Power tool including an anti-vibration handle

Abstract

A power tool includes a tool operable to work on a workpiece, a drive mechanism coupled to the tool and operable to move the tool, a housing defining an interior, the drive mechanism disposed at least partially within the interior, and a handle having a first end and a second end. The first end is fixed to the housing and the second end is spaced apart from the housing to define a gap therebetween. An insert is fixedly attached to the housing and the second end to fill the gap. The insert is more flexible than the handle and the housing. The housing includes a first engaging portion and the handle includes a second engaging portion each engageable with the insert to substantially fixedly attach the insert to the housing and the handle, and the insert includes a third engaging portion, and a fourth engaging portion.

What is claimed is: 
     
         1 . A power tool comprising:
 a tool operable to work on a workpiece;   a drive mechanism coupled to the tool and operable to move the tool;   a housing defining an interior, the drive mechanism disposed at least partially within the interior;   a handle having a first end and a second end, the first end fixed to the housing, the second end spaced apart from the housing to define a gap therebetween;   an insert fixedly attached to the housing and the second end to fill the gap, the insert being more flexible than the handle and the housing, wherein the housing includes a first engaging portion and the handle includes a second engaging portion each engageable with the insert to substantially fixedly attach the insert to the housing and the handle, and wherein the insert includes a third engaging portion, and a fourth engaging portion.   
     
     
         2 . The power tool of  claim 1 , wherein the drive mechanism includes a motor and is operable to move the tool in a reciprocating fashion. 
     
     
         3 . The power tool of  claim 1 , wherein the housing includes a first portion and a separate second portion that attach to one another to define the housing. 
     
     
         4 . The power tool of  claim 1 , wherein the insert includes a plurality of corrugations disposed between the third engaging portion and the fourth engaging portion. 
     
     
         5 . The power tool of  claim 4 , wherein the corrugations are disposed within the gap. 
     
     
         6 . The power tool of  claim 1 , wherein one of the first engaging portion and the third engaging portion includes a first slot and the other of the first engaging portion and the third engaging portion includes a first rib sized to be received by the first slot. 
     
     
         7 . The power tool of  claim 6 , wherein one of the second engaging portion and the fourth engaging portion includes a second slot and the other of the first engaging portion and the third engaging portion includes a second rib sized to be received by the second slot. 
     
     
         8 . The power tool of  claim 6 , wherein the second engaging portion includes a second slot and a pair of pins and the fourth engaging portion includes a second rib sized to engage the second slot and a pair of gussets, each gusset including an aperture sized to receive one of the pair of pins. 
     
     
         9 . The power tool of  claim 1 , wherein the insert includes an extension that includes a slot, and the handle includes a projection that is received by the slot such that the projection is movable within the slot. 
     
     
         10 . The power tool of  claim 1 , further comprising a plurality of corrugations formed as part of the handle and the housing and positioned adjacent the first end of the handle. 
     
     
         11 . A power tool comprising:
 a housing that defines a main portion including an interior and a D-shaped handle having a first leg that extends from the main portion and a second leg spaced apart from the main portion to define a gap;   a drive mechanism disposed within the interior; and   an insert fixedly attached to the main portion and the second leg to fill the gap, the insert being more flexible than the main portion and the D-shaped handle.   
     
     
         12 . The power tool of  claim 11 , wherein the housing including a first side portion and a separate second side portion, each of the first side portion and the second side portion cooperating to define the main portion and the D-shaped handle. 
     
     
         13 . The power tool of  claim 11 , wherein the main portion includes a first engaging portion and the D-shaped handle includes a second engaging portion each engageable with the insert to substantially fixedly attach the insert to the main portion and the D-shaped handle. 
     
     
         14 . The power tool of  claim 13 , wherein the insert includes a third engaging portion, and a fourth engaging portion including an extension. 
     
     
         15 . The power tool of  claim 14 , wherein the insert includes a plurality of corrugations disposed between the third engaging portion and the fourth engaging portion. 
     
     
         16 . The power tool of  claim 14 , wherein one of the first engaging portion and the third engaging portion includes a first slot and the other of the first engaging portion and the third engaging portion includes a first rib sized to be received by the first slot. 
     
     
         17 . The power tool of  claim 16 , wherein one of the second engaging portion and the fourth engaging portion includes a second slot and the other of the first engaging portion and the third engaging portion includes a second rib sized to be received by the second slot. 
     
     
         18 . The power tool of  claim 16 , wherein the second engaging portion includes a second slot and a pair of pins and the fourth engaging portion includes a second rib sized to engage the second slot and a pair of gussets, each gusset including an aperture sized to receive one of the pair of pins. 
     
     
         19 . The power tool of  claim 14 , wherein the extension includes a slot and the handle includes a projection that is received by the slot such that the projection is movable within the slot. 
     
     
         20 . The power tool of  claim 11 , wherein the drive mechanism includes a motor and is operable to move the tool in a reciprocating fashion.