[0001] The present invention relates to a drive system for a nailer.
[0002] This patent application claims benefit of the filing date of copending
US provisional patent application number 62/244,143 entitled "High Inertia Driver
System" filed on October 20, 2015. This patent application is a continuation-in-part application of copending
US patent application 14/498,475 entitled "Nailer Driver Blade Stop" filed September
26, 2014, which is a nonprovisional patent application of
US provisional patent application number 61/961,247 entitled "Nailer Driver Blade
Stop" filed on October 9, 2013, to which benefit of priority is also claimed. This patent application is also a
continuation-in-part application of copending
US patent application 14/444,982 entitled "Power Tool Drive Mechanism" filed July
28, 2014.
[0003] This patent application incorporates by reference in its entirety
US provisional patent application number 62/244,143 entitled "High Inertia Driver
System" filed on October 20, 2015. This patent application incorporates by reference in its entirety copending
US patent application 14/498,475 entitled "Nailer Driver Blade Stop" filed September
26, 2014, which is a nonprovisional patent application of
US provisional patent application number 61/961,247 entitled "Nailer Driver Blade
Stop" filed on October 9, 2013, which is also incorporated by reference in its entirety herein. This patent application
also incorporates by reference in its entirety copending
US patent application 14/444,982 entitled "Power Tool Drive Mechanism" filed July
28, 2014.
[0004] Fastening tools, such as nailers, are used in the construction trades. However, many
fastening tools which are available do not provide an operator with fastener driving
mechanisms which exhibit reliable fastener driving performance. Many available fastening
tools do not adequately guard the moving parts of a nailer driving mechanism from
damage. These failures are even more pronounced during high energy and/or high-speed
driving. Improper driving of fasteners, failure of parts and damage to the tool can
occur. Additionally, undesired driver blade recoil and/or undesired driver blade return
dynamics can frequently occur and can result in misfires, jams, damage to the tool
and loss of work efficiency. This recoil energy in the driver blade can frequently
cause an unintentional driving of a second fastener. In the case of a cordless nailer
having mechanical return springs, this unintentional driving of a second nail can
be very common. Unintentionally driving a second nail can risk damage to the work
surface, jams, misfires, or tool failures. Many available fastening tools experience
misfire and produce unacceptable rates of damaged fasteners when fired. Further, many
available fastening tools do not adequately guard the moving parts of a nailer driving
mechanism from damage.
[0005] Additionally, a nailer which uses one or more return springs can experience spring
failure which can render a nailer inoperable. A nailer having such a failed spring
must be discarded or the failed spring must be replaced and the nailer repaired. Spring
failure, tool replacement or repair are inconvenient to an operator and incur unwanted
expenses.
[0006] In addition to the above, many available cordless nailer designs which do not use
a piston cylinder arrangement are only capable of driving finish nails. They are unable
to drive fasteners into concrete and/or metal. They are also inadequate to drive fasteners
into various types of hard or dense construction materials. There is a strong need
for a reliable and an effective fastener driving mechanism.
[0007] A high inertia driver system for a fastening tool is disclosed herein which has an
electric motor that drives a flywheel to contact a driver blade to drive a fastener
into a workpiece. The high inertia driver system also has a return system which prevents
the unintentional driving of a second fastener. The return system can use a return
spring and one or more bumpers that control the recoil energy of the driver blade
after driving a fastener into a workpiece. The high inertia driver system achieves
a long operational life for the fastening tool in part by increasing the number of
return cycles of the driver blade free of a return spring failure.
[0008] In an embodiment, the fastening tool can also have a cupped flywheel. The cupped
flywheel can have a flywheel ring. In an embodiment, at least a portion of the cupped
flywheel can be cantilevered over at least a portion of said motor and/or motor housing.
The cupped flywheel can have a contact surface. The cupped flywheel can have a geared
flywheel ring. In an embodiment, the cupped flywheel can have a mass in a range of
from about 28.4 g to about 570 g. In another embodiment, the fastening tool can have
a cantilevered flywheel which can have a diameter in a range of from about 0.02 m
to about 0.3 m. The cantilevered flywheel can be adapted to rotate at an angular speed
of from about 500 rads/s to about 1500 rads/s. The cantilevered flywheel can be adapted
to have a flywheel energy in a range of from about 10 J to about 500 J or greater,
such as 1500 J.
[0009] The cupped flywheel portion can radially surround at least a portion of the motor.
The motor which is provided can have an inner rotor or an outer rotor. Additionally,
the motor provided can be a brushed motor or a brushless motor.
[0010] In an embodiment, a high inertia drive mechanism for a nailer can have an electric
motor having a rotor and a rotor shaft coupled to a flywheel. The motor can be adapted
to rotate said flywheel. The flywheel can be adapted to impart a force upon a driver
blade when a portion of the flywheel is contacted with a portion of a driver blade.
When a portion of the flywheel is contacted with a portion of a driver blade, the
driver blade can be driven at a speed of 30 m/s or less. The flywheel can have a speed
15000 rpm, or less. In an embodiment, the speed of the driver blade is in a range
of 10 m/s to 30 m/s. In an embodiment, the flywheel can have an inertia in a range
of 0.10 g*m^2 - 0.40 g*m^2, when a portion of the flywheel is contacted with a portion
of a driver blade. In an embodiment, the pinch force imparted by a portion of the
flywheel to a driver blade when in contact with a portion of the driver blade can
be in a range of 222 N - 2669 N. The mass of the driver blade can be in a range of
80 g to 200 g.
[0011] In an embodiment, a nailer can have an electric motor having a rotor having a rotor
shaft coupled to a flywheel. The driver blade can be driven when a portion of the
flywheel is contacted with a portion of the driver blade. The nailer can have a return
system having a spring adapted to be compressed at least in part during a return cycle
when said driver blade returns after driving a faster into a workpiece. The return
system can achieve 24000 return cycles, 42000 return cycles, 60000 return cycles,
100000 return cycles or greater, without, or free of, a spring failure. In an embodiment,
the nailer can have the mass of the driver blade in a range of 50 g to 500 g, or 80
g to 200 g. The flywheel can have an inertia is in a range of 0.10 g*m^2 - 0.40 g*m^2
when said portion of the flywheel is contacted with said portion of the driver blade.
A pinch force can be imparted by the flywheel when in contact with a portion of the
driver blade in a range of 222 N to 2669 N. The contact by a portion of the flywheel
to a portion of the driver blade can drive the driver blade at a speed in a range
of 10 m/s to 30 m/s.
[0012] A method of operating a nailer can have the steps of: providing a flywheel; generating
an inertia of said flywheel of 0.10 g*m^2, or greater; contacting a portion of the
flywheel with a portion of the driver blade, said contacting driving said driver blade;
providing a return system having a spring adapted to be compressed at least in part
during a return cycle when said driver blade returns after driving a faster into a
workpiece; and said return system achieving, or executing, 24000 return cycles, or
greater, without a spring failure. In an embodiment, the flywheel can be a cantilevered
flywheel. The fastener can be a nail, or other type of fastener.
[0013] In an embodiment, the method of operating a nailer can also have the steps of: providing
a first operating mode, wherein said driver blade speed is a first speed; and providing
a second operating mode, wherein said driver blade speed is a second speed different
from said first speed. Optionally, the first operating mode, wherein said driver blade
speed can be a first speed in a range of 13000 m/s to 15000 m/s; and the second operating
mode, wherein said driver blade speed can be a second speed in a range of 7000 m/s
to 12900 m/s.
[0014] In an embodiment, the method of operating a nailer can have the step of driving the
driver blade at a driver blade speed of 30 m/s or less. In an embodiment, the mass
of the driver blade can be 80 g, or greater.
[0015] The method of operating a nailer can also have the step of contacting a portion of
the flywheel with a portion of the driver blade when the inertia of the flywheel is
in a range of 0.10 g*m^2 - 0.40 g*m^2. In an embodiment, the method of operating a
nailer can have the step of contacting a portion of the flywheel with a portion of
the driver blade when the flywheel has a speed 15000 rpm or less.
[0016] In an embodiment, the method of operating a nailer can have the step of imparting
a pinch force of 222 N or greater from a portion of the flywheel to a driver blade,
when a portion of the flywheel contacts a portion of the driver blade.
[0017] The present invention in its several aspects and embodiments solves the problems
discussed above and significantly advances the technology of fastening tools. The
present invention can become more fully understood from the detailed description and
the accompanying drawings, wherein:
FIG. 1 is a knob-side side view of an exemplary nailer having a fixed nosepiece assembly
and a magazine;
FIG. 2 is a nail-side view of an exemplary nailer having a fixed nosepiece assembly
and a magazine;
FIG. 2A is a detailed view of a fixed nosepiece with a nosepiece insert and a mating
nose end of a magazine;
FIG. 2B is a detailed view of a nosepiece insert having a blade stop viewed from the
channel side;
FIG. 2C is a perspective view illustrating the alignment of the nailer, magazine,
nails and nail stop;
FIG. 2D is a detailed view of a nosepiece insert having a blade stop viewed from the
fitting side;
FIG. 3 is a first perspective view of a driver blade in conjunction a return bumper
system;
FIG. 3A shows a driver blade at a home position;
FIG. 3B shows a driver blade aligned to be driven to drive a nail;
FIG. 3C shows a driver blade being driven and contacting the head of a nail;
FIG. 3D shows a driver blade positioned for driving a nail into a workpiece;
FIG. 3E shows a driver blade beginning a return phase;
FIG. 3F shows a driver blade making contact with a bumper;
FIG. 3G shows a driver blade pivoting into alignment to strike a blade stop;
FIG. 3H shows a driver blade tip striking the driver blade stop;
FIG. 3I shows a driver blade being drawn into the home position;
FIG. 3J shows a driver blade at rest in its home position;
FIG. 4 is a cross-sectional view of a rebound control mechanism;
FIG. 5 is a detailed view of the home magnet which can interact with the driver blade
tip;
FIG. 6 is a close up view of an angled upper bumper;
FIG. 7 is a detailed view of a driver blade ear which can impact an angled surface
of an upper bumper;
FIG. 8 is a close up view of a driver blade in a return configuration showing a driver
blade ear proximate to an impact point;
FIG. 9 is a driver blade stop close up view in which the driver blade tip is in contact
with the driver blade stop;
FIG. 10 is a driver blade stop close up view in which the driver blade tip is not
in contact with the driver blade stop;
FIG. 11 is a close up view of the tail portion of the driver blade at the moment of
contact with a bumper;
FIG. 12A shows a curving bumper;
FIG. 12B shows a bumper having two bumper materials;
FIG. 12C shows a bumper having three bumper materials;
FIG. 12D shows a bumper having a shock absorber cell;
FIG. 12E shows a bumper having two axial layers;
FIG. 12F shows a bumper having a bumper backstop;
FIG. 13 is a perspective view of a driver blade and a center bumper;
FIG. 14 is a perspective view of a driver blade and a flat bumper;
FIG. 15 is a perspective view of a high inertia flywheel;
FIG. 16 is side view of the high inertia flywheel proximate to a driver blade;
FIG. 17 is a top view of the high inertia flywheel proximate to a driver blade;
FIG. 18A is a first embodiment of a high inertia flywheel;
FIG. 18B is a second embodiment of a high inertia flywheel;
FIG. 19 is a cross-section of a high inertia flywheel;
FIG. 20 is a perspective view of a cupped flywheel positioned for assembly onto an
inner rotor motor;
FIG. 21 is a side view of the cupped flywheel positioned for assembly onto the inner
rotor motor;
FIG. 22 is a front view of the cupped flywheel;
FIG. 23A a side view of a drive mechanism having the cupped flywheel which is frictionally
engaged with a driver profile;
FIG. 23B is a cross-sectional view of the drive mechanism having the cupped flywheel
which is frictionally engaged with the driver profile;
FIG. 24 is a perspective view of the drive mechanism having the cupped flywheel and
the driver which is in an engaged state;
FIG. 25 is a side view of a partial driver assembly having the cupped flywheel;
FIG. 26 is a sample of exemplary driver blade speed data using a high inertia driver
system;
FIG. 27 is a graph of an example of driver blade position data using a high inertia
driver system;
FIG. 28A is a graph of return spring kinetic energy;
FIG. 28B is a data table for an exemplary high inertia driver system showing dry fire
data.
FIG. 29 is a graph of framer dryfire drive velocities;
FIG. 30A shows an exemplary shallow depth wet fire test chart; and
FIG. 30B shows an exemplary deep depth wet fire test chart.
[0018] Herein, like reference numbers in one figure refer to like reference numbers in another
figure.
[0019] In a fastening tool such as a nailer, energy effects associated with the return of
a driver blade after driving a nail can cause the driver blade to move in unpredictable
and hard to control manners which can cause a misfire or mechanical damage to the
fastening tool. The embodiments disclosed herein solve the problems regarding driver
blade movement during the return phase. The effects of the driver blade return on
a return system having one or more return springs can cause the springs to fail thereby
requiring maintenance. The embodiments herein of the high inertia driver system solve
the problem of return spring failure and achieve a long-life driver blade return system.
The high inertia driver system can include, in an embodiment, a motor, flywheel and
driver blade.
[0020] The inventive fastening tool can have of a variety of designs and can be powered
by a number of power sources. For example, power sources for the fastening tool can
be manual, pneumatic, electric, combustion, solar or use other (or multiple) sources
of energy. In an embodiment, the fastening tool can be cordless and the driver blade
stop can be used in a framing nailer, wood nailer, concrete nailer, metal nailer,
steel nailer, or other type of nailer, or fastening tool. The nailer driver blade
stop can be used in a broad variety of nailers whether cordless, with a power cord,
gas assisted, or of another design. Herein, the embodiments of the high inertia driver
system can be used to achieve a framing nailer, or other nailer, having a long-life
driver return system.
[0021] The nailer driver blade stop and/or high inertia driver system disclosed herein can
be used with fastening tools, including but not limited to, nailers, drivers, riveters,
screw guns and staplers. Fasteners, which can be used with the driver blade stop,
can be in non-limiting examples, roofing nails, finishing nails, duplex nails, brads,
staples, tacks, masonry nails, screws and positive placement/metal connector nails,
pins, rivets and dowels. The inventive fastening tool can be used to drive fasteners
into a broad variety of work pieces, such as wood, composites, metal, steel, drywall,
amorphous materials, concrete and other hard and soft building materials.
[0022] In an embodiment the nailer driver blade stop and/or high inertia driver system can
be used in fastening tools for the following applications: framing (metal or wood),
fencing, decking, creating basement water barriers, and installing furring strips
in concrete structures (carpet tack strips). In an embodiment, the nailer driver blade
stop can be used with cordless nailers having high drive energies, such as to drive
fasteners into concrete, framing, metal connecting members, structural steel, composites,
or for duplex stapling.
[0023] Additional areas of applicability of the present invention can become apparent from
the detailed description provided herein. For example, the nailer driver blade stop
and/or high inertia driver system in its several embodiments and many aspects can
be employed for use with fastening tools other than nailers and can be used with fasteners
other than nails, such as pins. The detailed description and specific examples herein
are not intended to limit the scope of the invention.
[0024] FIG. 1 is a side view of an exemplary nailer having a magazine viewed from the pusher
side
90 and showing the pusher
140. A magazine
100 which is constructed according to the principles of the present invention is shown
in operative association with a nailer
1. In this FIG. 1 example, nailer
1 is a cordless nailer. However, the nailer can be of a different type and/or a different
power source. Nailer
1 can have a housing
4 and a motor
5000 (FIG. 15), which can be in an inner rotor motor. The motor
5000 is disposed in the housing
4, and drives a nail driving mechanism for driving nails fed from the magazine
100. A handle
6 extends from housing
4 to a base portion
8 having a battery pack
10. Battery pack
10 is configured to engage a base portion
8 of handle
6 and provides power to the motor
5000 such that nailer
1 can drive one or a series nails fed from the magazine
100. Nailer
1 can have a nosepiece assembly
12 which is coupled to housing
4.
[0025] The magazine
100 can optionally be coupled to housing
4 by coupling member
89. The magazine
100 has a nose portion
103 which can be proximate to the fixed nosepiece assembly
300. The nose portion
103 of the magazine
100 which has a nose end
102 that engages a fixed nosepiece assembly
300. A base portion
104 of magazine
100 by base coupling member
88 can be coupled to the base portion
8 of a handle
6. The base portion
104 of magazine
100 is proximate to a base end
105 of the magazine
100. The magazine can have a magazine body
106 with an upper magazine
107 and a lower magazine
109. An upper magazine edge
108 is proximate to and can be attached to housing
4. The lower magazine 109 has a lower magazine edge
101.
[0026] The magazine includes a nail track
111 sized to accept a plurality of nails
55 therein. The upper magazine
107 can guide at least one end of a nail. In another embodiment, lower magazine
109 can guide another portion of the nail or another end of the nail. In an embodiment,
the plurality of nails
55 can have nail tips which are supported by a lower liner
95. The plurality of nails
55 are loaded into the magazine
100 by inserting them into the nail track
111 through a nail feed slot which can be located at or proximate to the base end
105. The plurality of nails
55 can be moved through the magazine
100 towards the fixed nosepiece assembly
300, or generally, the nosepiece assembly
12, by a force imparted by contact from the pusher assembly
110.
[0027] FIG. 1 illustrates an example embodiment of the fixed nosepiece assembly
300 which has an upper contact trip
310 and a lower contact trip
320. The lower contact trip
320 can be guided and/or supported by a lower contact trip support
325. The fixed nosepiece assembly
300 also can have a nose
332 which can be designed to have a nose tip
333. When the nose
332 is pressed against a workpiece, the lower contact trip
320 and the upper contact trip
310 can be moved toward the housing
4 and a contact trip spring
330 is compressed. The fixed nosepiece assembly
300 is adjustable and has a depth adjust member that allows the user to adjust the driving
characteristics of the fixed nosepiece assembly
300. A depth adjustment wheel
340 can be rotated to affect the position of a depth adjustment rod
350. The position of the depth adjustment rod
350 also affects the distance between nose tip
333 and insert tip
355 (e.g. FIG. 2A). In an embodiment, depth adjustment can be achieved by changing the relative
distance between the upper contact trip
310 and the lower contact trip
320.
[0028] In an embodiment, one or more of a magazine screw
337 can be used to reversibly fix the nosepiece assembly
300 to the magazine
100. The fixed nosepiece assembly
300 can fit with the magazine
100 by a magazine interface
380. In an embodiment, the pusher assembly
110 can be placed in an engaged state by the movement of the pusher
140 into the nail track
111 and in the direction of loading fasteners (e.g. nails) to push the plurality of nails
55 toward the nose end
102.
[0029] FIG. 2 is a side view of exemplary nailer
1 viewed from a nail-side
58. Allen wrench
600 is illustrated as reversibly secured to the magazine
100.
[0030] FIG. 2A is a detailed view of the nosepiece assembly
300 from the channel side
412 which mates with the nose end
102 of the magazine
100. A nosepiece insert
410 and the nose end
102 of the magazine
100 can be reversibly fit together by a fastening means. In an embodiment, the magazine
screw
337 can be turned to reversibly fit nosepiece insert
410 and the nose end
102 together. In an embodiment, the nail channel
352 can be formed when the nosepiece insert
410 is mated with the nose end
102 of the magazine
100.
[0031] FIG. 2A, detail A, illustrates a detail of the nosepiece insert
410 from the channel side
412. As illustrated, the nosepiece insert
410 has a rear mount screw hole
417 for a nail guide insert screw
421. Nosepiece insert
410 can also have a blade guide
415 and nail stop
420. Nosepiece insert
410 can be fit to nosepiece assembly
300. Nosepiece insert
410 can also have a nosepiece insert screw hole
422 within one or more of an interface seat
425 to secure the nosepiece insert into the fixed nosepiece assembly
300. In an embodiment, the nosepiece insert
410 has a nose
400 with an insert tip
355 and is inserted into the fixed nosepiece assembly
300. In an embodiment, the nosepiece insert
410 is configured such that a driver blade
54 overlaps at least a portion of a blade guide
415 which optionally can extend under a nose plate
33 mounted on a forward face of the housing
4.
[0032] Nosepiece insert
410 can be secured to the fixed nosepiece assembly
300 by one or more of a nosepiece insert screw
401 through a respective insert screw hole
422. In an embodiment, the driver blade stop
800 can be a portion of, or a piece attached to, the nosepiece insert
410 (FIGS. 2B and 2D). In an embodiment, the nosepiece insert
410 can be joined to the fixed nosepiece assembly
300 by a nail guide insert screw
421 through the rear mount screw hole
417, or can be a separate piece attached to the nosepiece insert
410 (FIGS. 2B and 2D). One or more prongs
437 on the fixed nosepiece assembly
300 can respectively have a screw hole
336 for inserting the magazine screw
337.
[0033] FIG. 2A detail B is a front detail of the face of the nose end
102 having nose end front side
360. The nose end
102 can have a nose end front face
359 which fits with channel side
412. The nose end
102 can have a nail track exit
353. For example, a loaded nail
53 is illustrated exiting nail track exit
353. A screw hole
357 for magazine screw
337 that secures the nose end
102 to the nosepiece assembly
300 is also shown.
[0034] FIG. 2B is a detailed view of a nosepiece insert
410 viewed from the channel side
412. The nosepiece insert
410 has a nose
400, an insert tip
355, and an insert centerline
423. The channel side
412 has a blade guide
415 and a nail stop
420. The nail stop
420 can be in line with said plurality of nails
55 along a nail stop centerline
427 (FIG. 2C). The nail stop centerline
420 can be offset from the insert centerline
423 which achieves the receipt of nails to the nail stop
420 in a configuration in which the longitudinal axis
1127 of the plurality of nails
55 (FIG. 2C) is collinear, or parallel in alignment, with the longitudinal centerline
1027 of the nail track
111.
[0035] FIG. 2C is a perspective view illustrating the alignment of an embodiment of the
nailer
1, magazine
100, plurality of nails
55 and nail stop
420. FIG. 2C illustrates the nail stop
420, the nail stop centerline
427, a longitudinal centerline
927 of the magazine
100, a longitudinal centerline
1027 of the nail track
111, a longitudinal centerline
1127 of the plurality of nails 55 and a longitudinal centerline
1227 of the nailer
1.
[0036] Offset angle
G can be 14 degrees. In an embodiment, nail stop centerline
427 can be collinear with a longitudinal centerline
927 of the magazine
100, a longitudinal centerline
1027 of the nail track
111 and the longitudinal centerline
1127 of the plurality of nails
55. A wide range of angles and orientations for the nail stop
420 can be used.
[0037] FIG. 2D is a detailed view of the nosepiece insert
410 viewed from the fitting side
430. Optionally, the fitting side
430 can have a magnet stop
435 and a magnet seat
440 which are adapted for the mounting of a nosepiece magnet
445. The fitting side
430 can have a rear mount
450, and a mount
455 that receives a screw to secure nosepiece insert
410 to the fixed nosepiece assembly
300. The fitting side
430 can have lower trip seat
460 which fits into a portion of nosepiece assembly
300. In another embodiment, at least a portion of insert
410 can have magnetic properties. A magnetic portion of insert
410 can be used to guide the driver blade
54.
[0038] FIG. 3 is a perspective view of a return system
6000 which can have one or more of a return spring. In non-limiting example, FIG. 3 shows
first return spring
2071 and second return spring
2072.
[0039] FIG. 3 is a perspective view of the driver blade 54 in conjunction with a return
bumper system
900. In an embodiment, the return bumper system
900 can control the movement of the driver blade
54 during a return phase after driving the loaded nail
53. The return bumper system
900 can have a bumper
899 having a bump surface
970 against which a pivot portion
1499 having a pivot surface
1500 of the tail portion
56 of the driver blade
54, can impact during the return phase. As shown in FIG. 3 a single of the bumper
899 having a single of the bump surface
970 can be used.
[0040] Herein, the "bumper
899" is a reference to one or more bumpers used to form the return bumper system
900. Herein, the "pivot portion
1499" is a reference to one or more portions of driver blade
54 that impact the return bumper system
900 and that are used to contribute to the pivoting of the driver blade
54 upon impact with one or more of the bumper
899. Herein, the "pivot surface
1500" is a reference to one or more pivot surfaces of the return bumper system
900.
[0041] FIG. 3 shows an example embodiment of the driver blade
54, the blade stop
800, the return bumper system
900 and a home magnet
700. The driver blade
54 has two projections, herein referred to as driver blade ears, and respectively referred
to as a first driver blade ear
1100 and second driver blade ear
1200. In this example, the total surface area which constitutes the pivot surface
1500 is separated into two portions with one portion on each ear. Specifically, the first
driver blade ear
1100 can have a first pivot surface
1510 and the second driver blade ear
1200 can have a second pivot surface
1520. Because the example embodiment of FIG. 3 has a first driver blade ear
1100 and second driver blade ear
1200, the return bumper system
900 has two of the bumper
899. A first bumper
910 having a first bump surface
971 is configured to receive an impact from the first driver blade ear
1100. A second bumper
920 having a second bump surface
972 is configured to receive an impact from the second driver blade ear
1200.
[0042] At the moment of impact by the driver blade
54 upon the return bumper system
900, FIG. 3 shows the first pivot surface
1510 in tangential contact with the first bumper
910, as well as the second pivot surface
1520 in tangential contact with a second bumper
920. The simultaneous interactions of the first pivot surface
1510 against the first bump surface
971 and the second pivot surface
1520 against the second bump surface
972 will cause the driver blade axis
549 to articulate away from the nail driving axis
599, such as is shown in FIG. 3I. In the example of FIG. 3, the return bumper system
900 is located distally from the nail stop
800, and is referred to as an upper bumper system having a first upper bumper
911 a second upper bumper
922. As shown in FIG. 3, the first driver blade ear
1100 can be guided by a first driver blade guide
2100 and the second driver blade ear
1200 can be guided by a second driver blade guide
2200.
[0043] FIGS. 3A-J illustrate an example of a nail driving and return cycle for an embodiment
of a fastening tool having the driver blade
54 and using the driver blade stop
800. FIGS. 3A-J, specifically show an example of the movements of the driver blade
54, beginning with the driver at the home position (FIG. 3A), through driving a nail
(FIGS. 3B, C and D), through the nail blade return phase (FIGS. E, F, G, H and I),
and to the return of the driver blade
54 once again to its home position (FIG. J, and also FIG. A).
[0044] FIG. 3A illustrates a section showing the driver blade
54 at a rest position and/or home position. Herein, the terms "driver blade" and "driver
profile" are used synonymously to encompass a nail driving member of the fastening
tool. The terms "driver profile" and "driver blade" are used synonymously whether
the driving member is made of one piece or multiple pieces. Multiple pieces of a "driver
profile" and "driver blade" can be separate, integrated, move together or move separately.
The driver blade
54 can be a single part made from a single material, such as a single investment cast
steel part, or can be made of multiple parts and/or multiple materials.
[0045] In an embodiment, the flywheel
665 (FIG. 3C) can be a high inertia flywheel
2665 (FIGS. 15-20). Herein, disclosure regarding the use of flywheel
665 also applies to use of the high inertia flywheel
2665. As shown, the driver blade
54 can have a long slender nail contacting element
1001 integral with and/or attached to the driver blade, a driver blade tip portion
552, a driver blade tip
500, a driver blade tail portion
56 and a driver blade body
1000. Herein, references to the driver blade
54 also are intended to encompass its portions and parts, such as the driver blade
54, the tip portion
552, or the driver blade tip
500.
[0046] One or more magnets, or mechanical catch systems, can be used to limit the rebound
of the driver blade
54 during its return phase which occurs after driving a fastener into a workpiece. FIG.
3A shows the driver blade
54 at a home position having the driver blade tip portion
552 arranged in contact with a home seat
760 of the home magnet holder
750. In an embodiment, the home seat
760 can reversibly hold the driver blade in the home position. In an embodiment, the
driver blade stop
800 can stop the driver blade
54 without causing a concentration of wear and/or high stress on a portion of the driver
blade body
1000, such as a tip portion
552, or the driver blade tip
500. In an embodiment, the driver blade tip
500 can have a 2 mm or greater overlap with a strike surface
810 of the driver blade stop
800. Mechanical elements can also be used to align the driver blade
54 to strike the driver blade stop
800. In a non-limiting example, a hinged or spring loaded member can be used with, or
instead of, a magnet to reversibly position the driver blade tip and/or the driver
blade tip
500 in its home position. In another embodiment, a lifter spring can be used with, or
without, a magnet.
[0047] FIG. 3A shows the driver blade
54 at a home position in which it is resting between driving cycles and/or awaiting
being triggered to drive a nail. The driver blade body
1000 is shown in a resting state and not moving. Herein, the term "home position" means
the configuration in which the position of the driver blade is such that it is available
to begin a fastener driving cycle. For example, as shown in FIG. 3A, the tip portion
552 of the driver blade
54 is proximate to the home magnet
700. In a "home position", the tip portion
552 and/or a portion of driver blade
54 is reversibly magnetically held by the home magnet
700. The home magnet
700 can magnetically attract the tip portion
552 toward a home seat
760 against which the tip portion
552 can rest. The home position can be configured such that the driver blade is affected
by the magnetic force of the home magnet
700, but not held or in direct physical contact with the home magnet
700 itself, or the home magnet holder
750 home. The driver blade
54 can have a rest position which is the same position as the home position. Optionally,
a portion of driver blade
54 can have contact with one or more of a bumper
899 when in the home state.
[0048] Herein, an articulation angle
719 (FIG. 3A) is the angle formed between a driver blade axis
549 and a drive path
399 and/or a nail driving axis
599 and/or the nail channel
352. The articulation angle
719 can be the angle at which the driver blade
54 and/or the driver blade axis
549 and/or the driver blade's longitudinal centerline and/or a driver blade's body articulates
away from the nail driving axis
599. In an embodiment, in the home position, the driver blade
54 can strike the driver blade stop
800 at a first value of an articulation angle
719, as well as have a home position and/or rest at a different value of the articulation
angle
719.
[0049] Numeric values and ranges herein, unless otherwise stated, are intended to have associated
with them a tolerance and to account for variances of design and manufacturing. Thus,
a number is intended to include values "about" that number. For example, a value X
is also intended to be understood as "about X". Likewise, a range of Y-Z, is also
intended to be understood as within a range of from "about Y-about Z". Unless otherwise
stated, significant digits disclosed for a number are not intended to make the number
an exact limiting value. Variance and tolerance is inherent in mechanical design and
the numbers disclosed herein are intended to be construed to allow for such factors
(in non-limiting e.g., ± 10 percent of a given value). Likewise, the claims are to
be broadly construed in their recitations of numbers and ranges.
[0050] As shown in FIG. 3A, the driver blade can have a home position at an articulation
angle
719 from the drive path
399 and/or nail driving axis
599 and/or nail channel
352. The articulation angle
719 can have a value sufficient to configure the tip portion
552 such that it is not aligned to strike any portion of the loaded nail
53. In an embodiment, the articulation angle
719 can be greater than 0.2º as measured from the driver blade axis
549 to nail driving axis
599. For example, the articulation angle
719 can be in a range of from 0.2º to 15°º, or greater. In an embodiment, the driver
blade axis
549 can have an articulation angle
719 of 0.80º from the nail driving axis
599 when the driver blade
54 is in an at rest position. In an embodiment, a dampening of the mechanical movement
of the driver blade
54 can be achieved at least in part by articulating the driver blade out of the driving
path during its return phase by impacting with an angled surface on the bumper
899. In an embodiment, the tip portion
552 can also be moved to a position out of the driving path by the home magnet
700, which magnetically attracts the driver blade
54. During the return phase, as the driver blade rebounds off the bumpers
899 and toward the next nail to be fired, the driver blade stop
800 can be used to limit the advance of the driver blade toward the nosepiece assembly
12 and/or the loaded nail
53. This can prevent the driver blade
54 from rebounding into the driving path to hit and potentially drive and/or dislodge
a next nail. When the driver blade
54 for a nailer is displaced from the drive path, unintended contact and/or the duration
of contact with the flywheel
665, and driving mechanism is reduced resulting in a quiet flywheel-based tool.
[0051] As shown in FIG. 3A, the tip portion
552 can rest at a distance of a blade stop gap
803 (FIG. 10) from the driver blade stop
800 and the driver blade tip
500. In an embodiment, when in the home position, a blade stop gap
803 (FIG. 10) can be present between the driver blade stop
800 and the strike surface
810 of tip portion
552. In an embodiment, the driver blade stop
800 can be in a range of from 1 mm to 25 mm, or greater. In an embodiment, a blade stop
gap
803 distance of 8 mm or greater can be used and can prevent the driver blade tip
500 from wearing off, become misshaped, damaged or rounded. FIG. 3A also shows the tail
portion
56 of driver blade
54. In an embodiment, the tail portion
56 can be a portion of the driver blade body
1000. The driver blade body
1000 can have portions that are used to guide and/or control the movement of the driver
blade
54 while being driven, as well as portions that can be used to control the driver blade
54 during its return phase. A contact of a portion of the driver blade
54, such as the tail portion
56 with the bumper
899, such as a first bumper
910 and/or a second bumper
920, when the driver blade
54 is in a home position is optional.
[0052] FIG. 3A shows the return system
6000 having a return bumper system
900 which can have one or more of the bumper
899. The second bumper
920 is shown which is configured to be the second upper bumper
922 having the second bump surface
972. The bumper
899 can have a bumper height
1979 (FIG. 11) in a range of greater than 2 mm, such as in a range of from 2 to 25 mm.
The bumper
899 can have a bumper width
1978 (FIG. 11) in a range of from 5 to 30 mm. The bumper
899 can have a bumper depth
1976 (FIG. 3) in a range of from 2 to 25 mm. The bumper can have a bumper density in a
range of from 0.50 g/cm^3 to 10.0 g/cm^3.
[0053] FIG. 3B shows the driver blade
54 aligned to drive a nail. As shown in FIG. 3B, a movable member, such as a pinch roller
655, exerts a force upon at least a portion of the driver blade
54 moving the driver blade axis
549 into alignment to position driver blade
54 to drive a nail into a workpiece. The pinch roller
655 can exert an alignment force
657 against a portion of the driver blade body
1000. The alignment force
657 can overcome the attractive force of the home magnet
700 and pivot the driver blade axis
549 to align and/or be configured collinearly with the nail driving axis
599 and with the drive path
399. The example of FIG. 3B shows, by alignment arrow
1657, the pivoting of the driver blade axis
549 to be aligned and/or be configured collinearly with the nail driving axis
599.
[0054] FIG. 3C shows the driver blade
54 being driven and in contact with the head of a nail
53. In FIG. 3C, the flywheel
665, which rotates as shown by the directional arrow
1665, is shown in reversible and temporary frictional contact with and driving the driver
blade
54. The temporary contact by flywheel
665, to the driver blade
54, imparts energy to the driver blade
54 to move in the direction of driving arrow
1054 and to drive a nail
53. FIG. 3C shows the driver blade tip
500 in contact with a nail head
592 of the loaded nail
53.
[0055] In an embodiment, the flywheel can be a "high mass flywheel" that can have a significant
mass, such as 75 grams or greater, such as 90 grams and can have significant momentum
when rotating. The momentum and/or kinetic energy present in the driver blade
54 can be significant, such as 35 Joules or greater, such as 40 Joules even after a
driving of a nail has occurred. For example, residual kinetic energy present in the
driver blade
54 can be high after the driving of a nail into a soft material, and/or after driving
a short nail. Because the soft material does not absorb as much energy as a harder
material, this can result in the driver blade
54 having a high momentum at the end of the return stroke when it can impact the bumper
899.
[0056] In an embodiment, the flywheel for a nailer
1, such as a framing nailer, when used for driving fasteners into wood can rotate at
a high power, such as a value of from 10000 rpm to 15000 rpm, or 12000 rpm to 15000
rpm, or about 13000 rpm and can have an inertia in a range of from 0.000010 kg to
m/s^2 to 0.000030 kg-m/s^2, such as or 0.000015 kg-m/s^2, or 0.000022 kg-m/s^2. In
an embodiment, the driver blade
54 speed for a nailer for wood can be 12 m/s to 30 m/s. In an embodiment, the nailer
1 can have the depth adjustment wheel
340 set the depth adjust set for a depth for nailing of 2 inch smooth shank nails into
soft wood, such as spruce, pine, and fur lumber, or plywood sheathing and/or plywood
sheeting.
[0057] In another embodiment, the flywheel for the nailer when used for driving fasteners
into hard and dense materials, such as concrete, steel or metal. The flywheel can
rotate at a value of from 12000 rpm to 20000 rpm, or 13000 rpm to 16000 rpm. In such
applications, the flywheel can have an inertia in a range 0.000020 kg-m/s^2 to 0.000040
kg-m/s^2. The driver blade
54 can have a driving speed from 21 m/s to 41 m/s for driving 1/2" nails into wood,
into structural steel and/or concrete. In an embodiment, the driver blade
54 can have a driver speed of about 37 m/s and store 75-110 J in the driver blade
54 and/or driver assembly.
[0058] FIG. 3D shows the driver blade
54 in the process of driving the loaded nail
53 into a workpiece. The driver blade
54 and the tip portion
552 (FIGS. 3F-3J) have advanced along the nail driving axis
599 and along the drive path
399 such that the tip portion
552 has passed into the nail channel
352 to drive the loaded nail
53. The direction of movement of the driver blade
54 is shown by driving arrow
1054.
[0059] FIG. 3E shows the driver blade 54 beginning the return phase, which can begin the
moment a fastener has been driven. FIG. 3E depicts a moment at which, the loaded nail
53 has been driven into the workpiece, the high inertia flywheel
2665 (FIGS. 15-19), has been retracted and the return path
1222 is free of obstacles along its length to allow the return of the driver blade
54. In an embodiment, the return path
1222 can be route taken by the tail portion
56 of the driver blade
54 from the moment a drive is complete until the tail portion
56 impacts the bumper
899 and/or another return stop member. Recoil arrow
1056 shows the change in direction from when the driver blade
54 transitions from the direction indicated by driving arrow
1054 to the direction indicated by a return arrow
1058.
[0060] The driver blade stop
800 disclosed herein allows for operation of a power tool, such as the nailer
1, using higher driver speeds. The driver blade stop
800 can also be used at high return speeds of the driver blade
54, for example up to 61 m/s, while reducing or preventing bounceback. Reducing or preventing
bounceback eliminates misfire or the breaking of the collation of a nail from other
collated nails when no driving event is yet intended for such collated fastener. In
an embodiment, driver blade speeds during a driving action can be in a range of from
7.6 m/s to 61 m/s. The driver blade stop
800 can be used in high energy fastening tools that have an elastic-type return system,
such as in a concrete nailer. Additionally, the driver blade stop
800 can be used in a nailer that generates a driving pressure from 517 KPa to at least
103 MPa.
[0061] In embodiments, misfires can occur when the residual momentum or energy causes the
driver blade to impact a bumper or driver blade stop
800 after driving the loaded nail
53. The residual momentum of the driver blade
54 after striking the bumper or driver blade stop
800 can cause the driver blade
54 to continue back down the nail channel
352 toward a next nail. A misfire or improper driving of the driver blade
54, can lead to jams, bent nails and damage to the fastening tool. An uncontrolled return
of the driver blade
54 can cause a misalignment of nails, or a partial broken collation, or a broken collation
which leave an improperly aligned nail in the nail channel
352. To reduce or prevent misfire, the driver blade
54 recoil movements can be dampened and/or controlled by using a magnetic catch, a bumper,
an isolator and/or a dampener material to dissipate momentum. In an embodiment, a
mechanical stop can be used to receive a driver blade impact after it returns and
bounces off one or more bumpers, or other object. The driver blade stop can act as
a mechanical beat piece and/or piece to receive impacts from the driver blade
54. The driver blade stop
800 can be hardened investment cast steel. In an embodiment, the home magnet
700 having an attractive force upon the driver blade
54 can be used alone, or in combination with an angled upper bumper to attract the driver
blade tip
500 into the driver blade stop area and force it to impact in the driver blade stop which
limits bounce-back, movement into the drive path to hit another nail and the recoil
of the driver blade
54. In an embodiment, the home magnet
700 holder can limit the vertical displacement and the area of the driver blade tip
500 which impacts the mechanical stop.
[0062] The speed of the driver blade during its return to the home position is referred
to herein as a return speed. The return speed can vary depending upon the driver blade
54, as well as the workpiece into which the fastener is driven. When a fastener is driven
without misfire, the return speed can be in a range of 3.0 m/s to 46 m/s, such as
27 m/s. Misfire conditions can result in a return speed in a range of from 15 m/s
to 61 m/s, such as 38 m/s.
[0063] FIG. 3F shows the driver blade
54 making contact with the bumper
899. FIG. 3F shows the return of the driver blade
54 in the direction of the return arrow
1058. FIG. 3F shows the driver blade
54 return motion at the moment where the second pivot surface
1520 of pivot portion
1499 has just made a contact with a portion of the bumper
899, such as the second upper bumper
922. The second upper bumper
922 can have a second pivot point
996 (see also FIG. 11), which in the example of FIG. 3F, is the first portion of the
second upper bumper
922 to be contacted by the second pivot surface
1520 of pivot portion
1499. FIG. 3F shows the driver blade axis
549 still aligned and/or still configured collinearly with the nail driving axis
599 and in alignment with the drive path
399. At this point in the return phase, after the loaded nail
53 has been driven and the return of the driver blade
54 has cleared the tip portion
552 from the nail channel
352, the next nail
554 is advanced into the nail channel
352 for driving by the driver blade
54.
[0064] FIG. 3G shows the driver blade
54 during the return phase pivoting into alignment to strike the driver blade stop
800. The contact of the tail portion
56 with the bumper can cause a pivoting of the orientation of the driver blade
54 which prevents the driver blade
54 from rebounding to strike the next nail head
556 (FIGS. 3A-3B) and prevents the tool from misfiring. The pivoting motion is shown
by pivot arrow
1970. In the example embodiment of FIG. 3G, the second pivot surface
1520 is at an angle to, not parallel to and not coplanar with, the pivot surface
1500, such as the second pivot surface
1520. The second bumper causes the driver blade
54 to pivot away from the nail driving axis
599. The action of the second pivot surface
1520 of pivot portion
1499 against the driver blade
54 moves the driver blade axis
549 out of alignment with the nail driving axis
599 and the drive path
399. The pivoting of the driver blade
54 configures the driver blade axis
549 to have an angle greater than zero (0º) with the nail driving axis
599 and the drive path
399. The pivoting of the driver blade
54 configures the driver blade axis
549 such that the driver blade
54 is not collinear, or coplanar, with the nail driving axis
599 and the drive path
399. FIG. 3G shows the measure of the displacement of the driver blade
54 from the nail driving axis
599 and/or the drive path
399 as an articulation angle
719. In an embodiment, the articulation angle
719 can be in a range of from 1º to 25º. In an embodiment, at least a portion of the
driver blade
54 can contact the bumper
899 and/or the blade stop
800 a number of times. Repetitive contact of the driver blade between the bumper
899 and the driver blade stop
800 can prevent misfire under conditions in which the driver blade
54 has a high mechanical energy after a fastener, such as a concrete nail is driven.
[0065] In an embodiment, an impact of a portion of a driver blade upon the bumper
899 can cause a deformation of the bumper
899 which can be temporary and/or reversible. In an embodiment, the bumper
899 can be resilient and can maintain its mass after repeated impact of a portion of
the driver blade
54. Herein, the term deformation period is the period of time during which a resilient
embodiment or memory embodiment of the bumper
899 is deformed prior to return to its shape prior to impact, or approximately to its
shape prior to impact, or near to its shape prior to impact. In an embodiment, the
bumper
899 can have a deformation time in a range of from 0.5 ms (0.0005 s) to 1000 ms (10 s).
In an embodiment, the deformation period can be equal to or near zero (0) seconds
and the impact can be elastic or near elastic. In an embodiment, the bumper
899 can have an operating life of 50,000 to 150,000 return phases and/or impacts from
the driver blade, such as 50,000 or greater return phases, 65,000 or greater return
phases, or 75,000 or greater return phases, or 100,000 or greater return phases.
[0066] FIG. 3H shows the moment in the return phase when the driver blade tip
500 is striking the driver blade stop
800 and the driver blade tip
500 of the tip portion
552 is striking the strike surface
810 of the driver blade stop
800. FIG. 3H shows the driver blade
54 configured to have the driver blade axis
549 positioned at the articulation angle
719 from the nail driving axis
599 and/or the drive path
399. In FIG. 3H, the articulation angle
719 aligns and/or configures the driver blade axis
549 such that at least a portion of the driver blade
54, such as the tip portion
552, will strike the driver blade stop
800 when moving in a strike direction shown by strike arrow
1810.
[0067] FIG. 3I shows the driver blade
54 seated in its home position against the home seat
760 after having struck the strike surface
810 of the driver blade stop
800 and at least a portion of driver blade
54 being magnetically attracted by home magnet
700. In an embodiment, after striking the driver blade tip
500 against the strike surface
810, the driver blade
54 can still have a kinetic energy and have a motion away from the strike surface
810. While the driver blade
54 moves away from the strike surface
810, the magnetic attraction from home magnet
700 of at least a portion of the driver blade
54, can dampen and/or stop further motion of the tip portion
552 away from the strike surface
810. In an embodiment, the magnetic attraction of the tip portion
552 by the home magnet
700 can dampen and overcome the kinetic energy retained by the driver blade
54, can pull the tip portion
552 toward and frictionally against the home seat
760 and can stop further axial movement of the driver blade
54. The magnetic influence pulling the tip portion
552 toward and frictionally against the home seat
760 can dampen and/or stop the movement of the driver blade
54 and bringing the driver blade
54 to a rest state in a home position. As shown in FIG. 3I, the driver blade axis
549 can be displaced by the articulation angle
719 by a pivot resulting from a portion of the driver blade
54 with the bumper
899.
[0068] The articulation angle
719 can cause the driver blade axis
549 to be oriented such that the tip portion
522 can strike the driver blade stop
800. After the driver blade
54 strikes the driver blade stop
800, the driver blade axis
549 can remain oriented along the displacement axis
779, or can vary from being collinear with that axis. FIG. 3I also shows the direction
of movement of the driver blade axis
549 from the displacement axis
779 toward the home axis
799 by home arrow
1760. The home magnet
700 can have a strong enough attraction to pull the tip portion
552 into a home position under a broad variety of operation conditions. In the embodiment
of FIG. 3I, a home angle
717 is shown as an instance of the articulation angle
719 when the driver blade
54 is at a home position. In this example, the home angle
717 can result from a first articulation of the driver blade
54 which aligns the driver blade axis
549 to strike the driver blade stop
800 and forms a strike angle
729, and a second articulation happens after the driver blade tip
500 strikes the driver blade stop
800. The second articulation is the articulation which aligns the driver blade axis
549 in a home position forming a dampening angle
739. In the example of FIG. 3I, home angle
717 results from the sum of the strike angle
729 and the dampening angle
739.
[0069] As depicted in FIG. 3A, FIG. 3J shows the driver blade
54 at rest in its home position waiting for the triggering of another nail driving cycle.
[0070] FIG. 4 is a cross-sectional view of a rebound control mechanism. FIG. 4 shows a close
up view of the driver blade tip
500 contacting the strike surface
810. Overlap of the driver strike surface
810 by a portion of the driver blade tip
500 is illustrated. In the embodiment of FIG. 4, the home magnet holder
750 can be used to separate the home magnet
700 from the driver blade tip
500.
[0071] FIG. 5 is a detailed view of the home magnet
700 which can magnetically attract the tip portion
552.
[0072] FIG. 6 is a close up view of an embodiment having one or more angled bumper
899. In the embodiment of FIG. 6, one or more of the bumper
899 having an angled shape can be used for impact by a driver blade ear
1100 and
1200 (FIG. 3) and the bumper
899 with an angled shape can absorb energy and articulate the driver blade tip
500. In the embodiment of FIG. 6, during the return stroke of the driver blade
54 after driving a nail
53, a blade guide
2050 can guide the driver blade into the one or more of the bumper
899 on the return stroke. In an embodiment, a blade guide
2050 can be used in conjunction with a return spring
2075 which can optionally be coaxial to the blade guide
2050 or otherwise located to dampen the energy of the return stroke. Optionally, the driver
blade can have one or more projecting portions (respectively referred to as an "ear").
The driver blade can have one or more ears which can impact one or more of the upper
bumper and can upon contact with the one or more of the bumper
899 and can move the driver blade axis
549 such that the driver blade axis
549 is not collinear with the driving axis
599.
[0073] FIG. 7 is a detailed view of a section of driver blade
54 having the second driver blade ear
1200 which can impact the second bump surface
972 of the second bumper
920 which is at an angle from the second pivot surface
1520. The bumper
899 and/or the driver blade
54 can have one or a number of angled contact surfaces. In an embodiment, a bumper angle
973 (FIG. 11) of the bumper
899 can cause the tip
500 of the driver blade to radially move away from the driving axis to contact the nail
stop.
[0074] Herein, this motion is also referred to as articulation. The bumper angle
973 of an upper bumper can cause the tip of the driver blade to radially move away or
articulate away from the nail driving axis
599 toward the driver blade stop
800 and/or a position proximate to and/or in contact with a magnet, such as the home
magnet
700. The articulation angle can vary widely and can be in a range of from greater than
zero to greater than 30º, or in a range of from 0.05º to 25º.
[0075] FIG. 8 is a close-up view of the driver blade in a return configuration showing the
second driver blade ear
1200 proximate to a pivot point
987 of the bumper
899. In an embodiment, the driver blade
54 and driver blade tip
500 can be articulated from the nail driving axis
599 at an articulation angle
719 of about 1º, or 2º, or 3º, or 4º, or 5º.
[0076] FIG. 9 is a close-up view in which the driver blade tip
500 is in contact with the driver blade stop
800.
[0077] FIG. 10 is a close-up view in which the driver blade tip
500 is in contact with the driver blade stop
800.
[0078] FIG. 10 shows the driver blade
54 at rest in a home position in which the tip portion
552 can have the driver blade tip
500 that is seated in a home seat
760. The home seat can have a home seat thickness
763. The home magnet holder
750 can provide support for at least a part of home magnet
700. The home seat
760 can be a portion of the home magnet holder
750 or can optionally be a separate piece. The home seat thickness can be used to limit
the magnetic force attracting the driver blade
54.
[0079] FIG. 11 is a close up view of the tail portion
56 of the driver blade
54 at the moment of contact with the bumper
899. In the example of FIG. 11, the driver blade
54 has returned after striking a nail
53 along the nail driving axis
599 and in alignment with the drive path
399. This return path is only one of many variations of return paths which can cause a
portion of the driver blade
54 to impact upon the bumper
899. In the example of FIG. 11, the driver blade axis
549 is collinear and/or along the nail driving axis
599. FIG. 11 shows the precise moment when at least a portion of a pivot surface
1500 of a pivot portion
1499 of a tail portion
56 contacts a second pivot point
996 of a second bumper
920. A second bumper
920 is shown having a second bump surface
972. The second bumper
920 has a bumper angle
973 between the second bump surface
972 and the second bumper side
977. In this embodiment, the second bumper side
977 is perpendicular to the second bumper base line
978 of the second bumper base
979. At the depicted moment of contact in FIG. 11, the second pivot surface
1520 of pivot surface
1500 is coplanar with pivot plane
1519. Pivot plane
1519, pivot surface
1520 and pivot plane
1519 are shown to be coplanar in FIG. 11 and are also shown as perpendicular to the second
bumper side
977.
[0080] Thus, the pivot surface
1500 is parallel to the second bumper base line
978. FIG. 11 shows a pivot angle
974 which is formed between the pivot surface
1500 and the second bump surface
972. The displacement of the driver blade axis
549 can occur as shown by a displacement arrow
1972. The contact of the pivot surface
1500 to the second pivot point
996 causes the driver blade
54 to pivot such that the driver blade axis
549 moves out of alignment with the nail driving axis
599 and shown by articulation arrow
1971. As the pivoting and/or tilting increases the articulation angle
719 increases.
[0081] FIGS. 12A-12F show a variety of types of the bumper
899. The bumper
899 can be a single bumper or multiple bumpers. The bumpers can be made from any material
which can absorb and/or withstand a shock and/or impact from a portion of the driver
blade
54.
[0082] FIG. 12A shows a curving bumper. A bumper
899 can be of any shape which can impart a moment resulting in an articulation and/or
pivot of the driver blade
54 upon impact. FIG. 12A shows an crescent shaped bumper made from a bumper material
980 which can reversibly deform when impacted by a portion of the driver blade
54 from the impact direction shown by impact direction arrow
2000.
[0083] FIG. 12B shows a bumper having two bumper materials which are layered perpendicularly
to impact direction arrow
2000, such as the first bumper material
981 and a second bumper material
981 which can be different. FIG. 12C shows the bumper
899 having three bumper materials, such as first bumper material
981, the second bumper material
982 and a third bumper material
983. FIG. 12D shows the bumper
899 made from a first bumper material
981 and having a shock absorber cell
984. FIG. 12E shows a bumper
899 having two axial layers, and having a first bumper material
981 and a second bumper material
982. FIG. 12F shows the bumper
899 having a bumper backstop
985.
[0084] FIG. 13 is a perspective view of the driver blade
54 and the bumper
899, which is a center bumper
930. The return bumper system
900 can have the center bumper
930 to receive an impact from a portion of a driver blade body
1000. The center bumper
930 can have bump surface
970 that causes the driver blade
54 to articulate upon impact with the center bumper
930.
[0085] FIG. 14 is a perspective view of the driver blade
54 and a flat bumper
940. The bumper
899 can have an impact surface
992 which is perpendicular to the driver blade axis
549. The tail portion
56 has a bump surface
970 which is not parallel to the impact surface
992 and will cause the driver blade
54 to articulate such that the driver blade axis
549 will move out of alignment with the nail driving axis
599 and/or the drive path
399 and form an articulation angle
719.
[0086] FIG. 15 is a perspective view of the high inertia flywheel
2665. The flywheel
2665, which is rotated by a motor
5000 can be of a variety that is cantilevered over at least a portion of the motor and/or
motor housing (FIGS. 20-25), or not cantilevered. Both non-cantilevered and cantilevered
flywheels can be high inertia flywheels which can drive the driver blade
54. Motor
5000 can have a motor windings
5001 (FIG. 19) that impart rotation to the rotor shaft
550 (FIG. 19).
[0087] FIG. 15 also shows a driver blade
54 having the driver blade body
1000. The high inertia flywheel
2665 can impart a pinch force on the driver blade body
1000 being driven by the high inertia flywheel
2665.
[0088] The high inertia flywheel
2665 can have one or more flywheel grooves
2660, such as a first flywheel groove
2661 and a second flywheel groove
2662. The driver blade
54 can have a plurality of blade fins
2700, such as first blade fin
2701 which can be frictionally engaged by the first flywheel groove
2661, and a second blade fin
2702 (FIG. 17) which can be friction ally engaged by the second flywheel groove
2662.
[0089] In an embodiment, the high inertia flywheel
2665 can have a mass in a range of 50 g to 1000 g. In an embodiment, the high inertia
flywheel
2665 can have a mass ranging from 100 g to 500 g depending on the kind of nailer used.
[0090] In other examples, the high inertia flywheel
2665 disclosed herein can have a mass in a range of from less than 28.4 g to greater than
1418 g.
[0091] The high inertia flywheel
2665 can have an outer diameter from small, such as from less than 0.02 m to quite large,
such as greater than 0.6 m. For example a high inertia flywheel
2665 can have a portion, such as a flywheel body portion and/or a flywheel outer diameter
having a diameter which can be 0.001 m to 0.6 m.
[0092] In an embodiment, the mass of the driver blade
54 is 80 g or greater, such as in a range of from 80 g to 200 g. For example, the driver
blade
54 can have a mass in a range of from 85 g to 170 g.
[0093] In an embodiment, the high inertia driver system can rotate a flywheel at a rotational
speed of 15000 rpm or less. Optionally a high inertia flywheel
2665 of the high inertia driver system can have a speed in a range of 7000 rpm - 15000
rpm. Optionally, the high inertia flywheel
2665, can be a cantilevered flywheel. In an embodiment, the high inertia flywheel
2665, can be operated at a rotational speed of from less than 2500 rpm to 15000 rpm, such
as, 7500 rpm, or 12500 rpm.
[0094] The high inertia driver system, the high inertia flywheel
2665 can have a rotational speed in a range of 700 rad/s - 1600 rad/s. For example, any
of the flywheels disclosed herein can be operated at any rotational speed in the range
of from 700 rads/s to 1600 rads/s.
[0095] In an embodiment of the high inertia driver system, the high inertia flywheel
2665, can be operated such that the speed of a flywheel portion and/or a portion of contact
surface
2715 can be in a range of from less than less than 10 m/s to 30 m/s, or greater. Optionally,
the high inertia flywheel
2665, can be a cantilevered flywheel. For example the cupped flywheel
702 can be operated such that speed of a flywheel portion and/or a portion of contact
surface
2715 is 1.5 m/s to 30 m/s.
[0096] In an embodiment of the high inertia driver system, the high inertia flywheel
2665 can have an inertia in a range of 0.10 g*m^2 or greater, such as in a range of 0.10
g*m^2 - 0.40 g*m^2 when a portion of the flywheel is contacted with a portion of a
driver blade
54.
[0097] In an embodiment of the high inertia driver system, the high inertia flywheel
2665 can impart a pinch force from a portion of the flywheel to a portion of the driver
blade when the flywheel
2665 contacts the driver blade of 222 N or greater, such as in a range of 222 N to 2669
N. For example, the high inertia driver system can produce a pinch force in the range
of 222 N to 2669 N.
[0098] In an embodiment, the pinch force imparted by a portion of the flywheel
2665 to a driver blade when in contact with a portion of the driver blade can be in a
range of 222 N - 2669 N. The mass of the driver blade can be in a range of 80 g to
200 g.
[0099] In an embodiment, when a portion of the high inertia flywheel
2665 is contacted with a portion of the driver blade
54, the driver blade can be driven at a speed in a range of from 30 m/s to less than
10 m/s. For example, the driver blade
54 can have a speed of 0.8 m/s to 30 m/s, when the flywheel can have a speed 15000 rpm,
or less.
[0100] FIG. 16 is a side view of the configuration shown in FIGS. 15 and 16 in which the
high inertia flywheel
2655 is proximate to a driver blade
54. The high inertia flywheel
2665 is shown engaged with driver blade
54 and imparting a driving force, which can be a pinch force, to the driver blade body
1000.
[0101] FIG. 17 shows a top view of the configuration of FIG. 15 and shows the motor
5000 and a partial cross-section of the high inertia flywheel
2665. The first flywheel groove is shown frictionally engaged with the first blade fin
2701 and the second flywheel groove
2662 is shown frictionally engaged with the second blade fin
2702.
[0102] FIG. 18A is a first embodiment of the high inertia flywheel
2665. The high inertia flywheel
2665 has the first flywheel groove
2661 and the second flywheel groove
2662.
[0103] FIG. 18B is a second embodiment of a high inertia flywheel
2668. The high inertia flywheel
2668 has the first flywheel groove
2661, the second flywheel groove
2662 and a third flywheel groove
2663.
[0104] FIG. 19 is a cross-sectional view of the high inertia flywheel
2665 shown in FIGS. 15 and 16 showing the motor windings
5001 of motor
5000 which drives and/or rotates the high inertia flywheel
2665. The high inertia flywheel
2665 is shown cantilevered over at least a part of the motor
5000 and can have any of the characteristics of mass, speed, rotation, geometry, and engagement
with the driver blade
54 or other characteristics disclosed herein.
[0105] In an embodiment, the high inertia driver system can have a number of operational
modes which operate the flywheel
2655, under different operating conditions.
[0106] For example in one embodiment, in a first operating mode of the high inertia flywheel
2665, the speed is in a range of from 12000 rpm to 15000 rpm, such as 13000 rpm; and in
the second operating mode of the high inertia flywheel
2665, speed is in a range of from 7000 rpm to 12000 rpm, such as 11000 rpm.
[0107] In an embodiment, the high inertia driver system can be used in a framing nailer
having a low speed driver blade
54 in which the speed, can be 25 m/s, or less. Low speed driver blades can result in
lower impact speed on the bumper
899, or to be controlled by bumper system
900.
[0108] In an example a framing nailer having a flywheel inertia of 2.25 10^-4 kg m^2 and
a flywheel speed of 13000 rpm experienced a 23 percent lower return spring life than
a framing nailer using a high inertia driver system having a flywheel inertia of 2.77
10^-4 kg m^2 and a flywheel speed of 11000 rpm. The increase in flywheel inertia and
reduction of flywheel speed in this example was found to not materially affect tool
weight, readiness to fire, tool reliability, and nail penetration (power). This example
found a reduction in flywheel speed and driver speed prolonged the useful life of
elastic return elements connected to the driver, such as stranded wire return springs.
[0109] In an embodiment, the kinetic energy transferred to the return springs when using
the high inertia driver system is reduced by 23 percent in a comparative test.
[0110] FIG. 20 is a perspective view of a third embodiment of a high inertia flywheel in
the form of the cupped flywheel
702 shown as positioned for assembly onto a motor
5000. FIG. 20 illustrates the motor
5000 having a motor housing
510 and a first housing bearing
520 which bears a rotor shaft
550 driven by an inner rotor
540 (FIG. 23A). The motor can alternatively be a frameless motor which does not include
a motor housing, or which can have only a partial motor housing which covers part
of a longitudinal length of the motor. FIG. 20 also illustrates the cupped flywheel
702 as a cantilevered flywheel. For example the cupped flywheel
702 can have a mass of less than 14 g to 1418 g, or greater. In another example, the
cupped flywheel
702 can have a mass of from less than 10 g to 1000 g, or greater. In an embodiment, the
cupped flywheel
702 can have an inertia from less than 5 J(kg*m^2), 7.5 J(kg*m^2) to 600 J(kg*m^2), or
greater.
[0111] FIG. 20 shows the cupped flywheel
702 in a disassembled state and in coaxial alignment with a rotor centerline
1400. In an embodiment, the cupped flywheel
702 can have a flywheel body
710 and at least one of a flywheel opening and/or a plurality of flywheel openings
720. In an embodiment, the cupped flywheel
702 can have a geared flywheel ring
762. Optionally, the cupped flywheel
702 can have a flywheel bearing
770 which can interface with the rotor shaft
550.
[0112] FIG. 21 is a side view of the cupped flywheel
702, positioned for assembly onto the motor
5000. The cupped flywheel can be positioned such that a flywheel axial centerline
1410 is collinear with a rotor centerline
1400. In an embodiment, the cupped flywheel
702 can be frictionally attached to the rotor shaft
550 by means of fitting the flywheel bearing
770 onto a portion of the rotor shaft
550. In other embodiments, the cupped flywheel
702 can be attached to the rotor shaft
550 by other means, such as using a lock and key configuration, using a "D" shaped shaft
portion mated with a "D" shaped portion of the flywheel bearing
770, using fasteners such a screw, a linchpin, a bolt, a wed, or any other means. In an
embodiment, the inner rotor
540 (FIG. 23B) and/or the rotor shaft
550 and the cupped flywheel
702 and/or the flywheel bearing
770 can be manufactured as one piece, or multiple pieces.
[0113] FIG. 22 is a front view of the cupped flywheel
702 having a number of the flywheel openings
720 in the flywheel body
710. The flywheel ring
1750 is shown extending radially away from the center of the cupped flywheel
702 and the flywheel bearing 770. There is no limitation to the number of flywheel rings
which can be used. Optionally, one or more flywheel rings can be located along the
length of the cupped flywheel
702. Each flywheel ring can have a contact surface to impart energy to a moveable member.
Multiple flywheel rings can power multiple members, or the same member.
[0114] FIG. 23A and 23B shown the cupped flywheel
702 is shown in an assembled state. FIG. 23A is a side view of a drive mechanism having
the cupped flywheel
702, which is frictionally engaged with a driver profile
610 and/or the driver blade
54. In FIG. 23A, the mating of the flywheel ring
1750 with the driver profile
610 is shown. There is no limitation as to the means by which the flywheel
702 imparts energy to the driver profile
610 and/or the driver blade
54. In the example of FIG. 23A, the flywheel ring
1750 is a geared flywheel ring
762 having a first gear groove
783 and a second gear groove
787 which is shown in frictional contact with driver profile
610 and, more specifically, a first profile tooth
611 and a second profile tooth
613. By this frictional contact, at least a portion of the rotational energy developed
in the cupped flywheel
702 is imparted to the driver profile
610 propelling the driver profile through a driving action to cause the driver blade
54 to drive a nail
53.
[0115] FIG. 23B is a cross-sectional view of a drive mechanism having the cupped flywheel
702, which is frictionally engaged with the driver profile
610. As shown, the flywheel ring
1750 is cantilevered over at least a portion of the motor
5000. In an embodiment, the flywheel ring
1750 can be cantilevered over the entirety of the inner rotor motor, or any portion of
the motor
5000. The cup shape of the cupped flywheel
702, when coupled to the rotor shaft
550, configures the flywheel ring
1750 radially and in a cantilevered configuration about at least a portion of inner rotor
motor and/or motor housing
510 and/or inner rotor
540. The flywheel ring
1750 can be positioned along the rotor centerline
1400 at a position at which the flywheel ring
1750 is positioned such that a portion of each of the motor housing
510, the stator
530, the inner rotor
540 and the rotor shaft
550 is radially within a flywheel ring inner circumference
707. The flywheel ring inner circumference
707 can have a diameter which optionally is the same or different from the flywheel inner
diameter
706. The flywheel ring inner circumference
707 can be separated from the motor housing
510 by a flywheel motor clearance
701. There is no limitation as to the dimension of the flywheel motor clearance
701. The flywheel motor clearance
701 can be in a range of from less than a millimeter to one third of a meter, or more.
[0116] In the example embodiment of FIG. 23B, the flywheel ring inner circumference
707 can be the same as a flywheel inner circumference
709. The flywheel inner circumference
709 can be the same or different from the flywheel ring inner circumference
707. The flywheel inner circumference
709 can have any dimension which is separated from the motor housing
510 by a clearance. The flywheel inner circumference
709 can be at least in part overlap at least a portion of the inner rotor motor and/or
the motor housing
510. The flywheel inner circumference
709 can at least, in part, radially encompass at least a part of inner rotor motor and/or
the motor housing
510.
[0117] FIG. 24 is a perspective view of the drive mechanism having the cupped flywheel
702 as a high inertia flywheel and the driver profile
610 is in an engaged or contact state. The flywheel can be the cupped flywheel
702, such as the high inertia flywheel. The driving action of the driver blade
54 can be used to drive a fastener, such as a nail
53, into a workpiece. The driver profile
610 and/or the driver blade
54 can be moved into frictional contact with the flywheel
702 when the cupped flywheel is in a cantilevered state. The driver blade
54 is propelled to physically contact the fastener such that the fastener is driven
into a workpiece. The driving action of the driver blade
54 can begin when the driver profile
610 makes contact with the flywheel
702. Upon contact by the driver profile
610 with the flywheel
702, the driver profile
610 is propelled toward the fastener positioned in the nosepiece
12. The driver blade
54 can physically contact the fastener such that the fastener is driven into a workpiece.
After the fastener is driven into the workpiece, the driver blade
54 returns to its resting position. In an embodiment, the driver profile
610 can be driven by being in frictional contact with the rotating flywheel ring
1750 of the cupped flywheel
702.
[0118] There is no limitation regarding the diameter or dimensions of any of the various
embodiments of the flywheel disclosed herein, such as the cantilevered flywheel, the
cupped flywheel, or the high inertia flywheel, or other type of cantilevered flywheel
having at least a portion projecting over at least a portion of the motor
5000. In other example embodiments, the cupped flywheel
702 can have a number of flywheel struts, or cupped flywheel
702 can have a flywheel mesh structure, or other structure.
[0119] In FIG. 24, the driving process is shown at a point of the driving sequence in which
the driver profile
610 is frictionally engaged the cupped flywheel
702. At this stage the flywheel, will impart energy to the driver profile
610 and/or the driver blade
54. This energy will propel the driver blade
54 toward the nosepiece
12. There is no limitation to the driving force which can be imparted to the driver blade
54. For example, any of the flywheels disclosed herein can impart a driving force in
a range of from less than 2 J to 1000 J, or greater. For example the cupped flywheel
702 can impart a driving force to the driver blade
54 of less than 1 J to 1000 J, or greater.
[0120] There is no limitation to the torque generated by the inner rotor motor, such as
motor
5000. For example, any of the flywheels disclosed herein can be driven by the motor
5000 which can generate a torque in the range of from less than 0.005 Nm to 10 Nm, or
greater. For example, the motor
5000 can generate any torque in the range of from less than 0.005 Nm to 10 Nm, or greater.
[0121] There is no limitation to the speed of the driver blade
54 at which any of the many types and variations of flywheels operate. For example,
any of the driver blades
54 disclosed herein can be operated at any speed in the range of from less than 3.0
m/s to 122 m/s, or greater. In a power tool and/or fastening tool having a flywheel,
such as the cupped flywheel
702, the driver blade
54 which can have a speed of for example, 0.8 m/s to 122 m/s, or greater.
[0122] FIG. 25 is a side view of a driver assembly having the cupped flywheel
702. FIG. 25 shows an example embodiment of a nailer drive mechanism at the state in which
the driver profile
610 has initially and tangentially made frictional contact with the flywheel ring
1750. This is a position analogous to that depicted in FIG. 24. In the moment of the activation,
the driver assembly includes an activation mechanism
820, having an activation member
830. The activation member
830 imparts a force along an engagement axis
1800 which causes the driver profile
610 to come into frictional contact with flywheel
702 to effect a driving motion of driver blade
54. The movement of the activation member
830 is reversible and illustrated by a double pointed engagement movement arrow
835. FIG. 25 also illustrates an embodiment of a driver blade return mechanism
1700 which absorbs recoil energy and guides the driver blade
54 back to its resting state, prior to another driving action.
[0123] FIG. 26 is a sample of exemplary driver blade speed data using a high inertia driver
system. FIG. 26 shows a comparison between the speed profile of a driver blade driven
by the high inertia driver system compared to the speed profile of a stock, not having
the high inertia driver system.
[0124] FIG. 27 is a graph of an example of driver blade position data using a high inertia
driver system.
[0125] FIG. 28A is a graph showing return spring kinetic energy.
[0126] FIG. 28B is a data table for an exemplary high inertia driver system showing dry
fire data.
[0127] FIG. 29 is a graph showing framer dryfire drive velocities.
[0128] FIG. 30A shows an exemplary shallow depth wet fire test chart.
[0129] FIG. 30B shows an exemplary deepest depth wet fire test chart.
[0130] The scope of this disclosure is to be broadly construed. It is intended that this
disclosure disclose equivalents, means, systems and methods to achieve the devices,
activities and mechanical actions disclosed herein. For each mechanical element or
mechanism disclosed, it is intended that this disclosure also encompass in its disclosure
and teaches equivalents, means, systems and methods for practicing the many aspects,
mechanisms and devices disclosed herein. Additionally, this disclosure regards a fastening
tool and its many aspects, features and elements. Such a tool can be dynamic in its
use an operation, this disclosure is intended to encompass the equivalents, means,
systems and methods of the use of the tool and its many aspects consistent with the
description and spirit of the operations and functions disclosed herein. The claims
of this application are likewise to be broadly construed.
[0131] The description of the inventions herein in their many embodiments is merely exemplary
in nature and, thus, variations that do not depart from the gist of the invention
are intended to be within the scope of the invention. Such variations are not to be
regarded as a departure from the spirit and scope of the invention.