Abstract:
A device and method for driving a first prong of a multi-pronged fastener into a first board and bending a second prong angularly to give it a desired orientation with respect to the first prong. The invention involves an alignment structure, a first driver for driving the fastener into the first board, and a second driver for impacting and bending the second prong angularly with respect to the first prong.

Description:
TECHNICAL FIELD 
     This invention relates to carpentry, building, and construction, and more particularly to an apparatus and method for driving multi-pronged fasteners into two or more boards. 
     BACKGROUND 
     My U.S. Pat. Nos. 5,684,324 and 5,927,923 describe two-and three-pronged fasteners that can be used to join adjacent deck boards to each other and/or to a joist below them while not being visible from the surface. My U.S. patent application Ser. No. 09/271,962, filed Mar. 18, 1999, now U.S. Pat. No. 6,071,054 describes a three-prong fastener that is particularly useful in securing two deck boards to each other and to an underlying joist when the deck boards are oriented diagonally relative to the joists. This fastener is shown in FIG. 1 hereto, and is shown securing adjacent deck boards to each other in FIGS. 2 and 3. 
     FIG. 1 shows three-pronged fastener  500  with forward-facing prongs  514  and  516  and rearward-facing prong  515 . FIG. 2 shows several such fasteners joining deck boards  508 ,  510  to each other and to joists  509 ,  511 ,  513 , where deck boards  510  are oriented diagonally to joists  509 ,  511 ,  513 . As shown in FIG. 3, forward facing prongs  514 ,  516  are first driven into deck board  508  and joist  513 , respectively, and deck board  510  is then hammered against rearward-facing prong  515  to drive the latter into deck board  510 . 
     Staple driving devices are used in carpentry, as well as building and construction work. In such uses, both points of a staple are typically driven into the same board or boards. My U.S. patent application Ser. No. 09/137,012, filed Aug. 20, 1998, now U.S. Pat. No. 6,098,865 describes a staple driving device that can be used to quickly, easily, and securely drive a two-pointed staple fastener into a deck board and a joist below it, such that the staple is not visible from above the deck. This device is shown in FIGS. 4-6 hereto. The staple driving device has alignment structure  10 , driver  12 , staples  14 , magazine  16 , alignment plate  18 , handle  20 , and hammer  22 . 
     Alignment structure  10  has first board abutment surface  24  and second board abutment surface  26  which abut respectively first board surface  28  of first board  30  and second board surface  32  of second board  34 . First board  30  is above second board  34 . First board  30  and second board  34  are oriented to each other so as to form included angle  36 , at junction  38  (indicated in FIG. 4) of less than 180°, e.g., approximately 90°, in FIGS. 4-6. Alignment structure  10  defines staple delivery channel  44 . When abutment surfaces  24 ,  26  abut board surfaces  28 ,  32 , staple delivery channel  44  is near junction  38 . As seen in FIG. 5, the device is positioned to drive first point  40  of staple  14  into first board surface  28  and second point  42  of staple  14  into second board surface  32 . Magazine  16  is fitted partially within alignment structure  10 . Magazine  16  defines staple supply channel  48  which joins staple delivery channel  44 , so that staples  14  which are retained within staple supply channel  48  may pass into staple delivery channel  44 . Driver  12  has striking portion  50  with broadened striking head  52 , stock  54 , and driving portion  56 . Driver  12  is slidably fitted within alignment structure  10 . Driving portion  56  is sized to be capable of sliding within staple delivery channel  44 . Alignment plate  18  is fastened to alignment structure  10  so that it can abut third board surface  64  of first board  30 . The device has handle  20 , having grips  66  fastened to alignment structure  10 . As shown in FIG. 6, the device has two internal springs  68  disposed within driving channel  62  so that, when driver  12  is driven forward, by a hammer blow delivered to striking head  52 , for example, internal springs  68  are compressed between stock  54  of driver  12  and compression surface  70  that bounds driving channel  62  within alignment structure  10 . 
     SUMMARY 
     The invention, in general, features a device for driving a first prong of a multi-pronged fastener into an adjacent board and bending a second fastener prong, so that it has a desired orientation with respect to the board. The device includes an alignment structure, a first driver, and a second driver. The alignment structure has a first abutment surface for abutting one of the boards. The alignment structure defines a fastener delivery channel that ends near the junction of the boards. The first and second drivers are movably connected to the alignment structure. The first driver is positioned so as to be able to contact the fastener and to drive the first prong into one of the boards. The second driver is positioned so as to be able to contact the second prong and bend it angularly with respect to the first prong. 
     In operation, the abutment surface of the alignment structure is brought into contact with one of the boards. The first driver is activated, so that it impacts a fastener situated in the fastener delivery channel and drives the first prong into one of the boards. The second driver is also activated so that it impacts the second prong and bends it angularly with respect to the first prong. 
     Preferred embodiments are adapted to drive a three-pronged fastener, so as to join a first deck board to a joist beneath it, where the first deck board and joist are oriented at right angles to each other, and to bend a rearward-facing prong, so that it projects from the first deck board at approximately a 90° angle, so that the rearward-facing prong is positioned to be driven into a second deck board. Alternately, the device may be adapted to drive fasteners and bend prongs at any desired angle. 
     Preferred embodiments include a third driver for bending the third prong, which extends from the board, in an alternate direction. Embodiments with a third driver may include a mechanism for detecting the orientation of the upper board and selectively engaging either the second or third driver for bending the third prong in either of two directions. Mechanical catches, levers, linkages, wedges, rollers, springs, pivots, as well as electrical, electromagnetic, magnetic, hydraulic, or pneumatic devices may be used to selectively engage either the second or third driver. The second and third drivers may be activated, so as to impact and bend the third prong, by the motion of elements connected to the first driver. In other embodiments, the second or third driver may be connected to the first driver, so that all drivers are activated simultaneously. 
     Preferred embodiments further include an alignment plate, attached to the alignment structure. The alignment plate may be spaced relative to the fasteners to align the prongs for driving them into boards, when the alignment plate abuts one of the boards. Preferred embodiments further also include a magazine containing a plurality of multi-pronged fasteners to be driven successively into boards, a handle for grasping the device, or springs to return the drivers and other components to their initial positions after the fasteners are driven and/or bent. 
     The force required to activate the drivers may be supplied manually, or by a pneumatic, hydraulic, elastic, electrical, electromagnetic, electrostatic, magnetic, combustion, or explosive device. For example, the force may be provided by a hammer blow, gunpowder, a spring, an electric motor, an internal combustion engine, or a compressed air device. The force required to activate the drivers may be supplied from an offset orientation, for example, with cams, rollers, or linkages. 
     Embodiments of the invention may include one or more of the following advantages. The device may be used to drive different points of a multi-pronged fastener into one or more boards and to bend another prong in a desired direction. The device may facilitate connecting boards in a way that conceals the fasteners. The device may reduce workers&#39; time in building, construction, or carpentry work. The device may be adapted to hold a plurality of fasteners. Fasteners may be driven and bent in one continuous operation. One source may provide the energy required to drive and bend respective prongs of the fasteners. The device may be used with fasteners that have any cross-sectional profile, for example, round, circular, square, or rectangular. The fasteners may be made of a metal, such as steel, copper, aluminum, a metal alloy, or any suitable material. The device can be used with boards of wood, foam, plastic, fiberglass, or any suitable material. 
     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
    
    
     DESCRIPTION OF DRAWINGS 
     FIG. 1 shows a three-pointed fastener for securing boards to each other. 
     FIG. 2 shows a top view of FIG. 1 fasteners securing adjacent floorboards to ajoist. 
     FIG. 3 is a partial sectional view, taken at III—III of FIG. 2, showing a fastener of FIG. 1 securing adjacent floorboards to ajoist. 
     FIG. 4 is a perspective view of a two-pointed staple driving device. 
     FIG. 5 is a side vertical sectional view of the staple driving device of FIG.  4 . 
     FIG. 6 is a top horizontal sectional view of the staple driving device of FIG.  4 . 
     FIG. 7 is a top horizontal sectional view of a fastener driving device. 
     FIG. 8 is a top horizontal sectional view of the fastener driving device of FIG. 7 with a bent prong. 
     FIG. 9 is a front view of the fastener driving device of FIG.  7 . 
     FIG. 10 is a side vertical sectional view of an alternate fastener driving device. 
     FIG. 11 is a side vertical sectional view of another alternate fastener driving device. 
     FIG. 12 is a top horizontal sectional view of the fastener driving device of FIG.  11 . 
     FIG. 13 is a front vertical sectional view of the fastener driving device of FIG.  11 . 
     FIG. 14 is a top horizontal sectional view of a fastener driving device. 
     FIG. 15 is a top horizontal sectional view of a fastener driving device. 
     FIG. 16 is a perspective view of an alternate configuration for first and second drivers for a fastener driving device. 
     FIG. 17 is a perspective view of an alternate configuration for first, second, and third drivers for a fastener driving device. 
    
    
     Like reference symbols in the various drawings indicate like elements. 
     DETAILED DESCRIPTION 
     Referring to FIGS. 7-9, there is shown a fastener driving device employing alignment structure  710 , first driver  712 , fasteners  714 , magazine  716 , second driver  720 , and third driver  721 . 
     Alignment structure  710  has first abutment surface  716  and second abutment surface  717 . Abutment surfaces  716 ,  717  are flat surfaces oriented at an angle to each other that give alignment structure  710  a wedge shape. As seen in FIGS. 7-9, alignment structure  710  is positioned at junction  738  of first board  730  and second board  734 , so that first abutment surface  716  rests against first board  730  and second abutment surface  717  rests against second board  734 . Board  730  is a deck board, and board  734  is a supporting joist thereunder. 
     The structure and operation of alignment structure  710 , first driver  712 , and alignment plate  718  are similar to the corresponding elements of the staple driving device described in my U.S. patent application Ser. No. 09/137,012, filed Aug. 20, 1998, which is incorporated herein by reference. 
     Driver  712  is slidably connected to alignment structure  710  and is capable of moving in fastener delivery channel  756  toward junction  738  so as to contact fastener  714  and drive its two parallel, forward-facing prongs into boards  730 ,  734 . Second and third drivers  720 ,  721  (shown diagrammatically in FIG. 7) are also slidably connected to alignment structure  10 . Second and third drivers  720 ,  721  are capable of moving toward junction  738 . Second driver  720  moves substantially parallel to second abutment surface  717  and third driver  721  moves substantially parallel to first abutment surface  716 . 
     Each of fasteners  714  has rear prong  715 , which is not driven into either of boards  730 ,  734  by first driver  12 . (Fasteners  714  are similar in design to fastener  500  of FIG. 1.) Thus, when fastener  714  has been driven into boards  730 ,  734 , rear prong  715  is in position to be contacted by second or third drivers  720 ,  721  and bent. FIG. 8 shows rear prong  715  bent by third driver  721 , so that it is perpendicular to deck board  730  in position to be driven into the next deck board to be added. If the device were placed on the other side of joist  734 , second driver  720  would be used instead. FIG. 9 is a front view of a fastener driving device showing alignment structure  710 , alignment plate  718 , fastener  714 , and relative positions of second and third drivers  720 ,  721  (in phantom). 
     First driver  712  may be activated, so as to drive fastener  714  into boards  730  or  734 , and second or third drivers  720 ,  721  may be activated, so as to move toward and bend rear prong  715 , by any appropriate mechanism or technique. For example, drivers  712 ,  720 ,  721  may be activated manually, such as with a hammer strike, as well as by pneumatic, electromagnetic, magnetic, electrostatic, or explosive devices. The force required to activate drivers may be delivered directly to drivers or through any appropriate mechanism or technique, for example linkages, cams, cables, springs, pivots, or rollers. The forces required to activate either of second or third drivers  720 ,  721  may be provided by the motion of first driver  712  through an appropriate linkage. 
     First, second, and third drivers  712 ,  720 ,  721  are preferably slidingly connected to alignment structure  710 . Each driver may reside in a channel, for example fastener delivery channel  756  (FIGS.  7  and  8 ), defined by alignment structure  710 . Alternately, drivers may be connected to alignment structure  710  by grooves, levers, linkages, rollers, gears, or any other suitable connection. 
     Fastener driving devices according to the invention may be configured so that only one of the second and third drivers  720 ,  721  is engaged so as to move toward and bend rear prong  715 , or so that neither of second and third drivers  720 ,  721  are so engaged. There are many mechanisms or techniques that may be employed for engaging or disengaging second and third drivers. For example, second and third drivers  720 ,  721  may be automatically engaged or disengaged by a trigger or button projecting from abutment surfaces  716 ,  717  that contacts one of boards  730  or  734 , or by an external linkage or button. 
     FIG. 10 shows one approach for selectively engaging only one of second and third drivers  720 ,  721 . The alternate fastener driving device of FIG. 10 has button  885 , which passes through alignment plate  818 , which rests on top of deck board  730 . Button  885  is pivotally connected to lever  886 , post  887 , and engagement rod  889 . Engagement rod  889  passes through alignment plate  818  and alignment structure  810 , and contacts third driver  821 . Bias spring  890  is between lever  886  and alignment plate  818 . Placing alignment plate against first board  830  raises button  885  and causes lever  886  to compress bias spring  890 . The movement of lever  886  also presses engagement rod  889  downward, so that engagement rod  889  pushes third driver  821  into position for engagement. A similar arrangement of a button, lever, and rod is also used to engage driver  820 . 
     FIGS. 11-13 show another alternate fastener driving device in which force delivered to alternate first driver  912  compresses first or second drive springs  932 ,  933 . Energy stored in compressed first or second drive springs  932 ,  933  is used to activate respective second or third drivers  920 ,  921  in order to contact and bend rear prong  715  of fastener  714 . 
     The embodiment of FIGS. 11-13 employs alignment structure  910  that defines first and second abutment surfaces  916 ,  917 , alignment plate  918 , fastener  714  with rear prong  715 , alternate first driver  912 , compression springs  968 , second driver  920 , third driver  921 , first slide member  930 , second slide member  931 , first drive spring  932 , second drive spring  933 , first guide plate  934 , second guide plate  935 , first drive catch  936 , second drive catch  937 , first catch bias spring  938 , second catch bias spring  939 , first engagement button  940 , second engagement button  941 , first lever  942 , second lever  943 , first post  944 , second post  945 , first engagement bias spring  946 , second engagement bias spring  947 , first engagement rod (not shown, as it is obscured by other elements) and second engagement rod  949 . 
     Alternate first driver  912  has spring compression member  951 , which projects upwardly and first and second spring release wedges  952 ,  953 , which project laterally. 
     In the use of the embodiment of FIGS. 11-13 shown, alignment structure  910  is situated at the junction of boards  730 ,  734 , so that alignment plate  918  rests against first board  730 . As shown in FIG. 11, the presence of first board  730  elevates second engagement button  941  so that it slides upward relative to alignment plate  918 . The motion of second engagement button  941  is translated through the pivotal movements of second lever  943  about second post  945  to compress second engagement bias spring  947  and to lower second engagement rod  949 , which is slidably connected to alignment plate  918  and alignment structure  910 . The lowering of second engagement rod  949  causes it to press against second guide plate  935 , which, in turn, lowers second slide member  931 . Second drive spring  933  is disposed between second slide member  931  and third driver  921 . Thus, the elements connected to second engagement button  941  engage third driver  921  for contacting and bending rear prong  715  of fastener  714 . Similar elements, which connect first engagement button  940  to second driver  920 , engage second driver  920  for contacting and bending rear prong  715  when first engagement button  940 , rather than second engagement button  941 , is elevated. 
     With the alignment structure  910  situated at junction  738  between boards  730 ,  734 , the embodiment of FIGS. 11-13 is positioned to drive fastener  714  into boards  730 ,  734  and bend rear prong  715 . Alternate first driver  912  is activated—by a hammer blow, for example, or by any other suitable technique—so that alternate first driver  912  is propelled toward junction  738 , and compression springs  968  are compressed. During its motion toward junction  738 , alternate first driver  912  contacts fastener  714 —thereby driving fastener  714  into boards  730 ,  734 —and spring compression member  951  contacts second slide member  931 —thereby pushing second slide member  931  in the direction of junction  738  and compressing second drive spring  933  between second slide member  931  and third driver  921 . Third driver  921  is slidably connected to alignment structure  910 ; however, third driver  921  is held in place, relative to alignment structure  910 , by second drive catch  937 . Second drive catch  937  is slidably connected to alignment structure  910 . Second catch bias spring  939 , which is compressed between alignment structure  910  and second drive catch  937 , detains second drive catch  937  in an upward position where it blocks the motion of third driver  921 . As alternate first driver  912  approaches junction  738 , however, second spring release wedge  953  comes in camming contact with second drive catch  937 , thus pushing second drive catch  937  downward and further compressing second catch bias spring  939 . At approximately this point, alternate first driver  912  has driven fastener  714  into boards  730 ,  734  but rear prong  715  protrudes at a 40° angle to the vertical board surface. When second spring release wedge  953  has lowered second drive catch  937  sufficiently, so that it no longer impedes the movement of third driver  921 , the energy stored in compressed second drive spring  933  is released, forcing second driver  921  toward the opposing second abutment surface  917 , so that second driver  921  contacts and bends rear prong  715  to form approximately a 90° angle with respect to first board  734 . 
     Similar elements, which connect first slide member  930  to second driver  930  and which lower first drive catch  936 , are involved in a similar process for bending rear prong  715  in the opposite angular direction, when activated by a respective button (not shown). 
     After fastener  714  has been driven into boards  730 ,  734  and rear prong  715  has been bent, compressions springs  968  expand, thus propelling alternate first driver  912  away from junction  738 . Likewise, second drive spring  933  expands, so that third driver  921  moves away from junction  738  and second slide member  931  moves away from third driver  921 . 
     FIG. 14 shows a fastener driving device in which second driver  1120  and third driver  1121  project through respective first and second apertures  1174 ,  1175  in alignment structure  1110 . In this embodiment, second and third drivers  1120 ,  1121  are activated by imparting force to second striking head  1170  or third striking head  1171 , so that either second or third driver  1120 ,  1121  will impact and bend rear prong  715 . After rear prong  715  has been bent, return spring  1172  pushes either second or third driver  1120 ,  1121  back to its respective initial position. 
     FIGS. 15-17 relate to fastener driving devices in which the second or third drivers, which impact and bend rearward-facing prongs, are connected to the first driver. Referring to FIG. 15, there is shown a fastener driving device having triangular driving element  1276  connected on top of first driver  1212  by connection post  1278 . In the position shown in FIG. 15, triangular driving element  1276  is positioned to impact and bend rear prong  715  away from first board  730 , so that rear prong  715  will be oriented at approximately a 90° angle to first board  730 . In this embodiment, triangular driving element  1276 , rather than the alternate forms of second and third drivers described above, is used to bend rear prong  715 . When driver  1212  is activated and advances toward junction  738 , second camming surface  1281  comes in camming contact with and bends rear prong  715 . While second driving surface is bending rearward facing prong  715 , first driver  1212  contacts fastener  714  and drives its forward-facing prongs into boards  730 ,  734 . Triangular driving element  1276  may be fixed, relative to first driver  1212 . Alternately, triangular driving element may be pivotable about post  1278 , so that first camming surface  1280  can be oriented so that it comes in camming contact with and bends rear prong  715 , as first driver  1212  advances toward junction  738 . Like the second and third drivers in the embodiments described above, first camming surface  1280  and second camming surface  1281  are used to bend rear prong  715  in opposing directions. 
     Referring to FIG. 16, there is shown an alternative driver assembly, in which second driver  1220 ′ is integrally connected on top of first driver  1212 ′. In this configuration, driving surface  1282 ′ of first driver  1212 ′ drives forward-facing prongs of a fastener into boards. In the same movement of first driver  1212 ′, first camming surface  1280 ′ of second driver  1220 ′ impacts and, through camming contact with a rear prong, bends the rear prong. Alternately, as seen in FIG. 17, third driver  1221 ″ may be connected below first driver  1212 ″. In this embodiment, third driver  1221 ″, having second camming surface  1281 ″, is engaged by rotating the driver assembly about axis  1284 ″, so that third driver  1221 ″ is above first driver  1212 ″. It will be understood that fastener driving devices that employ driver assemblies like the ones in FIGS. 16-17 may be designed to have the engaged second or third driver below, instead of above, the first driver. 
     A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the device may be constructed so as to bend rear prong  715  to any desired angle. Further, in addition to the foregoing description, there are other techniques for activating second and third drivers  920 ,  921  by the movement of alternate first driver  912 . For example, the movement of alternate first driver  912  may trigger a pneumatic device that activates second and third drivers  920 ,  921 . Accordingly, other embodiments are within the scope of the following claims.