Power tools with titanium hammer cases and associated flange interfaces

1. A power tool, comprising:

an external titanium housing having a forward portion and an opposing rearward portion and a cavity extending therebetween, wherein the titanium housing has a body of titanium with at least a major portion thereof, including a rear section thereof, having a thin wall with a substantially constant thickness;

an interface flange residing in the titanium housing cavity; and an external motor housing extending rearward of the external titanium housing and attached to the interface flange, wherein the interface flange is internal with respect to the external titanium housing and external motor housing,

wherein the interface flange has a plurality of corner detents extending outwardly thereby defining at least a portion of an outermost curvilinear perimeter thereof, the corner detents provide an interference fit with corners of an inner surface of the titanium housing; and

wherein the interface flange comprises at least one transversely extending recess, and wherein the titanium housing comprises at least one inwardly extending projection that cooperates with the at least one transversely extending recess.

2. A power tool, comprising:

an external titanium housing having a forward portion and an opposing rearward portion and a cavity extending therebetween, wherein the titanium housing has a body of titanium with at least a major portion thereof, including a rear section thereof, having a thin wall with a substantially constant thickness;

an interface flange residing in the titanium housing cavity; and an external motor housing extending rearward of the external titanium housing and attached to the interface flange, wherein the interface flange is internal with respect to the external titanium housing and external motor housing,

wherein the interface flange has a plurality of corner detents extending outwardly thereby defining at least a portion of an outermost curvilinear perimeter thereof, the corner detents provide an interference fit with corners of an inner surface of the titanium housing; and

wherein the interface flange has opposing front and rear ends and an outerwall extending therebetween with at least one attachment feature on the outerwall residing between the front and rear ends, wherein the titanium housing body has at least one cooperating attachment feature residing on an internal surface thereof residing proximate a rear end portion of the titanium housing body, and wherein the interface flange and titanium housing body attachment features tightly abut to define a mechanical joint and wherein the interface flange attachment feature comprises at least one recess, and wherein the titanium housing body attachment feature comprises at least one inwardly extending projection.

3. A power tool, comprising:

an external titanium housing having a forward portion and an opposing rearward portion and a cavity extending therebetween, wherein the titanium housing has a body of titanium with at least a major portion thereof, including a rear section thereof, having a thin wall with a substantially constant thickness;

an interface flange residing in the titanium housing cavity; and an external motor housing extending rearward of the external titanium housing and attached to the interface flange, wherein the interface flange is internal with respect to the external titanium housing and external motor housing,

wherein the interface flange has a plurality of corner detents extending outwardly thereby defining at least a portion of an outermost curvilinear perimeter thereof, the corner detents provide an interference fit with corners of an inner surface of the titanium housing;

wherein the interface flange has opposing front and rear ends and an outerwall extending therebetween with at least one attachment feature on the outerwall residing between the front and rear ends, wherein the titanium housing body has at least one cooperating attachment feature residing on an internal surface thereof residing proximate a rear end portion of the titanium housing body, and wherein the interface flange and titanium housing body attachment features tightly abut to define a mechanical joint; and

wherein the interface flange attachment feature comprises at least one transversely extending recess, and wherein the titanium housing body attachment feature comprises at least one inwardly extending projection.

4. The power tool of claim 3 , wherein the power tool is an impact wrench and the titanium housing is a hammer case.

5. The power tool of claim 3 , wherein the titanium housing body is a deep drawn titanium body, wherein the forward portion has a cylindrical shape, and wherein the rearward portion has a curvilinear shape.

6. The power tool of claim 3 , wherein the interface flange can withstand a pull out force of 1000 lbs. for two seconds.

7. The power tool of claim 3 , wherein the titanium housing body is a monolithic unitary body of deep drawn titanium that has a thin wall of substantially constant thickness.

8. A hammer case for a power tool impact wrench, comprising:

a thin wall titanium shell tapering from a smaller cylindrical forward section to a larger curvilinear rearward section, with at least the curvilinear rearward section having a wall with a substantially constant wall thickness; and

an interface flange residing in a cavity of the shell, wherein the interface flange comprises an outermost perimeter profile that is curvilinear and defines a plurality of outwardly extending detents that provide an interference fit with the shell wall of the hammer case, so that when the interface flange is press fit with the shell small air gap spaces reside on opposing sides of each detent prior to permanent fixation with epoxy or adhesive, and wherein, in use, the small gap spaces are closed with adhesive or epoxy; and

wherein the interface flange comprises at least one transversely extending recess and the titanium shell comprises at least one inwardly extending projection that cooperates with the at least one transversely extending recess.

9. A hammer case for a power tool impact wrench, comprising:

a thin wall titanium shell tapering from a smaller cylindrical forward section to a larger curvilinear rearward section, with at least the curvilinear rearward section having a wall with a substantially constant wall thickness;

an interface flange residing in a cavity of the shell, wherein the interface flange comprises an outermost perimeter profile that is curvilinear and defines a plurality of outwardly extending detents that provide an interference fit with the shell wall of the hammer case, so that when the interface flange is press fit with the shell small air gap spaces reside on opposing sides of each detent prior to permanent fixation with epoxy or adhesive, and wherein, in use, the small gap spaces are closed with adhesive or epoxy;

wherein the interface flange has opposing front and rear ends and an outerwall extending therebetween with at least one attachment feature on the outerwall residing between the front and rear ends, wherein the titanium shell has at least one cooperating attachment feature residing on an internal surface thereof residing proximate an end of the rearward section, and wherein the interface flange and shell attachment features tightly abut to define a mechanical joint, and wherein the interface flange attachment feature comprises at least one recess, and wherein the titanium shell attachment feature comprises at least one inwardly extending projection.

10. A hammer case for a power tool impact wrench, comprising:

a thin wall titanium shell tapering from a smaller cylindrical forward section to a larger curvilinear rearward section, with at least the curvilinear rearward section having a wall with a substantially constant wall thickness;

an interface flange residing in a cavity of the shell, wherein the interface flange comprises an outermost perimeter profile that is curvilinear and defines a plurality of outwardly extending detents that provide an interference fit with the shell wall of the hammer case, so that when the interface flange is press fit with the shell small air gap spaces reside on opposing sides of each detent prior to permanent fixation with epoxy or adhesive, and wherein, in use, the small gap spaces are closed with adhesive or epoxy;

wherein the interface flange has opposing front and rear ends and an outerwall extending therebetween with at least one attachment feature on the outerwall residing between the front and rear ends, wherein the titanium shell has at least one cooperating attachment feature residing on an internal surface thereof residing proximate an end of the rearward section, and wherein the interface flange and shell attachment features tightly abut to define a mechanical joint; and

wherein the interface flange attachment feature comprises at least one transversely extending recess, and wherein the titanium shell attachment feature comprises at least one inwardly extending projection.

11. The hammer case of claim 10 , wherein there are six substantially equally spaced apart interface flange detents providing interference fit interleaved with adjacent gap spaces.

12. The hammer case of claim 10 , wherein the interface flange is bonded to the hammer case so that a rear surface of the flange is flush with a rear of the hammer case, and wherein the interface flange can withstand a pull out force of 1000 lbs. for two seconds.

13. The hammer case of claim 10 , wherein the titanium housing is a monolithic unitary body that is formed from deep drawn titanium.