AU735843B2 - Self-powered fastener system - Google Patents

Description

Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

(ORIGINAL)

a a Name of Applicant: Actual Inventor: Address for Service: Invention Title: INNOVATIVE QUALITY PRODUCTS CORPORATION of 10945 Alder Circle, Dallas, Texas 75238, United States of America William D. ARMSTRONG DAVIES COLLISON CAVE, Patent Attorneys, of 1 Little Collins Street, Melbourne, Victoria 3000, Australia "SELF-POWERED FASTENER SYSTEM" The following statement is a full description of this invention, including the best method of performing it known to us: -1- P:\OPER\DBW\10822-95.DIV 3/3/99 2 SELF-POWERED FASTENER SYSTEM Field of the Invention The present invention relates to a system for driving a fastener and a powered fastener. In particular, the present invention relates to self-powered fasteners and systems for driving them into hardened solid structures such as concrete or structural steel. More specifically, the invention relates to a ""non-free flight low velocity self-powered fastener system comprising a powered fastener bearing a power charge of rapidly combustible and consumable material which together with a tool for activating the powered fastener provide a combustion or detonation chamber which results in a high specific power of the powered fastener and essentially complete consumption of the power charge.

Background of the Invention The present invention is related to driving fasteners into :...ohardened structures such as concrete ceilings and floors, concrete columns and structural steel members such as I-beams.

When such fasteners are to be driven, the working quarters are sometimes cramped with existing structures and equipment. This may result in awkward or limited access to the sites to which the fasteners are to be mounted. This is especially the case with ceilings, which frequently require the use of poles to hold the driving tool in place. Compounding these circumstances is the frequent requirement that a large number of fasteners be mounted, as in the case of suspended ceilings, as known in the art. Thus, efforts have been undertaken to improve worker productivity, while not sacrificing safety. Fasters have been driven into such structures using various explosive, detonatable, ignitable or combustible charges.

P:\OPER\DBW\10822-95.DIV -3/3/99 3 Various types of systems have been used in the prior art.

Such systems are characterized as low velocity (discharging a fastener at less than approximately 300 feet/second), medium velocity (discharging a fastener at a velocity of 300-500 feet/second), high velocity (discharging a fastener at a velocity of greater than 500 feet/second), and zero stand-off systems. All but the zero stand-off systems are characterized as being ballistic in nature, because the fasteners can attain free flight. Such systems have safety concerns analogous to handling firearms, but have found application in imbedding fasteners in particularly hard structures in which considerable penetration depths of the fasteners are desired.

The zero stand-off type systems do not achieve free flight of the fasteners. These systems have reduced similarities to 15 firearms, but often at the expense of sufficient power to achieve the desired holding penetration in the target structure.

S• A common characteristic of this second type of system is to use the presence of the target structure or work surface as a necessary prerequisite to actuating the firing of the power charge. This is typically achieved by providing a barrel structure having a bore therein for holding a power charge or cartridge and a fastener. The fastener extends out of the barrel and into contact with the work surface. When the barrel is driven toward the work surface, the fastener is driven inwardly 25 toward the cartridge and serves as a firing pin for detonating or igniting the charge in the cartridge. This results in the compressed ignition gases resulting from the ignited power charge forcing the fastener out of the barrel and into the work surface of the target structure. Hence, as a result of the cooperation of the work surface, barrel, power charge and fastener, with the fastener functioning as a firing pin, a relatively safe, non-ballistic or non-free flight system is provided. Unfortunately, in the prior art systems, the power achieved and hence the degree of penetration of the fastener into the target structure are limited.

P:\oPER\DBW\10822-95.DIV 3/3/99 4 Summary of the Invention In accordance with the present invention there is provided a system for driving a fastener into a work surface, comprising in combination: a fastener having a penetration end, a shaft and a receptacle head end, and a power charge, said receptacle head end having a cavity having an entrance portion and a cavity end portion for receiving said power charge and maintaining a gap between said power charge and the entirety of said cavity end portion; a tool including: a barrel including a bore having a muzzle for receiving said fastener, a surface for supporting said fastener in a stationary position, a spring-biased firing pin for driving into said power charge to ignite said power charge, and an exhaust chamber connected to said bore for receiving exhaust gases, said supporting surface and said receptacle head end defining a space in which combustion of said power charge •oe.oi takes place, wherein said fastener penetration end extends out of the end of said tool muzzle and is to be placed in contact with said work surface, whereby said work surface, said fastener penetration end, said fastener receptacle head end, said supporting surface and said firing pin cooperate to ignite said power charge to drive said fastener into said work surface.

The present invention also provides a powered fastener to be driven by a tool for igniting a power charge, said fastener including: a penetration end, a shaft, a receptacle head end for receiving a power charge, and a power charge, said receptacle head end having a cavity having an entrance portion and a cavity end portion for receiving said power charge and maintaining a gap between said power charge and the entirety of said cavity end portion.

A preferred embodiment of a tool and two embodiments of a powered fastener are provided in accordance with the present invention. In the tool embodiment, a tool having a barrel and p:\OPER\DBW\10822-95.DIV 3/3/99 5 associated housing is provided which supports a spring-biased firing pin. Exhaust ports (preferably frusto-conical in shape) are provided which lead to an exhaust chamber for noise reduction having spring-biased baffles disposed therein. The barrel has a bore which defines a fastener receiving and discharge chamber. A first embodiment of a fastener is provided having a primerless power charge (preferably of nitrocellulose) fitted to a receptacle at the end thereof with the receptacle having a cylindrical portion and a conical portion. The preferred power charge is nitrocellulose composition which is press fit into the cylindrical portion of the fastener head receptacle. An air space or gap exists between the power charge and the conical portion of the receptacle. The power charge is sealed at its outer surface by an acetone coating. An angle clip having an essentially inverted conical concave surface is mounted on the fastener. The angle clip is press fit or friction S•fit onto the fastener at a shoulder or step in the e• *e 6 fastener. The shape of the concave surface conforms to the bevelled entrance to the tool muzzle so as to align the fastener within the base. The tool is adapted to be threadably mounted on a pole. In operation, a powered fastener is placed in the muzzle of the tool. The penetration or pointed end of the fastener extends outwardly from the muzzle end of the barrel. The head of the fastener, bearing the power charge is supported against a shoulder in the bore of the barrel, at the base of the receiving and discharge chamber. The vertical alignment of the fastener is assisted by the angle clip in contact with the beveled entrance to the nuzzle. The fastener point is placed against the target work surface. When a vertical thrusting force is applied to the handle end of the tool opposite the muzzle end, the firing pin is forced against the power charge of the fastener. The fastener does not move, as in the prior art. Rather, the firing pin penetrates the power charge material. The concussion of the firing pin impact on the power charge combined with a shearing force of the firing pin penetrating the power charge material results in deformation and friction within the power charge, causing the power charge to ignite or detonate. The resulting combustion gases expand and force the fastener into the target work surface. The space between the receiving and discharge chamber shoulder and the fastener head serves as the combustion chamber. The specific conical portion of the fastener head receptacle cavity serves to enhance the propulsion of the fastener toward the work surface by providing a source of air for detonation and as a surface against which the resulting gases expand. As the fastener leaves the tool, the spring which biases the firing pin forces the remainder of the tool up against the target P:\OPER\DBW\10822-95.DIV 3/3/99 7 work surface, thereby restoring the firing pin to its at-rest position. This action also helps to maintain the angle clip attached to the fastener flush against the work surface. The fastener slides relative to the concave surface on the angle clip as it is driven, thus retaining the angle clip on the fastener. As the fastener passes the exhaust ports, the expanding gases are forced through the ports into the exhaust chamber. As the gases pass through the baffles, the gases cause the spaces between the baffles to become pressurized, thereby expanding the spaces, forcing the baffles apart. This compresses the baffle spring disposed within the exhaust chamber. The exhaust gas energy is dissipated, thereby reducing noise out of the muzzle.

A second embodiment of the powered fastener provides an 15 insert also having a cylindrical portion and a conical portion which is fitted to the fastener head receptacle. The insert in turn holds the power charge. The operation of the charge is otherwise the same.

It is contemplated that the tool can be provided with an S 20 increased stroke, for driving longer fasteners, with the attendant dimensions of the components of the tool also increased. The operation of the tool having increased stroke is otherwise the same. Similarly, the tip of the firing pin can be provided with a shoulder or step or other reduced area surface, so that by decreasing the surface area in impact with the power charge, the pressure applied is increased for the same applied force.

Preferred embodiments of the present invention are hereinafter described, by way of example only, with reference to the accompanying drawings.

Brief Description of the Drawings FIG. 1 is a perspective view of a worker using a preferred embodiment of the fastener system of the present invention to install a fastener in the ceiling; FIG. 2 is a perspective view of a preferred embodiment of the fastener system of the present invention showing a tool and P:\OPE\DB9W\1082295.DIV 3/3/99 8 a fastener which together define the system; FIG. 3 is a sectional view of a tool according to a preferred embodiment of the present invention; FIG. 4 is an exploded perspective view of a tool according to a preferred embodiment of the present invention; FIG. 5 is a fragmentary sectional view of the muzzle of the tool with a fastener mounted therein in accordance with a preferred embodiment of the present invention; FIG. 6 is a sectional view taken along line 6-6 of FIG. 3; FIG. 7 is a fragmentary sectional view of the fastener receiving chamber of the tool with a fastener received therein; FIG. 8 is a fragmentary sectional view of a first embodiment of a fastener having a power charge; FIG. 9 is a fragmentary sectional view of an alterative 15 embodiment of a fastener bearing a power charge; and FIG. 10 is a sectional view of the fastener system in operation discharging a fastener.

oo 9 Detailed Description of the Invention FIG. 1 illustrates generally the application of the present invention, showing a worker W fastening a fastener 100 (FIG. 2) havine an anr bracket or clip A bearing a ceiling wire CW to a conL :e ceiling C using a tool 10 attached to a pole P. FIG. 2 shows a perspective view of a tool 10 according to the present invention having a muzzle 12 for receiving a powered fastener 1 00 bearing angle clip A. Tool 10 is threadably attached to pole adapter 14 by threads 15 on external shaft 18 of a spring-biased firing rod discussed below. Pole adapter 14 is in turn threadably fastened to pole P. As explained below, by application of a vertical thrusting force T, the worker W is able to actuate the spring-biased firing rod and thereby detonate or ignite the power charge of the powered fastener 100 so as to drive the powered faste-er 100 into concrete ceiling C (or other hardened structural member).

20 FIG. 3 is a sectional view of tool 10 in assembled form. FIG. 4 is an exploded perspective view showing the components of tool 10 as they are assembled together to the configuration shown in FIG. 3. As shown in FIGS. 3 and 4, tool 10 is comprised of a barrel 25 having muzzle 12 and exhaust ports 22. Muzzle 12 is the opening to fastener receiving and discharge chamber 24 which communicates with firing pin cylinder 26, firing rod cylinder 28 and firing rod shoulder cylinder Fastener receiving and discharge chamber 24, firing pin cylinder 26, firing rod cylinder 28 and firing rod shoulder cylinder 30 are coaxially aligned.

Eccentrically disposed about barrel 20 is an exhaust chamber housing 32 defining exhaust chamber 33 in which are mounted an exhaust chamber housing top end cap 34, a 10 plurality of baffles 36, and exhaust chamber housing bottom end cap 38. End caps 24, 38 are each provided with keys 39 (FIG. 2) which engage and align with housing 32. Baffle spring 40 disposed between end cap 38 and the lowermost baffle 36, biases baffles 36 into the upper region of exhaust chamber 33 proximate to exhaust ports 22. Firing rod 42 having firing pin 44 and firing rod shoulder 46 is slidably and reciprocatingly disposed within barrel 20. Firing pin 44 has tip 45 and is disposed so as to reciprocate within firing pin cylinder 26 and extend into the lower region of fastener receiving and discharge chamber 24, thereby having a stroke S. Firing rod 42 reciprocates within firing rod cylinder 28 and extends into firing 15 rod shoulder cylinder 30 defined by firing rod shoulder housing 48 which is threadably engaged by threads 49 with the bottom of barrel 20. The stroke of firing rod 42 is approximately 1 inch. Firing rod 42 is biased by spring 43 disposed within firing rod shoulder cylinder 30. The bottom of firing rod 42 is threadably engaged by threads 15 with pole adapter 14 which is threadably engageable by threads 17 with pole P (FIGS. 1 and Exhaust cwnmber housing 32 is held in position at top end cap 3" 'y barrel rim 52 and biased against barrel rim 52 firing rod shoulder housing 48 contacting bottom nd cap 38. As shown in FIG. muzzle 12 has bevte entrance 53 so as to accommodate a fastener 100 having )ointed end or tip 108 with an angle clip A attached ther to and at fastener shoulder or step 109. Angle clip A 11 typically have a long ceiling wire CW attached thereto at hole 111 (FIG.2). Angle clip A has inverted conical concave surface 55 which is shaped to fit within beveled entrance 53. This surface serves to support and guide the fastener 100 as it is 11 driven. Surface 55 also assists in stopping the fastener 100, should the fastener i00 be driven into a softer material than anticipated. The eccentric offset of housing 32 permits proper alignment of the combined fastener 100 and angle clip A.

Sectional end view 6-6 of FIG. 3 is shown in FIG. 6. Therein are shown the eccentric or off-center holes 64 for accommodating barrel 20. Exhaust holes 56, 58 (in phantom) are shown. The exhaust holes are staggered, as shown, between successive baffles so as to effect a tortuous, rather than direct, flow path F (FIG.

11) of the exhaust gases from fastener receiving and discharge chamber 24 through exhaust ports 22 into exhaust chamber 33. The baffles 36 are arranged 15 eccentrically around barrel 20 in accordance with the eccentric alignment of housing 32.

FIG. 7 shows the positioning of a powered fastener 100 in fastener receiving and discharge chamber 24, with the reciprocating motion R of firing pin 44 and 20 discharge direction D shown. As explained below, fastener receiving and discharge chamber 24 cooperates with fastener head 102 receptacle 104 to create a combustion chamber for the power charge 118 which is placed in receptacle 104.

25 FIGS. 8 and 9 illustrate the details of fastener 100. Head 102 is formed integrally with shaft 106, having a penetration end, typically in the form of point or tip 108 (FIG. 5) and provided with an essentially cylindrical open end 110 having a shallow conical surface 112. Cylindrical wall 114 and conical surface 112 define a receiving and combustion chamber 116 within fastener 100 for receiving a charge 118 of combustible material.

12 Charge 118 may be made of any suitable material which will sustain a burn throughout the traversal of fastener 100 along the receiving and discharge chamber 24. A preferred material is a nitrocellulose compound or composition having in excess of 85 wt% nitrocellulose, and also having suitable stabilizers crafts and resins, as known in the art, which result in a density and porosity which permit a rapid burn rate upon detonation. Such compound eliminates the requirement of a primer. A source of such compound is Armtec Defense Products Co., Coachella, California. An advantage of this particular power charge material is that virtually complete consumption of the power charge :occurs when detonated.

S: 15 The power charge 118 is formed into a pellet or plug which is press fit into receptacle 104. One means of mounting power charge 118 is to use the receptacle 104 to punch a pellet-shaped plug out of a sheet or strip of power charge material in cookie-cutter fashion with the resulting plug being press fit within receptacle 104. Alternatively, an adhesive can be applied to adhere the charge to the inside surface of cylindrical wall 114. The charge 118 may be flush with the opening of head 102 (FIG. 8) or may protrude 25 slightly beyond the opening (FIGS. 7 and 9).

FIG. 9 shows an alternative embodiment of a charge 118 mounted in fastener 100 by an insert 120 which has rim 122 for close proximity to receiving and discharge chamber 24. The insert 120 has both cylindrical 123 and conical 125 portions, as in the first embodiment.

The tool 10 and fastener 100 may be made of any suitable material as known in the art. Typically, the firing rod 42 is made type S7 tool steel, other parts of 13 tool 10 are made of type 4140 tool steel, with the housing 32 made of compression pipe stainless steel.

The pole P is made of aluminum or fiberglass. The fastener 200 is made of type 1062 wire.

It is contemplated that the stroke S of tool can be altered by changing the appropriate dimensions of the consitituent parts, in order to drive a fastener 100 of increased length. Such would be the case when a fastener 100 is to be driven through several inches of wood into a concrete or steel surface. Normally, only a one inch penetration into concrete is required.

However, the length of the fastener would be increased to go through such a combined structure. Therefore, the S 0stroke would have to be increased from approximately 1 S':0 15 inch to approximately 5 inches. Of course, the stroke could be altered for other lengths.

Referring now to the FIGS., the operation of the system is as follows: A fastener 100 having angle clip A slidably 20 attached near the point 108 of the fastener is placed in muzzle 12 of tool 10. Angle clip A rests in beveled entrance 53. Tool 10 is threadably fastened to pole P.

Penetration end or point 108 is placed against the work surface, for example, ceiling C, with the tool 10 held in an essentially vertical orientation. A vertical upward thrusting force T is appliqd to pole P to compress biasing spring 43 and to cause firing rod 42 to move upwardly toward fastener 100. The typical thrusting force is on the order of 20-30 pounds, which is within the capability of the ordinary worker in the field. The tip 45 of firing pin 44 has a diameter of approximately 0.100 inch corresponding to an area of approximately 0.00786 square inches, resulting in a pressure of on the order of 2500-4000 pounds/square 14 inch. Pressures as high as 6000 pounds/square inch are contemplated. As shown in FIG. ii, firing pin 44 penetrates power charge 118 disposed in receptacle 104 of fastener i00 to a depth of approximately 0.080-0.100 inch. This penetration causes a shearing action and deformation of the power charge material. Friction is also generated which is sufficient to ignite or detonate power charge 118. Because fastener i00 extends substantially over the diameter of the bore of fastener 10 receiving and discharge chamber 24, the space defined by receptacle 104 including the conical surface 112 and the portion of receiving and discharge chamber 24 beneath receptacle 104 defines the expanding combustion chamber in which the power charge rapidly burns and through which the fastener 100 travels. The pressure exerted by expanding gases drives the fastener 100 into the work surface C. As the receptacle 104 of fastener 100 clears the exhaust ports 22, the exhaust gases are forced into exhaust chamber 33 of exhaust chamber housing 32. The pressure of the exhaust gases flowing through baffles 36 expands the spring-biased baffles 36, thereby compressing baffle spring 40. This dissipates the energy of the gases, thereby reducing the noise of the discharge of the fastener 100 from muzzle 12.

Simultaneously with the discharge of fastener 100 from chamber 24, spring 43 serves to force barrel 20 (and hence the remainder of tool 10) upwardly (shown as direction U) such that rim 52 contacts work surface

C.

This action restores the firing rod shoulder 46, firing rod 42 and firing pin 44 to their respective rest positions, with firing rod shoulder 46 in contact with the base 51 of firing rod shoulder housing 48.

As will be noted by one skilled in the art, this operation requires the fastener 100 to be held P:\OPER\DBW\10822-95.DIV 3/3/99 15 against a hardened work surface in order for the firing pin 44 to ignite or detonate the power charge 118. Thus, the likelihood of discharging a fastener directly into an unwanted surface, such as a worker's hand, is significantly reduced. In addition, no free flight of the fastener is achieved, yet the fastener can be satisfactorily driven into a hardened work surface.

It is contemplated that the firing pin 44 may be stepped down or otherwise shaped at the tip 45 so as to reduce the area contacting the power charge 104. This will result in increased oo. 10 pressures for the same applied thrusting force T.

~It is contemplated that the extent to which the point 108 extends out of the muzzle 12 can be altered by the shape and extent of the beveled entrance 53.

The tool 10 and fastener 100 have been shown as operating in a vertically upward direction. It is also contemplated that the tool and fastener system in accordance with the present invention can be operated in other orientations.

Although certain presently preferred embodiments of the invention have been described herein, it will be apparent to 20 those skilled in the art to which the invention pertains that variations and modifications of the described embodiments may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention be limited only to the extent required by the appended claims and the applicable rules of law.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims (17)

1. A system for driving a fastener into a work surface, comprising in combination: a fastener having a penetration end, a shaft and a receptacle head end, and a power charge, said receptacle head end having a cavity having an entrance portion and a cavity end portion for receiving said power charge and maintaining a gap between said power charge and the entirety of said cavity end portion; a tool including: a barrel including a bore having a muzzle for receiving said fastener, a surface for supporting said fastener in a stationary position, a spring-biased firing pin -for driving into said power charge to ignite said power charge, and an exhaust chamber connected to said bore for receiving exhaust gases, said supporting surface and said receptacle head end defining a space in which combustion of said power charge takes place, wherein said fastener penetration end extends out of the V end of said tool muzzle and is to be placed in contact with said work surface, whereby said work surface, said fastener penetration end, said fastener receptacle head end, said supporting surface and said firing pin cooperate to ignite said power charge to drive said fastener into said work surface.

2. A system as in claim 1, wherein said tool further comprises a plurality of baffles disposed in said exhaust chamber and biased therein by a spring, said baffles being interconnected by air passages and having spaces therebetween, said spaces being expandable as exhaust gases enter said baffles and compress said spring, thereby serving to reduce the sound of detonation in said tool.

3. A system as in claim 1, wherein said tool further comprises a plurality of frusto-conical exhaust ports leading from said base to said exhaust chamber.

4. A system as in claim 1, wherein said tool further comprises P:\OPER\DBW\10822-95.DIV 3/3/99 17 a beveled entrance to said muzzle for accommodating an angle clip arranged on said powered fastener.

A system as in claim 1, wherein said tool further comprises a firing rod bearing said firing pin, said firing rod having a shoulder which is biased by a spring.

6. A system as in claim i, wherein said tool further comprises an end adapted to threadably engage a pole. S.

7. A system as in claim i, wherein said tool exhaust chamber comprises a housing which is eccentrically mounted around said barrel.

8. A system as in claim i, wherein said tool has a stroke of approximately 1 inch.

9. A system as in claim 1, wherein said tool has a stroke of approximately 5 inches.

10. A system as in claim i, wherein said power charge of said .4 44 fastener comprises a nitrocellulose compound.

11. A system as in claim i, wherein said muzzle includes a beveled entrance for accommodating an angle clip arranged on said powered fastener.

12. A system as in claim 11, wherein said fastener includes an angle clip mounted therein having an inverted conical concave surface for engaging said beveled entrance.

13. A system as in claim 1, wherein said powered fastener further comprises an insert disposed between said power charge and said receptacle head end, said insert having a cylindrical entrance portion leading to a conical portion, said power charge received within said insert cylindrical portion with a space between said power charge and said conical portion. P:\OPER\DBW\10822-95.DIV 3/3/99 18

14. A powered fastener to be driven by a tool for igniting a power charge, said fastener including: a penetration end, a shaft, a receptacle head end for receiving a power charge, and a power charge, said receptacle head end having a cavity having an entrance portion and a cavity end portion for receiving said power charge and maintaining a gap between said power charge and the entirety 10 of said cavity end portion.

15. A powered fastener as in claim 14, wherein said power S.. charge comprises a nitrocellulose compound.

16. A powered fastener as in claim 14, wherein said fastener includes an angle clip mounted thereon having an inverted conical concave surface for engaging said beveled surface.

17. A powered fastener as in claim 14, further comprising an insert disposed between said power charge and said receptacle head end, said insert having a cylindrical entrance portion leading to a conical portion, said power charge received within said insert cylindrical portion with a space between said power charge and said conical portion. DATED this 3rd day of March, 1999 INNOVATIVE QUALITY PRODUCTS CORPORATION By its Patent Attorneys DAVIES COLLISON CAVE