Clutch mechanism for reciprocating saws

Abstract

A reciprocating saw including a housing, a spindle mounted for reciprocating motion within the housing, a gear rotatably mounted within the housing, a wobble shaft rotatably mounted within the housing, a wobble plate rotatably mounted on the wobble shaft and connected to the spindle, and a clutch drivingly connecting the gear to the wobble shaft. The clutch includes a clutch driver rotatably positioned within the housing adjacent the wobble shaft, and the clutch driver includes a recess for insertably receiving a portion of the wobble shaft. The clutch driver can also include a relief ledge for providing clearance between the clutch driver and the wobble plate. The clutch can further include a first clutch disk connected with the gear and positioned between the gear and the clutch driver, and a second clutch disk connected with the clutch driver and positioned between the gear and the first clutch disk.

We claim:  
     
       1. A reciprocating saw comprising: 
       a housing;  
       a spindle mounted for reciprocating motion within said housing;  
       a gear rotatably mounted within said housing;  
       a wobble shaft rotatably mounted within said housing for rotation about an axis and having an end adjacent said gear;  
       a wobble plate rotatably mounted on said wobble shaft and connected to said spindle; and  
       a clutch drivingly connecting said gear to said wobble shaft, said clutch including a clutch driver rotatably positioned within said housing adjacent said wobble shaft, said clutch driver including a recess in driving engagement with said end of said wobble shaft, said recess surrounding said axis.  
     
     
       2. A saw as claimed in claim  1 , further comprising an axle rotatably mounted within said housing, said clutch driver and said wobble shaft being positioned about said axle. 
     
     
       3. A saw as claimed in claim  2 , wherein said clutch driver includes an orifice for receiving said axle, and wherein said recess substantially surrounds said axle. 
     
     
       4. A saw as claimed in claim  1 , wherein said clutch driver and said wobble shaft are mounted for rotation about a rotational axis, and wherein said recess is asymmetrical with respect to said rotational axis. 
     
     
       5. A saw as claimed in claim  1 , wherein said recess includes an inner contour, wherein said end includes an outer contour, and wherein said outer contour of said end substantially matches said inner contour of said recess. 
     
     
       6. A saw as claimed in claim  1 , wherein said clutch further includes: 
       a first clutch disk connected with said gear and positioned between said gear and said wobble shaft; and  
       a second clutch disk connected with said clutch driver and positioned between said gear and said first clutch disk.  
     
     
       7. A saw as claimed in claim  1 , wherein said clutch driver includes a relief ledge for providing clearance between said clutch driver and said wobble plate. 
     
     
       8. A saw as claimed in claim  1 , wherein said gear includes a recess extending into said gear, and wherein said clutch is at least partially positioned within said recess of said gear. 
     
     
       9. A reciprocating saw comprising: 
       a housing;  
       a spindle mounted for reciprocating motion within said housing;  
       a gear rotatably mounted within said housing; and  
       a clutch operatively positioned between said gear and said spindle said clutch including:  
       a clutch driver rotatably positioned within said housing operatively between said gear and said spindle:  
       a first clutch disk connected with said gear and positioned between said gear and said clutch driver; and  
       a second clutch disk connected with said clutch driver and positioned between said gear and said first clutch disk.  
     
     
       10. A saw as claimed in claim  9 , wherein said clutch driver includes a hub portion, and wherein said first and second clutch disks are mounted about said hub portion. 
     
     
       11. A saw as claimed in claim  10 , wherein said gear is mounted about said hub portion. 
     
     
       12. A saw as claimed in claim  9 , wherein said gear includes a plurality of grooves, and wherein said first disk includes a plurality of splines positioned within said grooves. 
     
     
       13. A saw as claimed in claim  9 , wherein said clutch driver includes a plurality of grooves, and wherein said second clutch disk includes a plurality of splines positioned within said grooves. 
     
     
       14. A saw as claimed in claim  9 , wherein said gear includes a recess, and wherein said first and second clutch disks are positioned within said recess. 
     
     
       15. A reciprocating saw comprising: 
       a housing;  
       a spindle mounted for reciprocating motion within said housing;  
       a gear rotatably mounted within said housing, wherein said gear includes a recess extending into said gear;  
       a wobble shaft rotatably mounted within said housing;  
       a wobble plate rotatably mounted on said wobble shaft and connected to said spindle; and  
       a clutch drivingly connecting said gear to said wobble shaft, said clutch including a clutch driver rotatably positioned within said housing adjacent said wobble shaft, said clutch driver including a surface in facing relation to said wobble plate, said surface including a relief ledge for providing clearance between said clutch driver and said wobble plate, wherein said clutch is at least partially positioned within said recess of said gear.  
     
     
       16. A saw as claimed in claim  15 , wherein said clutch driver includes a recess housing a portion of said wobble shaft. 
     
     
       17. A reciprocating saw comprising: 
       a housing;  
       a spindle mounted for reciprocating motion within said housing;  
       a gear rotatably mounted within said housing, said gear including first and second opposed ends and a first recess extending into said first end and a second recess extending into said second end;  
       a drive mechanism for driving said gear;  
       a clutch drivingly connecting said gear to said spindle, said clutch being at least partially positioned within said first recess; and  
       a biasing member at least partially positioned within said second recess.  
     
     
       18. A saw as claimed in claim  17 , wherein said biasing member comprises a spring that biases said gear toward said clutch.