The features and advantages of the present disclosure may be better understood by reference to the accompanying drawings in which like reference numerals refer to like elements.
Turning now to
The cap nailer/stapler 10 additionally includes a handle 20 that forms a portion of the housing 12 and includes a first end 20a that is attached to the power nailer 24 and extends to a second, rear end, 20b along a longitudinal handle axis 21. A vertical plane B (best shown in
A space is provided between the handle 20 and the nail magazine 26 to provide space for the user's fingers to wrap around the handle 20. A trigger 23 is provided on the handle 20 to selectively operate the cap nailer/stapler 10 when the trigger 23 is compressed to drive a nail into a work surface. When the trigger 23 is compressed, a surge of compressed air flows to the power nailer 24, which causes the power nailer 24 to eject a nail along the nail axis 28, as is known in the art.
The cap nailer/stapler 10 additionally includes a cap magazine 60 and a shuttle 40 to translate a fastener cap 200 from a second end 64 of the cap magazine 60 to under the power nailer 24 such that the nail extends through the fastener cap 200 when ejected from the power nailer 24. Accordingly, when the nail is ejected from the power nailer 24, the tip of the nail extends through the fastener cap 200 that is positioned below the power nailer 24 by the shuttle 40. The fastener cap 200 has a relatively large surface area, causing the compressive force of the nail to act on the work surface across the surface area of the fastener cap 200, and not only the small surface area of the nail head. Accordingly, the fastener caps 200 allow the ejected nails to rigidly maintain the workpiece in the selected position. Fastener caps 200 are normally formed from durable, but slightly flexible, materials such as galvanized steel, stainless steel, or plastic, or any resilient metal suitable for exposure to inclement weather. In other embodiments, fastener caps 200 may be made from other materials such as tin.
The cap magazine 60 is formed as a substantially cylindrical hollow tube that includes open first and second ends 62, 64 and a longitudinal axis 61 that extends through the center of the cap magazine 60 therebetween. The cap magazine 60 may extend from housing 12 at an oblique angle with respect to the handle 20. Specifically, as shown in
Embodiments where the cap magazine 60 is oriented at an oblique angle to the handle 20, as discussed above, limits the horizontal distance that the cap magazine 60 extends from power nailer 24 (i.e. the projection perpendicular to the longitudinal axis of the tool), which limits the size of the footprint of the front end of the cap nailer/stapler 10. The reduced footprint allows the tool to be used in tighter interior corners than would be possible with conventional cap nailers that have a cap magazine that extends substantially perpendicular to the longitudinal axis of the tool.
The cap magazine 60 may extend from the housing 12 at an oblique angle with the power nailer 24. Specifically, as shown in
As shown in
The air piston 30 includes a shaft 32 that may reciprocate longitudinally through the air piston 30 against the biasing force of an internal spring (not shown). The internal spring biases the shaft 32 to the first position where the shaft 32 is substantially within the air piston 30 and the second end 41 is in proximity with the output of the power nailer 24. When the exhaust compressed air enters the air piston 30, the air acts on the shaft 32 to propel the shaft 32 toward the front end (i.e. the side with the power nailer 24) of the cap nailer/stapler 10 against the biasing force of the spring.
shuttle 40 is rotatably mounted to the housing 12 on a pivot point 34 such that the linear motion of the shaft 32 is transferred to reciprocating curved motion of the second end 41 of the shuttle 40. The second end 41 of the shuttle 40 includes a cap aperture 42, which has a diameter that is slightly smaller than the diameter of the fastener caps 200 used with the cap nailer/stapler 10. As shown in FIG, 15, the shuttle 40 may include a round valley 48 that is coaxial with the fastener cap 200 and has a diameter slightly larger than the diameter of the fastener caps 200 used with the cap nailer/stapler 10. As the shuttle 40 translates to and reaches the second position, the bottom most fastener cap 200 slides through the cap magazine 60 and onto the shuttle 40. The fastener cap 200 may be held on the moving shuttle 40 by the cap resting within the valley 48. After receiving a fastener cap 200 from the cap magazine 60, the shuttle 40 translates to the first position below the power nailer 24 and substantially in-line with the nail axis 28, the compressed air within the air piston 30 eventually bleeds off, allowing the internal biasing spring to translate the shaft 32 away from the front end of the cap nailer/stapler 10.
As is known in the art, a charge of compressed air flows from the air inlet 22 to the power nailer 24 when the user presses the trigger 23 of the cap nailer and a nail, stapler, brad, or similar fastener, is expelled from the power nailer 24. Because the nail exits the power nailer 24 with a significant amount of force, the tip and the body of the nail extend through the fastener cap 200 that is held on the shuttle 40. As the nail travels through the fastener cap 200, a portion of the energy within nail is transferred to the fastener cap 200, which causes the fastener cap 200 to elastically deform because the center of the fastener cap 200 is pressed downward by the nail with the outer edge being retained by the periphery of the cap aperture 42.
Eventually, the fastener cap 200 deforms enough to cause the diameter of the downward projection of the fastener cap 200 to be smaller than the diameter of the cap aperture 42, allowing the fastener cap 200 to move through the cap aperture 42 and contact the work surface along with the nail. As discussed above, as the compressed air drives the power nailer 24, the air flows to the air piston 30 causing the shuttle 40 to reciprocate to the cap magazine 60 to obtain a new fastener cap 200 for use when the trigger 23 is pressed again.
In the embodiments shown in
Turning now to
A bracket 150 is connected to the housing 12 of the cap nailer/stapler 10 and extends below the second end 64 of the cap magazine 60. The bracket 150 includes an upwardly extending leaf spring 152 provided between the bracket 150 and the second end 64 of the cap magazine 60 to bias the stack of fastener caps 200 within the cap magazine 60 to a level in-line with the bottom edge of the cap magazine 60. The leaf spring 152 includes an inclined surface 152a that is positioned to be contacted by the shuttle 140 as the shuttle 140 reciprocates from the proximity of the power nailer 24 toward the proximity of the cap magazine 60.
As the leading edge of the shuttle 140 contacts the inclined section 152a of the leaf spring, the shuttle 140 compresses the leaf spring 152 between the bracket 150 and the shuttle 140, allowing the shuttle 140 to pass over the leaf spring 152. Accordingly, when the cap aperture 142 of the shuttle 140 is in the proximity of the second end 64 of the cap magazine 60, the bottom most fastener cap 200 falls to the first end 141 (and within the valley 148) of the shuttle 140 and is reciprocated toward the power nailer 24 as the air pressure within the air piston 30 bleeds away. As the leading edge of the shuttle 140 moves away from the leaf spring 152, the leaf spring 152 expands to again retain the next fastener cap 200 (now the bottom most fastener cap 200) within the cap magazine 60.
Turning now to
The cap magazine 60 includes a track 66 formed by two outwardly extending arms 66a that extend in opposite directions along the same plane. The track 66 may be formed either on the outer cylindrical surface of the cap magazine 60 or within the internal volume 65 of the cap magazine 60. A slot 68 is defined between the arms 66a of the track 66. In the preferred embodiment, each of the track 66 and the slot 68 extend along substantially the entire length of the cap magazine 60 from the first end 62 to the proximity of the second end 64 in parallel to the longitudinal axis 61 of the cap magazine 60.
A bracket 90 is provided with two legs 91 that extend inwardly toward each other along the same plane and are slidingly received within the track 66. The bracket 90 includes a pin 92 that extends through the bracket 90 that rotatably receives a coiled spring 96, with the coils of the spring 96 tightly would around the pin 92. A fixed end 97 of the coil spring 96 is fixed to the cap magazine 60 in proximity to the second end 64. The coil spring 96 operates to bias the bracket 90 toward the second end 64 of the cap magazine along the track 66.
The latch 80 is rotatably connected to the pin 92, such that the latch 80 is rotatable along an axis perpendicular to the longitudinal axis 61 of the cap magazine 60. The latch 80 includes a first portion 82 that is extendable through the slot 68 into the hollow internal volume 65 of the cap magazine 60. The first portion 82 is sized such that when the first portion 82 normally extends into the internal volume, or bore, 65 of the cap magazine 60 a distance preferably approximately equal to one quarter of the internal diameter of the cap magazine 60. In other embodiments, the first portion 82 may extend into the internal volume, or bore, 65 of the cap magazine 60 a length between about one-eighth to about one-half of the inner diameter of the cap magazine 60.
The latch 80 includes a second end, or handle, 84 on the opposite end of the latch 80 from the first portion 82. The second end 84 is biased inward toward the first end 62 of the cap magazine 60 (in the direction X shown in
In operation, when the first portion 82 is withdrawn from the internal volume 65 additional caps 36 can be inserted into the internal volume 65 of the cap magazine 60. Alternatively, if caps 36 have been inserted above the first portion 82 the latch 80 may be rotated in the Y direction to withdraw the first portion 82 from the internal volume 65 of the cap magazine 60. The latch 80 and bracket 90 can then be lifted upward along the track 66 toward the first end 62 of the cap magazine 60 against the biasing force of the coil spring 86 until the first portion 82 of the latch 80 is above the stack of fastener caps 200. When the second end 84 of the latch 80 is released, the biasing compression spring 86 rotates the latch 80 in the direction X, which causes the first portion 82 to reenter the internal volume 65 of the cap magazine 60.
A backstop or finger 110 may also be provided on the cap magazine 60. In the embodiment shown in
In operation, when additional fastener caps 200 are inserted into the cap magazine 60 above the second end 114 of the backstop 110, the weight of the stack of fastener caps 200 presses the second end 114 downward until the second end 114 moves into the side aperture 67 of the cap magazine 60, allowing the stack of fastener caps 200 to be completely inserted into the cap magazine 60. If the stack of fastener caps 200 below the second end of the backstop 110 need to be removed, the user may manipulate the operator 116 to pull the extended end 114 out of the internal volume 65 through the side aperture 67 to provide clearance to remove the stack of fastener caps 200. After the operator 116 is released, the extended end 114 of the backstop reextends within the inner volume 65 of the cap magazine 60 due to the internal biasing force of the backstop 110.
Turning now to
The fastener cap 200 preferably is made out of plastic or metal such as galvanized steel, stainless steel, or any resilient metal suitable for exposure to inclement weather. The fastener cap 200 has a generally disc-like, circular shape that includes an outer peripheral wall 201 and a top surface 202. Preferably, at least one flat surface 203 is formed or manufactured into a portion 204 of the outer peripheral wall 201. While a preferred embodiment contemplates a fastener cap 200 having a circular shape, in alternate embodiments the fastener cap 200 may have other shapes so long as it can be attached to the sheet material and substrate.
To use the fastener cap 200 with the pneumatic nailer/stapler 10, and as shown in
The adhering strip 220 may be made of a polyester tape such as MYLAR, a thin paper with an adhesive backing, or a cured adhesive. In an alternate embodiment, the adhering strip 220 may instead be an adhesive outer wrapper that surrounds the entire circumference of the stack 210. In yet other embodiments, the outer wrapper may be made of a non-adhesive paper such as cellophane or shrink wrap that is fixed to the stack 210 of fastening caps 200. Optionally, the adhering strip 220 (or outer wrapper) may also act as a surface 222 that contains lettering such as, by way of example, advertising, branding or instructions. In an alternate embodiment, the adhering strip 220 may instead be an adhering outer wrap that surrounds the entire circumference of the stack 210.
Once the stack 210 is formed, it may be loaded into a cap magazine 60 (
Once the stack 210 has been depleted, another stack 210 may be loaded within the cap magazine 60. A portion 224 of the adhering strip 220 coextensive with the distal end 213 of the stack 210 may be colored or otherwise marked so as to contrast with the remainder of the adhering strip 200 in order to indicate that the stack 210 is nearing depletion.
The advantages associated with the collation of the fastener caps 200 are numerous. In prior-art collations, caps are often kept together in a stack through the use of a retaining cord such as a mandrill or string that extends through a hole in the center of each fastening caps. Once the caps are loaded into the magazine, the retaining cord must be removed so that the caps may be dispensed. When the retaining cord is removed, the caps my have a tendency to flip over, requiring that time be used rearranging the caps so that they do not jam the pneumatic nailer/stapler. Moreover, the retaining cord, upon its removal, also creates extra waste around a worksite. In contrast, the adhering strip (or outer wrapper) remains affixed to the fastener cap.
The use of the adhering strip (or outer wrap) 220 also simplifies the loading process, as no retaining string needs to be removed from the stack 210—the stack 210 simply is placed within the magazine. Moreover, collated caps also simplify the loading process as compared to fastener caps that are assembled in a coiled, side-by-side configuration, which must be threaded from the magazine into a feeding mechanism.
The present collation of fastener caps 200 eliminates the “wasting” of caps. If a stack 210 breaks in “partial stacks” these stack 210 may easily be loaded into the cap magazine 60. In contrast, if a coil of caps tears, the coil may have to be removed, reloaded and/or rethreaded. Moreover, smaller portions of a coil may have to be discarded, thus wasting caps.
Finally, although the collated stack 210 may be made of fastener caps 200 each having a hole in their center, preferably the top surface 202 of the fastener 202 will be continuous. The absence of a hole in the center of the top surface 202 will increase the ability of the fastener cap 200 to seal out water after being fastened to the sheet material and substrate, in addition to allowing a nail or other type of fastener to be inserted through the center of the fastener cap 200.
The foregoing disclosure is the best mode devised by the inventors for practicing this disclosure. It is apparent, however, that apparatus incorporating modifications and variations will be obvious to one skilled in the art. Inasmuch as the foregoing disclosure is intended to enable one skilled in the pertinent art to practice the instant disclosure, it should not be construed to be limited thereby but should be construed to include aforementioned obvious variations and be limited only by the spirit and scope of the following claims.
It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this disclosure.
This application claims priority to U.S. provisional application No. 60/832,255, which was filed on Jul. 20, 2006, and is hereby fully incorporated by reference herein. This application relates to U.S. utility application number ______, (attorney docket number 10710-1005 (PTG 1577 PUS)) titled “Cap Collation System,” which is filed on Mar. 7, 2007, the same day as the subject application, and additionally relates to U.S. utility application number ______, (attorney docket number 10710-1006 (PTG 1566 PUS)) titled “Cap Nailer and Feed System,” which is also filed Mar. 7, 2007, the same day as the subject application, both of which are fully incorporated by reference herein.
Number | Date | Country | |
---|---|---|---|
60832255 | Jul 2006 | US |