The present invention relates to an internal combustion fastener driving tool.
Fastener driving tools, also known as impulse tools, have been developed that use internal combustion as a power source to drive fasteners such as nails into a work piece or substrate. The tools ignite a fuel/air mixture in a combustion chamber to forcibly drive a piston, which then ejects the fastener from the tool. The effectiveness of the prior art is largely limited to their efficiency in rapidly igniting the complete volume of fuel/air mixture. If insufficient volumes of fuel ignite, the device delivers unsuitable driving forces to the fastener. If the tool produces unreliable power outputs the fasteners may be driven to unsatisfactory depths or insufficiently seated. Prior art devices have attempted to address these inefficiencies by making a larger tool and wasting larger volumes of fuel.
Some prior art tools also suffer from what is known as misfire or non-fire. This occurs when the tool is operated in low temperature conditions or at high altitude and hot conditions. The cause of the phenomenon is; (a) insufficient atomization and mixing of the air/fuel; (b) an insufficient fuel/air ratio; (c) low air density.
One such prior art tool is described in U.S. Pat. No. 5,213,247 (Gschwend et al). This device includes a network of mechanisms that operate to measure a specific quantity of fuel and then draw that fuel, along with air, into a combustion chamber by mechanically expanding the combustion chamber volume. A drawback of this device is that the fuel and gas are not mixed sufficiently, which decreases the efficiency of combustion.
A further disadvantage of such prior art tools is the tool mass (weight and physical size) required for a given output of energy. Furthermore, such tools draw fuel and air into the combustion chamber with partial vacuum. As a consequence the fuel/air mixture is ignited at a low pressure, which leads to a low burn rate and further inefficiency. This is particularly problematic in that the less efficient an internal combustion fastener driving tool is, the more susceptible the device is to output fluctuations that result in ignition failures and unsatisfactory driving forces to the fastener.
Also prior art impulse tools such as those used in nail and fixing in the building industry have limitations in their use. Such tools have the capability of producing 70 to 100 joules of output energy. These tools will only produce their manufactured claimed output under optimal conditions ie; 24C @ sea level and a relevant humidity level of approximately 40%. If these optimum conditions change, so does the power output by as much as 25%, and in some cases they do not fire at all. This means that nails and fixers sometimes protrude and are only driven 80 to 90% of the manufactured depth, and thus the work piece may not meet building standards. This may also lead the operator to have to use a traditional hammer to finish the job.
Some impulse tool manufactures have developed tools to produce in excess of 100 joules, but such tools have ended up being a far larger unit for consumers to reasonably expect to purchase.
All prior art combustion tools used for fixing, suffer from gumming up and need to be cleaned regularly. This is caused by incomplete combustion in the tool. Carbon, lubricants and other bi-products of combustion and exhaust gases build up deposits within the combustion chamber, driver piston and head.
The present invention seeks to provide a fastener driving tool that will ameliorate or overcome at least one of the deficiencies of the prior art.
According to a first aspect the present invention consists in a hand-held power tool, the operational power of which is provided by a gas combustion mechanism, said gas combustion mechanism comprising a first combustion chamber, a second chamber within a driving cylinder having an aft end and a fore end, said first combustion chamber in fluid communication with said second chamber via said aft end, at least one fan assembly, a driver assembly having a piston and driver movable within said driving cylinder between said aft end and said fore end, and a drive motor operably connected to said driver assembly, wherein in use, whilst said piston is at or near said fore end of said driving cylinder, said fan assembly introduces air into said first combustion chamber and said second chamber thereby at least partially pressuring the air there within, fuel gas is introduced into said combustion chamber from a fuel supply port, the air and fuel gas being mixed to form an air/fuel gas mixture therein, said drive motor operably moves said piston to a position at or near said aft end thereby compressing said air/fuel gas mixture within said first combustion chamber so that said air/fuel mixture is ignited within the combustion chamber to impart motion onto said piston and to facilitate the operation of the tool.
Preferably said fan assembly has a first external induction fan for introducing air into said first combustion chamber.
Preferably said fan assembly has a second internal circulation fan disposed within said first combustion chamber.
Preferably said second internal circulation fan is shrouded by a shroud having a free end portion that is frusto-conical in shape.
Preferably said first combustion chamber is frusto-conically shaped in a region near where it adjoins said driving cylinder.
Preferably said piston has an aft surface having a concave toroidal shape therein for redirecting air centrally forced thereon by said fan assembly.
Preferably a separate exhaust cavity is at least partially disposed externally around said first combustion chamber and said driving cylinder, said exhaust cavity having an exhaust vent located near the fore end of said driving cylinder.
Preferably a plurality of apertures interconnect said exhaust cavity with said first combustion chamber, and an air ducting shroud disposed near said apertures prevents air from passing there through when air is being introduced into said combustion chamber by said fan assembly.
Preferably at least one exhaust port in communication with said exhaust cavity is located in said driving cylinder near its aft end, said exhaust port being closed by said piston when same has travelled to said aft end of said driving cylinder.
Preferably said exhaust port closes prior to the air inlet side of said combustion chamber, thereby allowing supercharged air to be introduced into said combustion chamber.
Preferably said tool further comprises a movable tool nose assembly and a trigger assembly both operably connected to an ECM for the control and actuation of the fan assembly, drive motor and gas supply port.
Preferably said fan assembly and said drive motor are operably powered by a battery.
Preferably said drive motor is adapted to act as a generator operably connected to ECM for charging of said battery.
Preferably said air/fuel mixture is ignited by an ignition process initiated by multiple high tension sparks.
Preferably said multiple high tension sparks are emitted from a plurality of igniters.
Preferably in one embodiment the air is introduced into the combustion chamber and driver by a turbine/fan compressor.
Preferably the air is introduced into the combustion chamber and driver by a positive displacement rotary vane compressor.
Preferably the air introduced into the combustion chamber and driver is super-charged and a holding mechanism holds the driver assembly against super-charged air until ignition takes place.
Preferably the increase in tool output energy is a result of supercharging.
According to a second aspect the present invention consists in a hand-held power tool, operational power of which is provided by a gas combustion mechanism, said gas combustion mechanism comprising a first combustion chamber, and a second chamber within a driving cylinder having an aft end and a fore end, said first combustion chamber in fluid communication with said second chamber via said aft end, and a driver assembly having a piston and driver movable within said driving cylinder between said aft end and said fore end, and a drive motor operably connected to said driver assembly, wherein in use the volume of said first combustion chamber and said second chamber is fluidally pressurized in first and second stages, where said first stage comprises introducing supercharged air into said first combustion chamber and said second chamber via a fan whilst said piston is at or near said fore end of said driving cylinder and subsequently a fuel gas is introduced into said combustion chamber from a fuel supply port, the air and fuel gas being mixed to form an air/fuel gas mixture therein, and in said second stage said drive motor moves said piston to said aft end thereby compressing said fuel/gas mixture in said first combustion chamber so that said air/fuel mixture is ignited within the combustion chamber to impart motion onto said piston and to facilitate the operation of the tool.
The operation of tool 100 will now be described. A user (not shown) holds tool 100 by support handle (pistol grip) 34. Preferably the user's index finger is placed on firing trigger 3. The touch sensor 35 alerts the Electronic Control Module (ECM) 27 that tool 100 is to be operated. ECM 27 actuates the electrical circuit to the induction and circulation fan motor 102 to operate at twelve volts. This results in the external induction fan 103 and internal circulation fan 104 to drive air from external of tool 100 in through air intake filter 21. External air is force fed into the combustion chamber 106 and driver cylinder chamber 107 as charged air. Simultaneously ECM 27 checks the position of drive motor 101, which is in communication with driver 14 and piston 15 via drive motor gear 7 and driver gear rack 11. The drive motor 101 repositions driver 14 and piston 15 so that the underside of piston 15 is resting on bumper 8, see
Gas delivery jet 33 is extended into chamber 106 in close proximity to rear of fan 104. As the fuel exits jet 33 the rapidly rotating blades of fan 104 accelerate the vaporization and expansion reaction of the fuel gas as well as rapidly circulating and mixing the air and fuel together in chambers 106 and 107.
Tool 101 is then raised off the substrate allowing movable tool nose portion 5 to extend. Tool nose portion 5 in communication with housing 17 slides forward, allowing air to circulate around 106 and 107 and exit through exhaust ports 16. The firing trigger 3 is then released resetting the ECM 27 back to the start cycle status.
A hand-held power tool as described in the abovementioned embodiment overcomes the disadvantages of the prior art prior by achieving:
The above mentioned embodiment of the present invention overcomes the disadvantages and difficulties of the prior art by:
In a modification of the first embodiment not shown, motor 101 is replaced by a coil spring assembly positioned inside cylinder 13 acing upon the underside of driver piston 15. A locking mechanism in mechanical communication with driver 14 will also be necessary to achieve driver piston and driver assembly return when chambers 106 and 107 are under pressure resulting in a charged air system.
In a second embodiment,
It should be understood that although various air pump (compressor) mechanisms such as external induction fan 103, turbine/fan 201 and rotary vane air pump 203 have been described in the abovementioned embodiments for the super-charging of tool 100, it is not limited to these particular mechanisms, and other air pump mechanisms may be utilised.
Where higher efficiency pump mechanisms, such as turbine/fan 201 or rotary vane air pump 203 are used in a hand held internal combustion nail fastener tool 100 utilizing a super-charging combustion process as described, it is possible to dispense with driver motor 101, drive motor gear 7 and driver gear rack 11. To combat the charged air effect in combustion chamber 106 it would be necessary to incorporate a driver piston locking holding mechanism (not shown), to hold the driver mechanism 14 and 15 in place at the top of the driver cylinder 13 until ignition has taken place. As combustion pressure rises in combustion chamber 106, typically in excess of 10 bar, the gas combustion pressure acting upon driver piston 15 will overcome the driver assembly locking mechanism (not shown) and eject a nail at high velocity from tool 100. The driver assembly locking mechanism may be configured so that the driver assembly 14 and 15 is held at the top of the cylinder 13 until a pressure of typically say 1.5 bar exists in combustion chamber 106.
The terms “comprising” and “including” (and their grammatical variations) as used herein are used in inclusive sense and not in the exclusive sense of “consisting only of”.
Number | Date | Country | Kind |
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2008902501 | May 2008 | AU | national |
2008903770 | Jul 2008 | AU | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/AU2009/000629 | 5/20/2009 | WO | 00 | 11/19/2010 |
Publishing Document | Publishing Date | Country | Kind |
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WO2009/140728 | 11/26/2009 | WO | A |
Number | Name | Date | Kind |
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4483280 | Nikolich | Nov 1984 | A |
5213247 | Gschwend et al. | May 1993 | A |
6938811 | Ehmig et al. | Sep 2005 | B2 |
8091751 | Tanaka | Jan 2012 | B2 |
8113403 | Tanaka et al. | Feb 2012 | B2 |
20080314952 | Tamura et al. | Dec 2008 | A1 |
Number | Date | Country |
---|---|---|
0056989 | Aug 1982 | EP |
WO2005110684 | Nov 2005 | WO |
WO2007099819 | Sep 2007 | WO |
Entry |
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International Search Report from related PCT/AU2009/000629. |
Number | Date | Country | |
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20110068142 A1 | Mar 2011 | US |