EXTERNAL FORCE FASTENING PULLER

Abstract

A power-operated fastener driver is described, comprising a housing that defines a cylinder support section, a drive unit support section, and a handle section spaced apart from the drive unit support section. The power-operated fastener driver includes a cylinder, a piston that can be moved within the cylinder from a top dead center (TDC) position to a bottom dead center (BDC) position, a drive blade attached to the piston to move with it along a drive axis from the TDC position towards the BDC position, a lifting device operable to move the piston and drive blade together from the BDC position towards the TDC position, and a drive unit supported by the drive unit support section and operatively connected to the lifting device.The externally operated fastener driver further comprises a user interface supported by the housing and a circuit board located in the housing and positioned between the drive unit support section and the handle section.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of copending U.S. patent application No. 18 / 178,104, filed March 3, 2023, which claims priority to U.S. Provisional Patent Application No. 63 / 391,491, filed July 22, 2022, and U.S. Provisional Patent Application No. 63 / 316,510, filed March 4, 2022, the entire contents of which are incorporated herein by reference. FIELD OF THE INVENTION

[0002] The present invention relates to power-operated fastener drivers, in particular gas spring-operated fastener drivers. BACKGROUND OF THE INVENTION

[0003] Various fastener drivers are known in the art for driving fasteners (e.g., nails, tacks, staples, etc.) into a workpiece. These fastener drivers operate using various means known in the art (e.g., compressed air generated by an air compressor, electrical power, a flywheel mechanism, etc.), but these designs often encounter performance, size, and cost limitations. SUMMARY OF THE INVENTION

[0004] The present invention, in one aspect, provides a power-operated fastener driver comprising a housing defining a cylinder support portion, a drive unit support portion, and a handle portion spaced from the drive unit support portion. The handle portion is configured to releasably attach a battery pack thereto. The power-operated fastener driver includes a cylinder within the cylinder support portion and a piston movable within the cylinder from a top dead center (TDC) position to a driven or bottom dead center (BDC) position.The power-operated fastener driver further includes a driving blade attached to the piston for movement therewith along a driving axis from the top dead center (TDC) position toward the bottom dead center (UTP) position to drive a fastener into a workpiece, a lifting device operable to move the piston and driving blade together from the bottom dead center (UTP) position toward the top dead center (TDC) position, and a drive unit supported by the drive unit support portion and operatively connected to the lifting device. The drive unit includes a brushless direct current (BLDC) motor. The power-operated fastener driver further includes a user interface supported by the housing and a circuit board located within the housing and disposed between the drive unit support portion and the handle portion.The circuit board receives electrical power from the battery pack and includes a plurality of power switches for switching the motor and an electronic processor for controlling and receiving inputs from the user interface.

[0005] According to another aspect, the present invention provides a power-operated fastener driver comprising a housing, a cylinder disposed within the housing, a piston movable within the cylinder from a top dead center (TDC) position to a driven or bottom dead center (BDC) position, a driving blade attached to the piston and movable therewith along a driving axis from the TDC position toward the BDC position to drive a fastener into a workpiece, a lifting device operable to move the piston and the driving blade together from the BDC position toward the TDC position, and a drive unit disposed within the housing and operatively connected to the lifting device. The drive unit comprises a motor having a first output shaft extending along a motor axis.The fastener driver further includes an inner frame positioned within the housing and including a drive unit housing portion in which at least a portion of the drive unit is received, a bumper connected to and extending from the inner frame, and a workpiece contact assembly connected to the housing and movable from an extended position to a retracted position in response to contact with a workpiece. The workpiece contact assembly includes a biasing member biasing the workpiece contact assembly to the extended position. The fastener driver further includes a magazine configured to receive fasteners. The magazine includes a first end and a second end opposite the first end.A muzzle assembly is connected to the first end of the magazine and includes a channel from which successive fasteners are driven from the magazine. The workpiece contact assembly is engageable with the bumper in response to an applied force that moves the workpiece contact assembly beyond the retracted position.

[0006] According to another aspect, the present invention provides a power-operated fastener driver comprising a magazine assembly configured to receive fasteners. The magazine assembly includes a first end and a second end. A muzzle assembly includes a channel from which successive fasteners are driven from the magazine assembly. The fastener driver further includes a slider assembly slidably connected to the magazine assembly. The slider assembly is configured to bias the fasteners within the magazine assembly toward the channel. The slider assembly includes a slider body, a cover connected to the slider body, and a blanking element connected to the slider body. The blanking element is located between the slider body and the cover.The slider body and the blank-fire safety element are selectively movable relative to one another. The slider assembly is adjustable between a first state in which the slider body and the blank-fire safety element are configured to move together toward the channel and a second state in which relative movement has occurred between the slider body and the blank-fire safety element. The fastener driver further includes a pocket disposed at the second end of the magazine assembly and receiving at least a portion of the slider body when the slider body is proximate the second end of the magazine assembly, and a workpiece contact assembly movable relative to the muzzle assembly between an extended and a retracted position.In a first position of the blank-fire safety element relative to the magazine assembly, the workpiece contact element is configured to slide past the blank-fire safety element in response to movement toward the retracted position. In a second position, the blank-fire safety element prevents movement of the workpiece contact assembly toward the retracted position when a predetermined number of fasteners remain in the magazine assembly. The slider unit is configured to transition from the first state to the second state before the predetermined number of fasteners is reached in the magazine assembly.

[0007] Further features and aspects of the invention will become apparent upon consideration of the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of a gas spring powered fastener driver having a magazine and a workpiece contact assembly according to an embodiment of the invention. Fig. 2A is another perspective view of the gas spring driven fastener driver of Fig. 1. Fig. 2B1 is a cross-sectional view of the gas spring-operated fastener driver of Fig. 1 along line 2B 1--2B1 from Fig. 2A. Fig. 2B2 is a cross-sectional view of another gas spring-operated fastener driver of Fig. 1 along line 2B 1--2B1 from Fig. 2A. Fig. 2C is a cross-sectional view of the gas spring-operated fastener driver of Fig. 1 along line 2C--2C from Fig. 2A. Fig. 3 is a partial sectional view of the gas spring driven fastener driver of Fig. 1, with parts removed for clarity. Fig. 4 is another partial sectional view of the gas spring driven fastener driver of Fig. 1, with parts removed for clarity. Fig. 5 is a plan view of the gas spring driven fastener driver of Fig. 1. Fig. 6A is a cross-sectional view of the gas spring-operated fastener driver of Fig. 1 along the Fig. 2A, showing, among other things, a storage chamber cylinder, a cylinder, a piston having a first configuration, a drive blade, and a bumper. Fig. 6B is a perspective view of the piston and the driving blade of Fig. 6A. Fig. 6C is an exploded view of the piston and the drive blade of Fig. 6A. Fig. Figure 6D is a cross-sectional view of the piston and the driving blade of Fig. 6A along line 6D--6D from Fig. 6B. Fig. 6E is a cross-sectional view of the gas spring-operated fastener driver of Fig. 1 along the Fig. 2A, showing, among other things, a storage chamber cylinder, a cylinder, a piston with a second configuration, a driving blade, and a bumper. Fig. 6F is a perspective view of the piston and the driving blade of Fig. 6E. Fig. 6G is an exploded view of the piston and the drive blade from Fig. 6E. Fig. 6H is a cross-sectional view of the piston and the driving blade of Fig. 6A along line 6H--6H from Fig. 6F. Fig. 6I is a perspective view of another piston and another driving blade having a similar configuration as in Fig. 6E. Fig. 6J is a cross-sectional view of the piston and the driving blade of Fig. 6A along the line 6J-6J from Fig. 6I. Fig. Figure 7A is a schematic view of the gas spring driven fastener driver of Fig. 1, showing a driving blade in a driven or bottom dead center position. Fig. Figure 7B is a schematic view of the gas spring driven fastener driver of Fig. 1, showing a driving blade in a top dead center position prior to actuation. Fig. Figure 8 is a cross-sectional view of a portion of the storage chamber cylinder of Fig. 6A along the Fig. Line 8--8 shown in Figure 6A. Fig. 9A is a lower end view of the bumper of Fig. 6A according to one embodiment. Fig. 9B is a perspective view of the bumper of Fig. 9A. Fig. 9C is a side view of the bumper from Fig. 9A. Fig. 9D is a side view of a bumper fitted with the gas spring driven driver from Fig. 1 can be used, according to a further embodiment. Fig. 9E is a lower end view of the bumper from Fig. 9D. Fig. 9F is a perspective view of the bumper from Fig. 9D. Fig. 9G is a cross-sectional view of a portion of a storage chamber cylinder associated with the bumper of Fig. 9D can be used. Fig. 9H is a cross-sectional view of the power-operated fastener driver of Fig. 1 along line 9H--9H from Fig. 3, which shows the storage chamber cylinder with a different configuration and the bumper with a different configuration. Fig. 9I is a cross-sectional view of the storage chamber cylinder of Fig. 9H along the line 9H--9H from Fig. 3. Fig. 9J is an upper end view of the bumper from Fig. 9H. Fig. 9K is a perspective view of the bumper from Fig. 9H. Fig. 9L is a lower end view of the bumper from Fig. 9H. Fig. 9M is another perspective view of the bumper from Fig. 9H. Fig. 10 is a rear view of the gas spring driven fastener driver of Fig. 1. Fig. 11 is a cross-sectional view of the gas spring driven fastener driver of Fig. 1, which runs along line 11--11 from Fig. 2A and shows a gearbox. Fig. 12 is a perspective view of the gearbox of Fig. 11, which shows a gearbox housing. Fig. 13 is a perspective view of the gearbox of Fig. 11, whereby the gearbox housing of Fig. 12 away. Fig. 14 is a cross-sectional view of the gearbox of Fig. 11 along line 14--14 from Fig. 11. Fig. 15 is a cross-sectional view of the gearbox of Fig. 11 along line 15--15 from Fig. 11. Fig. 16 is a cross-sectional view of the gearbox of Fig. 11 along line 16--16 from Fig. 11. Fig. 17 is a perspective view of the magazine from Fig. 1. Fig. 18 is another perspective view of the magazine from Fig. 1. Fig. 19 is a perspective view of the magazine from Fig. 1 with a part removed, showing a slide arrangement. Fig. 20A is an enlarged perspective view of the slide assembly of Fig. 19. Fig. 20B is another enlarged perspective view of the slider assembly of Fig. 19. Fig. 21A shows a workpiece contact arrangement of Fig. 1 connected blank firing safety element in a first position when more than a predetermined number of fastening means are in the magazine. Fig. 21B shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in the first position when there are more than a predetermined number of fasteners in the magazine. Fig. 21C shows the workpiece contact arrangement from Fig. 1 connected blank firing safety element in a second position when more than a predetermined number of fasteners are in the magazine. Fig. 21D shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in the second position when there are more than a predetermined number of fasteners in the magazine. Fig. 21E shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in a third position when there are more than a predetermined number of fasteners in the magazine. Fig. 21F shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in the third position when there are more than a predetermined number of fasteners in the magazine. Fig. 22A shows a workpiece contact arrangement of Fig. 1 connected blank firing safety element in a first position when there is one more than the predetermined number of fastening means in the magazine. Fig. 22B shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in the first position when there is one more than the predetermined number of fasteners in the magazine. Fig. 22C shows the workpiece contact arrangement from Fig. 1 connected blank firing safety element in a second position when there is one more than the predetermined number of fasteners in the magazine. Fig. 22D shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in the second position when there is one more than the predetermined number of fasteners in the magazine. Fig. 22E shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in a third position when there is one more than the predetermined number of fasteners in the magazine. Fig. 22F shows the workpiece contact arrangement from Fig. 1 connected blank firing safety link in the third position when there is one more than the predetermined number of fasteners in the magazine. Fig. 23A shows a workpiece contact arrangement of Fig. 1 connected blank firing safety element in a first position when the predetermined number of fasteners is in the magazine. Fig. 23B shows the workpiece contact arrangement from Fig. 1 connected blank firing safety element in a second position when the predetermined number of fasteners is in the magazine. Fig. 24 is a perspective view of a gas spring powered fastener driver having a magazine and a workpiece contact assembly according to another embodiment of the invention. Fig. 25 is another perspective view of the gas spring driven fastener driver of Fig. 24. Fig. 26A is a cross-sectional view of the gas spring-operated fastener driver of Fig. 24 along line 26--26 from Fig. 25 and shows a circuit board configuration according to an embodiment of the invention. Fig. 26B is a cross-sectional view of the gas spring-operated fastener driver of Fig. 24 along line 26--26 from Fig. 25 and shows a circuit board configuration according to another embodiment of the invention. Fig. 27 is an enlarged perspective view of the gas spring driven fastener driver of Fig. 24. Fig. 27A is an enlarged perspective view of a gas spring-operated fastener driver according to another embodiment of the invention showing a bumper to an inner frame. Fig. 28 is an enlarged cross-sectional view of the gas spring-operated fastener driver of Fig. 24 along line 28--28 from Fig. 27. Fig. Figure 28A is an enlarged cross-sectional view of the gas spring-operated fastener driver of Fig. 27A along line 28A--28A from Fig. 27A. Fig. 29 is a perspective view of the magazine from Fig. 24, which shows a slide arrangement. Fig. 30 is a cross-sectional view of the magazine from Fig. 29 along the line 30--30 in Fig. 29. Fig. 31 is another perspective view of the magazine from Fig. 24. Fig. 31A is a perspective view of the slide assembly of Fig. 29. Fig. 31B is a perspective view of a spring assembly of the slide assembly of Fig. 29. Fig. 31C is a perspective view of a slider assembly according to another embodiment of the invention. Fig. 31D is a partially exploded view of the slide assembly of Fig. 31C. Fig. 32 shows a workpiece contact arrangement from Fig. 24 connected blank firing safety link when there are more than a predetermined number of fasteners in the magazine. Fig. 33 shows a workpiece contact arrangement from Fig. 1 connected blank firing safety link if there is one more than the predetermined number of fasteners in the magazine. Fig. 34 shows a workpiece contact arrangement from Fig. 1 connected blank firing safety link when the predetermined number of fasteners is in the magazine. Fig. 35 shows a schematic view of a gearbox for use with the fastener driver of Fig. 1 or Fig. 24 relative to its drive axis.

[0008] Before embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and may be practiced or carried out in various ways. Furthermore, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be considered limiting.

[0009] Furthermore, the articles "ein / e" and "der / die / das" should not be interpreted to mean "exactly one" or "only one" unless usage clearly indicates otherwise. Rather, these articles should be understood to mean "at least one" or "one or more." When the phrases "der / die / das" or "der / die / das" are used to refer to a noun previously introduced by the indefinite article "ein / e," "der / die / das" and "der / die / das" mean "at least one" or "one or more," unless usage clearly indicates otherwise.

[0010] Additionally, although certain drawings depict hardware and software residing within particular devices, it should be understood that these images are for illustrative purposes only. In some embodiments, the depicted components may be combined or separated into separate software, firmware, and / or hardware. For example, rather than being located within and performed by a single electronic processor, logic and processing may be divided among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links.

[0011] That is, if the claims claim an apparatus or system, for example, as comprising an electronic processor or other element arranged in a particular manner, for example, to perform multiple purposes, the claim or claim element shall be interpreted to mean one or more electronic processors (or other elements), any one of the one or more electronic processors (or other elements) being arranged according to the claim to perform, for example, some or all of the multiple purposes, for example, jointly. These electronic processors and processing may thus, to reiterate, be distributed. DETAILED DESCRIPTION

[0012] According to Fig. 1 and Fig. 6, a gas spring-operated fastener driver 10 can be operated to drive fasteners (e.g., nails, tacks, staples, etc.) held in a magazine 14 into a workpiece. The fastener driver 10 includes an inner cylinder 18 and a movable piston 22 disposed within the cylinder 18 ( Fig. 6A, Fig. 7A, Fig. 7B). According to Fig. 6A to 7B, the fastener driver 10 further includes a driving blade 26 attached to and movable with the piston 22. The fastener driver 10 does not require an external air pressure source, but instead includes an external storage chamber cylinder 30 of pressurized gas in fluid communication with the cylinder 18. In the illustrated embodiment, the cylinder 18 and the movable piston 22 are disposed within the storage chamber cylinder 30. The driver 10 further includes a fill valve (not shown) connected to the storage chamber cylinder 30. When connected to a pressurized gas source, the fill valve allows the storage chamber cylinder 30 to be refilled with pressurized gas if a leak has previously occurred. The fill valve may, for example, be configured as a Schrader valve.

[0013] As in Fig. 6A and Fig. 6B and explained below, the driving blade 26 has a body 26c, lifting teeth 26a extending from one side of the body 26c, and locking teeth 26b extending from an opposite side of the body 26c. In the illustrated embodiment, the body 26c of the driving blade 26 has a first surface and a second surface opposite the first surface. Each of the lifting teeth 26a has a first surface and a second surface opposite the first surface, and each of the locking teeth 26b has a first surface and a second surface opposite the first surface. The first surface of the body 26c, each of the first surfaces of the lifting teeth 26a, and each of the first surfaces of the locking teeth 26b are arranged in a first plane 26e ( Fig. 6D). The second surface of the body 26c, each of the second surfaces of the lifting teeth 26a and each of the second surfaces of the locking teeth 26b are arranged in a second plane 26f ( Fig. 6E). In other embodiments, such as the one shown in Fig. 6H to 6J, the locking teeth 26b are not located in the first and second planes, but may be disposed between the first and second planes. An opening 26d extends through the body 26c between the first surface and the second surface. Accordingly, the opening 26d is oriented perpendicular to both the first plane and the second plane.

[0014] In the embodiment of Fig. 6A to 6D, the piston 22 comprises a first portion 22a and a second portion 22b formed integrally with the first portion 22a. The first portion 22a is substantially cylindrical and has a first diameter D1 ( Fig. 6D), while the second portion 22b is substantially oval and has a first dimension D2 ( Fig. 6D) and a second dimension D3 ( Fig. 6C) which is smaller than the first dimension D1. In the embodiment of Fig. 6A to 6D, the first diameter D1 measures approximately 1.0 inch (or approximately 24 mm), the first dimension D2 measures approximately 0.5 inch (approximately 13 mm), and the second dimension D3 measures approximately 0.4 inch (or approximately 10 mm). As used herein, "approximately" means plus or minus 0.2 inch (or approximately 5 mm). The second portion 22b includes a slot 22c extending therethrough. The slot 22c bifurcates the second portion 22b, forming a first leg 22d and a second leg 22e on opposite sides of the slot 22c. The first leg 22d includes an opening 22f, and the second leg 22e includes a bore 22g ( Fig. 6D). The opening 22f is aligned with (e.g., coincident with) the bore 22g. The diameters of the opening 22f and the bore 22g are approximately 0.12 inches (or approximately 3.05 mm). The slot 22c is sized and shaped to receive the driving blade 26 such that the opening 26d is aligned with (e.g., coincident with) the opening 22f and the bore 22g of the second portion 22b. A pin 32 is received in the aligned openings 26d, 22f, and the bore 22g to connect the piston 22 to the driving blade 26. The pin 32 is substantially cylindrical and has a diameter of approximately 0.116 inches (or approximately 2.95 mm). In the embodiment of Fig. 6A through 6D, the piston 22 is constructed from a first material (e.g., aluminum), and the drive blade 26 and pin 32 are constructed from a second material (e.g., steel). In other embodiments, the piston 22, the drive blade 26, and the pin 32 may be constructed from the same second material (e.g., steel).

[0015] In the embodiment of Fig. 6E to 6G, the piston 22 has a different configuration than the piston 22 of Fig. 6A to 6D. Therefore, only the differences between the piston 22 from Fig. 6E to 6G and the piston 22 from Fig. 6A to 6D. In the embodiment of Fig. 6E to 6G, the first portion 22a and the second portion 22b are separate components that are screwed together. For this purpose, the first portion 22a includes a recess 34a at one end and a threaded bore 34b extending from the recess 34a at least partially through the first portion 22a. The recess 34a circumscribes the threaded bore 34b. The second portion 22b has a threaded projection 36 extending therefrom. The second portion 22b is connected to the first portion 22a via the threaded engagement therebetween. In particular, the threaded projection 36 is designed to engage the threaded bore 34b. In the connected state, the second portion 22b sits in the recess 34a of the first portion 22a. In the embodiment of Fig. 6E to 6G, the first portion 22a of the piston 22 is constructed from a first material (e.g., aluminum) and the second portion 22b of the piston 22, the drive blade 26, and the pin 32 are constructed from a second material (e.g., steel). In other embodiments, both the first and second portions 22a, 22b of the piston 22, the drive blade 26, and the pin 32 may be constructed from the same second material (e.g., steel). In the illustrated embodiment, a central longitudinal axis extending through the threaded bore 34a is aligned with a central longitudinal axis of the first portion 22a. Accordingly, a central longitudinal axis extending through the second portion 22b is also aligned with the central longitudinal axis of the first portion 22a, and the central longitudinal axis of the first portion 22a extends centrally through the slot 22c.In other embodiments, the central longitudinal axis extending through the threaded bore 34a may be offset from the central longitudinal axis of the first portion 22a. In this case, the central longitudinal axis extending through the second portion 22b may also be offset relative to the central longitudinal axis of the first portion 22a, such that the central longitudinal axis of the first portion 22a is not centered through the slot 22c.

[0016] The piston 22 from Fig. 6E to 6G has a similar size to the piston 22 from Fig. 6A to 6D. Therefore, in the embodiment of Fig. 6E to 6G, as in the embodiment of Fig. 6A to 6D, the first diameter D1 measures approximately 1.0 inch (or approximately 24 mm), the first dimension D2 measures approximately 0.5 inch (or approximately 13 mm), the second dimension D3 measures 0.4 inch (or approximately 10 mm), the diameters of the opening 22f and the bore 22g measure approximately 0.12 inch (or approximately 3.05 mm), and the diameter of the pin measures approximately 0.116 inch (or approximately 2.95 mm).

[0017] The piston 22 and the drive blade 26 from Fig. However, 6E to 6G may also be suitable for larger power-operated fastener drivers and therefore have other (e.g. larger) dimensions, as shown in Fig. 6H to 6J. In the embodiment of Fig. 6H to 6J, the first diameter measures approximately 1.7 inches (or approximately 43 mm), the first dimension D2 measures approximately 0.8 inches to 0.9 inches (or approximately 20 mm to 22.3 mm), the second dimension D3 measures approximately 1.1 inches (or approximately 28 mm), the diameters of the opening 22f and the bore 22g measure approximately 0.18 inches (or approximately 4.5 mm), and the diameter of the pin 32 measures approximately 0.18 inches (or approximately 4.5 mm). As previously mentioned, the pin 32 is pressed into the bore 22g.

[0018] According to Fig. 6A to 7B, the cylinder 18 and the driving blade 26 define a driving axis 38. During a driving cycle, the driving blade 26 and the piston 22 are between a top dead center (OTC) position ( Fig. 7B) and a driven or bottom dead center (BDC) position ( Fig. 7A). The fastener driver 10 further comprises a lifting assembly 42 ( Fig. 3, 4, 6 and 11-13), which has a lifting device 44 ( Fig. 6A) driven by a motor 46 ( Fig. 3, 4, 11-12) and which moves the driving blade 26 from the driven position to the TDC position.

[0019] In operation, the lifting assembly 42 drives the piston 22 and the driving blade 26 toward the TDC position by energizing the motor 46. As the piston 22 and the driving blade 26 are driven toward the TDC position, the gas above the piston 22 and the gas in the storage chamber cylinder 30 are compressed. Before the TDC position is reached, the motor 46 is deactivated, and the piston 22 and the driving blade 26 are held in a standby position located between the TDC position and the UDC position (e.g., the driven position) until they are released by actuation of a trigger 48 ( Fig. 1) by a user. When released, the pressurized gas above the piston 22 and within the storage chamber cylinder 30 drives the piston 22 and the driving blade 26 into the driven position, thereby driving a fastener into the workpiece. The illustrated fastener driver 10 therefore operates on a gas spring principle, utilizing the lift assembly 42 and the piston 22 to further compress the gas in the cylinder 18 and the storage chamber cylinder 30. Further details regarding the structure and operation of the fastener driver 10 are set forth below.

[0020] According to Fig. 6A to 7B, the storage chamber cylinder 30 surrounds the cylinder 18. The cylinder 18 has an annular inner wall 50 designed to guide the piston 22 and the driving blade 26 along the driving axis 38 to compress the gas in the storage chamber cylinder 30. The storage chamber cylinder 30 has an annular outer wall 54 circumferentially surrounding the inner wall 50. The cylinder 18 is thus designed to be axially mounted to the storage chamber cylinder 30.

[0021] According to Fig. 6A, the driver 10 includes a bumper 60 positioned under the piston 22 to stop the piston 22 in the driven position ( Fig. 7A) and to absorb the impact energy of the piston 22. The bumper 60 is designed to distribute the impact force of the piston 22 evenly across the entire bumper 60 when the piston 22 is rapidly decelerated upon reaching the driven position (i.e., bottom dead center position). The bumper 60 may be formed of any suitable resilient material (e.g., rubber). It is possible that a piston 22 constructed wholly or partially of a stronger material, such as steel (as described above), may be able to withstand the high shocks experienced during a cold firing event. As the tool becomes cold, the stiffness of the bumper 60 increases, and instead of a soft rubber absorbing the impact, the bumper 60 is no longer compressed as much, absorbing less energy and causing greater stress on the piston 22.A steel piston 22 can withstand this impact better than an aluminum piston 22 due to its higher strength.

[0022] As in Fig. 9A through 9G, in the illustrated embodiments, the bumper 60 may have an asymmetric shape and include an asymmetric opening 62 extending therethrough. The bumper 60 defines a first bumper plane 60a and a second bumper plane 60b that is perpendicular to the first bumper plane 60a. The drive axis 38 extends in the second bumper plane 60b. In the illustrated embodiments, the bumper 60 includes an upper portion having a first circumferential dimension and a lower portion having a second circumferential dimension that is greater than the first circumferential dimension. In the illustrated embodiment, the opening 62 is generally oval. As shown, the opening 62 is asymmetric in the first bumper plane 60a and symmetric in the second bumper plane 60b that is perpendicular to the drive axis 38 and the first bumper plane 60a.In other embodiments, the opening 62 may be asymmetrical about both the first and second bumper planes 60a, 60b. Furthermore, the opening 62 has a height H1 extending along the first bumper plane 60a and a width W1 extending along the second bumper plane 60b. As shown, the width W1 is greater than the height H1. In the illustrated embodiments, a slot 30a extending through the storage chamber cylinder 30 and receiving the sheet has a height H2 and a width W2. As shown in the illustrated embodiments, the width W2 of the slot 30a is substantially similar to the width W1 of the opening 62, but the height H2 of the slot 30a is much smaller than a height H1 of the opening 62. In some embodiments, the height H2 of the slot 30a is half or less than half the height H1 of the opening 62.

[0023] In the in the Fig. 8 through 9G, the bumper 60 may include a key 64 (e.g., a male component) configured to be received in a complementary keyway 68 (e.g., a female component) of the storage chamber cylinder 30 (e.g., an internal frame member or housing). The use of the key 64 and keyway 68 prevents the bumper 60 from rotating during the firing operation. In the illustrated embodiment, the key 64 of the bumper 60 may include one or more projections, and the keyways 68 of the storage chamber cylinder 30 may be complementary recesses that each receive one of the projections of the bumper 60. As shown, the bumper 60 includes two projections 64 disposed side by side on the same side of the asymmetric opening 62.In other embodiments, the bumper 60 may include any number of protrusions 64 arranged in any suitable configuration. In other embodiments, such as in FIG. Fig. 9I to 9M, the one or more keys 64 (e.g., male components) may extend from the storage chamber cylinder 30, and the one or more keyways 68 (e.g., the female components) may be formed on the bumper. In the embodiment of Fig. 9I to 9M there are three keyways 68. On each opposite side of the second bumper plane 60b there is at least one keyway 68. As in Fig. 9L, there is a keyway 68 on a first side of the second bumper plane 60b and two keyways 68 on a second, opposite side of the second bumper plane 60b. In other words, there is one keyway 68 that lies at least partially in the first bumper plane 60a and one keyway 68 on each side of the first bumper plane 60a. In the embodiment shown in Fig. In the embodiment illustrated in Figure 9I, the keys 64 are curved projections or grooves that extend along the wall of the storage chamber cylinder 30 parallel to the drive axis 38. The keyways 68 are also curved recesses in the second outer periphery of the bumper 60. Regardless of the configuration of the keys / keyways, the keys / keyways cause the bumper 60 to have a generally asymmetric shape about the first bumper plane 60, the second bumper plane 60b, or both the first and second bumper planes 60s, 60b. In the illustrated embodiment, the bumper 60 has a generally asymmetric shape about the first and second bumper planes 60a, 60b. In addition, the keys / keyways are designed to clock the bumper 60 in the correct or predetermined orientation so that the opening 62 is correctly aligned with respect to the storage chamber cylinder 30 and its slot 30a.

[0024] In addition, the upper section of the bumper 60 in the Fig. 9A to 9F, an angled outer surface 70 defining the first outer dimension (e.g., an outer diameter) that tapers from a top end to a middle section. In contrast, the lower section has a substantially straight outer surface 72 defining a substantially constant second outer dimension (e.g., outer diameter) from the middle section to a bottom end. In other embodiments (e.g., Fig. 9D to 9F), the lower portion may alternatively have a tapered edge 72a such that the lower portion has both a straight outer surface 72 and an angled outer surface 72a. Regardless of the embodiment, the upper portion may have a different cross-sectional shape than the lower portion.

[0025] It should be noted that although the bumpers 60 with the keys 64 and the cylinders 30 with the keyways 68 are shown with respect to the power fastener driver illustrated, the bumper and cylinder configurations can also be used in power fastener drivers with other configurations (e.g., a roofing nailer).

[0026] The asymmetrical shape of the bumper 60 and its asymmetrical opening 62 are designed to accommodate the lifting teeth 26a and the locking teeth 26b on each side of the bumper 60, but also allow the opening 62 to be smaller at its opposite ends, thus allowing the bumper 60 to be smaller overall. In particular, the shape of the opening 62 allows the bumper 60 to be smaller, since clearance is only required on the opposite sides of the driving blade 26. On the other hand, if the opening 62 were circular (rather than oval), the bumper 60 would have thinner walls at the top and bottom of the bumper 60 and would therefore need to have a larger outer dimension to compensate. The configuration of the bumper 60 therefore allows the size of the storage chamber cylinder 30 to be reduced, resulting in a tool with a narrower width.The shape of the opening 62 also significantly reduces the stress on the bumper 60 during compression. In conventional designs, a cutout for the drive blade may have a smaller clearance, but it is similar in size and shape to the slot 30a in the accumulator chamber cylinder. In other words, the heights of conventional cutouts are much closer to the heights of the slots in the accumulator chamber cylinder. This results in a large stress concentration on the bumper on one side of the cutout.

[0027] According to Fig. 1 and Fig. 2, the driver 10 comprises a housing 80 with a cylinder support section 84 in which the storage chamber cylinder 30 is at least partially arranged, a drive unit support section 88 in which the motor 46 and a gear 92 are at least partially arranged, a handle section 91 and a connecting section 93 which has one or more circuit boards 95a, 95b ( Fig. 3 and Fig. 4) and a user interface 97. The handle portion 91 defines a handle axis 91' that intersects the driving axis 38. In other words, the handle axis 91' is aligned in a plane 98 that bisects the driver 10 and passes through the driving axis 38 ( Fig. 4). In other embodiments, the handle axis 91' lies in a plane that is offset from the driving axis 38 by less than 10 mm. In other embodiments, the handle axis 91' lies in a plane that is offset from the driving axis 38 by less than 5 mm. In other embodiments, the handle axis 91' lies in a plane that is offset from the driving axis 38 by 1 mm to 5 mm. Furthermore, in the illustrated embodiment, both the cylinder support portion 84 and the connecting portion 93 extend between the drive unit support portion 88 and the handle portion 91. Accordingly, the drive unit support portion 88 and the handle portion 91 are spaced apart from one another. Furthermore, the drive unit support portion 88 is spaced from the handle portion 91 in the direction of the magazine 14 (and the muzzle assembly 400 and the second end 548 of the workpiece contact assembly 540).In the illustrated embodiment, the cylinder support portion 84, the drive unit support portion 88, the handle portion 91, and the connecting portion 94 are integrally formed together (e.g., by a casting or molding process, depending on the material used). As described in more detail below, the gear 92 raises the driving blade 26 from the driven position to the standby position.

[0028] According to Fig. 3 and Fig. 4, a first circuit board 95a and a second circuit board 95b are both supported within the connecting portion 93 of the housing. In addition, a third circuit board 95c is supported within the drive unit support portion 88. In the illustrated embodiment, the first circuit board 95a is the power supply board, the second circuit board 95b is a user interface board, and the third circuit board 95c is a motor circuit board. The first circuit board 95a is in electrical communication with a power source (e.g., a battery pack 90). The first circuit board 95a is thus powered by the power source. The second circuit board 95b includes one or more displays (e.g., one or more lights or LEDs). As shown, the first circuit board 95a is located below the second circuit board 95b within the connecting portion 93. The third circuit board 95c is located below the motor 46 and is connected thereto.The third circuit board 95c is in electrical connection with the motor 46. The second circuit board 95b and the third circuit board 95c are in electrical connection with the first circuit board 95a.

[0029] According to Fig. 4, the motor 46 is disposed within the drive unit support portion 88 to provide torque to the gearbox 92 upon activation. The battery pack 90 is received and supported by a battery pack mounting interface 390 of the handle portion 91. The battery pack 90 can be electrically connected to the motor 46 to power the motor 46 via the first circuit board 95a. In alternative embodiments, the driver can be powered from an alternative power source, such as an AC input (i.e., from a wall outlet) or from an alternative DC input (e.g., an AC / DC converter).

[0030] According to Fig. 4, the gearbox 92 supplies torque from the motor 46 to the lifting device 44. The gearbox 92 includes a drive shaft 94 and a first output shaft 96 extending along a first output shaft axis 96'. In the illustrated embodiment, the first output shaft axis 96' intersects the driver axis 38. In other words, the handle axis 91' and the first output shaft axis 96' lie in the plane 98 that bisects the driver 10 and also contains the driver axis 38. In other embodiments, such as in Fig. 35, the first output shaft axis 96' lies in a plane that is offset from the drive axis 38 by a first distance X. The first distance X may be less than about 10 mm (where approximately plus or minus 0.1 mm means). In other embodiments, the first distance X may be less than about 5 mm. In other embodiments, the first distance X may be between about 1 mm and 5 mm. In the embodiment of Fig. 35, the first distance X is less than about 1.5 mm. Regardless, the motor 46 is generally in line with the handle portion 91. As shown, the motor 46 is therefore located between the handle 91 and the magazine 14 (and thus between the muzzle assembly 400 and the second end 548 of the workpiece assembly 540). That is, the motor 46 is generally located below the handle 91 when the tool 10. According Fig. 4, the first output shaft 96 rotates a drive gear 100a, which drives an output gear 100b. In the illustrated embodiment, the gears 100a, 100b are intermeshing spur gears. A second output shaft 101 extends from the output gear 100b. The second output shaft 101 drives the lifting device 44, which in turn moves the driving blade 26 from the driven position to the ready position, as explained in more detail below. In the illustrated embodiment, the second output shaft 101 extends along a second output shaft axis 101' that is parallel to the first output shaft axis 96' and the plane 98. As shown, the second output shaft axis 101' extends in a plane that is laterally offset from the driving axis 38 and the plane 98 by a second distance Y. As shown, the second distance Y is also greater than the first distance X. As mentioned above, in some embodiments, such as in Fig. 35, the drive axis 38 is arranged between the first output axis 96' and the second output axis 101'. In the illustrated embodiment, the second distance Y is approximately 15.6 mm. In other embodiments, the second distance is between approximately 5 mm and approximately 30 mm or between approximately 10 mm and approximately 20 mm. As illustrated, the first motor axis 96' and the second motor axis 101' are spaced apart from each other by a third distance Z. In the illustrated embodiment, the third distance Z may be approximately 17 mm. In other embodiments, the third distance Z may be between approximately 10 mm and approximately 30 mm or between approximately 15 mm and approximately 20 mm. Accordingly, the drive axis 38 may be arranged at a distance of less than 10% of the third distance Z, measured from the first output axis 96'.

[0031] Since the motor 46 and the drive unit support section 88 are in line with the handle section 91, as shown in Fig. As shown in Figure 10, the driver 10 is more compact than conventional fastener drivers 10 in which the motor is offset from the handle portion. This is because only the output gear 101b and the second output shaft 101, and not the entire gearbox 92, need be offset from the drive axis 38 and the plane 98 to transmit torque to the jack 44.

[0032] As in Fig. As shown in Figure 11, the transmission 92 is designed as a planetary transmission with a first planetary gear stage 104 and a second planetary gear stage 106. In alternative embodiments, the transmission may be a single-stage planetary transmission or a multi-stage planetary transmission with any number of planetary gear stages. The first planetary gear stage 104 includes a ring gear 112, a carrier 116 ( Fig. 11 and Fig. 15), a sun gear 120 and a plurality of planet gears 124 connected to the carrier 116 for relative rotation therewith. The sun gear 120 is drivingly connected to the drive shaft 94 and meshes with the planet gears 124. The ring gear 112 has a toothed inner peripheral portion 128. In the illustrated embodiment, the ring gear 112 is mounted in the first planetary gear stage 104 on a transmission housing 132 ( Fig. 12) disposed adjacent to the motor 46 so that it cannot rotate relative to the transmission housing 132. The plurality of planetary gears 124 are rotatably supported on the carrier 116 and are engageable (i.e., meshed) with the toothed inner peripheral portion 128.

[0033] As in Fig. 11 and Fig. 15, the driver 10 further includes a one-way clutch mechanism 154 integrated into the transmission 92. In particular, the one-way clutch mechanism 154 includes the carrier 116, which is also a component of the second planetary gear set 106. The one-way clutch mechanism 154 enables transmission of torque to the first output shaft 96 of the transmission 92 in a single (i.e., first) rotational direction (i.e., counterclockwise with respect to the reference frame of Fig. 3), however, prevents the motor 46 from rotating in response to the application of torque to the first output shaft 96 of the gearbox 92 in an opposite, second direction of rotation (e.g., clockwise with respect to the reference frame of Fig. 3B) is driven in the reverse direction. In the illustrated embodiment, the one-way clutch mechanism 154 is integrated into the first planetary gear stage 104 of the transmission 92. In alternative embodiments, the one-way clutch mechanism 154 may be integrated, for example, into the second planetary gear stage 106.

[0034] As in Fig. 15, the one-way clutch mechanism 154 further includes a plurality of lugs 158 defined on an outer periphery of the carrier 116. Furthermore, the one-way clutch mechanism 154 includes a plurality of rolling elements 166 engageable with the respective lugs 158, and a ramp 170 adjacent each of the lugs 158 along which the rolling element 166 is movable. The illustrated rolling elements 166 extend from a disk 174. Each of the ramps 170 is inclined such that the rolling elements 166 are further away from a rotational axis 178 of the carrier 116 (into the side, as in Fig. 15) as the rolling elements 166 move further away from the respective lugs 158. According to Fig.14, the carrier member 116 of the one-way clutch mechanism 154 is located in the same planetary gear stage of the transmission 92 as the ring gear member 112 (i.e., in the first planetary gear stage 104). The rolling elements 166 are engageable with the second inner peripheral portion 140 of the ring gear member 112 when torque is applied to the first output shaft 96 in the second rotational direction (i.e., when the rolling elements 166 move along the ramps 170 away from the respective lugs 158). A biasing mechanism (e.g., a spring 182) is located between each of the rolling elements 166 and the carrier member 116. The springs 182 bias the rolling elements 166 toward the second inner peripheral portion 140 (and away from the lugs 158).

[0035] During operation of the one-way clutch mechanism 154, the rolling elements 166 are rotated in the first direction of rotation (ie, counterclockwise according to the frame of reference of Fig. 3) of the first output shaft 96 in close proximity to the respective lugs 158. However, when the piston 22 / drive blade 26 has reached the standby position, the rolling elements 166 move in an opposite, second rotational direction (ie, clockwise according to the frame of reference of Fig. 3) away from the respective lugs 158. More specifically, when the first output shaft 96 rotates a small amount (e.g., 1 degree) in the second rotational direction, the rolling elements 166 roll away from the respective lugs 158 along the ramps 170 and engage the second inner peripheral portion 140 on the ring gear 112, thereby preventing further rotation of the first output shaft 96 in the second rotational direction. Consequently, the one-way clutch mechanism 154 prevents the transmission 92 from applying torque to the engine 46 that could otherwise initiate reverse gearing or cause the engine 46 to rotate in a reverse direction when torque is applied to the first output shaft 96 in an opposite, second rotational direction (e.g., when the piston 22 and the drive blade 26 have reached the ready position).

[0036] According to Fig. 11 and Fig. 16, the second planetary gear stage 106 comprises a ring gear 190, a carrier 194 ( Fig. 11) and a plurality of planetary gears 198 connected to the carrier 194 for relative rotation therewith. The carrier 116 of the first planetary gear stage 104 further includes an output pinion 202 that meshes with the planetary gears 198, which in turn are rotatably mounted on the carrier 194 of the second planetary gear stage 106 and mesh with a toothed inner peripheral portion 206 of the ring gear 190. The ring gear 190 of the second planetary gear stage 106, like the ring gear 112, is fixed relative to the transmission housing 136. The carrier 194 is operatively connected to the first output shaft 96 for relative rotation therewith. Furthermore, the carrier 194 is operatively connected to the first output shaft 96 to rotate the first output shaft 96 and thus the drive gear 100a of the spur gear assembly.

[0037] Although not shown, the driver 10 further includes a torque limiting electronic clutch mechanism that limits an amount of torque transmitted to the first output shaft 96 and the lifting device 44.

[0038] According to Fig. 4, Fig. 6 and Fig. 12, the lifting device 44, which is a component of the lifting assembly 42, is rotationally coupled to the second output shaft 101, which in turn is driven by engagement of the output gear 100b with the drive gear 100a. The lifting device 44 includes a hub 260 with an opening 264. One end of the second output shaft 101 extends through the opening 264 and is rotatably attached to the lifting device 44. Further, according to Fig. 12, the hub 260 is formed from two plates 272A, 272B and includes a plurality of drive pins 276 extending between the plates 272A, 272B. The illustrated lifting device 44 includes four drive pins 276; however, in other embodiments, the lifting device 44 may include three or more drive pins 276. The drive pins 276 may be sequentially engaged with the driving blade 26 to raise the driving blade 26 from the driven position to the standby position.

[0039] The illustrated lifting device 44 further includes a disc element 282 disposed adjacent to the lower plate 272B ( Fig. 12). The disc element 282 is rotationally fixedly connected to the second output shaft 101 and the lifting device 44. The disc element 282 carries a magnet 300. In particular, the disc element 282 can be considered a retaining element for preventing axial movement of the drive pins 276 and the magnet 300 relative to the second output shaft axis 101'.

[0040] The driver 10 further includes a sensor (e.g., a Hall-effect sensor, not shown) located near the lifting device 44. As mentioned above, the lifting device 44 includes the magnet 300 carried by the disk member 282. The sensor and the magnet 300 are configured to indicate a position of the driver blade 26 (i.e., the ready position).

[0041] According to Fig. 4, as mentioned above, the driving blade 26 includes lifting teeth 26a along its length, and the respective drive pins 276 are engageable with the lifting teeth 26a when the driving blade 26 is moved back from the driven position to the standby position. The illustrated driving blade 26 includes eight lifting teeth 26a, such that two revolutions of the lifting device 44 move the driving blade 26 from the driven position to the standby position.

[0042] As explained above, the driving blade 26 further includes axially spaced locking teeth or projections 26b formed on and extending from the driving blade 26 opposite the lifting teeth 26a.

[0043] As mentioned above, the elevator 42 moves the flysheet 26 from the driven position to the ready position. The sensor determines the position of the flysheet 26 in response to sensing the magnet 300, which is disposed on the disc member 282 and rotates with the elevator 44. Specifically, the magnet 300 is aligned with the sensor when the flysheet 26 reaches the ready position, thereby deactivating the motor 46 in response to an output signal from the sensor to stop the flysheet 26 in the ready position.

[0044] In relation to Fig. 6A, the driver 10 further includes a locking assembly 350 having a pawl or latch 354 for selectively holding the driving blade 26 in the ready position and a magnet (not shown) for releasing the latch 354 from the driving blade 26. In other words, the locking assembly 350 is movable between a locked state in which the driving blade 26 is held in the ready position against a biasing force (i.e., the pressurized gas in the storage chamber cylinder 30), and a released state in which the driving blade 26 is allowed to be driven from the ready position to the driven position by the biasing force. The latch 354 is pivotally mounted on the muzzle guide 330 by a shaft 362 about a locking axis 366 (which, as shown in Fig. 6A, extends into the side). The locking axis 366 is parallel to the second output shaft axis 101' of the second output shaft 101.

[0045] According to Fig. 6A, the locking assembly 350 is disposed proximate the side 322 of the driving blade 26. Furthermore, the latch 354 is configured to rotate about the shaft 362 relative to the locking axis 366 upon actuation of the electromagnet, such that a tip 378 of the latch 354 is configured to engage a stop surface (not shown) of the mouth assembly 400 as the latch 354 is moved toward the driving blade 26.

[0046] The latch 354 is movable between a locked position (corresponding to the locked state of the locking assembly 350), in which the latch 354 engages one of the projections 318A on the driving blade 26 to hold the driving blade 26 in the ready position against the biasing force of the compressed gas, and a released position (corresponding to the released state of the locking assembly 350), in which the driving blade 26 can be driven from the ready position to the driven position by the biasing force of the compressed gas. Furthermore, the stop surface against which the latch 354 can abut when the electromagnet is de-energized limits the extent to which the latch 354 can rotate counterclockwise with respect to the reference frame of Fig. 6A is rotatable about the locking axis 366.

[0047] A shooting cycle for the driver 10 is shown and described in detail below. Fig. 7B, before initiating a shooting cycle, the driving blade 26 is held in the ready position, with the piston 22 near the top dead center in the cylinder 18. More precisely, the first drive pin 276' ( Fig. 6A) on the lifting device 44 in engagement with a lowest tooth 26a' ( Fig. 6A) of the axially spaced lifting teeth 26a on the driver blade 26, and the rotational position of the lifting device 44 is maintained by the one-way clutch mechanism 154. In other words, as already described, the one-way clutch mechanism 154 prevents the motor 46 from being driven back by the gear 92 when the lifting device 44 holds the driver blade 26 in the standby position. In addition, in the standby position of the driver blade 26, the latch 354 can be engaged with a lowermost tooth 26b' ( Fig. 6A) on the flyblade 26, although it need not necessarily be in contact with the flyblade 26 and serve to hold it in the ready position. Rather, the latch 354 at this time serves a safety function to prevent the flyblade 26 from being accidentally released if the overrunning clutch mechanism 154 fails.

[0048] When the trigger 48 is pulled to initiate a firing cycle, the solenoid is energized to pivot the latch 354 from the locked position to the release position, thereby repositioning the latch 354 so that it can no longer engage the locking teeth 26b (which defines the released state of the locking assembly 350). At approximately the same time, the motor 46 is activated to rotate the first output shaft 96 and the elevator 44 with respect to the reference frame of Fig. 6A counterclockwise, thereby moving the driving blade 26 upwards a small distance beyond the standby position before the lowest tooth 26a' on the driving blade 26 slides off the drive pin 276' (at the TDC position of the driving blade 26). Thereafter, the piston 22 and the driving blade 26 are forced downward toward the driven position ( Fig. 7A). While the driving blade 26 is moved toward the driven position, the motor 46 remains activated to continue the counterclockwise rotation of the lifting device 44.

[0049] According to Fig. 6A, when a fastener is driven into a workpiece, the piston 22 impacts the bumper 60 to rapidly decelerate the piston 22 and the driving blade 26 and ultimately stop the piston 22 in the driven or bottom dead center position.

[0050] Shortly after the driver blade 26 reaches the driven position, a first of the drive pins 276 on the elevator 44 engages one of the lifting teeth 26a on the driver blade 26, and continued counterclockwise rotation of the elevator 44 raises the driver blade 26 and the piston 22 toward the ready position. Shortly thereafter, and before the elevator 44 completes a full rotation, the solenoid is deactivated, allowing the latch 354 to re-engage the driver blade 26 and slide around the locking teeth 26b while the upward movement of the driver blade 26 continues (defining the locked state of the locking assembly 350).

[0051] After one complete rotation of the lifting device 44 has taken place, the latch 354 holds the driving blade 26 in an intermediate position between the driven position and the ready position, while the lifting device 44 continues to rotate counterclockwise (in the frame of reference of Fig. 4) rotates until the first drive pin 276' re-engages with another of the lifting teeth 26a on the fly tying blade 26. Continued rotation of the lifting device 44 raises the fly tying blade 26 to the ready position detected by the sensor, as described above.

[0052] According to Fig. 2A to 2C and 17 to 23B, the driver 10 further includes a muzzle assembly 400 disposed at one end of the magazine 14.

[0053] The magazine 14 includes a magazine housing 404 designed to receive the fasteners to be driven into the workpiece by the power-operated fastener driver. The magazine housing 404 ( Fig. 1) has a first end 408 and a second end 412 opposite the first end 408. The magazine housing 404 further includes a first side 416 and a second side 420 ( Fig. 17 and Fig. 18) opposite the first side 416, and a lower side 424 and an upper side 428 extending between the first and second sides 416 and 420, respectively.

[0054] As in Fig. 2C, Fig. 17, Fig. 18, the illustrated magazine housing 404 is formed from a base portion 440 and a cover portion 444. In particular, the cover portion 444 is slidably connected to the base portion 440. In addition, the base portion 440 and the cover portion 444 together form a fastener channel 448 ( Fig. 2C) extending from the first end 408 to near the second end 412 of the magazine housing 404. The fastener channel 448 is configured to receive the fasteners.

[0055] In particular, according to Fig. 2C and 17 to 20, the first side 416 of the magazine housing 404 includes a projection 460 ( Fig. 17), which has a recess 464 ( Fig. 20). The recess 464 extends along the first side 416 from near the second end 412 toward the first end 408. More specifically, the recess 464 extends parallel to and in communication with the fastener channel 448. The first side 416 further defines an opening or window 468 ( Fig. 2C and Fig. 17) in conjunction with the recess 464 near the first end 408 of the magazine housing 404.

[0056] According to Fig. 19 to 23B, the magazine 14 further includes a slide assembly 480 disposed in the fastener channel 448 of the magazine housing 404. The slide assembly 480 is slidably connected to the magazine 14 and is configured to bias the fasteners in the magazine 14 toward the muzzle assembly 400. As shown in Fig. 19 to 20B, the illustrated slide assembly 480 includes a first portion or slide body 484 and a second portion or blank firing safety element 488 movably connected to the slide body 484. The magazine 14 includes first springs 492a, 492b ( Fig. 2C) which are designed to exert a biasing force on the slide assembly 480 to move the slide assembly 480 in the direction of arrow 496 ( Fig. 2A and Fig. 18). In addition, the blank-fire safety element 488 is actuated by a second spring 500 ( Fig. 20B) is movably connected to the slide body 484 (e.g., an extension 484a of the slide body 484). Thus, the slide body 484 of the slide assembly 480 can move selectively relative to the blank-fire safety element 488. The biasing force of the second spring 500 is independent of the biasing force of the first springs 492a, 492b. The slide assembly 480 is movable into a first state in which the slide body 484 and the blank-fire safety element 488 move together in the direction of arrow 496, and into a second state in which a relative movement has occurred between the slide body 484 and the blank-fire safety element 488, as described in more detail below.

[0057] According to Fig. 2A to 2B2, the muzzle assembly 400 is disposed at the first end 408 of the magazine housing 404. The muzzle assembly 400 generally includes a first portion, the base portion 510, which is connected to the first end 408 of the magazine housing 404, and a second portion, the cover portion 514, which is connected to the base portion 510. The base portion 510 of the muzzle assembly 400 is attached to the magazine housing 404. The cover portion 514 of the muzzle assembly 400 substantially covers the base portion 510. In the illustrated embodiment, the cover portion 514 is pivotally connected to the base portion 510 by a locking mechanism 518. The muzzle assembly 400 collectively defines a firing channel 522 (of which Fig. 6A, only a portion is shown) extending along the drive axis 38. The firing channel 522 communicates with the fastener channel 448 of the magazine housing 404 (e.g., through an opening 526 in the base portion 510) to receive a fastener from the magazine housing 404. The muzzle assembly 400 further includes a distal end 530 at one end of the firing channel 522 ( Fig. 6A). The driving blade 26 is received within the firing channel 522 to drive the fastener out of the firing channel 522 and out of the distal end 530 of the muzzle assembly 400 and into a workpiece, as previously explained.

[0058] According to Fig. 2A, Fig. 2B1 and Fig. 2B2, the driver 10 includes a workpiece contact assembly 540 extending along one side of the orifice assembly 400. The workpiece contact assembly 540 includes a first end 544 ( Fig. 2B1, Fig. 2B2 and Fig. 2C) and a second, opposite end 548 that can be engaged with a workpiece during a shooting operation. The workpiece contact assembly 540 includes a plurality of sections 552, 556, each section 552, 556 being formed by a plurality of interconnected segments. A pair of springs 564a, 564b ( Fig. 2B1, 2B2, and 2C) are configured to bias the workpiece contact assembly 540 toward an extended position. The workpiece contact assembly 540 is configured to move from the extended position to a retracted position when the workpiece contact assembly 540 is pressed against a workpiece.

[0059] A first portion 552 of the workpiece contact assembly 540 is positioned closer to the top 428 of the magazine housing 404 than to the bottom 424. The first portion 552 includes the first end 544 of the workpiece contact assembly 540. The first portion 552 further includes an arm 574 having a bore 578. The arm 574 is movable relative to the housing 80. Specifically, a fixed pin 570 is connected to the housing 80 and movably received in the bore 578 of the arm 574. The first spring 564a surrounds the pin 570 and is seated between the housing 80 and a first end of the arm 574. The second spring 564b is located in the bore 578 and is seated between a distal end of the pin 570 and a bottom surface of the bore 578. The arm 574 includes a screw portion 612. The second section 556 includes the second end 548, which is configured to engage a workpiece.The first and second sections 552, 556 are connected by a drive-depth adjustment mechanism 600, which adjusts the effective length of the workpiece contact assembly 540. In particular, the screw portion 612 connects the first section 552 to the second section 556.

[0060] According to Fig. 2B and Fig. 2C, the driving depth adjustment mechanism 600 includes a support member 604, an adjustment knob 608, and the screw portion 612. In the illustrated embodiment, the pair of springs 564a, 564b are at least partially supported by the driving depth adjustment mechanism 600. The springs 564a, 564b achieve the same spring force on the workpiece contact assembly 540 with a shorter stroke (distance between extended and retracted positions) compared to a single spring. In the illustrated embodiment, the springs 564a and 564b have different stiffnesses, but in other embodiments, the stiffnesses may be the same. In the illustrated embodiment, there are two springs 564a, 564b, but in other embodiments, more than two springs with the same or different stiffnesses may be present. The support member 604 at least partially supports the arm 570. The adjustment knob 608 is rotatably mounted on the arm 570.As mentioned above, the screw portion 612 extends between the first section 552 and the second section 556 of the workpiece contact assembly 540. One end of the second section 556 is screwed to the screw portion 612. Further, the arm 574, and therefore the screw portion 612, is non-rotatably connected to the adjustment knob 608. Accordingly, the screw portion 612 and the adjustment knob 608 are rotatably supported by the arm 570. By rotating the adjustment knob 608, the second section 556 is screwed axially along the screw portion 612 to adjust a projecting length of the workpiece contact assembly 540 relative to the distal end 530 of the orifice assembly 400. More specifically, rotation of the adjustment knob 608 moves the second section 556 relative to the first section 552 to adjust an effective length of the workpiece contact assembly 540. In this respect, the adjustment knob 608 can be referred to as an actuator. As shown in . Fig. 2B1 and Fig. 2B2, a detent mechanism 610 is engageable with the adjustment knob 608 to prevent the adjustment knob 608 from freely rotating. As shown, the adjustment knob 608 includes a plurality of grooves or recesses 608a in its outer surface. The detent mechanism 608 includes a ball 610a (e.g., a detent) and a spring 610b (e.g., a biasing mechanism) that biases the ball 610a into one of the grooves 608a of the adjustment knob 608.

[0061] The driving depth adjustment mechanism 600 adjusts the depth to which a fastener is driven into the workpiece. Specifically, the driving depth adjustment mechanism 600 adjusts the length by which the workpiece contact assembly 540 protrudes relative to the distal end 530 of the muzzle assembly 400, thereby changing the distance between the distal end 530 of the muzzle assembly 400 and the workpiece contact assembly 540 in the extended position. In other words, the driving depth adjustment mechanism 600 adjusts how far the workpiece contact assembly 540 extends beyond the muzzle assembly 400 to engage a workpiece. The larger the gap between the distal end 530 of the muzzle assembly 400 and the workpiece, the shallower the depth to which a fastener is driven into the workpiece.Thus, the position of the workpiece contact assembly 540 relative to the muzzle assembly 400 is adjustable to adjust the depth to which a fastener is driven. In the illustrated embodiment, the spring 610b urges the ball 610a into one of the grooves 608a of the adjustment knob 608 to hold the adjustment knob 608, and thus the workpiece contact assembly 400, at the selected depth. When the user wishes to adjust the depth, the user rotates the adjustment knob 608 against the bias of the spring 610a to selectively rotate the adjustment knob 608.

[0062] As in Fig. 2B to 2C and Fig. As shown in Figures 21A through 23B, the workpiece contact assembly 540 further includes an engagement portion 640 (e.g., a dead-fire safety member). In the illustrated embodiment, the first section 552 includes the dead-fire safety member 640. The dead-fire safety member 640 is disposed substantially at the first end 544 of the workpiece contact assembly 540 and, in particular, is connected to the arm 570.

[0063] According to Fig. 19 to 23B, the power-operated fastener driver 10 further comprises a blank firing safety arrangement 650 ( Fig. 23A and Fig. 23B). The anti-blanking assembly 650 prevents the power-operated fastener driver 10 from operating when the number of fasteners remaining in the magazine 14 falls below a predetermined number. The anti-blanking assembly 650 includes the anti-blanking element 488 of the slider assembly 480 and the anti-blanking member 640. The extension 484a of the slider body 484 and the anti-blanking element 488 are disposed within and movable (e.g., slidable) in the fastener channel 448 of the magazine 14. The anti-blanking element 488 is selectively received within the opening 468 of the magazine 14. The anti-blanking element 488 is configured to prevent movement of the workpiece contact assembly 540 when a predetermined number of fasteners (e.g., 0, 1, 2, 4, etc.) remain in the magazine 14.

[0064] The blank firing safety element 488 is movable between a first, non-blocking or bypassing position (e.g. Fig. 21A to 22E) and a second, blocking position ( Fig. 23A to 23B). When the blank-fire safety element 488 does not extend through the opening 468 of the magazine 14, the blank-fire safety element 488 is in the bypass position, so that the blank-fire safety member 640 and the workpiece contact assembly 540 can move from the extended position to the retracted position ( Fig. 21A to 22E). That is, in the bypass position, the blank-fire safety member 640 is designed to slide past the opening 468 (and, depending on the number of remaining fasteners, past the blank-fire safety element 488) when moving toward the retracted position. Furthermore, when the blank-fire safety element 488 is in the bypass position, the slide assembly 480 is in the first state, so that the slide body 484 and the blank-fire safety element 488 move together. When the blank-fire safety element 488 is in the blocking position, at least a portion of the blank-fire safety element 488 ( Fig. 23A to 23B) through the opening 468 of the magazine 14 where it obstructs the retraction of the blank firing safety member 640 and therefore prevents movement of the workpiece contact assembly 540 from the extended position toward the retracted position.

[0065] In operation, as in Fig. As shown in Figures 21A through 21E, when more than the predetermined number of fasteners are present in the magazine 14, the first and second sections 484, 488 of the slide assembly 480 move together, biased by the first springs 492a, 492b, in the direction of arrow 496 of the magazine 14 in an incremental manner as successive fasteners from the collected fastener strip are dispensed from the muzzle assembly 400. At this time, the opening 468 remains open, and the blank-fire safety element 488 remains in the bypass position.

[0066] In a scenario where the predetermined number of fasteners remaining in the magazine 14 is reached, the blank firing safety element 488 is in the blocking position and therefore engages the blank firing safety member 640, as shown in Fig. 23A and Fig. 23B. Upon reaching the blocking position, the dead-shooting element 488 blocks the dead-shooting member 640 of the workpiece contact assembly 540, and retraction of the workpiece contact assembly 540 is prevented to prevent further activation of the power fastener driver 10. In this scenario, the movement of the slider assembly 480 may remain in the first state (i.e., the first and second portions 484, 488 move together) until the dead-shooting element 488 is moved to the blocking position.

[0067] However, in a scenario where fasteners of certain sizes (e.g., fasteners with a certain shaft length or diameter) are loaded into the magazine 14, it may happen that the obliquely arranged collected fastener strip in the fastener channel only allows a partial movement of the blank firing safety element 488 towards the blocking position when the predetermined number of fasteners remaining in the magazine 14 is reached. That is, as in Fig. As shown in Figures 22A through 22E, the deadlock element 488 may be in an intermediate position between the bypass position and the blocking position, in which the deadlock element 488 only slightly blocks the deadlock member 640 and the workpiece contact assembly 540. Furthermore, other tolerances associated with the particular size fasteners used and / or with the driver 10 as a whole may cause the deadlock element 488 to move to the intermediate position. In this case, for example, if the number of remaining fasteners is one greater than the predetermined number of fasteners, the deadlock element 488 is in the intermediate position.When the blanking element 488 is in the intermediate position, it is possible for the workpiece contact assembly 540 (and in particular the blanking member 640) to nominally engage the blanking element 488 during retraction and move the blanking element 488 toward the bypass position, thereby allowing continued retraction of the workpiece contact assembly 540 to facilitate a final fastener firing cycle. When the blanking element 488 is moved from the intermediate position to the bypass position, the slider assembly 480 transitions from the first state to the second state in which relative movement has occurred between the slider body 484 and the blanking element 488.

[0068] That is, the blanking member 640 may nominally engage the blanking element 488 during retraction to move the blanking element 488 toward the bypass position against the bias of the second spring 500, thereby sliding past the blanking element 488 into the retracted position to facilitate the final firing cycle. In this scenario, the movement of the slider assembly 480 transitions from the first state to the second state after the final fastener firing cycle (i.e., the blanking element 488 has moved relative to the slider body 484 against the bias of the second spring 500).Once the last fastener firing cycle is completed and the predetermined number of fasteners remain, the dead-fire safety element 488 extends through the opening 468 and blocks the dead-fire safety member 640 and thus the workpiece contact assembly 540 from moving to the retracted position to prevent a "dead-fire" cycle in which a driver blade 26 is driven from the TDC position to the UDC position without a fastener in the firing channel 522.

[0069] When the predetermined number of fasteners remain and the deadlock element 488 is in the blocking position, the deadlock element 488 cannot transition from the first to the second state. Accordingly, when the predetermined number of nails remain, the deadlock element 488 is positioned such that there is sufficient engagement between the deadlock element 488 and the deadlock member 640, and thus the workpiece contact assembly 540, to prevent a "deadlock" cycle.

[0070] Another configuration of a gas spring driven fastener driver 1010 is shown in Fig. 24 to 34. The gas spring-operated fastener driver 10 is similar to the gas spring-operated fastener driver 10 described above. Therefore, like structures are designated by like reference numerals plus "1000," and only the differences will be described herein. As shown in Fig. 26A, in the illustrated embodiment, the cylinder 1030 is defined in part by an inner frame 1031 (e.g., an inner housing). In particular, the inner frame 1031 is connected to the cylinder 1030. The inner frame 1031 also supports, at least in part, the lift assembly 1042 and the motor 1046. The inner frame 1031 is constructed of a material that is more robust than plastic, e.g., metal. Accordingly, the housing 1080 is constructed of a plastic material. The inner frame 1031 is thus made of a harder, stronger, and more robust material (e.g., metal) than the material (e.g., plastic) from which the housing 1080 is formed. The inner frame 1031 also includes elastomeric elements 1031' (e.g., bumpers) connected to its bottom surface.In the illustrated embodiment, two bumpers 1031' are present, but in other embodiments there may be a single bumper or more than two bumpers. In the illustrated embodiment, the bumpers 1031' are formed of rubber, but in other embodiments, other materials capable of absorbing shocks and reducing force peaks may be used. In addition, the motor 1046 and its first output shaft 1096 are offset relative to the drive axis 1038. In addition, the lifting device 1044 and its second output shaft 1101 are also offset relative to the drive axis 1038. In the embodiment of . Fig. 24 to 34, the axis 1096' of the first output shaft 1096 of the motor 1046 and the axis 1101' of the second output shaft 1101 of the lifting device 1044 coincide.

[0071] As in Fig. 26A, the configuration of the circuit board is similar to that described above with respect to Fig. 3 and Fig. 4. That is, as described in Fig. 26A, the driver 1010 includes the first or power supply circuit board 1095a, the second or user interface circuit board 1095b, and the third or motor circuit board 1095c. The gas spring-operated fastener driver 1010 is shown in Fig. 26B and shows a different circuit board configuration. As shown in Fig. 26B, the driver 1010 includes a first circuit board 1095a', which is a unified power and control circuit board, a user interface 1097, and a second circuit board 1095c', which is the motor circuit board.

[0072] As in Fig. 26B, the unified power and control circuit board 1095a' extends within the housing 1080 and is generally disposed between the drive unit support portion 1088 and the handle portion 1091. As shown, the unified power and control circuit board 1095a' extends from the drive unit support portion 1088 at least partially through the connecting portion 1093 toward the handle portion 1091. The unified power and control circuit board 1095a' is received in the channels 1099 in the housing 1080. The user interface 1097 is accessible via the connecting portion 1093. The unified power and control circuit board 1095a' is connected to the user interface 1097, which includes a display unit 1097'. The display unit 1097' includes indicators 1097a' (e.g., for low battery, overtemperature, etc.).) and one or more buttons 1097b' for selecting an operating mode of the driver 1010. The one or more buttons 1097b' of the user interface 1097 are oriented substantially parallel to the unified power and control circuit board 1095a', such that pressing the one or more buttons 1097b' moves the one or more buttons 1097b' toward the unified power and control circuit board 1095a'. In particular, pressing one or more buttons 1097b' results in a translational movement of the one or more buttons 1097b' toward the unified power and control circuit board 1095a'. The translational movement of the one or more buttons 1097b' causes the one or more buttons 1097b' to activate a switch located either in the user interface 1097 itself or on the unified power and control circuit board 1095a'.The unified power and control board 1095a' may also include an electronic processor for controlling and receiving inputs from the user interface 1097, and further includes one or more switches (e.g., FETs) for directing an electrical current from the battery pack 90 to the motor 1046. The switches are selectively closed in response to control signals received from the electronic processor to direct the electrical current from the battery pack 90 to the motor 1046. Additionally, the unified power and control board 1095a' may include a fuse (e.g., a surface-mount fuse, a high-resistance fuse trace, etc.).

[0073] Another configuration of the magazine 1014 is in Fig. 24 to 34. The magazine 1014 is similar to the magazine 14 described above. Therefore, like structures are designated by like reference numerals plus "1000", and only the differences will be described here.

[0074] The magazine 1014 includes a magazine housing 1404 designed to receive the fasteners to be driven into the workpiece by the power-operated fastener driver 1010. The magazine housing 1404 ( Fig. 24, Fig. 29) has a first end 1408 and a second end 1412 opposite the first end 1408. The magazine housing 1404 further includes a first portion 1700 and a second portion 1704 connected by a cover 1708 at the second end 1412 of the magazine 1014. The first portion 1700 includes the bottom surface 1424 and the second portion 1704 includes the top surface 1428. The first portion 1700 also includes a pocket or recess 1430 at or adjacent the second end 1412. The pocket 1430 is located on the second side 1420 and is closer to the bottom surface 1424 than to the top surface 1428. The first side 1416 and the second side 1420 are each formed at least partially from the first portion 1700 and the second portion 1704. In addition, the first section 1700 and the second section 1704 together form the fastener channel 1448 ( Fig. 29, Fig. 30) extending from the first end 1408 to near the second end 1412 of the magazine housing 1404. The fastener channel 1448 is configured to receive the fasteners.

[0075] In particular, according to Fig. 25 and Fig. 29, a gap or track 1712 is defined on the second side 1420 between the first portion 1700 and the second portion 1704. The track 1712 extends along the length of the magazine housing 1404 from near the second end 1412 toward the first end 1408. As shown at least in Fig. 26A, the first portion 1700 includes a recess 1716 extending along the first side 1416 from near the second end 1412 toward the first end 1408. More specifically, the recess 1716 extends parallel to and in communication with the fastener channel 1448. As shown in Fig. 29 to 31, a guide member 1720 is connected to the second end 1412 of the first portion 1700 and spaced from the second portion 1704. The guide member 1720 extends parallel to the recess 1716 and defines a portion of the fastener channel 1448. That is, the guide member 1720 includes an opening 1724 ( Fig. 30) extending along its length and receiving a head of each of the fasteners.

[0076] As in Fig. 29 to 31B, the magazine 1014 further includes a slide assembly 1480. The slide assembly 1480 is slidably coupled to the magazine 1014 and is configured to bias the fasteners in the magazine 1014 toward the muzzle assembly 1400. As shown in Fig. 25 to 26A, 29 to 31B, the illustrated slide assembly 1480 includes a first portion or slide body 1484, a slide finger 1730 pivotally connected to the slide body 1484, and a second portion or blank-fire safety element 1488 movably connected to the slide body 1484. The slide assembly 1480 further includes a spring assembly 1734 ( Fig. 31B), which includes a roller 1738 carried by the slider body 1484 and a spring 1742 carried by the roller 1738. A stationary end 1742a of the spring 1742 is connected to the magazine housing 1404. The spring assembly 1734 is designed to exert a biasing force on the slider assembly 1480 to move the slider assembly 1480 in the direction of arrow 1496 ( Fig. 25) to move.

[0077] According to Fig. 25 and Fig. 29 and Fig. 30, the slider body 1484 is carried by both the first and second portions 1700, 1704 of the magazine housing 1404 and is at least partially disposed on either side of the fastener channel 1448. The slider assembly 1480 is movable from a first position ( Fig. 29), in which the slider body 1484 is arranged at or adjacent to the second end 1412, to a second position in which the slider body 1484 is arranged at or adjacent to the first end 1408. In the first position, at least a portion of the slider body 1484 is located within the pocket 1430. As in Fig. 29, an inner surface of the pocket 1430 covers an outer surface of the slider body 1484. The pocket 1430 protects the slider assembly 1480 from impact if the driver 1010 is dropped. As shown, the slider body 1484 includes a main portion 1746a disposed on the second side 1420 and adjacent the track 1412. The main portion 1746a pivotally supports the slider finger 1730 ( Fig. 30). The slider body 1484 also includes an arm 1746b extending from the main portion 1746a and disposed on the second side 1416. The arm 1746b is received in the recess 1716 ( Fig. 26A, Fig. 30) of the magazine housing 1404 and is movable relative thereto. The arm 1746b comprises a first recess 1746c through which the guide element 1420 ( Fig. 25) and a second recess 1746d in which the blank-fire safety element 1488 and a second spring 1500 ( Fig. 26A and Fig. 30).

[0078] In the embodiment of Fig. 31A, the slider body 1484, including the main part 1746a and the arm 1746b, are formed as a single piece. In other embodiments, such as in Fig. 31C and Fig. 31D, the slider body 1484 may be formed from two or more parts. In particular, the slider body 1484 may be formed as shown in Fig. 31D, a cap or cover 1746c formed separately from and connected to the arm 1746b. The arm 1746b includes a central recess 1748a, a first lateral recess 1748b on a first side of the central recess 1748a, and a second lateral recess 1748c on a second, opposite side of the central recess 1748a. Each of the recesses 1748a, 1748b, 1748c is configured to receive at least a portion of the blank-fire safety element 1488 and the second spring 1500. The arm 1746b includes a plurality of bores 1752. The blank-fire safety element 1488 includes a first end 1756a ( Fig. 31C) spaced from the arm 1746b, and a second end 1756b ( Fig. 31D) disposed between the arm 1746b and the cap 1746c. The second end 1756b includes a pair of projections 1757 extending outwardly therefrom. The blank-fire prevention element 1488 is received in and movable relative to the central recess 1748a, one of the two projections 1757 is received in and movable relative to the first lateral recess 1748b in the arm 1746b, and the other of the two projections 1757 is received in and movable relative to the second lateral recess 1748c in the arm 1746b. The spring 1500 is located between the blank-fire prevention element 1488 and a surface of the central recess 1748a. The cap 1746c is snap-fitted to the slider body 1484, and in particular to the arm 1746b. The cap 1746c includes a plurality of projections 1760 ( Fig. 31D) extending therefrom. Each of the projections includes a hook 1761. One of the plurality of projections 1760 is received in each of the plurality of bores 1752 of the arm 1746b, such that the hook 1761 prevents removal of the cap 1746c from the slider body 1484.

[0079] The slider finger 1730 includes a first end 1730a disposed between the main portion 1746a of the slider body 1484 and the magazine housing 1404, and a second end 1730b extending outwardly from the main portion 1746a of the slider body 1484. The slider finger 1730 is pivotally connected to the main portion 1746a by a pin 1730c extending through the slider finger 1730 at a location between the first end 1730a and the second end 1730b. The slider finger 1730 is movable between an engaged position in which the first end 1730a is positioned within the fastener channel 1448 and is configured to engage the last fastener in the fastener channel 1448, and a disengaged position in which the first end 1730a is at least partially removed from the track 1712. A spring 1730d ( Fig. 29) biases the slider finger 1730 into the engaged position. A force applied to the second end 1730b of the slider finger 1730 temporarily moves the slider finger 1730 from the engaged position to the disengaged position, allowing the slider assembly 1480 to be moved relative to the magazine housing 1014. When the force is removed from the second end 1730b of the slider finger 1730, the bias of the spring 1730d returns the slider finger 1730 to the engaged position.

[0080] In addition, the blank-fire safety element 1488 is secured by the second spring 1500 ( Fig. 26 and Fig. 30) is movably connected to the slide body 1484 (e.g., the arm 1746b of the slide body 1484). Thus, the slide body 1484 of the slide assembly 1480 can selectively move relative to the blank-fire safety element 1488. The biasing force of the second spring 1500 is independent of the biasing force of the spring assembly 1734. The slide assembly 1480 is movable into a first state in which the slide body 1484 and the blank-fire safety element 1488 move together in the direction of arrow 1496, and into a second state in which a relative movement has occurred between the slide body 1484 and the blank-fire safety element 1488, as described in more detail below.

[0081] As in the previous embodiment, the orifice assembly 1400 ( Fig. 24 and Fig. 25) is disposed at the first end 1408 of the magazine housing 1404 and has a similar structure and the reference numerals plus "1000," which will not be repeated here. Similarly, the driver 1010 includes a workpiece contact assembly 1540 that is similar to the workpiece contact assembly 1540, so the reference numerals plus "1000" are used, and only the differences are discussed here. A single spring 1750 ( Fig. 32 to 34) is designed to bias the workpiece contact assembly 1540 toward an extended position. The workpiece contact assembly 1540 is designed to move from the extended position to a retracted position (in Fig. 27 to 29) when the workpiece contact assembly 1540 is pressed against a workpiece. The first portion 1552 includes an arm 1754 that is movable relative to the housing 1080. The spring 1750 surrounds the arm 1754. The arm 1754 includes an engagement portion 1640 (e.g., a blank firing safety member) and a screw portion 1758. In the illustrated embodiment, the first portion 1552 includes the blank firing safety member 1640. The blank firing safety member 1640 is disposed substantially at the first end 1544 of the workpiece contact assembly 1540 and, in particular, is connected to the arm 1754. As shown in Fig. 32, the spring 1750 is located between the inner frame 1031 and the blank firing safety link 1640.

[0082] According to Fig. 24 and 27 to 29, the driving depth adjustment mechanism 1600 is similar to the driving depth adjustment mechanism described above and functions in a similar manner as described above. Therefore, similar structures are designated by similar reference numerals plus "1000." Fig. 24, the driving depth adjustment mechanism 1600 includes two support members 1604a, 1604b, the adjustment knob 1608, and the screw portion 1758. The support members 1604a, 1604b support the arm 1754. One of the support members 1604a is at least partially positioned within the housing 1080 and is supported by the inner frame 1031. One of the support members 1604b is supported by the other support member 1604a. The adjustment knob 1608 is located between the support members 1604a, 1604b and is rotatably mounted on the arm 1754. As mentioned above, the screw portion 1758 extends between the first section 1552 and the second section 1556 of the workpiece contact assembly 1540. One end of the second section 1556 is screwed to the screw portion 1566b. Furthermore, the arm 1754, and therefore the screw portion 1758, is rotationally connected to the adjustment knob 1608.Accordingly, the screw portion 1758 and the adjustment knob 1608 are rotatably supported by the arm 1754. By rotating the adjustment knob 1608, the second section 1556 is screwed axially along the screw portion 1758 to adjust a protruding length of the workpiece contact assembly 1540 relative to the distal end of the orifice assembly 1400.

[0083] The blank firing safety member 1640 is designed to protect the inner frame 1031 and in particular the bumpers 1031' ( Fig. 28A) when the workpiece contact assembly 1540 moves beyond the retracted position (e.g., any subsequent movement of the workpiece contact assembly 1540 in a retraction direction), such as when the driver 1010 is subjected to an impact event (e.g., when the driver 1010 is dropped). Accordingly, the inner frame 1031 defines a stop surface 1032 ( Fig. 28A) that contacts the blanking safety member 1640 when subjected to significant force. For example, if the driver 1010 is dropped and lands with the muzzle assembly 1400 facing down, the force exerted on the workpiece contact assembly 1540 upon contact with the ground would push the workpiece contact assembly 1540 beyond the retracted position. The stop surface 1032 of the inner frame 1031 is therefore designed to limit movement of the blanking safety member 1640 of the workpiece contact assembly 1540 (e.g., upon dropping), thereby protecting the components of the workpiece contact assembly 1540 and the drive depth adjustment mechanism 1600.In other words, because the dead-shot safety member 1640 of the workpiece contact assembly 1540 contacts the inner housing 1031 and not the support member 1604a, the structure of the workpiece contact assembly 1540 and the drive depth adjustment mechanism 1600 is reinforced to limit or prevent bending / breaking if, for example, the tool is dropped. Furthermore, the bumpers 1031' slow the impact and reduce the peak forces acting on the components of the workpiece contact assembly 1540 and the drive depth adjustment mechanism 1600. In other embodiments, the muzzle assembly 1400 (e.g., the base portion 1510), which is typically constructed of a harder, more robust material (e.g., metal), may include a stop surface instead of the inner frame 1031.

[0084] According to Fig. 25 and 29 to 34, the power-operated fastener driver 1010 further comprises a blank firing safety arrangement 1650 ( Fig. 32 to 34) that functions similarly to the blank-fire safety assembly 1650 described above. The blank-fire safety assembly 1650 prevents the power-operated fastener driver 1010 from operating when the number of fasteners remaining in the magazine 1014 falls below a predetermined value. The blank-fire safety assembly 1650 includes the blank-fire safety element 1488 of the slider assembly 1480 and the blank-fire safety member 1640. The arm 1746b of the slider body 1484 and the blank-fire safety element 1488 are arranged in the recess 1716 of the magazine 1014 and are movable (e.g., slidable) therein. The blank-fire safety element 1488 is selectively received in the opening 1468 ( Fig. 26) of the magazine 1014. In the illustrated embodiment, the opening 1468 is at least partially formed by the inner frame 1030, as shown in Fig. 26. The dead-shot safety element 1488 is designed to prevent movement of the workpiece contact assembly 1540 when a predetermined number of fasteners (e.g., 0, 1, 2, 4, etc.) remain in the magazine 1014.

[0085] The blank firing safety element 1488 is movable between a first, non-blocking or bypassing position (e.g. Fig. 32 and Fig. 33) and a second, blocking position ( Fig. 34). When the blank-fire safety element 1488 does not extend through the opening 1468 of the magazine 1014, the blank-fire safety element 1488 is in the bypass position so that the blank-fire safety member 1640 and the workpiece contact assembly 1540 can move from the extended position toward the retracted position ( Fig. 32 and Fig. 33). That is, in the bypass position, the blank-fire safety member 1640 is designed to slide into the opening 1468 (and, depending on the number of remaining fasteners, the blank-fire safety element 1488) upon movement toward the retracted position. Furthermore, when the blank-fire safety element 1488 is in the bypass position, the slide assembly 1480 is in the first state, so that the slide body 1484 and the blank-fire safety element 1488 move together. When the blank-fire safety element 1488 is in the blocking position, at least a portion of the blank-fire safety element 1488 ( Fig. 34) into the opening 1468 of the magazine 1014, where it obstructs the retraction of the blank firing safety member 1640 and therefore prevents movement of the workpiece contact assembly 1540 from the extended position toward the retracted position.

[0086] In operation, as in Fig. 32, when more than the predetermined number of fasteners are present in the magazine 1014, the first and second sections 1484, 1488 of the slide assembly 1480 move together, biased by the spring assembly 1734, in the direction of arrow 1496 of the magazine 1014 in an incremental manner as successive fasteners from the collected fastener strip are dispensed from the muzzle assembly 1400. At this time, the opening 1468 remains open and the blank-fire safety element 1488 remains in the bypass position.

[0087] In a scenario where the predetermined number of fasteners remaining in the magazine 1014 is reached, the blank firing safety element 1488 is in the blocking position and therefore engages the blank firing safety member 1640, as shown in Fig. 34. Upon reaching the blocking position, the deadlock element 1488 blocks the deadlock member 1640 of the workpiece contact assembly 1540, and retraction of the workpiece contact assembly 1540 is prevented to prevent further activation of the power fastener driver 1010. In this scenario, the movement of the slider assembly 1480 may remain in the first state (i.e., the first and second portions 1484, 1488 move together) until the deadlock element 1488 is moved to the blocking position.

[0088] However, in a scenario where fasteners of certain sizes (e.g., fasteners with a certain shaft length or diameter) are loaded into the magazine 1014, it may happen that the obliquely arranged collected fastener strip in the fastener channel only allows a partial movement of the blank firing safety element 1488 towards the blocking position when the predetermined number of fasteners remaining in the magazine 1014 is reached. That is, as in Fig.33, the deadlock element 1488 may be in an intermediate position between the bypass position and the blocking position, in which the deadlock element 1488 only slightly blocks the deadlock member 1640 and the workpiece contact assembly 1540. Furthermore, other tolerances associated with the particular size fasteners used and / or with the driver 1010 as a whole may cause the deadlock element 1488 to move to the intermediate position. In this case, for example, if the number of remaining fasteners is one greater than the predetermined number of fasteners, the deadlock element 1488 is in the intermediate position.When the blanking element 1488 is in the intermediate position, it is possible for the workpiece contact assembly 1540 (and in particular, the blanking member 1640) to nominally engage the blanking element 1488 during retraction and move the blanking element 1488 toward the bypass position, thereby allowing continued retraction of the workpiece contact assembly 1540 to facilitate a final fastener firing cycle. When the blanking element 1488 is moved from the intermediate position to the bypass position, the slider assembly 1480 transitions from the first state to the second state in which relative movement has occurred between the slider body 1484 and the blanking element 1488.

[0089] That is, the blanking member 1640 may nominally engage the blanking element 1488 during retraction to move the blanking element 1488 toward the bypass position against the bias of the second spring 1500, thereby sliding past the blanking element 1488 into the retracted position to facilitate the final firing cycle. In this scenario, the movement of the slider assembly 1480 transitions from the first state to the second state after the final fastener firing cycle (i.e., the blanking element 1488 has moved relative to the slider body 1484 against the bias of the second spring 1500).Once the last fastener firing cycle is completed and the predetermined number of fasteners remain, the dead-fire safety element 1488 extends into the opening 468 and blocks the dead-fire safety member 1640 and thus the workpiece contact assembly 1540 from moving to the retracted position to prevent a "dead-fire" cycle in which a driver blade 1026 is driven from the TDC position to the UDC position without a fastener in the firing channel 1522.

[0090] When the predetermined number of fasteners remain and the deadlock element 1488 is in the blocking position, the deadlock element 488 cannot transition from the first to the second state. Accordingly, when the predetermined number of nails remain, the deadlock element 1488 is positioned such that there is sufficient engagement between the deadlock element 1488 and the deadlock member 1640, and thus the workpiece contact assembly 1540, to prevent a "deadlock" cycle.

[0091] 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 described invention. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 18 / 178,104

[0001] US 63 / 391,491

[0001] US 63 / 316,510

[0001]

Claims

[1] Power-operated fastener driver, comprising: a housing defining a cylinder support portion, a drive unit support portion, and a handle portion spaced from the drive unit support portion, the handle portion being configured to removably connect a battery pack thereto; a cylinder within the cylinder support section; a piston movable within the cylinder from a top dead center (TDC) position to a driven or bottom dead center (BDC) position; a driving blade attached to the piston, which can be moved with the piston along a driving axis from the TDC position towards the UDC position in order to drive a fastener into a workpiece; a lifting device operable to move the piston and the driving blade together from the UTP position towards the TTP position; a drive unit supported by the drive unit support portion and operatively connected to the lifting device, the drive unit comprising a brushless direct current (BLDC) motor; a housing-borne user interface; and a circuit board disposed within the housing and between the drive unit support portion and the handle portion, the circuit board receiving electrical power from the battery pack and including a plurality of power switches for switching the motor and an electronic processor for controlling the user interface and receiving inputs therefrom. [2] The power-operated fastener driver of claim 1, wherein the power switches are selectively closed in response to control signals received from the electronic processor to direct electrical current from the battery pack to the motor. [3] The power-operated fastener driver of claim 1, wherein the circuit board is a first circuit board, the power-operated fastener driver further comprising a second circuit board disposed in the drive unit support portion of the housing adjacent the motor, and the second circuit board comprising a speed sensor that provides a motor speed output signal to the electronic processor. [4] The power-operated fastener driver of claim 1, wherein the housing further comprises a connecting portion extending between the drive unit support portion and the handle portion, the connecting portion being spaced from the cylinder support portion, and the circuit board being at least partially disposed within the connecting portion. [5] A power-operated fastener driver according to claim 4, wherein the user interface is carried by the connecting portion. [6] The power-operated fastener driver of claim 5, wherein the user interface comprises a display unit having a button for selecting an operating mode of the power-operated fastener driver, and wherein the circuit board comprises a switch actuated by the button in response to a depression of the button. [7] A power-operated fastener driver comprising: a housing; a cylinder arranged in the housing; a piston movable within the cylinder from a top dead center (TDC) position to a driven or bottom dead center (BDC) position; a driving blade attached to the piston, which can be moved with the piston along a driving axis from the TDC position towards the UDC position in order to drive a fastener into a workpiece; a lifting device operable to move the piston and the driving blade together from the UTP position towards the TTP position; a drive unit disposed within the housing and operatively connected to the lifting device, the drive unit comprising a motor having a first output shaft extending along a motor axis; an inner frame disposed within the housing and comprising a drive unit housing portion in which at least a portion of the drive unit is housed; a bumper connected to and extending from the inner frame; a workpiece contact assembly connected to the housing and movable from an extended position to a retracted position in response to contact with a workpiece, the workpiece contact assembly including a biasing member biasing the workpiece contact assembly to the extended position; a magazine configured to receive fasteners, the magazine comprising a first end and a second end opposite the first end; a muzzle assembly connected to the first end of the magazine and including a channel from which successive fasteners are driven from the magazine; wherein the workpiece contact assembly is engageable with the bumper in response to an applied force moving the workpiece contact assembly beyond the retracted position. [8] A power-operated fastener driver according to claim 7, wherein the workpiece contact assembly comprises: a first portion defining a first end, the first portion comprising an arm, an engagement portion connected to the first end, and a screw portion opposite the engagement portion, and a second portion connected to the first portion and defining a second end opposite the first end, the second end being adapted to contact the workpiece, wherein the screw portion connects the first section to the second section, and wherein the engagement portion is configured to contact the bumper in response to the applied force moving the workpiece contact assembly beyond the retracted position. [9] The power-operated fastener driver of claim 8, wherein a drive depth adjustment mechanism comprises a knob connected to and rotatable from the arm, and wherein the knob is configured to adjust a projecting length of the second end of the second portion of the workpiece contact assembly relative to a distal end of the muzzle assembly. [10] A power-operated fastener driver according to claim 9, wherein the biasing member is disposed between the inner frame and the engaging portion. [11] A power-operated fastener driver according to claim 7, wherein the inner frame is constructed of metal. [12] A power-operated fastener driver according to claim 7, wherein the biasing member is disposed between the inner frame and the workpiece contact assembly. [13] A power-operated fastener driver according to claim 7, further comprising a housing-borne user interface; and a circuit board disposed within the housing and between a drive unit support portion and a handle portion, the circuit board receiving electrical power from a battery pack and including a plurality of power switches for switching the motor and an electronic processor for controlling the user interface and receiving inputs therefrom. [14] A power-operated fastener driver comprising: a magazine assembly configured to receive fasteners, the magazine assembly comprising a first end and a second end; a muzzle assembly including a channel from which successive fasteners are driven from the magazine assembly; a slide assembly slidably connected to the magazine assembly, the slide assembly being configured to bias the fasteners within the magazine assembly toward the channel, the slide assembly comprising: a slide body, a cover connected to the slide body and a blank-fire prevention element connected to the slider body, the blank-fire prevention element being arranged between the slider body and the cover, the slider body and the blank-fire prevention element being selectively movable relative to one another, the slider arrangement being adjustable between a first state in which the slider body and the blank-fire prevention element are designed to move together towards the channel and a second state in which relative movement has occurred between the slider body and the blank-fire prevention element; a pocket disposed at the second end of the magazine assembly, which receives at least a portion of the slider body when the slider body is adjacent the second end of the magazine assembly, and a workpiece contact assembly movable relative to the muzzle assembly between an extended position and a retracted position, wherein in a first position of the blank firing safety element relative to the magazine assembly, the workpiece contact element is designed to slide past the blank firing safety element in response to movement toward the retracted position, and in a second position, the blank firing safety element prevents movement of the workpiece contact assembly toward the retracted position when a predetermined number of fasteners remain in the magazine assembly, and wherein the slider unit is designed to transition from the first state to the second state before the predetermined number of fasteners in the magazine assembly is reached. [15] The power-operated fastener driver of claim 14, wherein an inner surface of the pocket covers an outer surface of the slider body such that the pocket protects the slider assembly from impact in the event the power-operated fastener driver is accidentally dropped. [16] The power-operated fastener driver of claim 14, wherein the slider assembly is configured to transition from the first state to the second state when one more than the predetermined number of fasteners is in the cartridge assembly. [17] The power-operated fastener driver of claim 14, wherein the dead-shooting element has an intermediate position between the first position and the second position, and the transition from the first state to the second state occurs when the dead-shooting element is moved from the intermediate position to the first position. [18] The power-operated fastener driver of claim 14, wherein the dead-shooting element is in the second position when the predetermined number of fasteners remain such that the dead-shooting element cannot transition from the first state to the second state. [19] The power-operated fastener driver of claim 14, wherein the slider assembly includes a spring carried by the slider body and biasing the blanking member relative to the slider body, the spring being disposed between the slider body and the cover. [20] A power-operated fastener driver according to claim 14, further comprising a user interface carried by a housing; and a circuit board disposed within the housing and between a drive unit support portion and a handle portion of the housing, the circuit board receiving electrical power from a battery pack and including a plurality of power switches for switching a motor and an electronic processor for controlling the user interface and receiving inputs therefrom.

Images