Powered fastener driver with buckle cap delivery

Abstract

A powered fastener driver includes: a housing; a front end piece; a driver blade movable within the front end piece between a ready position and a driven position; a piston coupled to the driver blade; a driver cylinder in which the piston is movable; a storage chamber cylinder containing pressurized gas therein and in fluid communication with the driver cylinder; a lifting mechanism for moving the driver blade to a ready position; and a motor coupled to the lifting mechanism to drive the lifting mechanism. An on-board air compressor is driven by the motor and is driven while the lifting mechanism is driven. The feed system is in fluid communication with the onboard air compressor and includes a primary feed mechanism adjacent the front end piece and a secondary feed mechanism adjacent the front end piece. The primary feed mechanism and the secondary feed mechanism are actuated by compressed air received from an onboard air compressor.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 514,688, filed on July 20, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to powered fastener drivers, and more particularly to powered fastener drivers that simultaneously deliver a buckle nut. Background Art

[0004] Powered fastener drivers are used to drive fasteners (e.g., nails, tacks, staples, etc.) into a workpiece. Such fastener drivers typically include a magazine in which the fasteners are stored and a pusher mechanism for individually transferring the fasteners from the magazine to a fastener drive channel, wherein the fasteners are struck by the driver blades during the fastener driving operation. For certain applications that include padding, such as roofing felt, house wrap, foam insulation panels, etc., it is necessary to include a buckle cap through which the fasteners are driven. Each buckle cap extends the surface area of ​​the head of the fastener to prevent the fastener from piercing the padding and to prevent the padding from being torn from the work surface after it is installed and before an outer sheath is installed thereon, for example, due to high winds. Summary of the invention

[0005] In one aspect, the present disclosure provides a powered fastener driver having: a housing; a front end piece extending from the housing; a driver blade movable between a ready position and a driven position within the front end piece; a piston coupled to the driver blade to move therewith; a driver cylinder movable within the driver cylinder; a reservoir cylinder containing pressurized gas therein and in fluid communication with the driver cylinder; a lifting mechanism for moving the driver blade to a ready position; a motor coupled to the lifting mechanism, the motor driving the lifting mechanism; an onboard air compressor driven by the motor, wherein the onboard air compressor is driven while the lifting mechanism is driven; and a feed system in fluid communication with the onboard air compressor, wherein the feed system includes a primary feed mechanism adjacent to the front end piece and a secondary feed mechanism adjacent to the front end piece, wherein the primary feed mechanism and the secondary feed mechanism are actuated by compressed air received from the onboard air compressor.

[0006] In another aspect, the present disclosure provides a powered fastener driver comprising: a housing; a front end member extending from the housing; a driver blade movable within the front end member between a ready position and a driven position; a piston coupled to the driver blade to move therewith; a driver cylinder in which the piston is movable; a reservoir cylinder containing pressurized gas therein and in fluid communication with the driver cylinder; a lifting mechanism for moving the driver blade to a ready position; a motor coupled to the lifting mechanism, the motor driving the lifting mechanism; an onboard air compressor driven by the motor A drive, wherein the onboard air compressor is driven while the lifting mechanism is driven; a fastener feeding mechanism, which is adjacent to the front end piece and is fluidly connected to the onboard air compressor, wherein the fastener feeding mechanism is actuated by compressed air from the onboard air compressor to feed fasteners into a fastener drive channel within the front end piece; and a buckle cap feeding mechanism, which is adjacent to the front end piece and is fluidly connected to the onboard air compressor, wherein the buckle cap feeding mechanism is actuated by compressed air from the onboard air compressor to feed the buckle cap to a position forward of the fastener drive channel to allow the fastener to be driven through the buckle cap during operation of the powered fastener driver.

[0007] In yet another aspect, the present disclosure provides a method of operating a powered fastener driver, the method comprising: energizing a motor; releasing a driver blade to drive a fastener into a workpiece; closing a solenoid valve coupled to an onboard air compressor; driving the onboard air compressor to provide compressed air to a feed system; actuating a primary feed mechanism with compressed air from the onboard air compressor; actuating a secondary feed mechanism with compressed air from the onboard air compressor; and returning the driver blade to a ready position.

[0008] Other features and aspects of the present disclosure will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a perspective view of a gas spring powered fastener driver.

[0010] Figure 2 yes Figure 1 Front view of a gas spring powered fastener driver.

[0011] Figure 3 yes Figure 1 Rear view of the gas spring powered fastener driver.

[0012] Figure 4 yes Figure 1 Left side view of a gas spring powered fastener driver.

[0013] Figure 5 yes Figure 1 Right side view of the gas spring powered fastener driver.

[0014] Figure 6 yes Figure 1 Top view of a gas spring powered fastener driver.

[0015] Figure 7 yes Figure 1 Another right side view of the gas spring powered fastener driver with various parts removed for clarity.

[0016] Figure 8 yes Figure 1 Another top view of a gas spring powered fastener driver with various parts removed for clarity.

[0017] Fig. 9 yes Figure 1 Schematic diagram of a gas spring powered fastener driver.

[0018] Fig.10 It is a display operation Figure 1 A flow chart of a first portion of a method of driving a gas spring powered fastener.

[0019] Fig.11 It is a display operation Figure 1 A flow chart of a second portion of a method of driving a gas spring powered fastener.

[0020] Before explaining any embodiments of the present disclosure in detail, it should be understood that the present disclosure is not limited in its application to the construction details and component arrangements set forth in the following description or shown in the following figures. The present disclosure can have other embodiments and can be practiced or performed in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered restrictive. DETAILED DESCRIPTION

[0021] refer to Figures 1 to 8, a gas spring powered fastener driver 100 is shown. The gas spring powered fastener driver 100 is operable to drive fasteners (such as nails from a coil or coil) into a workpiece while delivering button caps. Each button cap is placed in front of the fastener so that the fastener is driven through the button cap. The fastener driver 100 includes a housing 102 having a first housing shell 104 coupled to a second housing shell 106. The housing 102 includes a head portion 108 having a handle portion 110 and a drive unit housing portion 112 extending therefrom. The housing 102 also includes a battery receiving seat portion 114 extending opposite to the head portion 108 between the handle portion 110 and the drive unit housing portion 112. It will be understood that the battery receiving seat portion 114 is sized and shaped to receive a removable battery pack thereon or therein.

[0022] The gas spring powered fastener driver 100 further includes a fastener feeding portion 118 in front of the drive unit housing portion 112. The fastener feeding portion 118 extends from the front end 120 to the fastener magazine receiving seat 122. A workpiece contact bracket 124 is slidably disposed on the front end 120. As shown, the fastener magazine receiving seat 122 is generally cylindrical and is sized and shaped to receive coiled fasteners therein. A fastener magazine cover 126 is rotatably disposed on the fastener magazine receiving seat 122 and provides access to a fastener magazine removably disposed in the fastener magazine receiving seat 122. The fastener magazine is a can-type magazine containing a coiled strip of nails. During operation of the fastener driver 100, individual fasteners are sequentially loaded from the fastener magazine to the front end 120 via the fastener feeding portion 118.

[0023] like Figure 2 As best shown in FIG. 1 , the fastener feeding portion 118 and the fastener magazine receiving seat 122 extend from the front end piece 120 toward a first side of the gas spring powered fastener driver 100 relative to a central axis 130 extending through a center 132 of the front end piece 120. In particular, the fastener feeding portion 118 and the fastener magazine receiving seat 122 are located on the left side of the gas spring powered fastener driver 100. Further, a fastener feeding axis 136 extending through a center 138 of the fastener feeding portion 118 and the fastener magazine receiving seat 122 forms a first fastener feeding angle A relative to the central axis 130 of the gas spring powered fastener driver 100. 1F In certain aspects, the first fastener feed angle A 1FLess than or equal to forty-five degrees (45°), such as less than or equal to forty degrees (40°), less than or equal to thirty-five degrees (35°), less than or equal to thirty degrees (30°), less than or equal to twenty-five degrees (25°), or less than or equal to twenty degrees (20°). Further, the first fastener feed angle A 1F Greater than or equal to five degrees (5°), such as greater than or equal to ten degrees (10°), or greater than or equal to fifteen degrees (15°). It will be appreciated that, in another aspect, the first fastener feed angle A 1F The first fastener feed angle A described herein 1F The range between the maximum value and the minimum value is within the range of and includes any value in the maximum value or the minimum value.

[0024] The gas spring powered fastener driver 100 also includes a nut feeding portion 140 in front of the fastener feeding portion 118 and in front of the front end piece 120 to deliver the nut in front of the front end piece 120 so that when the fastener is driven into the workpiece, the fastener is driven through the nut. The nut feeding portion 140 extends from the front end piece 120 to a nut magazine receiving seat 142. The nut magazine receiving seat 142 is generally oval and is sized and shaped to receive a circle of nut therein. A nut magazine cover 144 is rotatably disposed on the nut magazine receiving seat 142 and provides access to a nut magazine that can be removably disposed within the nut magazine receiving seat 142. The nut magazine is a reel that contains a wound strip of arranged nut caps that are tangentially connected to each other in a continuous band. During operation of the gas spring powered fastener driver 100 , individual buckle caps are sequentially loaded from a buckle cap magazine via the buckle cap feed portion 140 in front of the nose piece 120 .

[0025] like Figure 2 As best shown in FIG. 1 , the nut feeding portion 140 and the nut magazine receiving seat 142 extend from the front end 120 toward a second side of the gas spring powered fastener driver 100 opposite the fastener feeding portion 118 and the fastener magazine receiving seat 122 relative to the central axis 130. In particular, the nut feeding portion 140 and the nut magazine receiving seat 142 are located on the right side of the gas spring powered fastener driver 100. Further, a nut feeding axis 146 extending through the center 148 of the nut feeding portion 140 and the nut magazine receiving seat 142 forms a first nut feeding angle A relative to the central axis 130 of the gas spring powered fastener driver 100. 1BC In certain aspects, the first buckle cap feed angle A 1BC Less than or equal to thirty degrees (30°), such as less than or equal to twenty-five degrees (25°), less than or equal to twenty degrees (20°), or less than or equal to fifteen degrees (15°). Further, the first cap feeding angle A 1BCGreater than or equal to two degrees (2°), such as greater than or equal to five degrees (5°), greater than or equal to seven degrees (7°), or greater than or equal to ten degrees (10°). It will be understood that, on the other hand, the first buckle cap feed angle A 1BC The first buckle cap feed angle A described in this article 1BC The range between the maximum value and the minimum value is within the range of and includes any value in the maximum value or the minimum value.

[0026] like Figure 4 As shown in FIG. 1 , the gas spring powered fastener driver 100 further defines a drive axis 150 along which a fastener is driven from the gas spring powered fastener driver 100 into a workpiece. The fastener feed axis 136 extending through the fastener feed portion 118 and the fastener magazine receptacle 122 forms a second fastener feed angle A relative to the drive axis 150 of the gas spring powered fastener driver 100. 2F In certain aspects, the second fastener feed angle A 2F Greater than or equal to sixty degrees (60°), such as greater than or equal to sixty-five degrees (65°), greater than or equal to seventy degrees (70°), or greater than or equal to seventy-three degrees (73°). Further, the second fastener feed angle A 2F Less than or equal to eighty-five degrees (85°), such as less than or equal to eighty degrees (80°), or less than or equal to seventy-five degrees (75°). It will be appreciated that, on the other hand, the second fastener feed angle A 2F The second fastener feed angle A described herein 2F The range between the minimum and maximum values ​​is within the range of and includes any value between the minimum and maximum values.

[0027] In addition, a nut feeding axis 146 extending through the nut feeding portion 140 and the nut magazine receiving seat 142 forms a second nut feeding angle A relative to the drive axis 150 of the gas spring powered fastener driver 100. 2BC In certain aspects, the second buckle cap feed angle A 2BC Greater than or equal to seventy degrees (70°), such as greater than or equal to seventy-five degrees (75°), greater than or equal to eighty degrees (80°), or greater than or equal to eighty-three degrees (83°). Further, the second cap feeding angle A 2BC Less than or equal to ninety degrees (90°), such as less than or equal to eighty-seven degrees (87°), or less than or equal to eighty-five degrees (85°). It will be understood that, on the other hand, the second buckle cap feed angle A 2BC The second buckle cap feed angle A described in this article 2BC The range between the minimum and maximum values ​​is within the range of and includes any value between the minimum and maximum values.

[0028] like Figure 4 and Figure 5 , the gas spring powered fastener driver 100 includes an intermediate support frame 160 extending between the handle portion 110 and the drive unit housing portion 112. Specifically, the intermediate support frame 160 includes a support arm 162 extending substantially parallel to the drive axis 150. The support arm 162 includes a first end 164 and a second end 166. A first collar 168 is attached to or otherwise extends from the first end 164 of the support arm 162 and extends at least partially around the handle portion 110. A second collar 170 is attached to or otherwise extends from the second end 166 of the support arm 162 and extends at least partially around the drive unit housing portion 112.

[0029] The second collar 170 of the intermediate support frame 160 provides support for an onboard air compressor 180 disposed between a motor 182 (e.g., a brushless direct current (BLDC) motor) and a gearbox 184. Further, the intermediate support frame 160 supports a solenoid valve 186 that is located below and adjacent to the onboard air compressor 180 and is in fluid communication with the onboard air compressor 180. The onboard air compressor 180 is also in fluid communication with a feed system 188 that includes at least a primary feed mechanism (e.g., a fastener feed mechanism 190) and a secondary feed mechanism (e.g., a buckle cap feed mechanism 192) actuated by compressed air from the onboard air compressor 180. The feed system 188 feeds a primary deliverable (e.g., a fastener) via the fastener feed mechanism 190 and feeds a secondary deliverable (e.g., a buckle cap) via the buckle cap feed mechanism 192.

[0030] The fastener feed mechanism 190 includes a fastener feed cylinder 194 and a fastener feed piston 196. In addition, the fastener feed mechanism 190 includes a fastener feed piston head 198 coupled to the fastener feed piston 196, and a fastener feed spring 200 between the fastener feed piston head 198 and the bottom of the fastener feed cylinder 194. Thus, the fastener feed piston 196 is spring loaded and moves between a fastener removal position when compressed air fills the fastener feed cylinder 194 and compresses the fastener feed spring 200, and a ready position or fastener feed position (to deliver fasteners) when air pressure is released from the feed system 188 and the fastener feed spring 200 is decompressed. The fastener feed piston 196 is coupled to a fastener pusher 202 that moves down the line of fasteners to engage the next fastener and move the next fastener into position within the fastener drive channel of the nose piece 120 when the spring-loaded fastener feed piston 196 returns to the ready position. The fastener pusher 202 is coupled to the end of the fastener feed piston 196 opposite the fastener feed piston head 198.

[0031] The nut feeding mechanism 192 includes a nut feeding cylinder 204 and a nut feeding piston 206. The nut feeding mechanism 192 also includes a nut feeding piston head 208 coupled to the nut feeding piston 206, and a nut feeding spring 210 between the nut piston head 208 and the bottom of the nut feeding cylinder 204. Thus, the nut feeding piston 206 is spring loaded and moves between a nut removal position when compressed air fills the nut feeding cylinder 204 and compresses the nut feeding spring 210, and a ready position or nut feeding position (to deliver a nut) when air pressure is released from the feeding system 188 and the nut feeding spring 210 is decompressed. The nut feed piston 206 is coupled to a nut pusher 212 which moves down the row of nut caps to engage the next nut cap and move the next nut cap into position in front of the front end 120 and the fastener drive channel when the spring loaded nut feed piston 206 returns to the ready position. The nut pusher 212 is coupled to the end of the nut feed piston 206 opposite the nut feed piston head 208.

[0032] Figure 7 and Figure 8 The gas spring powered fastener driver 100 is shown to further include a reservoir cylinder 220 disposed within the head portion 108 of the housing 102. The reservoir cylinder 220 includes a driver cylinder 222 disposed therein. Further, a movable piston 224 is slidably disposed within the driver cylinder 222. A driver blade 226 is connected to the movable piston 224. As shown, the driver blade 226 includes a proximal end 227 and a distal end 228. The proximal end 227 of the driver blade 226 is connected to the movable piston 224. When the movable piston 224 moves to a top dead center (TDC) (i.e., retracted or ready) position within the driver cylinder 222 and the gas spring powered fastener driver 100 is ready to be fired, the distal end 228 of the driver blade 226 is adjacent to the nose piece 120. Upon firing, for example, when the trigger 229 in the handle portion 110 is depressed or otherwise pulled and sends a signal to the controller, the distal end 228 of the driver blade 226 is moved into the front end 120 to drive the fastener from within the front end 120 through the buckle cap and into the workpiece until the movable piston 224 reaches a bottom dead center (BDC) (i.e., extended or driven) position within the driver cylinder 222.

[0033] The gas spring powered fastener driver 100 further includes a lifting mechanism 230 operably coupled to the motor 182 via the gearbox 184. The lifting mechanism 230 includes a rotary lifter 232 that selectively engages the driver blade 226. The lifting mechanism 230 and the rotary lifter 232 are driven by the motor 182 to move the driver blade 226 from the fired position to the ready position, and in the process, the piston 224 is moved from the BDC position to the TDC position. In addition, when the motor 182 drives the lifting mechanism 230, the motor also drives the onboard air compressor 180 to provide air to the fastener feeding mechanism 190 and the nut feeding mechanism 192.

[0034] Figure 8 The onboard air compressor 180 is shown to include a compressor gear 240 to which a first end of a connecting rod 242 is attached. A compressor piston 244 is connected to a second end of the connecting rod 242 and reciprocates within a piston cylinder 246 when the compressor gear 240 rotates and drives the connecting rod 242. As further shown, the compressor gear 240 engages a drive gear 248 on the motor 182. Thus, when the motor 182 rotates to return the piston 224 to the TDC position and the driver blade 226 to the ready position, the drive gear 248 drives the compressor gear 240 to reciprocate the compressor piston 244 within the onboard air compressor 180 to provide compressed air to components in fluid communication with the onboard air compressor 180.

[0035] refer to Fig. 9 , a schematic diagram of a gas spring powered fastener driver 300 is shown. It will be understood that the schematic diagram of the gas spring powered fastener driver 300 is a schematic illustration of the gas spring powered fastener driver 100 shown above, and where applicable, similar components are the same, although not numbered the same as above. For example, the motor 302 is the same as the motor 182 disclosed above, the onboard air compressor 314 is the same as the onboard air compressor 180 disclosed above, and so on.

[0036] As shown, the gas spring powered fastener driver 300 includes a motor 302. A battery pack 304 is operably coupled to the motor 302. A controller 306 is also operably coupled to the motor 302, and a trigger 308 is operably coupled to the controller 306. When the trigger 308 is pulled, depressed, or otherwise activated, the controller 306 receives a signal therefrom and, in response, activates the motor 302. As shown, a gearbox 310 is operably coupled to the motor 302, and a lift mechanism 312 is operably coupled to the gearbox 310. Thus, when the motor 302 is activated, the motor transmits rotational motion to the lift mechanism 312 through the gearbox 310 to move the driver blade 313 from the driven position to the ready position.

[0037] An onboard air compressor 314 is also operably coupled to the motor 302. A feeding system 316 having a fastener feeding mechanism 317 and a nut feeding mechanism 318 is in fluid communication with the onboard air compressor 314 via a first air line 320 and a second air line 322. Specifically, the fastener feeding mechanism 317 is in fluid communication with the onboard air compressor 314 via the first air line 320, and the nut feeding mechanism 318 is in fluid communication with the onboard air compressor 314 via the second air line 322. Fig. 9 As further shown in FIG. 3 , the solenoid valve 324 is in fluid communication with the onboard air compressor 314 via a third air line 326. Thus, when the motor 302 is activated to rotate the lift mechanism 312 and move the driver blade from the driven position to the ready position, the motor 302 also drives the onboard air compressor 314 to provide compressed air to the fastener feeding mechanism 317 and the nut feeding mechanism 318. When the motor 302 is activated, the controller 306 sends a signal to the solenoid valve 324 to close the solenoid valve 324. Thus, the onboard air compressor 314 builds up air pressure within the fastener feeding mechanism 317 and the nut feeding mechanism 318. When the driver blade reaches the ready position (TDC), the motor 302 stops and the controller 306 sends a signal to the solenoid valve 324 to open the solenoid valve 324 and release the air pressure to the surrounding atmosphere.

[0038] Fig. 9The gas spring powered fastener driver 300 is also shown to include a position sensor 328 adjacent to the driver blade 313 to detect the position of the driver blade 313, and a safety latch 330 adjacent to the driver blade 313 to selectively engage and prevent the driver blade 313 from being driven. The safety latch 330 is operably coupled to a latch solenoid 332. The position sensor 328 and the latch solenoid 332 are operably coupled to the controller 306 to send signals to or receive signals from the controller 306. In the event that the controller 306 detects that the driver blade 313 has not returned to the ready position, the gas spring powered fastener driver 300 enters a jam clearing mode in which the motor 302 rotates with the latch solenoid 332 de-energized and the safety latch 330 engages the driver blade 313. Further, in the jam clearing mode, air is not provided to the feed system 316 to prevent additional fasteners and buckle nuts from being fed into their respective ready positions.

[0039] Fig.10 and Fig.11 is a flow chart illustrating a method 400 of operating a gas spring powered fastener driver, such as the gas spring powered fastener driver 100 described herein. Fig.10 At frame 402 of the method 400, when a trigger on a gas spring powered fastener driver is pressed, toggled, depressed or otherwise actuated and a safety lock is deactivated, the method 400 begins. The safety lock is located on a sliding workpiece contact bracket and includes a magnet, the presence of which is detected or not detected by a Hall sensor. At frame 404, in response to the trigger being pressed and the safety lock being deactivated, the method 400 includes energizing and activating the motor. At frame 406, the method 400 includes energizing the latch solenoid to disengage the safety latch. At frame 408, the method 400 includes rotating the lifting mechanism, and at frame 410, the method 400 includes releasing the driver blade to drive the fastener into the workpiece. At the same time, at frame 412, the method 400 includes energizing and closing the solenoid valve. Thereafter, at frame 414, the method 400 includes driving an onboard air compressor and providing compressed air to the feed system.

[0040] At frame 416, the method 400 includes actuating a primary feed mechanism, such as a fastener feed mechanism, by driving a fastener feed piston in a downward direction in response to increased air pressure provided by the onboard air compressor. Additionally, at frame 418, the method 400 includes actuating a secondary feed mechanism, such as a nut feed mechanism, by driving a nut feed piston in a downward direction in response to increased air pressure provided by the onboard air compressor. At frame 420, the method 400 further includes returning the driver blade to the ready position by continuing to rotate the lift mechanism. Thereafter, the method 400 proceeds to Fig.11Decision block 422.

[0041] Move to Fig.11 At decision block 422, method 400 includes detecting or otherwise determining whether the driver blade is in a ready position. The position of the driver blade is determined using a magnet and a Hall sensor. The magnet can be set on the lifter of the lifting mechanism, and when the angular position of the lifter corresponds to the driver blade being in a ready position, the corresponding signal is transmitted to the controller. If the driver blade is not in the ready position at decision block 422, method 400 enters a jam clearing mode. Specifically, method 400 proceeds to frame 424, and method 400 includes engaging a safety latch to prevent the driver blade from moving forward. The safety latch is engaged by de-energizing the latch solenoid. Thereafter, at frame 426, method 400 includes de-energizing the solenoid valve and opening the solenoid valve to the feeding system to prevent actuation of the feeding system, such as the main feeding mechanism and the secondary feeding mechanism. At frame 427, method 400 includes releasing air pressure when the compressor is driven. This prevents more deliverables from being forced into the firing chamber, thereby preventing the waste of nail jams or caps. At box 428 , the method 400 includes energizing and activating the motor to return the driver blade to the ready position. Thereafter, the method 400 returns to decision block 422 .

[0042] Returning to decision block 422, if the driver blade is in the ready position, the method 400 proceeds to frame 430. At frame 430, the method 400 includes de-energizing and deactivating the motor. Further, simultaneously or substantially simultaneously, at frame 432, the method 400 includes de-energizing and opening the solenoid valve. At frame 434, the method 400 includes releasing air pressure from the system (i.e., in response to opening the solenoid). At frame 436, the method 400 includes returning the main feed mechanism (e.g., fastener feed mechanism) to the ready position and loading the main deliverable member (e.g., fastener) into the front end member of the gas spring powered fastener driver (e.g., into the fastener drive channel in the front end member). When the air pressure is released, the fastener feed mechanism returns to the ready position when the spring-loaded fastener feed piston in the fastener feed mechanism returns to the ready position. At box 438, method 400 includes returning the secondary feeding mechanism (e.g., the buckle cap feeding mechanism) to the ready position and loading the secondary deliverable member (e.g., the buckle cap) to a position forward of the fastener drive channel of the front member, for example. Upon releasing the air pressure, the fastener feeding mechanism returns to the ready position when the spring-loaded fastener feed piston within the buckle cap feeding mechanism returns to the ready position. Thereafter, method 400 ends.

[0043] Various features of the present disclosure are set forth in the following claims.

[0044] Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure described.

Claims

1. A powered fastener driver, comprising: case; a front end member extending from the housing; a driver blade movable within the front end member between a ready position and a driven position; a piston coupled to the driver blade for movement therewith; an actuator cylinder in which the piston is movable; a reservoir cylinder containing pressurized gas therein and in fluid communication with the actuator cylinder; a lifting mechanism for moving the driver blade to the ready position; a motor, the motor being connected to the lifting mechanism, the motor driving the lifting mechanism; an onboard air compressor driven by the motor, wherein the onboard air compressor is driven at the same time as the lifting mechanism is driven; and A feed system is in fluid communication with the onboard air compressor, wherein the feed system includes a primary feed mechanism adjacent to the front end piece and a secondary feed mechanism adjacent to the front end piece, wherein the primary feed mechanism and the secondary feed mechanism are actuated by compressed air received from the onboard air compressor.

2. The powered fastener driver of claim 1, further comprising a fastener feeding portion extending from the nose piece and a fastener magazine receiver coupled to the fastener feeding portion, wherein: The fastener magazine receptacle is configured to receive an aligned fastener therein.

3. The powered fastener driver of claim 2, wherein: The main feed mechanism includes a fastener feed mechanism having a fastener feed cylinder and a spring-loaded fastener feed piston therein.

4. The powered fastener driver of claim 3, wherein: The spring loaded fastener feed piston moves between a fastener extraction position and a fastener feed position in which fasteners are delivered into the fastener drive channel in the nose piece.

5. The powered fastener driver of claim 4, further comprising a fastener pusher coupled to an end of the spring loaded fastener feed piston, wherein: The fastener pusher moves along the line of fasteners to remove the next fastener in the fastener extraction position.

6. The powered fastener driver of claim 1, further comprising a nut feed portion extending from the front end and a nut magazine receiver coupled to the nut feed portion, wherein: The button cap magazine receptacle is configured to receive arranged button caps therein.

7. The powered fastener driver of claim 6, wherein: The secondary feed mechanism includes a buckle-cap feed mechanism having a buckle-cap feed cylinder and a spring-loaded buckle-cap feed piston therein.

8. The powered fastener driver of claim 7, wherein: The spring loaded nut feed piston moves between a nut removal position and a nut feed position in which a nut is delivered into a nut drive channel in the front end.

9. The powered fastener driver of claim 8, further comprising a nut pusher coupled to an end of the spring loaded nut feed piston, wherein: The buckle cap pusher moves along the arranged buckle caps to take out the next buckle cap in the buckle cap taking-out position.

10. A powered fastener driver comprising: case; a front end member extending from the housing; a driver blade movable within the front end member between a ready position and a driven position; a piston coupled to the driver blade for movement therewith; an actuator cylinder in which the piston is movable; a reservoir cylinder containing pressurized gas therein and in fluid communication with the actuator cylinder; a lifting mechanism for moving the driver blade to the ready position; a motor, the motor being connected to the lifting mechanism, the motor driving the lifting mechanism; an onboard air compressor driven by the motor, wherein the onboard air compressor is driven at the same time as the lifting mechanism is driven; a fastener feeding mechanism adjacent the nose piece and in fluid communication with the onboard air compressor, wherein the fastener feeding mechanism is actuated by compressed air from the onboard air compressor to feed fasteners into fastener drive passages within the nose piece; and A buckle nut feeding mechanism is adjacent to the front end piece and is in fluid communication with the onboard air compressor, wherein the buckle nut feeding mechanism is actuated by compressed air from the onboard air compressor to feed a buckle nut into a position forward of the fastener drive channel to allow a fastener to be driven through the buckle nut during operation of the powered fastener driver.

11. The powered fastener driver of claim 10, further comprising a fastener feeding portion extending from the nose piece and a fastener magazine receiver coupled to the fastener feeding portion, wherein: The fastener feeding mechanism extends along the fastener feeding portion to extract and deliver fasteners to the front end piece.

12. The powered fastener driver of claim 11, wherein: The fastener feed mechanism includes a fastener feed cylinder and a spring-loaded fastener feed piston therein, and wherein the spring-loaded fastener feed piston moves between a fastener extraction position and a fastener feeding position, in which one of a plurality of aligned fasteners is engaged and in which one of a plurality of aligned fasteners is delivered into the fastener drive channel.

13. The powered fastener driver of claim 12, wherein: The spring loaded fastener feed piston is biased to the fastener extraction position by compressed air from the onboard air compressor and is biased to the fastener feed position by a spring when the compressed air is released from the fastener feed cylinder.

14. The powered fastener driver of claim 10, further comprising a nut feed portion extending from the front end and a nut magazine receiver coupled to the nut feed portion, wherein: The buckle cap feeding mechanism extends along the buckle cap feeding portion to take out and deliver the buckle cap to the front of the front end piece.

15. The powered fastener driver of claim 14, wherein: The nut feeding mechanism includes a nut feeding cylinder and a spring-loaded nut feeding piston therein, and wherein the spring-loaded nut feeding piston moves between a nut removal position and a nut feeding position, in which one of a plurality of arranged nut caps is engaged and in which one of a plurality of arranged nut caps is delivered to the front of the fastener drive channel.

16. The powered fastener driver of claim 15, wherein: The spring loaded nut feed piston is biased to the nut extraction position by compressed air from the onboard air compressor and is biased to the nut feed position by a spring when the compressed air is released from the nut feed cylinder.

17. A method of operating a powered fastener driver, the method comprising: Energize the motor; releasing the driver blade to drive the fastener into the workpiece; Close the solenoid valve connected to the onboard air compressor; driving the onboard air compressor to provide compressed air to the feed system; actuating a primary feed mechanism with compressed air from the onboard air compressor; actuating a secondary feed mechanism with compressed air from the onboard air compressor; as well as Return the drive blade to the ready position.

18. The method of claim 17, further comprising: When the driver blade is detected to be in the ready position, de-energizing the motor; as well as Open the solenoid valve to release air pressure from the feed system.

19. The method of claim 18, further comprising: returning the main feed mechanism to a ready position; as well as A primary deliverable is loaded into the driver channel of the powered fastener driver.

20. The method according to claim 19, further comprising: Returning the secondary feeding mechanism to the ready position; as well as A secondary deliverable is loaded in front of the driver channel of the powered fastener driver.

21. The method of claim 17, further comprising: detecting that the drive blade is not in the ready position; engaging a safety latch to prevent forward movement of the drive blade; opening the solenoid valve to prevent air flow to the feed system; as well as Activate the motor.

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