Abstract:
An apparatus is provided for packaging fasteners such as screws, that is to be worn by a user. The packaging device includes a tray with a plurality of wells, each well accommodating the shank of a respective fastener. An attachment device is used for securing a tray to a user. In a preferred dispensing method, fasteners may be dispensed from the tray using a magnetized screwdriver bit which is placed over the head of the fastener, followed by withdrawing the screwdriver bit with the fastener magnetically attached.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a device for packaging fasteners, and in particular, to a device to be worn by a user for packaging and dispensing fasteners. 
     Steel metal ducts are used in the heating, ventilating, and air conditioning (“HVAC”) industry. Adjacent sections of the metal ducts are typically connected to each other by hex-head, self-tapping screws with integral washers, e.g., “tech screws”. In the HVAC industry, the task of connecting adjacent sections of a sheet metal duct normally occurs on lifts and in confined spaces. 
     A typical HVAC insulation will require an HVAC worker to insert anywhere from two to ten screws per duct joint. The conventional method used by the HVAC worker involves the use of a screwdriver or drill with a magnetic hex socket and an apron full of tech screws. The HVAC worker removes an individual tech screw from his apron and then, by hand, places the screw into the hex socket followed by screwing the tech screw through the sections of the sheet metal duct. This screw installation process is complicated by gloves which are traditionally worn by the HVAC worker. It is estimated that about 30% of the tech screws intended to be inserted into the sheet metal duct sections are dropped and/or lost by the HVAC worker as he or she attempts to hand place the tech screws into the hex socket. 
     One disadvantage with the present method of inserting a tech screw into adjacent sections of sheet metal duct is that the method is laborious, slow and costly. Accordingly, there is a need in the HVAC industry, and other similar industries, for a lightweight, portable system that will increase the productivity of workers and decrease the costs associated with the time consuming manual insertion of tech screws into the hex socket and the cost associated with lost screws. 
     Screw guns with feeding and locating fasteners for insertion into a workpiece are generally known in the art. However, the conventional designs are not practical for HVAC employment as these designs are overly complex and therefore costly. Further, these conventional screw guns tend to be bulky and not easy to use, especially when working in confined spaces such as those associated with HVAC installations. 
     For example, known power operated devices for feeding and locating fasteners, like those disclosed by U.S. Pat. No. 5,031,489 to Young et al. and U.S. Pat. No. 5,015,127 to Hockman, require that a fastener driver be connected to an air supply to power the device and to a hopper or the like in order to continuously feed the driver with fasteners. Such devices limit their application because of their lack of mobility and unwieldiness. Accordingly, such devices are not practical for use in confined spaces, such as when working on a scaffolding or a lift. Similar devices for feeding and locating fasteners have strips which carry the screws and are swingedly suspended from the device, such as disclosed in U.S. Pat. No. 3,910,324 to Nasiatka and U.S. Pat. No. 4,581,964 to Takatsuru. These devices are also not practical for use in confined spaces because of the added weight and awkwardness associated with the devices. 
     U.S. Pat. No. 4,936,169 to Parsons discloses a portable device for positioning and inserting fasteners wherein an applicator is positioned adjacent to a positioning mechanism containing a rotatable cylinder which includes a plurality of chambers for housing fasteners. However, the Parsons device has a number of drawbacks including that it is bulky, the operator is required to align a screw with the applicator by hand before he can insert a second screw into a workpiece, and the screw is not readily visible prior to insertion. 
     My application Ser. No. 09/877,036 filed Jun. 11, 2001 discloses an improved screw gun for inserting fasteners, including tech screws. The disclosed screw gun and method provides a substantial improvement over the prior art. However, if this device is not used, there remains a need in the industry for a device for carrying fasteners. 
     Additionally, the prior art also generally discloses various devices for holding screws on other objects including U.S. Pat. Nos. 2,012,615; 3,321,074; 3,342,327; 3,718,252; 3,885,669; 4,019,631; 4,027,417; 4,151,912; 4,930,630; 4,955,476; 5,509,728; 5,522,687; and 5,578,760. However, these devices have certain drawbacks and/or are not applicable to the present invention. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with the present invention, a device is provided for packaging fasteners which is worn by a user. The device includes a plurality of holes in which fasteners such as screws may be disposed and is to be worn by a user such as on the user&#39;s wrist or attached to a belt worn by the user. The screws are dispensed from the device by a user placing a magnetized screwdriver bit e.g., a hex socket, on the head of the screw in the device and then removing the screw from the device. In the preferred embodiment, the screw is removed from the device by rotating the bit and pulling the screwdriver with the screw attached magnetically away from the device. 
     According to one aspect of the present invention, an apparatus is provided for packaging fasteners which is to be worn by a user. The apparatus includes a tray having a plurality of wells. Each well accommodates a shank of a respective fastener. The tray has a first side opposite a second side. An attachment device is provided for securing the tray to the user. 
     According to another aspect of the present invention, an apparatus is provided for packaging fasteners which may be worn by a user or located near the user. The apparatus includes a tray having a plurality of wells. Each well accommodates a shank of a respective fastener. The tray has a first side opposite a second side, each side having a plurality of wells to provide an apparatus to package a number of fasteners. The apparatus is preferably a plastic molded shell. The shanks of the fasteners are inserted into the wells and there is clearance between the shanks and the wells. The fasteners are to be maintained in the apparatus by an adhesive on the surface of the tray which will adhere the head of the fastener (the washer portion in the case of a tech screw) to the tray. The fastener may be removed from the tray by placing the bit of a screwdriver over the head of the fastener and rotating the bit to break the adhesive seal and withdraw the fastener. An attachment device may be provided for securing the tray to the user, although the apparatus may be used without being secured to the user. 
     According to another aspect of the present invention, a system is provided for packaging fasteners. The system includes a plurality of fasteners, each fastener having a shank with a shank diameter. The system also includes a tray having a plurality of wells. Each well accommodates the shank of a respective fastener. The tray has a first side opposite a second side. An attachment device is provided for securing the tray to the user. 
     According to yet another aspect of the present invention, a method is provided for dispensing fasteners. The method comprises attaching a tray to a user in which the tray has a plurality of fasteners, each disposed in a respective one of a plurality of wells. A magnetized screwdriver bit is placed over the fastener. The screwdriver bit with a magnetically attached fastener is then withdrawn from the tray. 
     One feature of the present invention relates to a packaging device that is worn by a user for dispensing screws. Further, the packaging device allows a user to dispense, i.e., remove, individual screws from a tray by placing the bit, e.g., a hex socket, of a screwdriver on the head of the screw in the tray followed by withdrawing the screwdriver and attached screw from the tray. Consequently, an advantage of the present invention is provided by a user not having to manually insert a screw into the screwdriver bit by fishing one&#39;s hand into an apron full of screws and then hand placing, i.e., inserting, the screw into the screwdriver bit. 
     An additional advantage of the present system is a decrease in the costs associated with the installation of HVAC systems. The decrease in costs is provided by a decrease in installation time associated with a worker not having to manually hand place screws into a screwdriver bit, and the costs associated with not dropping and losing screws which typically occurs when manually hand placing screws into a screwdriver bit. 
     Further features and advantages of the present invention will be set forth in, or apparent from, the detailed description of preferred embodiments thereof which follows. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 is a front, side and top perspective view of a device for packaging fasteners that is to be worn by a user in accordance with the present invention; 
     FIG. 2 is a front, side and top perspective view of the packaging device of FIG. 1 attached to a wrist of the user schematically showing the removal of a fastener from the device using a drill with screwdriver bit; 
     FIG. 3 is an exploded top view with a portion broken-away of the device of FIG. 1; 
     FIG. 4 is a front, side and top perspective view of a metal frame of the device of FIG. 1; 
     FIG. 5 is a plan view of a strap for attaching the packaging device to a user of the device of FIG. 1; 
     FIG. 6 is a side view of the strap of FIG. 5; 
     FIG. 7 is a front, side and top perspective view with a portion broken-away of an alternative packing device, according to the present invention; and 
     FIG. 8 a  is a front, side and bottom perspective view of a plastic tray and FIG. 8 b  is a cross-sectional view with a portion broken-away of the plastic tray of FIG. 8 a . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIGS. 1-3, a fastener packaging device  10  includes a tray  12 , a frame  14 , and a strap  16 . Tray  12  comprises a plurality of holes, i.e., wells  14   a , formed in a side  20 . Advantageously, a second plurality of wells  18   b  are formed in an opposing side  22 , with wells  18   b  being offset from wells  18   a  in side  20  (best shown in FIG.  3 ). 
     Tray  12  may be composed of a number of suitable materials which include plastic and styrofoam. If tray  12  is composed of styrofoam, the plurality of wells  18   a ,  18   b  may be formed using a hot wire to provide smooth and stronger wells  18 . 
     The plurality of wells  18   a ,  18   b  accommodate a plurality of fasteners such as hex screws  24   a ,  24   b , respectively. Hex screws  24  have a hexagonal head  26  and a shank  28 . The diameter of wells  18  may be dimensioned to be slightly larger than that of shank  28 , equal to that of shank  28 , or slightly smaller than that of shank  28 . If the well diameter is slightly smaller than the diameter of shank  28 , screw  24  will be held in place in tray  12  by a tight fitting relationship. 
     Alternatively, in a preferred arrangement, wells  18  are slightly larger than the diameter of the shank  28  so that hex screws  24  can be rapidly placed into tray  12 . Advantageously, a coating of pressure sensitive adhesive material  30  is disposed on the surface of sides  20 ,  22  prior to insertion of screws  24  in wells  18 . As a result, screws  24  will be held in tray  12  as a result of adhesive  30  which will dry after screws  24  are inserted. Screws  24  are held in tray  12  by an adhesive force sufficient to keep screws  24  in tray  12  yet allow screws  24  to be readily removed from tray  12  via extraction using a screwdriver with magnetic bit as discussed below. 
     Referring to FIGS. 1-3, along with FIG. 4, tray  12  includes two tracks  32 ,  34  on opposing side walls  36 ,  38 , respectively. Frame  14  is composed of a suitable material such as metal and includes two opposing rails  40 ,  42  complimentary to tracks  32 ,  34 , respectively, thereby allowing frame  14  to slidingly engage with tracks  32 ,  34  respectively as denoted by arrow  44  (FIG.  3 ). Rails  41 ,  43  disposed perpendicular to respective rails  40 ,  42  abut side  45  of tray  12  thereby preventing tray  12  from sliding therebeyond. 
     Referring now to FIGS. 5 and 6, along with FIGS. 2 and 4, strap  16  is attached to frame  14  by a loop  46  which encircles rail  48  extending between rails  41 ,  43 . Strap  16  also includes complimentary Velcro strips, namely a piece of fabric of small hooks  49  and a corresponding fabric of small loops  50 . Strap  16  provides means to removeably attach fastener packaging device  10  to a user such as at a wrist  52 . To accomplish this, a strap end  54  is wrapped around wrist  52  and threaded around rail  56  which extends parallel to rail  48 . Strap end  54  is pulled so that fastener packing device  10  fits securely to wrist  52  and Velcro strips  49 ,  50  are the mated with one another to hold tray  12  in place. 
     Referring now specifically to FIGS. 2 and 3, screws  24  are dispensed from tray  12  using a drill  60  with a magnetic bit  62  which has a socket shape to accommodate and subsequently drive hexagonal head  26 . The user places screwdriver bit  62  on one head  26 , and then with a slight turning action of screwdriver bit  62 , screw  24  is withdrawn from tray  12 . Depending on how tight the fit is between well  18  and shank  28  of screw  24  as well as the strength of adhesive  30 , it may not be necessary to use a slight turning action to remove screw  24  from well  18 . After all of screws  18   a  have been removed from tray  12 , the user can slide tray  12  from frame  14  in a direction opposite to arrow  44  (FIG.  3 ). The user then rotates tray  12  such that side  22  faces away from wrist  52 , and slides tray  12  back on frame  14  with the plurality of screws  18   b  now accessible for insertion into screwdriver bit  62 . 
     Referring now to FIG. 7, in an alternative embodiment, rather than attaching the fastener packaging device to the wrist of a user, a fastener packing device  710  is attached to a belt  770  worn by a user. A frame  716  includes opposing rails  740 ,  742  which are adapted to slidingly engage with the complementary tracks  32 ,  34  respectively, of tray  12 . Rails  743  and an opposite rail (not shown) abut the surface of side  45  of tray  12  to prevent tray  12  from sliding therepast. A strap  772  is looped around belt  770  and wrapped around an end of a shaft  774  pivotally engaged with frame  716  for free movement therewith. Strap  772  thus provides means for attaching packaging device  710  to the user. 
     In an alternative embodiment, rather than a styrofoam tray such as tray  12 , tray  812  is formed from two thin plastic shells,  882 ,  884 , joined with one another (FIGS. 8 a  and  8   b . An internal plastic web  878  formed from shells  882 ,  884 , defines wells  818 . Wells  818  accommodate shafts  828  of screws  824 . 
     A plurality of bores  886  with sidewall surfaces  888 , respectively, are formed in side surfaces  820 ,  822 . Each bore  886  leads to, and is associated with, the entrance of a respective well  818 . The diameter of bores  886  is larger than the diameter of wells  818  and is sufficient to accommodate the diameter of heads  26  of screws  24 . Sidewall surfaces  888  of bores  886  help guide screwdriver bit  62  (FIG. 2) into place over heads  26  of screws  24 , during the extraction of screws  24  from tray  812  using the extraction method described above with reference to tray  12 . 
     A pressure sensitive adhesive  830  is applied to the surface of tray  812  at the base of bores  886  which surrounds wells  818 . When screws  24  are inserted into tray  812 , adhesive  830  will come in contact with heads  26  of screws  24 , thereby holding screws  24  in tray  812 . 
     Tray  812  may be used alone or attached to the user by means as shown in FIGS. 1-7 and described above. 
     Although the invention has been described above in relation to preferred embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these preferred embodiments without departing from the scope and spirit of the invention.