Powered fastener driver

Abstract

A powered fastener driver includes a housing defining a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion. The handle portion defines a handle axis. The piston is movable within the cylinder from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position. A drive vane is attached to the piston for movement with the piston along a drive axis from a TDC position toward a BDC position to drive the fastener into the workpiece. The lifter is operable to move the piston and the drive vane in unison from the BDC position toward the TDC position. The drive unit is supported by the drive unit support portion and is operably coupled to the lifter. The drive unit includes a motor having a first output shaft extending along a motor axis. The motor is positioned below the handle. The handle axis and the motor axis intersect the drive axis.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to co-pending U.S. Provisional Patent Application No. 63 / 391,491 filed on July 22, 2022 and co-pending U.S. Provisional Patent Application No. 63 / 316,510 filed on March 4, 2022, the entire contents of each of which are incorporated herein by reference. Technical Field

[0003] The utility model relates to a power fastener driver, and more particularly to a gas spring power fastener driver. Background Art

[0004] Various fastener drivers are known in the art for driving fasteners (e.g., nails, tacks, staples, etc.) into a workpiece. These fastener drivers operate using various means known in the art (e.g., compressed air generated by an air compressor, electrical energy, flywheel mechanisms, etc.), but these designs typically encounter power, size, and cost limitations. Utility Model Content

[0005] On the one hand, the utility model provides a powered fastener driver, which includes a housing, which defines a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion. The handle portion defines a handle axis. The cylinder is positioned in the cylinder support portion. The piston can move from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position in the cylinder. The drive blade is attached to the piston for moving from the TDC position toward the BDC position along the drive axis with the piston to drive the fastener into the workpiece. The lifter is operable to move the piston and the drive blade in unison from the BDC position toward the TDC position. The drive unit is supported by the drive unit support portion and is operably connected to the lifter. The drive unit includes a motor having a first output shaft extending along the motor axis. The motor is positioned below the handle. The handle axis and the motor axis intersect with the drive axis.

[0006] On the other hand, the utility model provides a powered fastener driver, which includes: a housing; a cylinder in the housing; a piston, which can move from a top dead center (TDC) position to a driving position or a bottom dead center (BDC) position in the cylinder; a driving blade, which is attached to the piston and is used to move along the driving axis with the piston from the TDC position toward the BDC position to drive the fastener into the workpiece; a lifter, which is operable to move the piston and the driving blade from the BDC position toward the TDC position; a drive unit, which is operably connected to the lifter to provide torque to the lifter, so that the lifter rotates; a buffer, which is supported by the housing and is configured to stop the piston and the driving blade at the BDC position; a key, which is connected to one of the buffer or the housing; and a keyway, which is connected to the other of the buffer or the housing. The key is received in the keyway to guide the buffer relative to the housing and prevent relative rotation between the buffer and the housing.

[0007] On the other hand, the utility model provides a powered fastener driver, which includes: a housing; a cylinder, which is in the housing; a piston, which can move from a top dead center (TDC) position to a driving position or a bottom dead center (BDC) position in the cylinder; a drive blade, which is attached to the piston and is used to move along the drive axis with the piston from the TDC position toward the BDC position to drive the fastener into the workpiece; a lifter, which is operable to move the piston and the drive blade from the BDC position toward the TDC position; a drive unit, which is operably connected to the lifter to provide torque to the lifter, thereby rotating the lifter; and a workpiece contact assembly, which is connected to the housing and can move from an extended position to a retracted position in response to contact with the workpiece. The workpiece contact assembly includes: a fixed column, which is connected to the housing; an arm, which includes a hole for receiving the column; a first spring, which surrounds the column and is disposed between the housing and the first end of the arm; and a second spring, which is located in the hole and is disposed between the distal end of the column and the bottom surface of the hole.

[0008] On the other hand, the utility model provides a powered fastener driver, which includes: a cassette assembly, which is configured to receive fasteners; a nose assembly, which includes a channel, from which a continuous fastener from the cassette assembly is driven; and a pusher assembly, which is slidably connected to the cassette assembly. The pusher assembly is configured to bias the fasteners in the cassette assembly toward the channel, and the pusher assembly includes a pusher body and a blank-fire locking member connected to the pusher body. The pusher body and the blank-fire locking member can be selectively moved relative to each other. The pusher assembly can be adjusted between a first state and a second state, in which the pusher body and the blank-fire locking member are configured to move toward the channel together in unison, and in the second state, relative movement has occurred between the pusher body and the blank-fire locking member. The powered fastener driver further includes a workpiece contact assembly, which can move between an extended position and a retracted position relative to the nose assembly. In a first position of the dry-fire lockout member relative to the magazine assembly, the workpiece contact element is configured to slide past the dry-fire lockout member in response to movement toward the retracted position, and in a second position, the dry-fire lockout member prevents the workpiece contact assembly from moving toward the retracted position when a predetermined number of fasteners remain in the magazine assembly. The advancer assembly is configured to transition from the first state to the second state before the predetermined number of fasteners in the magazine assembly is reached.

[0009] On the other hand, the utility model provides a powered fastener driver, which includes a housing, which defines a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion. The handle portion defines a handle axis. The cylinder is positioned in the cylinder support portion. The piston can move from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position in the cylinder. The drive blade is attached to the piston for moving from the TDC position toward the BDC position along the drive axis with the piston to drive the fastener into the workpiece. The lifter is operable to move the piston and the drive blade in unison from the BDC position toward the TDC position. The lifter includes a plurality of drive pins, and at least one of the drive pins is configured to engage the drive blade when the drive blade is moved from the BDC position toward the TDC position. The drive unit is supported by the drive unit support portion and is operably connected to the lifter. The drive unit includes a motor and a second output shaft, the motor having a first output shaft extending along the motor axis, the second output shaft being operably connected to the first output shaft. The motor is positioned below the handle. The second output shaft extends along an axis parallel to the motor axis, and the lifter is operably coupled to the second output shaft.

[0010] On the other hand, the utility model provides a power fastener driver, which includes a housing, which defines a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion. The cylinder is in the cylinder support portion. The piston can move from the top dead center (TDC) position to the drive position or the bottom dead center (BDC) position in the cylinder. The drive blade is attached to the piston for moving along the drive axis from the TDC position toward the BDC position with the piston to drive the fastener into the workpiece. The drive blade includes a plurality of teeth extending along one side of the drive blade. The lifter is operable to move the piston and the drive blade in unison from the BDC position toward the TDC position. The lifter includes a plurality of drive pins that can engage with these teeth when the drive blade returns from the BDC position to the TDC position. The drive unit is supported by the drive unit support portion and is operably connected to the lifter. The drive unit includes a motor having a motor axis. The motor is positioned below the handle. The motor axis lies in a plane parallel to the drive axis and within about 10 mm of the drive axis, and the motor axis and the drive axis are contained in an imaginary plane bisecting the housing.

[0011] On the other hand, the utility model provides a power fastener driver, which includes a housing, which defines a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion. The handle portion defines a handle axis. The cylinder is in the cylinder support portion, and the piston can move from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position in the cylinder. The piston includes a first portion and a second portion threadedly connected to the first portion. The second portion includes a groove, an orifice extending through the second portion and communicating with the groove, and a hole extending through the second portion and communicating with the groove. The orifice is aligned with the hole. A drive blade is attached to the second portion of the piston for moving along the drive axis from the TDC position toward the BDC position with the piston to drive the fastener into the workpiece. The drive blade includes a body having a first surface extending in a first plane, a second surface extending in a second plane parallel to the first plane opposite to the first surface, and an orifice extending from the first surface through the body to the second surface. The body is received in the groove so that the orifice of the body is aligned with the orifice of the second part of the piston and the hole of the second part of the piston. Lifting teeth extend from one side of the body, and the lifting teeth each include a first surface extending in a first plane and a second surface extending in a second plane. The pin extends through the aligned orifice of the body, the orifice of the second part of the piston, and the hole of the second part of the piston to attach the drive blade to the piston. The lifter is operable to engage one of the lifting teeth so that the piston and the drive blade move in unison from the BDC position toward the TDC position. The drive unit is supported by the drive unit support portion and is operably connected to the lifter. The drive unit includes a motor having a first output shaft extending along the motor axis.

[0012] Other features and aspects of the present invention will become apparent by considering the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a perspective view of a gas spring powered fastener driver including a cassette and a workpiece contact assembly according to an embodiment of the present invention.

[0014] Figure 2A yes Figure 1 Another perspective view of the gas spring powered fastener driver.

[0015] Figure 2B1 yes Figure 1 The gas spring powered fastener driver is along Figure 2A A cross-sectional view taken along line 2B1--2B1.

[0016] Figure 2B2 yes Figure 1 Another gas spring powered fastener driver along Figure 2A A cross-sectional view taken along line 2B1--2B1.

[0017] Figure 2C yes Figure 1 The gas spring powered fastener driver is along Figure 2A A cross-sectional view taken along line 2C--2C.

[0018] Figure 3 yes Figure 1 A partial cross-sectional view of a gas spring powered fastener driver with various portions removed for clarity.

[0019] Figure 4 yes Figure 1 Another partial cross-sectional view of a gas spring powered fastener driver with various portions removed for clarity.

[0020] Figure 5 yes Figure 1 Top view of a gas spring powered fastener driver.

[0021] Fig. 6A yes Figure 1 The gas spring powered fastener driver is along Figure 2A The cross-sectional view taken along line 6A--6A is shown, inter alia, showing the reservoir cylinder, the cylinder, the piston having the first configuration, the drive blade, and the damper.

[0022] Figure 6B yes Fig. 6A A three-dimensional view of the piston and drive blades.

[0023] Figure 6C yes Fig. 6A Exploded view of the piston and drive vanes.

[0024] Fig.6D yes Fig. 6A The piston and drive blades move along Figure 6B A cross-sectional view taken along line 6D--6D.

[0025] Fig. 6E yes Figure 1 The gas spring powered fastener driver is along Figure 2A The cross-sectional view taken along line 6E--6E is shown, inter alia, showing the reservoir cylinder, the cylinder, the piston having the second configuration, the drive blade, and the buffer.

[0026] Fig. 6F yes Fig. 6E A three-dimensional view of the piston and drive blades.

[0027] Figure 6G yes Fig. 6E Exploded view of the piston and drive vanes.

[0028] Figure 6H yes Fig. 6A The piston and drive blades move along Fig. 6F A cross-sectional view taken along line 6H--6H.

[0029] Fig.6I Is with Fig. 6E A perspective view of another piston and another drive blade having a similar configuration to the piston and drive blade.

[0030] Figure 6J yes Fig. 6A The piston and drive blades move along Fig.6I A cross-sectional view taken along line 6J-6J.

[0031] Fig. 7A yes Figure 1 Schematic diagram of a gas spring powered fastener driver showing the drive blade in the driven or bottom dead center position.

[0032] Figure 7B yes Figure 1 Schematic diagram of a gas spring powered fastener driver showing the drive blade in the top dead center position prior to actuation.

[0033] Figure 8 yes Fig. 6A The storage chamber cylinder part along Fig. 6A A cross-sectional view taken along line 8--8 is shown.

[0034] Fig.9A According to an embodiment Fig. 6A A bottom end view of the buffer member.

[0035] Fig. 9B yes Fig.9A A three-dimensional view of a buffer member.

[0036] Fig. 9C yes Fig.9A A side view of a buffer member.

[0037] Fig.9D According to another embodiment, Figure 1 A side view of a buffer used with a gas spring powered fastener.

[0038] Fig.9E yes Fig.9D A bottom end view of the buffer member.

[0039] Fig.9F yes Fig.9D A three-dimensional view of a buffer member.

[0040] Figure 9G It is possible to Fig.9D A cross-sectional view of a portion of a cylinder used with a buffer member and a storage chamber.

[0041] Figure 9H yes Figure 1 The powered fastener driver Figure 3 A cross-sectional view taken along line 9H--9H of FIG. 1 shows a storage chamber cylinder having another confirmed configuration and a buffer member having another configuration.

[0042] Fig.9I yes Figure 9H The storage chamber cylinder along Figure 3 A cross-sectional view taken along line 9H--9H.

[0043] Figure 9J yes Figure 9H An upper end view of the buffer member.

[0044] Figure 9K yes Figure 9H A three-dimensional view of a buffer member.

[0045] Figure 9L yes Figure 9H A bottom end view of the buffer member.

[0046] Figure 9M yes Figure 9H Another three-dimensional view of the buffer member.

[0047] Fig.10 yes Figure 1 Rear view of the gas spring powered fastener.

[0048] Fig.11 yes Figure 1 The gas spring powered fasteners are along Figure 2A A cross-sectional view taken along line 11--11 shows the transmission device.

[0049] Fig.12 yes Fig.11 A perspective view of a transmission showing the transmission housing.

[0050] Fig.13 yes Fig.11 A perspective view of a transmission device, wherein the Fig.12 transmission housing.

[0051] Fig.14 yes Fig.11 The transmission device follows Fig.11 A cross-sectional view taken along line 14--14.

[0052] Fig.15 yes Fig.11 The transmission device follows Fig.11A cross-sectional view taken along line 15--15.

[0053] Fig.16 yes Fig.11 The transmission device follows Fig.11 A cross-sectional view taken along line 16--16.

[0054] Fig.17 yes Figure 1 A three-dimensional image of a cassette.

[0055] Fig.18 yes Figure 1 Another stereoscopic view of the cassette.

[0056] Fig.19 yes Figure 1 A perspective view of the cassette with a portion removed showing the thruster assembly.

[0057] Fig. 20A yes Fig.19 Detailed perspective view of the thruster assembly.

[0058] Fig. 20B yes Fig.19 Another detailed perspective view of the thruster assembly.

[0059] Fig.21A Demonstrates that when there are more fasteners in the magazine than a predetermined number of fasteners, the Figure 1 The dry fire lockout link of the workpiece contact assembly is in the first position.

[0060] Fig.21B Demonstrates that when there are more fasteners in the magazine than a predetermined number of fasteners, the Figure 1 The dry fire lockout link of the workpiece contact assembly is in the first position.

[0061] Fig. 21C Demonstrates that when there are more fasteners in the magazine than a predetermined number of fasteners, the Figure 1 The dry fire lock link of the workpiece contact assembly is in the second position.

[0062] Fig.21D Demonstrates that when there are more fasteners in the magazine than a predetermined number of fasteners, the Figure 1 The dry fire lock link of the workpiece contact assembly is in the second position.

[0063] Fig.21E Demonstrates that when there are more fasteners in the magazine than a predetermined number of fasteners, the Figure 1 The dry fire lock link of the workpiece contact assembly is in the third position.

[0064] Fig.21F Demonstrates that when there are more fasteners in the magazine than a predetermined number of fasteners, the Figure 1The dry fire lock link of the workpiece contact assembly is in the third position.

[0065] Fig.22A Demonstrates that when there is one more fastener in the magazine than the predetermined number, the fastener is connected to Figure 1 The dry fire lockout link of the workpiece contact assembly is in the first position.

[0066] Fig. 22B Demonstrates that when there is one more fastener in the magazine than the predetermined number, the fastener is connected to Figure 1 The dry fire lockout link of the workpiece contact assembly is in the first position.

[0067] Fig. 22C Demonstrates that when there is one more fastener in the magazine than the predetermined number, the fastener is connected to Figure 1 The dry fire lock link of the workpiece contact assembly is in the second position.

[0068] Fig.22D Demonstrates that when there is one more fastener in the magazine than the predetermined number, the fastener is connected to Figure 1 The dry fire lock link of the workpiece contact assembly is in the second position.

[0069] Fig.22E Demonstrates that when there is one more fastener in the magazine than the predetermined number, the fastener is connected to Figure 1 The dry fire lock link of the workpiece contact assembly is in the third position.

[0070] Fig.22F Demonstrates that when there is one more fastener in the magazine than the predetermined number, the fastener is connected to Figure 1 The dry fire lock link of the workpiece contact assembly is in the third position.

[0071] Fig.23A shows that when a predetermined number of fasteners are present in the magazine, the fasteners are coupled to the Figure 1 The dry fire lockout link of the workpiece contact assembly is in the first position.

[0072] Fig. 23B shows that when a predetermined number of fasteners are present in the magazine, the fasteners are coupled to the Figure 1 The dry fire lock link of the workpiece contact assembly is in the second position.

[0073] Fig.24 1 is a perspective view of a gas spring powered fastener driver including a cassette and a workpiece contact assembly according to another embodiment of the present invention.

[0074] Fig.25 yes Fig.24 Another perspective view of the gas spring powered fastener driver.

[0075] Fig.26 yes Fig.24The gas spring powered fastener driver is along Fig.25 A cross-sectional view taken along line 26--26.

[0076] Fig. 27 yes Fig.24 Detailed perspective view of the gas spring powered fastener driver.

[0077] Fig.28 yes Fig.24 The gas spring powered fastener driver is along Fig. 27 A detailed cross-sectional view taken along line 28--28.

[0078] Fig.29 yes Fig.24 A perspective view of the cassette showing the thruster assembly.

[0079] Fig.30 yes Fig.29 The box along Fig.29 A cross-sectional view taken along line 30--30.

[0080] Fig.31 yes Fig.24 Another stereoscopic view of the cassette.

[0081] Fig.31A yes Fig.29 A perspective view of the propeller assembly.

[0082] Fig.31B yes Fig.29 A perspective view of the spring assembly of the thruster assembly.

[0083] Fig.32 Demonstrates that when there are more fasteners in the magazine than a predetermined number of fasteners, the Fig.24 The dry-fire lockout link of the workpiece contact assembly.

[0084] Fig.33 Demonstrates that when there is one more fastener in the magazine than the predetermined number, the fastener is connected to Figure 1 The dry-fire lockout link of the workpiece contact assembly.

[0085] Fig.34 shows that when a predetermined number of fasteners are present in the magazine, the fasteners are coupled to the Figure 1 The dry-fire lockout link of the workpiece contact assembly.

[0086] Fig.35 Shown with Figure 1 or Fig.24 A schematic diagram of a transmission device used with a fastener driver relative to its drive axis.

[0087] Before explaining any embodiment of the utility model in detail, it should be understood that the application of the utility model is not limited to the details of the component construction and arrangement set forth in the following description or shown in the following drawings. The utility model can have other embodiments and can be practiced or executed in a variety of different ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered as limiting. DETAILED DESCRIPTION

[0088] refer to Figure 1 6, the gas spring powered fastener driver 10 is operable to drive fasteners (e.g., nails, tacks, staples, etc.) held in a magazine 14 into a workpiece. The fastener driver 10 includes an inner cylinder 18 and a movable piston 22 ( Fig. 6A , Fig. 7A , Figure 7B ). refer to FIG. 6A to FIG. 7B , the fastener driver 10 further includes a drive blade 26, which is attached to the piston 22 and can move therewith. The fastener driver 10 does not require an external air pressure source, but rather includes an external storage chamber cylinder 30 of pressurized gas that is in fluid communication with the cylinder 18. In the illustrated embodiment, the cylinder 18 and the movable piston 22 are positioned within the storage chamber cylinder 30. The driver 10 further includes a filling valve (not shown) coupled to the storage chamber cylinder 30. When connected to a compressed gas source, the filling valve allows the storage chamber cylinder 30 to be refilled with compressed gas if any leakage occurs before. For example, the filling valve can be configured as a Schrader valve.

[0089] like Fig. 6A and Figure 6B As shown and discussed below, the drive blade 26 has a body 26c, a lifting tooth 26a extending from one side of the body 26c, and a locking tooth 26b extending from an opposite side of the body 26c. In the illustrated embodiment, the body 26c of the drive blade 26 has a first surface and a second surface opposite the first surface. Each lifting tooth 26a has a first surface and a second surface opposite the first surface, and each locking tooth 26b has a first surface and a second surface opposite the first surface. The first surface of the body 26c, the first surface of each lifting tooth 26a, and the first surface of each locking tooth 26b are positioned on a first plane 26e ( Fig.6D The second surface of the body 26c, the second surface of each lifting tooth 26a, and the second surface of each locking tooth 26b are positioned in the second plane 26f ( Fig. 6E ). In other embodiments, such as FIG. 6H to FIG. 6JIn the illustrated embodiment, the locking teeth 26b may not be in the first plane and the second plane, but may be positioned between the first plane and the second plane. The aperture 26d extends through the body 26c between the first surface and the second surface. Accordingly, the aperture 26d is oriented perpendicular to the first plane and the second plane.

[0090] exist FIG. 6A to FIG. 6D In the embodiment of the present invention, the piston 22 includes a first portion 22a and a second portion 22b integrally formed with the first portion 22a. The first portion 22a is generally cylindrical and has a first diameter D1 ( Fig.6D ), while the second portion 22b is generally oval and has a first dimension D2 ( Fig.6D ) and a second dimension D3 ( Figure 6C ).exist FIG. 6A to FIG. 6D In the embodiment of the present invention, the first diameter D1 measures approximately 1.0 inches (or approximately 24 mm), the first dimension D2 measures approximately 0.5 inches (approximately 13 mm), and the second dimension D3 measures approximately 0.4 inches (or approximately 10 mm). As used herein, "approximately" means plus or minus 0.2 inches (or approximately 5 mm). The second portion 22b includes a slot 22c extending therethrough. The slot 22c bifurcates the second portion 22b, thereby defining a first leg 22d and a second leg 22e on opposite sides of the slot 22c. The first leg 22d includes an orifice 22f, and the second leg 22e includes a hole 22g ( Fig.6D ). Orifice 22f is aligned with (e.g., coincides with) hole 22g. The diameter of orifice 22f and the diameter of hole 22g are approximately 0.12 inches (or approximately 3.05 mm). The size and shape of groove 22c are configured to receive drive blade 26 so that orifice 26d is aligned with (e.g., coincides with) orifice 22f and hole 22g of second portion 22b. Pin 32 is received within the aligned orifices 26d, 22f and hole 22g to couple piston 22 with drive blade 26. Pin 32 is generally cylindrical and has a diameter of approximately 0.116 inches (or approximately 2.95 mm). FIG. 6A to FIG. 6D In the embodiment of the present invention, the piston 22 is constructed of a first material (e.g., aluminum), and the drive blade 26 and the pin 32 are constructed of a second material (e.g., steel). In other embodiments, the piston 22, the drive blade 26, and the pin 32 can be constructed of the same second material (e.g., steel).

[0091] exist FIG. 6E to FIG. 6G In the embodiment of the present invention, the configuration of the piston 22 is FIG. 6A to FIG. 6D The configuration of the piston 22 is different. Therefore, only FIG. 6E to FIG. 6G The piston 22 and FIG. 6A to FIG. 6D The difference between the piston 22. FIG. 6E to FIG. 6GIn the embodiment of, the first part 22a and the second part 22b are different components that are threadedly connected to each other. To this end, the first part 22a includes a recess 34a located at one end and a threaded hole 34b that at least partially extends from the recess 34a through the first part 22a. The recess 34a surrounds the threaded hole 34b. The second part 22b has a threaded protrusion 36 extending from it. The second part 22b is connected to the first part 22a via a threaded engagement therebetween. Specifically, the threaded protrusion 36 is configured to be matingly connected to the threaded hole 34b. When connected, the second part 22b is placed in the recess 34a of the first part 22a. FIG. 6E to FIG. 6G In the embodiment of the present invention, the first portion 22a of the piston 22 is constructed of a first material (e.g., aluminum), and the second portion 22b of the piston 22, the drive blade 26, and the pin 32 are constructed of a second material (e.g., steel). In other embodiments, the first portion 22a and the second portion 22b of the piston 22, the drive blade 26, and the pin 32 may be constructed of the same second material (e.g., steel). In the illustrated embodiment, the central longitudinal axis extending through the threaded hole 34a is aligned with the central longitudinal axis of the first portion 22a. Accordingly, the central longitudinal axis extending through the second portion 22b is also aligned with the central longitudinal axis of the first portion 22a, and the central longitudinal axis of the first portion 22a extends centrally through the slot 22c. In other embodiments, the central longitudinal axis extending through the threaded hole 34a may be offset relative to the central longitudinal axis of the first portion 22a. In this case, the central longitudinal axis extending through the second portion 22b may also be offset relative to the central longitudinal axis of the first portion 22a, so that the central longitudinal axis of the first portion 22a does not extend centrally through the slot 22c.

[0092] FIG. 6E to FIG. 6G The size of the piston 22 is FIG. 6A to FIG. 6D The piston 22 is similar. Therefore, in FIG. 6E to FIG. 6G In the embodiment, similar to FIG. 6A to FIG. 6D In an embodiment, the first diameter D1 measures approximately 1.0 inches (or approximately 24 mm), the first dimension D2 measures approximately 0.5 inches (or approximately 13 mm), the second dimension D3 measures 0.4 inches (or approximately 10 mm), the diameter of the orifice 22f and the diameter of the hole 22g measure approximately 0.12 inches (or approximately 3.05 mm), and the diameter of the pin measures approximately 0.116 inches (or approximately 2.95 mm).

[0093] However, FIG. 6E to FIG. 6G The piston 22 and drive blade 26 of the embodiment may also be adapted for use with larger powered fastener drivers and may therefore have other sizes (e.g., larger sizes), such as FIG. 6H to FIG. 6J As shown. FIG. 6H to FIG. 6JIn the embodiment of the present invention, the first diameter measures about 1.7 inches (or about 43 mm), the first dimension D2 measures about 0.8 inches to 0.9 inches (or about 20 mm to 22.3 mm), the second dimension D3 measures about 1.1 inches (or about 28 mm), the diameter of the orifice 22f and the diameter of the hole 22g measure about 0.18 inches (or about 4.5 mm), and the diameter of the pin 32 measures about 0.18 inches (or about 4.5 mm). As described above, the pin 32 is pressed into the hole 22g.

[0094] refer to FIG. 6A to FIG. 7B , the cylinder 18 and the drive blade 26 define a drive axis 38. During a drive cycle, the drive blade 26 and the piston 22 may be at a top dead center (TDC) position ( Figure 7B ) and the drive position or bottom dead center (BDC) position ( Fig. 7A ). The fastener driver 10 further includes a lifting assembly 42 ( Figure 3 , Figure 4 , Figure 6 and Figures 11 to 13 ), the lifting assembly has a lifter 44 ( Fig. 6A ), the lifter is driven by motor 46 ( Figure 3 , Figure 4 and Figure 11 to Figure 12 ) provides power and moves the drive blade 26 from the drive position to the TDC position.

[0095] In operation, the lift assembly 42 drives the piston 22 and the drive blade 26 toward the TDC position by energizing the motor 46. As the piston 22 and the drive blade 26 are driven toward the TDC position, the gas above the piston 22 and the gas within the reservoir cylinder 30 are compressed. Before reaching the TDC position, the motor 46 is deactivated and the piston 22 and the drive blade 26 are held in a ready position between the TDC position and the BDC position (drive position) until the user activates the trigger 48 ( Figure 1 ) and is released. When released, the compressed gas above the piston 22 and in the reservoir cylinder 30 drives the piston 22 and the drive blade 26 to the drive position, thereby driving the fastener into the workpiece. The illustrated fastener driver 10 thus operates on the gas spring principle using the lifting assembly 42 and the piston 22 to further compress the gas in the cylinder 18 and the reservoir cylinder 30. Further details about the structure and operation of the fastener driver 10 are provided below.

[0096] refer to FIG. 6A to FIG. 7B, the storage chamber cylinder 30 surrounds the cylinder 18. The cylinder 18 has an annular inner wall 50 that is configured to guide the piston 22 and the drive vane 26 along the drive axis 38 to compress the gas in the storage chamber cylinder 30. The storage chamber cylinder 30 has an annular outer wall 54 that circumferentially surrounds the inner wall 50. In this way, the cylinder 18 is configured to be axially fixed to the storage chamber cylinder 30.

[0097] refer to Fig. 6A The actuator 10 includes a buffer 60 located below the piston 22 to stop the piston 22 in the driving position ( Fig. 7A ) and absorbs the impact energy from the piston 22. The buffer 60 is configured to evenly distribute the impact force of the piston 22 throughout the buffer 60 when the piston 22 rapidly decelerates when reaching the drive position (i.e., the bottom dead center position). The buffer 60 can be formed of any suitable elastic material (e.g., rubber). It is conceivable that a piston 22 constructed in whole or in part of a stronger material such as steel (as discussed above) can withstand the high impact caused by a cold firing event. This is because when the tool becomes cold, the stiffness of the buffer 60 increases, and instead of the soft rubber absorbing the impact, the buffer 60 no longer compresses as much, absorbs less energy, and causes higher stress on the piston 22. The stronger steel piston 22 is better able to withstand such impacts than the aluminum piston 22.

[0098] like FIG. 9A to FIG. 9GAs shown, in the illustrated embodiment, the buffer 60 can have an asymmetric shape and include an asymmetric opening 62 extending through the buffer. The buffer 60 defines a buffer first plane 60a and a buffer second plane 60b perpendicular to the buffer first plane 60a. The drive axis 38 extends in the buffer second plane 60b. In the illustrated embodiment, the buffer 60 includes an upper portion having a first peripheral dimension and a lower portion having a second peripheral dimension greater than the first peripheral dimension. In the illustrated embodiment, the opening 62 is generally oval. As shown, the opening 62 is asymmetric across the buffer first plane 60a and symmetric across the buffer second plane 60b, which is perpendicular to the drive axis 38 and the buffer first plane 60a. In other embodiments, the opening 62 can be asymmetric about both the buffer first plane 60a and the buffer second plane 60b. In addition, the opening 62 has a height H1 extending along the buffer first plane 60a and a width W1 extending along the buffer second plane 60b. As shown, the width W1 is greater than the height H1. In the illustrated embodiment, the blade-accommodating slot 30a extending through the storage chamber cylinder 30 has a height H2 and a width W2. As shown in the illustrated embodiment, the width W2 of the slot 30a is substantially similar to the width W1 of the opening 62, but the height H2 of the slot 30a is much less than the height H1 of the opening 62. In some embodiments, the height H2 of the slot 30a is half the height H1 of the opening 62 or less than half the height of the opening.

[0099] exist Figures 8 to 9G In the illustrated embodiment, the buffer 60 may include a key 64 (e.g., a convex component) that is configured to be received in a complementary keyway 68 (e.g., a concave component) of the storage chamber cylinder 30 (e.g., an inner frame member or housing). The use of the key 64 and the keyway 68 prevents the buffer 60 from rotating during a firing event. In the illustrated embodiment, the key 64 of the buffer 60 may include one or more protrusions, and the keyway 68 of the storage chamber cylinder 30 may be complementary recesses, each of which receives one of the protrusions of the buffer 60. As shown, the buffer 60 has two protrusions 64 that are positioned adjacent to each other on the same side of the asymmetric opening 62. In other embodiments, there may be any suitable number of protrusions 64 on the buffer 60 oriented in any suitable configuration. In other embodiments (such as FIG. 9I to FIG. 9M In an embodiment of the present invention, one or more keys 64 (e.g., male components) may extend from the reservoir cylinder 30, and one or more key slots 68 (e.g., female components) may be formed on the buffer. FIG. 9I to FIG. 9M In the embodiment of FIG. 6A , there are three key slots 68. At least one key slot 68 is positioned on each of the opposite sides of the second plane 60b of the buffer. Figure 9LAs shown, one keyway 68 is positioned on a first side of the bumper second plane 60b, and two keyways 68 are positioned on a second, opposite side of the bumper second plane 60b. In other words, one keyway 68 is at least partially positioned in the bumper first plane 60a, and there is one keyway 68 on each side of the bumper first plane 60a. Fig.9I In the illustrated embodiment, the key 64 is a curvilinear protrusion or groove extending parallel to the drive axis 38 along the wall of the storage chamber cylinder 30. Similarly, the keyway 68 is a curvilinear recess in the second outer periphery of the buffer 60. Regardless of the configuration of the key / keyway, the key / keyway causes the buffer 60 to have a generally asymmetrical shape with respect to the buffer first plane 60, the buffer second plane 60b, or both the buffer first plane 60s and the buffer second plane 60b. In the illustrated embodiment, the buffer 60 has a generally asymmetrical shape with respect to both the buffer first plane 60a and the buffer second plane 60b. In addition, the key / keyway is configured to control the buffer 60 in a correct or predetermined orientation so that the opening 62 is correctly oriented relative to the storage chamber cylinder 30 and its slot 30a.

[0100] In addition, 9A to 9F In the illustrated embodiment, the upper portion of the bumper 60 has an angled outer surface 70, thereby defining a first outer dimension (e.g., outer diameter) that tapers from the upper end to the middle portion. In contrast, the lower portion has a substantially straight outer surface 72, thereby defining a second outer dimension (e.g., outer diameter) that is substantially constant from the middle portion to the lower end. In other embodiments (e.g., FIG. 9D to FIG. 9F ), the lower portion may alternatively include a tapered edge 72a, such that the lower portion includes a straight outer surface 72 and an angled outer surface 72a. Regardless of the embodiment, the upper portion may have a different cross-sectional shape than the lower portion.

[0101] It should be noted that while the buffer 60 having a key 64 and the cylinder 30 having a keyway 68 are shown with respect to the illustrated powered fastener nailer, the buffer and cylinder configuration may be used with powered fastener nailers having other configurations (eg, roofing nailers).

[0102] The asymmetric shape of the buffer 60 and its asymmetric opening 62 are configured to accommodate the lifting teeth 26a and the locking teeth 26b on each side of the buffer 60, and also allow the opening 62 to be smaller at its opposite ends, so that the buffer 60 makes the tool smaller overall. More specifically, the shape of the opening 62 allows the buffer 60 to be smaller because clearance is only required on opposite sides of the drive blade 26. In contrast, if the opening 62 is circular (rather than elliptical), the buffer 60 will have thinner walls on the top and bottom of the buffer 60, and therefore will need to have larger external dimensions to compensate. Therefore, the configuration of the buffer 60 enables the size of the storage chamber cylinder 30 to be reduced, ultimately obtaining a tool with a smaller width. The shape of the opening 62 also significantly reduces the stress in the buffer 60 during compression. In conventional designs, the cutout for the drive blade can have a reduced gap, but its size and shape are set to be similar to the size and shape of the slot 30a in the storage chamber cylinder. In other words, the height of the conventional cutout is closer to the height of the slot of the storage chamber cylinder. This can cause a large stress concentration on the buffer on one side of the cut.

[0103] refer to Figure 1 2, the driver 10 includes a housing 80 having: a cylinder support portion 84, in which the reservoir cylinder 30 is at least partially positioned; a drive unit support portion 88, in which the motor 46 and the transmission 92 are at least partially positioned; and a handle portion 91, which defines a handle axis 91' that intersects the drive axis 38. In other words, the handle axis 91' is oriented in a plane 98 that bisects the driver 10 and extends through the drive axis 38 ( Figure 4 ). In other embodiments, the handle axis 91' is located in a plane that is offset less than 10 mm relative to the drive axis 38. In other embodiments, the handle axis 91' is located in a plane that is offset less than 5 mm relative to the drive axis 38. In other embodiments, the handle axis 91' is located in a plane that is offset between 1 mm and 5 mm relative to the drive axis 38. In addition, in the illustrated embodiment, the cylinder support portion 84 extends between the drive unit support portion 88 and the handle portion 91. Accordingly, the drive unit support portion 88 and the handle portion 91 are spaced apart from each other. In addition, the drive unit support portion 88 is spaced apart from the handle portion 91 in a direction toward the cassette 14 (as well as the nosepiece assembly 400, and the second end 548 of the workpiece contact assembly 540). In the illustrated embodiment, the cylinder support portion 84, the drive unit support portion 88, and the handle portion 91 are formed integrally with each other as a single piece (e.g., using a casting process or a molding process, depending on the materials used). As described in further detail below, the transmission 92 lifts the drive blade 26 from the drive position to the ready position. Reference Figure 4, the motor 46 is positioned within the drive unit support portion 88 for providing torque to the transmission 92 when activated. The battery pack 90 is received and supported by the battery pack attachment interface of the handle portion 91. The battery pack 90 can be electrically connected to the motor 46 for supplying power to the motor 46. In alternative embodiments, the drive can be powered by an alternative power source, such as an AC voltage input (i.e., from a wall outlet), or by an alternative DC voltage input (e.g., an AC / DC converter).

[0104] refer to Figure 4 , the transmission 92 provides torque from the motor 46 to the lift 44. The transmission 92 includes an input shaft 94 and a first output shaft 96 extending along a first output shaft axis 96'. In the illustrated embodiment, the first output shaft axis 96' intersects the drive axis 38. In other words, similar to the handle axis 91', the first output shaft axis 96' is contained in a plane 98 that bisects the drive 10 and also contains the drive axis 38. In other embodiments (such as Fig.35 In an embodiment of the present invention, the first output shaft axis 96' is located in a plane that is offset by a first distance X relative to the drive axis 38. The first distance X can be less than about 10 mm (where "about" means plus or minus 0.1 mm). In other embodiments, the first distance X can be less than about 5 mm. In other embodiments, the first distance X can be between about 1 mm and 5 mm. Fig.35 In the embodiment of the present invention, the first distance X is less than about 1.5 mm. In any case, the motor 46 is generally in line with the handle portion 91. As shown, the motor 46 is thus positioned between the handle 91 and the magazine 14 (and thus the nose assembly 400, and the second end 548 of the workpiece assembly 540). That is, when the tool 10 is in use, the motor 46 is generally located below the handle 91. Figure 4 , the first output shaft 96 rotates a drive gear 100a, which is operable to drive a driven gear 100b. In the illustrated embodiment, the gears 100a, 100b are meshing spur gears. A second output shaft 101 extends from the driven gear 100b. The second output shaft 101 is operable to drive a lifter 44, which in turn is operable to move the drive blade 26 from a drive position to a ready position, as explained in more detail below. In the illustrated embodiment, the second output shaft 101 extends along a second output shaft axis 101' that is parallel to the first output shaft axis 96' and the plane 98. As shown, the second output shaft axis 101' extends in a plane that is laterally offset a second distance Y relative to the drive axis 38 and the plane 98. In addition, as shown, the second distance Y is greater than the first distance X. As described above, in some embodiments (such as Fig.35In the embodiment of the present invention, the drive axis 38 is located between the first output axis 96' and the second output axis 101'. In the embodiment shown, the second distance Y is about 15.6mm. In other embodiments, the second distance is between about 5mm and about 30mm or between about 10mm and about 20mm. As shown, the first motor axis 96' and the second motor axis 101' are spaced apart from each other by a third distance Z. In the embodiment shown, the third distance Z can be about 17mm. In other embodiments, the third distance Z can be between about 10mm and about 30mm or between about 15mm and about 20mm. Accordingly, the drive axis 38 can be positioned to be less than 10% of the third distance Z as measured from the first output axis 96'.

[0105] Because Fig.10 The motor 46 and drive unit support portion 88 are shown in line with the handle portion 91, so the driver 10 is more compact than conventional fastener drivers 10 in which the motor is offset relative to the handle portion. This is because only the driven gear 101b and the second output shaft 101, rather than the entire transmission 92, need to be offset relative to the drive axis 38 and the plane 98 to provide torque to the lifter 44.

[0106] refer to Fig.11 , the transmission 92 is configured as a planetary transmission having a first planetary gear stage 104 and a second planetary gear stage 106. In alternative embodiments, the transmission may be a single-stage planetary transmission, or a multi-stage planetary transmission including any number of planetary gear stages. The first planetary gear stage 104 includes a ring gear 112, a planet carrier 116 ( Fig.11 and Fig.15 ), a sun gear 120 and a plurality of planetary gears 124 coupled to the planet carrier 116 for relative rotation therewith. The sun gear 120 is drivingly coupled to the input shaft 94 and meshes with the planetary gears 124. The ring gear 112 includes a toothed inner peripheral portion 128. In the illustrated embodiment, the ring gear 112 in the first planetary gear stage 104 is fixed to a transmission housing 132 ( Fig.12 ), thereby preventing the ring gear from rotating relative to the transmission housing 132. A plurality of planetary gears 124 are rotatably supported on the planet carrier 116 and can engage (ie mesh) with the toothed inner peripheral portion 128.

[0107] refer to Fig.11 and Fig.15 The drive 10 further includes a one-way clutch mechanism 154 incorporated into the transmission 92. More specifically, the one-way clutch mechanism 154 includes a planet carrier 116 that is also a component of the second planetary gear stage 106. The one-way clutch mechanism 154 allows rotation in a single (i.e., first) direction (i.e., in Figure 3 The torque is transmitted to the first output shaft 96 of the transmission 92 in the reference frame of FIG. 1 ) while preventing the motor 46 from responding to the torque being transmitted in the opposite second rotational direction (e.g., in the reference frame of FIG. 1 ). Figure 3 The one-way clutch mechanism 154 is coupled to the first planetary gear stage 104 of the transmission 92. In an alternative embodiment, for example, the one-way clutch mechanism 154 may be coupled to the second planetary gear stage 106.

[0108] Continue to refer Fig.15 , the one-way clutch mechanism 154 also includes a plurality of protrusions 158 defined on the outer periphery of the planet carrier 116. In addition, the one-way clutch mechanism 154 includes: a plurality of rolling elements 166 that can engage with corresponding protrusions 158; and a ramp 170 adjacent to each protrusion 158 along which the rolling element 166 can move. The rolling elements 166 shown extend from a disk 174. Each ramp 170 is inclined in such a manner that when the rolling element 166 moves away from the corresponding protrusion 158, the rolling element 166 moves away from the rotation axis 178 (such as the rotation axis 178 of the planet carrier 116). Fig.15 Refer to Fig.14 , the planet carrier 116 of the one-way clutch mechanism 154 is in the same planetary gear stage (i.e., the first planetary gear stage 104) of the transmission 92 as the ring gear 112. In response to applying a torque on the first output shaft 96 in the second rotational direction (i.e., when the rolling elements 166 move away from the corresponding protrusions 158 along the ramps 170), the rolling elements 166 can engage with the second inner peripheral portion 140 of the ring gear 112. A biasing mechanism (e.g., a spring 182) is positioned between each rolling element 166 and the planet carrier 116. The spring 182 biases the rolling elements 166 toward the second inner peripheral portion 140 (and away from the protrusions 158).

[0109] In operation of the one-way clutch mechanism 154, the rolling element 166 rotates in a first rotational direction of the first output shaft 96 (i.e., in Figure 3 However, when the piston 22 / drive blade 26 has reached the ready position, the rolling element 166 responds to the rotation in the opposite second rotation direction (i.e., in the reference frame of FIG. Figure 31 (clockwise in the reference frame of ), applies torque on the first output shaft 96 to move away from the corresponding protrusion 158. More specifically, when the first output shaft 96 rotates a small amount (e.g., 1 degree) in the second rotational direction, the rolling element 166 rolls along the ramp 170 away from the corresponding protrusion 158 and engages the second inner peripheral portion 140 on the ring gear 112, thereby preventing the first output shaft 96 from further rotating in the second rotational direction. Therefore, the one-way clutch mechanism 154 prevents the transmission device 92 from applying torque to the motor 46 in response to the application of torque on the first output shaft 96 in the opposite second rotational direction (i.e., when the piston 22 and the drive blade 26 have reached the ready position), which may otherwise reverse drive or cause the motor 46 to rotate in the opposite direction.

[0110] refer to Fig.11 and Fig.16 The second planetary gear stage 106 includes a ring gear 190, a planet carrier 194 ( Fig.11 ) and a plurality of planet gears 198 coupled to the planet carrier 194 for relative rotation therewith. The planet carrier 116 of the first planetary gear stage 104 further includes an output pinion 202 meshing with the planet gears 198, which in turn are rotatably supported on the planet carrier 194 of the second planetary gear stage 106 and meshing with a toothed inner peripheral portion 206 of the ring gear 190. Similar to the ring gear 112, the ring gear 190 of the second planetary gear stage 106 is fixed relative to the transition housing 136. The planet carrier 194 is operably coupled to the first output shaft 96 for relative rotation therewith. In addition, the planet carrier 194 is operably coupled to the first output shaft 96 to rotate the first output shaft 96 and, thereby, rotate the drive gear 100a of the spur gear arrangement.

[0111] Although not shown, the drive 10 further includes a torque limiting electronic clutch mechanism that limits the amount of torque transferred to the first output shaft 96 and the lifter 44 .

[0112] refer to Figure 4 , Figure 6 and Fig.12 , a lifter 44 as a component of the lift assembly 42 is coupled for co-rotation with the second output shaft 101, which in turn is driven by engagement of the driven gear 100b with the drive gear 100a. The lifter 44 includes a hub 260 having an opening 264. The end of the second output shaft 101 extends through the opening 264 and is rotationally fixed to the lifter 44. Continue to refer to Fig.12, the hub 260 is formed by two plates 272A, 272B and includes a plurality of drive pins 276 extending between the plates 272A, 272B. The illustrated lifter 44 includes four drive pins 276; however, in other embodiments, the lifter 44 may include three or more drive pins 276. The drive pins 276 may in turn engage the drive blade 26 to lift the drive blade 26 from the drive position to the ready position.

[0113] The illustrated riser 44 further includes a lower plate 272B ( Fig.12 ) is positioned. The disk member 282 is coupled to the second output shaft 101 and the lifter 44 for co-rotation. The disk member 282 supports the magnet 300. Specifically, the disk member 282 can be considered as a retaining member for preventing the drive pin 276 and the magnet 300 from axially moving relative to the second output shaft axis 101'.

[0114] The drive 10 further includes a sensor (e.g., a Hall Effect sensor, not shown) located proximate to the lifter 44. As discussed above, the lifter 44 includes a magnet 300 supported by the disk member 282. The sensor and magnet 300 are configured to indicate the position of the drive blade 26 (i.e., the ready position).

[0115] refer to Figure 4 As described above, the drive blade 26 includes lifting teeth 26a along its length, and the corresponding drive pin 276 can engage with the lifting teeth 26a when the drive blade 26 returns from the drive position to the ready position. The illustrated drive blade 26 includes eight lifting teeth 26a, so that two revolutions of the lifter 44 move the drive blade 26 from the drive position to the ready position.

[0116] As described above, the drive blade 26 further includes an axially spaced locking tooth or protrusion 26 b formed by extending from the drive blade 26 opposite the lifting tooth 26 a .

[0117] As described above, the lifting assembly 42 moves the driving blade 26 from the driving position to the ready position. The sensor determines the position of the driving blade 26 in response to detecting the magnet 300, which is positioned on the disk member 282 and rotates together with the lifter 44. Specifically, when the driving blade 26 reaches the ready position, the magnet 300 is aligned with the sensor, and the motor 46 is deactivated in response to the output signal from the sensor to stop the driving blade 26 in the ready position.

[0118] refer to Fig. 6AThe actuator 10 further includes a latch assembly 350 having a pawl or latch 354 for selectively retaining the drive blade 26 in the ready position and a solenoid (not shown) for releasing the latch 354 from the drive blade 26. In other words, the latch assembly 350 is movable between a locked state, in which the drive blade 26 is retained in the ready position against a biasing force (i.e., the pressurized gas in the reservoir cylinder 30), and a released state, in which the drive blade 26 is allowed to be driven from the ready position to the drive position by the biasing force. The latch 354 is rotated about a latch axis 366 (e.g., a latch axis 366) by a shaft 362 on the nosepiece guide 330. Fig. 6A The latch axis 366 is parallel to the second output shaft axis 101 ′ of the second output shaft 101 .

[0119] refer to Fig. 6A , the latch assembly 350 is positioned adjacent to the side 322 of the drive blade 26. In addition, the latch 354 is configured to rotate about the axis 362 relative to the latch axis 366 via actuation of the solenoid, such that the tip 378 of the latch 354 is configured to engage a stop surface (not shown) of the nose bridge assembly 400 when the latch 354 moves toward the drive blade 26.

[0120] The latch 354 can be moved between a locked position (consistent with the locked state of the latch assembly 350) and a released position (consistent with the released state of the latch assembly 350), in which the latch 354 engages with one of the protrusions 318A on the drive blade 26 to resist the biasing force of the compressed gas and hold the drive blade 26 in the ready position, and in which the drive blade 26 is allowed to be driven from the ready position to the driven position by the biasing force of the compressed gas. In addition, when the solenoid is de-energized, the stop surface against which the latch 354 can engage limits the movement of the latch 354 when returning to the locked state. Fig. 6A The degree of rotation about the latch axis 366 in the counterclockwise direction in the reference frame.

[0121] The operation of the firing cycle of the driver 10 is described and detailed below. Figure 7B Before the firing cycle is initiated, the drive blade 26 is held in the ready position with the piston 22 near top dead center in the cylinder 18. More specifically, the first drive pin 276' ( Fig. 6A ) and the lowest tooth 26a' ( Fig. 6A) is engaged, and the rotational position of the lifter 44 is maintained by the one-way clutch mechanism 154. In other words, as previously described, when the lifter 44 holds the drive blade 26 in the ready position, the one-way clutch mechanism 154 prevents the motor 46 from being reversely driven by the transmission 92. In addition, when the drive blade 26 is in the ready position, the latch 354 can engage with the lowest tooth 26b' ( Fig. 6A ) is engaged, but not necessarily in contact with the drive blade 26 and serves to keep the drive blade in the ready position. On the contrary, at this time, the latch 354 provides a safety function to prevent the drive blade 26 from accidentally firing when the one-way clutch mechanism 154 fails.

[0122] When the trigger 48 is pulled to initiate the firing cycle, the solenoid is energized to pivot the latch 354 from the locked position to the released position, thereby repositioning the latch 354 so that it can no longer engage the locking tooth 26b (thus defining the released state of the latch assembly 350). At about the same time, the motor 46 is activated to cause the first output shaft 96 and the lifter 44 to rotate along the first output shaft 96 and the lifter 44. Fig. 6A The piston 22 rotates counterclockwise in the reference frame of the drive blade 26, thereby slightly shifting the drive blade 26 upward past the ready position (at the TDC position of the drive blade 26) before the lowest tooth 26a' on the drive blade 26 slides off the drive pin 276'. Thereafter, the piston 22 and the drive blade 26 are pushed downward to the drive position ( Fig. 7A ). When the driving blade 26 is displaced toward the driving position, the motor 46 remains activated to cause the lifter 44 to continue to rotate counterclockwise.

[0123] refer to Fig. 6A As the fastener is driven into the workpiece, the piston 22 strikes the buffer 60 to rapidly decelerate the piston 22 and the drive blade 26, ultimately stopping the piston 22 in the drive position or bottom dead center position.

[0124] Shortly after the drive blade 26 reaches the drive position, the first drive pin 276 on the lifter 44 engages one of the lift teeth 26a on the drive blade 26, and continued counterclockwise rotation of the lifter 44 lifts the drive blade 26 and the piston 22 toward the ready position. Shortly thereafter and before the lifter 44 completes one full rotation, the solenoid is de-energized, allowing the latch 354 to reengage the drive blade 26 and ratchet around the locking tooth 26b (thereby defining the locked state of the latch assembly 350) as the drive blade 26 continues to shift upward.

[0125] After one full rotation of the lifter 44 has occurred, the latch 354 holds the drive blade 26 in an intermediate position between the drive position and the ready position while the lifter 44 continues (in Figure 4) is rotated counterclockwise until the first drive pin 276' reengages the other lifting tooth 26a on the drive blade 26. Continued rotation of the lifter 44 lifts the drive blade 26 to the ready position, which is detected by the sensor as described above.

[0126] refer to FIG. 2A to FIG. 2C as well as Figures 17 to 23B , the driver 10 further includes a nose bridge assembly 400 positioned at the end of the magazine 14.

[0127] The magazine 14 includes a magazine body 404 that is configured to receive fasteners to be driven into a workpiece by a powered fastener driver. Figure 1 ) has a first end 408 and a second end 412 opposite the first end 408. The cassette body 404 further includes a first side 416 and a second side 420 ( Figure 17 to Figure 18 ) and a bottom side 424 and a top side 428 extending between the first side 416 and the second side 420, respectively.

[0128] like Figure 2C , Fig.17 and Fig.18 As shown, the illustrated cassette body 404 is formed by a base portion 440 and a cover portion 444. Specifically, the cover portion 444 is slidably coupled to the base portion 440. In addition, the base portion 440 and the cover portion 444 cooperatively define a fastener channel 448 ( Figure 2C ), the fastener channel extends from the first end 408 of the cassette body 404 to near the second end 412. The fastener channel 448 is configured to receive a fastener.

[0129] Special References Figure 2C and Fig.17 20, the first side 416 of the cassette body 404 includes a protrusion 460 (FIG. 20) defining a recess 464 (FIG. 20). Fig.17 ). Recess 464 extends along first side 416 from near second end 412 toward first end 408. More specifically, recess 464 extends parallel to and communicates with fastener passage 448. First side 416 further defines an opening or window 468 ( Figure 2C and Fig.17 ).

[0130] refer to Figures 19 to 23B , the cassette 14 further includes a pusher assembly 480 positioned within the fastener channel 448 of the cassette body 404. The pusher assembly 480 is slidably coupled to the cassette 14 and is configured to bias the fasteners in the cassette 14 toward the nose bridge assembly 400. Figures 19 to 20BAs shown, the illustrated pusher assembly 480 includes a first portion or pusher body 484 and a second portion or blank-fire lock member 488 movably coupled to the pusher body 484. The magazine 14 includes first springs 492a, 492b ( Figure 2C ), these first springs are configured to apply a biasing force to the pusher assembly 480 to cause the pusher assembly 480 to move along arrow 496 ( Figure 2A and Fig.18 ) direction. In addition, the empty-fire locking member 488 is moved by the second spring 500 ( Fig. 20B ) is movably coupled to the thruster body 484 (e.g., an extension 484a of the thruster body 484). In this manner, the thruster body 484 of the thruster assembly 480 can be selectively moved relative to the blank fire lock member 488. The biasing force of the second spring 500 is independent of the biasing force of the first springs 492a, 492b. The thruster assembly 480 can be moved between a first state, in which the thruster body 484 and the blank fire lock member 488 move together in unison in the direction of arrow 496, and a second state, in which relative movement has occurred between the thruster body 484 and the blank fire lock member 488, as discussed further below.

[0131] refer to Figure 2A to Figure 2B2 , the nose bridge assembly 400 is positioned at the first end 408 of the cassette body 404. The nose bridge assembly 400 generally includes a first base portion 510 coupled to the first end 408 of the cassette body 404 and a second cover portion 514 coupled to the base portion 510. The base portion 510 of the nose bridge assembly 400 is fixed to the cassette body 404. The cover portion 514 of the nose bridge assembly 400 substantially covers the base portion 510. In the illustrated embodiment, the cover portion 514 is pivotally coupled to the base portion 510 by a latch mechanism 518. The nose bridge assembly 400 cooperatively defines a firing channel 522 extending along the drive axis 38 (at Fig. 6A Only a portion of the firing channel is shown in FIG. 4 ). The firing channel 522 communicates with the fastener channel 448 of the cassette body 404 (e.g., through an opening 526 in the base portion 510) to receive fasteners from the cassette body 404. The nosepiece assembly 400 further has a portion located in the firing channel 522 ( Fig. 6A ) at one end of the distal end 530. The drive blade 26 is received in the firing channel 522 for driving the fastener from the firing channel 522 out of the distal end 530 of the nose bridge assembly 400 and into the workpiece, as discussed above.

[0132] refer to Figure 2A , Figure 2B1 and Figure 2B2The driver 10 includes a workpiece contact assembly 540 extending along one side of the nose assembly 400. The workpiece contact assembly 540 includes a first end 544 ( Figure 2B1 , Figure 2B2 and Figure 2C ) and an opposite second end 548 that can engage with a workpiece during a firing operation. The workpiece contact assembly 540 includes a plurality of sections 552, 556, wherein each section 552, 556 is formed by a plurality of interconnected sections. A pair of springs 564a, 564b ( Figure 2B1 , Figure 2B2 and Figure 2C ) is configured to bias the workpiece contact assembly 540 toward the extended position. The workpiece contact assembly 540 is configured to move from the extended position toward the retracted position when the workpiece contact assembly 540 is pressed against the workpiece.

[0133] The first section 552 of the workpiece contact assembly 540 is positioned closer to the top side 428 of the cassette body 404 than to the bottom side 424. The first section 552 includes a first end 544 of the workpiece contact assembly 540. The first section 552 further includes an arm 574, which includes a hole 578. The arm 574 is movable relative to the housing 80. Specifically, the fixed post 570 is coupled to the housing 80 and is movably received in the hole 578 of the arm 574. The first spring 564a surrounds the post 570 and is disposed between the housing 80 and the first end of the arm 574. The second spring 564b is positioned within the hole 578 and is disposed between the distal end of the post 570 and the bottom surface of the hole 578. The arm 574 includes a screw portion 612. The second section 556 includes a second end 548 configured to engage a workpiece. The first section 552 and the second section 556 are coupled together by a drive depth adjustment mechanism 600, which adjusts the effective length of the workpiece contact assembly 540. In particular, the screw portion 612 couples the first section 552 to the second section 556.

[0134] Refer to Figure 2B and Figure 2C, the drive depth adjustment mechanism 600 includes a support member 604, an adjustment knob 608, and a screw portion 612. In the illustrated embodiment, the pair of springs 564a, 564b are at least partially supported by the drive depth adjustment mechanism 600. Compared to a single spring, the springs 564a, 564b achieve the same spring force on the workpiece contact assembly 540 while having a reduced stroke (the distance between the extended position and the retracted position). In the illustrated embodiment, the springs 564a, 564b have different stiffnesses, but in other embodiments, the stiffnesses may be the same. In the illustrated embodiment, there are two springs 564a, 564b, but in other embodiments, there may be more than two springs with the same or different stiffnesses. The support member 604 at least partially supports the arm 570. The adjustment knob 608 is rotatably supported on the arm 570. As described above, the screw portion 612 extends between the first section 552 and the second section 556 of the workpiece contact assembly 540. One end of the second section 556 is threadedly connected to the screw portion 612. In addition, the arm 574 and therefore the screw portion 612 are rotatably connected to the adjustment knob 608. Accordingly, the screw portion 612 and the adjustment knob 608 are rotatably supported by the arm 570. The rotation of the adjustment knob 608 axially screws the second section 556 along the screw portion 612 to adjust the protruding length of the workpiece contact assembly 540 relative to the distal end 530 of the nose bridge assembly 400. More specifically, the rotation of the adjustment knob 608 moves the second section 556 relative to the first section 552 to adjust the effective length of the workpiece contact assembly 540. In this way, the adjustment knob 608 can be referred to as an actuator. Figure 2B1 and 2B2 As shown, a stop mechanism 610 can engage with the adjustment knob 608 to prevent the adjustment knob 608 from rotating freely. As shown, the adjustment knob 608 includes a plurality of grooves or recesses 608a in its outer surface. The stop mechanism 608 includes a ball 610a (e.g., a stop device) and a spring 610b (e.g., a biasing mechanism) that biases the ball 610a into one of the grooves 608a of the adjustment knob 608.

[0135] The drive depth adjustment mechanism 600 adjusts the depth to which the fastener is driven into the workpiece. In particular, the drive depth adjustment mechanism 600 adjusts the length of the workpiece contact assembly 540 protruding relative to the distal end 530 of the nose cradle assembly 400, thereby changing the distance between the distal end 530 of the nose cradle assembly 400 and the workpiece contact assembly 540 in the extended position. In other words, the drive depth adjustment mechanism 600 adjusts the distance that the workpiece contact assembly 540 extends through the nose cradle assembly 400 to abut against the workpiece. The larger the gap between the distal end 530 of the nose cradle assembly 400 and the workpiece, the shallower the depth to which the fastener will be driven into the workpiece. In this way, the position of the workpiece contact assembly 540 relative to the nose cradle assembly 400 is adjustable to adjust the depth to which the fastener is driven. In the illustrated embodiment, the spring 610b biases the ball 610a into one of the grooves 608a of the adjustment knob 608 to retain the adjustment knob 608 at a selected depth, and thus retain the workpiece contact assembly 400 at a selected depth. When the user wants to adjust the depth, the user rotates the adjustment knob 608 against the bias of the spring 610 a to selectively rotate the adjustment knob 608 .

[0136] As shown in Figure 2B to Figure 2C and FIG. 21A to FIG. 23B As shown, the workpiece contact assembly 540 further includes an engagement portion 640 (e.g., a dry fire lockout link). In the illustrated embodiment, the first section 552 includes the dry fire lockout link 640. The dry fire lockout link 640 is substantially positioned at the first end 544 of the workpiece contact assembly 540 and is specifically coupled to the arm 570.

[0137] refer to Figures 19 to 23B The powered fastener driver 10 further includes a dry-fire lock assembly 650 ( Fig.23A and Fig. 23B ). When the number of fasteners remaining in the magazine 14 drops below a predetermined value, the dry fire lock assembly 650 prevents the powered fastener driver 10 from operating. The dry fire lock assembly 650 includes a dry fire lock member 488 of the pusher assembly 480, and a dry fire lock link 640. The extension 484a of the pusher body 484 and the dry fire lock member 488 are positioned within the fastener channel 448 of the magazine 14 and are movable (e.g., slidable) within the fastener channel. The dry fire lock member 488 is selectively received in the opening 468 of the magazine 14. The dry fire lock member 488 is configured to prevent the workpiece contact assembly 540 from moving when a predetermined number of fasteners (e.g., 0, 1, 2, 4, etc.) remain in the magazine 14.

[0138] The dry fire lock member 488 can be in a first non-blocking or bypass position (e.g., FIG. 21A to FIG. 22E ) and the second blocking position ( FIG. 23A to FIG. 23BWhen the blank-fire lock member 488 is not extended through the opening 468 of the magazine 14, the blank-fire lock member 488 is in the bypass position, so that the blank-fire lock link 640 and the workpiece contact assembly 540 can move from the extended position to the retracted position ( FIG. 21A to FIG. 22E That is, in the bypass position, the dry fire lockout link 640 is configured to slide through the opening 468 (and, depending on the number of fasteners remaining, the dry fire lockout member 488) in response to movement toward the retracted position. Additionally, when the dry fire lockout member 488 is in the bypass position, the pusher assembly 480 is in a first state such that the pusher body 484 and the dry fire lockout member 488 move in unison. When the dry fire lockout member 488 is in the blocking position, at least a portion of the dry fire lockout member 488 ( FIG. 23A to FIG. 23B ) protrudes through the opening 468 of the magazine 14, at which opening the dry fire lock member interferes with the retraction of the dry fire lock link 640, thereby preventing the workpiece contact assembly 540 from moving from the extended position toward the retracted position.

[0139] In operation, FIG. 21A to FIG. 21E As shown, in the case where there are more than a predetermined number of fasteners in the magazine 14, as successive fasteners from the chain-type fastener strip are discharged from the nosepiece assembly 400, the first portion 484 and the second portion 488 of the pusher assembly 480 are biased by the first springs 492a, 492b to move in unison in an incremental manner in the direction of the arrow 496 of the magazine 14. At this time, the opening 468 remains open and the blank-fire lock member 488 remains in the bypass position.

[0140] In the scenario when the remaining fasteners in the magazine 14 reach a predetermined number, the blank fire lock member 488 is in the blocking position and thus engages the blank fire lock link 640, as shown in FIG. FIG. 23A to FIG. 23B When the blocking position is reached, the dry fire lockout member 488 blocks the dry fire lockout link 640 of the workpiece contact assembly 540, and retraction of the workpiece contact assembly 540 is blocked to prevent further activation of the powered fastener driver 10. In this scenario, the movement of the advancer assembly 480 can remain in the first state (i.e., wherein the first portion 484 and the second portion 488 move in unison) until the dry fire lockout member 488 moves to the blocking position.

[0141] However, in a scenario where fasteners of a particular size (e.g., fasteners having a particular shank length or diameter) are placed in magazine 14, the deflected chain fastener strips within the fastener channel may only allow the dry-fire lock member 488 to move partially toward the blocking position when the number of fasteners remaining in magazine 14 reaches a predetermined number. FIG. 22A to FIG. 22EAs shown, the dry-fire locking member 488 can be in an intermediate position between the bypass position and the blocking position, in which the dry-fire locking member 488 only slightly blocks the dry-fire locking link 640 and the workpiece contact assembly 540. In addition, other tolerances associated with the particular size of the fastener used and / or associated with the driver 10 as a whole can cause the dry-fire locking member 488 to move to the intermediate position. In this case, for example, when the number of remaining fasteners is one more than the predetermined number of fasteners, the dry-fire locking member 488 is in the intermediate position. When the dry-fire locking member 488 is in the intermediate position, the workpiece contact assembly 540 (specifically the dry-fire locking link 640) can nominally engage the dry-fire locking member 488 during retraction and move the dry-fire locking member 488 toward the bypass position, thereby allowing the workpiece contact assembly 540 to continue to retract to achieve the final fastener firing cycle. When the dry fire lock member 488 moves from the intermediate position to the bypass position, the thruster assembly 480 transitions from the first state to the second state in which relative movement has occurred between the thruster body 484 and the dry fire lock member 488 .

[0142] That is, the empty-fire lockout link 640 can nominally engage the empty-fire lockout member 488 during retraction to move the empty-fire lockout member 488 toward the bypass position against the bias of the spring second spring 500, and thus slide past the empty-fire lockout member 488 to the retracted position to achieve the final firing cycle. In this scenario, after the final fastener firing cycle, the movement of the pusher assembly 480 is transformed from the first state to the second state (i.e., the empty-fire lockout member 488 has moved relative to the pusher body 484 against the bias of the second spring 500). Once the final fastener firing cycle is completed and a predetermined number of fasteners remain, the empty-fire lockout member 488 protrudes through the opening 468 and blocks the empty-fire lockout link 640 and therefore the workpiece contact assembly 540 from moving to the retracted position, thereby preventing a "empty-fire" cycle in which the driver blade 26 is driven from the TDC position to the BDC position without a fastener in the firing channel 522.

[0143] When a predetermined number of fasteners remain and the dry-fire lockout member 488 is in the blocking position, the dry-fire lockout member 488 cannot be transitioned from the first state to the second state. Accordingly, when a predetermined number of nails remain, the dry-fire lockout member 488 is positioned so that the dry-fire lockout member 488 is fully engaged with the dry-fire lockout link 640 and thus the workpiece contact assembly 540 to prevent a "dry-fire" cycle.

[0144] Another configuration of the cassette 1014 is Figures 24 to 341000. Cassette 1404 is similar to cassette 14 described above. Therefore, like structures will be identified with like reference numerals plus "1000", and only the differences will be described herein.

[0145] Magazine 1014 includes a magazine body 1404 that is configured to receive fasteners to be driven into a workpiece by powered fastener driver 1010. Magazine body 1404 ( Fig.24 and Fig.30 ) has a first end 1408 and a second end 1412 opposite the first end 1408. The cassette body 1404 further includes a first portion 1700 and a second portion 1704 coupled to each other at the second end 1412 of the cassette by a cover 1708. The first portion 1700 includes a top side 1428, and the second portion 1704 includes a bottom side 1424. The first side 1416 and the second side 1420 are each at least partially formed by both the first portion 1700 and the second portion 1704. In addition, the first portion 1700 and the second portion 1704 cooperatively define a fastener channel 1448 (FIG. 2 and Fig.30 ), the fastener channel extends from the first end 1408 of the cassette body 1404 to near the second end 1412. The fastener channel 1448 is configured to receive a fastener.

[0146] Special References Fig.25 and Fig.29 A gap or track 1712 is defined on the second side 1420 between the first portion 1700 and the second portion 1704. The track 1712 extends along the length of the cassette body 1404 from near the second end 1412 toward the first end 1408. Fig.26 As shown, the first portion 1700 includes a recess 1716 extending along the first side 1416 from near the second end 1412 toward the first end 1408. More specifically, the recess 1716 extends parallel to the fastener channel 1448 and communicates with the fastener channel. Figure 29 to Figure 31 As shown, guide member 1720 is coupled to second end 1412 of first portion 1700 and is spaced apart from second portion 1704. Guide member 1720 extends parallel to recess 1716 and defines a portion of fastener channel 1448. That is, guide member 1720 includes an opening 1724 ( Fig.30 ), which receives the head of each fastener.

[0147] refer to Figures 29 to 31B , the cassette 1014 further includes a pusher assembly 1480. The pusher assembly 1480 is slidably coupled to the cassette 1014 and is configured to bias the fasteners in the cassette 1014 toward the nose bridge assembly 1400. Figure 25 to Figure 26 and Figures 29 to 31BAs shown, the illustrated thruster assembly 1480 includes a first portion or thruster body 1484, a thruster finger 1730 pivotally coupled to the thruster body 1484, and a second portion or dry-fire lock member 1488 movably coupled to the thruster body 1484. The thruster assembly 1480 further includes a spring assembly 1734 ( Fig.31B ), the spring assembly having a roller 1738 supported by the pusher body 1484 and a spring 1742 supported by the roller 1738. The fixed end 1742a of the spring 1742 is coupled to the cassette body 1404. The spring assembly 1734 is configured to apply a biasing force to the pusher assembly 1480 to cause the pusher assembly 1480 to move along the arrow 1496 ( Fig.25 ) direction.

[0148] about Fig.25 and Figure 29 to Figure 30 , the pusher body 1484 is supported by both the first portion 1700 and the second portion 1704 of the cassette body 140 and is at least partially positioned on both sides of the fastener channel 1448. As shown, the pusher body 1484 includes a main portion 1746a positioned on the second side 1420 and adjacent to the track 1412. The main portion 1746a pivotally supports the pusher finger 1730. The pusher body 1484 also includes an arm 1746b extending from the main portion 1746a and positioned on the second side 1416. The arm 1746b is received in the recess 1716 of the cassette body 1404 and is movable relative to the recess. The arm 1746b includes a first recess 1746c, through which the guide member 1420 extends, and a second recess 1746d, in which the dry fire lock member 1488 is received.

[0149] The pusher finger 1730 includes a first end 1730a positioned between the main portion 1746a of the pusher body 1484 and the cassette body 1404 and a second end 1730b extending outwardly from the main portion 1746a of the pusher body 1484. The pusher finger 1730 is pivotally coupled to the main portion 1746a by a pin 1730c extending through the pusher finger 1730 at a position between the first end 1730a and the second end 1730b. The pusher finger 1730 is movable between an engaged position, in which the first end 1730a is positioned within the fastener channel 1448 and is configured to engage the last fastener in the fastener channel 1448, and a disengaged position, in which the first end 1730a is at least partially removed from the track 1712. The spring 1730d ( Fig.29) biases the pusher finger 1730 to the engaged position. The force applied to the second end 1730b of the pusher finger 1730 temporarily moves the pusher finger 1730 from the engaged position to the disengaged position so that the pusher assembly 1480 can move relative to the cassette body 1014. When the force is removed from the second end 1730b of the pusher finger 1730, the bias of the spring 1730d returns the pusher finger 1730 to the engaged position.

[0150] In addition, the dry fire locking member 1488 is provided with a second spring 1500 ( Fig.26 and Fig.30 ) is movably coupled to the thruster body 1484 (e.g., arm 1746b of the thruster body 1484). In this manner, the thruster body 1484 of the thruster assembly 1480 can be selectively moved relative to the dry fire lock member 1488. The biasing force of the second spring 1500 is independent of the biasing force of the spring assembly 1734. The thruster assembly 1480 can be moved between a first state, in which the thruster body 1484 and the dry fire lock member 1488 move together in unison in the direction of arrow 1496, and a second state, in which relative movement has occurred between the thruster body 1484 and the dry fire lock member 1488, as discussed further below.

[0151] Similar to the previous embodiment, the nose bridge assembly 1400 ( Fig.24 and Fig.25 ) is positioned at the first end 1408 of the cassette body 1404 and includes similar structure and reference numerals plus "1000" and are not repeated here. Figures 24 to 28 , the driver 1010 includes a workpiece contact assembly 1540 similar to the workpiece contact assembly 1540, such that the reference numeral "1000" is used and only the differences will be discussed herein. A single spring 1750 ( Figure 32 to Figure 34 ) is configured to bias the workpiece contact assembly 1540 toward the extended position. The workpiece contact assembly 1540 is configured to move from the extended position toward the retracted position (eg, Figure 27 to Figure 29 The first section 1552 includes an arm 1754 that is movable relative to the housing 1080. The first spring 1754 surrounds the arm 1754. The arm 1754 includes an engagement portion 1640 (e.g., a dry-fire lockout link) and a screw portion 1758. In the illustrated embodiment, the first section 1552 includes the dry-fire lockout link 1640. The dry-fire lockout link 1640 is substantially positioned at the first end 1544 of the workpiece contact assembly 1540 and is specifically coupled to the arm 1754.

[0152] refer to Figure 27 to Figure 29The drive depth adjustment mechanism 1600 is similar to the drive depth adjustment mechanism described above and operates in a similar manner as described above. Therefore, similar structures are identified using similar reference numerals plus "1000".

[0153] refer to Fig.25 and Figures 29 to 34 The powered fastener driver 1010 further includes a dry-fire lock assembly 1650 ( Figure 32 to Figure 34 ), which operates similarly to the above-described dry fire lockout assembly driver 1650. When the number of fasteners remaining in the magazine 1014 drops below a predetermined value, the dry fire lockout assembly 1650 prevents the powered fastener driver 1010 from operating. The dry fire lockout assembly 1650 includes a dry fire lockout member 1488 of the pusher assembly 1480, and a dry fire lockout link 1640. The arm 1746b of the pusher body 1484 and the dry fire lockout member 1488 are positioned within the recess 1716 of the magazine 1014 and are movable (e.g., slidable) within the recess. The dry fire lockout member 488 is selectively received in the opening 1468 ( Fig.26 In the illustrated embodiment, the opening 1468 is at least partially formed by the inner frame 1030, as shown in FIG. Fig.26 The blank-fire lockout member 1488 is configured to prevent the workpiece contact assembly 1540 from moving when a predetermined number of fasteners (eg, 0, 1, 2, 4, etc.) remain in the magazine 1014 .

[0154] The dry fire lock member 1488 can be in a first non-blocking or bypass position (e.g., Figure 32 to Figure 33 ) and the second blocking position ( Fig.34 When the blank fire lock member 1488 is not extended through the opening 1468 of the magazine 1014, the blank fire lock member 1488 is in the bypass position so that the blank fire lock link 1640 and the workpiece contact assembly 1540 can move from the extended position to the retracted position ( Figure 32 to Figure 33 ). That is, in the bypass position, the dry fire lock link 1640 is configured to slide into the opening 1468 (and, depending on the number of fasteners remaining, the dry fire lock member 1488) in response to movement toward the retracted position. In addition, when the dry fire lock member 1488 is in the bypass position, the pusher assembly 1480 is in a first state such that the pusher body 1484 and the dry fire lock member 1488 move in unison. When the dry fire lock member 1488 is in the blocking position, at least a portion of the dry fire lock member 1488 ( Fig.34 ) protrudes into the opening 1468 of the magazine 1014, where the dry fire lock member interferes with the retraction of the dry fire lock link 1640, thereby preventing the workpiece contact assembly 1540 from moving from the extended position toward the retracted position.

[0155] In operation, Fig.32 As shown, in the case where there are more than a predetermined number of fasteners in the magazine 1014, as successive fasteners from the chain-type fastener strip are discharged from the nosepiece assembly 1400, the first portion 1484 and the second portion 1488 of the pusher assembly 1480 are biased by the spring assembly 1734 to move in unison in an incremental manner in the direction of the arrow 1496 of the magazine 1014. At this time, the opening 1468 remains open and the blank-fire lock member 1488 remains in the bypass position.

[0156] In the scenario when a predetermined number of fasteners remain in magazine 1014, blank fire lock member 1488 is in the blocking position and thus engages blank fire lock link 1640, as shown in FIG. Fig.34 When the blocking position is reached, the dry fire lockout member 1488 blocks the dry fire lockout link 1640 of the workpiece contact assembly 1540, and retraction of the workpiece contact assembly 1540 is blocked to prevent further activation of the powered fastener driver 1010. In this scenario, the movement of the advancer assembly 1480 can remain in the first state (i.e., wherein the first portion 1484 and the second portion 1488 move in unison) until the dry fire lockout member 1488 moves to the blocking position.

[0157] However, in a scenario where fasteners of a particular size (e.g., fasteners having a particular shank length or diameter) are placed in magazine 1014, the deflected chain fastener strips within the fastener channel may only allow dry-fire lock member 1488 to partially move toward the blocking position when a predetermined number of fasteners remain in magazine 1014. Fig.33As shown, the dry-fire lock member 1488 can be in an intermediate position between the bypass position and the blocking position, in which the dry-fire lock member 1488 only slightly blocks the dry-fire lock link 1640 and the workpiece contact assembly 1540. In addition, other tolerances associated with the particular size of fasteners used and / or associated with the driver 1010 as a whole can cause the dry-fire lock member 1488 to move to the intermediate position. In this case, for example, when the number of remaining fasteners is one more than the predetermined number of fasteners, the dry-fire lock member 1488 is in the intermediate position. When the dry-fire lock member 1488 is in the intermediate position, the workpiece contact assembly 1540 (specifically the dry-fire lock link 1640) can nominally engage the dry-fire lock member 1488 during retraction and move the dry-fire lock member 1488 toward the bypass position, thereby allowing the workpiece contact assembly 1540 to continue to retract to achieve the final fastener firing cycle. When the dry fire lock member 1488 moves from the intermediate position to the bypass position, the thruster assembly 1480 transitions from the first state to the second state in which relative movement has occurred between the thruster body 1484 and the dry fire lock member 1488 .

[0158] That is, the dry fire lock link 1640 can nominally engage the dry fire lock member 1488 during retraction to move the dry fire lock member 1488 toward the bypass position against the bias of the second spring 1500, and thus slide past the dry fire lock member 1488 to the retracted position to achieve the final firing cycle. In this scenario, after the final fastener firing cycle, the movement of the pusher assembly 1480 transitions from the first state to the second state (i.e., the dry fire lock member 1488 has moved relative to the pusher body 1484 against the bias of the second spring 1500). Once the final fastener firing cycle is completed and a predetermined number of fasteners remain, the dry fire lockout member 1488 protrudes into the opening 468 and blocks the dry fire lockout link 1640, and therefore the workpiece contact assembly 1540, from moving to the retracted position, thereby preventing a "dry fire" cycle in which the drive blade 1026 is driven from the TDC position to the BDC position in the absence of a fastener in the firing channel 1522.

[0159] When a predetermined number of fasteners remain and the dry-fire lockout member 1488 is in the blocking position, the dry-fire lockout member 488 cannot be transitioned from the first state to the second state. Accordingly, when a predetermined number of nails remain, the dry-fire lockout member 1488 is positioned so that the dry-fire lockout member 1488 is fully engaged with the dry-fire lockout link 1640 and thus the workpiece contact assembly 1540 to prevent a "dry-fire" cycle.

[0160] Although the invention 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 invention described.

Claims

1. A powered fastener driver, characterized in that: include: a housing defining a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion, the handle portion defining a handle axis; a cylinder within the cylinder support portion; a piston movable within the cylinder from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position; a drive blade attached to the piston for moving with the piston along the drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece; a lifter operable to move the piston and the drive blade in unison from the BDC position toward the TDC position; as well as a drive unit supported by the drive unit support portion and operably coupled to the lifter, the drive unit including a motor having an output shaft extending along a motor axis, the motor being positioned below the handle, Wherein, the handle axis and the motor axis intersect with the drive axis.

2. The powered fastener driver of claim 1, wherein: The output shaft is a first output shaft, and wherein the drive unit further includes a driving gear, a driven gear, and a second output shaft, wherein the driving gear is operably connected to the first output shaft, the driven gear is meshed with the driving gear, the second output shaft is operably connected to the driven gear and has a rotation axis parallel to the motor axis, and wherein the second output shaft is operably connected to the lifter to provide torque to the lifter, thereby causing the lifter to rotate around the rotation axis.

3. The powered fastener driver of claim 1, wherein: The handle axis, the motor axis and the drive axis are all contained in an imaginary plane that bisects the housing.

4. The powered fastener driver of claim 1, wherein: The drive blade includes a plurality of teeth extending along a side of the drive blade, and the lifter includes a plurality of drive pins, and wherein each of the drive pins is engageable with a corresponding tooth of the plurality of teeth when the drive blade returns from the BDC position to the TDC position.

5. The powered fastener driver of claim 1, further comprising a bumper supported by the housing and configured to stop the piston and the driver blade in the BDC position.

6. The powered fastener driver of claim 1, further comprising a latch assembly for selectively preventing the drive blade from moving to the BDC position, the latch assembly being positioned on a side of the drive axis opposite the lifter.

7. A powered fastener driver, characterized in that: include: a housing defining a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion; a cylinder within the cylinder support portion; a piston movable within the cylinder from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position; a drive blade attached to the piston for movement with the piston along the drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece, the drive blade including a plurality of teeth extending along a side of the drive blade; a lifter operable to move the piston and the drive blade in unison from the BDC position toward the TDC position, the lifter including a plurality of drive pins engageable with the teeth when the drive blade returns from the BDC position to the TDC position; as well as a drive unit supported by the drive unit support portion and operably coupled to the lifter, the drive unit including a motor having a motor axis, the motor being positioned below the handle, The motor axis is located in a plane parallel to the drive axis and within about 10 mm from the drive axis.

8. The powered fastener driver of claim 7, wherein: The motor includes a first output shaft extending along the motor axis, and wherein the drive unit further includes a driving gear, a driven gear, and a second output shaft, wherein the driving gear is operably connected to the first output shaft, the driven gear is meshed with the driving gear, the second output shaft is operably connected to the driven gear and has a rotation axis parallel to the motor axis, and wherein the second output shaft is operably connected to the lifter to provide torque to the lifter, thereby causing the lifter to rotate around the rotation axis.

9. The powered fastener driver of claim 7, wherein: A handle axis of the handle intersects the drive axis.

10. The powered fastener driver of claim 7, further comprising a bumper supported by the housing and configured to stop the piston and the driver blade in the BDC position.

11. The powered fastener driver of claim 7, further comprising a latch assembly for selectively preventing the drive blade from moving to the BDC position, the latch assembly being positioned on a side of the drive axis opposite the lifter.

12. The powered fastener driver of claim 11, wherein: The plurality of teeth are a plurality of first teeth extending along a first side of the drive blade, wherein the drive blade further includes a plurality of second teeth extending along an opposite second side of the drive blade, and wherein the latch assembly further includes a latch configured to selectively engage one of the plurality of second teeth to prevent the drive blade from moving to the BDC position.

13. A powered fastener driver, characterized in that: include: a housing defining a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion, the handle portion defining a handle axis; a cylinder within the cylinder support portion; a piston movable within the cylinder from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position; a drive blade attached to the piston for moving with the piston along the drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece; a lifter operable to move the piston and the drive blade in unison from the BDC position toward the TDC position, the lifter comprising a plurality of drive pins, at least one of the drive pins being configured to engage the drive blade when moving the drive blade from the BDC position toward the TDC position; as well as a drive unit supported by the drive unit support portion and operably coupled to the lifter, the drive unit comprising a motor and a second output shaft, the motor having a first output shaft extending along a motor axis, the second output shaft operably coupled to the first output shaft, the second output shaft extending along an axis parallel to the motor axis, the motor being located below the handle, Wherein, the lifter is operably coupled to the second output shaft.

14. The powered fastener driver of claim 13, wherein: The second output shaft is located further away from the drive axis than the first output shaft.

15. The powered fastener driver of claim 13, wherein: The motor axis is laterally offset relative to the drive axis in a first direction, and wherein the axis of the second output shaft is laterally offset relative to the drive axis in a second direction opposite to the first direction.

16. The powered fastener driver of claim 13, wherein: The motor axis of the first output shaft intersects the drive axis.

17. The powered fastener driver of claim 13, wherein: The drive blade includes a plurality of teeth extending along a side of the drive blade, and wherein the drive pins are engageable with the teeth when moving the drive blade from the BDC position toward the TDC position.

18. The powered fastener driver of claim 13, further comprising a bumper supported by the housing and configured to stop the piston and the driver blade in the BDC position.

19. The powered fastener driver of claim 13, further comprising a latch assembly including a latch pivotally supported on a latch shaft for selectively preventing the drive blade from moving to the BDC position, the latch shaft extending along an axis parallel to the axis of the second output shaft.

20. The powered fastener driver of claim 19, wherein: The latch axis and the axis of the second output shaft are located on opposite sides of the motor axis.

21. A powered fastener driver, characterized in that: include: case; a cylinder within the housing; a piston movable within the cylinder from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position; a drive blade attached to the piston for moving with the piston along the drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece; a lifter operable to move the piston and the drive blade from the BDC position toward the TDC position; a drive unit operably coupled to the lifter to provide torque to the lifter to rotate the lifter; a damper supported by the housing and configured to stop the piston and the drive blade at the BDC position; a key coupled to one of the buffer or the housing; as well as a keyway coupled to the other of the buffer or the housing, The key is received in the keyway to rotationally guide the buffer relative to the housing and prevent relative rotation between the buffer and the housing.

22. The powered fastener driver of claim 21, wherein: The bumper defines an opening extending therethrough, the opening being configured to receive the drive blade, the opening having a height and a width greater than the height.

23. The powered fastener driver of claim 21, wherein: The buffer defines a first buffer plane, a second buffer plane perpendicular to the first buffer plane, and an opening extending through the buffer, the opening being configured to receive the drive blade, the shape of the buffer being asymmetric with respect to both the first plane and the second plane, and the opening being asymmetric with respect to the first buffer plane.

24. A powered fastener driver, characterized in that: include: case; a cylinder within the housing; a piston movable within the cylinder from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position; a drive blade attached to the piston for moving with the piston along the drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece; a lifter operable to move the piston and the drive blade from the BDC position toward the TDC position; a drive unit operably coupled to the lifter to provide torque to the lifter to rotate the lifter; as well as a workpiece contact assembly coupled to the housing and movable from an extended position to a retracted position in response to contact with a workpiece, the workpiece contact assembly comprising: a fixing post coupled to the housing, an arm including a hole for receiving the post, a first spring surrounding the post and disposed between the housing and the first end of the arm, and A second spring is located within the bore and disposed between the distal end of the post and the bottom surface of the bore.

25. The powered fastener driver of claim 24, wherein: The first spring and the second spring have different stiffnesses.

26. A powered fastener driver, characterized in that: include: a cassette assembly configured to receive a fastener; a nose bridge assembly including a channel through which successive fasteners from the cassette assembly are driven; a pusher assembly slidably coupled to the cassette assembly, the pusher assembly being configured to bias the fasteners within the cassette assembly toward the channel, the pusher assembly comprising: The thruster body, and a dry fire lock member coupled to the thruster body, the thruster body and the dry fire lock member being selectively movable relative to each other, the thruster assembly being adjustable between a first state in which the thruster body and the dry fire lock member are configured to move together in unison toward the passageway and a second state in which relative movement between the thruster body and the dry fire lock member has occurred; and a workpiece contact assembly movable relative to the nose assembly between an extended position and a retracted position, wherein, in a first position of the dry-fire locking member relative to the magazine assembly, the workpiece contact element is configured to slide past the dry-fire locking member in response to movement toward the retracted position, and in a second position, the dry-fire locking member prevents movement of the workpiece contact assembly toward the retracted position when a predetermined number of fasteners remain in the magazine assembly, and Wherein the pusher assembly is configured to transition from the first state to the second state before the predetermined number of fasteners in the cassette assembly is reached.

27. The powered fastener driver of claim 26, wherein: The pusher assembly is configured to transition from the first state to the second state when there is one more fastener in the cassette assembly than the predetermined number.

28. The powered fastener driver of claim 26, wherein: The dry fire lock member has an intermediate position between the first position and the second position, and a transition from the first state to the second state occurs when the dry fire lock member moves from the intermediate position to the first position.

29. The powered fastener driver of claim 26, wherein: When the predetermined number of fasteners remain, the blank fire lock member is in the second position such that the blank fire lock member cannot transition from the first state to the second state.

30. A powered fastener driver, characterized in that: include: a housing defining a cylinder support portion, a drive unit support portion, and a handle portion spaced apart from the drive unit support portion, the handle portion defining a handle axis; a cylinder within the cylinder support portion; a piston movable within the cylinder from a top dead center (TDC) position to a drive position or a bottom dead center (BDC) position, the piston comprising a first portion and a second portion threadedly coupled to the first portion, the second portion comprising a slot, an orifice extending through the second portion and communicating with the slot, and a hole extending through the second portion and communicating with the slot, the orifice being aligned with the hole; a drive blade attached to the second portion of the piston for moving with the piston along the drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece, the drive blade comprising: a body having a first surface extending in a first plane, a second surface opposite the first surface and extending in a second plane parallel to the first plane, and an aperture extending through the body from the first surface to the second surface, the body being received within the slot such that the aperture of the body is aligned with the aperture of the second portion of the piston and the bore of the second portion of the piston, and lifting teeth extending from one side of the body, each of the lifting teeth including a first surface extending in the first plane and a second surface extending in the second plane, and a pin extending through the aligned aperture of the body, the aperture of the second portion of the piston, and the hole of the second portion of the piston to attach the drive blade to the piston, a lifter operable to engage one of the lift teeth to move the piston and the drive blade in unison from the BDC position toward the TDC position; as well as A drive unit is supported by the drive unit support portion and operably coupled to the lifter, the drive unit including a motor having a first output shaft extending along a motor axis.

31. The powered fastener driver of claim 30, wherein: The first portion is constructed of a first material, and the second portion is constructed of a second material different from the first material.

32. The powered fastener driver of claim 30, wherein: The first portion is constructed from aluminum and the second portion is constructed from steel.

33. The powered fastener driver of claim 30, wherein: The drive blade further includes locking teeth extending from a side of the body opposite the side having the lifting teeth, the locking teeth each including a first surface extending in the first plane and a second surface extending in the second plane.

34. The powered fastener driver of claim 30, wherein: The drive blade further includes locking teeth extending from a side of the body opposite the side having the lifting teeth, each of the locking teeth being located between the first plane and the second plane.

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