Machine and method for collating wire nails having shank keyways

Abstract: Wire nails (10) are collated by means (102) for conveying the nails (10) in a parallel alignment and by means (100) comprising a wheel (138) for engaging keyways (28) defining flat surfaces (30) on the shanks (14) of the nails (10). Each nail (10) is rotated by the wheel (138), about an axis of its shank (14) to orient the keyways (28) of the nails similarly with all the flat surfaces (30) defining a plane. The wheel (138) fits between end surfaces (36,38) defined by the keyways (28) also so as to cause axial alignment of the nails (10) and to cause the keyways (28) that have been engaged by the wheel (138) to define a continuous channel.

Description: This invention pertains to a novel combination of mechanisms in a machine for collating wire nails having a novel configuration wherein the shank of each nail has a keyway. This invention pertains also to a novel method for collating such nails. Typically, as used in pneumatically powered or combustion-powered nail-driving tools, wire nails having D-shaped or variant heads are collated by adhesively applied tapes or other collating media to form a strip. The shanks of the collated nails are oriented in closely spaced, parallel relation to one another and, except at one end of the strip, the head of each nail overlies the head of another nail. Various strips of collated wire nails having D-shaped heads are exemplified in Lingle US-A-3,152,334, Leistner US-A-3,861,526, and Shelton et al. US-A-3,966,042. Powers US-A-3,359,582 discloses a die assembly for making a wire nail having such a head. Similar strips of collated wire nails having variant heads are exemplified in Juilfs US-A-2,940,081 and Becht US-A-3,481,459. None of the D-shaped or variant heads disclosed in the foregoing patents defines a complete circle when viewed axially. In a known machine for collating wire nails, the nails are conveyed into a zone where adhesively applied tapes or other collating media are applied, via two endless bands having pockets holding the nail shanks. The endless bands are similar to bandsaw blades. The nail shanks are held in closely spaced, parallel relation to one another and the nail tips tend to be generally aligned with one another, in a plane defined by the shank axes. Desirably, the nail heads are oriented similarly and precisely, and the nail tips are aligned precisely with one another. In actual practice, it is difficult to orient the nails precisely in a rotational sense and in an axial sense when collating the nails. If a nail is not oriented precisely in a strip of collated nails, and if the strip is fed to a pneumatically powered or combustion-powered nail-driving tool, the nail may be damaged when driven. Furthermore, the tool and other nails in the strip may be also damaged. GB-A-1,022,175 discloses a method of, and apparatus for, collating a strip of nails for use in a nail driving tool. The method involves positioning the nails with the heads of adjacent nails overlapping, the shanks being slightly spaced apart. The nails arranged in this way are conveyed to a station where an adhesive is applied. The apparatus includes a pair of opposed looped straps which convey the strip of nails. A strip of collated wire nails wherein each nail has a novel configuration including a radially offset, circular head and a shank having a keyway, among other features, is disclosed in a copending application filed simultaneously herewith, under application No. 91309045.2 (EP-A-0 481 635). The co-pending application claims priority from USSN 597,025 and has Attorneys reference 80/4083/02. This invention makes advantageous use of the keyways of such nails to provide a novel combination of mechanisms in a machine for collating such nails and also provide a novel method for collating such nails. According to a first aspect of this invention a machine for collating similar wire nails, wherein each nail has a head and a shank, and wherein the shank has an axis, a tip spaced axially from the head, and a keyway located between the head and the tip, the machine includes: (a) conveying means for conveying the nails through an orienting zone in such manner that the shanks of the nails are disposed in parallel relation to one another, that the axes of the shanks of the nails define a plane, and that the tips of the shanks of the nails are generally aligned with one another, and, (b) engaging means for engaging the keyways as the nails are conveyed through the orienting zone and for rotating each nail about the axis of its shank as in the rotational sense necessary to provide a similar orientation for the keyways of all the nails conveyed through the orienting zone the engaging means being disengaged from the keyways after orientating them. This invention provides a novel combination of mechanisms in a machine for collating such nails. The novel combination comprises a nail-conveying mechanism, which is similar to the nail-conveying mechanism of a nail-collating machine known heretofore, and a keyway-engaging mechanism, which is novel. The nail-conveying mechanism conveys the nails through an orienting zone. The nail shanks are disposed in parallel relation to one another. The axes of the nail shanks define a plane. The nail tips tend to be generally aligned with one another. The keyway-engaging mechanism is arranged for engaging the keyways as the nails are conveyed through the orienting zone. The keyway-engaging mechanism is arranged, moreover, for rotating each nail about its shank axis to such extent as may be then necessary to cause its keyway and the keyways of the other nails conveyed through the orienting zone to be similarly oriented in a rotational sense. The keyway-engaging mechanism is disengaged from the keyways after engaging the keyways. Preferably, the keyway of each nail defines a flat surface, which is engaged by the engaging mechanism as such nail is conveyed through the orienting zone. The engaging means engages the flat surface in such manner that the flat surfaces of the nails conveyed through the orienting zone define a plane. Thus, if the flat surface on each nail is parallel to its shank axis, the plane defined by the flat surfaces is parallel to the plane defined by the shank axes. Preferably, the engaging apparatus comprises a wheel, which is rotatable freely about its axis. The wheel is movable toward and away from an operative position and is biased toward the operative position. In the operative position, the wheel is adapted to fit removably into the keyway of each nail and to engage the flat surface defined by such keyway. Also, a camming member may be provided for camming the shank of each nail toward the wheel in such manner that such nail is rotatable on the camming member, about the axis of the shank of such nail. If each nail is similar to a preferred embodiment disclosed in the copending application noted above, the keyway of each nail defines two end surfaces intersecting the flat surface defined by such keyway, preferably at acute angles relative to the axis of the shank of such nail. Also, such flat surface may conform to a parallelogram having two longer edges and two shorter edges and defining two acute angles and two obtuse angles, whereupon each of the end surfaces is bounded partly by one of the shorter edges. Hence, the engaging apparatus, which may comprise the wheel noted above, may be also adapted to fit at least partly into the keyway of each nail and to engage one of the end surfaces defined by such keyway so as to cam the shank of such nail axially to such extent as may be then necessary to cause the shank tip of such nail and the shank tips of the other nails conveyed through the orienting zone to be precisely aligned with one another in an axial sense. According to a second aspect of this invention a method comprises the steps of (a) conveying the nails through an orienting zone in such manner that the shanks of the nails are disposed in parallel relation to one another, that the axes of the shanks of the nails define a plane, and that the tips of the shanks of the nails tend to be generally aligned with one another, and, (b) orienting the nails as the nails are conveyed through an orienting zone by (i) engaging the keyway of the shank of each nail and, (ii) rotating each nail as necessary to cause the keyway of the shank of each nail conveyed through the orienting zone to be similarly oriented in a rotational sense. This invention provides a novel method for collating such nails. The nails are conveyed, through an orienting zone. The nails are oriented as they are conveyed through the orienting zone. The nails are oriented by engaging the keyway of each nail and by rotating such nail to such extent as may be then necessary to cause the keyway of such nail and the keyways of the other nails conveyed through the orienting zone to be similarly oriented in a rotational sense. If the keyway of the shank of each nail defines a flat surface, which is engaged in the engaging step, the rotating step may be then performed in such manner that the flat surfaces engaged in the engaging step define a plane. As noted above, if the flat surface is parallel to the axis of the shank, the plane defined by the flat surfaces is parallel to the plane defined by the axes of the shanks of the nails. If the keyway of the shank of each nail defines two end surfaces intersecting the flat surface defined by such keyway, the engaging step is performed in such manner that the flat surface defined by such keyway is engaged between the end surfaces. One of the end surfaces can be also engaged by the engaging mechanism so as to cam the shank of such nail axially to such extent as may be then necessary to cause the tip of the shank of such nail and the tips of the shanks of the other nails conveyed through the orienting zone to be precisely aligned with one another. A preferred embodiment of this invention will now be described with reference to the accompanying drawings; in which:- Figure 1 is a plan view of a portion of a strip of collated wire nails, which have been collated in a manner according to this invention; Figure 2, on a slightly enlarged scale compared to Figure 1, is a sectional view taken through one of the wire nails, along line 2--2 of Figure 1, in a direction indicated by arrows; Figure 3 is a sectional view taken through the same nail, along line 3--3 of Figure 2, in a direction indicated by arrows; Figure 4 is an elevational view of the strip shown in Figure 1. Portions of the shanks of the wire nails, between the tips of such nails and two collating tapes, have been omitted; Figure 5 is a fragmentary, elevational view of one of the wire nails and the collating tapes, as taken from one side of the strip shown in Figures 1 and 4; Figure 6 is a sectional view taken through the strip, along line 6--6 of Figure 4, in a direction indicated by arrows; Figure 7, on a smaller scale, is a semi-diagrammatic, perspective view of a novel combination of nail-conveying and keyway-engaging mechanisms, in a machine for collating wire nails in a manner constituting a preferred mode for carrying out this invention; Figure 8 is a fragmentary, plan view of certain elements of the novel combination coacting with a group of such nails; Figure 9 is a fragmentary, elevational view of certain elements of the novel combination coacting with a group of such nails; and, Figure 10 is a fragmentary, end view of certain elements of the novel combination coacting with one such nail. A preferred embodiment of the improved combination provided by this invention and a preferred mode for carrying out the improved method provided by this invention are described below. As mentioned above, a strip of collated wire nails wherein each nail has a novel configuration including a radially offset, circular head and a shank having a keyway, which is located between the head and a pointed tip of the shank, is disclosed in the copending application identified above. A strip S of collated wire nails 10, each having the novel configuration noted above, is shown in Figures 1, 4, 5, and 6. The wire nails 10 are collated in a manner according to this invention. An exemplary nail 10 is described below. The nail 10 has a unique head 12, by which the nail 10 is distinguished from wire nails known heretofore, and other unique features. The nail 10 has a shank 14 integral with the head 12. The shank 14 defines an axis and has a tip 16. Preferably, as shown, the tip 16 conforms to the unique tip disclosed in Sygnator US-A-4,927,309, Alternatively, the shank 12 may have a conventional tip (not shown) having four facets. The head 12 has a circumferential edge 20 conforming to a complete circle and defining an axis in radially offset relation to the axis of the shank 14. Thus, in other words, the head 12 is radially offset in one direction relative to the shank 14. The head 12 defines a complete circle when viewed axially. The head 12, at a top portion, has two planar surfaces spaced from the shank 14, namely a first surface 22 and a second surface 24. The second surface 24 intersects the first surface 22 along a crest 26, which extends across the head 12, which has a small radius approximately 2.4mm (approximately 0.093 inch) and which is shorter than a diameter of the complete circle defined by the circumferential edge 20 of the head 12. The first surface 22 is oriented at an obtuse, included angle of about 168° relative to the second surface 24 and the second surface 24 is oriented at a right angle relative to the axis of the shank 14. The shank 14 is formed with a keyway 28 defining a flat surface 30, which is parallel to the axis of the shank 14 and to the direction of radial offset of the head 12 relative to the shank 14, and which is spaced axially from the head 12. The flat surface 30 conforms to a parallelogram having two longer, axially extending sides 32, 34, and two shorter, transversely extending sides 36, 38. These longer and shorter sides define two acute angles (e.g. about 34° each) and two obtuse angles (e.g. about 146° each) as shown. The keyway 28 is bounded by two flat surfaces 40, 42, which respectively intersect the flat surface 30 at the shorter sides 36, 38. The flat surface 40 is bounded by the side 36 and by a curved edge 44 and is oriented at an acute angle (e.g. about 45°) relative to the axis of the shank 14 and at an obtuse angle (e.g. about 135°) relative to the flat surface 30. The flat surface 42 is bounded by the side 38 and by a curved edge 46 and is oriented at an acute angle (e.g. about 45°) relative to the axis of the shank 14, at an obtuse angle (e.g., about 135°) relative to the flat surface 30, and at a right angle relative to the flat surface 40. The keyway 28 provides a datum for orienting the collated nails 10 with their shanks 14 in parallel relation to one another and with their heads 12 offset in a common direction relative to their shanks 14. At a lower portion, the head 12 of the nail 10 has a cavity 50, which is bordered by an annular rib 52 except where the shank 14 adjoins the head 12. As contrasted with a head (not shown) that is planar at its lower portion, the head 12 tends to be less prone to separating from the shank 14, particularly if the head 12 is struck at a localized region spaced from the shank 14, e.g. where suggested by a wide arrow in Figure 2. At the annular rib 52, the lower portion of the head 12 defines a tangent plane, which is oriented at a right angle relative to the axis of the head 12, and at a right angle relative to the shank 14. As shown in Figures 4, 5, and 6, the collated nails 10 of the strip S are collated via conventional collating tapes 62, 64, applied adhesively to opposite sides of the shanks 14 of the collated nails 10, in parallel relation to the flat surfaces 30 defined by the keyways 28 on the shanks 14 of the collated nails 10. The collating tapes 62, 64, are oriented at an acute angle (e.g. about 36°) relative to a plane normal to the axes of the shanks 14 of the collated nails 10. The nails 10 in the strip S are collated in such manner that their shanks 14 are oriented in closely spaced, parallel relation to one another, whereby their shanks 14 may be nearly contiguous to one another. The nails 10 in the strip S are collated in such manner that their heads 12 are offset in a common direction relative to their shanks 14 and in such manner that, except at one end of the strip S (its right end in Figure 3) where the nail 10 to be first or next driven is located, the head 12 of each nail 10 overlies the head 12 of another nail 10. Collectively, as shown, the keyways 28 on the shanks 14 of the collated nails 10 define an open channel 66, which extends along the strip S . As disclosed in the copending application noted above, the open channel 66 is useful in guiding the strip S through a nail-feeding magazine (not shown) to a pneumatically powered or combustion-powered nail-driving tool (not shown) of a known type. As shown in Figures 7, 8, and 9, the nails 10 are collated in a machine 100 comprising a preferred embodiment of a novel combination of a nail-conveying mechanism 102 and a keyway-engaging mechanism 104. The nail-conveying mechanism 102 is similar to the nail-conveying mechanism of a nail-collating machine known heretofore. The nail-conveying mechanism 102 comprises two endless bands 110, 112, which are similar to bandsaw blades, and which have respective portions 114, 116, movable in parallel relation to each other, as has an upper edge 118, which is formed with nail shank-receiving pockets 120. The endless band 112 has an upper edge 122, which is formed with nail shank-receiving pockets 124. In the machine 100, as in a nail-collating machine known heretofore, the nails 10 are loaded onto the band portions 114, 116, in such manner that the shank 14 of each nail 10 rests in one of the pockets 120 of the band portion 114 and in one of the pockets 124 of the band portion 116, at a desired angle (e.g. about 56°) relative to each of the band portions 114, 116, as shown in plan view in Figure 8. Thus, the shanks 14 are disposed in closely spaced, parallel relation to one another. Also, the axes of the shanks 14 define a plane, which may be substantially horizontal, as shown. Moreover, the tips 16 of the shanks 14 of the nails 10 tend to be generally aligned with one another. However, as indicated by a bracket A in Figure 7, the tips 16 may prove to be significantly misaligned. As explained above, it is undesirable for the tips 16 to be significantly misaligned. The keyway-engaging mechanism 104 comprises a base 130, a pedestal 132 welded to the base 130, an arm 134 mounted to the pedestal 132 so as to be pivotally movable about a pin 136, and a wheel 138 mounted to the arm 134 so as to be freely rotatable about a spindle 140. The pin 136 is mounted to the pedestal 132, above the base 130. The spindle 140 is mounted to the arm 134, away from the pin 136. A threaded stud 142 is threaded into a threaded socket (not shown) in the base 130, extends freely through an aperture 144 extending through the arm 134, and is secured to the base 130 by a threaded nut 146. A coiled spring 150 is disposed around the threaded stud 142, between the base 130 and a washer 152 on the threaded stud 142. The washer 152 and the coiled spring 150 are retained on the threaded stud 142 by two threaded nuts 154, 156, which are threaded onto the threaded stud 142 in such manner that the coiled spring 150 is compressed between the washer 152 and the base 130. Thus, the coiled spring 150 biases the arm 134 in a counterclockwise sense, as shown, so as to bias the wheel 138 downwardly toward an operative position. An adjustable stop 160 having a threaded shank 162 is threaded into a threaded socket (not shown) in the base 130 to a desired depth, which is adjustable to accommodate nail shanks of different dimensions, and is secured to the base 130 by a threaded unit 164. The adjustable stop 160 limits pivotal movement of the arm 134 in a counterclockwise sense, as shown, so as to limit downward movement of the wheel 134 toward its operative position. A camming member 170 having a camming surface 172 is mounted on the base 130 by two fasteners 174 (See Figure 7) having threaded shanks (not shown) each passing through a washer 176, through an elongate slot 178 (one shown) in the camming member 170, into a threaded socket (not shown) in the base 130. The camming member 170 is disposed near the band portion 114 so that the camming surface 172 is adapted to cam the shank 14 of each nail 10 out of the pockets 120, toward the wheel 138, in such manner that such nail 10 is rotatable on the camming surface 172, about the axis of the shank 14 of such nail 10. It is contemplated that a similar camming member (not shown) may be also disposed near the band portion 116. In its operative position, the wheel 138 is adapted to fit into the keyway 28 of each nail 10 and to engage the flat surface 30 defined by such keyway 28, between the end surfaces 40, 42, defined thereby. As each nail 10 is conveyed through an orienting zone, in which the wheel 138 coacts with the camming member 170, the wheel 138 engages the shank 14 of such nail 10 whereupon the wheel 138 may roll on such shank 14 in such manner that the arm 134 is pivoted slightly in a clockwise sense, as shown. Thereupon, the wheel 138 rotates such nail 10 on the camming surface 172 of the camming member 170, about the axis of the shank 14 of such nail 10, to such extent as may be then necessary to cause the keyway 28 of such nail 10 and the keyways 28 of the other nails 10 conveyed through the orienting zone to be similarly oriented in a rotational sense. Preferably, as shown, the flat surfaces 30 of such keyways 28 define a plane, which faces upwardly and is parallel to the plane defined by the axes of the shanks 14. The stop 160 is adjusted so as to limit pivotal movement of the arm 134, as biased by the coiled spring 150, to a selected limit. The limit is selected so that the wheel 138 is tangent to the flat surface 30 of the nail 10 being engaged by the wheel 138 and engaging a crest of the surface 172 when such surface 30 is parallel to the plane defined by the axes of the shanks 14. Thus, when the selected limit is reached, the wheel 130 cannot rotate each nail 10 beyond a rotated position where the flat surface 30 of the keyway 28 of such nail 10 faces upwardly and coincides with the plane defined by those surfaces 30. In its operative position, the wheel 138 is adapted to fit between the end surfaces 40, 42, defined by the keyway 28 of each nail 10. Moreover, the wheel 138 is adapted to bear against one of those surfaces 40, 42, as such nail 10 is conveyed through the orienting zone, so as to cam the shank 14 of such nail 10 axially to such extent as may be then necessary for the tip 16 of the shank 14 of such nail 10 and the tips 16 of the shanks 14 of the other nails 10 conveyed through the orienting zone to be precisely aligned, as indicated by a bracket B in Figure 7. In most if not all instances, if the wheel 138 engages one of those surfaces 40, 42, the wheel 138 engages the surface 40 nearer to the head 12 of the nail 10. As shown fragmentarily in Figure 7, a keyway-engaging mechanism 104' similar to the keyway-engaging mechanism 104 may be also provided in the machine 100, at a location close to the location (not shown) where two collating tapes, such as the collating tapes 62, 64, shown in Figure 6, or other collating media (not shown) are applied in a known manner. The keyway-engaging mechanism 104' corrects for such minor misorientation of each nail 10, either in a rotational sense or in an axial sense, as may be due to vibrations of the endless bands 110, 112, or to similar causes. Accordingly, in a preferred mode for carrying out the novel method provided by this invention via the machine 100, the nails 10 are conveyed through the orienting zone in such manner that the shanks 14 are disposed in closely spaced, parallel relation to one another. Moreover, the axes of the shanks 14 define a plane, and the tips 16 tend to be generally aligned with one another. Additionally, the nails 10 are oriented as the nails 10 are conveyed through the orienting zone by employing the wheel 138 to engage the flat surface 30 defined by the keyway 28 of each nail 10, between the end surfaces 40, 42, defined by such keyway 28. The wheel 138 rotates such nail 10 to such extent as may be then necessary to cause such flat surface 30 and the flat surfaces 30 defined by the keyways 28 of the other nails 10 conveyed through the orienting zone to be similarly oriented in a rotational sense and to define a plane, which is parallel to the plane defined by the axes of the shanks 14 of the nails 10. The wheel 138 can engage one of the end surfaces 40, 42, defined thereby so as to cam the shank 14 of such nail 10 axially to such extent as may be then necessary to cause the tip 16 of the shank 14 of each nail 10 and the tips 16 of the shanks 14 of the other nails 10 conveyed through the orienting zone to be precisely aligned with one another in an axial sense. Thus, the nails 10 conveyed through the orienting zone are aligned similarly in an axial sense. Herein, all references to precise alignment are subject to normal tolerances involved in nail manufacture, and to normal tolerances involved in machine design and machine operation.

Claims: A machine (100) for collating similar wire nails (10) wherein each nail (10) has a head (12) and a shank (14), and wherein the shank has an axis, a tip (16) spaced axially from the head (12), and a keyway (28) located between the head (12) and the tip (16), the machine including: (a) conveying means (102) for conveying the nails (10) through an orienting zone in such manner that the shanks (14) of the nails (10) are disposed in parallel relation to one another, that the axes of the shanks (14) of the nails define a plane, and that the tips (16) of the shanks (14) of the nails (10) are generally aligned with one another, and, (b) engaging means (104) for engaging the keyways (28) as the nails (10) are conveyed through the orienting zone and for rotating each nail (10) about the axis of its shank as in the rotational sense necessary to provide a similar orientation for the keyways (28) of all the nails (10) conveyed through the orienting zone, the engaging means (104) being disengaged from the keyways (28) after orientating them. A machine according to claim 1, wherein the engaging means (104) comprises a wheel (138), which is arranged to fit removably into the keyway (28) of the shank (14) of each nail (10) and to engage a flat surface defined by the keyway (28) of the shank (14) of the nail (10). A machine according to claim 2, in which the engaging means (104) also includes means (170) for camming at least part of the shank (14) of each nail toward the wheel (138), the nail is conveyed past the wheel (138), so that the nail is individually rotated, on the camming means (170). A machine according to claim 2 or 3, wherein the wheel (138) is freely rotatable about its axis, the wheel (138) being movable towards and away from an operative position and being biased toward the operative position, and wherein the wheel (138) in its operative position is adapted to fit between end surfaces (36,38) defined by the keyway (28) on the shank (14) of each nail (10) and to engage one of the end surfaces (36,38) to cam the shank (14) of each nail (10) axially to cause the tip (16) of the shank (14) of the nails (10) conveyed through the orienting zone to be precisely aligned with one another in an axial sense. A method for collating similar wire nails (10) wherein each nail has a head (12) and a shank (14), with an axis, a tip (16) spaced axially from the head (12), and a keyway (28) located between the head (12) and the tip (16), the method comprising steps of (a) conveying the nails (10) through an orienting zone in such manner that the shanks (14) of the nails (10) are disposed in parallel relation to one another, that the axes of the shanks (14) of the nails (10) define a plane, and that the tips (16) of the shanks (14) of the nails (10) tend to be generally aligned with one another, and, (b) orienting the nails (10) as the nails are conveyed through an orienting zone by (i) engaging the keyway (28) of the shank (14) of each nail (10) and, (ii) rotating each nail (10) as necessary to cause the keyway (28) of the shank (14) of each nail (10) conveyed through the orienting zone to be similarly oriented in a rotational sense.

Inventors: BERGSTROM DONALD E, GABRIEL WILLIAM L, MEDITZ REINHOLD, SYGNATOR HENRY A, WRIGHT ROBERT W, BERGSTROM, DONALD E., GABRIEL, WILLIAM L., MEDITZ, REINHOLD, SYGNATOR, HENRY A., WRIGHT, ROBERT W.
Applicants: ILLINOIS TOOL WORKS, ILLINOIS TOOL WORKS INC.
Application year: 1991
Main classification: B65B15
IPC codes: B21G3, B65D85, B65B15, F16B15