring 69 are positioned within their respective slots 54, 234. The pin 152 is positioned in the pin-receiving bore 47 extending through the left upper handle 34b,and the biasing spring 150 and the outer portions of the biasing spring 150 are seated against the locking tabs 96 of the left side lower handle portion 86band the upper handle spacer 36. The right upper handle 34ais stacked on the assembly next, with the cut-out 50 seating against the anti-impingement pin 28, and pins are passed through bores 46a,46band 46c.Finally, the right lower handle 86ais stacked on the right upper handle 34a.The locking tabs 96 interlink to hold the handle portions 86aand 86btogether. The anti-impingement pin 28 outer portion 171 extends through the bore 100 such that the shoulder 173 seats against the right side lower handle 86a,and a pivot washer 135 fits over the anti-impingement pin 28 and the extension 172 is peened. The various rivets are then put in place to secure the laminate structure together.

[0102] The novel laminate construction of the locking pliers 10 further allows for a simple and economic progressive stamping process for fabricating several of the components discussed and described herein, requiring a minimal number of die patterns.

[0103] In the embodiment disclosed in conjunction with FIG. 2, the biasing spring 150 comprises a coil spring. FIG. 28 illustrates a portion of an alternative embodiment of the pliers 10, in which the biasing spring comprises an extension spring 151 that has one end coupled to the upper jaw and the other end coupled to the lower jaw. The extension spring 151 serves to bring the pliers 10 to an open position when the pair of pliers 10 is released from its closed and locked position. The extension spring 151 also tends to retain the upper and lower jaw elements 26, 27 in a parallel or near-parallel relationship to allow for a better gripping angle. In such an embodiment, the upper and lower jaw elements include a suitable connector to which the spring connects.

[0104] Examples of suitable connectors are illustrated in FIGS. 29 and 30. In one exemplary embodiment illustrated in FIG. 29, the components 70aof the lower jaw is assembly 16 defines a spring connection extension 78 that extends from the component 70a.In FIG. 30A, an exemplary upper jaw element 26 defines a generally T-shaped slot 126. This generally T-shaped slot is designed to receive a generally T-shaped upper jaw insert 128 of the type illustrated in FIG. 30B. The T-shaped upper jaw insert 128 includes a head portion 130 and a spring connection portion 131. The extension spring 151 has one end coupled to the spring connection portion 131 of the T-shaped upper jaw insert 128 and a second end coupled to the spring connection extension 78 of lower jaw assembly 16. In yet another embodiment, rather than providing a T-shaped slot and separate jaw insert 128, the upper jaw element 26 simply includes a spring connector extending from the upper extension surface 124, proximate the T-shaped slot of the jaw element 26 illustrated in FIG. 30A.

[0105] In yet another embodiment, a leaf spring 120, such as that illustrated in FIGS. 31A and 31B, provides a biasing force tending to bias the connection arm 110 upwards (towards the upper handle assembly 12). The leaf spring 120 may be formed from spring steel and may be coupled via rivets to one, or both, of the right and left side lower handle portion 86a,86b.In addition to tending to bias the connection arm 110 to a bias position, the leaf spring 120 also tends to maintain the pliers 10 in their closed and locked position when the pliers are placed in their closed and locked position because the leaf spring 120 will tend to bias the connecting arm 110 such that it remains in a “locked” relationship with the locking portion of the pivot release member 212. Further, when the release lever 21 is depressed and the connection arm 110 is disengaged from the release lever 21, the spring 120 will tend to force the pliers to their open position. The use of such a leaf spring 120 does not require any modification of connection arm 110 to accommodate the existence of the leaf spring 120 within the cavity defined by the lower handle assembly 14. The leaf spring 120 may simply be riveted to one of the L-shaped locking tabs 96.

[0106] Further, the configurations of the upper and lower jaw elements 26 and 27 may be different from those illustrated above. In particular, V-notched, straight and curved jaw configurations are envisioned. Still further, in the illustrative embodiment described above, the actuator 210 of the release mechanism 21 extends from the top of the upper handle assembly 12. Likewise, in the embodiment described above employing the pivot release member 213 illustrated in FIG. 10, the top portion of the release member 213 extends from the top of the upper handle assembly 12. Other embodiments, such as the one illustrated in FIG. 32, are envisioned wherein the upper handle portion 12 includes side slots 313 and a lever 314 or other suitable mechanism extends sidewise from the upper handle assembly such that the side lever may be activated to unlock the pliers 10. In such an embodiment, the side lever may be adjustable for left-handed or right-handed operation. In such an embodiment the top portion of the release lever 213 may be eliminated entirely or retained.

[0107] A still further embodiment involves the construction of the upper handle assembly 12. As discussed above, the upper handle assembly 12 is sized such that, as the pliers 10 are opened and closed, there is little or no gap created between the upper handle assembly 12 and the lower handle assembly 14. Alternative embodiments are envisioned where such a gap is intentionally introduced and is controlled to form wire cutters and/or wire strippers. Such an alternate embodiment is generally illustrated in FIG. 20 where the upper handle assembly is sized such that a controlled gap 250 can be established through proper adjustment of the adjustment screw 30. In the illustrative embodiment the gap 250 defines several wire strippers 252 of several sizes and a wire cutter 254.

[0108] While the invention has been described in connection with the illustrative embodiments discussed above, those skilled in the art will recognized that many variations may be made without departing from the present invention. For example, the components of the locking pliers disclosed herein may be formed from different materials than described herein. Accordingly, the above description of several embodiments is made by way of example and not for purposes of limitation. The present invention is intended to be limited only by the spirit and scope of the following claims.