IMPROVEMENTS IN ROOFING WASHER-DISPENSING MACHINE

Abstract: In a roofing washer-dispensing machine (10) having improved features, a novel magazine (50) comprises a substantially box-like container (52) with a substantially open face, for a stack of circular roofing washers (12) having inserts, and a substantially rigid rod (80) mounted removably to a top wall of the box so as to extend downwardly into the central apertures of the stack washers, except for the lowermost washer, so as to restrain the remaining washers. The machine comprises a shuttle arranged to displace the lowermost washer from the stack when it is desired to dispense such washer. The shuttle (130) includes a novel arrangement of means overlying and underlying marginal portions of such washer.

Description: This invention pertains to improvements in a washer-dispensing machine, according to the preamble of claim 1. US-A-4 890 968, as well as EP-A-0 255 746 disclose an improved machine for fastening one or more layers of roofing material, such as a blanket of roofing insulation or a roofing membrane, to an underlayment, such as a wooden roof or a corrugated metal roof. The improved machine dispenses roofing washers individually onto such material and drives a fastener having a head, such as a screw, through a central aperture of each dispensed through such material, and into the underlayment, until the head of the fastener bears against such dispensed washer. The improved machine disclosed in US-A-4 890 968 is satisfactory for many applications, particularly if substantially square roofing washers are used, as disclosed in such copending application. It has been found, however, that it can be difficult to use circular roofing washers in such a machine. Thus, there has been a need, to which this invention is addressed for further improvements in such a machine. Herein, as in the US-patent noted above, such terms as "roof" and "roofing" are to be broadly understood, so as to cover roofs, decks, ceilings, and similar structures. Typically, such a machine is equipped with a shuttle. The shuttle is arranged to displace the lowermost washer from the stack when it is desired to dispense such washer. The washer-dispensing machine may be a washer-dispensing and fastener-driving machine, as exemplified by the improved machine disclosed in the patent noted above. It is the object of the invention to provide improved features in and for a washer-dispensing machine useful to dispense stackable roofing washers individually from a stack of such washers. These features permit such a machine to be advantageously used with circular roofing washers as well as with substantially square roofing washers. Typically, a roofing washer of either shape has a central aperture and is stackable with similar washers. The object is solved by the features of claim 1. According to one aspect of this invention, a novel magazine is provided for such a machine. The novel magazine is operative with a stack of roofing washers with their central apertures aligned vertically. Broadly, the novel magazine comprises a washer-containing structure and a washer-restraining structure, as described below. The washer-containing structure, which in a preferred embodiment is a box-like container, is arranged for containing such a stack of roofing washers but permitting the lowermost washer in the contained stack to be horizontally displaced from such stack. In the preferred embodiment, the lowermost washer may be horizontally displaced through a substantially open face of the box-like container. It is contemplated that, when it is desired to dispense the lowermost washer, the lowermost washer may be thus displaced by the shuttle of such a washer-dispensing machine. It is preferred for the washer-containing structure also to permit the lowermost washer in such a stack contained by the containing means to be edgewise engaged. It is contemplated that, when it is desired to dispense the lowermost washer, the lowermost washer may be thus engaged by the shuttle of such a washer-dispensing machine. The washer-restraining structure, which comprises an elongate member, is arranged for coacting with the containing means, and with an upper group of the washers in such a stack contained by the containing means. The upper group excludes the lowermost washer in the stack. The washer-restraining structure coacts therewith so as to restrain the washers in the upper group against being inverted accidentally in the stack and against being displaced with the lowermost washer. Preferably, the washer-restraining structure comprises an elongate member mounted to the containing means so as to extend downwardly into the central apertures of the washers in such a stack contained by the containing structure, except for the lowermost washer in the stack. It is preferred for the washer-containing structure to comprise outer walls defining a container with a substantially open face. These walls include a top wall, two side walls integral with the top wall, and a face wall opposite to the substantially open face and integral with the top and side walls. The container is arranged to contain such a stack of roofing washers. The substantially open face permits the lowermost washer in such a stack contained by the washer-containing structure to be horizontally displaced from the stack. In a preferred construction, the substantially open face is open between the side walls, substantially to the top wall. Also, each side wall has a flange extending inwardly from the lower edge of such side wall so as to underlie marginal portions of the lowermost washer in such a stack contained by the containing means. Moreover, the lower edge of the face wall is disposed so as to permit the lowermost washer in the stack to be edgewise engaged, as mentioned above. Furthermore, if the restraining means comprises an elongate member, as mentioned above, the elongate member is mounted removably to the top wall. According to another aspect of this invention, improved features are provided in a washer-dispensing machine useful to dispense stackable roofing washers individually from a stack of such washers nested with one another. These features are useful particularly but not exclusively if each such washer has an outer margin with a circular edge. Thus, the washer-dispensing machine with improved features provided by this invention comprises a base and a container, which is mounted to the base. The container is constructed so as to contain such a stack of such roofing washers, and so as to permit the lowermost washer in the stack to be horizontally displaced from the stack, when it is desired to dispense such washer. Also, the washer-dispensing machine with improved features provided by this invention comprises means for restraining the remaining washers in such a stack contained by the container so that the remaining washers in the stack are not displaced with the lowermost washer. The container and restraining means described in the preceding paragraph may be advantageously provided by the improved magazine described above. Such container and restraining means may be alternatively provided by the washer-containing and washer-restraining components of the washer-dispensing and fastener-driving machine disclosed in the copending application noted above. Furthermore, the washer-dispensing machine with improved features provided by this invention comprises a shuttle. The shuttle is mounted to the base for horizontal movement between a washer-engaging position and a washer-releasing position. The shuttle is adapted to engage the lowermost washer in such a stack contained by the container and to displace the lowermost washer as the shuttle moves from the washer-engaging position to the washer-releasing position. The shuttle is adapted to release the displaced washer as the shuttle next moves from the washer-releasing position to the washer-engaging position. The shuttle includes means for overlying a portion of the outer margin of the lowermost washer in such a stack contained by the container upon engagement of the shuttle with the lowermost washer and means for underlying at least a portion of the outer margin of the lowermost washer upon engagement of the shuttle therewith. Preferably, the overlying means comprises a blade-like member. Such a member is useful particularly but not exclusively if the outer margin of each washer has a circular edge. Also, in a preferred construction, the washer-dispensing machine with improved features provided by this invention comprises means mounted to the base for providing a positive stop for such a washer displaced by the shuttle when the shuttle reaches the first position. Preferably, if each washer has an outer margin with a circular edge, the positive stop has a concave portion adapted to receive such a washer displaced by the shuttle. The concave portion may be V-shaped. These and other objects, features, and advantages of this invention are evident from the following description of a preferred embodiment of this invention, with reference to the accompanying drawings. Figure 1 is a partly fragmentary, upper perspective view of a washer-dispensing and fastener-driving machine constituting a preferred embodiment of this invention. Such machine is shown as provided with a novel magazine according to one aspect of this invention. Figures 2 and 3 are enlarged, perspective views of the novel magazine, as seen from different vantages. A stack of roofing washers, which the novel magazine is designed to contain, is shown in phantom lines in Figure 2. A portion of one such washer is shown in full lines in Figure 3. Figure 4 is a sectional view of the novel magazine, as taken along line 4--4 of Figure 2, in a direction indicated by arrows. Three such washers are shown in full lines. Figure 5 on a larger scale compared to Figures 2 through 4, is a sectional view of the novel magazine, as taken along line 5--5 of Figure 2, in a direction indicated by arrows. One such washer is shown in full lines. Figure 6, on a larger scale compared Figure 1, is a partly fragmentary, upper perspective view of the washer-dispensing and fastener-dispensing machine shown in Figure 1, as seen without the novel magazine shown in Figures 2 through 5. One such washer is shown in full lines. Figure 7, on a similar scale, is a lower perspective view of the same machine. One such washer is shown in full lines. Figure 8, on a larger scale compared to Figures 6 and 7, is a fragmentary, upper plan view of a shuttle of the same machine. An outline of one such washer is shown in phantom lines. Figure 9, on an even larger scale, is a sectional view of the shuttle, as taken along line 9--9 of Figure 8, in a direction indicated by arrows. Figures 10 and 11, on an intermediate scale compared to Figures 6 and 7 and to Figure 8, are fragmentary, cross-sectional details showing sequential operations of the shuttle and certain associated components of the same machine. While this invention is susceptible of embodiment in various forms, there is shown in the drawings and will be hereinafter described a preferred embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the invention and is not intended to limit this invention to the specific embodiment illustrated. A washer-dispensing and fastener-driving machine 10, as shown in Figures 1, 6 and 7, constitutes the preferred embodiment of this invention. The machine 10, except as described herein, is similar to the washer-dispensing and fastener-driving machine illustrated and described as a preferred embodiment in the copending application noted above and functions similarly. The copending application noted above is incorporated herein by reference. The machine 10 is used to fasten a sheet or sheets of roofing material, such as a roofing membrane overlying a blanket of roofing insulation, to an underlayment, such as a wooden roof or a corrugated metal roof, by roofing screws having heads and integral washers. The sheet of roofing material, the underlayment, and the screws are not shown. A composite roofing washer 12, which is to be later described, is disposed between the head and integral washer of each roofing screw and the sheet of roofing material. The machine 10 dispenses such washers 12 individually onto the sheet of roofing material, at spaced intervals, and drives such a screw through a central aperture of each dispensed washer 12, through the sheet or sheets of roofing material, and into the underlayment, until the head and integral washer of the driven screw bear against such dispensed washer 12. The machine 10 is equipped with a pair of rollers 14, 16, which are journalled on opposite ends of an axle 18. The rollers 14, 16, enable the machine 10 to be manually moved to another location. The machine 10 comprises a base 20, which conforms substantially to the base disclosed in the copending application noted above. A kick plate 22 is mounted to the base 20, between the rollers 14, 16, as shown. The base 20 includes two side plates 24, 26, and other components, which are assembled in a manner disclosed in the copending application noted above. Also, the axle 18 extends through suitable apertures in the side plates 24, 26. The machine 10 comprises a magazine-receiving chute 30, which is defined by two front uprights 32, 34, two side walls 36, 38, and a rear wall 40. The front uprights 32, 34, the side walls 36, 38, and the rear wall 40 are assembled by machine screws (not shown) to the side plates 24, 26. A gate 42 is provided, which is similar to the gate disclosed in the copending application noted above, and which functions similarly. The gate 42 is mounted to the base 20, beneath the rear wall 40, for vertical movement through a limited range toward and away from a lowermost position, in which the gate 42 is shown in Figure 10. The gate 42 is biased toward the lowermost position by coiled springs 44 (one shown) acting between the rear wall 40 and the gate 42. In accordance with an important aspect of this invention, a magazine 50 is inserted removably into the magazine-receiving chute 30. The magazine 50 comprises, as a washer-containing structure, a substantially box-like container 52, as defined by a top wall 54, two side walls 56, 58, and a face or front wall 60. The side walls 56, 58, are integral with the top wall 54. The face or front wall 60 is integral with the top wall 54, and with the side walls 56, 58. The container 52 has a substantially open face opposite to the face or front wall 60. The substantially open face is open between the side walls 56, 58, from the lower edges of the side walls 56, 58, substantially to the top wall 54. The substantially open face is bounded at its upper edge by a narrow strip 62, which is integral with the top wall 54, and with the side walls 56, 58. The narrow strip 62 reinforces the container 52. The side wall 56 is provided at its lower edge with a flange 66 extending inwardly. The side wall 58 is provided at its lower edge with a flange 68 extending inwardly. Except for the flanges 66, 68, the box 52 is open at its lower end. The face or front wall 60 has a lower edge 70, which is spaced above a plane comprising the lower edges of the side walls 56, 58. The side walls 56, 58, are cut-away as shown in Figures 3 and 4, respectively at curved edges 72, 74, which meet the lower edge 70 of the front or face wall 60. The magazine 50 comprises, as a washer-restraining structure, an elongate, substantially rigid rod 80, which is mounted removably to the top wall 54 so as to extend downwardly, as shown. A tubular fitting 82 having an annular flange 84 at its lower end and defining an upwardly opening, J-shaped slot 86 extends through a central aperture 88 in the top wall 54. The tubular fitting 82 is welded at the annular flange 84. A knob 90 is mounted at a threaded connection (not shown) to the upper end of the rod 80 and is secured thereto by a locking nut 92. A coiled spring 94, which is deployed around the rod 80, between the tubular fitting 82 and the locking nut 92, biases the rod 80 upwardly. A pintle 96, which extends radially and integrally from the rod 80, coacts with the upwardly opening, J-shaped slot 86 so as to enable the rod 86 to be removably mounted to the top wall 54. Means are provided for latching the magazine 50 releasably when the magazine 50 is received by the chute 30. The latching means comprises a horizontal rib 98, which is welded to the front or face wall 60 of the container 52, and a latching hook 100, which is mounted to the front upright 32 via a stub shaft (not shown) enabling the latching hook 100 to rotate in a latching direction, which is counterclockwise in Figures 1 and 6, and to rotate oppositely. The latching hook 100 is biased in the latching direction by a coiled spring 102 deployed around the stub shaft. The coiled spring 102 coacts between the front upright 32 and the latching hook 100. The latching hook 100 must be oppositely rotated so as to permit the magazine 50 to be downwardly inserted into the chute 30. Next, when the magazine 50 is received by the chute 30 and the latching hook 100 is released, the latching hook 100 overlies the horizontal rib 98 so as to latch the magazine 50 releasably within the chute 30. When the rod 80 is removed from the top wall 54, the container 52 can be easily filled with a stack of such roofing washers 12, through the substantially open face of the container 52. When the rod 80 is remounted to the top wall 54, the rod 80 extends downwardly into the central apertures of the roofing washers 12 in the stack contained by the container 52, except for the lowermost washer 12 in the contained stack. The rod 80 is sized so as not to extend below the washer 12 overlying the lowermost washer 12 in the contained stack. When the lowermost washer 12 in the stack is displaced horizontally from the stack (in a manner to be later described) the rod 80 restrains the remaining washers 12 in the stack against being displaced horizontally from the stack. Moreover, if the machine 10 is tipped accidentally or deliberately, the rod 80 restrains the remaining washers 12 in the stack against being inverted accidentally in the container 52 and prevents those washers 12 that are above the rear wall 40 of the chute 30 from falling accidentally from the container 52. As shown, each composite roofing washer 12 comprises a metal washer plate 110. The metal washer plate 110 is stamped from a sheet of galvanized steel so as to be generally circular around its outer edge 112, so as to have annular reinforcing ribs, and so as to have a countersunk portion 114. The countersunk portion 114 includes a central aperture, which is circular. Moreover, each composite roofing washer 12 comprises a thermoplastic insert 120 molded from a polymeric material, such as high density polyethylene or polypropylene. High density polyethylene is preferred. The thermoplastic insert 120 is molded so as to have a central hub 122. The central hub 122 is split diametrically into two halves, which are snap-fitted or molded through the central aperture of the metal washer plate 110. Flanged portions of the halves of the central hub 122 fit beneath the metal washer plate 110 so as to interlock the thermoplastic insert 120 and the metal washer plate 110. The thermoplastic insert 120 has a central aperture 124 extending through the central hub 122 and constituting the central aperture of the composite roofing washer 12. The thermoplastic insert 120 has a central socket 126, which is adapted to receive the head and integral washer of one of the screws mentioned above. The central socket 126 has an annular lip adapted to be snap-fitted over the integral washer received by the central socket 126. In a stack of such washers 12, except for the uppermost and lowermost washers 12 of the stack, the central hubs 122 nest into the central sockets 126. Suitable composite roofing washers, as exemplified by the composite roofing washers 12, and suitable screws, as mentioned herein, are available commercially from ITW-Buildex (a division of Illinois Tool Works Inc.) of Itasca, Illinois. The machine 10 comprises a shuttle 130, which is mounted to the base 20 for horizontal movement between a washer-engaging position and a washer-releasing position. Broadly, except as described herein, the shuttle 130 is similar to the shuttle of the improved machine disclosed in the copending application noted above and functions similarly. However, as described herein, the shuttle 130 embodies important features distinguishing the shuttle 130 therefrom. In the copending application noted above, the normal position of the shuttle described therein corresponds to the washer-releasing position of the shuttle 130, and the displaced position of the shuttle described therein corresponds to the washer-engaging position of the shuttle 130. As shown in Figures 8 and 9, the shuttle 130 has opposite, coplanar, gate-supporting surfaces 132, 134, along its side edges 136, 138. The side edges 136, 138, fit slidably into longitudinal grooves in the side plates 24, 26, as shown in Figure 9, in which the side plates 24, 26, are shown fragmentarily, in phantom lines. The shuttle 130 has longitudinal grooves 140, 142, which divide the gate-supporting surfaces 132, 134, from a washer-supporting surface 144 of the shuttle 130 and from a washer-driving portion 146 of the shuttle 130. The gate-supporting surfaces 132, 134, define a plane coinciding with the lowermost position of the gate 42. In its lowermost position, the gate 42 rests on the gate-supporting surfaces 132, 134. The washer-supporting surface 144 is U-shaped and embraces a rearwardly opening, U-shaped cut-out 148 in the shuttle 130, as shown. The washer-supporting surface 144 defines a plane, which is spaced below the plane defined by the gate-supporting surfaces 132, 134. The washer-driving portion 146 has a concave edge 150, which conforms substantially to the outer edge 112 of the metal washer plate 110 of each composite roofing washer 12. The concave edge 150 terminates at the washer-supporting surface 144. Thus, the shuttle 130 is adapted to engage one such washer 12, as suggested in phantom lines in Figure 8, so that marginal portions of its metal washer plate 110 rest on the washer-supporting portion 144, between the gate-supporting portions 132, 134, so that its countersunk portion 114 is accommodated by the U-shaped cut-out 148, and so that an arcuate portion of the outer edge 112 of its metal washer plate 110 is embraced by the concave edge 150 of the washer-driving portion 146. A blade-like member 160 is welded onto the washer-driving portion 146 as to extend longitudinally along the washer-driving portion 146. A tip 162 of the blade-like member 160 extends over the concave edge 150 of the washer-engaging portion 144. When such a washer 12 is engaged by the shuttle 130 so that the washer-supporting portion 144 supports marginal portions of the same washer 12, and so that an arcuate portion of the outer edge 112, of its metal part 110 is embraced by the concave edge 150 of the washer-engaging portion 144, the tip 162 overlies some of the arcuate portion embraced by such edge 150. A brace 170 (see Figure 8) is fixed by machine screws (not shown) to the shuttle 130. The brace 170, at its opposite ends, has pivot pins 172, 174. The pivot pin 172 extends through a longitudinal slot 176 (see Figure 1) in the side plate 24. The pivot pin 174 extends through a similar slot (not shown) in the side plate 26. The washer-dispensing and fastener-driving machine 10 comprises shuttle-biasing means, shuttle-moving means, and fastener-driving means disclosed in the copending application noted above and function similar. These means include a mechanical linkage 180, which is similar to the mechanical linkage disclosed in the copending application noted above. The shuttle 130 is biased by the shuttle-biasing means (not shown) to its washer-releasing position and is linked via the pivot pins 172, 174, to the mechanical linkage 180. Actuation of the mechanical linkage 180 to move the shuttle 130 to its washer-engaging position from its washer-releasing position is effected by manual movement of a screw-feeding tube 182 in a downward direction and is similar to actuation of the mechanical linkage disclosed in the copending application noted above. The screw-feeding tube 182 is similar to a screw-feeding tube disclosed in the same application. When the shuttle 130 is used to displace one of the aforesaid washers 12 to the washer-releasing position of the shuttle 130 (see Figure 11) the displaced washer 12 is positioned beneath a nosepiece 190. The nosepiece 190 is welded to the bight 192 of a U-shaped bracket 194, which is mounted by machine screws (not shown) between the side plates 24, 26. An aperture 194 permitting a screw to pass therethrough is provided in the bight 192 of the bracket 194. The nosepiece 190, which is one component of the fastener-driving means of the machine 10, is similar to the nosepiece disclosed in the copending application noted above. The bracket 194 is similar to the U-shaped bracket disclosed in the same application. A cross-piece 200 having a concave, V-shaped portion 202 (see Figures 7, 10 and 11) is mounted by machine screws (not shown) between the side plates 24, 26. The cross-piece 200, at the V-shaped portion 202, provides a positive stop for the displaced washer 12. The V-shaped portion 202 engages the circular edge of the displaced washer 12 so as to center the displaced washer 12 beneath the nosepiece 190. After the displaced washer 12 has been centered beneath the nosepiece 190 and the shuttle 130 has moved from its washer-releasing position to its washer-engaging position, the fastener-driving means of the machine 10 may be then operated to drive a screw having a head and an integral washer through the central aperture of the displaced washer 12, through the sheet or sheets of roofing material, and into the underlayment, until the head and integral washer of the screw are received by the central socket 126 of the displaced washer 12. Operation of the fastener-driving means of the machine 10 is similar to operation of the fastener-driving means disclosed in the copending application noted above.

Claims: A washer-dispensing machine (10) arranged to dispense stackable roofing washers (12) having central apertures individually from a stack of such washers with their central apertures aligned vertically and equipped with a shuttle (130), which is arranged to displace the lowermost washer from the stack when it is desired to dispense the last-mentioned washer, including a magazine (50) comprising containing means (52) for containing such a stack of such washers (12) but permitting the lowermost washer in the contained stack to be horizontally displaced from the contained stack, as by the shuttle (130) of the washer-dispensing machine, when it is desired to dispense the last-mentioned washer; characterized by restraining means comprising an elongate member (80) mounted to the containing means (52) so as to extend downwardly into the central apertures of the washers (12) in such a stack contained by the containing means except for the lowermost washer in the contained stack for restraining the washers in the upper group against being inverted accidentally if the washer-dispensing machine is tipped and against being displaced with the lowermost washer in the contained stack. The washer-dispensing machine of claim wherein the containing means (52) is constructed so as to permit the lowermost washer in such a stack contained by the containing means to be edgewise engaged, as by the shuttle (130) of the washer-dispensing machine, when it is desired to dispense the last-mentioned washer. The washer-dispensing machine of claim 1 or 2, wherein the containing means (52) comprises outer walls defining a container arranged to contain such a stack of roofing washers, the container having a substantially open face permitting the lowermost washer in such a stack contained by the containing means to be horizontally displaced from the contained stack, said walls including a top wall (54), two side walls (56, 58) integral with the top wall, and a face wall (60) opposite to the substantially open face and integral with the top and side walls. The washer-dispensing machine of claim 3, wherein the side (56, 58) and face (60) walls of the magazine respectively have lower edges, and wherein the subtantially open face is open between the side walls, from the lower edges of the side walls substantially to the top wall (54). The washer-dispensing machine of claim 3 or 4 wherein each side wall (56, 58) of the magazine has a flange (66, 68) extending inwardly from the lower edge of such side wall so as to underlie marginal portions of the lowermost washer in such a stack contained by the container. The washer-dispensing machine of one of claims 3 to 5, wherein the lower edge of the face wall (60) of the magazine is disposed so as to permit the lowermost washer in such a stack contained by the container to be edgewise engaged at a location near the lower edge of the face wall, as by the shuttle (130) of the washer-dispensing machine, when it is desired to dispense the last-mentioned washer. The washer-dispensing machine of one of claims 3 to 6 wherein the elongate member (80) is mounted removably to the top wall (54) so as to extend downwardly into the central apertures of the washers (12) in such a stack contained by the container except for the lowermost washer in the contained stack. The washer-dispensing machine of one of claims 1 to 7, wherein the shuttle (130) is mounted to a base (20) for horizontal movement between a washer-engaging position and a washer-releasing position, beneath a fastener feeding means (182, 190, 194, 195), the shuttle (130) including means for overlying a portion of the outer margin (112) of the lowermost washer (12) in such a stack contained by the container upon engagement of the shuttle with the last-mentioned washer and means for underlying at least a portion of the outer margin of the last-mentioned washer upon engagement of the shuttle therewith. The washer-dispensing machine of claim 8 further comprising means mounted to the base (20) for providing a positive stop (200) for such a washer displaced by the shuttle (130) when the shuttle reaches the washer releasing position. The washer-dispensing machine of claim 9 wherein the positive stop (200) has a concave portion (202) adapted to receive such a displaced washer (12) having an outer margin (112) with a circular edge. The washer-dispensing machine of claim 10 wherein the concave portion (202) of the positive stop (200) is V-shaped. The washer-dispensing machine of one of claims 8 to 11, wherein the means for overlying a portion of the outer margin of the lowermost washer of such a stack contained by the container upon such engagement of the shuttle therewith comprises a blade-like member (160).

Inventors: BEACH, JOHN R., HASAN, SYED RIAZ-UL
Applicants: ILLINOIS TOOL WORKS INC.
Application year: 1990
Main classification: E04D15
IPC codes: B25B23, E04D15