Impact-driven plastic fasteners

• US 6,168,362 B1
• Filed: 06/25/1998
• Issued: 01/02/2001
• Est. Priority Date: 02/18/1994
• Status: Expired due to Term

• Current Assignee: Utility Composites International Limited
• Original Assignee: Utility Composites International Limited
• Inventors: Showers, Nancy, Tucker, Pamela S.
• Primary Examiner(s): WILSON, NEILL R
• Application Number:
  US09/104,866
• Time in Patent Office: 922 Days
• Field of Search: 411/442, 411/443, 411/444, 411/446, 411/457, 411/908, 411/920, 206/343, 206/345
• US Class Current: 411/442
• CPC Class Codes: B29C 70/12 using fibres of short length, e.g. in the form of a mat non-woven fabrics per se D04H1/00
• CPC Class Codes: B29K 2995/0077 Yield strength; Tensile strength
• CPC Class Codes: B29K 2995/0082 Flexural strength; Flexion stiffness
• CPC Class Codes: F16B 15/0015 Staples
• CPC Class Codes: F16B 15/08 formed in integral series but easily separable
• CPC Class Codes: Y10S 411/908 Resinous material
• CPC Class Codes: Y10S 411/92 Staple

Abstract

A continuous impact-driven fastener pack made of ultra-high strength plastic composite materials, for example, thermoplastic or thermoset materials for use in standard impact driving fasteners machines. The individual fasteners have sufficient compressive strength and flexural modulus such that the fastener may be used with commodity woods for construction, furniture making, or for building boats. Further, this fastener pack is non-corrodible and provides plastic fasteners having a length/diameter ratios of a working nail or staple, e.g., heretofore unavailable.

Claims

1. A plastic staple, the staple comprising a plastic composite, the plastic composite comprising a compression strength greater than about 20,000 psi and a flexural modulus greater than about 1.2×

10⁶ psi, wherein the staple has an slenderness ratio of up to about 38.

2. The staple of claim 1 wherein the staple is configured for use in an impact driving staple machine.

3. The staple of claim 1 wherein the plastic composite comprises a thermoset material.

4. The staple of claim 1 wherein the plastic composite comprises a thermoplastic material.

5. The staple of claim 1 wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising polyphenylene sulfide.

6. The staple of claim 1 wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising polyetherimide.

7. The staple of claim 1 wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising polyamide-imide.

8. The staple of claim 1 wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising fiber-filled polyphthalamide, the fiber filled polyphthalamide comprising about 10 to about 200 parts by weight reinforcing fibers per hundred parts by weight of polyphthalamide component.

9. The staple of claim 1 wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage.

10. The staple of claim 1 wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the plastic composite comprises a thermoplastic material.

11. The staple of claim 1 wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple.

12. The staple of claim 1 wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple, and wherein the plastic composite comprises a thermoplastic material.

13. The staple of claim 1 wherein the compression strength of the staple is substantially greater than a compression strength of a metal staple comprising an slenderness ratio about equal to the slenderness ratio of the staple, and wherein the flexural modulus of the staple is substantially greater than a flexural modulus of the metal staple.

14. The staple of claim 1 wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple, and wherein the plastic composite comprises a thermoplastic material, and wherein the compression strength of the staple is substantially greater than a compression strength of a metal staple comprising an slenderness ratio about equal to the slenderness ratio of the staple, and wherein the flexural modulus of the staple is substantially greater than a flexural modulus of the metal staple.

15. The staple of claim 1 wherein the staple is configured for use in an impact driving machine.

16. The staple of claim 1 wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple, and wherein the plastic composite comprises a thermoplastic material, and wherein the compression strength of the staple is substantially greater than a compression strength of a metal staple comprising an slenderness ratio about equal to the slenderness ratio of the staple, and wherein the flexural modulus of the staple is substantially greater than a flexural modulus of the metal staple, and wherein the staple is configured for use in an impact driving machine.

17. The plastic staple as defined in claim 1, further comprising a second plastic staple, wherein at least the first and second staples are coupled together to form a staple pack.

18. The plastic staple as defined in claim 17, wherein the staple pack is configured for use in an impact driving machine.

19. A plastic staple, the staple comprising a plastic composite having a compression strength greater than about 20,000 psi, a flexural modulus greater than about 1.2 million psi, and a slenderness ratio that is greater than about 18 and less than about 38.

20. The plastic staple as defined in claim 19, wherein the slenderness ratio is greater than about 25.

21. The plastic staple as defined in claim 19, wherein the slenderness ratio is greater than about 30.

22. The plastic staple as defined in claim 19, further comprising a second plastic staple, wherein at least the first and second staples are coupled together to form a staple pack.

23. The plastic staple as defined in claim 22, wherein the staple pack is configured for use in an impact driving machine.

24. The staple of claim 22, wherein the staple pack is configured for use in an impact driving staple machine.

25. The staple of claim 19, wherein the plastic composite comprises a thermoset material.

26. The staple of claim 19, wherein the plastic composite comprises a thermoplastic material.

27. The staple of claim 19, wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising polyphenylene sulfide.

28. The staple of claim 19, wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising polyetherimide.

29. The staple of claim 19, wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising polyamide-imide.

30. The staple of claim 19, wherein the plastic composite comprises a thermoplastic material, the thermoplastic material comprising fiber-filled polyphthalamide, the fiber filled polyphthalamide comprising about 10 to about 200 parts by weight reinforcing fibers per hundred parts by weight of polyphthalamide component.

31. The staple of claim 19, wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage.

32. The staple of claim 19, wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the plastic composite comprises a thermoplastic material.

33. The staple of claim 19, wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple.

34. The staple of claim 19, wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple, and wherein the plastic composite comprises a thermoplastic material.

35. The staple of claim 19, wherein the compression strength of the staple is substantially greater than a compression strength of a metal staple comprising a slenderness ratio about equal to the slenderness ratio of the staple, and wherein the flexural modulus of the staple is substantially greater than a flexural modulus of the metal staple.

36. The staple of claim 19, wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple, and wherein the plastic composite comprises a thermoplastic material, and wherein the compression strength of the staple is substantially greater than a compression strength of a metal staple comprising a slenderness ratio about equal to the slenderness ratio of the staple, and wherein the flexural modulus of the staple is substantially greater than a flexural modulus of the metal staple.

37. The staple of claim 19, wherein the staple is configured for use in an impact driving machine.

38. The staple of claim 19, wherein the staple is driveable through a material comprising a hardness of up to about 1150 pounds without deformation or breakage, and wherein the staple is substantially fixed within the material, and wherein attempted removal of the staple results in substantial breakage of the staple prior to removal of the staple, and wherein the plastic composite comprises a thermoplastic material, and wherein the compression strength of the staple is substantially greater than a compression strength of a metal staple comprising a slenderness ratio about equal to the slenderness ratio of the staple, and wherein the flexural modulus of the staple is substantially greater than a flexural modulus of the metal staple, and wherein the staple is configured for use in an impact driving machine.

39. A plastic staple, the staple comprising a plastic composite having a compression strength greater than about 20,000 psi, a flexural modulus greater than about 1.2 million psi, and a slenderness ratio that is greater than about 25 and less than about 38.

40. A plastic staple, the staple comprising a plastic composite having a compression strength greater than about 20,000 psi, a flexural modulus greater than about 1.2 million psi, and a slenderness ratio that is greater than about 30 and less than about 38.