1. Field of the Invention
The present invention is directed to a lockout mechanism for a fastener driving tool used to install fasteners in a substrate, for example in an overhead application.
2. Description of the Related Art
A variety of different fastening driving tools exist for driving fasteners into numerous substrates, including tools used to install fasteners in situations where a significant separation between the user and the muzzle of the tool exists such as when a user wants to drive a fastener into a ceiling substrate. In these situations, fasteners may be loaded individually into the muzzle end of the tool while charges to drive the fasteners may be fed into the tool at a position behind a piston. Combustion of a charge causes the piston to be driven forward, thereby driving the fastener forward and into the substrate.
Due to the separation that may exist between the user and the muzzle of the tool, several tools employ an apparatus for extending the user's reach and for firing the tool. Oftentimes, tools with these extensions are fired by compressing the tool against the substrate or work surface and then providing a secondary compressive force to the entire apparatus to cause the tool to fire.
One drawback of tools operating in this fashion is the possibility of inadvertent actuation or misfiring. Applying too much pressure initially may cause the tool to actuate prematurely, which may cause the fastener to be driven in an undesired location or orientation. Alternatively, this pressure may cause the firing sequence to occur out of order, for example, causing the firing pin to release without sufficient force to combust a cartridge, resulting in a misfire of the tool.
One solution to this problem is described in U.S. Pat. No. 7,896,210, titled “Fastener Actuation System,” and which was invented by two of the inventors named here. The '210 patent describes a system including a tool and a pole assembly couplable to the tool. The pole assembly includes a lockout mechanism that prevents the tool from firing when the tool is oriented generally below a horizontal level. While this lockout mechanism is successful at preventing unintended firing of the tool, it adds additional weight to the pole assembly. In addition, the tool still may be subject to misfiring if the pole assembly is not attached.
What is needed is a fastener actuation system that overcomes the drawbacks described above.
In one embodiment, a fastener actuation system may include: a fastener actuation tool coupled to a pole assembly, the tool comprising: a housing having a barrel assembly slidable therein, the barrel assembly having a muzzle end and a breech end, a piston slidable within the barrel assembly, a breech block coupled to the housing, a firing pin assembly slidable within the breech block, a trigger sleeve, and a lockout mechanism proximate a rearward end of the tool. The system also may include a pole assembly comprising: a pole extending substantially along a length of the pole assembly, an internal rod within, and slidable with respect to, the pole, and a sleeve external to the pole and coupled to the internal rod. The lockout mechanism may include a receptacle and a ball, where the lockout mechanism operatively engages the internal rod and trigger sleeve when the ball is disposed within the receptacle and does not operatively engage the trigger sleeve when the ball is not disposed within the receptacle. When the ball is not disposed within the receptacle, a gap between the trigger sleeve and a bottom of the receptacle may be about ⅜″.
The lockout mechanism may include a shaft generally aligned with the internal rod and a spring disposed around the shaft. The trigger sleeve may include a protrusion extending rearwardly that may be generally aligned with the internal rod. In addition, the housing may include a cavity having an internal wall, the trigger sleeve may include a protrusion extending rearwardly, and the ball may have a diameter, where the protrusion is spaced a radial distance from the internal wall at least a distance as large as the diameter. Moreover, a forward end of the lockout mechanism, which may taper inwardly, may be spaced a distance from the internal wall smaller than the diameter.
In another embodiment, a fastener actuation tool may include: a housing, a barrel assembly at least partially contained within, and slidable with respect to, the housing, a piston within, and slidable with respect to, the barrel assembly and the housing, a breech block generally fixed with respect to the housing, a firing pin assembly at least partially contained within, and slidable with respect to, the breech block, a trigger sleeve slidable with respect to the housing and the firing pin assembly, and a lockout mechanism disposed rearward of the trigger sleeve, the lockout mechanism including a ball and a receptacle, the ball disposed within the receptacle when the tool is in an acceptable firing position. The lockout mechanism also may include a shaft extending rearward from the receptacle. The barrel assembly further may include a cocking rod, wherein depressing the barrel assembly causes the cocking rod to contact the firing pin assembly and move the firing pin assembly into a ready-to-fire position.
The housing may include a cavity having a tapered rear end. Similarly, the receiver may include a flange having a tapered underside, and the rear end and the underside may taper at substantially the same rate. In addition, the trigger sleeve may include a rearward facing protrusion, which the receptacle may be configured to receive. There also may be a gap between the protrusion and a bottom of the receptacle when the lockout mechanism is disposed in a forwardmost position and the ball is not disposed within the receptacle. The housing may include an internal wall forming a generally cylindrical cavity, and the trigger sleeve may include a protrusion generally coaxial with the cavity, where a distance between the internal wall and the protrusion is at least as large as a diameter of the ball.
In still another embodiment, a fastener actuation tool may include: a housing having an internal wall forming a cavity having at least a first section and a second section, a barrel assembly at least partially extending forward of the housing's front end, a triggering mechanism slidable within the first section of the cavity, the second section of the cavity including an open rearward end and connection means configured to connect the tool to a pole assembly, and a lockout mechanism partially disposed in the cavity's first section and partially disposed in the cavity's second section, where the lockout mechanism may include a spring configured to bias the mechanism to a rearward resting position. There may be a flange between the first and second sections of the cavity and a retainer extending outward from the shaft of the lockout mechanism, and the spring may be disposed between the flange and the retainer.
The lockout mechanism may include a ball, a receptacle, and a flange surrounding an open end of the receptacle. The ball may be configured to be received by the receptacle when the tool is oriented with the barrel assembly pointed upwards and to be disposed within the cavity, outside the receptacle, when the tool is oriented with the barrel assembly pointed horizontally. At angles in between, the tool may be designed, e.g., with a certain flange angle or receptacle depth, to locate the ball within or outside the receptacle. Preferably the receptacle depth may be at least about ½ the ball diameter. In addition, the first section of the cavity may include a generally cylindrical portion, and the flange may be spaced radially from the generally cylindrical portion a distance less than the diameter of the ball.
These and other features and advantages are evident from the following description of the present invention, with reference to the accompanying drawings.
Details of one embodiment of a tool 12 with which lockout mechanism 100 may be used may be described in U.S. Pat. No. 7,896,210, column 3, line 26—column 5, line 39 of which are incorporated herein by reference.
As seen in
Wall 24 may be formed as an internal wall as part of housing 20. Alternatively, coupler 72 may couple to housing, e.g., via threaded engagement at rear 21 of housing. Coupler 72 may be open at at least one end, and wall 24 may be formed within coupler 72, inward from the open end.
Coupler 72 may include one or more openings 73 about its perimeter, and housing 20 similarly may include one or more openings 71 about its perimeter. As coupler 72 is rotated about housing 20, opening 73 may align with opening 71, and fastener 75 may be inserted and/or threaded through both to prevent reverse rotation of coupler 72.
Tool 12, e.g., at coupler 72 may include connection means 77 to releasably couple tool 12 to pole assembly 14, e.g., with coupler 74. As seen in
Pole assembly 14 may include a pole 78 extending substantially the length of pole assembly 14 to a handle. Pole assembly 14 may come in various lengths, e.g., about 3 ft., about 6 ft. or about 8 ft. lengths, so that tool system 10 may be adaptable to a variety of uses. In addition, pole assembly 14 may include one or more extenders for coupling to a forward end of pole assembly 14 in order to further lengthen pole assembly 14. Moreover, pole 78 may have an outer diameter of between about ½ inch and about 2 inches, preferably between about ¾ inch and about 1½ inches, still more preferably about 1 inch. Pole 78 may also have an inner diameter of between about ¼ inch and about 1½ inches, preferably between about ½ inch and about 1 inch, still more preferably about ¾ inches.
Second coupler 74 may extend a predetermined distance inside pole 78, for example, via a threaded or interference fit, which may serve to reinforce pole 78. Second coupler 74 may extend between about 1 inch and about 6 inches into pole 78, preferably between about 1 inch and about 4 inches. In one embodiment, second coupler 74 may also fit over the end of pole 78 and extend a second predetermined distance along outside of pole 78. Alternatively, or in addition, assembly 14 may also include a reinforcing sleeve 76 proximate second coupler 74 and extending around an outer surface of pole 78. Reinforcing sleeve may be coupled to pole 78 and/or to second coupler 74, for example, through the use of one or more fasteners 75a. Like fasteners 75, fasteners 75a also may prevent reverse rotation of pole 78 relative to second coupler 74.
Pole assembly additionally includes an internal rod 82 within pole 78, which may extend substantially along the length of pole 78. Internal rod 82 may be coupled to cap 84, preferably proximate one end of rod 82. As with pole 78, internal rod 82 may come in various lengths, each of which is preferably shorter than its corresponding pole 78 length. For example, a 3 foot pole 78 may have an internal rod 82 about 31 inches long, a 6 foot pole 78 may have an internal rod 82 about 67 inches long, and an 8 foot pole 78 may have an internal rod 82 about 91 inches long. Internal rod 82 may also be sized smaller than inner diameter of pole 78. Preferably, internal rod 82 may have a diameter about half that of inner diameter of pole 78.
Cap 84 may be coupled in various ways to internal rod, such as by press fitting cap 84 over internal rod 82. Alternatively, connector such as pin 86 may pass through cap 84 and internal rod 82, as well as sleeve 88. Pole 78 may have one or more slots along which pin may travel, so as to allow sleeve 88 to move along a length of pole 78, thereby actuating tool system 10. Slots 80 may have a length between about ½ inch and about 6 inches, preferably between about ½ inch and about 2 inches, still more preferably between about ½ inch and about 1 inch, and in one embodiment, about ¾ inch. In addition, sleeve 88 may extend substantially along the length of pole 78 in order to provide a user with a variety of hand placement options. Sleeve 88 may be between about 10% and about 85% a length of pole 78, preferably between about 40% and about 85%, still more preferably between about 65% and about 85%. However, sleeve 88 may also be relatively short, for example between about 4 inches and about 6 inches, which may provide adequate surface area for a user's hand while requiring less material to make sleeve 88. In this case, sleeve 88 may be coupled to a secondary sleeve proximate second coupler 74.
Turning to the detail view of
Alternatively, second coupler 74 may not have separate flange 120. Instead, opening 118 of second coupler may be larger than opening 116 of first coupler 72, such that flange may be created by abutment of first coupler 72 with second coupler 74.
Shaft 102 may include a connector 114, which also may be considered abutment means, between lockout mechanism 100 and internal rod 82. Connector 114 may be a collar or retainer 113 configured to fit around shaft 102 and to increase radial extent of shaft 102. Alternatively, shaft 102 may have a threaded end, and connector 114 may comprise a nut configured to thread onto shaft, e.g., a locking nut that may resist unthreading.
Lockout mechanism 100 may include spring 110, which preferably is a compression spring. Spring 110 may surround shaft 102 and may be disposed between flange 120 and connector 114. As such, spring 110 may serve one or more purposes, e.g., biasing lockout mechanism 100 to an initial, pre-firing position and inhibiting misfiring by biasing lockout mechanism 100 away from trigger sleeve.
At an opposite end of shaft 102 from connector 114, lockout mechanism 100 may include a receptacle or receiver 104 for receiving one or more balls 112. Receiver 104 may include a cradle or well 106 configured to receive ball 112 when tool is oriented in an acceptable configuration, e.g., upward or generally above a horizontal. Well 106 may have a depth smaller than a diameter of ball 112, such that ball 112 may roll out of well more easily as tool 12 is lowered from an upright configuration. The deeper well 106 is, the longer ball 112 may be retained within well 106, permitting firing of tool 12. Conversely, a shallower well 106 may allow ball 112 to be roll out more easily. Well 106 may have a depth between about 10% and about 90% of the radius of ball 112, preferably between about 25% and about 75% of the radius, and in one embodiment, about 50% of the radius.
Lockout mechanism 100 also may include tapered flange 108 surrounding open end of well 106. In one embodiment, flange 108 may taper downwards from an outer edge to open end of well 106 between about 5 degrees and about 30 degrees, preferably about 15 degrees. In addition, flange may extend radially outward a sufficient distance to prevent ball 112 from falling behind flange, i.e., to prevent flange 108 from being between trigger sleeve 60 and ball 112.
At the same time, flange 108 may not extend outward so far as to contact walls of housing cavity 19. As seen in
Similarly, well 106 may partially receive protrusion 68 extending rearward from trigger sleeve 60 when tool is oriented in an unacceptable configuration, e.g., generally at or below a horizontal. In this configuration, ball 112 may not be disposed within well 106. Additionally, lockout mechanism 100 may be configured such that, when ball 112 is not disposed in well 106, a lockout gap LG may remain between trigger sleeve 60 and rod 82, even when rod 82 is translated to a fully forward position. By preventing contact between protrusion 68 of trigger sleeve 60 and rod 82, trigger sleeve 60 is prevented from sliding forward and releasing firing pin, which would lead to firing of tool. Gap may be between about 1/16″ and about 1″, preferably between about ¼″ and about ½″, and in one embodiment, about ⅜″.
In addition to tip of protrusion 68 being spaced apart from a bottom of well 106, protrusion 68 may have a tapered end, e.g., forming a frustoconical portion, so that sides of protrusion 68 also are spaced from sides of well 106. Spacing may be large enough to prevent inadvertent contact between protrusion 68 and lockout mechanism 100 while being small enough to prevent ball 112 from passing through the gap and into well 106. This sidewall spacing gap may be generally equal to lockout gap LG proximate the bottom of protrusion 68.
Turning now to
Turning further to
Actuating lockout mechanism 100 forward also may cause spring 110 to compress against nut 114.
After firing, the user may release the sleeve 88 or relieve forces caused by actuation of sleeve 88. For example, one or both of springs 58 and 110 may extend back to their initial positions, biasing trigger sleeve 60 and lockout mechanism 100, respectively, to rearward configurations, at which point tool system 10 may be readied for reloading and/or refiring.
Turning to
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific exemplary embodiments and methods herein. The invention should therefore not be limited by the above described embodiments and methods, but by all embodiments and methods within the scope and spirit of the invention as claimed.
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