System and method for driving a fastener

An apparatus for driving a fastener (1300) including a nose (1202) having a passageway including a first channel portion (1204) and a second channel portion (1214). The first channel portion is adapted to receive a first fastener body portion (1302) and the second channel portion adapted to receive a second fastener body portion (1304). The first and second fastener body portions are obliquely angled relative to one another. The apparatus also includes a driver blade (120) configured to apply a force to a first end of the fastener for driving the fastener at least partially from the passageway.

FIELD

The present invention relates in general to fasteners, and, more particularly, to a system and method for driving a fastener.

BACKGROUND

A wide variety of fastener configurations for securing structural members to other members are known. In one example, a deck fastener may be used for securing decking members to associated joists in the construction of an exterior deck, or the like. It is desirable that deck fasteners be configured for securing decking members to associated joists without a fastener head protruding from a deck surface. An example of a fastener having such a configuration is described in U.S. Pat. No. 5,927,923 (hereinafter “923 patent”), which is incorporated herein by reference. Fasteners as described for example in the '923 patent have an irregular geometric configuration including multiple body/prong portions angularly oriented relative to each other.

As a result of the irregular geometric configuration of such fasteners they have been driven manually without the use of a guiding tool or automated driving tool such as a pneumatic nailer. To achieve improved efficiency in driving such fasteners, there is a need for an improved system and method for driving such fasteners and a method of collating such fasteners.

DETAILED DESCRIPTION

For ease of explanation, systems consistent with the invention may be shown and described herein in connection with the fastener described in the '923 patent. For example, a fastener123may include a long body135and a short body134, which may be obliquely angled relative to one another, i.e., at an angle that is neither parallel nor perpendicular. It will be recognized, however, a system and method consistent with the present invention will be useful in connection with a wide variety of fastener configurations. In addition, exemplary embodiments may be described herein in connection with fastening of decking members to associated joists. It is to be understood, however, that a system and method consistent with the invention may be useful in connection with fasteners configured for use with any type of material including wood, composite materials, concrete, metal, plastic, textiles and other materials. The exemplary embodiments described herein are thus provided only by way of illustration, and are not intended to be limiting.

Turning toFIG. 1, there is illustrated one exemplary embodiment of a system for driving a fastener consistent with the present invention. The system includes a tool body121which is only partially shown. The tool body121may be the body of a commercially available tool for driving a driver blade120. The tool may be configured for driving the blade120outward from the tool body121using pneumatic, electrical, manual or other means. In one exemplary embodiment, the tool may be a commercially available pneumatic nailer.

In the illustrated exemplary embodiment, a nose or adapter122is affixed, e.g. removably, to the tool body. The nose122includes a channel124for receiving the driver blade120as the driver blade is forced outwardly from the tool body121. A fastener123may be positioned in the channel124beneath the driver blade120. As the driver blade120is forced outwardly from the tool body, the blade120may contact the top of the fastener123to force the fastener outward from the end125of the channel and into a target, such as a decking member, positioned beneath the nose122. As will be recognized by those of ordinary skilled in the art, the tool may be configured to provide or impart a desired level of force to the fastener through the blade to achieve a desired depth of penetration of the fastener into the target member.

The fastener123may be positioned in the channel124by pusher132which may be biased against one or more fasteners, e.g., by an associated spring133. The pusher132and the spring133may be assembled in a magazine131for receiving a plurality of fasteners. The pusher132may engage the last of a group of fasteners, e.g. as shown inFIG. 1, and the magazine131may guide the fasteners into the channel124under the bias force of the spring133. The magazine131may be configured to direct the fasteners into the channel124from either side of the tool or the front or back of the tool.

With reference also toFIG. 2, the adapter122may include a guide member126. A top portion of the guide member126may be pivotally secured to the adapter122by a fastener127such as a screw, bolt, pin or rod. A bottom portion of the guide member adjacent the bottom125of the channel124may be biased by a spring129to intersect a portion of the channel124. One end of the spring may be coupled to the guide member and the other end may be disposed in an opening130formed in a pocket128for receiving the guide member. When bias force of the spring129is overcome, the bias member may be forced into the pocket130and may not intersect the channel124.

As shown, the guide member126may be biased to intersect only a portion of the channel124to allow the driver blade120to force a long body135of the fastener123past the guide member without forcing the guide member126into the pocket128. As the fastener123is forced downward, a short body134of the fastener may contact the guide member126. The guide member126may guide the short body134through the channel124under the force of the spring129. As the short body134of the fastener exits the nose, the guide member126may be forced completely out of the path of the fastener123and into the pocket128.

In the foregoing manner, when the guide member126is positioned to intersect a portion of the channel124, an opening may be defined which may be generally complimentary to the geometry of the long body135. The opening defined by the channel124and the guide member126may at least partially restrict the movement of the fastener123other than generally along the axis of the channel124. The fastener123may, in the foregoing manner, resist becoming cocked within the channel124, or otherwise moving out of a desired alignment relative to the nose122.

The guide member126may be provided in a variety of configurations, and may include one or more guiding components.FIG. 3, for example, illustrates first300and second302spring biased rollers which may act as guide members. The rollers300,302may intersect at least a portion of the channel124. Similar to the previous embodiment, the rollers300,302may only intersect a portion of the channel124, such that the long body135of the fastener123can pass though the channel124without moving the rollers300,302. When the short body134of the fastener123contacts each roller300,302, the roller300,302may be driven out of the channel124, i.e., laterally displaced, to allow passage of the short body134. Similarly,FIG. 4illustrates a configuration of cam members400,402,404which may act as guide members. The cam members400,402,404may intersect a portion of the channel124and may pivotally move relative to the channel when contacted by the short body134of the fastener.

FIGS. 5 and 6illustrate spring steel members500,600,602having a first end affixed to a nose122and a second end positioned to intersect the channel124. The spring steel members may move from the path of a fastener upon contact with the short body thereof. As is clearly evident from the illustrated embodiments, a variety of configurations of spring steel members may be utilized for movably intersecting at least a portion of the channel124. For example, as shown inFIG. 5, the spring steel members500may be provided as generally linear members, at least a portion thereof extending into the channel124. The spring steel members500may resiliently deflect under contact by the short body134, allowing the short body134to pass through the channel124. In a related manner, the spring steel members600,602may also be provided including at least a portion thereof having an at least partially arcuate shape. Two such possible configurations are shown inFIG. 6.

Consistent with the various foregoing embodiments, the system may utilize one or more guide members capable of intersecting at least a portion of the channel, in at least one position of the guide members, to at least partially restrict or control the movement of the long body135relative to the channel124in at least one direction. The guide members may be movable relative to the channel to permit the passage of the short body134of the fastener123. In the foregoing manner, the system may include a passage for driving a fastener having a first body portion, e.g., the long body135, and a second body portion, e.g., the short body134. The passage may include a first channel portion for receiving the long body135of the fastener123. The one or more guide members may be movable to define a second channel portion for receiving the short body134. In the illustrated embodiments, guide members may be moved, deflected, deformed, etc. to permit passage of the short body134when contacted by the short body134. In various additional embodiments, the guide members may also be biased and/or moved by a power supply such as an air, gas, electric, or other power source.

Turning now toFIG. 7, there is illustrated an exemplary magazine305coupled to a nose302and affixed to a tool body301in a system consistent with the present invention. The nose302may be configured as described above, and the magazine305may be configured to receive a plurality of collated fasteners, e.g. a collated strip300of fasteners. The collated strip300of fasteners may include a plurality of separate fasteners secured to each other, e.g. by an adhesive, in a manner that allows separation of each fastener from the collated strip300as the fastener is driven through the nose302by the tool.

As shown, the nose302may include an opening303for receiving the fasteners and orienting the fasteners in the channel124. The fasteners may be fed into the opening303by a pusher309, which may be biased against the strip300of fasteners by a spring308. The fasteners may ride along a guide rail306, as shown. An opening307may be provided in the magazine to accommodate an external knob or handle304useful for retracting the pusher for loading the fasteners.

FIG. 8illustrates an alternative magazine configuration including an extended top311and bottom rail321for enclosing and guiding the short body134of the fasteners.FIG. 9illustrates an exemplary magazine configuration with a collated strip300of fasteners collated at an angle θ relative to each other to facilitate feeding of the fasteners into the nose.

Turning toFIGS. 10 through 14, another exemplary embodiment of a system1200for driving a fastener consistent with the present invention is shown. The system1200is adapted for use with an offset fastener1300, such as shown inFIG. 15. As depicted, the exemplary offset fastener1300may generally include a fastener main body1302and a fastener short body1304. The fastener main body1302and short body1304may be obliquely angled relative to one another such that the main body1302and short body1304neither parallel nor perpendicular relative to one another. Additionally, the fastener main body1302and short body1304may be coupled via an offset1306. The offset1306may laterally displace the main body302and the short body1304relative to one another, etc.

As shown inFIG. 10, the system1200may generally include a tool body121, which may include a commercially available apparatus for driving a fastener using a driver blade120. The driver blade may be driven outwardly from the tool body121using pneumatic, electrical, mechanical, etc. driving means. For example, the tool body121may be a commercially available pneumatic or electrical nailer.

A nose1202may be coupled to the tool body121to align a first channel1204in the nose1202with the driver blade120of the tool body121. The first channel1204may at least partially receive the driver blade120when the driver blade is driven outwardly from the tool body121. The main body1302of a fastener1300may be at least partially received in the channel1204beneath the driver blade120. The driver blade120may be driven outwardly from the tool body121to contact at least a portion of the fastener1300to force the fastener1300outwardly from the end1206of the nose1202. The force applied by the driver blade120to the fastener1300, as well as the outward travel of the driver blade120may be adapted to force the fastener1300from the nose1202to achieve a desired penetration depth of the fastener1300into a target member.

The fastener1300may be positioned in the first channel1204by a pusher1208, which may be biased against one or more fasteners, e.g., by an associated spring1210. In one embodiment, the pusher1208and spring1210may be associated with a magazine1212, which may be coupled to the nose1202and may be adapted to deliver one or more fasteners1300to the nose1202. The magazine1212may have a variety of configurations for delivering one or more fasteners1300to the first channel1204from a variety of positions relative to the tool body121, e.g., from either side, the front, or the back of the tool body121. For example, as shown a fastener1300amay be positioned to be fed into the channel1204once the fastener1300has been driven from the channel1204.

With additional reference also toFIGS. 11 and 12, the nose1202may include a second channel1214adapted to accommodate the short body1304of the fastener1300. The first and second channels1204,1214may intersect one another, e.g., to accommodate the offset1306of the fastener. As shown inFIGS. 10 and 11, the first and second channels1204,1214may be separated by a web1215, shown in the partial cross-sectional views inFIGS. 10 and 11. As shown inFIGS. 12a-12c, the geometry and orientations of the first and second channels1204a-c,1214a-cmay vary according to different configurations of the fastener1300. The at least partial intersection between the first and second channels1204a-c,1214a-cmay accommodate the offset portion1306of the fastener1300. Of course, the configurations depicted inFIGS. 12a-care merely exemplary configurations. Numerous alternative configurations may also be provided consistent with the present invention.

The channels1204,1214accommodating the main body1302and short body1304of the fastener1300may at least partially guide or stabilize the fastener1300in the nose1202and as the fastener is driven from the nose1202. For example, the main body1302of the fastener1300may be disposed in, and travel through, the first channel1204. The first channel1204may have geometry that may be generally complimentary to the geometry of the main body1302of the fastener1300. Movement of the fastener1300, other than axially through the channels1204,1214, may be at least partially restricted by the complimentary geometries of the main body1302and the first channel1204. Furthermore, the main body1302of the fastener1300may be at least partially supported, e.g., against buckling upon impact with a target member, by the complimentary geometry of the first channel1204. Similarly, or alternatively, the second channel1214may have a geometry that is generally complimentary to the short body1304of the fastener1300, and may also at least partially restrict the movement of the fastener1300in the first and second channels1204,1214. As mentioned, the at least partial intersection between the first and second channels1204,1214may accommodate the offset1306connecting the main body1302and short body1304of the fastener1300, allowing the fastener1300to be forced down the channels1204,1214and to be delivered from the nose1202. Accordingly, consistent with the present invention a system is provided including a passage for driving a fastener having first and second body portions, i.e., offset main and short body portions1302,1302. The passage may include first and second channel portions adapted to receive first and second portions of the fastener.

Turning toFIG. 13, an embodiment of a side-feed magazine1212coupled to a nose1202. The magazine1212may introduce fasteners1300, e.g., from a collated strip of fasteners, into the nose1202via a receiving opening1216. The opening1216may orient the fasteners1300relative to the first and second channels1204,1214to be driven by the tool121. As previously discussed, the fasteners may be biased toward the nose1202, e.g., by a spring1210acting through a pusher1208. As shown, the magazine1212may include a handle1218for retracting the pusher for loading fasteners1300into the magazine. The offset1306of the fastener1300may be carried on a rail1220, thereby aligning the fasteners1300with the opening1216.

FIG. 14depicts another magazine1212badapted to deliver fasteners1300a,1300bto the back of the tool1202. The magazine1212bmay be structurally similar to the magazine1212described with reference to the embodiment ofFIG. 13. However, as shown inFIG. 14, the fasteners1300a,1300bmay be oriented to be delivered to the first and second channels1204,1214from a rear of the nose1202.

According to one aspect, there is disclosed an apparatus for driving a fastener including a nose having a passageway including a first channel portion and a second channel portion. The first channel portion may be adapted to receive a first fastener body portion and the second channel portion may be adapted to receive a second fastener body portion. The first and second fastener body portions may be obliquely angled relative to one another. The apparatus may also include a driver blade configured to apply a force to a first end of the fastener for driving the fastener at least partially from the passageway.

According to another aspect, there is provided an apparatus for driving a fastener having a long body portion and a short body portion obliquely angled relative one another. The apparatus include a body defining a channel configured to receive the fastener therein. A driver blade is provided capable of forcing said fastener from an end of said channel. The apparatus may also include a guide member biased toward a first position intersecting at least a portion of the channel.