Feeding and driving assembly for a combination staple-cap fastener

• US 6,478,209 B1
• Filed: 05/09/2000
• Issued: 11/12/2002
• Est. Priority Date: 02/18/2000
• Status: Expired due to Term

• Current Assignee: National Nail Corp
• Original Assignee: National Nail Corp
• Inventors: Bruins, Roger C., Vanden Berg, Roger A.
• Primary Examiner(s): Smith, Scott A.
• Assistant Examiner(s): CHUKWURAH, NATHANIEL C
• Application Number:
  US09/567,421
• Time in Patent Office: 917 Days
• Field of Search: 227/15, 227/16, 227/18, 227/114, 227/116, 227/119, 227/136, 227/138
• US Class Current: 227/16
• CPC Class Codes: B25C 5/1693 co-ordinating with the feed of a second item
• CPC Class Codes: E04D 2015/045 by nailing

Abstract

A fastener applying device for causing a driven staple to be driven through a disk-like cap to create a staple-cap fastener for securely attaching flexible or deformable materials to a substrate. The device includes an automatic stapler capable of automatically driving a staple into the substrate. The device also has a cap feeding device including a magazine containing a reel of caps positioned generally edge-to-edge and joined in a continuous strip, such as by an adhesive tape. The cap strip is fed from the reel into a guide track which feeds the leading cap of the strip into a driving region disposed below the discharge end of the staple driver. The guide track defines thereon stops which straddle the driving region, and which positionally contact the structure into which the fastener is to be driven.

Claims

1. A cap feeding device for an automatic powered fastener driver having a magazine which contains a plurality of fasteners and which supplies a fastener to a driving zone for driving engagement with a fastener driving member which is movably supported on a driving head for engaging and forwardly driving the fastener out of the driving zone into a building structure such as a roof, said cap feeding device comprising:

a housing defining therein a storage space for a plurality of thin disk-like caps which are connected together in sidewardly adjacent edge-to-edge relationship so as to define an elongate flexible cap strip, the strip having portions which are disposed in generally superimposed relationship for compact storage within the storage space of the housing, the housing defining therein a discharge passage for permitting a leading end of the cap strip to be discharged therethrough;

an elongate guideway extending from said discharge passage and terminating in a remote end disposed generally at said driving zone for slidably guiding the leading end of the cap strip from the discharge passage to the driving zone;

said guideway defining an elongate support surface which extends from said discharge passage and which terminates at a remote free end which is disposed directly sidewardly adjacent said driving zone, said support surface slidably supporting the leading end of said cap strip thereon so that the leading cap of said strip is positionable at a lead-in position defined at the free end of said support surface in laterally spaced but generally sidewardly aligned relation with said driving zone;

a cap driving arrangement including a driving member which directly drivingly engages the leading cap as disposed in said lead-in position for advancing the leading cap from the lead-in position into the driving zone; and

a resilient hold-down member engaged with an upper surface of the cap disposed in said lead-in position for preventing rearward movement thereof along the guideway.

2. A device according to claim 1, wherein the guideway has a pair of stop members which are fixed to and project outwardly in parallel relationship from the front free edge thereof in straddling relationship to the driving zone for sidewardly guiding the cap which is advanced from the lead-in position into the driving zone, said sidewardly spaced stops having lower surfaces thereon which are adapted to directly abuttingly contact the wall structure so that the fastener is driven through the cap into the wall structure during a fastener driving operation.

3. A device according to claim 1, wherein the cap has a recess formed in and opening downwardly from the upper surface thereof, and said resilient hold-down member projecting into the recess of the cap disposed at said lead-in position for preventing forward or rearward displacement of said cap except when the cap is advanced into the driving zone by the driving member.

4. A device according to claim 3, wherein the hold-down member comprises an elongate cantilevered spring member having a free end thereof resiliently urged into a position wherein it projects into the recess of the cap at the lead-in position.

5. A device according to claim 1, wherein said guideway defines a shallow upwardly opening channel having an inner bottom surface which defines said support surface and having side walls which join to said bottom wall and project upwardly therefrom, the sideward spacing between said side walls being such as to closely confine the caps therebetween as the leading end of the cap strip slidably moves from the discharge passage to the lead-in position, and said side walls having wall parts which are cantilevered forwardly beyond the leading edge of said bottom wall so as to sidewardly straddle said driving zone and the cap which is advanced forwardly from the lead-in position into the driving zone.

6. The device according to claim 5, wherein the wall parts which straddle the driving zone have bottom surfaces which extend in angled relationship relative to the elongate direction of the guideway and which supportingly engage an exposed surface of the wall structure into which the fastener is to be driven so as to permit the cap disposed within the driving zone to at least partially engage the surface of the wall structure prior to the fastener being driven through the cap.

7. A device according to claim 1, wherein the fastener comprises a staple having two legs which project through the cap, the staple having a maximum width which is about 50% of the cap diameter.

8. The device according to claim 1, wherein the caps are connected together in edge-to-edge relationship by an elongate flexible tape which is adhesively connected to the individual caps so as to define the elongate flexible cap strip, said adhesive tape having a width which is significantly less than the diameter of the caps.

9. A driving feeding device for a staple, comprising:

a staple driving unit including a driving head having a staple guide member fixed to one end thereof and terminating in a discharge end, and a staple driver slidably supported along the guide member for ejecting a staple along a first axis which extends lengthwise of the guide member;

a staple cartridge mounted to said driving unit for supporting a stack of channel-like staples so that an endmost staple of the stack is positioned for engagement with the staple driver during driving movement thereof;

a cap feeding device coupled to said driving unit for intermittently and sequentially feeding a thin disk-like cap into a driving position disposed adjacent and substantially aligned with the discharge end o the guide member, said cap feeding device including;

(a) a magazine for containing an elongate cap strip defined by a plurality of thin disk-like caps disposed in closely adjacent edge-to-edge positional relationship and serially connected by a connecting member,

(b) the caps having a shallow dome-shaped configuration when viewed in cross-section and constructed of a plastic material so as to be resiliently deformable when a staple is driven therethrough,

(c) a track arrangement extending from a discharge of said magazine to said driving region for movably supporting thereon a length of said cap strip so that a leading cap of said length is disposed in a lead-in position which is sidewardly spaced from said driving position,

(d) a cap advancing device for advancing a cap from said lead-in position to said driving position wherein it is penetrated by the staple discharged along said first axis by said staple driver; and

said staples as provided in the staple cartridge having a crown width of about 35% to about 50% of the cap diameter.

10. A device according to claim 9, wherein the connecting member joining the caps together to define the elongate cap strip comprises an elongate flat adhesive tape which extends continuously along the cap strip and is adhesively joined to each cap along said strip, said tape having a width which is significantly smaller than the diameter of the caps.

11. A device according to claim 10, wherein the staple which penetrates the cap also penetrates the tape to assist in effecting transverse separation of the tape.

12. A device according to claim 11, wherein the staple which penetrates the cap extends in angled relationship relative to both the longitudinal and transverse directions of the elongate flat adhesive tape and is sized so that both legs of the staple penetrate both the cap and the tape.

13. A driving feeding device for a staple/cap fastener comprising:

a staple driving unit including a driving head having a staple guide member fixed to one end thereof and terminating in a discharge end, and a staple driver slidably supported within the guide member for ejecting a staple along a first axis which extends lengthwise of the guide member;

an elongate staple cartridge fixed to said driving head and projecting transversely therefrom, said cartridge defining therein a support rail which extends along a second axis in generally transverse and intersecting relation to said first axis, said rail being adapted to support a stack of channel-like staples thereon so that an endmost staple of the stack is positioned for engagement with the staple driver during extending driving movement thereof;

a cap feeding device fixedly coupled to said staple driving unit for intermittently and sequentially feeding a thin disk-like cap into a driving position disposed closely adjacent and substantially aligned with the discharge end of the guide member, said cap feeding device including;

(a) a magazine for containing an elongate cap strip defined by a plurality of thin disk-like caps disposed in closely adjacent edge-to-edge positional relationship and serially connected by a connecting member,

(b) a track arrangement extending from a discharge of said magazine to said driving position, said track arrangement being adapted to movably support thereon a length of said cap strip so that a leading cap of said length is disposed in a lead-in position which is substantially adjacent but sidewardly spaced from said driving position, said track arrangement including a guide track having a discharge end which defines said lead-in position, and said track arrangement guiding movement of the cap from the lead-in position to the driving position along a third axis which substantially transversely intersects said first axis,

(c) a cap advancing device cooperating with at least one of the caps on said guide track and being intermittently movable between advanced and retracted positions for advancing a cap from said lead-in position to said driving position wherein it is aligned with and penetrated by the staple discharged along said first axis by said staple driver,

(d) a resilient hold-down device positioned adjacent the discharge end of said guide track and cooperatively engaged with the cap disposed at said lead-in position for preventing significant backward displacement of said cap along the guide track; and

a handle fixedly interconnected to said drive head for permitting manual manipulation of the device.

14. A driving feeding device for a staple/cap fastener, comprising:

a staple driving unit including a driving head having a staple guide member fixed to one end thereof and terminating in a discharge end, and a staple driver slidably supported within the guide member for ejecting a staple along a first axis which extends lengthwise of the guide member;

an elongate staple cartridge fixed to said driving head and projecting transversely therefrom, said cartridge defining therein a support rail which extends along a second axis in generally transverse and intersecting relation to said first axis, said rail being adapted to support a stack of channel-like staples thereon so that an endmost staple of the stack is positioned for engagement with the staple driver during extending driving movement thereof;

a cap feeding device fixedly coupled to said staple driving unit for intermittently and sequentially feeding a thin disk-like cap into a driving position disposed closely adjacent and substantially aligned with the discharge end of the guide member, said cap feeding device including;

(a) a magazine for containing an elongate cap strip defined by a plurality of thin disk-like caps disposed in closely adjacent edge-to-edge positional relationship and serially connected by a connecting member,

(b) a track arrangement extending from a discharge of said magazine to said driving position, said track arrangement being adapted to movably support thereon a length of said cap strip so that a leading cap of said length is disposed in a lead-in position which is substantially adjacent but sidewardly spaced from said driving position, said track arrangement including a guide track having a discharge end which defines said lead-in position, and said track arrangement guiding movement of the cap from the lead-in position to a driving position defined within said driving region along a third axis which substantially transversely intersects said first axis, said third axis when viewed in a plane perpendicular to said first axis extending at an angle of at least about 30°

relative to said second axis,

(c) a cap advancing device cooperating with at least one of the caps on said guide track and being intermittently movable between advanced and retracted positions for advancing a cap from said lead-in position to said driving position wherein it is aligned with and penetrated by the staple discharged along said first axis by said staple driver; and

a handle fixedly interconnected to said drive head for permitting manual manipulation of the device.

15. A device according to claim 14, wherein said third axis, when viewed in a plane perpendicular to said first axis, extends at an angle of about 45°

relative to said second axis.

16. A driving feeding device for a staple/cap fastener comprising:

a staple driving unit including a driving head having a staple guide member fixed to one end thereof and terminating in a discharge end, and a staple driver slidably supported within the guide member for ejecting a staple along a first axis which extends lengthwise of the guide member;

an elongate staple cartridge fixed to said driving head and projecting transversely therefrom, said cartridge defining therein a support rail which extends along a second axis in generally transverse and intersecting relation to said first axis, said rail being adapted to support a stack of channel-like staples thereon so that an endmost staple of the stack is positioned for engagement with the staple driver during extending driving movement thereof;

a cap feeding device fixedly coupled to said staple driving unit for intermittently and sequentially feeding a thin disk-like cap into a driving position disposed closely adjacent and substantially aligned with the discharge end of the guide member, said cap feeding device including;

(a) a magazine for containing an elongate cap strip defined by a plurality of thin disk-like caps disposed in closely adjacent edge-to-edge positional relationship and serially connected by a connecting member,

(b) a track arrangement extending from a discharge of said magazine to said driving position, said track arrangement being adapted to movably support thereon a length of said cap strip so that a leading cap of said length is disposed in a lead-in position which is substantially adjacent but sidewardly spaced from said driving position, said track arrangement including a guide track having a discharge end which defines said lead-in position, and said track arrangement guiding movement of the cap from the lead-in position to a driving position defined within said driving region along a third axis which substantially transversely intersects said first axis,

(c) said track arrangement including a pair of stop members cantilevered forwardly from said lead-in position and disposed on opposite sides of said driving position with the latter opening vertically between the sidewardly spaced stop members, said stop members on lower surfaces thereof defining sloped contact surfaces adapted to be positioned in abutting engagement with a wall surface so as to position the track arrangement in an inclined relationship relative to the wall surface when the device is being used to discharge a staple into the wall structure,

(d) a cap advancing device cooperating with at least one of the caps on said guide track and being intermittently movable between advanced and retracted positions for advancing a cap from said lead-in position to said driving position wherein it is aligned with and penetrated by the staple discharged along said first axis by said staple driver; and

a handle fixedly interconnected to said drive head for permitting manual manipulation of the device.

17. A device according to claim 16, wherein the cap positioned in the driving position remains connected to the cap in the lead-in position prior to discharge of the staple, and the cap in the driving position having at least a leading edge portion thereof disposed in contact with the wall surface when the sloped contact surfaces on the stop members are engaged with the wall surface.

18. A driving feeding device for a staple/cap fastener, comprising:

a staple driving unit including a driving head having a staple guide member fixed to one end thereof and terminating in a discharge end, and a staple driver slidably supported within the guide member for ejecting a staple along a first axis which extends lengthwise of the guide member;

an elongate staple cartridge fixed to said driving head and projecting transversely therefrom, said cartridge defining therein a support rail which extends along a second axis in generally transverse and intersecting relation to said first axis, said rail being adapted to support a stack of channel-like staples thereon so that an endmost staple of the stack is positioned for engagement with the staple driver during extending driving movement thereof;

a cap feeding device fixedly coupled to said staple driving unit for intermittently and sequentially feeding a thin disk-like cap into a driving position disposed closely adjacent and substantially aligned with the discharge end of the guide member, said cap feeding device including;

(a) a magazine for containing an elongate cap strip defined by a plurality of thin disk-like caps disposed in closely adjacent edge-to-edge positional relationship and serially connected by a connecting member,

(b) a track arrangement extending from a discharge of said magazine to said driving position, said track arrangement being adapted to movably support thereon a length of said cap strip so that a leading cap of said length is disposed in a lead-in position which is substantially adjacent but sidewardly spaced from said driving position, said track arrangement including a guide track having a discharge end which defines said lead-in position, and said track arrangement guiding movement of the cap from the lead-in position to a driving position defined within said driving region along a third axis which substantially transversely intersects said first axis,

(c) a cap advancing device cooperating with at least one of the caps on said guide track and being intermittently movable between advanced and retracted positions for advancing a cap from said lead-in position to said driving position wherein it is aligned with and penetrated by the staple discharged along said first axis by said staple driver, the cap advancing device including a driving projection which when in the retracted position directly abuttingly engages a rear edge of the cap in the lead-in position for effecting direct advancing thereof into the driving position; and

a handle fixedly interconnected to said drive head for permitting manual manipulation of the device.

19. A portable driving feeding device for a staple/cap fastener adapted for securement to a wall structure, said device comprising:

a staple driving unit including a driving head and a staple driver slidably supported for movement relative to the driving head along a first direction for ejecting a staple along said first direction from a discharge end of said driving head;

a staple cartridge stationarily mounted to said driving unit for supporting a stack of channel-like staples so that the endmost staple of the stack is positioned for engagement with a staple driver during driving movement thereof, said stack of staples being movably supported for advancing movement along a second direction which substantially transversely intersects said first direction so that the endmost staple of the stack is positioned for engagement by the staple driver;

a cap feeding device coupled to the staple driving unit for intermittently and sequentially feeding a thin disk-like cap into a driving position which is defined along said first direction and is disposed adjacent and substantially aligned with the discharge end of said driving head;

said cap feeding device including a magazine containing an elongate cap strip defined by a plurality of thin disk-like caps disposed in closely adjacent edge-to-edge positional relationship and serially connected by an elongate flat adhesive tape which extends continuously along the cap strip and is adhesively joined to an upper surface of each cap along said strip;

said cap feeding device further including a track arrangement extending from a discharge of said magazine to said driving region for movably supporting thereon a length of said cap strip so that an endmost cap of said length is disposed in said driving position and the next adjacent cap of said length is disposed in a lead-in position which is sidewardly adjacent said driving position, said cap strip being oriented such that the adhesive tape secured to said caps faces toward the discharge end of the staple driving head;

said cap feeding device also including a cap advancing device for advancing a cap from said lead-in position to said driving position wherein it is penetrated by the staple discharged along said first direction by said staple driver;

a stop structure disposed adjacent the discharge end of said track arrangement and having stop surfaces adapted for positional contact with a wall structure, said stop structure defining sidewardly spaced guide members for sidewardly positioning the cap when disposed in said driving position; and

said staple having a crown width which is less than the width of the cap and which is positioned so that both legs of the staple penetrate the cap and the crown of the staple extends transversely relative to the adhesive tape so that the staple crown effectively functions as a cutting edge to facilitate transverse tearing of the tape when the cap in the driving position is separated from the strip.

20. A device according to claim 19, wherein said adhesive tape has a width which is substantially less than the width of the caps to minimize adhesive contact area between the tape and the caps, and at least one of the legs of the staple penetrating the tape during driving of the staple through the cap so as to facilitate transverse tearing of the tape.

21. A device according to claim 19, wherein the staple as it penetrates the cap is oriented such that the crown of the staple extends at an acute angle relative to both the longitudinal and transverse dimensions of the tape, and the length of the staple crown is such that both legs of the staple penetrate the tape and the cap.

22. A driving feeding device for a staple/cap fastener, comprising:

a staple driving unit including a driving head having a staple guide member fixed to one end thereof and terminating in a discharge end, and a staple driver slidably supported along the guide member for ejecting a staple along a first path which extends lengthwise of the guide member;

a staple cartridge mounted to said driving unit for supporting a stack of channel-like staples so that an endmost staple of the stack is positioned for engagement with the staple driver during driving movement thereof;

a cap feeding device coupled to said driving unit for intermittently and sequentially feeding a thin disk-like cap into a driving position disposed adjacent and substantially aligned with the discharge end of the guide member, said cap feeding device including;

(a) a magazine for containing an elongate cap strip defined by a plurality of thin disk-like caps disposed in closely adjacent edge-to-edge positional relationship and serially connected by a connecting member,

(b) a track arrangement extending from a discharge of said magazine to said driving region for movably supporting thereon a length of said cap strip so that a leading cap of said length is disposed in a lead-in position which is sidewardly spaced from said driving position, and

(c) a cap advancing device for advancing a cap from said lead-in position to said driving position wherein it is penetrated by the staple discharged along said first axis by said staple driver; and

said caps being formed as thin circular disk-like members constructed of a plastic material, said staples having a crown width which is less than the diameter of the cap, and said discharged staple being positioned so as that both legs thereof are driven through the cap disposed in said driving position.

23. The device according to claim 22, wherein the cap has a shallow dome-shaped configuration which is resiliently deformed when the staple is driven through the cap.