Powered fastener driver

Abstract

A powered fastener driver is disclosed that includes a piston movable within an inner cylinder from a top dead center (TDC) position to a driven position or a bottom dead center (BDC) position. The piston has a diameter of less than 45 mm, and a stroke length of the piston between a TDC position and a BDC position is greater than 60 mm and less than 90 mm as measured.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 464,217, filed on May 5, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The utility model relates to a dynamic fastener driver. Background Art

[0004] Powered fastener drivers are used to drive fasteners (e.g., nails, tacks, staples, etc.) into a workpiece. Such fastener drivers typically include a magazine in which the fasteners are stored and a fastener delivery mechanism for individually transferring the fasteners from the magazine to a fastener driving channel, wherein the fasteners are struck by a driver blade during a fastener driving operation. Utility Model Content

[0005] In some aspects, the technology described herein relates to a powered fastener driver comprising: a housing; an inner cylinder located within the housing; a piston capable of moving within the inner cylinder from a top dead center (TDC) position to a driven position or a bottom dead center (BDC) position, the piston having a diameter of less than 45 mm, and a stroke length of the piston between the TDC position and the BDC position measuring greater than 60 mm and less than 90 mm; a driver blade attached to the piston for moving with the piston along a drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece, the driver blade The driver blade includes: a first end, a second end and a plurality of drive teeth extending from one side between the first end and the second end; a lifter capable of being operated to move the piston and the driver blade from the BDC position toward the TDC position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth, and wherein the drive pins are positioned on the body along an imaginary circle that is coaxial with the rotation axis of the lifter and has a diameter of less than 40 mm; and a drive unit operably connected to the lifter to provide torque to the lifter to rotate the lifter.

[0006] In some embodiments, the powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

[0007] In some embodiments, in response to continued activation of the drive unit to rotate the lifter, the driver blade is configured to reciprocate between the top dead center position and the bottom dead center position at a frequency of at least 2 Hertz.

[0008] In some aspects, the technology described herein relates to a powered fastener driver comprising: a housing; an inner cylinder located within the housing; a piston capable of moving from a top dead center (TDC) position to a driven position or a bottom dead center (BDC) position within the inner cylinder, the piston having a circumferential groove, a diameter of less than 45 mm, and a stroke length of the piston between the TDC position and the BDC position measuring greater than 60 mm and less than 90 mm; a sealing ring positioned within the circumferential groove and configured to engage an inner surface of the inner cylinder, the sealing ring having a thickness of 2 mm to 5.5 mm; a driver blade attached to the driver blade to the piston, for moving along the drive axis with the piston from the TDC position toward the BDC position so as to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end and a plurality of drive teeth extending from one side between the first end and the second end; a lifter, the lifter being operable to move the piston and the driver blade from the BDC position toward the TDC position, wherein the lifter comprises a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; and a drive unit, the drive unit being operably connected to the lifter to provide torque to the lifter, thereby rotating the lifter.

[0009] In some embodiments, the circumferential groove in the piston is a first circumferential groove, and wherein the piston further includes a second circumferential groove and a third circumferential groove, a first guide ring positioned in the second circumferential groove and a second guide ring positioned in the third circumferential groove, each of the first guide ring and the second guide ring being configured to engage the inner surface of the inner cylinder.

[0010] In some embodiments, the powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

[0011] In some aspects, the technology described herein relates to a powered fastener driver comprising: a housing; an inner cylinder located within the housing; an outer reservoir cylinder positioned within the housing and comprising a pressurized gas in fluid communication with the inner cylinder, wherein the outer reservoir cylinder comprises a first end and a second end opposite the first end, and wherein the second end of the outer reservoir cylinder is not concentric with the first end of the outer reservoir cylinder; a piston capable of moving from a top dead center (TDC) position to a driven position or a bottom dead center (BDC) position within the inner cylinder, the piston having a circumferential groove, a diameter of less than 45 mm, and a stroke length of the piston between the TDC position and the BDC position measured to be greater than 60 mm and less than 90 mm; a sealing ring positioned within the circumferential groove and configured to engage an inner surface of the inner cylinder; a driver blade attached to the piston for moving with the piston along a drive axis from the TDC position toward the BDC position so as to A fastener is driven into a workpiece, the driver blade comprising: a first end, a second end and a plurality of teeth extending from one side between the first end and the second end; a lifter operable to move the piston and the driver blade from the BDC position toward the TDC position, wherein the lifter comprises a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; and a drive unit operably connected to the lifter to provide torque to the lifter to rotate the lifter; wherein the outer storage chamber cylinder defines a volume, wherein a first portion of the volume is defined on a first side of the drive axis and a second portion of the volume is defined on a second side of the drive axis, and wherein the second portion is larger than the first portion, and wherein the housing defines a head portion, a drive unit housing portion and a handle portion spaced apart from the drive unit housing portion, and wherein the second portion of the volume is at least partially positioned between the drive unit housing portion and the handle portion.

[0012] In some embodiments, the drive pins are positioned on the body along an imaginary circle coaxial with the axis of rotation of the lifter and having a diameter less than 40 mm.

[0013] In some embodiments, the powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

[0014] In some embodiments, the circumferential groove in the piston is a first circumferential groove, and wherein the piston further includes a second circumferential groove and a third circumferential groove, a first guide ring positioned in the second circumferential groove and a second guide ring positioned in the third circumferential groove, each of the first guide ring and the second guide ring being configured to engage the inner surface of the inner cylinder.

[0015] In some aspects, the technology described herein relates to a powered fastener driver comprising: a housing; a nosepiece extending from the housing; an inner cylinder located within the housing; a piston movable within the inner cylinder from a top dead center (TDC) position to a driven position or a bottom dead center (BDC) position, the piston having a stroke length of the piston between the TDC position and the BDC position measured to be greater than 60 mm and less than 90 mm; a driver blade attached to the piston for moving with the piston along a drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end, and a drive blade extending between the first end and the BDC position. a plurality of drive teeth extending from one side between the first and second ends; a lifter operable to move the piston and the driver blade from the BDC position toward the TDC position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; a drive unit operably coupled to the lifter to provide torque to the lifter to rotate the lifter; a canister magazine coupled to the nose frame, the arrayed fasteners being receivable in the canister magazine; and a fastener delivery mechanism disposed adjacent to the nose frame for individually delivering the arrayed fasteners in the canister magazine to the driver channels in the nose frame.

[0016] In some embodiments, the powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

[0017] In some embodiments, in response to continued activation of the drive unit to rotate the lifter, the driver blade is configured to reciprocate between the top dead center position and the bottom dead center position at a frequency of at least 2 Hertz.

[0018] In some aspects, the technology described herein relates to a powered fastener driver comprising: a housing; a nose frame extending from the housing; a workpiece contact support at least partially surrounding the nose frame, wherein the workpiece contact support is movable relative to the nose frame; an inner cylinder located within the housing; a piston movable within the inner cylinder from a top dead center (TDC) position to a driven position or a bottom dead center (BDC) position, the piston having a stroke length of the piston between the TDC position and the BDC position measured to be greater than 60 mm and less than 90 mm; and a driver blade attached to the piston for moving with the piston along a drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece. , the driver blade includes: a first end, a second end, a plurality of drive teeth extending from one side between the first end and the second end, and an actuator tooth; a lifter, the lifter is operable to move the piston and the driver blade from the BDC position toward the TDC position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; a drive unit, the drive unit is operably connected to the lifter to provide torque to the lifter to rotate the lifter; and a fastener delivery mechanism, the fastener delivery mechanism is disposed adjacent to the nose frame, wherein, as the driver blade returns to the ready position, the fastener delivery mechanism is actuated by the actuator tooth on the driver blade to load fasteners into the nose frame.

[0019] In some embodiments, the piston includes a first circumferential groove, a second circumferential groove, and a third circumferential groove, and wherein a sealing ring is positioned in the first circumferential groove and is configured to engage an inner surface of the inner cylinder, a first guide ring is positioned in the second circumferential groove, and a second guide ring is positioned in the third circumferential groove, and each of the first guide ring and the second guide ring is configured to engage an inner surface of the inner cylinder.

[0020] In some embodiments, the powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

[0021] In some embodiments, the fastener delivery mechanism includes a torsion spring that biases the pusher on the support column toward the fastener as the pusher moves along the fastener.

[0022] In some embodiments, the pusher includes at least one ramp surface terminating in at least one groove, and as the pusher moves against the fastener, the at least one ramp surface pushes the pusher away from the fastener until the at least one groove is aligned with the fastener, and biases the pusher toward the fastener until the at least one groove fits around the fastener.

[0023] In some aspects, the technology described herein relates to a powered fastener driver comprising: a housing; an inner cylinder located within the housing; a piston capable of moving from a top dead center (TDC) position to a driven position or a bottom dead center (BDC) position within the inner cylinder, the piston having a stroke length of the piston between the TDC position and the BDC position measured to be greater than 60 mm and less than 90 mm; a driver blade attached to the piston for moving with the piston along a drive axis from the TDC position toward the BDC position to drive a fastener into a workpiece In the embodiment of the present invention, the driver blade includes: a first end, a second end and a plurality of drive teeth extending from one side between the first end and the second end, the first end being cylindrical and defining an impact surface configured to impact and drive a fastener; a lifter, the lifter being operable to move the piston and the driver blade from the BDC position toward the TDC position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; and a drive unit, the drive unit being operably connected to the lifter to provide torque to the lifter, thereby rotating the lifter.

[0024] 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

[0025] Figure 1 It is a three-dimensional view of a gas spring powered fastener driver according to an embodiment of the utility model.

[0026] Figure 2 yes Figure 1 Side view of a gas spring powered fastener driver.

[0027] Figure 3 yes Figure 1 Another perspective view of a portion of a gas spring powered fastener driver with portions removed for clarity.

[0028] Figure 4 yes Figure 1 The gas spring powered fastener driver along Figure 2 A cross-sectional view taken along line 4--4.

[0029] Figure 5 yes Figure 1 The gas spring powered fastener driver along Figure 1 A cross-sectional view taken along line 5--5.

[0030] Figure 6 yes Figure 1 A perspective view of a piston of a gas spring powered fastener driver.

[0031] Figure 7 yes Figure 6 Piston edge Figure 6 A cross-sectional view taken along line 7--7.

[0032] Figure 8 yes Figure 1 A perspective view of a drive blade of a gas spring powered fastener driver.

[0033] Fig. 9 yes Figure 1 A plan view of the drive blade of a gas spring powered fastener driver.

[0034] Fig.10 yes Figure 1 A side view of the driver blade of a gas spring powered fastener driver.

[0035] Fig.11 yes Figure 1 A plan view of the lifter mechanism and latch actuator assembly of a gas spring powered fastener driver.

[0036] Fig.12 yes Fig.11 Exploded view of the lift mechanism.

[0037] Fig.13 yes Fig.11 A plan view of the lift mechanism with a portion removed.

[0038] Fig.14 yes Fig.11 Exploded view of the latch actuator assembly.

[0039] Fig.15 yes Fig.11 A plan view of the latch actuator assembly.

[0040] Fig.16 yes Figure 1 A left side view of the fastener delivery mechanism of the fastener driver.

[0041] Fig.17 yes Fig.16 Right side view of the fastener delivery mechanism.

[0042] Fig.18 is used for Fig.16 A perspective view of a pusher of a fastener delivery mechanism.

[0043] Fig.19 yes Fig.16 Side plan view of the thruster.

[0044] 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

[0045] refer to Figure 1 , the gas spring powered fastener driver 10 is operable to drive fasteners (e.g., nails) held within a canister magazine 14 into a workpiece. The fastener driver 10 includes a housing 18 having a first housing shell 22 coupled to a second housing shell 26. The housing 18 includes a head portion 30 having a handle portion 34 extending therefrom and a drive unit housing portion 38. The housing 18 also includes a battery receptacle portion 42 extending from the handle portion 34 and sized and shaped to receive a removable battery pack 46. As shown, the fastener driver 10 further includes a trigger 50 extending outwardly from the handle portion 34 of the housing 18. Further, the magazine 14 extends from a nosepiece 54 that is coupled to the housing 18 and extends therefrom.

[0046] refer to Figure 1 and Figure 2 , the magazine 14 includes a tank portion 58 in which the arrayed fasteners are arranged in a coil. The magazine 14 also includes a straight or linear portion 66 that is coupled to the nose 54 of the fastener driver 10. The fasteners are sequentially delivered from the tank portion 58 by a fastener delivery mechanism 74, through the linear portion 66, and into the driver channel 70 ( Figure 4 ).

[0047] Figure 3 to Figure 4The internal components of the fastener driver 10 are shown. As shown, the fastener driver 10 includes a reservoir cylinder 100 disposed within the head portion 30 of the housing 18. The driver cylinder 104 is positioned within the reservoir cylinder 100, and the movable piston 108 is positioned within the driver cylinder 104. The fastener driver 10 further includes a driver blade 112, which is attached to the piston 108 and can move therewith. The driver blade 112 includes a first end 116 and a second end 120 opposite the first end 116. The first end 116 is a free end, and the second end 120 is coupled to the piston 108.

[0048] The fastener driver 10 does not require an external air pressure source, but rather the reservoir cylinder 100 includes pressurized gas in fluid communication with the driver cylinder 104. The driver 10 further includes a fill valve assembly 124 ( Figure 5 ). When connected to a source of compressed gas, the filling valve assembly 124 allows the storage chamber cylinder 100 to be refilled with compressed gas if any leaks previously occurred. The filling valve assembly 124 can be configured as a Schrader valve, a Presta valve, a Dunlop valve, or some other similar valve.

[0049] The piston 108, the driver cylinder 104, and the reservoir cylinder 100 operate together as a drive mechanism for driving the driver blade 112. In other embodiments, the drive mechanism may include a pneumatic drive mechanism powered by pressurized air from an external source (e.g., an air compressor or tank). Further, the drive mechanism may be powered by a flywheel, another mechanical device, or another source.

[0050] refer to Figure 5, the driver cylinder 104 and the driver blade 112 define a drive axis 130. During the drive cycle, the driver blade 112 and the piston 108 can move between a top dead center ("TDC") (i.e., retracted or ready) position and a bottom dead center ("BDC") (i.e., extended or driven) position. In the illustrated embodiment, the stroke length L1 of the driver blade 112 between the TDC position and the BDC position is measured to be approximately 70 mm (e.g., 2.8 inches), which is less than conventional drivers. In some embodiments, the stroke length can be measured to be between less than about 65 mm (e.g., 2.5 inches) and greater than about 90 mm (e.g., 3.5 inches). For example, in some embodiments, the stroke length can be measured to be between 60 mm and 90 mm. In other embodiments, the stroke length L1 can be measured to be between about 67 mm (e.g., 2.6 inches) and about 85 mm (e.g., 3.3 inches). In some embodiments, the stroke length L1 is about 73 mm or less. The term "about" as used herein means plus or minus 5% of the value. As discussed in more detail below, a reduced stroke length L1 may be achieved for a variety of reasons. Figure 3 As shown, the fastener driver 10 further includes a lift mechanism 140 that is powered by a motor 144 and is operable to move the driver blade 112 from the BDC position toward the TDC position.

[0051] Furthermore, the fastener driver 10 includes a circuit board 148 ( Figure 3 The circuit board 148 is electrically connected to the battery receptacle portion 42 and the battery pack 46 when engaged therewith, and provides DC power to the motor 144 (eg, a brushless direct current (BLDC) motor).

[0052] In operation, the lift mechanism 140 drives the piston 108 and the driver blade 112 toward the TDC position along the drive axis 130 by energizing the motor 144. As the piston 108 and the driver blade 112 are driven toward the TDC position, the gas above the piston 108 and the gas within the reservoir cylinder 100 are compressed. Just before reaching the TDC position, the motor 144 is deactivated, thereby stopping the piston 108 and the driver blade 112 in a "ready" position where the piston 108 and the driver blade 112 are retained until released by the user activating the trigger 50. When the piston 108 moves to the top dead center (TDC) (i.e., retracted or ready) position within the driver cylinder 104 and the fastener driver 10 is ready to be fired, the first end of the driver blade 112 is adjacent to the nosepiece 54. When released, the compressed gas above the piston 108 and within the reservoir cylinder 100 drives the piston 108 and the driver blade 112 to the BDC position along the drive axis 130, thereby driving the fastener 62 into the workpiece. Upon firing, the first end 116 of the driver blade 112 moves into the nosepiece 54 to drive the fastener 62 from the drive channel 70 of the nosepiece 54 into the workpiece until the piston 108 reaches the bottom dead center (BDC) (i.e., extended or driven) position within the driver cylinder 104. The illustrated fastener driver 10 thus operates on the gas spring principle using the lift mechanism 140 and the piston 108 to compress the gas within the driver cylinder 104 and the reservoir cylinder 100 in preparation for a fastener driving cycle.

[0053] Moreover, as described in more detail below, the latch actuator assembly 160 ( Fig.11 ) cooperates with the lifting mechanism 140 to selectively engage the driver blade 112 and maintain the driver blade 112 in the ready position before the latch actuator assembly 160 is actuated by the lifting mechanism 140 to release the driver blade 112 into the nose cradle 54 to drive the fastener from the fastener driver 10 into the workpiece.

[0054] like Figure 3 As depicted, the fastener driver 10 further includes a sensor bracket 180 disposed at least partially above the lift mechanism 140. The sensor bracket 180 includes a first sensor 184 configured to sense the angular (or rotational) position of the lift mechanism 140 and a second sensor 188 that senses the linear position of a workpiece contact bracket 200 slidably disposed on the nose 54. For example, the sensors 184, 188 are Hall effect sensors configured to sense the presence of a magnet or magnetic field. The workpiece contact bracket 200 includes a magnet 204 that is sensed by the second sensor 188 when the workpiece contact bracket 200 engages with the workpiece and slides on the nose 54. When the magnet 204 is sensed, the fastener driver 10 is allowed to fire.

[0055] like Figure 3 As shown, the fastener driver 10 includes a depth adjuster 220 having a threaded shaft 224 that threadably engages the workpiece contact bracket 200. The depth adjuster 220 is rotatable to change the linear position of the workpiece contact bracket 200 relative to the nose 54. This changes the depth to which a fastener discharged from the fastener driver 10 is driven into the workpiece.

[0056] refer to Figure 5 , the driver cylinder 104 has an annular inner wall 250 that is configured to guide the piston 108 and the driver blade 112 along the drive axis 130 to compress the gas in the storage chamber cylinder 100. The annular inner wall 250 includes a first end 254 and a second end 258 opposite the first end 254. The annular inner wall 250 has a first inner diameter D1 that is substantially constant between the first end 254 and the second end 258. The first diameter D1 can measure between about 33 mm and about 45 mm. In the illustrated embodiment, the first diameter measures about 37 mm.

[0057] Continue to refer Figure 5 , the storage chamber cylinder 100 has an annular outer wall 270 that circumferentially surrounds the inner wall 250. More specifically, the storage chamber cylinder 100 extends from a first end 274 to a second end 278. Each of the illustrated first end 274 and second end 278 of the storage chamber cylinder 100 is circular, respectively. The first end 254 of the driver cylinder 104 is attached to the first end 274 of the storage chamber cylinder 100. The first ends 254, 274 may be attached in any suitable manner (e.g., press fit engagement, threaded engagement, etc.). A seal 282 is disposed between the first end 254 of the driver cylinder 104 and the first end 274 of the storage chamber cylinder 100. The seal 282 prevents pressurized gas from escaping between the storage chamber cylinder 100 and the driver cylinder 104.

[0058] The storage chamber cylinder 100 includes a first portion 286 and a second portion 290 adjacent to the first portion 286. The first portion 286 is adjacent to the first end 274 and has a substantially constant second inner diameter D2. The first portion 286 defines a first longitudinal axis 294 that is colinear with the drive axis 130. The second portion 290 is adjacent to the second end 278. The second portion 290 extends from the first portion 286 toward the second end 278. The second end 278 has a third inner diameter D3 that is variable along the length of the second portion 290 between the first portion 286 and the second end 278. As shown, the third diameter D3 generally increases from the first portion 286 to the second end 278. The second portion 290 defines a second longitudinal axis 298 that is coaxial with the second end 278. In other words, the second end 278 defines a second longitudinal axis 298 that extends through the center of the second end 278. The second longitudinal axis 298 extends parallel to the drive axis 130 and is spaced apart from the drive axis (e.g., from Figure 5 As shown in the reference system of FIG. 1 , the second longitudinal axis 298 is radially below the first longitudinal axis 294 / drive axis 130). As shown, in the illustrated embodiment, the second longitudinal axis 298 is generally closer to the handle portion 34 than the drive axis 130 and the first longitudinal axis 294. The first longitudinal axis 294 and the second longitudinal axis 298 are offset, respectively. Accordingly, the reservoir cylinder 100 is not concentric with the driver cylinder 104. Moreover, as shown, the reservoir cylinder 100 has a volume. A first portion 100' of the volume is generally defined on a first side of the drive axis 130, while a second portion 100" of the volume is generally defined on an opposite second side of the drive axis 130. The second portion 100" has a larger volume than the first portion 100'. The driver 10 further includes an end cap 302 positioned at the second end 278. The end cap 302 fluidly seals the driver cylinder 104 and the reservoir cylinder 100 relative to the external atmosphere.

[0059] The second longitudinal axis 298 is spaced apart from the first longitudinal axis 294 by an offset distance H. The offset distance H between the first longitudinal axis 294 and the second longitudinal axis 298 is between about 3% and about 25% of the third diameter D3 at the second end 278. In some embodiments, the offset distance H is between about 3% and about 20% of the third diameter D3 at the second end 278. In further embodiments, the offset distance H is between about 3% and about 15% of the third diameter D3 at the second end 278. In yet further embodiments, the offset distance H is between about 3% and about 10% of the third diameter D3 at the second end 278. In the illustrated embodiment, the offset distance H is about 3.5% of the third diameter D3 at the second end 278.

[0060] The non-concentric configuration of the driver cylinder 104 and the reservoir cylinder 100 can reduce the overall size of the driver 10 and can facilitate positioning of the driver 10 in a small space during use of the driver 10. Specifically, the overall height of the driver 10 can be reduced compared to conventional drivers. In addition, this configuration shifts the center of mass of the cylinders 104, 100 closer to the second end 278 (where the handle portion 34 of the driver 10 is located) of the driver 10. Figure 1 to Figure 2 ), which can improve the balance and / or handling of the actuator 10 when in use. Moreover, the length L2 of the reservoir cylinder 100 can be less than the length of the reservoir cylinder of a conventional actuator. In the illustrated embodiment, the length L2 measures approximately 148 mm. In other embodiments, the length L2 of the reservoir cylinder 100 between the first end 274 and the second end 278 can be in the range of approximately 125 mm to 180 mm. Additionally, the non-concentric configuration of the actuator cylinder 104 and the reservoir cylinder 100 is one of the factors that can reduce the stroke length L1 of the actuator blade 112. This is because, despite the smaller footprint of the actuator 10, the reservoir cylinder 100 can still accommodate the necessary amount of gas. The amount of pressurized gas can be in the range of approximately 134 cm3 to approximately 420 cm3. In the illustrated embodiment, the amount of pressurized gas can be approximately 270 cm3. Thus, while the stroke length L1 is reduced and the footprint of the actuator is reduced, the large volume of the reservoir cylinder 100 can still achieve a pressure of pressurized gas that applies an impact force of 245 lbf at TDC in the illustrated embodiment. In other embodiments, while the stroke length L1 is reduced and the footprint of the actuator is reduced, the large volume of the reservoir cylinder 100 can still achieve a pressure of pressurized gas that applies an impact force of 100 lbf to 410 lbf at TDC. In other embodiments, while the stroke length L1 is reduced and the footprint of the actuator is reduced, the large volume of the reservoir cylinder 100 can still achieve a pressure of pressurized gas that applies an impact force of 200 lbf to 300 lbf on the piston 108 at TDC. In other embodiments, while the stroke length L1 is reduced and the footprint of the actuator is reduced, the large volume of the reservoir cylinder 100 can still achieve a pressure of pressurized gas that applies an impact force of greater than 200 lbf at TDC on the piston 108. In the illustrated embodiment, this allows for a favorable compression ratio of no more than about 1.38:1. In some embodiments, the compression ratio may be as high as about 1.6: 1. Furthermore, the low compression ratio reduces the lifting shear stress experienced by the lifter 380 of the lift mechanism 140 during operation.

[0061] Reference Figure 6 to Figure 7In the illustrated embodiment, the piston 108 includes a first portion 310 and a second portion 314 that are integrally formed with the first portion 310 or otherwise coupled to the first portion. The first portion 310 defines a plurality of grooves 318a, 318b, 318c (e.g., circumferential grooves) that each extend around its circumference. In the illustrated embodiment, the second groove 318b has a greater depth than the first groove 318a and the third groove 318c. In the illustrated embodiment, the second portion 314 is integrally formed with the first portion 310. In some embodiments, the second portion 314 can be coupled to the first portion 310 via a threaded engagement or via a fastener. The second portion 314 is coupled to the driver blade 112. In the illustrated embodiment, the driver blade 112 is coupled to the first portion 310 via a fastener 322 (e.g., a pin, Figure 4 and Figure 5 ) is coupled to the piston 108, but in other embodiments, the driver blade 112 may be coupled to the piston in other ways (e.g., threaded engagement).

[0062] In the illustrated embodiment, the piston 108 includes a smaller diameter than pistons in other gas spring powered fastener drivers. The first portion 310 defines a maximum diameter D4 of the piston 108. In the illustrated embodiment, the diameter of the second portion 314 is generally smaller than the diameter of the first portion 310. Due to the reduced size of the piston 108 (e.g., the first portion 310 thereof), the pressure of the compressed gas required to move the piston 108 and the driver blade 112 from the TDC position to the BDC position with sufficient force to fully drive a nail into a workpiece increases.

[0063] The second groove 318b of the first part 310 receives therein a sealing ring 326b, which seals the piston 108 relative to the driver cylinder 104. As shown, the sealing ring 326b is configured as a "quad ring". When configured as a quad ring, the sealing ring 326b includes a cross-sectional shape having four protrusions 326b', wherein adjacent protrusions 326b' are equidistantly spaced. In other embodiments, the sealing ring 326b can be an O-ring with a conventional cylindrical cross-section. Whether using a quad ring or an O-ring, the sealing ring 326b is made of an elastomer or a plastic material having a material composition for reducing friction with the inner wall of the driver cylinder 104 during sliding contact. Each of the O-ring and the quad ring preferably has a thickness between about 2mm and 5.5mm. Additionally, each of the first groove 318a and the third groove 318c also includes a guide ring 326a, 326c. In the illustrated embodiment, the guide rings 326a, 326c are O-rings.

[0064] In the illustrated embodiment, the maximum diameter D4 measures about 37 mm (e.g., 1.5 inches). Thus, the total surface area of ​​the piston 108 is about 1075 mm2. In other embodiments, the maximum diameter D4 of the piston 108 measures less than about 45 mm, and the total surface area exposed to the compressed gas in the driver cylinder 104 is less than about 1590 mm2. Additionally, the pressure of the compressed gas required to move the piston 108 and the driver blade 112 from the TDC position to the BDC position with sufficient force to fully drive the nail into the workpiece is at least about 102 psi, which is greater than the pressure of a conventional gas spring driver when the piston is in the TDC position. Despite the reduced overall size of the driver 10, the non-concentric configuration of the reservoir cylinder 100 and the driver cylinder 104 and the smaller diameter D4 of the piston 108 enable sufficient pressure to drive the piston 108. Additionally, the thickness of the sealing ring 326b and the use of the guide rings 326a, 326c help reduce penetration caused by increased internal pressure. Furthermore, the thickness of the seal ring 326b increases the compression of the seal to approximately 10%, which is at least twice that of seals used in conventional drivers.

[0065] refer to Figures 4 to 5 , the actuator 10 includes a buffer 330 positioned below the piston 108 to stop the piston 108 in the driven position or BDC position and absorb the impact energy from the piston 108. The buffer 330 is configured to evenly distribute the impact force of the piston 108 across the buffer 330 when the piston 108 is rapidly decelerated when reaching the BDC position. The buffer 330 may be formed of any suitable elastic material (e.g., rubber).

[0066] refer to Figures 8 to 10 , details of the driver blade 112 are shown. As shown, the second end 120 includes a hole 346 sized and shaped to receive a pin 322 therethrough to attach the driver blade 112 to the piston 108. The driver blade 112 further includes a driver tip at the first end 116 of the driver blade 112. The driver tip is configured to strike and drive the fastener 62. Here, the driver tip is generally cylindrical and defines a strike face 118 having a maximum dimension of 10 mm. In other embodiments, the maximum dimension of the strike face 118 can be in the range of 5 mm to 15 mm.

[0067] The driver blade 112 includes a plurality of axially spaced drive teeth 350 on a first side of the driver blade 112 between the first end 116 and the second end 120 of the driver blade 112. As described in more detail below, the drive teeth 350 are configured to engage the lift mechanism 140 to move the driver blade 112 to the TDC (i.e., retracted or ready) position. The driver blade 112 also includes a plurality of axially spaced locking tabs 354 on a second side of the driver blade 112 opposite the first side of the driver blade 112 and opposite the teeth 350, between the first end 116 and the second end 120 of the driver blade 112. As described in more detail below, the locking tabs 354 are configured to engage the latch actuator assembly 160 to hold the driver blade 112 in the TDC (i.e., retracted or ready) position before being released to the BDC (i.e., extended or driven) position. The driver blade 112 includes a guide groove 358 formed along the length of the driver blade 112 from the first end 116 to the second end 120. Fig.10 The driver blade 112 is also shown to include an actuator tooth 362 extending from the driver blade 112 in a direction perpendicular to the drive tooth 350. After the fastener driver 10 is fired, as the driver blade 112 returns to the TDC (i.e., retracted or ready) position, the actuator tooth 362 actuates the fastener delivery mechanism 74 and loads the fastener into the nosepiece 54, as described in detail below.

[0068] Figures 11 to 13 Details of the lift mechanism 140 are depicted. As shown, the lift mechanism 140 includes a lifter 380 having a body and a plurality of drive pins 396 supported on the body. The body includes a central hub 384 having an upper disc 388 and a lower disc 392 extending radially outward from the central hub 384 and axially spaced from each other. A plurality of drive pins 396 are mounted within the lifter 380. Each drive pin 396 is coupled to both the upper disc 388 and the lower disc 392. The drive pins 396 include a drive pin 396' that is configured to engage a drive tooth 350' (e.g., a lowermost drive tooth) that is closest to the first end 116 of the driver blade 112 in the ready position. About Fig.13, the drive pin 396' is oriented along an imaginary circle coaxial with the axis of rotation of the lifter 380 and having a fifth diameter D5, which in this case is about 26.62 mm. In other embodiments, the fifth diameter D5 can be in the range of about 18 mm to 40 mm. The remaining drive pins 396 are oriented along an imaginary circle coaxial with the axis of rotation of the lifter 380 and having a sixth diameter D6 greater than the fifth diameter D5. In this case, the sixth diameter measures about 28.25 mm. In other embodiments, the fifth diameter D6 can be in the range of about 18 mm to 40 mm. Due to the reduced stroke length L1, the diameters D5 and D6 of the lifter 380 are also reduced relative to the lifters of conventional drives. In the illustrated embodiment, there are six drive pins 396, each corresponding to an aperture 398 in the lifter 380. Additionally, there are apertures 390 positioned between adjacent drive pins 396. In the illustrated embodiment, there are five apertures 390. In other embodiments, there may be more or fewer drive pins 396 / apertures 398 and more or fewer apertures 399. In the illustrated embodiment, the drive pins 396' are positioned at an angle a1 of about 51 degrees relative to the adjacent drive pins 396. Additionally, the remaining drive pins 396 are positioned at an angle a2 of about 46 degrees relative to the adjacent drive pins 396. In other embodiments, these angles a1 and a2 may be in the range of about 40 degrees to about 60 degrees. Although in the illustrated embodiment, the lifter 380 includes a body and a drive pin 396, in other embodiments, the lifter 380 may be an integrally formed piece.

[0069] The lifter 380 further includes a cam 400 extending upwardly from the upper plate 388. As described in detail below, the cam 400 is configured to actuate the latch actuator assembly 160. In particular, the cam 400 is configured to actuate the latch actuator assembly 160 at an angle A1 ( Fig.13 ) engages and actuates the latch actuator assembly 160. In certain aspects, the angle A1 is in the range of about 20 degrees to about 45 degrees. In the illustrated embodiment, the angle A1 measures about 25.3 degrees. It should be understood that the angle A1 can be within a range between the maximum and minimum values ​​of A1 disclosed herein, and includes any of the maximum and minimum values.

[0070] A magnet holder 404 is disposed adjacent to the upper disk 388, and a bolt 408 extends through the magnet holder 404, securing the lift mechanism 140 to a drive shaft 410 ( Figure 3 ). Further, the magnet 412 is disposed in a recess 414 of the magnet holder 404, and the magnet 412 is disposed on the sensor bracket 180 ( Figure 3 ) to control the motor 144 ( Figure 3) and a first sensor 184 (operable coupled thereto for operation of the lifting mechanism 140 Figure 3 ) detection. Therefore, when the magnet holder 404 is Fig.12 When mounted on the lifter 380, the magnet 412 is nested within the cam 400. The bolt 408 extends through the hole 422 in the magnet holder 404 and the hole 426 in the lifter 380 and threadedly engages the drive shaft 410, which is keyed to the hole 426 in the lifter 380 to prevent the lifter 380 from rotating relative to the motor shaft.

[0071] Reference again Fig.12 , the lower plate 392 of the lifter 380 is formed with a peripheral recess 430 below the radial position of the cam 400 on the upper plate 388 of the lifter 380, such that the peripheral recess 430 overlaps the cam 400 in the axial direction. As described in detail below, when the fastener driver 10 is fired and the driver blade 112 is moved to the BDC (i.e., extended or driven) position into the nose 54 to force the fastener out therefrom and into the workpiece, the peripheral recess 430 provides clearance for the driver blade 112.

[0072] Fig.11 and Figure 14 to Figure 15 Details of the latch actuator assembly 160 are shown. As illustrated, the latch actuator assembly 160 includes a base plate 450 formed with a semi-cylindrical recess 454 that is sized and shaped to fit around a lift mechanism 140, such as around a lifter 380. A spring retainer 458 extends from an upper surface of the base plate 450 of the latch actuator assembly 160. The spring retainer 458 is configured to receive an end of a spring 460 ( Figure 5 ), which is mounted in a compressed form between the spring retainer 458 of the latch actuator assembly 160 and the workpiece contact bracket 200 ( Figure 5 ) to bias the workpiece contact bracket 200 along the nose bridge 54 away from the spring retainer 458.

[0073] The latch actuator assembly 160 includes a generally rectangular shuttle housing 462 disposed on an upper surface of the base plate 450. It should be understood that the shuttle housing 462 can be integrally formed with the base plate 450. As shown, the shuttle housing 462 includes a longitudinal axis 466 formed at an angle A2 relative to the longitudinal axis 470 of the base plate 450. In a particular aspect, the angle A2 measures about 60 degrees to about 75 degrees. In the illustrated embodiment, the angle A2 is about 67 degrees. It should be understood that the angle A2 can be within a range between the maximum and minimum values ​​of A2 disclosed herein, and include any of the maximum and minimum values.

[0074] The shuttle housing 462 includes a slot 472 formed in the upper surface of the shuttle housing 462 at least partially along the length of the upper surface and along the longitudinal axis 466. The shuttle housing 462 also includes a recess 476 that is sized and shaped to slidably or movably receive the shuttle 480 therein. Fig.14 As shown, the first shuttle spring 484 and the second shuttle spring 488 are arranged to be parallel to each other and parallel to the longitudinal axis 466 of the shuttle housing 462, between the closed end 492 of the shuttle housing 462 (and the recess 476) and the shuttle member 480 in compression within the recess 476 to bias the shuttle member 480 outward from the recess 476 and the open end 496 of the shuttle housing 462 (and the recess 476) so that a portion of the shuttle member 480 extends into the semi-cylindrical recess 454.

[0075] like Fig.15 As shown, the latch actuator assembly 160 further includes a guide rib 500 extending vertically from the lower surface of the base plate 450. The guide rib 500 extends along the entire length of the base plate 450 and is parallel to the longitudinal axis 470. The size and shape of the guide rib 500 are determined to be aligned with the guide groove 358 ( Figures 8 to 9 ) and acts as a guide for the driver blade as the driver blade 112 moves between the TDC (ie, retracted or ready) position and the BDC (ie, extended or driven) position.

[0076] Figure 14 to Figure 15 It is further shown that the base plate 450 is formed with a curved slot 504 extending through the base plate 450 (i.e., extending from the upper surface to the lower surface). As the shuttle 480 moves linearly within the shuttle housing 462, a portion of the latch assembly 508 engages with the curved slot 504 and rotates therein. Fig.14 As shown, the latch assembly 508 includes a latch 512 including a first end 516 and a second end 520. A support post 524 extends vertically in a first direction from a lower surface of the latch 512. An actuator post 528 extends vertically from the upper surface in a second direction opposite to the first direction and opposite to the support post 524.

[0077] When the latch actuator assembly 160 is assembled, the actuator post 528 extends through the curved slot 504 and into the hole 532 formed in the shuttle 480. The support post 524 is configured to cooperate with and rotate within a hole (not shown) formed in the nosepiece 54. Therefore, as the shuttle 480 moves linearly back and forth within the shuttle housing 462, the latch assembly 508 rotates about the support post 524 and the second end 520 of the latch 512 moves back and forth. As described in more detail below, the lift mechanism 140 rotates to actuate the latch actuator assembly 160.

[0078] The operation of the lift mechanism 140 and the latch actuator assembly 160 to fire and reset the driver blade 112 is as follows. In the ready position, the motor 144 is de-energized and stationary. The drive pin 396' engages with the lowermost drive tooth 350'. The cam 400 on the lifter 380 is adjacent to and contacts the end of the shuttle 480 extending from the open end 496 of the shuttle housing 462. As shown, in the ready position, the magnet 412 in the magnet holder 404 on the lifter 380 is in a position to be sensed by the first sensor 184 in the sensor bracket 180. Moreover, the second end 520 of the latch 512 engages with one of the locking protrusions 354 on the driver blade 112 (e.g., the locking protrusion 354' closest to the first end 116 of the driver blade 112). Therefore, the latch 512 overcomes the force of the gas spring (i.e., the compressed gas in the storage chamber cylinder 100) to keep the driver blade 112 locked in the TDC (i.e., retracted or ready) position.

[0079] When the user actuates the trigger 50 of the fastener driver 10, the motor 144 is energized and operates from Figure 5 and Fig.11 4, 488 and also rotates the lifter 380 of the lift mechanism 140 counterclockwise. As the lifter 380 rotates, the cam 400 on the lifter 380 pushes the shuttle 480 into the shuttle housing 462 against the force of the springs 484, 488. As the shuttle 480 moves into the shuttle housing 462, it pushes the actuator post 528 along the curved slot 504 formed in the base plate 450 of the latch actuator assembly 160, and the latch assembly 508 rotates on the support post 524 within the hole 536 of the nosepiece 54. The second end 520 of the latch 512 rotates away from the driver blade 112 into a position where the latch 512 disengages the locking protrusion 354 and remains away from the locking protrusion 354.

[0080] As disclosed herein, as the lifter 380 rotates, the cam 400 remains in contact with the shuttle 480 at an angle A1 that is within a range between 20° and 45° (and including 20° and 45°). The shape of the cam 400 keeps the shuttle 480 from being dialed into the shuttle housing 462, which in turn keeps the second end 520 of the latch 512 rotated to a position away from the driver blade 112 and away from the locking protrusion 354. As the lifter 380 continues to rotate counterclockwise to the firing position, the latch 512 remains out of contact with the locking protrusion 354, while the peripheral notch 430 on the lower disk 392 of the lifter 380 remains away from the drive tooth 350. In the firing position, the drive pin 396 on the lifter 380 is away from the drive tooth 350 on the driver blade 112. As a result, the driver blade 112 is released and the force of the compressed gas behind the piston 108 and within the reservoir cylinder 100 drives the piston 108 and the driver blade 112 into the nosepiece 54 toward the BDC (i.e., extended or driven position) to expel the fastener from the fastener driver 10 and drive the fastener into the workpiece.

[0081] After the driver blade 112 is released and fired by the compressed gas in the reservoir cylinder 100, the motor 144 continues to rotate the lift mechanism 140 counterclockwise. When the cam 400 rotates past the latch actuator assembly 160, the shuttle 480 is released and the springs 484, 488 bias the shuttle 480 toward the lift 380, and the second end 520 of the latch 512 moves toward the driver blade to a position where the latch 512 can engage one of the locking protrusions 354 if the motor 144 fails. As the lift 380 rotates, the drive pins 396 sequentially engage the drive teeth 350 on the driver blade 112 to move the driver blade 112 in a direction away from the nose 54 and return the driver blade 112 to the TDC (i.e., retracted or ready) position. Specifically, one of the drive pins 396" engages the uppermost drive tooth 350", while the other drive pins 396 sequentially engage each corresponding tooth 350. As the lifter 380 returns the driver blade 112 to the TDC (i.e., retracted or ready) position, the piston 108 compresses the gas within the reservoir cylinder 100. Also, as the driver blade 112 returns to the TDC (i.e., retracted or ready) position, as it passes each locking tab 354, the locking tab 354 rotates the latch 512 away from the driver blade 112 against the springs 484, 488 that return the latch 512 toward the driver blade 112. The motor 144 continues to rotate the lift mechanism 140 counterclockwise until the driver blade 112 returns to the TDC (i.e., retracted or ready) position and the magnet 412 on the lifter 380 is detected by the first sensor 184 in the sensor bracket 180 to send a signal to the controller to de-energize the motor 144. The drive pin 396' again engages the lowermost drive tooth 350', and the second end 520 of the latch 512 engages the locking projection 354' closest to the first end 116 of the driver blade 112 to hold the driver blade 112 in the ready position until the trigger 50 is again pressed by the user. It should be understood that the illustrated fastener driver 10 operates on the gas spring principle using the lift mechanism 140 and the piston 108 to further compress the gas within the driver cylinder 104 and the reservoir cylinder 100.

[0082] Figures 16 to 19Details of the fastener delivery mechanism 74 are shown. As shown, the fastener delivery mechanism 74 includes a support column 604 slidably disposed within a bracket 608 on the nose bridge 54. The support column 604 includes a proximal end 612 and a distal end 616. A spring 620 is mounted in compression adjacent the proximal end 612 of the support column 604 to bias the support column 604 toward a barrel 624 of the nose bridge 54. An advancer 628 is mounted on the distal end 616 of the support column 604 via a hinge pin 632. A torsion spring 636 is disposed on the hinge pin 632 to bias the advancer 628 about the hinge pin 632 toward the nose bridge 54.

[0083] The fastener delivery mechanism 74 also includes a first rocker arm 640 rotatably mounted on the nosepiece 54 via a first post 644 (e.g., a threaded fastener). The first rocker arm 640 includes a forked end 648 that fits around a transverse post 652 on the distal end of the support post 604. As shown, the fastener delivery mechanism 74 also includes a second rocker arm 656 rotatably mounted on the nosepiece 54 via a second post 660 and mounted to the first rocker arm 640 via a third post 664. A spring-loaded actuator 668 is mounted on the free end of the second rocker arm 656. The spring-loaded actuator 668 can rotate in only a single direction toward the delivery end of the fastener driver 10 against the force of a spring that returns it to a vertical position.

[0084] refer to Fig.18 and Fig.19 , showing the pusher 628 in more detail. The pusher 628 includes a body 670 including a first end 674, a second end 678, a top 682, and a bottom 686. A first pair of hinge cylinders 690 extend from the bottom 686 of the body 670 near the first end 674 in a generally downward direction. A second pair of hinge cylinders 694 extend from the bottom 686 of the body 670 near the second end 678 in a generally downward direction. The pairs of hinge cylinders 690, 694 are spaced apart from each other to form an opening adapted for the distal end 616 of the support column 604. The hinge pin 632 is adapted to pass through the two pairs of hinge cylinders 690, 694 and a hole formed in the distal end 616 of the support column 604.

[0085] As shown, the pusher 628 includes a first ramp structure 700 extending from the bottom 686 of the body 670 toward the top 682. The first ramp structure 700 is narrowest at the bottom 686 and widest at the top 682. The first ramp structure 700 terminates in a first groove 704 near the top 682, which is sized and shaped to receive a portion of a fastener therein. The pusher 628 includes a second ramp structure 710 extending from the bottom 686 of the body 670 toward the top 682. The second ramp structure 710 is narrowest at the bottom 686 and widest at the top 682. The second ramp structure 710 terminates in a second groove 714 near the top 682, which is sized and shaped to receive a portion of a fastener therein. The pusher 628 further includes a third ramp structure 720 extending from the bottom 686 of the body 670 toward the top 682. The third ramp structure 720 is narrowest at the bottom 686 and widest at the top 682. The third ramp structure 720 terminates in a third recess 724 adjacent the top 682 that is sized and shaped to receive a portion of a fastener therein.

[0086] When the driver blade 112 is fired or moved to the BDC (i.e., extended or driven) position, the actuator tooth 362 on the driver blade 112 moves past the spring-loaded actuator 668, which briefly rotates downward before the spring force returns it to the upright position. As the driver blade 112 is returned to the TDC (i.e., retracted or ready) position by the lift mechanism 140, as described herein, the actuator tooth 362 on the driver blade 112 engages the spring-loaded actuator 668 to cause the second rocker arm 656 to rotate downward. Fig.17 This causes the first rocker arm 640 to rotate counterclockwise. Fig.17 The pusher 628 is rotated clockwise as viewed in the figure, and the support column 604 is moved away from the barrel 624 of the nosepiece 54. As the support column 604 moves away from the barrel 624, the ramp structures 700, 710, 720 on the pusher 628 move against the fastener to be loaded and rotate the pusher 628 outward from the fastener, overcoming the spring force provided by the torsion spring 636, until the grooves 704, 714, 724 are aligned with the fastener to be loaded. When the grooves 704, 714, 724 are aligned with the fastener, the torsion spring 636 biases the pusher 628 toward the nosepiece 54 so that the grooves 704, 714, 724 fit around the fastener. The spring 620 then biases the support post 604 in an upward direction toward the barrel 624 of the nosepiece 54 and loads the fasteners held within the recesses 704, 714, 724 of the pusher 628 into the barrel 624 in the ready position to be ejected from the fastener driver 2000 and driven into the workpiece when the trigger 50 is actuated.

[0087] As described above, the reduced stroke length L1 of the driver blade 112 achieves a reduced size of the lifter 380. That is, the drive pin 396 can be oriented on an imaginary circle with reduced diameters D5, D6. The reduced size of the lifter 380 allows the operation of the motor 144 to be more efficient. That is, the reduced size of the lifter 380 reduces the required lifter torque and gear train load while maintaining the effectiveness of the fastener driver 10. In addition, the reduced size of the lifter 380 and the reduced size of the piston 108 reduce the size and weight of the fastener driver while the fastener driver 10 has the same or better performance. In the illustrated embodiment, the lifter torque is measured to be approximately 165in-lbs. Additionally, the drive cycle of the fastener 10 is also shorter. Because the motor 144 is more efficient, the user can fire 4.3 nails per second, which is more than the number of nails per second that can be driven by a conventional driver. Accordingly, the driver blade 112 is configured to reciprocate between the TDC position and the BDC position at a frequency of at least about 2 hertz (Hz). In other embodiments, the driver blade 112 is configured to reciprocate between the TDC position and the BDC position at a frequency of about 3.25 Hz. In other embodiments, the driver blade 112 is configured to reciprocate between the TDC position and the BDC position at a frequency of about 2 Hz to about 5 Hz. Moreover, when reciprocating at a frequency of at least 3.25 Hz, the stroke length L1 of the piston 108 between the TDC position and the BDC position is about 70 mm or less. Moreover, when reciprocating at a frequency of at least 3.25 Hz, the stroke length L1 of the piston 108 between the TDC position and the BDC position is about 65 mm or greater. Moreover, when reciprocating at a frequency of at least 2 Hz, the stroke length L1 of the piston 108 between the TDC position and the BDC position is about 65 mm or greater. Moreover, because the motor 144 is more efficient, the driver 10 can drive more fasteners without the thermal shutdown of the motor 144. That is, the temperature of the motor 144 can be measured (e.g., by a sensor) and monitored by the circuit board 148. When the temperature rises above a predetermined threshold temperature, the circuit board 148 will no longer allow the motor 144 to be driven, which results in a thermal shutdown of the motor.

[0088] In the illustrated embodiment, the driver can drive at least 1560 nails without thermal shutdown. In some embodiments, the driver can drive at least 480 nails without thermal shutdown. In some embodiments, the driver can drive at least 500 nails without thermal shutdown. In some embodiments, the driver can drive at least 700 nails with thermal shutdown. In some embodiments, the driver can drive at least 800 nails with thermal shutdown. In some embodiments, the driver can drive at least 900 nails with thermal shutdown. In some embodiments, the driver can drive at least 1000 nails without thermal shutdown. In some embodiments, the driver can drive at least 1100 nails without thermal shutdown. In some embodiments, the driver can drive at least 1200 nails without thermal shutdown. In some embodiments, the driver can drive at least 1300 nails without thermal shutdown. In some embodiments, the driver can drive at least 1400 nails without thermal shutdown. In some embodiments, the driver can drive at least 1500 nails without thermal shutdown.

[0089] The drive unit is configured to remain continuously activated for more than 100 seconds when the driver blade is reciprocated at a frequency of at least 3.25 Hz. The drive unit is configured to remain continuously activated for more than 100 seconds when the driver blade is reciprocated at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for more than 360 seconds when the driver blade is reciprocated at a frequency of at least 3.25 Hz. The drive unit is configured to remain continuously activated for more than 360 seconds when the driver blade is reciprocated at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for 100 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 3.25 Hz. The drive unit may be configured to remain continuously activated for 100 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for 150 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 3.25 Hz. The drive unit may be configured to remain continuously activated for 150 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for 200 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 3.25 Hz. The drive unit may be configured to remain continuously activated for 200 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for 250 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 3.25 Hz. The drive unit may be configured to remain continuously activated for 250 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for 300 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 3.25 Hz. The drive unit may be configured to remain continuously activated for 300 seconds to 360 seconds when the driver blade is reciprocated at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for 100 to 200 seconds while reciprocating the driver blade at a frequency of at least 3.25 Hz. The drive unit may be configured to remain continuously activated for 100 to 200 seconds while reciprocating the driver blade at a frequency of at least 2 Hz. The drive unit may be configured to remain continuously activated for 150 to 300 seconds while reciprocating the driver blade at a frequency of at least 3.25 Hz. The drive unit may be configured to remain continuously activated for 150 to 300 seconds while reciprocating the driver blade at a frequency of at least 2 Hz.

[0090] 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.

[0091] Various features of the invention are set forth in the appended claims.

Claims

1. A powered fastener driver, characterized in that: The powered fastener driver includes: case; an inner cylinder, the inner cylinder being located in the housing; a piston movable within the inner cylinder from a top dead center position to a driven position or a bottom dead center position, the piston having a diameter less than 45 mm and a stroke length of the piston between the top dead center position and the bottom dead center position measuring greater than 60 mm and less than 90 mm; a driver blade attached to the piston for movement with the piston along the drive axis from the top dead center position toward the bottom dead center position to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end, and a plurality of drive teeth extending from one side between the first end and the second end; a lifter operable to move the piston and the driver blade from the bottom dead center position toward the top dead center position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth, and wherein the drive pins are positioned on the body along an imaginary circle coaxial with the axis of rotation of the lifter and having a diameter less than 40 mm; and A drive unit is operably coupled to the lifter to provide torque to the lifter, thereby rotating the lifter.

2. The powered fastener driver of claim 1, wherein: The powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

3. The powered fastener driver of claim 2, wherein: The powered fastener driver further includes an outer reservoir cylinder positioned within the housing and including pressurized gas in fluid communication with the inner cylinder, wherein the outer reservoir cylinder includes a first end and a second end opposite the first end, and wherein the second end of the outer reservoir cylinder is not concentric with the first end of the outer reservoir cylinder.

4. The powered fastener driver of claim 3, wherein: The inner cylinder includes a first end and a second end opposite the first end, and wherein the first end of the inner cylinder is coupled to the first end of the outer reservoir cylinder.

5. The powered fastener driver of claim 4, wherein: The outer reservoir cylinder defines a volume, wherein a first portion of the volume is defined on a first side of the drive axis and a second portion of the volume is defined on a second side of the drive axis, and wherein the second portion is larger than the first portion.

6. The powered fastener driver of claim 5, wherein: The housing defines a head portion, a drive unit housing portion, and a handle portion spaced apart from the drive unit housing portion, and wherein the second portion of the volume is at least partially positioned between the drive unit housing portion and the handle portion.

7. The powered fastener driver of claim 1, wherein: In response to continued activation of the drive unit to rotate the lifter, the driver blade is configured to reciprocate between the top dead center position and the bottom dead center position at a frequency of at least 2 Hertz.

8. The powered fastener driver of claim 7, wherein: The piston has a stroke length of 65 mm or greater between the top dead center position and the bottom dead center position when reciprocating at a frequency of at least 2 Hz.

9. The powered fastener driver of claim 8, wherein: The drive unit is configured to remain continuously activated while reciprocating the driver blade at a frequency of at least 2 Hz for more than 100 seconds.

10. The powered fastener driver of claim 1, wherein: The piston comprises a circumferential groove, wherein a sealing ring is positioned within the circumferential groove, and wherein the sealing ring has a thickness of 2 mm to 5.5 mm.

11. The powered fastener driver of claim 10, wherein: The sealing ring is a star-shaped ring.

12. A powered fastener driver, characterized in that: The powered fastener driver includes: case; an inner cylinder, the inner cylinder being located in the housing; a piston movable within the inner cylinder from a top dead center position to a driven position or a bottom dead center position, the piston having a circumferential groove, a diameter less than 45 mm, and a stroke length of the piston between the top dead center position and the bottom dead center position measuring greater than 60 mm and less than 90 mm; a sealing ring positioned within the circumferential groove and configured to engage an inner surface of the inner cylinder, the sealing ring having a thickness of 2 mm to 5.5 mm; a driver blade attached to the piston for movement with the piston along the drive axis from the top dead center position toward the bottom dead center position to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end, and a plurality of drive teeth extending from one side between the first end and the second end; a lifter operable to move the piston and the driver blade from the bottom dead center position toward the top dead center position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; and A drive unit is operably coupled to the lifter to provide torque to the lifter, thereby rotating the lifter.

13. The powered fastener driver of claim 12, wherein: The sealing ring is a star-shaped ring.

14. The powered fastener driver of claim 12, wherein: The circumferential groove in the piston is a first circumferential groove, and wherein the piston further includes a second circumferential groove and a third circumferential groove, a first guide ring positioned in the second circumferential groove and a second guide ring positioned in the third circumferential groove, each of the first guide ring and the second guide ring being configured to engage the inner surface of the inner cylinder.

15. The powered fastener driver of claim 12, wherein: The powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

16. A powered fastener driver, characterized in that: The powered fastener driver includes: case; an inner cylinder, the inner cylinder being located in the housing; an outer reservoir cylinder positioned within the housing and comprising pressurized gas in fluid communication with the inner cylinder, wherein the outer reservoir cylinder comprises a first end and a second end opposite the first end, and wherein the second end of the outer reservoir cylinder is not concentric with the first end of the outer reservoir cylinder; a piston movable within the inner cylinder from a top dead center position to a driven position or a bottom dead center position, the piston having a circumferential groove, a diameter less than 45 mm, and a stroke length of the piston between the top dead center position and the bottom dead center position measuring greater than 60 mm and less than 90 mm; a sealing ring positioned within the circumferential groove and configured to engage an inner surface of the inner cylinder; a driver blade attached to the piston for movement with the piston along the drive axis from the top dead center position toward the bottom dead center position to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end, and a plurality of teeth extending from one side between the first end and the second end; a lifter operable to move the piston and the driver blade from the bottom dead center position toward the top dead center position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; and a drive unit operably coupled to the lifter to provide torque to the lifter to rotate the lifter; wherein the outer reservoir cylinder defines a volume, wherein a first portion of the volume is defined on a first side of the drive axis and a second portion of the volume is defined on a second side of the drive axis, and wherein the second portion is larger than the first portion, and Wherein the housing defines a head portion, a drive unit housing portion, and a handle portion spaced apart from the drive unit housing portion, and wherein the second portion of the volume is at least partially positioned between the drive unit housing portion and the handle portion.

17. The powered fastener driver of claim 16, wherein: The drive pins are positioned on the body along an imaginary circle coaxial with the axis of rotation of the lifter and having a diameter less than 40 mm.

18. The powered fastener driver of claim 17, wherein: The powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

19. The powered fastener driver of claim 16, wherein: The inner cylinder includes a first end and a second end opposite the first end, and wherein the first end of the inner cylinder is coupled to the first end of the outer reservoir cylinder.

20. The powered fastener driver of claim 16, wherein: The circumferential groove in the piston is a first circumferential groove, and wherein the piston further includes a second circumferential groove and a third circumferential groove, a first guide ring positioned in the second circumferential groove and a second guide ring positioned in the third circumferential groove, each of the first guide ring and the second guide ring being configured to engage the inner surface of the inner cylinder.

21. A powered fastener driver, characterized in that: The powered fastener driver includes: case; a nose bridge extending from the housing; an inner cylinder, the inner cylinder being located in the housing; a piston movable within the inner cylinder from a top dead center position to a driven position or a bottom dead center position, the piston having a stroke length of the piston between the top dead center position and the bottom dead center position measured to be greater than 60 mm and less than 90 mm; a driver blade attached to the piston for movement with the piston along the drive axis from the top dead center position toward the bottom dead center position to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end, and a plurality of drive teeth extending from one side between the first end and the second end; a lifter operable to move the piston and the driver blade from the bottom dead center position toward the top dead center position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; a drive unit operably coupled to the lifter to provide torque to the lifter to rotate the lifter; a canister magazine coupled to the nosepiece and into which the array of fasteners can be received; and A fastener delivery mechanism is disposed adjacent the nose bridge for individually delivering the aligned fasteners within the canister magazine to the driver channels in the nose bridge.

22. The powered fastener driver of claim 21, wherein: The powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

23. The powered fastener driver of claim 22, wherein: The powered fastener driver further includes an outer reservoir cylinder positioned within the housing and including pressurized gas in fluid communication with the inner cylinder, wherein the outer reservoir cylinder includes a first end and a second end opposite the first end, and wherein the second end of the outer reservoir cylinder is not concentric with the first end of the outer reservoir cylinder.

24. The powered fastener driver of claim 23, wherein: The inner cylinder includes a first end and a second end opposite the first end, and wherein the first end of the inner cylinder is coupled to the first end of the outer reservoir cylinder.

25. The powered fastener driver of claim 24, wherein: The outer reservoir cylinder defines a volume, wherein a first portion of the volume is defined on a first side of the drive axis and a second portion of the volume is defined on a second side of the drive axis, and wherein the second portion is larger than the first portion.

26. The powered fastener driver of claim 25, wherein: The housing defines a head portion, a drive unit housing portion, and a handle portion spaced apart from the drive unit housing portion, and wherein the second portion of the volume is at least partially positioned between the drive unit housing portion and the handle portion.

27. The powered fastener driver of claim 21, wherein: In response to continued activation of the drive unit to rotate the lifter, the driver blade is configured to reciprocate between the top dead center position and the bottom dead center position at a frequency of at least 2 Hertz.

28. The powered fastener driver of claim 27, wherein: The piston has a stroke length of 65 mm or greater between the top dead center position and the bottom dead center position when reciprocating at a frequency of at least 2 Hz.

29. The powered fastener driver of claim 28, wherein: The drive unit is configured to remain continuously activated while reciprocating the driver blade at a frequency of at least 2 Hz for more than 100 seconds.

30. The powered fastener driver of claim 21, wherein: The piston comprises a circumferential groove, wherein a sealing ring is positioned within the circumferential groove, and wherein the sealing ring has a thickness of 2 mm to 5.5 mm.

31. The powered fastener driver of claim 21, wherein: The piston has a diameter of less than 45 mm, and wherein the drive pins are positioned on the body along an imaginary circle coaxial with the axis of rotation of the lifter and having a diameter of less than 40 mm.

32. A powered fastener driver, characterized in that: The powered fastener driver includes: case; a nose bridge extending from the housing; a workpiece contact support at least partially surrounding the nose bridge, wherein the workpiece contact support is movable relative to the nose bridge; an inner cylinder, the inner cylinder being located in the housing; a piston movable within the inner cylinder from a top dead center position to a driven position or a bottom dead center position, the piston having a stroke length of the piston between the top dead center position and the bottom dead center position measured to be greater than 60 mm and less than 90 mm; a driver blade attached to the piston for moving with the piston along the drive axis from the top dead center position toward the bottom dead center position to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end, a plurality of drive teeth extending from one side between the first end and the second end, and an actuator tooth; a lifter operable to move the piston and the driver blade from the bottom dead center position toward the top dead center position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; a drive unit operably coupled to the lifter to provide torque to the lifter to rotate the lifter; and A fastener delivery mechanism is disposed adjacent the nose bridge, wherein the fastener delivery mechanism is actuated by the actuator teeth on the driver blade to load fasteners into the nose bridge as the driver blade returns to the ready position.

33. The powered fastener driver of claim 32, wherein: The piston includes a first circumferential groove, a second circumferential groove and a third circumferential groove, and wherein a sealing ring is positioned in the first circumferential groove and is configured to engage an inner surface of the inner cylinder, a first guide ring is positioned in the second circumferential groove, and a second guide ring is positioned in the third circumferential groove, and each of the first guide ring and the second guide ring is configured to engage an inner surface of the inner cylinder.

34. The powered fastener driver of claim 32, wherein: The powered fastener driver further includes a source of pressurized gas in fluid communication with the inner cylinder, wherein an impact force of the pressurized gas acting on the piston at the top dead center position is greater than 200 lbf.

35. The powered fastener driver of claim 32, wherein: The piston has a diameter of less than 45 mm, and wherein the drive pins are positioned on the body along an imaginary circle coaxial with the axis of rotation of the lifter and having a diameter of less than 40 mm.

36. The powered fastener driver of claim 32, wherein: The fastener delivery mechanism includes a pusher mounted on a support post, and when the actuator teeth actuate the delivery mechanism, the pusher moves into contact with the fastener, and a spring biases the support post and the pusher toward the nose bridge to load the fastener into the barrel of the nose bridge.

37. The powered fastener driver of claim 36, wherein: The fastener delivery mechanism includes a torsion spring that biases the pusher on the support column toward the fastener as the pusher moves along the fastener.

38. The powered fastener driver of claim 37, wherein: The pusher includes at least one ramp surface terminating in at least one groove, and as the pusher moves against the fastener, the at least one ramp surface pushes the pusher away from the fastener until the at least one groove is aligned with the fastener, and biases the pusher toward the fastener until the at least one groove fits around the fastener.

39. The powered fastener driver of claim 38, wherein: The fastener delivery mechanism includes at least one rocker arm operably connected to the pusher, wherein, as the driver blade returns to the ready position, the at least one rocker arm is rotated by actuator teeth on the driver blade, and as the rocker arm rotates, the pusher moves along the fastener until the at least one groove fits around the fastener.

40. A powered fastener driver, characterized in that: The powered fastener driver includes: case; an inner cylinder, the inner cylinder being located in the housing; a piston movable within the inner cylinder from a top dead center position to a driven position or a bottom dead center position, the piston having a stroke length of the piston between the top dead center position and the bottom dead center position measured to be greater than 60 mm and less than 90 mm; a driver blade attached to the piston for movement with the piston along the drive axis from the top dead center position toward the bottom dead center position to drive a fastener into a workpiece, the driver blade comprising: a first end, a second end, and a plurality of drive teeth extending from one side between the first end and the second end, the first end being cylindrical and defining an impact surface configured to impact and drive a fastener; a lifter operable to move the piston and the driver blade from the bottom dead center position toward the top dead center position, wherein the lifter includes a body and a plurality of drive pins supported on the body, wherein each of the drive pins is configured to engage one of the drive teeth; and A drive unit is operably coupled to the lifter to provide torque to the lifter, thereby rotating the lifter.

41. The powered fastener driver of claim 40, wherein: The piston has a diameter of less than 45 mm, and wherein the drive pins are positioned on the body along an imaginary circle coaxial with the axis of rotation of the lifter and having a diameter of less than 40 mm.

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