CN220699506U

CN220699506U - Power fastener driver

Info

Publication number: CN220699506U
Application number: CN202290000224.0U
Authority: CN
Inventors: C·A·内特尔顿; L·F·米卡特-史蒂文斯; A·R·帕尔姆; A·D·瑟瓦斯; E·R·阿尔布雷希特; J·N·齐默尔曼; J·M·朱贝克; C·L·博纳特; D·J·谢里丹
Original assignee: Milwaukee Electric Tool Corp
Current assignee: Milwaukee Electric Tool Corp
Priority date: 2021-01-20
Filing date: 2022-01-20
Publication date: 2024-04-02
Anticipated expiration: 2032-01-20

Abstract

A fastener driver comprising: a housing defining a head portion and a handle portion; a drive mechanism positioned within the housing; a launching mechanism. The launching mechanism includes: a primary guide member supported within the head portion of the housing; a secondary guide member spaced apart from the primary guide member and supported within the head portion of the housing; a piston slidable along the main guide member and the sub guide member; a driver blade attached to the piston and configured to be movable along a drive axis; and a biasing member configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position. The lifter assembly is operated by the drive mechanism to return the piston and the driver blade toward a TDC position against the bias of the biasing member.

Description

Power fastener driver

Cross Reference to Related Applications

The present application claims priority from co-pending U.S. provisional patent application Ser. No. 63/180,722, U.S. provisional patent application Ser. No. 63/151,240, and U.S. provisional patent application Ser. No. 63/139,549, filed on month 1 and 20, 2021, filed on 28, year 4, and 19, all of which are incorporated herein by reference in their entireties.

Technical Field

The present utility model relates to a powered fastener driver, and more particularly to a battery powered fastener driver.

Background

Various fastener drivers are known in the art for driving fasteners (e.g., nails, tacks, staples, etc.) into a workpiece. These fastener drivers operate using various means known in the art (e.g., compressed air generated by an air compressor, electrical energy, flywheel mechanisms, etc.), but these designs typically suffer from power, size, and cost limitations.

Disclosure of Invention

In one aspect, the present utility model provides a fastener driver comprising: a housing defining a head portion and a handle portion; a drive mechanism positioned within the housing; and a launching mechanism, the launching mechanism comprising: a primary guide member supported within the head portion of the housing; a secondary guide member spaced apart from the primary guide member and supported within the head portion of the housing; a piston slidable along the main guide member and the sub guide member; a driver blade attached to the piston and configured to be movable along a drive axis. A biasing member is configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position, and a lifter assembly is operated by the drive mechanism to return the piston and the driver blade toward the TDC position against the bias of the biasing member.

Preferably, the primary guide member defines a first axis, and wherein the secondary guide member defines a second axis oriented parallel to the first axis and the drive axis.

Preferably, the jack assembly rotates about a third axis transverse to the first and second axes.

Preferably, the fastener driver further comprises a bracket coupled to move with the piston, and wherein a second bore is formed in the bracket and is sized to receive and support the secondary guide member along the second axis.

Preferably, the bracket comprises a first projection and a second projection vertically spaced apart from the first projection along the first axis, and wherein the first projection and the second projection each extend toward the riser assembly and selectively engage a pin of the riser assembly.

In another aspect, the present utility model provides a fastener driver comprising: a housing defining a head portion and a handle portion; a drive mechanism positioned within the housing; a launching mechanism, the launching mechanism comprising: a primary guide member supported within the head portion of the housing, a piston slidable along the primary guide member, a driver blade attached to the piston, and a biasing member configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position; a lifter assembly operated by the drive mechanism to return the piston and the driver blade toward the TDC position against the bias of the biasing member; and a frame located within the housing and configured to support the riser assembly and the primary guide member.

Preferably, the fastener driver further comprises a secondary guide member spaced apart from the primary guide member and supported within the head portion of the housing, wherein the secondary guide member is supported within the housing by the frame between the primary guide member and the riser assembly.

Preferably, the primary guide member defines a first axis, and wherein the secondary guide member defines a second axis oriented parallel to the first axis.

In another aspect, the present utility model provides a fastener driver comprising: a housing defining a head portion and a handle portion; a drive mechanism positioned within the housing; a firing mechanism including a piston and a driver blade, the piston and the driver blade being movable from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position; and a lifter assembly operated by the drive mechanism to rotate about an axis of rotation to return the piston and the driver blade toward the TDC position, the lifter assembly including a first eccentric pin and a second eccentric pin, the first eccentric pin being located at a first radial distance relative to the axis of rotation and the second eccentric pin being located at a second radial distance relative to the axis of rotation, the second radial distance being less than the first radial distance.

Preferably, the fastener driver further comprises a primary guide member supported within the head portion of the housing, wherein the primary guide member defines a first axis, and wherein the piston is slidable along the primary guide member.

Preferably, the rotational axis of the jack assembly is transverse to the first axis.

Preferably, the fastener driver further comprises a bracket coupled to move with the piston, wherein the bracket comprises a first protrusion and a second protrusion vertically spaced apart from the first protrusion along the first axis, and wherein the first eccentric pin is configured to engage the first protrusion and the second eccentric pin is configured to engage the second protrusion.

In another aspect, the present utility model provides a fastener driver comprising: a magazine configured to receive fasteners therein, the magazine comprising a magazine cover and a magazine body, the magazine cover having: a length extending along a longitudinal axis between the first end and the second end; a top surface having an opening defined therein proximate the second end; and a bottom surface opposite the top surface, and the cartridge body is slidably movable relative to the cartridge cover from a closed position to an open position for reloading the cartridge with fasteners; a nosepiece including a fastener driving channel from which successive fasteners from the magazine are driven, the nosepiece being adjacent the first end of the magazine cover; a latch coupled to the top surface of the cassette cover, the latch extending through an opening in the top surface of the cassette cover, the latch including a latch protrusion defining a first contact surface; a pusher body slidably coupled to the cartridge body, the pusher body including an arm member defining a second contact surface; and a biasing member configured to bias the pusher body and fasteners within the cartridge toward the nosepiece when the cartridge body is in a closed position, wherein the first contact surface and the second contact surface are engageable to retain the pusher body in a latched position when the cartridge body is in an open position.

In another aspect, the present utility model provides a fastener driver comprising: a magazine configured to receive chain-type fastener strips therein, the magazine comprising a magazine cover having a length extending along a longitudinal axis between a first end and a second end, a top surface, parallel side walls extending from opposite sides of the top surface, respectively, and a rib extending inwardly from at least one of the side walls along a first portion of the length of the magazine cover, the magazine cover being configured to receive the chain-type fastener strips between the side walls along a second portion of the length of the magazine cover, the rib being configured to limit installation or removal of chain-type fastener strips located within the first portion of the length of the magazine cover, and the magazine body being slidably movable relative to the magazine cover from a closed position to an open position for reloading the magazine with chain-type fastener strips; and a nosepiece including a fastener driving channel from which successive fasteners from the magazine are driven, the nosepiece being adjacent the first end of the magazine cover.

Preferably, the rib is a first rib extending inwardly from an end of a first one of the side walls, wherein the cassette further comprises a second rib extending inwardly from the first side wall along a first portion of the length of the cassette cover, wherein the second rib is parallel to the first rib, and wherein the second rib is configured to prevent the fastener strips of the chain belt from tipping in response to the cassette body moving from the open position to the closed position.

Preferably, the rib is a first rib extending inwardly from an end of a first one of the side walls, wherein the cassette further comprises a second rib extending inwardly from an end of a second side wall along a first portion of the length of the cassette cover, and wherein the first rib and the second rib define a gap between the first rib and the second rib having a width less than the width of the chain-strap fastener strips.

In another aspect, the present utility model provides a fastener driver comprising: a magazine configured to receive chain-type fastener strips therein, the magazine comprising a magazine cover and a magazine body, the magazine cover having a length extending along a longitudinal axis between a first end and a second end, a top surface, parallel side walls extending from opposite sides of the top surface, respectively, and a rib extending inwardly from at least one of the side walls along the length of the magazine cover, the magazine cover configured to pass through the second end of the magazine cover and receive the chain-type fastener strips therebetween, the rib configured to limit installation or removal of the chain-type fastener strips after insertion of the chain-type fastener strips through the second end of the magazine cover, and the magazine body being slidably movable relative to the magazine cover from a closed position to an intermediate position and pivotable relative to the magazine cover from the intermediate position to an open position to reload the magazine; and a nosepiece including a fastener driving channel from which successive fasteners from the magazine are driven, the nosepiece being adjacent the first end of the magazine cover.

In another aspect, the present utility model provides a fastener driver comprising: a housing defining a head portion and a handle portion; a drive mechanism positioned within the housing; a firing mechanism including a piston and a driver blade, the piston and the driver blade being movable from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position; and a lifter assembly operated by the drive mechanism to rotate about an axis of rotation, the lifter assembly including a unitary body having an input shaft coupled to the drive mechanism to receive torque from the drive mechanism and a hub selectively engaging a portion of the firing mechanism to return the piston and the driver blade toward the TDC position.

Preferably, the fastener driver further comprises a primary guide member supported within the head portion of the housing, wherein the primary guide member defines a first axis transverse to the axis of rotation, and wherein the piston is slidable along the primary guide member.

In another aspect, the present utility model provides a fastener driver comprising a magazine having a length extending along a longitudinal axis between a first end and a second end, the magazine configured to receive a chain-type fastener strip in the magazine, the chain-type fastener strip comprising a plurality of fasteners having crown sections and tips opposite the crown sections; a nosepiece including a fastener driving channel from which successive fasteners from the magazine are driven, the nosepiece being located adjacent the first end of the magazine; and a fastener alignment mechanism positioned adjacent the first end of the magazine, the fastener alignment mechanism including a magnetic element that generates a magnetic force on the tips of fasteners located adjacent the fastener driving channel to urge the tips of the fasteners toward the nosepiece, wherein the magnetic force urges the fasteners toward a loading position in which the fasteners are aligned with the fastener driving channel of the nosepiece.

In another aspect, the present utility model provides a fastener driver comprising: a magazine having a length extending along a longitudinal axis between a first end and a second end, the magazine configured to receive a strip of chain-band fasteners therein; and a nosepiece including a fastener drive channel from which successive fasteners from the magazine are driven, the nosepiece being located adjacent the first end of the magazine, the nosepiece including an inner surface configured to receive a cable secured to a workpiece during a fastener driving operation, the inner surface including a first portion having a first width and a second portion having a second width, the second width being greater than the first width.

Preferably, the fastener driver further comprises: a housing defining a head portion and a handle portion; a drive mechanism positioned within the housing; and a firing mechanism including a piston and a driver blade movable from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position.

Preferably, the fastener driver further comprises a lifter assembly operated by the drive mechanism to rotate about an axis of rotation to return the piston and the driver blade toward the TDC position.

In another aspect, the present utility model provides a fastener driver comprising: a housing defining a head portion and a handle portion; an end cap supported within the head portion, the end cap comprising a first recess, a second recess surrounded by the first recess, and an outer sleeve surrounding the first recess; a drive mechanism positioned within the housing; a launching mechanism, the launching mechanism comprising: a piston, a driver blade attached to the piston, a first biasing member having a first end supported within the piston and a second end disposed within a first recess of the end cap, and a second biasing member having a first end supported within the piston and a second end disposed within a second recess of the end cap, the first and second biasing members configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position; a gasket positioned between the second end of the first biasing member and the end cap, the gasket supported within the first recess of the end cap; and an elevator assembly operated by the drive mechanism to return the piston and the driver blade toward the TDC position against the bias of the first and second biasing members.

In another aspect, the present utility model provides a fastener driver comprising: a front end portion; a housing defining a head portion having a rear end, and a handle portion; a drive mechanism positioned within the housing; a battery pack coupled to the battery receptacle, the battery pack configured to provide power to the drive mechanism; and a launching mechanism, the launching mechanism comprising: a piston, and a driver blade attached to the piston, the driver blade configured to move from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position, wherein the fastener driver has a length defined between the front end and the rear end, and wherein the length is less than or equal to 18 centimeters.

In another aspect, the present utility model provides a fastener driver comprising: a housing defining a head portion and a handle portion; a drive mechanism positioned within the housing; a firing mechanism configured to actuate in response to an input from the drive mechanism, the firing mechanism comprising: a piston, a driver blade attached to the piston, and a biasing member configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position, wherein the biasing member stores at least 14.5 joules of energy when the driver blade is in the TDC position.

Preferably, the drive mechanism comprises a brushless DC motor.

Other features and aspects of the utility model will become apparent by consideration of the following detailed description and accompanying drawings.

Drawings

FIG. 1 is a perspective view of a powered fastener driver.

FIG. 2 is a side view of the powered fastener driver of FIG. 1 with a portion removed for clarity, showing the drive mechanism, firing mechanism, and lifter assembly.

FIG. 3 is a side view of the drive mechanism, firing mechanism, and lifter assembly of the powered fastener driver of FIG. 1.

Fig. 4 is a perspective view of a portion of the jack assembly and firing mechanism of fig. 3.

Fig. 5 is a perspective view of a portion of the jack assembly shown in fig. 4.

Fig. 6 is a top view of a portion of the jack assembly shown in fig. 4.

FIG. 7 is a perspective view of the magazine of the powered fastener driver of FIG. 1 showing the magazine in a closed position.

Fig. 8 is another perspective view of the cassette of fig. 7, showing the cassette in an open position.

Fig. 9 is a cross-sectional view of the cassette of fig. 7 along section line 7-7 in fig. 7.

Fig. 10 is another perspective view of the cassette of fig. 7 showing the pusher latch.

FIG. 11 is another perspective view of the cassette of FIG. 7 with a portion of the cassette removed for clarity to show the pusher latch and pusher body.

Fig. 12 is a side view of the pusher latch and pusher body.

Fig. 13 is a top perspective view of the pusher latch and pusher body of fig. 12.

FIG. 14 is a top perspective view of another embodiment of a magazine for use with the powered fastener driver of FIG. 1, showing the magazine in a closed position.

Fig. 15 is a bottom perspective view of the cassette of fig. 14, showing the cassette in an open position.

Fig. 16 is an enlarged bottom perspective view of the cassette of fig. 15.

Fig. 17 is a cross-sectional view of the cartridge of fig. 14 through section 16-16.

FIG. 18 is a bottom perspective view of a powered fastener driver including another embodiment of a magazine in a closed position.

FIG. 19 is a bottom perspective view of the powered fastener driver of FIG. 18 with the magazine in an open position.

FIG. 20 is a bottom perspective view of the cassette of FIG. 18, showing the cassette in a partially open intermediate position.

Fig. 21 is a bottom perspective view of the cartridge of fig. 18, showing the cartridge in a fully open position.

FIG. 22 is a cross-sectional view of the cassette of FIG. 18 through section 22-22 of FIG. 18.

FIG. 23 is a cross-sectional view of a powered fastener driver according to another embodiment, showing a drive mechanism, a firing mechanism, and a lifter assembly.

FIG. 24 is a side view of the drive mechanism, firing mechanism and lifter assembly of the powered fastener driver of FIG. 23.

Fig. 25 is a perspective view of the lifter assembly of the powered fastener driver of fig. 23.

FIG. 26 is a cross-sectional view of a portion of the powered fastener driver of FIG. 23, illustrating a fastener alignment mechanism.

FIG. 27 is a front view of a portion of the powered fastener driver of FIG. 23 showing the nose piece of the powered fastener driver.

Before any embodiments of the utility model are explained in detail, it is to be understood that the utility model is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The utility model is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Detailed Description

Fig. 1 illustrates a powered fastener driver 10 (e.g., a cable nailer) for driving fasteners 12 (e.g., nails of a fastener chain) held within a magazine 14 into a workpiece. Driver 10 includes a nosepiece 18 that receives fasteners from magazine 14 in sequence prior to each fastener driving operation. The nose piece 18 includes a contact latch 20 that allows the driver 10 to operate in a single shot mode. In some embodiments of the driver 10, the contact trip 20 may allow operation in a single shot mode and/or burst mode of operation. The driver 10 includes a housing 22 defining a head portion 26, a handle portion 30, and a battery receptacle portion 34 that receives a battery pack 38. In the illustrated embodiment, the housing 22 is longitudinally split into a first housing portion and a second housing portion at a parting line 24. The driver 10 further includes a belt clip 40 secured to the housing 22 adjacent the battery receptacle 34.

Referring to fig. 2, the driver 10 includes a trigger 42 that selectively provides power to a drive mechanism 46 enclosed within the handle portion 30 of the driver 10. The drive mechanism 46 includes an electric motor 50, a gear box 54 that receives torque from the motor 50, and an output shaft 56 that is driven by the gear box 54. In some embodiments, the motor 50 is a brush that receives power from the battery pack 38. In some embodiments of the drive 10, the motor 50 may be configured as a brushless Direct Current (DC) motor.

The powered fastener driver 10 includes a firing mechanism 62 within the head portion 26 of the housing 22. Firing mechanism 62 is coupled to drive mechanism 46 and is operable to perform fastener driving operations. Firing mechanism 62 includes a movable member (e.g., piston 66) for reciprocal movement within head portion 26, a biasing member (e.g., one or more compression springs 70, 72) disposed against piston 66, and a driver blade 74 (fig. 4) attached to piston 66. The biasing member 70 urges the piston 66 and the driver blade 74 within the head portion 26 toward a driven or Bottom Dead Center (BDC) position to drive the fastener 12 into a workpiece. In the illustrated embodiment, the biasing member includes a pair of nested compression springs 70, 72 that act cooperatively to urge the piston 66 and the driver blade 74 toward the BDC position.

The lifter assembly 58 is positioned between the drive mechanism 46 and the firing mechanism 62 and is operated by the drive mechanism 46 to return the piston 66 and the driver blade 74 toward a Top Dead Center (TDC) position against the bias of the biasing member 70. During the drive sequence, the biasing member 70 of the firing mechanism 62 urges the driver blade 74 and the piston 66 from the TDC position toward the BDC position to fire the fastener into the workpiece. The lifter assembly 58, driven by the drive mechanism 46, is operable to move the piston 66 and the driver blade 74 from the BDC position toward the TDC position to stop at an intermediate ready position less than the TDC position so that the firing mechanism 62 is ready for subsequent fastener driving operations.

Referring now to fig. 2 and 3, the driver 10 further includes a primary guide member (e.g., primary guide post 80) slidably supporting the piston 66 and a secondary guide member (e.g., secondary post 82) spaced from the primary guide post 80 slidably supporting a bracket 86 coupled for movement with the piston 66. The secondary post 82 is positioned between the primary guide post 80 and the riser assembly 58 and is configured to slidably support a bracket 86. Because in the illustrated embodiment, the piston 66 and the bracket 86 are integrally formed as a single piece, both the primary guide post 80 and the secondary guide post 82 slidably support the piston 66. In the illustrated embodiment, the primary guide axis 90 extends centrally through the primary guide post 80, and the secondary guide axis 94 extends centrally through the secondary post 82. The primary guide axis 90, the secondary guide axis 94, and the drive axis 78 are oriented parallel to each other and each transverse to the motor axis 76. The primary and secondary guide posts 80, 82 are each cylindrical posts that define guide surfaces that do not have any threads such that the piston 66 is free to move along the primary and secondary guide posts 80, 82 in response to rotation of the jack assembly 58.

Referring now to fig. 4, the jack assembly 58 and the piston 66 are shown in detail. The piston 66 defines: a first bore 116 sized to receive and support the main guide post 80 (fig. 3) along the main guide axis 90; a second bore 120 formed in the bracket 86 that is sized to receive and support the secondary guide post 82 (fig. 3) along the secondary guide axis 94, and a cavity 124 that surrounds the first bore 116 and is sized to receive the biasing member 70 (fig. 3). In the illustrated embodiment, the bracket 86 is integrally formed with the piston 66. In other embodiments, the bracket 86 may be formed separately from the piston 66 and may be coupled to the piston 66.

The bracket 86 includes a first tab 98 and a second tab 102 vertically spaced from the first tab 98 along the axis 94. The first and second projections 98, 102 each extend toward the jack assembly 58. In the illustrated embodiment, the first tab 98 extends farther from the bracket 86 (e.g., toward the riser assembly 58) than the second tab 102. In other words, the first tab 98 is longer than the second tab 102. The lifter assembly 58 includes a first eccentric pin 104 and a second eccentric pin 108 that selectively engage a respective one of the first and second projections 98, 102 formed on the bracket 86 of the piston 66. In the illustrated embodiment, the second eccentric pin 108 extends farther from the riser assembly 58 (e.g., toward the bracket 86) than the first eccentric pin 104 such that the second eccentric pin 108 is sized to engage the second protrusion 102. In other words, the second eccentric pin 108 is longer than the first eccentric pin 104. The configuration of the lifter assembly 58 and bracket 86 displaces the piston 66 and the driver blade 74 from the BDC position toward the TDC position during a single fastener driving cycle. Because the secondary guide member 82 is positioned adjacent to and in close proximity to the jack assembly 58 (e.g., in the bore 120), the physical deflection of the bracket 86, and thus the amount of bending stress experienced by the bracket 86, is reduced as the jack assembly 58 moves the piston toward the TDC position.

With continued reference to fig. 2 and 3, the fastener driver 10 includes a frame 112 coupled to the housing 22 for supporting the first ends of each of the main and secondary guide posts 80, 82 and the jack assembly 58. The frame 112 also defines a housing that is part of the gearbox 54 in which a gear train (not shown) is located. In other words, the gear case 54 is integrally formed on the frame 112. The output shaft 56 extends through an aperture of the frame 112 with the jack assembly 58 positioned adjacent to and in close proximity to a vertical face of the frame 112 oriented perpendicular to the axis 76. An end cap 114 within the housing 22 supports an opposite second end of each of the primary and secondary guide posts 80, 82. The end cap 114 includes a seat 115 (fig. 3) against which the top end of the spring 70 seats. The frame 112 is constructed as a single member that supports the jack assembly 58 while allowing for rotational movement of the jack assembly 58 and rigidly supports the primary and secondary guide posts 80, 82 within the housing 22. In the illustrated embodiment, the frame 112 has a first portion positioned within the head portion 26 of the housing 22 and a second portion positioned within the handle portion 30. The configuration of the frame 112 allows the firing mechanism 62 and the drive mechanism 46 to be assembled separately (e.g., as shown in fig. 3) and inserted into the housing 22. As a result, this allows for a more compact arrangement of the firing mechanism 62 and the drive mechanism 46, which reduces the overall size of the driver 10.

Referring now to fig. 2, the powered fastener driver 10 includes a length L defined between a forward end of the driver 10 (e.g., a forward end of the contact trip 20) and a rearward end of the housing 22 (e.g., the head portion 26). The length L of the driver 10 is less than or equal to 18 cm. In the illustrated embodiment, the length L is 16.5 cm. In some embodiments, the length L may be in the range of 12.5 cm to 18 cm. In some embodiments, the length L may be in the range of 12.5 cm to 16.5 cm.

Referring now to fig. 5 and 6, the lifter assembly 58 includes an outer circumferential surface 130. Each of the eccentric pins 104, 108 is disposed proximate the outer circumferential surface 130. Further, the first eccentric pin 104 is positioned at a first radial distance R1 relative to the rotational axis of the lifter assembly 58 (i.e., the motor axis 76). The second eccentric pin 108 is positioned at a second radial distance R2 that is less than the first radial distance R1 of the first eccentric drive pin 104. As such, the eccentric pins 104, 108 of the lifter assembly 58 are positioned at different radial distances R1, R2 relative to the axis 76. In other words, the eccentric pins 104, 108 are radially offset relative to each other.

Referring now to FIG. 2, as the piston 66 moves from a Bottom Dead Center (BDC) position to a Top Dead Center (TDC) position, the lifter assembly 58 rotates such that the second eccentric pin 108 engages the second protrusion 102 of the bracket 86 of the piston 66. Because the second eccentric pin 108 is positioned at a second radial distance R2 that is less than the first eccentric pin 104, the reaction torque that the spring 70 applies to the motor 50 is less when the piston 66 is stationary in the ready position between the BDC and TDC positions. In addition, because the first eccentric pin 104 is shorter than the second eccentric pin 108, only the second eccentric pin 108 is able to engage the second protrusion 102 during rotation of the lifter assembly 58. In other words, the first eccentric pin 104 has a first height and the second eccentric pin has a second height that is greater than the first height.

For example, the lifter assembly 58 is driven by the drive mechanism 46 to rotate in a first direction such that the first and second eccentric pins 104, 108 sequentially engage the first and second projections 98, 102, which returns the piston 66 and the driver blade 74 from the BDC position toward the TDC position. Since the radius R2 of the second eccentric pin 108 is smaller than the radius R1 of the first eccentric pin 104, the second eccentric pin 108 has a lower linear velocity than the linear velocity of the first eccentric pin 104 when the motor 50 rotates the lifter assembly 58. Thus, the higher linear velocity of the first eccentric pin 104 increases the firing rate by returning the piston 66 to the TDC position faster, while the lower linear velocity of the second eccentric pin 108 decreases the reaction torque on the motor 50.

In operation, at the end of the first drive cycle, the motor 50 rotates the output shaft 56, and thus the lifter assembly 58, about the motor axis 76 to drive the piston 66 and the driver blade 74 toward the TDC position, compressing the biasing member 70. Before reaching the TDC position, the motor 50 is deactivated and the piston 66 and the driver blade 74 remain in a ready position, which is between the TDC position and the BDC position, ending the first drive cycle. When the trigger 42 is actuated to initiate a subsequent second drive cycle, the motor 50 again rotates the lifter assembly 58, which releases the biasing member 70 and drives the piston 66 and the driver blade 74 toward the BDC position, which moves the driver blade 74 about the drive axis 78 and thus drives the fastener 12 into the workpiece. After releasing the biasing member 70, the lifter assembly 58 returns the piston 66 toward the TDC position in preparation for another subsequent drive cycle.

Referring now to fig. 7-11, the cassette 14 includes an outer cassette cover 132 and an inner cassette body 136 received within the outer cassette cover 132. The inner cassette body 136 is slidable relative to the outer cassette cover 132 between a first closed position (fig. 7) and a second open position (fig. 8). The cassette 14 includes: a top surface 140 secured to the driver (fig. 1); and a bottom surface 144 engaging the workpiece and opposite the top surface 140. The outer cassette cover 132 includes a first front portion 148 (fig. 1) adjacent the front end piece 18 and a second rear portion 152 adjacent the battery receptacle 34. The inner cassette body 136 includes a front portion 150 and a rear portion 154 opposite the front portion 148. For example, when the cassette 14 is in the closed position, the inner cassette body 136 is fully positioned within the interior cavity defined by the outer cassette cover 132 such that the front portion 150 and the rear portion 154 of the inner cassette body 136 are aligned with the front portion 148 and the rear portion 152 of the outer cassette cover 132, respectively. Thus, the cassette 14 has a length extending along the longitudinal axis 138 between the front and rear portions 148, 152 of the outer cassette cover 132. As the inner cassette body 136 moves toward the open position, the inner cassette body 136 slides (rightward from the reference frame of fig. 7 and leftward from the reference frame of fig. 8) until the front portion 150 of the inner cassette body 136 is positioned adjacent the rear portion 152 of the outer cassette cover 132. The cassette 14 has a length extending along the longitudinal axis 138 between a front portion 148 of the outer cassette cover 132 and a rear portion 154 of the inner cassette body 136.

A locking assembly 156 is positioned at the rear portion 152 of the inner cassette body 136. The locking assembly 156 includes a flange portion 160 (fig. 11) positioned within the inner cassette body 136 that secures the locking assembly 156 to the inner cassette body 136. Locking assembly 156 is configured to selectively couple inner cassette body 136 to outer cassette cover 132 to hold inner cassette body 136 in a closed position. In the illustrated embodiment, the latch bracket 164 is coupled to the outer cassette cover 132 near the rear portion 152 of the cassette 14, and a latch recess 168 (fig. 10) is formed in a side surface of the outer cassette cover 132.

The locking assembly 156 includes a latch member 170 that selectively engages the latch bracket 164 and seats within the latch recess 168 when the outer cassette cover is in the closed position (fig. 7). In the illustrated embodiment, the latch member 170 is biased (e.g., via a spring) toward a closed or latched position. To move the inner cassette body 136 toward the open position, the latch member 170 is actuated, releasing the latch bracket 164 to allow the inner cassette body 136 to extend from the outer cassette cover 132 toward the open position (fig. 8). In the open position, an operator can load fasteners into the magazine 14.

Referring to fig. 8 and 9, the inner cartridge body 136 includes an extrusion guide 172 that defines a fastener channel 176 in which the gun pins 12 are received (fig. 1). In the illustrated embodiment, the fastener channel 176 has a U-shape (shown in phantom in FIG. 9) that corresponds to the U-shape of the gun pin 12. In the illustrated embodiment, rail 172 is formed as two separate extrusions defining an edge portion 180 and two opposing side walls 184 adjacent edge portion 180. When the staples 12 are received in the fastener passages 176, each of the staples 12 is configured to ride on the edge portion 180 and the side walls 184 of the rail 172. In other embodiments, extrusion guide 172 may be formed as a single extruded structure. The outer cassette cover 132 further includes a pair of side surfaces 182 and a slot 186 recessed into the side surfaces 182. Slot 186 receives inner cassette body 136 such that inner cassette body 136 can slide relative to outer cassette cover 132.

Referring now to fig. 11-13, the cartridge 14 further includes a pusher body 188 (fig. 12, and 13) positioned within the fastener channel 176 of the cartridge 14 and a latch 196 (fig. 11) coupled to the top surface 140 of the outer cartridge cover 132. The pusher body 188 is slidably coupled to the magazine 14 and biases the chain belt fastener strips toward the front portion 148 of the magazine 14. In the illustrated embodiment, the cartridge 14 includes a biasing member (e.g., a rolling coil spring 192; fig. 12) configured to bias the pusher body 188 toward the front portion 148 of the cartridge 14 (i.e., toward the nose piece 18).

Latch 196 includes: a latch protrusion 216 received within an opening 204 defined in the top surface 140 of the outer cassette cover 132; and first and second protrusions 208, 212 oriented on each side of latch 196. The latch projection 216 is biased inwardly (e.g., downwardly from the frame of reference of fig. 10) through the opening 204 toward the flange portion 160 of the locking assembly 156. The latch projections 216 each define a contact surface 240. The contact surface 240 defines a first plane 244 oriented at an oblique angle A1 relative to a vertical reference plane 242 perpendicular to the longitudinal axis 138 of the cassette 14. The other side of the arms 208, 212 defines an arcuate section 238 opposite a contact surface 240. In the illustrated embodiment, the angle A1 is an acute angle (e.g., less than 90 degrees). In some embodiments, angle A1 is in the range of 10 degrees to 30 degrees. In some embodiments, angle A1 is about 15 degrees.

Pusher body 188 is configured to ride on edge portion 180 and sidewall 184 of rail 172. Pusher body 220 defines a main body 224 supporting biasing member 192, and first and second arm members 230, 232. Each arm member 230, 232 includes a contact surface 236 (fig. 13) configured to contact surfaces 240 (fig. 12 and 13) of the first and second projections 208, 212, respectively, of the latch 196. The pusher body 220 is selectively engageable with the latch 196 to retain the pusher body 220 in a latched position (e.g., for loading). In the illustrated embodiment, the contact surfaces 236 are each curvilinear and include a constant radius R1. As a result, a single line of contact (e.g., extending along the longitudinal axis 138 of the cartridge 14) is formed between the contact surface 236 of the pusher body 188 (e.g., at radius R1) and the contact surface 240 of the latch 196.

As the cartridge 14 moves toward the closed position, the pusher body 188 automatically adjusts from the latched position to the released position by engagement between the flange portion 160 of the locking assembly 156 and the latching protrusion 216 of the latch 196 as the inner cartridge body 136 slides toward the closed position. Translation of the flange portion 160 in the closing direction of the inner cartridge body 136, for example, causes the latch protrusion 216 to slide upward along the inclined surface of the flange portion 160, which deflects the latch 196 upward (e.g., from the frame of reference of fig. 10 and 12). As a result, the contact surface 240 of the latch 196 moves over the contact surface 236 of the pusher body 188, which releases the pusher body 188 to bias the chain-belt gun string toward the nose piece 18.

When the cassette is moved toward the open position, the user releases the locking assembly 156 and slides the inner cassette body 136 (fig. 8) and the pusher body 188 relative to the outer cassette cover 132. Movement of the pusher body 188 causes the arcuate members 238 (fig. 12) of the first and second arm members 230, 232 of the latch 196 to engage the arm members 208, 212 of the pusher body 188, which deflects the latch 196 upward (with reference to fig. 12) such that the arm members 208, 212 of the latch 196 move past (e.g., under) the arm members 208, 212 of the pusher body 188. Once the arm members 208, 212 of the latch 196 clear the arm members 230, 232 of the pusher body 188, the latch 196 is urged toward the position shown in fig. 12 (e.g., so that the contact surfaces 236, 240 are in proximity to each other). Once the user releases the inner cassette body 136, the biasing member 192 pushes the pusher body 188 forward (e.g., toward the front portion 148 of the outer cassette cover 132), which causes the contact surface 236 of each arm member 230, 232 of the pusher body 188 to engage the contact surface 240 of the latch 196. Thus, the pusher body 188 is maintained in the latched position against the bias of the biasing member 192. The user can now load fasteners into the fastener passages 176 of the magazine 14 from the front of the pusher body 188. The user may then load the chain belt gun nail strip 12 into the magazine 14 from the front of the pusher body 188. To adjust the pusher body 188 from the latched state to the normal operating state, the user pushes the inner cassette body 136 toward the closed position (fig. 7), which disengages the engagement between the contact surfaces 236, 240 as described above. As a result, the pusher body 188 releases and biases the chain belt gun string 12 toward the nose piece 18.

Fig. 14-17 illustrate a cassette 314 according to another embodiment of the present utility model. The cassette 314 is similar to the cassette 14 shown in fig. 7-11 and described above. Thus, like features are identified with like reference numerals increased by "300" and only differences between the two will be discussed.

The cassette 314 includes an outer cassette cover 432 and an inner cassette body 436 received within the outer cassette cover 432 and slidable relative to the outer cassette cover between a first closed position (fig. 14) and a second open position (fig. 15). The outer cassette cover 432 includes a first front end 448 (fig. 1) adjacent the front end piece 18 and a second rear end 452 (fig. 1) adjacent the battery receptacle 34 and has a length L extending along the longitudinal axis 438 between the front end 448 and the rear end 452. A locking assembly 456 is positioned at the rear end 454 of the inner cassette body 436 to selectively couple the inner cassette body 436 to the outer cassette cover 432 to hold the inner cassette body 436 in the closed position. The cartridge 314 further includes a pusher body 488 (fig. 14) positioned within the fastener channel 476 (fig. 17) of the cartridge 314 and a latch 496 (fig. 14) coupled to the top wall 440 of the outer cartridge cover 432. The pusher body 488 is slidably coupled to the cassette body 436 and biases the one or more fastener strips 312 toward the front end 448 of the cassette cover 432. The outer cassette cover 432 further includes a pair of parallel side walls 482 extending from opposite sides of the top wall 440 and a slot 486 in each of the side walls 482 in which the inner cassette body 436 is received such that the inner cassette body 436 can slide relative to the outer cassette cover 432.

Referring now to fig. 15-17, the outer cassette cover 432 includes an inner rib 513 and an outer rib 515 that each extend inwardly from each of the side walls 482 of the outer cassette cover 432. The inner and outer ribs 513, 515 are parallel and vertically spaced apart on each side of slot 486 (fig. 17). In the illustrated embodiment, the inner rib 513 and the outer rib 515 each extend a length L1 (fig. 15) of the outer cassette cover 432 that is a portion of the overall length L of the outer cassette cover 432. Fastener channel 476 defines a width W1 sized to receive chain belt fastener strip 312, and inner and outer ribs 513, 515 define gaps between the inner ribs and between the outer ribs, the gaps having a width W2 that is less than the width W1 of fastener channel 476 (fig. 17). Thus, the inner and outer ribs 513, 515 reduce the width W2 of the opening formed in the bottom of the outer cassette cover 432 to limit removal and/or installation of the chain-strap fastener strip 312 into the fastener channel 476. In some embodiments of the magazine 314, the length L1 of the inner and outer ribs 513, 515 may be equal to or greater than the length of the individual fastener strips 312 to limit removal of the fastener strips 312 when positioned within the length L1 of the magazine cover 432.

In the illustrated embodiment, the lengths L1 of the inner and outer ribs 513, 515 are approximately equal. In other embodiments, the length of the outer rib 515 may be greater than or less than the length of the inner rib 513. In other embodiments, the outer cassette cover 432 may include only one of the inner rib 513 or the outer rib 515. While the inner and outer ribs 513, 515 are illustrated as being a continuous structure, it should be understood that the ribs may alternatively be segmented or discontinuous structures.

The second length L2 of the outer cassette cover 432 is devoid of the inner and outer ribs 513, 515 and defines a mounting area into which the fastener strips 312 of chain belt can be inserted one by one when the cassette body 436 is in the open position (fig. 15). The length L2 may be equal to or greater than the length of a single fastener strip 312, which requires the cassette body 436 to be fully retracted to its open position, thus securing the pusher body 488 to the latch 496 as described above, and then installing a new fastener strip 312.

When the chain type fastener strip 312 is inserted into the magazine 314, the first chain type fastener strip 312 is inserted into the mounting region of the outer magazine cover 432 and moves toward the front end 448 of the outer magazine cover 432. The second fastener strip 312 is then inserted into the mounting area of the outer cassette cover 432. The inner cassette body 436 moves toward the closed position (fig. 14), which releases the pusher body 488 and biases the chain-linked fastener strip 312 toward the nose piece 18. The internal ribs 513 support the ends of the chain-strap fastener strip 312 when the pusher body 488 biases the chain-strap fastener strip 312. The internal ribs 513 prevent adjacent strips 312 from tipping up, ensure proper alignment of the fastener strips 312 within the magazine 314, and support the ends of the fastener strips 312 as fasteners are sequentially delivered from the magazine 14 to the nosepiece 18 (fig. 1) prior to each fastener driving operation.

The cassette 614 includes an outer cassette cover 732 and an inner cassette body 736 received within the outer cassette cover 732. The inner cassette body 736 is movable between a first closed position (fig. 18), a second intermediate position (fig. 20), and a third open position (fig. 19 and 21). The outer cassette cover 732 includes a first front end 748 adjacent the front end member 618 and a second rear end 752 adjacent the battery receptacle 634. The inner cassette body 736 includes a front end 750 and a rear end 754 opposite the front end 748. In the open position, the chain-type fastener strip 312 can be inserted through a mounting region 807 formed in the rear end 752 of the outer cassette cover 732. The cartridge 614 further includes a pusher body 788 (fig. 21) positioned within the fastener channel 776 of the cartridge 614, which is slidably coupled to the cartridge body 736 and biases the chain belt fastener strips 612 toward the front end 748 of the cartridge cover 732.

The locking assembly 756 is positioned at the rear end 754 of the inner cassette body 736 to selectively couple the inner cassette body 736 to the outer cassette cover 732 to retain the inner cassette body 736 in the closed position (fig. 18). The locking assembly 756 includes a latch member 770 that selectively engages the latch bracket 764 and seats within the latch recess 768 when the outer cassette cover 732 is in the closed position (fig. 18). The latch bracket 764 further defines a recess 809 sized to receive a tab 811 formed on the inner cassette body 736 when the cassette 614 is in the second intermediate position (fig. 20).

Referring now to fig. 20-22, the outer cassette cover 732 includes ribs 815 extending inwardly from each of the side walls 782 of the outer cassette cover 732. The fastener channel 776 defines a width W1 (fig. 22) sized to receive the chain belt fastener strip 612 and the ribs 815 define a gap therebetween having a width W2 that is less than the width W1 of the fastener channel 776. Thus, ribs 815 prevent the installation of fastener strips 612 through the bottom of outer cassette cover 732, thus requiring the installation of fastener strips 612 through installation area 807 at rear end 752 of cassette cover 732.

To insert the chain belt fastener strips 612 into the magazine 614, the latch members 770 of the locking assemblies 756 are actuated to allow the inner magazine body 736 to slidably move relative to the outer magazine cover 732. Once the inner cassette body 736 reaches the second intermediate position (fig. 20), the tab 811 on the inner cassette body 736 engages the recess 809 formed in the latch bracket 764 such that the inner cassette body 736 can pivot relative to the outer cassette cover 732 toward the third open position (fig. 21). In the open position, the chain fastener strips 612 can be inserted into the magazine 614 through a mounting region 807 formed in the rear end 752 of the outer magazine cover 732 and moved toward the front portion 748 of the outer magazine cover 732. Once the chain belt fastener strip 612 is inserted into the outer box cover 732, the inner box body 736 is pivoted back to the second intermediate position and then slidably moved toward the closed position (fig. 18), which releases the pusher body 788 and biases the chain belt fastener strip 612 toward the nose piece 618 as described above.

Fig. 23 illustrates a powered fastener driver 1010 according to another embodiment of the present utility model. The powered fastener driver 1010 is similar to the powered fastener driver 10 shown in fig. 1-13 and described above. Thus, like features are identified with like reference numerals increased by "1000", and only differences between the two will be discussed.

The powered fastener driver 1010 (e.g., a cable nailer) includes a magazine 1014 that holds fasteners 1012 (e.g., the nails of a chain of nails) and a nose piece 1018 that sequentially receives the fasteners 1012 from the magazine 1014 prior to each fastener driving operation. The driver 1010 includes a trigger 1042 that selectively enables a drive mechanism 1046 enclosed within the handle portion 1030 of the driver 1010. The drive mechanism 1046 includes an electric motor 1050 and a gearbox 1054 that receives torque from the motor 1050. The jack assembly 1058 is coupled to the drive mechanism 1046 and positioned between the drive mechanism 1046 and the firing mechanism 1062.

Firing mechanism 1062 includes a movable member (e.g., piston 1066) for reciprocal movement within head portion 1026, a biasing member (e.g., compression spring 1070) disposed against piston 1066, and a driver blade 1074 attached to piston 1066. Biasing members 1070, 1072 urge piston 1066 and driver blade 1074 toward a driven or Bottom Dead Center (BDC) position within head portion 1026 to drive fastener 1012 into a workpiece.

The lifter assembly 1058 is operated by the drive mechanism 1046 to return the piston 1066 and driver blade 1074 toward a Top Dead Center (TDC) position against the bias of the biasing members 1070, 1072. In the illustrated embodiment, the biasing member includes a pair of nested compression springs 1070, 1072 that cooperate to urge the piston 1066 and driver blade 1074 toward the BDC position. Compression springs 1070, 1072 include a first end supported within piston 1066 and a second end supported within end cap 1114. End cap 1114 includes a first outer recess 1117 and a second inner recess 1119 surrounded by first recess 1117. A first outer washer 1121 is supported within a first recess 1117 formed in the end cap 1114. A second internal gasket 1123 is supported within a second recess 1119 formed in the end cap 1114. End cap 1114 further includes an outer spring sleeve 1125 that retains a first washer 1123 within end cap 1114. A first washer 1123 is positioned between the second end of the first compression spring 1070 and the end cap 1114. A second washer 1125 is positioned between the second end of the second compression spring 1072 and the end cap 1114. In the illustrated embodiment, the spring sleeve 1125 is formed of a metallic material (e.g., steel) and the washers 1121, 1123 are formed of a plastic material. The spring sleeve 1123 reduces deformation of the outer washer 1117 and helps maintain the shape of the washer 1117.

Further, the compression springs 1070, 1072 are formed of a metallic material, such as 55 CrSi. The first outer compression spring 1070 has a first wire thickness T1 and the second inner compression spring has a second wire thickness T2 that is less than the first wire thickness T1. The outer compression spring 1070 includes a nominal outer diameter of 40 millimeters, an uncompressed length of 93 millimeters, and a stiffness of 8.7N/mm. In some embodiments, the nominal outer diameter of the external compression spring 1070 may be in the range of 30 millimeters to 50 millimeters. In some embodiments, the stiffness of the external compression spring 1070 may be in the range of 8.0N/mm to 10N/mm. The inner compression spring 1072 includes a nominal outer diameter of 25 millimeters, an uncompressed length of 93 millimeters, and a stiffness of 4.35N/mm. In some embodiments, the nominal outer diameter of the inner compression spring 1072 may be in the range of 30 millimeters to 50 millimeters. In some embodiments, the stiffness of the internal compression spring 1072 may be in the range of 3.0N/mm to 6.0N/mm. In some embodiments, the uncompressed length of the inner and outer compression springs 1070, 1072 may be in the range of 70 millimeters to 110 millimeters.

As shown in fig. 25, the jack assembly 1058 is formed as a unitary body having an output shaft 1056 and a hub 1013 that may also be considered the output shaft of the gearbox 1054, which selectively engages a portion of the firing mechanism 1062 to return the piston 1066 and the driver blade 1074 toward the TDC position. At the TDC position, the compression springs 1070, 1072 store a potential energy of at least 14.5 joules (J), which provides sufficient energy to fully seat the fastener into the workpiece. The fastener driver 1010 is capable of storing potential energy of at least 14.5J, with a total length L defined between a front end of the driver 1010 (e.g., the front end of the contact latch 1020) and a rear end of the housing 1022 (e.g., the head portion 1026) of 18 centimeters or less, and in some embodiments 16.5 centimeters or less due to the nested springs 1070, 1072 acting on the piston 1066. By nesting the dual springs 1070, 1072 with different stiffness, more potential energy can be stored in the driver 1010 than a single spring within the same space constraints. In other words, to achieve equivalent potential energy with a single compression spring, such a spring necessarily requires a longer uncompressed length to accommodate the greater amount of compression, which requires a greater overall length of the actuator (i.e., greater than 18 cm). Drivers 1010 having an overall length of 18 centimeters or less may be used in a narrower space than prior art fastener drivers having an overall length of greater than 18 centimeters.

For example, the hub 1013 may include eccentric pins 1104, 1008 that engage corresponding first and second protrusions 1098, 1102 (fig. 24) of the firing mechanism, which returns the piston 1066 and driver blade 1074 from the BDC position toward the TDC position. In the illustrated embodiment, the eccentric pins 1104, 1108 are secured within recesses 1017 (fig. 25) formed in the hub 1013 of the jack assembly 1058. In other embodiments, the eccentric pins 1104, 1108 may be integrally formed with the hub 1013.

The unitary construction of the jack assembly 1058 improves the performance and durability of the jack assembly 1058 by reducing the number of separately assembled parts in the jack assembly 1058. In the illustrated embodiment, the jack assembly 1058 is formed by forging a piece of raw material (e.g., steel, aluminum, etc.) into a desired form. The recess 1017 may be formed by machining the lifter assembly 1058 after the forging process is complete. In other embodiments, the eccentric pins 1104, 1108 may also be formed as part of the integral body of the lifter assembly 1058 during the forging process.

Referring now to fig. 26, the magazine 1014 is sized to receive a chain-type fastener strip having a plurality of fasteners 1012. Each of the fasteners 1012 includes a crown section 1021 and a head 1025 opposite the crown section 1021. The fastener 1012 is held in the chain-type fastener strip by chain-type tabs 1029 interconnecting the crown sections 1021 of the fastener 1012. The nose piece 1018 defines a fastener-driving channel 1031 from which successive fasteners 1012 provided from the magazine 1014 are driven during each fastener-driving operation.

The powered fastener driver 1010 can include a fastener alignment mechanism that urges the fastener 1012 adjacent the fastener drive channel 1031 of the nose piece 1018 toward a loading position. In the illustrated embodiment, the alignment mechanism can include a magnetic element 1033 positioned adjacent to the first front portion 1150 of the cassette 1014 and the front end piece 1018 of the driver 1010. In the illustrated embodiment, the magnetic element 1033 is positioned proximate the tip 1025 of the fastener 1012 near the fastener drive channel 1031 of the nose piece 1018. The magnetic element 1033 generates a magnetic force that interacts with the tip 1025 of the fastener 1012 and urges the tip upward (i.e., toward the nose piece 1018) from the reference frame of fig. 26. The use of the magnetic element 1033 aligns the fastener 1012 with the fastener driving channel 1031 without increasing resistance during fastener driving operations. In other embodiments, the magnetic element 1033 may be positioned near other sections of the fastener 1012. Additionally, or alternatively, one or more magnetic elements 1033 may be used to ensure alignment and upward biasing of the fastener 1012.

During a fastener driving event, the chain belt tab 1029 of a fastener 1012 positioned adjacent to the fastener driving channel 1031 may be split from an adjacent chain belt tab, which may cause the fastener 1012 to rotate. The magnetic force provided by magnetic element 1033 counteracts the rotation caused during the breaking process of chain belt tab 1029 to prevent over-rotation of fasteners 1012 within magazine 1014 (e.g., beyond the loading position) and to ensure proper alignment between fasteners 1012 and fastener drive channel 1031 before fasteners 1012 enter channel 1031. In the illustrated embodiment, the fastener axis 1035 extends centrally through the fastener 1012. When the fastener 1012 is in the loaded position (shown in phantom outline of the fastener 1012), the tip 1025 of the fastener 1012 may be pushed upward by the magnetic element 1033 (e.g., pre-tilt the fastener 1012), which causes the fastener axis 1035' to be non-parallel with the drive axis 1078 defined by the driver blade 1074. As the chain belt tab 1029 breaks, the fastener 1012 rotates to realign the fastener axis 1035' with the fastener axis 1035, thereby becoming parallel with the drive axis 1078 defined by the driver blade 1074.

Referring now to fig. 27, the nose piece 1018 of the powered fastener driver 1010 includes an inner surface 1039 sized to receive a cable that is fastened to a workpiece during a fastener driving operation. In the illustrated embodiment, the inner surface 1039 includes a first portion 1043 having a first width W1 and a second portion 1047 having a second width W2 that is greater than the first width W1. In other words, the inner surface 1039 is stepped to accommodate cables of different diameters during fastener driving operations. In some embodiments, the second portion 1047 may be movable relative to the first portion 1043 to adjust the width of the second portion 1047 of the nose piece 1018 to accommodate larger diameter cables. In the illustrated embodiment, the first portion of the nose piece has a width of 15.5 millimeters and the second portion of the nose piece has a width of 16.5 millimeters.

Although the utility model has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the utility model as described.

Various features of the utility model are set forth in the appended claims.

Claims

1. A fastener driver, comprising:

A housing defining a head portion and a handle portion;

a drive mechanism positioned within the housing;

a launching mechanism, the launching mechanism comprising:

a main guide member supported within the head portion of the housing,

a secondary guide member spaced apart from the primary guide member and supported within the head portion of the housing,

a piston slidable along the main guide member and the sub guide member,

a driver blade attached to the piston and configured to be movable along a drive axis, an

A biasing member configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position; and

a lifter assembly is operated by the drive mechanism to return the piston and the driver blade toward the TDC position against the bias of the biasing member.

2. The fastener driver of claim 1 wherein the primary guide member defines a first axis, and wherein the secondary guide member defines a second axis oriented parallel to the first axis and the drive axis.

3. The fastener driver of claim 2 wherein the lifter assembly rotates about a third axis transverse to the first and second axes.

4. The fastener driver of claim 2, wherein the piston includes a first bore sized to receive and support the primary guide member along the first axis.

5. The fastener driver of claim 4 further comprising a bracket coupled to move with the piston, and wherein a second bore is formed in the bracket and is sized to receive and support the secondary guide member along the second axis.

6. The fastener driver of claim 5 wherein the bracket is integrally formed with the piston.

7. The fastener driver of claim 5 wherein the bracket includes a first tab and a second tab vertically spaced from the first tab along the first axis, and wherein the first tab and the second tab each extend toward the riser assembly and selectively engage a pin of the riser assembly.

8. The fastener driver of claim 7 wherein the first projection extends farther from the bracket than the second projection.

9. The fastener driver of claim 4 wherein a cavity surrounds the first aperture and is sized to receive the biasing member.

10. The fastener driver of claim 1, further comprising:

a magazine configured to receive fasteners; and

a nosepiece including a fastener driving channel in which the driver blade is located, from which successive fasteners from the magazine are driven.

11. The fastener driver of claim 1, further comprising a frame located within the housing and configured to support the riser assembly and the primary guide member.

12. A fastener driver, comprising:

a housing defining a head portion and a handle portion;

a drive mechanism positioned within the housing;

a launching mechanism, the launching mechanism comprising:

a main guide member supported within the head portion of the housing,

a piston slidable along the main guide member,

a driver blade attached to the piston, an

A biasing member configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position;

A lifter assembly operated by the drive mechanism to return the piston and the driver blade toward the TDC position against the bias of the biasing member; and

a frame is located within the housing and configured to support the riser assembly and the primary guide member.

13. The fastener driver of claim 12 wherein the frame includes a first portion positioned within the head portion of the housing and a second portion positioned within the handle portion.

14. The fastener driver of claim 12 further comprising a secondary guide member spaced from the primary guide member and supported within the head portion of the housing, wherein the secondary guide member is supported within the housing by the frame between the primary guide member and the riser assembly.

15. The fastener driver of claim 14, further comprising an end cap positioned within the housing, wherein the frame is configured to support a first end of the primary guide member and a first end of the secondary guide member, and wherein the end cap is configured to support an opposite second end of the primary guide member and an opposite second end of the secondary guide member.

16. The fastener driver of claim 14 wherein the primary guide member defines a first axis, and wherein the secondary guide member defines a second axis oriented parallel to the first axis.

17. The fastener driver of claim 16 wherein the piston includes a first bore sized to receive and support the primary guide member along the first axis, and wherein a cavity surrounds the first bore and is sized to receive the biasing member.

18. The fastener driver of claim 17 wherein the drive mechanism comprises a gear box integrally formed with the frame.

19. The fastener driver of claim 12, further comprising:

a magazine configured to receive fasteners; and

20. A fastener driver, comprising:

a housing defining a head portion and a handle portion;

a drive mechanism positioned within the housing;

A firing mechanism including a piston and a driver blade, the piston and the driver blade being movable from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position; and

a lifter assembly operated by the drive mechanism to rotate about an axis of rotation to return the piston and the driver blade toward the TDC position, the lifter assembly comprising

A first eccentric pin located at a first radial distance relative to the axis of rotation, an

A second eccentric pin located at a second radial distance relative to the rotational axis, the second radial distance being less than the first radial distance.

21. The fastener driver of claim 20 wherein the lifter assembly includes an outer circumferential surface and each of the first and second eccentric pins is positioned adjacent the outer circumferential surface.

22. The fastener driver of claim 20 further comprising a primary guide member supported within the head portion of the housing, wherein the primary guide member defines a first axis, and wherein the piston is slidable along the primary guide member.

23. The fastener driver of claim 22, further comprising a frame located within the housing and configured to support the riser assembly and the primary guide member.

24. The fastener driver of claim 22 wherein the rotational axis of the lifter assembly is transverse to the first axis.

25. The fastener driver of claim 22 wherein the first eccentric pin has a first height and the second eccentric pin has a second height that is greater than the first height.

26. The fastener driver of claim 25, further comprising a bracket coupled to move with the piston, wherein the bracket includes a first protrusion and a second protrusion vertically spaced apart from the first protrusion along the first axis, and wherein the first eccentric pin is configured to engage the first protrusion and the second eccentric pin is configured to engage the second protrusion.

27. The fastener driver of claim 26 wherein the bracket is integrally formed with the piston.

28. The fastener driver of claim 26 wherein the first protrusion extends farther from the bracket than the second protrusion.

29. The fastener driver of claim 20, further comprising:

a magazine configured to receive fasteners; and

30. A fastener driver, comprising:

a magazine configured to receive fasteners therein, the magazine comprising

A cassette cover, the cassette cover having: a length extending along a longitudinal axis between the first end and the second end; a top surface having an opening defined therein proximate the second end; and a bottom surface opposite the top surface, and

a magazine body slidably movable relative to the magazine cover from a closed position to an open position for reloading the magazine with fasteners;

a nosepiece including a fastener driving channel from which successive fasteners from the magazine are driven, the nosepiece being adjacent the first end of the magazine cover;

A latch coupled to the top surface of the cassette cover, the latch extending through an opening in the top surface of the cassette cover, the latch including a latch protrusion defining a first contact surface;

a pusher body slidably coupled to the cartridge body, the pusher body including an arm member defining a second contact surface; and

a biasing member configured to bias the pusher body and fasteners within the cartridge toward the nosepiece when the cartridge body is in the closed position,

wherein the first contact surface and the second contact surface are engageable to retain the pusher body in a latched position when the cassette body is in the open position.

31. The fastener driver of claim 30 wherein the first contact surface defines a first plane oriented at an oblique angle relative to a vertical reference plane perpendicular to the longitudinal axis of the cartridge.

32. The fastener driver of claim 31 wherein the angle of inclination is an acute angle.

33. The fastener driver of claim 31 wherein the angle of inclination is in the range of 10 degrees to 30 degrees.

34. The fastener driver of claim 31 wherein the angle of inclination is about 15 degrees.

35. The fastener driver of claim 30 wherein the second contact surface is curvilinear.

36. The fastener driver of claim 30 wherein the second contact surface comprises a constant radius.

37. The fastener driver of claim 30 wherein the magazine body includes an extrusion rail defining a fastener channel in which a gun pin is received, and wherein the pusher body is configured to ride on the rail.

38. The fastener driver of claim 30, wherein a locking assembly is positioned at a rear end of the magazine body, and wherein the locking assembly is configured to selectively couple the magazine body to the magazine cover.

39. The fastener driver of claim 38, wherein the cassette cover includes a latch bracket and a latch recess, and wherein the locking assembly includes a latch member that selectively engages the latch bracket and seats within the latch recess when the cassette cover is in the closed position.

40. A fastener driver, comprising:

a magazine configured to receive a strip of chain-band fasteners therein, the magazine comprising

A cassette cover having a length extending along a longitudinal axis between a first end and a second end, a top surface, parallel side walls extending from opposite sides of the top surface, respectively, and a rib extending inwardly from at least one of the side walls along a first portion of the length of the cassette cover, the cassette cover being configured to receive the fastener strips between the side walls along a second portion of the length of the cassette cover, the rib being configured to limit installation or removal of the fastener strips located within the first portion of the length of the cassette cover, and

a magazine body slidably movable relative to the magazine cover from a closed position to an open position for reloading the magazine with a chain-type fastener strip; and

a nosepiece including a fastener driving channel from which successive fasteners from the magazine are driven, the nosepiece being adjacent the first end of the magazine cover.

41. The fastener driver of claim 40 wherein the magazine cover includes a mounting region formed along a second portion of the length of the magazine cover, and wherein the mounting region is free of the rib, thereby enabling insertion of a chain belt fastener strip between the side walls when the magazine body is in the open position.

42. The fastener driver of claim 40 wherein the rib is a first rib extending inwardly from an end of a first one of the side walls, wherein the magazine further comprises a second rib extending inwardly from the first side wall along a first portion of the length of the magazine cover, wherein the second rib is parallel to the first rib, and wherein the second rib is configured to prevent the fastener strips of the chain belt from tipping in response to the magazine body moving from the open position to the closed position.

43. The fastener driver of claim 40 wherein the rib is a first rib extending inwardly from an end of a first one of the side walls, wherein the magazine further comprises a second rib extending inwardly from an end of a second side wall along a first portion of the length of the magazine cover, and wherein the first rib and the second rib define a gap between the first rib and the second rib having a width less than the width of the chain-strap fastener strips.

44. The fastener driver of claim 40 wherein a locking assembly is positioned at the rear end of the magazine body, and wherein the locking assembly is configured to selectively couple the magazine body to the magazine cover.

45. The fastener driver of claim 44 wherein the cassette cover includes a latch bracket and a latch recess, and wherein the locking assembly includes a latch member that selectively engages the latch bracket and seats within the latch recess when the cassette cover is in the closed position.

46. A fastener driver, comprising:

A magazine cover having a length extending along a longitudinal axis between a first end and a second end, a top surface, parallel side walls extending from opposite sides of the top surface, respectively, and a rib extending inwardly from at least one of the side walls along the length of the magazine cover, the magazine cover being configured to pass through the second end of the magazine cover and to receive the fastener strips between the side walls, the rib being configured to limit installation or removal of the fastener strips after insertion of the fastener strips through the second end of the magazine cover, and

A cassette body slidably movable relative to the cassette cover from a closed position to an intermediate position and pivotable relative to the cassette cover from the intermediate position to an open position to reload the cassette; and

47. The fastener driver of claim 46 wherein the magazine cover includes a first end adjacent the nose piece and a second end opposite the first end, and wherein the magazine body includes a first end positioned adjacent the nose piece and a second end opposite the first end when the magazine body is in the closed position.

48. The fastener driver of claim 47 wherein a locking assembly is positioned at the second end of the cartridge body to selectively couple the cartridge body to the cartridge cover to retain the cartridge body in the closed position.

49. The fastener driver of claim 48 wherein the cassette cover includes a latch bracket and a latch recess, and wherein the locking assembly includes a latch member that selectively engages the latch bracket and seats within the latch recess when the cassette cover is in the closed position.

50. The fastener driver of claim 49 wherein the latch bracket defines a second recess sized to receive a tab formed on the cartridge body when the cartridge body is in the intermediate position.

51. A fastener driver, comprising:

a housing defining a head portion and a handle portion;

a drive mechanism positioned within the housing;

a lifter assembly operated by the drive mechanism to rotate about an axis of rotation, the lifter assembly comprising a unitary body having an input shaft coupled to the drive mechanism to receive torque from the drive mechanism and a hub selectively engaging a portion of the firing mechanism to return the piston and the driver blade toward the TDC position.

52. The fastener driver of claim 51 wherein the lifter assembly is formed from a forged, single piece of raw material.

53. The fastener driver of claim 51 wherein,

the hub includes first and second eccentric pins that engage first and second protrusions of the firing mechanism, respectively, to return the piston and the driver blade toward the TDC position.

54. The fastener driver of claim 53 wherein the lifter assembly includes an outer circumferential surface and each of the first and second eccentric pins is positioned adjacent the outer circumferential surface.

55. The fastener driver of claim 53 wherein the first eccentric pin has a first height and the second eccentric pin has a second height that is greater than the first height.

56. The fastener driver of claim 55 wherein the first protrusion extends further from the firing mechanism than the second protrusion, and wherein the first eccentric pin is configured to engage the first protrusion and the second eccentric pin is configured to engage the second protrusion.

57. The fastener driver of claim 51 further comprising a primary guide member supported within the head portion of the housing, wherein the primary guide member defines a first axis transverse to the axis of rotation, and wherein the piston is slidable along the primary guide member.

58. The fastener driver of claim 57 further comprising a frame located within the housing and configured to support the riser assembly and the primary guide member.

59. The fastener driver of claim 51 further comprising:

a magazine configured to receive fasteners; and

60. A fastener driver, comprising:

a magazine having a length extending along a longitudinal axis between a first end and a second end, the magazine configured to receive a chain-type fastener strip in the magazine, the chain-type fastener strip comprising a plurality of fasteners having a crown section and a tip opposite the crown section;

a nosepiece including a fastener driving channel from which successive fasteners from the magazine are driven, the nosepiece being located adjacent the first end of the magazine; and

a fastener alignment mechanism positioned adjacent the first end of the magazine, the fastener alignment mechanism including a magnetic element that generates a magnetic force on a fastener tip positioned adjacent the fastener drive channel to urge the fastener tip toward the nosepiece,

Wherein the magnetic force urges the fastener toward a loading position in which the fastener is aligned with the fastener driving channel of the nosepiece.

61. The fastener driver of claim 60 further comprising

A housing defining a head portion and a handle portion;

a drive mechanism positioned within the housing; and

a firing mechanism including a piston and a driver blade movable from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position, wherein the driver blade defines a driver axis.

62. The fastener driver of claim 61 further comprising a lifter assembly operated by the drive mechanism to rotate about an axis of rotation to return the piston and the driver blade toward the TDC position, and wherein the axis of rotation of the lifter assembly is transverse to the driver axis.

63. The fastener driver of claim 61 wherein the fastener axis extends centrally through the fastener.

64. The fastener driver of claim 63 wherein the fastener axis is non-parallel to a driver axis defined by the driver blade when the fastener is in the loading position.

65. The fastener driver of claim 63 wherein,

the fastener strip further includes a fastener strip tab sized to receive the crown sections of the fasteners, and

the chain belt tab engages a side wall of the magazine to prevent over-rotation of the fastener beyond the loading position.

66. The fastener driver of claim 64 wherein as the chain belt tab splits, the fastener rotates to realign the fastener axis to become parallel with the driver axis defined by the driver blade.

67. A fastener driver, comprising:

a magazine having a length extending along a longitudinal axis between a first end and a second end, the magazine configured to receive a strip of chain-band fasteners therein; and

a nosepiece including a fastener drive channel from which successive fasteners from the magazine are driven, the nosepiece being located adjacent the first end of the magazine, the nosepiece including an inner surface configured to receive a cable secured to a workpiece during a fastener driving operation, the inner surface including a first portion having a first width and a second portion having a second width, the second width being greater than the first width.

68. The fastener driver of claim 67 wherein the second portion is movable relative to the first portion to adjust a second width of the second portion of the nose piece.

69. The fastener driver of claim 67 wherein the first width is 15.5 millimeters.

70. The fastener driver of claim 67 wherein the second width is 15.5 millimeters.

71. The fastener driver of claim 67 further comprising:

a housing defining a head portion and a handle portion;

a drive mechanism positioned within the housing; and

a firing mechanism including a piston and a driver blade movable from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position.

72. The fastener driver of claim 71 further comprising an elevator assembly operated by the drive mechanism to rotate about an axis of rotation to return the piston and the driver blade toward the TDC position.

73. The fastener driver of claim 72 further comprising a primary guide member supported within the head portion of the housing, wherein the primary guide member defines a first axis transverse to the axis of rotation, and wherein the piston is slidable along the primary guide member.

74. The fastener driver of claim 73 wherein the rotational axis of the lifter assembly is transverse to the first axis.

75. A fastener driver, comprising:

a housing defining a head portion and a handle portion;

an end cap supported within the head portion, the end cap comprising

The first recess portion is provided with a first recess portion,

a second recess surrounded by the first recess, and

an outer sleeve surrounding the first recess;

a drive mechanism positioned within the housing;

a launching mechanism, the launching mechanism comprising

The piston is provided with a piston which is provided with a piston,

a driver blade attached to the piston,

a first biasing member having a first end supported within the piston and a second end disposed within the first recess of the end cap, an

A second biasing member having a first end supported within the piston and a second end disposed within a second recess of the end cap, the first and second biasing members configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position;

a gasket positioned between the second end of the first biasing member and the end cap, the gasket supported within the first recess of the end cap; and

A lifter assembly is operated by the drive mechanism to return the piston and the driver blade toward the TDC position against the bias of the first and second biasing members.

76. The fastener driver of claim 75 wherein,

the gasket is a first gasket that is configured to be positioned against the first,

a second washer is positioned between the second end of the second biasing member and the end cap, and

the gasket is supported within the second recess of the end cap.

77. The fastener driver of claim 75 wherein the outer sleeve of the end cap is formed of a metallic material and the washer is formed of a plastic material.

78. The fastener driver of claim 75 wherein the first compression spring has a first wire thickness and the second compression spring has a second wire thickness less than the first thickness.

79. The fastener driver of claim 75 further comprising:

a magazine configured to receive fasteners; and

80. A fastener driver, comprising:

a front end portion;

a housing defining a head portion having a rear end, and a handle portion;

a drive mechanism positioned within the housing;

a battery pack coupled to the battery receptacle, the battery pack configured to provide power to the drive mechanism; and

a launching mechanism, the launching mechanism comprising

Piston and its manufacturing method

A driver blade attached to the piston, the driver blade configured to move from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position,

wherein the fastener driver has a length defined between the front end and the rear end, and

wherein the length is less than or equal to 18 cm.

81. The fastener driver of claim 80 wherein the length is in the range of 12.5 cm to 18 cm.

82. The fastener driver of claim 80 wherein the length is in the range of 12.5 cm to 16.5 cm.

83. The fastener driver of claim 80, further comprising

A magazine configured to receive fasteners; and

A nosepiece including a fastener drive channel in which the driver blade is located, and a contact trip from which successive fasteners from the magazine are driven, the contact trip being configured to permit operation of the fastener driver, wherein a nose portion of the contact trip defines a nose portion of the fastener driver.

84. The fastener driver of claim 80, further comprising

A biasing member configured to move the piston and the driver blade from the TDC position toward the BDC position, an

85. The fastener driver of claim 84 wherein the biasing member comprises:

a first compression spring having a first end supported within the piston and a second end disposed within a first recess of the end cap, an

A second compression spring nested within the first compression spring, the second compression spring having a first end supported within the piston and a second end disposed within a second recess of the end cap.

86. The fastener driver of claim 85 wherein the first compression spring has a first wire thickness and the second compression spring has a second wire thickness that is less than the first wire thickness.

87. The fastener driver of claim 84 wherein the biasing member stores at least 14.5 joules of potential energy when the driver blade is in the TDC position.

88. A fastener driver, comprising:

a housing defining a head portion and a handle portion;

a drive mechanism positioned within the housing;

a firing mechanism configured to actuate in response to an input from the drive mechanism, the firing mechanism comprising

The piston is provided with a piston which is provided with a piston,

a driver blade attached to the piston, an

A biasing member configured to move the piston and the driver blade from a Top Dead Center (TDC) position toward a Bottom Dead Center (BDC) position,

wherein the biasing member stores at least 14.5 joules of energy when the driver blade is in the TDC position.

89. The fastener driver of claim 88, further comprising:

a lifter assembly operated by the drive mechanism to return the piston and the driver blade toward the TDC position against the bias of the first and second biasing members;

A magazine configured to receive fasteners; and

90. The fastener driver of claim 88 wherein the biasing member comprises:

91. The fastener driver of claim 90 wherein the first compression spring has a first wire thickness and the second compression spring has a second wire thickness less than the first wire thickness.

92. The fastener driver of claim 90 wherein the first compression spring has a nominal outer diameter in the range of 30 millimeters to 50 millimeters.

93. The fastener driver of claim 90 wherein the first compression spring has a stiffness in the range of 8.0N/mm to 10N/mm.

94. The fastener driver of claim 90 wherein the second compression spring has a nominal outer diameter in the range of 30 millimeters to 50 millimeters.

95. The fastener driver of claim 90 wherein the second compression spring has a stiffness in the range of 3.0N/mm to 6.0N/mm.

96. The fastener driver of claim 90 wherein the drive mechanism comprises a brushless DC motor.

97. The fastener driver of claim 90 wherein the first compression spring and the second compression spring each have an uncompressed length in the range of 70 millimeters to 110 millimeters.