Powered fastener driver and driver system

Abstract

A powered fastener driver and a driver system, the powered fastener driver including a driver blade movable from a top dead center position to a bottom dead center position for driving a fastener into a workpiece. The driver may include a lift assembly for providing a torque to move the driver blade from a bottom dead center position toward a top dead center position, the lift assembly including a rotary lift configured to be selectively engageable with the driver blade, the rotary lift having a plurality of lift pins and a roller disposed on at least one of the lift pins, wherein the roller comprises a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to the direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the driver blade comprises a lifting tooth having a crown disposed thereon, the crown portion is configured to engage with at least one of the plurality of cam portions.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 718,005, filed November 8, 2024, and U.S. Provisional Patent Application No. 63 / 620,242, filed January 12, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This utility model relates to a power fastener driver, and more specifically to a gas spring power fastener driver. Background Technology

[0004] Various fastener actuators are known in the art for driving fasteners (e.g., nails, thumbtacks, U-shaped nails, etc.) into a workpiece. These fastener actuators are operated using various means known in the art (e.g., compressed air generated by an air compressor, electrical energy, flywheel mechanisms, etc.) to drive the actuator blades from the top dead center position toward the bottom dead center position to strike the fastener and drive the fastener into the workpiece. Utility Model Content

[0005] In one aspect, the present invention provides a power fastener driver including a driver blade and a lifting assembly, the driver blade being movable from an upper dead center position to a lower dead center position for driving a fastener into a workpiece, the lifting assembly being used to provide torque to move the driver blade from the lower dead center position toward the upper dead center position, the lifting assembly including a rotary lifter configured to selectively engage with the driver blade, the rotary lifter having a plurality of lifting pins and a roller disposed on at least one of the lifting pins, and a motor configured to provide torque to the rotary lifter; wherein the roller includes a plurality of cam portions defined by cup-shaped recesses having a first radius oriented parallel to the rotational direction of the roller and a second radius perpendicular to the first radius, and wherein the driver blade includes lifting teeth having crowns disposed thereon, the crowns being configured to engage with at least one of the plurality of cam portions.

[0006] In some aspects, the technology described herein relates to a powered fastener driver comprising: a pressure vessel in which pressurized gas is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a driver blade coupled to move with the piston from the TDC position to the BDC position for driving a fastener into a workpiece; a lift assembly configured to selectively engage the driver blade to move the driver blade from the BDC position toward the TDC position; a housing in which the pressure vessel and the lift assembly are disposed, a first damper positioned between the pressure vessel and the housing; and a second damper positioned between the pressure vessel and the housing; wherein the first damper and the second damper are asymmetrically positioned relative to each other about a plane containing an axis along which the driver blade is movable; and wherein the first damper and the second damper are configured to dampen movement of the pressure vessel relative to the housing.

[0007] In some embodiments, the powered fastener driver further comprises a plurality of gear case bolts connecting the gear case to the motor case, the gear case bolts arranged in a gear case bolt pattern having an irregular quadrilateral shape when viewed perpendicular to a motor axis of a motor within the motor case.

[0008] In some embodiments, the quadrilateral shape includes at least one obtuse included angle greater than 90 degrees and at least one acute included angle less than 90 degrees measured between two adjacent gear case bolts and the motor axis.

[0009] In some embodiments, the lift assembly includes a rotary lifter configured to selectively engage the driver blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins, wherein the roller includes a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the driver blade includes a lift tool having a crown disposed thereon, the crown configured to engage at least one of the plurality of cam portions.

[0010] In some embodiments, the lift assembly includes a rotary lifter configured to selectively engage the driver blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins.

[0011] In some embodiments, the roller includes a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius.

[0012] In some embodiments, the driver blade includes a lift tool having a crown disposed thereon, the crown configured to engage with at least one of the plurality of cam portions.

[0013] In some aspects, the technology recited in the present utility patent relates to a powered fastener driver comprising: a pressure vessel in which pressurized gas is held; a piston movable within the pressure vessel from a top dead center (TDC) position to a bottom dead center (BDC) position by the pressurized gas; a driver blade coupled to move with the piston from the TDC position to the BDC position for driving a fastener into a workpiece; a lift assembly operable to move the driver blade from the BDC position toward the TDC position, the lift assembly including a motor positioned with a motor case and a gear train positioned within a gear case, the motor oriented along a motor axis; and a plurality of gear case bolts connecting the gear case and the motor case, the gear case bolts arranged in a gear case bolt pattern having an irregular quadrilateral shape when viewed perpendicular to the motor axis; wherein the quadrilateral shape includes at least one obtuse included angle greater than 90 degrees and at least one acute included angle less than 90 degrees measured between two adjacent gear case bolts and the motor axis.

[0014] In some embodiments, the powered fastener driver further includes a housing defining an inner surface within which the lift assembly is positioned, the housing including a protrusion extending inwardly from the inner surface, and a tool cartridge coupled to the housing by a tool cartridge fastener, the tool cartridge fastener engaging a tool cartridge fastener receiver in the protrusion.

[0015] In some embodiments, the tool cartridge includes a tool cartridge aperture that receives the tool cartridge fastener, the tool cartridge aperture positioned at an intermediate location between a proximal end of the tool cartridge and an opposing distal end of the tool cartridge, the proximal end of the tool cartridge feeding fasteners in alignment with the driver blade.

[0016] In some aspects, the technology described herein relates to a powered fastener driver system comprising: a powered fastener driver comprising a pressure vessel, a pressurized gas held therein; a piston, the piston being movable within the pressure vessel from a top dead center (TDC) position to a bottom dead center (BDC) position by the pressurized gas; a driver blade, the driver blade being coupled to move with the piston from the TDC position to the BDC position for driving a fastener into a workpiece; and a fill port in fluid communication with the pressure vessel, the pressurized gas being delivered into the pressure vessel through the fill port, the fill port comprising a first connector; a first fill adapter comprising a first adapter attachable with the first connector of the fill port to supply the pressurized gas from an external fluid supply to the pressure vessel; and a second fill adapter comprising a second adapter different from the first adapter and incompatible with the first connector of the fill port, thereby preventing the second fill adapter from supplying the pressurized gas from the external fluid supply to the pressure vessel.

[0017] In some embodiments, the powered fastener driver is one of a first set of powered fastener drivers, each of the powered fastener drivers having the first connector.

[0018] In some embodiments, the powered fastener driver system further comprises a second powered fastener driver having a second piston pressure vessel defining a second pressure vessel, and a second fill port coupled to the second pressure vessel, the second fill port being in communication with the second pressure vessel, the second fill port comprising a second connector attachable with the second adapter of the second fill adapter to supply the pressurized gas from the external fluid supply to the second pressure vessel.

[0019] In some embodiments, the powered fastener driver further comprises a fitting engaging the fill port, the fitting being coupled to the pressure vessel and defining a bore, an outer axial end surface, and a radial outer surface.

[0020] In some embodiments, the first fill adapter comprises a first adapter thread defining the first adapter, a radially inwardly extending shoulder, the shoulder being contactable with the outer axial end surface, and an adapter tip, the adapter tip being openable of a valve in the fill port when the first adapter and the first connector are engaged.

[0021] In some embodiments, the powered fastener driver system further comprises a fill adapter seal between the radial outer surface of the fitting and a seal receiver on a radial inner surface of the first fill adapter.

[0022] In some aspects, the technology recited in the present summary relates to a powered fastener driver comprising: a housing comprising an intake region having an air flow inlet, an exhaust region having an air flow outlet, a cylinder portion, and a motor containment portion; a pressure vessel in which pressurized gas is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a driver blade coupled to move with the piston from the TDC position to the BDC position for driving a fastener into a workpiece; a motor positioned within the motor containment portion and configured to provide torque to move the driver blade from the BDC position toward the TDC position; a fan coupled to the motor, the fan configured to generate a cooling air flow from the air flow inlet to the air flow outlet when the motor is activated; and a partition positioned within the housing between the motor and the motor containment portion to separate the intake region from the exhaust region and to block the cooling air flow expelled from the fan in the exhaust region from passing back into the intake region.

[0023] In some embodiments, the housing further comprises a battery receiving portion configured to be coupled to a power source capable of supplying current to the motor, the air flow inlet positioned on the battery receiving portion.

[0024] In some aspects, the technology recited in the present summary relates to a powered fastener driver comprising: a driver blade movable along a driver blade axis from a top dead center (TDC) position toward a bottom dead center (BDC) position for driving a fastener into a workpiece; a gas spring mechanism for driving the driver blade toward the BDC position; a rotary lifter for returning the driver blade from the BDC position toward the TDC position, the rotary lifter comprising at least one flange and a plurality of lifter pins extending from the flange, the rotary lifter movable to an axial home position relative to the driver blade axis whereby the driver blade can engage the lifter pins; a motor; a drive shaft extending along a drive shaft axis that is non-intersecting with the driver blade axis, the drive shaft coupled to the motor and configured to receive torque from the motor, the drive shaft coupled to the rotary lifter and configured to transmit torque to the rotary lifter to return the driver blade from the BDC position toward the TDC position, the drive shaft comprising a shoulder; and a spring positioned along the drive shaft axis between the shoulder and the flange, the spring configured to apply an axial biasing force to the rotary lifter along the drive shaft axis.

[0025] In some aspects, the technology recited in the Utility Model Patent relates to a powered fastener driver including a driver blade movable from a top dead center position to a bottom dead center position to drive a fastener into a workpiece; and a lift assembly to provide torque to move the driver blade from the bottom dead center position toward the top dead center position, the lift assembly including a rotary lifter configured to selectively engage the driver blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins, and a motor configured to provide torque to the rotary lifter; wherein the driver blade includes a lift tooth having a crown disposed thereon, the crown configured to engage the roller during movement of the driver blade toward the top dead center position.

[0026] In some aspects, the technology recited in the Utility Model Patent relates to a powered fastener driver including a driver blade movable from a top dead center position to a bottom dead center position to drive a fastener into a workpiece; and a lift assembly to provide torque to move the driver blade from the bottom dead center position toward the top dead center position, the lift assembly including a rotary lifter configured to selectively engage the driver blade, the rotary lifter having a plurality of lift pins, and a motor configured to provide torque to the rotary lifter; wherein at least one of the plurality of lift pins includes a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the driver blade includes a lift tooth having a crown disposed thereon, the crown configured to engage at least one of the plurality of cam portions during movement of the driver blade toward the top dead center position.

[0027] Other features and aspects of the Utility Model Patent will become apparent upon reading the following detailed description and reviewing the associated drawings. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 is a perspective view of a powered fastener driver in accordance with an embodiment of the Utility Model Patent.

[0029] Figure 2 is Figure 1 a perspective view of the powered fastener driver of

[0030] Figure 3 is a cross-sectional view of the powered fastener driver taken along section line 3-3 in Figure 1

[0031] Figure 4 is Figure 1 a partial side view of the powered fastener driver of

[0032] Figure 5 ​is a bottom view of the compression chamber.

[0033] Figure 6 is a cross-sectional view of the compression chamber of Figure 4 Figure 3

[0034] Figure 7 is a partial side view of the power fastener driver of Figure 2

[0035] Figure 8 is a partial cross-sectional view of the power fastener driver of Figure 2 Figure 2

[0036] Figure 9 is a partial perspective view of a motor of the lift assembly.

[0037] Figure 10 is a rear perspective view of a shroud of the motor.

[0038] Figure 11 is a perspective view of a rotary lifter and driver blade of the power fastener driver.

[0039] Figure 12 is a perspective view of a portion of the rotary lifter showing a last pin of the rotary lifter.

[0040] Figure 13 is a side view of the last pin of the rotary lifter.

[0041] Figure 14 is a partial perspective view of the driver blade showing a last tooth of the driver blade.

[0042] Figure 15 is a partial bottom view of the last tooth of the driver blade.

[0043] Figure 16 is a schematic view showing the engagement between the last tooth of the driver blade and the last pin of the rotary lifter.

[0044] Figure 17 is a detail view of a portion of the schematic view of Figure 16

[0045] is a perspective view of a power fastener driver according to another embodiment of the present utility model. Figure 18

[0046] is a perspective view of the power fastener driver of Figure 19 Figure 18 is a perspective view of the power fastener driver of​​​​​​

[0047] Figure 20 is a cross-sectional view of the powered fastener driver taken along section line 20-20 in Figure 18

[0048] Figure 21 Figure 18 is a partial side view of the powered fastener driver of

[0049] Figure 22 Figure 18 is a side view of the powered fastener driver of

[0050] Figure 23 Figure 22 is a cross-sectional view of the powered fastener driver taken along section line 23-23 in

[0051] Figure 24 Figure 23 is a cross-sectional view of the fitting and adapter engaging the fitting of

[0052] Figure 25 is a graphical representation of fill pressures for a plurality of fastener drivers grouped into sets adapted to be engaged by different adapters.

[0053] Figure 26 Figure 19 is a perspective view and cross-sectional view of the powered fastener driver of Figure 18

[0054] Figure 27 is a magnified perspective view and cross-sectional view of the powered fastener driver of Figure 26 Figure 18

[0055] Figure 28 Figure 27 is a side view of the drive shaft of the powered fastener driver of

[0056] Figure 29 Figure 27 is an end view of the drive shaft of the powered fastener driver of

[0057] Figure 30 Figure 27 is an end view of the rotary lifter flange of the powered fastener driver of

[0058] Figure 31 Figure 18 is a second side view of the powered fastener driver of

[0059] Figure 32 Figure 19 ​​​​​​​​​​​​​​Section line 32-32 in the middle Figure 18 Enlarged partial cross-sectional view of the power fastener driver.

[0060] Figure 33 It is along Figure 22 Section line 33-33 in the middle Figure 18 Front sectional view of the fastener driver.

[0061] Figure 34 It is along Figure 18 Section line 34-34 in the middle Figure 18 A cross-sectional view of the fastener driver.

[0062] Figure 35 yes Figure 18 A partial sectional view of a power fastener driver, wherein the spacer is positioned within the housing.

[0063] Before explaining any embodiment of this utility model in detail, it should be understood that the application of this utility model is not limited to the details of the construction and arrangement of the components described in the following description or shown in the drawings. This utility model can have other embodiments and can be practiced or implemented in various ways. Furthermore, it should be understood that the wording and terminology used in this utility model are for illustrative purposes and should not be considered restrictive. Detailed Implementation

[0064] Figures 1-3 A gas spring powered fastener actuator 100 according to the present invention is shown. The fastener actuator 100 is operable to drive fasteners (e.g., nails, thumbtacks, U-bolts, etc.) held in a toolbox 104 into a workpiece (not shown). The fastener actuator 100 includes a housing 108 (shown as a two-piece clamshell housing) supporting a drive assembly 112 and a lifting assembly 116. The drive assembly 112 is operable to drive the fastener, and the lifting assembly 16 is operable to reset the drive assembly 112, allowing the fastener actuator 100 to drive another fastener. The drive assembly 112 includes an inner cylinder 120 and a movable piston 124 positioned within the inner cylinder 120. The piston 124 is available within the inner cylinder 120 in a ready or top dead center (TDC) position (not shown) and a driven or bottom dead center (BDC) position. Figure 3The actuator blade 128 is coupled to the piston 124 and can move together with it along the drive axis (i.e., the actuator blade axis) A1. The fastener actuator 100 does not require an external pneumatic source to drive the fastener, but instead includes a storage chamber cylinder or outer cylinder 132 containing pressurized gas in fluid communication with the inner cylinder 120. In the illustrated embodiment, the outer cylinder 132 surrounds the inner cylinder 120, and the outer cylinder 132 and the inner cylinder 120 together form a compression chamber (i.e., storage chamber) 136. As the actuator blade 128 and the piston 124 move toward the ready position, the air in the compression chamber 136 (e.g., above the piston 124) is compressed, thereby increasing the amount of pressure acting on the piston 124. The lifting assembly 116 includes a motor 140 operatively coupled to a rotary lifter 144. The rotary lifter 144 can selectively engage the actuator blade 128, as will be discussed in further detail in this invention, to move the actuator blade 128 and the piston 124 to the ready position. In the illustrated embodiment, a one-way clutch 148 and a transmission device 152, such as a planetary transmission device, are disposed between the motor 140 and the rotary lift 144.

[0065] In operation, the lifting assembly 116 supplies torque generated by the electric motor 140 to the rotary lift 144 via a one-way clutch 148 and a transmission 152. Rotation of the rotary lift 144 causes the drive blade 128 to move from the driven position toward the ready position. The drive blade 128 and piston 124 move to the ready position, compressing the gas contained within the compression chamber 136. Therefore, the lifting assembly 116 provides torque to the rotary lift 144 to move the drive blade 128 to the ready position, thereby increasing the amount of pressure acting on the piston 124. To drive the fastener, the drive blade 128 releases from the ready position and moves toward the driven position due to the gas pressure acting on the piston 124. The compression chamber 136 is a sealed environment and therefore acts as a gas spring on the piston 124. As the drive blade 128 moves toward the BDC position, it contacts the fastener to drive it into the workpiece. Further details regarding certain structures of the fastener actuator 100 are given below.

[0066] See Figures 2-6 Compression chamber 136 is coupled to housing 108 and is capable of limited movement relative to housing 108. During fastener driver operation, piston 124 contacts buffer 156 upon reaching the driven position. Figure 3). The bumper 156 helps to dissipate excess energy that is not used to drive the fastener. However, the bumper 156 is supported by the outer cylinder 132 of the compression chamber 136, and contact between the piston 124 and the bumper 156 can also cause movement of the compression chamber 136. To prevent damage to the housing 108 due to movement of the compression chamber 136, a plurality (e.g., two, three, more than three) of compliant members or dampers 160 are provided between the compression chamber 136 and the housing 108. The dampers 160 are formed of a vibration-damping material. The dampers 160 can be compliant in that they deflect when a force is applied. The dampers 160 can include a rubber material. The dampers 160 are disposed between the housing 108 and the compression chamber 136 to support the compression chamber 136 relative to the housing 108 while allowing the compression chamber 136 to move relative to the housing 108.

[0067] With continued reference to Figures 4-6 , the compression chamber 136 includes a first flange 164 extending from the outer cylinder 132 and a second flange 168 extending from the outer cylinder 132 opposite the first flange 164. The first flange 164 is positioned on a first side of the drive axis Al, and the second flange 168 is positioned on a second side of the drive axis Al. The first flange 164 and the second flange 168 are asymmetric about a plane containing the drive axis Al. Rather, the first flange 164 and the second flange 168 are symmetric about a central vertical axis A2 Figure 5 and 6offset. The first flange 164 is generally rectangular in shape when viewed along the drive axis Al. The second flange 168 is also generally rectangular in shape when viewed along the drive axis Al. The length dimension of each of the first flange 164 and the second flange 168 is measured tangentially to the outer cylinder 132. The first flange 164 is offset from the central vertical axis A2 in a direction parallel to the length dimension, which causes the central vertical axis A2 to not bisect the first flange 164. Similarly, the second flange 168 is offset from the central vertical axis A2 in a direction parallel to the length dimension, which causes the central vertical axis A2 to not bisect the second flange 168. In the illustrated embodiment, the first flange 164 is offset in a first direction, and the second flange 168 is offset in a second direction opposite the first direction. The first flange 164 and the second flange 168 of the illustrated embodiment are offset by equal magnitudes. However, in other embodiments, the first flange 164 and the second flange 168 can be offset by different magnitudes. Further, in the illustrated embodiment, each of the first flange 164 and the second flange 168 is offset by an amount equal to less than half of its length. Thus, an overlap region is formed in which portions of each of the first flange 164 and the second flange 168 are vertically aligned. In other embodiments, the flanges 164, 168 can be offset by an amount greater than half of their respective lengths, which causes the overlap region to be non-existent. The first flange 164 and the second flange 168 are offset to utilize space within the housing 108, allowing for generally rectangular flanges 164, 168 and dampers 160, while minimizing the overall size of the housing 108. However, it should be understood that neither the first flange 164 nor the second flange 168 need be generally rectangular. The dampers 160 are positioned asymmetrically relative to one another about a plane containing the axis Al (e.g., A2-A2) along which the driver blade 128 is movable.

[0068] In the illustrated embodiment, each of the first flange 164 and the second flange 168 supports one of a pair of dampers 160. Each of the pair of dampers 160 corresponds in shape to the shape of the respective flange 164, 168 with which it is coupled. Thus, each of the pair of dampers 160 has a generally rectangular shape when viewed along the drive axis Al. In other embodiments, the dampers 160 can have different cross-sectional shapes depending on the shape of their associated flanges 164, 168 and the space within the housing 108. For example, the dampers 160 can have generally straight inner surfaces and curved outer surfaces, or the dampers 160 can vary in height along the length of the dampers 160, forming a non-standard cross-sectional shape.

[0069] Figure 2 and Figures 7-10Further details of the lift assembly 116 - particularly the motor 140 of the lift assembly 116 - are shown. As previously described, the lift assembly 116 includes a motor 140 that is operably coupled to the rotary lifter 144 via a one-way clutch 148 and a planetary transmission 152. The motor 140 is an internal rotor, brushless DC electric motor that receives power from a battery pack (B, Figure 18 ). The motor 140 includes an output shaft 172 that is coupled to an internal rotor 176 and the clutch 148 to transmit torque generated by the electric motor 140 to the transmission 152 via the clutch 148. A fan 180 is coupled to the internal rotor 176 for co-rotation therewith. In the illustrated embodiment, the fan 180 is integrally formed with the internal rotor 176 and disposed adjacent the clutch 148. The fan 180 draws air into the motor 140 due to rotation of the internal rotor 176, thereby assisting in cooling the motor 140. Air is also directed onto other components of the fastener driver 100, such as a controller 184 Figure 2 . The motor 140 further includes a housing 188 in which an external stator 192 is disposed. A shroud 196 is coupled to the housing 188 to assist in directing airflow through the motor 140. The output shaft 172 of the motor 140 extends beyond the housing 188 of the motor 140. The output shaft 172 is supported for rotation at one end by a bearing 200 coupled to the shroud 196 and is coupled to the internal rotor 176 at the other end. The fan 180 is disposed outside of the housing 188 of the motor 140, opposite the shroud 196. In the illustrated embodiment, the housing 188 of the motor 140 includes a baffle 204 having a constant diameter. The baffle 204 is disposed adjacent the fan 180 to assist in directing airflow generated by the fan 180. The housing 108 of the fastener driver 100 includes at least one inlet 208 adjacent the shroud 196 and at least one outlet 212 adjacent the fan 180 Figure 2 . In some embodiments, the housing 108 of the fastener driver 100 can further include an inlet (not shown) disposed adjacent the controller 184. The inlets 208 and outlets 212 accommodate airflow generated by the fan 180.

[0070] Referring to Figure 9 and Figure 10The shroud 196 is shaped such that an outer perimeter PI of the shroud 196 is related to an outer perimeter P2 of the housing 188 of the motor 140. However, the outer perimeter PI of the shroud 196 includes only three sides, rather than four sides, to match the outer perimeter P2 of the housing 188. The shroud 196 includes a plurality of holes 216 through which a plurality of fasteners 220 extend to couple the shroud 196 to the housing 188. In the illustrated embodiment, each of the plurality of holes 216 is positioned within a cylindrical protrusion 224. The cylindrical protrusions 224 help to align the shroud 196 with the housing 188 of the motor 140. The shroud 196 further includes a plurality of radially inwardly extending arms 228 that support a centrally positioned bearing seat 232. The bearing 200 and the output shaft 172 are supported within the bearing seat 232. In the illustrated embodiment, the shroud 196 includes five arms 228. However, in other embodiments, the shroud 196 can include more or fewer arms 228. A main body 236 of the shroud 196 is shaped to direct airflow into the motor 140. Thus, in the illustrated embodiment, the main body 236 is generally cylindrical and aligned with the stator 192 of the motor 140. In other embodiments, the main body 236 of the shroud 196 can have a different shape corresponding to a desired airflow. For example, the shroud 196 can not include a central bearing support, and the output shaft can be supported by another component of the motor. The shroud 196 can also have any number of arms or zero arms. In some embodiments, the shroud 196 can be disposed adjacent to the fan 180, rather than opposite the fan 180 as shown.

[0071] Figure 2 、 Figure 3 and Figures 11-17 Further details of the lift assembly 116, and in particular the rotating lift 144 of the lift assembly 116, are shown. As previously described, the rotating lift 144 selectively engages with the driver blade 128 to move the driver blade 128 along the drive axis Al from the driven position to the ready position. The driver blade 128 includes a plurality of lift teeth 240 extending laterally therefrom. The rotating lift 144 is coupled to the transmission 152 to receive torque from the motor 140 and includes a main body 244 having a pair of opposing plates (i.e., flanges) 248 between which a plurality of lift pins 252 are disposed. In the illustrated embodiment, the rotating lift 144 includes seven lift pins 252. As the rotating lift 144 rotates, each of the lift pins 252 in turn engages the lift teeth 240 of the driver blade 128 to move the driver blade 128 from the driven position to the ready position.

[0072] Referring to Figure 12 and Figure 13The last pin 252a of the plurality of lift pins 252 is shaped differently than the rest of the plurality of lift pins 252. When the driver blade 128 is at or near the ready position (i.e., TDC), the last pin 252a engages with the last tooth 240a of the lift teeth 240. Unlike the rest of the plurality of lift pins 252, a roller 256 (i.e., a blade engagement member) is disposed on the last pin 252a. The roller 256 is rotatable about the last pin 252a in the direction D. The roller 256 is shaped to engage with the last lift tooth 240a of the driver blade 128. In some embodiments, the roller 256 can be integrally formed with the last pin 252a, rather than being supported by the last pin 252a as shown. The roller 256 includes a plurality of cup-shaped recesses or cam portions 260 that are engageable with the last lift tooth 240a. In other embodiments, the cup-shaped recesses or cam portions 260 are not formed in the roller 256, but can be formed in one or more of the lift pins 252 themselves. The recesses or cam portions 260 can be defined directly in the last pin 252a, and the roller 256 can be omitted. The recesses or cam portions 260 can be generally concave. In the illustrated embodiment, the roller 256 includes eight cam portions 260. However, in other embodiments, the roller 256 can include more or fewer cam portions 260. A stop mechanism, shown as a spring 264 and an abutment plug 268 Figure 3 The stop mechanism, shown as a spring 264 and an abutment plug 268

[0073] Figure 14 and Figure 15 The last tooth 240a of the driver blade 128 is shown in more detail. The last tooth 240a of the driver blade 128 is positioned furthest from the piston 124 Figure 3) and engages the rotating elevator 144 when the driver blade 128 is at or near the ready position. The last tooth 240a of the driver blade 128 has a first radius Rl in a direction parallel to the drive axis Al. The first radius Rl defines the shape of the last tooth 240a to engage the roller 256. More specifically, the first radius Rl is shaped to engage the cam portion 260 of the roller 256. The last tooth 240a of the driver blade 128 further includes a crown 272 to reduce potential wear on the tooth 240a and the rotating elevator 144. In some cases, the driver blade 128 can rotate or twist about the drive axis Al during operation in the direction of arrow AA. The crown 272 is shaped as a second radius R2 or crown radius in a direction perpendicular to the drive axis Al and concentric with the arrow AA. The second radius R2 is shaped to allow the last tooth 240a to rotate about the drive axis Al relative to the rotating elevator 144. Thus, the driver blade 128 is able to twist about the drive axis Al relative to the rotating elevator 144 without causing undue wear on the rotating elevator 144.

[0074] Referring again to Figure 12 and Figure 13 , the cam portion 260 of the roller 256 is shaped to engage the crown 272 of the last tooth 240a. More specifically, each cam portion 260 of the illustrated embodiment is arcuate in two directions. A first cam portion radius R3 is applied tangentially to the direction of rotation of the roller 256 to create a cup-shaped recess that engages the last elevator tooth 240a. A second cam portion radius R4 is applied perpendicular to the first cam portion radius R3. The second cam portion radius R4 corresponds to the second radius R2 of the last tooth 240a and provides clearance for the driver blade 128 to rotate about the arrow AA relative to the roller 256 about the drive axis Al while limiting undue wear to the roller 256 and / or the last tooth 240a of the driver blade 128 due to rotation about the drive axis Al.

[0075] Figure 16 and Figure 17The last tooth 240a of the drive blade 128 and the cam portion 260 of the roller 256 are schematically shown. In the illustrated embodiment, the second radius R2 of the crown 272 defining the last tooth 240a is smaller than the radius R4 of the second cam portion. Therefore, the drive blade 128 can rotate relative to the roller 256 about the drive axis A1 while maintaining contact between the crown 272 and the cam portion 260. Maintaining contact with the crown 272 prevents contact between the edge 276 of the last tooth 240a and the roller 256 that could lead to premature wear of the last tooth 240a and / or the roller 256. In the illustrated embodiment, the radius R4 of the second cam portion of the roller 256 is 20% larger than the second radius R2 of the crown 272 defining the last tooth 240a. Therefore, as Figure 16 As shown, the last tooth 240a of the driver blade 128 can rotate two degrees while maintaining contact between the crown 272 and the cam portion 260. Figure 17 yes Figure 16 A detailed view shows the contact area between the crown 272 and the cam portion 260. (See attached image.) Figure 17 As shown, a gap 280 exists between the edge 276 of the last tooth 240a and the cam portion 260. Without a radius difference, a two-degree rotation can result in contact between the edge 276 and the roller 256. In other embodiments, the radius difference can be between 1% and 60%, depending on the desired amount of relative rotation about the drive axis allowed between the drive blades and the roller. In each embodiment, the radius of the cam portion of the roller is larger than the radius of the crown of the last tooth.

[0076] Figures 18-24 and Figures 26-35 Another gas spring powered fastener actuator 300 is shown. The gas spring powered fastener actuator 300 includes features similar to those of the gas spring powered fastener actuator 100, with the reference numeral "200" added. The gas spring powered fastener actuator 300 operates in a manner similar to that of the gas spring powered fastener actuator 100 as described above.

[0077] See Figure 18 , Figure 19 and Figures 20-24The gas spring powered fastener driver 300 includes a fill port 500 in fluid communication with a storage chamber 336 (i.e., a pressure vessel) into which pressurized gas is delivered, as defined by the volume within the inner cylinder 320 behind the piston 324 and within the outer cylinder 332, for example. The storage chamber 336 is in fluid communication with the cylinders (e.g., the inner cylinder 320 and the outer cylinder 332) into which pressurized gas is retained to exert pressure against the piston 324. The storage chamber 336 can be defined in a similar manner as the compression chamber (i.e., the storage chamber 136) of the gas spring powered fastener driver 100. During assembly of the gas spring powered fastener driver 300, pressurized gas can be delivered from an external fluid supply source FS to effect initial pressurization of the storage chamber 336. The same fill port 500 can transfer gas from the external fluid supply source FS into the storage chamber 336 to effect re-pressurization (i.e., re-filling) of the storage chamber 336 after an unexpected leak of the storage chamber 336 during use of the gas spring powered fastener driver 300.

[0078] In Figure 23 In embodiments of the gas spring powered fastener driver 300, the fill port 500 includes a threaded portion 504 engageable by a connector 508. The connector 508 is coupled to the storage chamber 336. The connector 508 includes a tool side 508a having a tool side thread 508b configured to secure to the threaded portion 504 and an opposite outer side 508c having an outer side thread 508d. The tool side 508a and the outer side 508c are separated by a shoulder 512. An o-ring 516 is positioned adjacent the shoulder 512 to assist in sealing the connector 508 to the storage chamber 336. The tool side thread 508b is attachable with the threaded portion 504 to secure the connector 508 to the fill port 500. The connector 508 further defines a bore 508e, an outer side axial end face 508f, and a radially outer surface 508g on which the tool side thread 508b and the outer side thread 508d are located. In the illustrated embodiment, the bore 508e varies in diameter along the fill axis FA along a length of the connector 508. The illustrated bore 508e includes a smaller size on the tool side 508a and a larger size on the outer side 508c, with the size transitioning axially along the fill axis FA near the shoulder 512. The bore 508e can include an internal thread 508h.

[0079] The outer side thread 508d of the connector 508 is selectively engageable by a plug 520 and an adapter 524 (i.e., a first adapter 524). In Figure 23In implementations, the plug 520 is secured to the connector 508. The plug 520 is generally dome-shaped. The plug 520 includes an internal thread 520a that is attachable to the external thread 508d. The internal thread 520a of the plug 520 is positioned on an inner surface of the plug 520 that is radially inward facing toward the fill axis FA. The plug 520 further includes an end wall 520b that inhibits access to the interior of the connector 508 when the plug 520 is attached to the connector 508. The end wall 520b includes a non-circular recess 520c that is engageable by a tool (not shown) to selectively attach the plug 520 to the connector 508. In the illustrated implementation, the recess 520c is a hexagonal receiver into which a hexagonal tool (e.g., an internal hex wrench) is received. The plug 520 further includes an o-ring receiver 520d (i.e., a seal receiver) that receives a plug o-ring 522 to further assist in sealing the plug 520 with the connector 508. When fully attached to the connector 508, the end wall 520b of the plug 520 abuts the axial end surface 508f of the connector 508.

[0080] In other implementations, features of the connector 508 can be integrally formed with the compression chamber 336. In such implementations, the thread 508d that is engageable by the plug 520 or the adapter 524 can be integral with the compression chamber 336.

[0081] Referring to Figure 24The fill port 500 is further sealed by a valve 528 (e.g., a Schrader valve) that includes a valve stem 532 and a valve core 536. The valve 528 can be positioned within the fill port 500 (and, in some cases, more specifically, within the connector 508). The valve core 536 can include threads 536a that engage with internal threads 508h of the bore 508e. The valve core 536 can be held stationary relative to the bore 508e by the engagement of the threads 536a and the internal threads 508h, or any other engagement (e.g., press fit, adhesive, etc.). The valve stem 532 can be movable relative to the valve core 536 between an open position that allows fluid to pass through the valve 528 and the fill port 500 and a closed position that prohibits fluid to pass through the valve 528 and the fill port 500. The valve 528 can be movable between its open and closed positions when the adapter 524 is engaged with and disengaged from the external threads 508d (i.e., the first connector). The illustrated valve 528 is a Schrader valve. However, other types of valves 528 are possible. For example, in other embodiments, the valve 528 can be a one-piece valve that is held in a closed position by the pressure exerted by the gas within the storage chamber 336 and can be moved to an open position by inserting a tip into the one-piece valve. The illustrated valve stem 532 can be biased toward the closed position by a spring within the valve 528. The open position of the valve stem 532 can correspond to a position pressed into the valve core 536 whereby there is a passageway between the valve stem 532 and the valve core 536.

[0082] With continued reference to Figure 24The adapter 524 (i.e., the first adapter) is generally annular and includes an internal thread 524a that can be attached to the external thread 508d of the connector 508. The adapter 524 further includes an adapter tip 524b and a radially inwardly extending shoulder 524c. When the adapter 524 is fully attached to the connector 508, the shoulder 524c can abut against the outer axial end surface 508f of the connector 508, and the adapter tip 524b can depress the valve stem 532 by an amount corresponding to interference I1. Interference I1 represents the movement of the valve stem 532 between its closed position and its open position. The adapter 524 further includes a primary filling channel 524d and at least one secondary filling channel 524e. In the illustrated embodiment, the two secondary filling channels 524e exist on opposite sides of the filling axis FA. When the adapter 524 is attached to the connector 508, the secondary filling channels 524e only interconnect the primary filling channel 524d with the hole 508e. Once adapter 524 is connected to connector 508, fluid (e.g., gas) from an external fluid source FS can flow from primary filling channel 524d into secondary filling channel 524e and through valve 528 into storage chamber 336. Adapter 524 further includes an O-ring receiver 524f (i.e., seal receiver) capable of receiving a filling adapter O-ring 526 (i.e., filling adapter seal). In the illustrated embodiment, the filling adapter O-ring 526 surrounds the filling axis FA and is generally circular in cross-section. In other embodiments, the filling adapter O-ring 526 may be positioned at other locations relative to the filling axis FA and may include one or more flat surfaces (i.e., the cross-sectional shape of the filling adapter O-ring 526 may be non-circular). In the illustrated embodiment, the O-ring receiver 524f (i.e., seal receiver) is positioned on the radially inner surface of adapter 524.

[0083] When adapter 524 is attached to connector 508, the filling adapter O-ring 526 serves as a seal between adapter 524 and connector 508. Because the filling adapter O-ring 526 is positioned between the radially outer surface 508g and the O-ring receiver 524f at the radially inner surface of adapter 524, the filling adapter O-ring 526 can be described as a radially outer seal. In other embodiments, the sealing element between adapter 524 and connector 508 may be located at different outer positions. The filling adapter O-ring 526 can be repositioned and / or replicated, for example, to an axially outer position between the outer axial end surface 508f and shoulder 524c. Conversely, the position of the filling adapter O-ring 526 between any other sealing element within the radially outer surface 508g or bore 508e can be described as an inner seal within connector 508.

[0084] During connection of the adapter 524 to the connector 508, the relative sizes of the adapter 524 and the connector 508 cause a seal to be formed between the adapter 524 and the connector 508 before the adapter 524 actuates the valve stem 532. More specifically, the axial lengths and positions of the threads 524a, the outer threads 508d, the fill adapter o-ring 526 (i.e., the fill adapter seal), and the adapter tip 524b are determined such that the fill adapter o-ring 526 seals against the connector 508 before the adapter tip 524b actuates (e.g., compresses) the valve stem 532.

[0085] Fluid from the external fluid source FS can pass through one or more hoses H (e.g., flexible hoses) to the pressure regulator PR and ultimately to the adapter 524 and the storage chamber 336. The pressure regulator PR regulates the pressure supplied by the external fluid supply source FS to a desired fill pressure. As Figure 24 As schematically shown in the middle, the pressure regulator PR can be positioned at an intermediate location in a supply line that receives external fluid from the external fluid source FS through a hose H and delivers the regulated pressure to another hose H and the adapter 524. In other implementations, the pressure regulator PR can be positioned adjacent to the external fluid source FS (e.g., without a hose H between the external fluid source FS and the pressure regulator PR), immediately adjacent to the adapter 524 (e.g., without a hose H between the pressure regulator PR and the adapter 524), and / or at any location in the supply line between the external fluid source FS and the storage chamber 336.

[0086] The adapter 524, the hose H, and the pressure regulator PR can be considered a first fill adapter FA1 that is connectable to the connector 508. The first fill adapter FA1 is connectable to the connector 508 (i.e., a first connector) and thus to the fill port 500 to supply regulated pressurized gas from the external fluid supply source FS to the storage chamber 336. A different fill adapter 524 (i.e., a second adapter) having different or similar hose H and pressure regulator PR can be considered a second fill adapter (not shown).

[0087] The plug 520 can be attached to the connector 508 during normal operation of the gas spring powered fastener driver 300, and the adapter 524 can be attached to the connector 508 during a fill or refill operation. To further inhibit accidental access to the plug 520 during normal operation of the gas spring powered fastener driver 300, the cap 530 can be secured to the housing 308 by fasteners 534. Prior to removal of the cap 530, the fasteners 534 can need to be loosened or removed from the housing 308 in order for a user to access the recess 520c by inserting a tool (e.g., an Allen key) into the housing 308. In the illustrated implementation, the cap 530 is located on the handle portion 308a of the housing 308. The cap 530 can be selectively coupled to the housing 308 to selectively close the fill port 500 when the adapter 524 is not connected with the first connector (the outer side threads 508d).

[0088] Referring to Figure 25 , the powered fastener driver system 700 can include a plurality of fastener drivers 300, 704, 708, 712, 716, 720, 724, 728, 732, 736, 740, 744, 748, 752. Depending on the target fill pressure requirements of the individual fastener drivers, the fastener drivers 300, 704, 708, 712, 716, 720, 724, 728, 732, 736, 740, 744, 748, 752 can be grouped into a first group 758, a second group 762, a third group 766, a fourth group 770, and a fifth group 774, with similar fastener drivers grouped together. Each of the fastener drivers 704, 708, 712, 716, 720, 724, 728, 732, 736, 740, 744, 748, 752 can include similar features to and operate similarly to the fastener driver 100, 300.

[0089] The adapter 524 (i.e., the first adapter of the first fill adapter FA1) can be attached with a connector on the fastener driver 300 (e.g., the connector 508, the “first connector”) and / or the same connector on the fastener driver 704 (e.g., the outer threads 508d). The same adapter 524 (i.e., the first adapter of the first fill adapter FA1) can be attached to both the fastener driver 300 and the fastener driver 704 to supply pressurized gas from the external fluid supply to the storage chamber 336 or a similar storage chamber on the fastener driver 704. The fastener drivers categorized in the same group (e.g., the first group 758) can include similar connectors (e.g., the first connector, the connector 508) for engaging the same adapter 524 (i.e., the first adapter of the first fill adapter). Different fill adapters (e.g., the second fill adapter) with different adapters, in other words, a second adapter 524 similar to but different from the adapter 524, e.g., including different inner threads 524a, can be designed to be incompatible with the first connector of the fill port 500. For example, the inner threads 524a of the second adapter 524 can be incompatible with the outer threads 508d, thereby preventing the second adapter 524 from supplying pressurized gas from the external fluid supply to the storage chamber 336 on the fastener driver 300 or the fastener driver 704.

[0090] Further, different fastener drivers (e.g., the fastener drivers 708, 712) in a different group (e.g., the second group 762) can include a connector 508 (e.g., the second connector), e.g., having different outer threads 508d than the outer threads 508d of the fastener drivers 300, 704, which enables the second adapter (i.e., the second adapter, the adapter 524 with different inner threads 524a) to be attached to the selected fastener drivers (708, 712).

[0091] In the illustrated embodiment, the first connector 508 can have a first thread pattern (outer side threads 508d of the fastener driver 300), and the first adapter 524 can have a second thread pattern (inner threads 524a of the first adapter 524) that is sized to engage the first thread pattern, while the second adapter (inner threads 524a of the second adapter 524) can be designed to not engage the first thread pattern. The thread patterns can differ in any one or more than one of small diameter, large diameter, depth, pitch, pitch diameter, helix angle, thread width, thread angle, root length, etc. In other embodiments, other types of mechanical structures different from thread sizes can be used to selectively allow and / or enable connection incompatibility and prohibition between the fill port 500 (e.g., of the fastener driver 300 and the first set 758) and the fill ports 500 of the other sets (the second through fifth sets 762, 766, 770, 774). For example, the inner and outer diameters of the fill port 500, the connector 508, and the fill adapter 524 can be sized to selectively allow and / or enable connection incompatibility and prohibition between the fill port 500 and the fill adapter 524 as compared to the fill ports 500 of the other sets (the second through fifth sets 762, 766, 770, 774). In other embodiments, the type and / or size of the quick connect coupler can be selectively allowed and / or enabled to cause connection incompatibility and prohibition between the fill port 500 and the fill adapter 524 as compared to the fill ports 500 of the other sets (the second through fifth sets 762, 766, 770, 774).

[0092] The sizes or other compatibility features between the fill port 500 and the fill adapter 524 can be selected to allow a desired type of fill adapter 524 to connect with a desired type of fill port 500. For example, if desired, the adapters 524 that are typically used with the outer side threads 508d on the fastener drivers 708, 712 of the second set 762 can also attach (i.e., be compatible) with the outer side threads 508d of the fastener drivers 300, 704 of the first set 758, but not with the fastener drivers 716, 720, 724 of the third set 766 (i.e., be incompatible). Various permutations are possible. Various numbers (e.g., one, two, three, four, more than four) of fastener drivers can exist in any given set 758, 762, 766, 770, 774. The illustrated system 700 includes five sets, however, the system 700 can include any number of sets (two, three, four, five, more than five).

[0093] Figure 26 and Figure 27A drive shaft 800 is shown extending along a drive shaft axis A3 that does not intersect (i.e., does not cross) a drive shaft axis Al (i.e., a driver blade axis Al) as defined by the driver blade 328. The drive shaft 800 is coupled to the motor 340 and is configured to receive torque from the motor 340. In some embodiments and similar to the fastener driver 100, the fastener driver 300 can include a one-way clutch 348 and a transmission 352, such as a planetary transmission, disposed between the motor 340 and the drive shaft 800. The drive shaft 800 includes an input end 800a connected to the one-way clutch 348, the transmission 352, and the motor 340 and an output end 800b connected to the rotary lifter 344. The rotary lifter 344 can include features similar to the rotary lifter 144.

[0094] Referring to Figures 27-30 , the drive shaft 800 includes a pair of input flat portions 800c and a pair of output flat portions 800d adjacent to a pair of arcuate portions 800e proximate the input end 800a and the output end 800b, respectively. The input flat portions 800c and the output flat portions 800d each provide two flat planar surfaces between the pair of opposing arcuate portions 800e about the drive shaft axis A3. There can be any number of input flat portions 800c and output flat portions 800d so long as torque can be transmitted from the one-way clutch 348, the transmission 352, and the motor 340 to corresponding shaped engagement surfaces 344a of the rotary lifter 344 via the drive shaft 800. Torque is transmitted to the engagement surfaces 344a of the rotary lifter 344 through each of the input flat portions 800c and the output flat portions 800d. The rotary lifter 344 shown further includes arcuate engagement surfaces 344b that mirror the shape of the arcuate portions 800e. The drive shaft 800 can provide torque to the rotary lifter 344 to return the driver blade 328 from the BDC position toward the TDC position.

[0095] The drive shaft 800 further includes a shoulder 800f that extends radially outward from the arcuate portions 800e proximate the output end 800b. The shoulder 800f protrudes from the arcuate portions 800e a distance Dl measured perpendicular to the drive shaft axis A3. The output end 800b of the drive shaft 800 further includes a cylindrical bearing support surface 800g. The bearing support surface 800g has an outer diameter that is smaller than the shoulder 800f. Referring to Figure 27 A bearing 804 is secured (e.g., by a press fit) to the bearing support surface 800g. The bearing 804 abuts a first side 800fl of the shoulder 800f.

[0096] A spring 808 (i.e., a biasing member) is positioned between the shoulder 800f and an upper plate 448 (i.e., a flange 448, as Figure 27More specifically, the spring 808 is positioned between the second side 800f2 of the shoulder 800f and the plate 448. The spring 808 exerts an axial biasing force along the drive shaft axis A3 toward the rotary lift 344 to bias the rotary lift toward an axial home position, whereby the rotary lift 344 is positioned at a height along the drive shaft axis A3 that is aligned with the drive blade axis Al and thus with the drive blade 328, and wherein the drive blade 328 is able to engage the lift pin 452 of the rotary lift 344. The spring 808 can be a compression spring, a leaf spring, or the like. The spring 808 can comprise one or more than one individual spring member.

[0097] Figures 31-34 A fastener 900 that secures the tool box 304 to the housing 308 and an irregular quadrilateral gear box bolt pattern 904 that provides space for the fastener 900 to engage the housing 308 are shown. In the illustrated implementation, the fastener 900 is a threaded fastener, such as a bolt or a screw. However, other fasteners (e.g., a quick connect finger or a snap) can be used. As Figure 31 shown, the fastener 900 can extend through a hole 304a of the tool box 304 at a middle location of the tool box 304 between a proximal end 304b closest to the drive blade axis Al and a distal end 304c thereof. The proximal end 304b of the tool box 304 feeds the fastener in alignment with the drive blade 328.

[0098] As Figures 32-34 shown, the bolt pattern 904 includes four bolts 908. Each bolt 908 is oriented along a bolt axis BA that is parallel to the drive shaft axis A3. The bolts 908 interconnect a clutch housing 348a in which the one-way clutch 348 is positioned and a transmission housing 352a in which the transmission 352 is positioned. A motor housing 388 in which the motor 340 is positioned is coupled to the clutch housing 348a. The housing 38 and the clutch housing 348a can be referred to together as a motor case housing 348b. Further, since the transmission housing 352a includes gears, the transmission housing 352a can be referred to as a gear box 352a. The motor case 348b can be generally cylindrical in shape and further include protrusions 348c that protrude radially outward from the generally cylindrical motor case 348b. Each protrusion 348c can include a hole 348d that is configured to receive one of the bolts 908. The gear box 352a can also be generally cylindrical in shape and further include protrusions 352b that protrude radially outward from the generally cylindrical gear box 352a. Each protrusion 352b can include a hole 352c that is configured to receive one of the bolts 908.

[0099] Figure 33 and Figure 34A fastener 900 is shown extending through the hole 304a into the interior of the housing 308. The housing 308 includes a sidewall inner surface 310a and a protrusion 310b extending inwardly from the sidewall inner surface 310a into the housing 308. The protrusion 310b includes a tool box fastener receiver 310c that is engaged by the fastener 900 to secure the tool box 304 to the housing 308. The tool box fastener receiver 310c extends inwardly along the protrusion 310b from the sidewall inner surface 310a. By positioning the protrusion 310b in the interior of the housing 308, the lateral width of the fastener driver 300 including the tool box 304 is reduced compared to known fastener drivers.

[0100] Figure 34 The gear case bolt pattern 904 is shown in detail. The gear case bolt pattern has an irregular quadrilateral shape in a plane that is perpendicular to the drive shaft axis A3 (which itself is coaxial with the motor 340, and thus is the motor axis). The irregular quadrilateral shape shown includes two regular included angles AN1 measured between two adjacent reference lines, each reference line extending from the drive shaft axis A3 and passing through the bolt axis BA of a corresponding bolt 908. The regular included angle AN1 is equal to 90 degrees. The term “regular” refers to a typical angle expected for a selected number of bolts 908 in the gear case bolt pattern 904, including the four bolts 908 around the 360 degree perimeter of the gear case 352a. The typical angle expected for a gear case bolt pattern 904 including four bolts would be 360 degrees / 4 bolts or 90 degrees. In other embodiments, the angle AN1 can be different, and no angle AN1 can be described as “regular.” The irregular quadrilateral shape includes at least one obtuse included angle AN2 measured between two adjacent gear case bolts 908 and the drive shaft axis A3. The irregular quadrilateral shape includes at least one acute included angle AN3 measured between two adjacent gear case bolts 908 and the drive shaft axis. The resulting shape positions at least one of the bolts 908 further inside (laterally closer to the drive shaft axis A3) within the housing 308 to provide space for the protrusion 310b and the fastener 900. Note that the three bolts 908 defining the two regular included angles AN1 are spaced apart from each other by a distance D2. The two bolts 908 defining the obtuse included angle AN2 are spaced apart from each other by a distance D3 that is greater than the distance D2. The two bolts 908 defining the acute angle AN3 are spaced apart from each other by a distance D4 that is less than the distance D2. The distances D2-D4 are shown as straight lines extending between the bolt axes BA. However, a similar statement can be made for the arc length between the bolts 908 reflected by the distances D2-D4.

[0101] Other irregular quadrilateral shapes of the gearbox bolt pattern 904 are possible. Similarly, other irregular non-quadrilateral shapes of the gearbox bolt pattern 904 are possible. For example, there can be fewer (one, two, three) or more (more than four) bolts 908. For example, for a gearbox bolt pattern 904 that includes five bolts, a regular bolt pattern would arrange the bolts at regular included angles of 72 degrees (360 degrees / 5 bolts) apart from one another, resulting in equal distances between bolt axes BA between each of the five bolts 908 (similar to distance D2 above, but between each of the five bolts). Irregular bolt patterns are contemplated whereby at least one of the five bolts 908 is positioned at less than regular (i.e., typical, uniform circumferential spacing) spacing (e.g., less than 72 degrees), and at least one of the bolts is positioned at more than typical angular spacing (e.g., more than 72 degrees).

[0102] Figure 35 An alternative air flow path through the housing 308 of the fastener driver 300 restricted by the partition 1000 is shown. As described above, the housing 308 includes a handle portion 308a, a cylinder portion 308b, a battery receiving portion 308c configured to receive a battery pack B, and a motor containment portion 308d in which the motor 340 is positioned. The battery pack B can be coupled to the battery receiving portion 308c to supply current to the motor 340. The housing 308 is divided by the partition 1000 into an intake region 309a and an exhaust region 309b. The intake region 309a includes an air flow inlet 408. The illustrated air flow inlet 408 is at a rear end of the battery receiving portion 308c. The air flow inlet 408 can be an inlet grille having a plurality of separate inlets. The exhaust region 309b includes air flow outlets 412. In the illustrated implementation, two air flow outlets 412 are present on each lateral side of the motor containment portion 308c (e.g., the left side ( Figure 31 ) and right side ( Figure 18)). The airflow outlet 412 can be positioned at an axial height along the drive shaft axis A3 corresponding to an axial height of the fan 380. In other words, the airflow outlet 412 is positioned on the motor containment portion 308c in communication with the exhaust region 309b. A partition 1000 is positioned within the housing 308 between the motor 340 (i.e., the motor housing 388) and the motor containment portion 308c. The partition 1000 can be a separate component from the housing 308 and the motor 340. Alternatively, the partition 1000 can be integrally formed as a single piece with either the housing 308 or the motor 340. The partition can inhibit the cooling airflow expelled from the fan 380 in the exhaust region 309b from re-entering the intake region 309a. In some embodiments, the partition 1000 can be made of a foam material. The partition 1000 can be made of a compliant material that is able to deflect. The fan 380 itself can be positioned within the exhaust region 309b.

[0103] Referring to Figure 35 Upon activation of the motor 340, the fan 380 can generate a cooling airflow as shown by path AF1 that enters the airflow inlet 408 and cools the controller 384 and optionally the terminals of the battery pack B before entering the shroud 396 and cooling the motor 340. In some embodiments, the shroud 396 can be removed. After passing through the motor 340, the cooling airflow AF1 enters the exhaust region 309b and exits the housing 308 through the airflow outlet 412. However, some air particles can be directed back to the intake region 309a along a redirected path AF2. The redirected path AF2 impinges on the partition 1000, which redirects the redirected path AF2 toward the airflow outlet 412, thereby inhibiting the heated air generated by the fan 380 from recirculating back into the motor 340.

[0104] The various features of the present utility model are recited in the claims.

Claims

1. A powered fastener driver characterized by, includes: a driver blade movable from a top dead center position to a bottom dead center position for driving a fastener into a workpiece; and a lift assembly for providing torque to move the driver blade from the bottom dead center position toward the top dead center position, the lift assembly including: a rotary lifter configured to be engageable with the driver blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins, and a motor configured to provide torque to the rotary lifter; wherein the roller includes a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the driver blade includes a lift tooth having a crown disposed thereon, the crown configured to engage at least one of the plurality of cam portions.

2. The powered fastener driver of Claim 1, wherein, the crown is defined by a crown radius oriented perpendicular to a drive axis of the driver blade, and wherein the crown radius is less than the second radius of the at least one of the plurality of cam portions.

3. The powered fastener driver of Claim 1, wherein, further including a pressure vessel in which a pressurized gas is held; a housing in which the pressure vessel and the lift assembly are disposed; and a damper positioned between the pressure vessel and the housing.

4. The powered fastener driver of Claim 3, wherein, the damper is a first damper and the power fastener driver further includes a second damper positioned between the pressure vessel and the housing, the first and second dampers are respectively supported by first and second flanges and are asymmetrically positioned relative to each other about a plane containing an axis along which the driver blade is movable.

5. The powered fastener driver of Claim 1, wherein, the lift assembly includes a motor positioned within a motor case and a gear train positioned within a gear case, the motor is oriented along a motor axis.

6. The powered fastener driver of Claim 5, wherein, further including a plurality of gear case bolts connecting the gear case and the motor case, the gear case bolts are arranged in a gear case bolt pattern, the gear case bolt pattern has an irregular quadrilateral shape when viewed perpendicular to the motor axis.

7. The powered fastener driver of Claim 6, wherein, the quadrilateral shape includes at least one obtuse included angle greater than 90 degrees and at least one acute included angle less than 90 degrees measured between two adjacent gear case bolts and the motor axis.

8. The powered fastener driver of claim 7, wherein, the quadrilateral shape includes at least one included angle equal to 90 degrees.

9. A powered fastener driver characterized by, includes: a pressure vessel in which a pressurized gas is held; a piston movable within the pressure vessel from a top dead center position to a bottom dead center position by the pressurized gas; a driver blade coupled to move with the piston from the top dead center position to the bottom dead center position for driving a fastener into a workpiece; a lift assembly configured to engage the driver blade to move the driver blade from the bottom dead center position toward the top dead center position; a housing in which the pressure vessel and the lift assembly are disposed, a first damper positioned between the pressure vessel and the housing; and a second damper positioned between the pressure vessel and the housing; wherein the first damper and the second damper are asymmetrically positioned relative to each other about a plane containing an axis along which the driver blade is movable; and wherein the first damper and the second damper are configured to dampen movement of the pressure vessel relative to the housing.

10. The powered fastener driver of Claim 9, wherein, Further comprising a plurality of gear case bolts connecting the gear case to the motor case, the gear case bolts arranged in a gear case bolt pattern having an irregular quadrilateral shape when viewed perpendicular to a motor axis of a motor within the motor case.

11. The powered fastener driver of claim 10, wherein, The quadrilateral shape includes at least one obtuse included angle greater than 90 degrees and at least one acute included angle less than 90 degrees measured between two adjacent gear case bolts and the motor axis.

12. The powered fastener driver of claim 11, wherein, The lift assembly includes a rotary lifter configured to be engageable with the driver blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins, wherein the roller includes a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the driver blade includes a lift tool having a crown disposed thereon, the crown configured to engage at least one of the plurality of cam portions.

13. The powered fastener driver of Claim 9, wherein, The lift assembly includes a rotary lifter configured to be engageable with the driver blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins.

14. The powered fastener driver of claim 13, wherein, The roller includes a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius.

15. The powered fastener driver of claim 14, wherein, The driver blade includes a lift tool having a crown disposed thereon, the crown configured to engage at least one of the plurality of cam portions.

16. A powered fastener driver characterized by, Comprising: a pressure vessel in which a pressurized gas is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center position to a bottom dead center position; a driver blade coupled to move with the piston from the top dead center position to the bottom dead center position for driving a fastener into a workpiece; a lift assembly operable to move the driver blade from the bottom dead center position toward the top dead center position, the lift assembly including a motor positioned with a motor case and a gear train positioned within a gear case, the motor oriented along a motor axis; and a plurality of gear case bolts connecting the gear case and the motor case, the gear case bolts arranged in a gear case bolt pattern having an irregular quadrilateral shape when viewed perpendicular to the motor axis; Wherein the quadrilateral shape includes at least one obtuse included angle greater than 90 degrees and at least one acute included angle less than 90 degrees measured between two adjacent gear box bolts and the motor axis.

17. The powered fastener driver of claim 16, wherein, The quadrilateral shape includes at least one included angle equal to 90 degrees.

18. The powered fastener driver of claim 16, wherein, Further comprising a housing defining an interior surface within which the lift assembly is positioned, the housing including a protrusion extending inwardly from the interior surface, and a tool box coupled to the housing by tool box fasteners that engage tool box fastener receivers in the protrusion.

19. The powered fastener driver of claim 18, wherein, The tool box includes a tool box aperture that receives the tool box fasteners, the tool box aperture positioned at an intermediate location between a proximal end of the tool box and an opposing distal end of the tool box, the proximal end of the tool box feeding fasteners in alignment with the driver blade.

20. The powered fastener driver of claim 18, wherein, The tool box is angled in a non-perpendicular manner relative to a drive axis along which the driver blade is movable.

21. A powered fastener driver system characterized by, Comprising: a powered fastener driver comprising a pressure vessel in which pressurized gas is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center position to a bottom dead center position; a driver blade coupled to move with the piston from the top dead center position to the bottom dead center position for driving a fastener into a workpiece; and a fill port in fluid communication with the pressure vessel through which pressurized gas is delivered into the pressure vessel, the fill port comprising a first connector; a first fill adapter comprising a first adapter attachable with the first connector of the fill port to supply pressurized gas from an external fluid supply to the pressure vessel; and a second fill adapter comprising a second adapter different from the first adapter and incompatible with the first connector of the fill port, thereby preventing the second fill adapter from supplying pressurized gas from the external fluid supply to the pressure vessel.

22. The powered fastener driver system of claim 21, wherein, The first connector is a first thread pattern, the first adapter is a second thread pattern sized to engage the first thread pattern, and the second adapter is a third set of threads sized to be unable to engage the first thread pattern.

23. The powered fastener driver system of claim 21, wherein, The powered fastener driver is one of a first set of powered fastener drivers, each of the powered fastener drivers having the first connector.

24. The powered fastener driver system of Claim 23, wherein, Further comprising a second powered fastener driver having a second piston pressure vessel defining a second pressure vessel and a second fill port coupled to the second pressure vessel, the second fill port in communication with the second pressure vessel, the second fill port comprising a second connector attachable with the second adapter of the second fill adapter to supply pressurized gas from the external fluid supply to the second pressure vessel.

25. The powered fastener driver system of Claim 24, wherein, The second power fastener driver is one of a second set of power fastener drivers, each of the power fastener drivers having the second connector.

26. The powered fastener driver system of claim 24, wherein, The second connector is unable to engage the first adapter of the first fill adapter.

27. The powered fastener driver system of claim 21, wherein, Further comprising a valve positioned within the fill port and movable between an open position and a closed position when the first fill adapter is engaged and disengaged from the first connector.

28. The powered fastener driver system of claim 27, wherein, The power fastener driver further comprises a cap engageable with the fill port to seal the valve when the first fill adapter is not connected with the fill port.

29. The powered fastener driver system of claim 21, wherein, The power fastener driver further comprises a fitting that engages the fill port, the fitting coupled to the pressure vessel and defining a bore, an outer axial end surface, and a radial outer surface.

30. The powered fastener driver system of Claim 29, wherein, The radial outer surface includes threads that define the first connector.

31. The powered fastener driver system of Claim 29, wherein, The first fill adapter includes a first adapter thread that defines the first adapter, a radially inwardly extending shoulder that is contactable with the outer axial end surface, and an adapter tip that is operable to open a valve in the fill port when the first adapter and the first connector are engaged.

32. The powered fastener driver system of claim 31, wherein, Further comprising a fill adapter seal between the radial outer surface of the fitting and a seal receiver on a radially inner surface of the first fill adapter.

33. The powered fastener driver system of claim 21, wherein, Further comprising a fill adapter seal between the first fill adapter and the fill port and a valve positioned within the fill port, wherein the axial length of the first adapter and the first connector along a fill axis and the axial position of the fill adapter seal along the fill axis are dimensioned such that when the first fill adapter is attached to the first connector, the fill port is sealed by the fill adapter seal before the first fill adapter actuates the valve.

34. A powered fastener driver characterized by: Comprising: a housing including an air intake region having an air flow inlet, an air exhaust region having an air flow outlet, a cylinder portion, and a motor containment portion; a pressure vessel in which pressurized gas is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center position to a bottom dead center position; a driver blade coupled to move with the piston from the top dead center position to the bottom dead center position for driving a fastener into a workpiece; a motor positioned within the motor containment portion and configured to provide torque to move the driver blade from the bottom dead center position toward the top dead center position; a fan coupled to the motor, the fan configured to produce a cooling air flow from the air flow inlet to the air flow outlet upon motor start-up; and a partition positioned within the housing and between the motor and the motor containment portion to separate the air intake region from the air exhaust region and to block the cooling air flow expelled from the fan in the air exhaust region from passing back into the air intake region. The partition is made of a foam material.

35. The powered fastener driver of claim 34, wherein, ​ 36. The powered fastener driver of claim 34, wherein the driver blade is configured to be moved from the first position to the second position by the driver blade being moved in a direction that is substantially parallel to the longitudinal axis of the driver blade. The fan is positioned within the exhaust region.

37. The powered fastener driver of Claim 34, wherein, The housing further includes a battery receiving portion configured to be coupled to a power source capable of supplying current to the motor, the airflow inlet being positioned on the battery receiving portion.

38. The powered fastener driver of claim 34, wherein, The airflow outlet is positioned on the motor receiving portion in communication with the exhaust region.

39. The powered fastener driver of Claim 34, wherein, The pressure vessel is positioned within the cylinder portion.

40. The powered fastener driver of Claim 34, wherein, Further comprising a shroud coupled to the motor, wherein the shroud is configured to direct a cooling airflow generated by the fan into the motor.

41. A powered fastener driver characterized by, Comprising: a driver blade movable from a top dead center position to a bottom dead center position for driving a fastener into a workpiece; a gas spring mechanism for driving the driver blade toward the bottom dead center position; a rotary lifter for returning the driver blade from the bottom dead center position toward the top dead center position, the rotary lifter including at least one flange and a plurality of lifter pins extending from the flange, the rotary lifter being movable relative to the driver blade axis to an axial home position whereby the driver blade is able to engage the lifter pins; a motor; a drive shaft extending along a drive shaft axis that is non-intersecting with the driver blade axis, the drive shaft being coupled to the motor and configured to receive torque from the motor, the drive shaft being coupled to the rotary lifter and configured to transmit torque to the rotary lifter to return the driver blade from the bottom dead center position toward the top dead center position, the drive shaft including a shoulder; and a spring positioned along the drive shaft axis between the shoulder and the flange, the spring being configured to apply an axial biasing force along the drive shaft axis to the rotary lifter.

42. The powered fastener driver of claim 41, wherein, The drive shaft includes an arcuate portion, a flat portion adjacent the arcuate portion through which torque is transmitted to the rotary lifter, and the shoulder extends radially outwardly from the arcuate portion.

43. The powered fastener driver of claim 42, wherein, The spring is positioned between the shoulder and the flange.

44. The powered fastener driver of claim 41, wherein the driver blade is configured to be moved from the first position to the second position by the driver blade being moved in a direction that is substantially parallel to the longitudinal axis of the driver blade. The spring is a leaf spring.

45. A powered fastener driver characterized by: Comprising: a driver blade movable from a top dead center position to a bottom dead center position for driving a fastener into a workpiece; and a lifter assembly for providing torque to move the driver blade from the bottom dead center position toward the top dead center position, the lifter assembly including a rotary lifter configured to be engageable with the driver blade, the rotary lifter having a plurality of lifter pins and a roller disposed on at least one of the lifter pins, and a motor configured to provide torque to the rotary lifter; wherein the driver blade includes a lifter tooth having a crown disposed thereon, the crown being engaged by the roller during movement of the driver blade toward the top dead center position.

46. A powered fastener driver characterized by: Comprising: a driver blade movable from a top dead center position to a bottom dead center position for driving a fastener into a workpiece; and a lifter assembly for providing torque to move the driver blade from the bottom dead center position toward the top dead center position, the lifter assembly including a lifting assembly for providing torque to move the driver blade from the bottom dead center position toward the top dead center position, the lifting assembly comprising a rotary lifter configured to be engageable with the driver blade, the rotary lifter having a plurality of lifting pins, and a motor configured to provide torque to the rotary lifter; wherein at least one of the plurality of lifting pins comprises a plurality of cam portions defined by a cup-shaped recess having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the driver blade comprises a lifting tooth having a crown disposed thereon, the crown configured to engage with at least one of the plurality of cam portions during movement of the driver blade toward the top dead center position.

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