Gas spring-operated fastening drive

Abstract

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

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 718,005, filed November 8, 2024, and U.S. Provisional Patent Application No. 63 / 620,242, filed January 12, 2024, the entire contents of which are incorporated herein by reference. Area of Revelation

[0002] The present disclosure relates to powered fastening actuators, in particular to gas spring powered fastening actuators. Background of the Revelation

[0003] Various fastener drivers are known for driving fasteners (e.g., nails, thumbtacks, staples, etc.) into a workpiece. These fastener drivers utilize various means known in the art (e.g., compressed air generated by an air compressor, electrical power, a flywheel mechanism, etc.) to drive a drive blade from a top dead center position to a bottom dead center position to strike a fastener and drive the fastener into a workpiece. Overview of Revelation

[0004] The present disclosure, in one aspect, provides a powered fastener driver comprising: a drive blade movable from a top dead center position to a bottom dead center position for driving a fastener into a workpiece; and a lift assembly for providing torque to move the drive blade from the bottom dead center position toward the top dead center position, the lift assembly comprising a rotary lifter configured to be selectively engaged with the drive blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins, and a motor configured to provide torque to the rotary lifter;wherein the roller has a plurality of cam portions defined by cup-shaped recesses having a first radius oriented parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the drive blade has a lifting tooth with a crown disposed thereon, the crown configured to engage at least one of the plurality of cam portions;

[0005] In some aspects, the techniques described herein relate to a powered fastener driver comprising: a pressure vessel holding a pressurized gas therein; a piston moveable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; a lift assembly configured to selectively engage the drive blade to move the drive blade from the BDC position toward the TDC position;a housing in which the pressure vessel and the lifting assembly are arranged, a first damper positioned between the pressure vessel and the housing, and a second damper positioned between the pressure vessel and the housing, wherein the first damper and the second damper are positioned asymmetrically relative to each other in a plane containing an axis along which the drive blade is movable, and wherein the first damper and the second damper are configured to dampen movement of the pressure vessel relative to the housing;

[0006] In some aspects, the techniques described herein relate to a powered fastener driver comprising: a pressure vessel holding a pressurized gas therein; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; an elevator assembly operable to move the drive blade from the BDC position toward the TDC position, the elevator assembly comprising a motor positioned within a motor housing and a gear train positioned within a gear housing, the motor aligned along a motor axis;and a plurality of transmission housing bolts connecting the transmission housing and the engine housing, the transmission housing bolts arranged in a transmission housing bolt pattern having an irregular quadrangular shape as viewed perpendicular to the engine axis; the quadrangular shape having at least one obtuse included angle, measured between two adjacent transmission housing bolts and the engine axis, of greater than 90 degrees and at least one acute included angle of less than 90 degrees.

[0007] In some aspects, the techniques described herein relate to a powered fastener drive system comprising: a fastener drive having a pressure vessel holding a pressurized gas; a piston moveable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; and a fill port in fluid communication with the pressure vessel through which pressurized gas is transferred into the pressure vessel, the fill port having a first port member;a first filling adapter having a first adapter connectable to the first connection element of the filling opening for directing pressurized gas from an external fluid supply into the pressure vessel; and a second filling adapter having a second adapter different from the first adapter and incompatible with the first connection element of the filling opening, thereby preventing the second filling adapter from directing pressurized gas from the external fluid supply into the pressure vessel.

[0008] In some aspects, the techniques described herein relate to a powered fastener driver comprising: a housing including an intake portion having an airflow inlet, an exhaust portion having an airflow outlet, a cylinder portion, and a motor housing portion; a pressure vessel holding a pressurized gas therein; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; a motor positioned within the motor housing portion and configured to provide torque to move the drive blade from the BDC position toward the TDC position;a fan connected to the motor, the fan configured to generate a cooling airflow between the airflow inlet and the airflow outlet upon activation of the motor; and a partition positioned within the housing between the motor and the motor housing portion to separate the intake region from the exhaust region and prevent the passage of the cooling airflow expelled by the fan in the exhaust region from re-entering the intake region.

[0009] In some aspects, the techniques described herein relate to a powered fastener driver comprising: a drive blade movable along a drive blade axis from a top dead center (TDC) position toward a bottom dead center (BDC) position to drive a fastener into a workpiece; a gas spring mechanism for driving the drive blade toward the BDC position; a rotary jack for returning the drive blade from the BDC position toward the TDC position, the rotary jack having at least one flange and a plurality of jack pins extending from the flange, the rotary jack movable to an axial home position relative to the drive blade axis, whereby the drive blade can engage the jack pins; a motor;a drive shaft extending along a drive shaft axis that does not intersect the drive blade axis, the drive shaft connected to the motor and configured to receive torque therefrom, the drive shaft connected to the rotary jack and configured to transmit torque thereto to return the drive blade from the BDC position toward the TDC position, the drive shaft having a shoulder; and a spring disposed between the shoulder and the flange along the drive shaft axis, the spring configured to apply an axial biasing force along the drive shaft axis to the rotary jack.

[0010] Further features and aspects of the disclosure 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 powered fastener driver according to an embodiment of the present disclosure. Fig. 2 is a perspective view of the fastening drive of Fig. 1, with part of the housing hidden. Fig. 3 is a cross-sectional view of the fastening drive taken along section line 3-3 in Fig. 2. Fig. 4 is a side view of a part of the fastening drive of Fig. 1, which represents a compression chamber. Fig. 5 is a bottom view of the compression chamber. Fig. 6 is a cross-sectional view of the compression chamber of Fig. 3, taken along section line 6-6 in Fig. 4. Fig. 7 is a side view of a part of the fastening drive of Fig. 2, which represents a lifting device. Fig. 8 is a cross-sectional view of a portion of the fastening drive of Fig. 2, taken along section line 8-8 in Fig. 2. Fig. 9 is a partial perspective view of a motor of the lifting device. Fig. 10 is a rear perspective view of a cover of the engine. Fig. 11 is a perspective view of a rotary jack and a drive blade of the powered fastener drive. Fig. 12 is a perspective view of a portion of the rotary jack, illustrating a final pin of the rotary jack. Fig. 13 is a side view of the last pin of the rotary jack. Fig. 14 is a partial perspective view of the drive blade illustrating a final tooth of the drive blade. Fig. Figure 15 is a partial bottom view of the last tooth of the drive blade. Fig. Figure 16 is a schematic representation of the engagement between the last tooth of the drive blade and the last pin of the rotary jack. Fig. 17 is a detailed view of a portion of the schematic diagram of Fig. 16. Fig. 18 is a perspective view of a powered fastener driver according to another embodiment of the present disclosure. Fig. 19 is a perspective view of the fastening drive of Fig. 18, with part of the housing hidden. Fig. 20 is a cross-sectional view of the fastener drive taken along section line 20-20 in Fig. 19. Fig. 21 is a side view of a portion of the fastening drive of Fig. 18. Fig. 22 is a side view of the fastening drive of Fig. 18, with part of the housing hidden to represent a compression chamber. Fig. 23 is a cross-sectional view of the fastening drive taken along section line 23-23 in Fig. 22, wherein a fitting and a plug engage in a filling opening. Fig. 24 is a cross-sectional view of the fitting from Fig. 23 and an adapter that engages with the fitting. Fig. Figure 25 is a graphical representation of the inflation pressures of a variety of fastener actuators, divided into groups and suitable for engagement with different adapters. Fig. 26 is a perspective cross-sectional view of the fastening drive of Fig. 18, taken along section line 26-26 in Fig. 19. Fig. 27 is an enlarged perspective view and cross-section of the fastening drive of Fig. 18 along section line 27-27 in Fig. 26. Fig. 28 is a side view of a drive shaft of the powered fastener drive of Fig. 27. Fig. 29 is an end view of the drive shaft of the powered fastener drive of Fig. 27. Fig. 30 is an end view of a rotary jack flange of the fastening drive of Fig. 27. Fig. 31 is a second side view of the fastening drive of Fig. 18. Fig. 32 is an enlarged partially cutaway view of the fastening drive of Fig. 18, taken from the section line 32-32 in Fig. 19. Fig. 33 is a front cross-sectional view of the fastening drive of Fig. 18, taken along section line 33-33 in Fig. 22. Fig. 34 is a cross-sectional view of the fastening drive of Fig. 18, taken along section line 34-34 in Fig. 18. Fig. 35 is a perspective, partially cutaway view of the fastening drive of Fig. 18, wherein a partition wall is arranged in the housing.

[0011] Before any 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. It is to be understood that the terms and terminology used herein are for the purpose of description and should not be considered limiting. Detailed description

[0012] The Fig. 1 through 3 illustrate a gas spring-operated fastener driver 100 in accordance with the present disclosure. The fastener driver 100 is used to drive fasteners (e.g., nails, thumbtacks, staples, etc.) located in a magazine 104 into a workpiece (not shown). The fastener driver 100 includes a housing 108, shown as a two-piece shell housing, and a drive assembly 112 for driving one fastener, and a lift assembly 116 for resetting the drive assembly 112 so that the fastener driver 100 can drive another fastener. The drive assembly 112 includes an inner cylinder 120 and a movable piston 124 disposed within the inner cylinder 120. The piston 124 is movable within the inner cylinder 120 between a standby or top dead center (TDC) position (not shown) and a driven or bottom dead center (BDC) position; Fig. 3) movable. A drive blade 128 is connected to the piston 124 and is movable therewith along a drive axis (i.e., drive blade axis) A1. The fastener driver 100 does not require an external supply of compressed air to drive a fastener, but rather includes a storage chamber cylinder or outer cylinder 132 containing a pressurized gas that is in fluid communication with the inner cylinder 120. In the illustrated embodiment, the outer cylinder 132 surrounds the inner cylinder 120, and the outer cylinder 132 and the inner cylinder 120 together form a compression chamber (i.e., a storage chamber) 136. As the drive blade 128 and piston 124 move toward the ready position, the air in the compression chamber 136 (e.g., above the piston 124) is compressed, thereby increasing the pressure acting on the piston 124. The lifting device 116 comprises a motor 140 which is connected to a rotary lifter 144.The rotary jack 144 is selectively engageable with the drive blade 128, as discussed in detail herein, to move the drive blade 128 and the piston 124 to the ready position. In the illustrated embodiment, a one-way clutch 148 and a gear train 152, such as a planetary gear train, are disposed between the motor 140 and the rotary jack 144.

[0013] In operation, the jack assembly 116 transmits the torque generated by the electric motor 140 to the rotary jack 144 via the one-way clutch 148 and the gearbox 152. Rotation of the rotary jack 144 moves the drive blade 128 from the driven position to the ready position. Movement of the drive blade 128 and piston 124 to the ready position compresses the gas contained in the compression chamber 136. In this way, the jack assembly 116 provides torque to the rotary jack 144 to move the drive blade 128 to the ready position, thereby increasing the pressure acting on the piston 124. To drive a fastener, the drive blade 128 is released from the ready position and moves toward the driven position due to the gas pressure acting on the piston 124. The compression chamber 136 is a sealed environment and therefore acts like a gas spring on the piston 124.As the drive blade 128 moves toward the BDC position, the drive blade 128 contacts the fastener and drives it into the workpiece. Further details regarding specific structures of the fastener driver 100 are described below.

[0014] As in the Fig. 2 to 6, the compression chamber 136 is connected to the housing 108 and can move relative to the housing 108 to a limited extent. During operation of the fastening drive, the piston 124 contacts a damper 156 ( Fig. 3) when it reaches the driven position. The damper 156 helps dissipate excess energy not used to drive the fastener. However, the damper 156 rests on the outer cylinder 132 of the compression chamber 136, and contact between the piston 124 and the damper 156 can also cause movement of the compression chamber 136. To prevent damage to the housing 108 from movement of the compression chamber 136, a plurality of compliant elements or dampers 160 (e.g., two, three, more than three) are disposed between the compression chamber 136 and the housing 108. The dampers 160 are formed of a vibration-damping material. The dampers 160 can be compliant enough to deflect when force is applied. The dampers 160 can be made of a rubber material.The dampers 160 are arranged between the housing 108 and the compression chamber 136 to allow the compression chamber 136 to move relative to the housing 108 while supporting the compression chamber 136 relative to the housing 108.

[0015] With continued reference to the Fig. 4 to 6, the pressure chamber 136 includes a first flange 164 extending from the outer cylinder 132 and a second flange 168 extending from the outer cylinder 132 opposite the first flange 164. The first flange 164 is disposed on a first side of the drive axis A1, and the second flange 168 is disposed on a second side of the drive axis A1. The first and second flanges 164, 168 are not symmetrical about a plane encompassing the drive axis A1. Rather, the first and second flanges 164, 168 are offset relative to a central vertical axis A2 ( Fig. 5 and Fig. 6). The first flange 164 has a generally rectangular shape when viewed along the drive axis A1. The second flange 168 also has a generally rectangular shape when viewed along the drive axis A1. A longitudinal dimension of the first and second flanges 164, 168 is measured tangentially to the outer cylinder 132. The first flange 164 is offset from the central vertical axis A2 in a direction parallel to the longitudinal dimension such that the central vertical axis A2 does not bisect the first flange 164. Similarly, the second flange 168 is offset from the central vertical axis A2 in a direction parallel to the longitudinal dimension such that the central vertical axis A2 does not bisect the second flange 168. In the illustrated embodiment, the first flange 164 is offset in a first direction and the second flange 168 is offset in a second direction opposite the first direction.The first and second flanges 164, 168 are offset by the same amount in the illustrated embodiment. However, in other embodiments, the first and second flanges 164, 168 may be offset by different amounts. Furthermore, in the illustrated embodiment, the first flange 164 and the second flange 168 are each offset by an amount less than half their length. This forms an overlap region in which portions of the first flange 164 and the second flange 168 are vertically aligned. In other embodiments, the flanges 164, 168 may be offset by an amount greater than half their respective lengths, such that no overlap region exists.The first and second flanges 164, 168 are staggered to utilize the space within the housing 108, thereby allowing generally rectangular flanges 164, 168 and dampers 160 while minimizing the overall size of the housing 108. However, it should be understood that neither the first flange 164 nor the second flange 168 need be generally rectangular. The dampers 160 are arranged asymmetrically with respect to one another about a plane (e.g., A2-A2) that includes an axis A1 along which the drive blade 128 is movable.

[0016] In the illustrated embodiment, each of the first and second flanges 164, 168 supports one of the pair of dampers 160. Each of the two dampers 160 conforms in shape to the shape of the respective flange 164, 168 to which it is connected. Thus, each of the two dampers 160 has a generally rectangular shape when viewed along the drive axis A1. In other embodiments, the dampers 160 may have a different cross-sectional shape depending on the shape of the associated flange 164, 168 and the space within the housing 108. For example, a damper 160 may have a generally straight inner surface and a curved outer surface, or a damper 160 may change its height along the length of the damper 160 and thus form a non-standard cross-sectional shape.

[0017] The Fig. 2 and 7 to 10 illustrate further details of the lifting device 116 and in particular the motor 140 of the lifting device 116. As previously mentioned, the lifting assembly 116 includes the motor 140, which is connected to the rotary jack 144 via the one-way clutch 148 and a planetary gear 152. The motor 140 is a brushless DC electric motor with an internal rotor, which is powered by a battery pack (B, Fig. 18). The motor 140 includes an output shaft 172 connected to an inner rotor 176 and to the clutch 148 to transmit the torque generated by the electric motor 140 via the clutch 148 to the gearbox 152. A fan 180 is connected to the inner rotor 176 to rotate therewith. In the illustrated embodiment, the fan 180 is formed integrally with the inner rotor 176 and is arranged adjacent to the clutch 148. The fan 180 draws air through the motor 140 due to the rotation of the inner rotor 176 and thus contributes to the cooling of the motor 140. The air is also directed over other components of the fastening drive 100, such as a control unit 184 ( Fig. 2). The motor 140 further includes a housing 188 in which an outer stator 192 is disposed. A cover 196 is connected to the housing 188 to direct the airflow through the motor 140. The output shaft 172 of the motor 140 extends beyond the housing 188 of the motor 140. The output shaft 172 is rotatably supported at one end by a bearing 200 connected to the cover 196 and is connected at the other end to the inner rotor 176. The fan 180 is disposed outside the housing 188 of the motor 140 opposite the cover 196. In the illustrated embodiment, the housing 188 of the motor 140 includes a constant diameter baffle 204. The baffle 204 is disposed adjacent the fan 180 to direct the airflow generated by the fan 180. The housing 108 of the fastening drive 100 includes at least one inlet 208 near the cover 196 and at least one outlet 212 near the fan 180 ( Fig. 2). In some embodiments, the housing 108 of the fastening drive 100 may also include an inlet (not shown) located adjacent to the controller 184. The inlet 208 and the outlet 212 serve to receive the airflow generated by the fan 180.

[0018] With reference to the Fig. 9 and Fig. 10, the cover 196 is shaped such that an outer periphery P1 of the cover 196 correlates with an outer periphery P2 of the housing 188 of the motor 140. However, the outer periphery P1 of the cover 196 includes only three sides, not four, to correspond to the outer periphery P2 of the housing 188. The cover 196 includes a plurality of openings 216 through which a plurality of fasteners 220 extend to connect the cover 196 to the housing 188. In the illustrated embodiment, each of the plurality of openings 216 is disposed within a cylindrical projection 224. The cylindrical projections 224 assist in aligning the cover 196 with the housing 188 of the motor 140. The cover 196 further includes a plurality of radially inwardly extending arms 228 that support a centrally located bearing recess 232. The bearing 200 and the output shaft 172 are journaled in the bearing recess 232.In the illustrated embodiment, the cover 196 includes five arms 228. However, in other embodiments, the cover 196 may include more or fewer arms 228. The body 236 of the cover 196 is shaped to direct airflow into the motor 140. In the illustrated embodiment, the body 236 is generally cylindrical and is aligned with the stator 192 of the motor 140. In other embodiments, the body 236 of the cover 196 may have a different shape to suit a desired airflow pattern. For example, the cover 196 may not include a central bearing, and the output shaft may be supported by another component of the motor. The cover profile 196 may also have any number of arms or no arms at all. In some embodiments, the cover 196 may be disposed adjacent to the fan 180 rather than opposite the fan 180 as shown.

[0019] The Fig. 2, 3, and 11 to 17 show further details of the lifting device 116, and in particular, the rotary jack 144 of the lifting device 116. As previously mentioned, the rotary jack 144 is selectively engaged with the drive blade 128 to move the drive blade 128 along the drive axis A1 from the driven position to the standby position. The drive blade 128 includes a plurality of jack teeth 240 extending laterally therefrom. The rotary jack 144 is connected to the gearbox 152 to receive torque from the motor 140 and includes a body 244 having a pair of opposed plates (i.e., flanges) 248 between which a plurality of jack pins 252 are disposed. In the illustrated embodiment, the rotary jack 144 includes seven jack pins 252.As the rotary jack 144 rotates, each of the jack pins 252 sequentially engages a jack tooth 240 of the drive blade 128 to move the drive blade 128 from the driven position to the ready position.

[0020] With reference to the Fig. 12 and Fig. 13, a last pin 252a of the plurality of lift pins 252 is shaped differently than the rest of the plurality of lift pins 252. The last pin 252a engages a last tooth 240a of the lift teeth 240 when the drive blade 128 is in or near the ready position (i.e., TDC). Unlike the remainder of a plurality of lift pins 252, a roller 256 (i.e., a blade engagement member) is disposed on the last pin 252a. The roller 256 is rotatable about the last pin 252a in a direction D. The roller 256 is shaped to engage the last lift pin 240a of the drive blade 128. In some embodiments, the roller 256 may be integrally formed with the last pin 252a and is not supported by the last pin 252a as shown. The roller 256 includes a plurality of cup-shaped recesses or cam portions 260 that can be engaged with the last lifting tooth 240a.The recesses or cam portions 260 may be generally concave in shape. In the illustrated embodiment, the roller 256 includes eight cam portions 260. However, in other embodiments, the roller 256 may include more or fewer cam portions 260. A detent mechanism, illustrated as spring 264 and plug 268 (. Fig. 3), is carried by the body 244 of the rotary jack 144 and engages the cam portions 260 of the roller 256 to prevent free rotation of the roller 256. During operation, the last tooth 240a of the drive blade 128 is engaged with the roller 256 as the drive blade 128 approaches the ready position. The ability of the roller 256 to rotate about the last pin 252a prevents excessive stress and wear on the last pin 252a that could be caused by sliding of the last tooth 240a of the drive blade 128 relative to the last pin 252a, and the shape of the cam portions 260 corresponds to a shape of the last tooth 240a of the drive blade 128 and assists in the alignment of the last tooth 240a of the drive blade 128 and the roller 256.

[0021] The Fig. 14 and Fig. 15 illustrate the last tooth 240a of the drive blade 128 in detail. The last tooth 240a of the drive blade 128 is furthest from the piston 124 ( Fig. 3) and engages the rotary jack 144 when the drive blade 128 is in or near the ready position. The last tooth 240a of the drive blade 128 has a first radius R1 in a direction parallel to the drive axis A1. The first radius R1 defines the shape of the last tooth 240a for engagement with the roller 256. In particular, the first radius R1 is shaped to engage the cam portions 260 of the roller 256. The last tooth 240a of the drive blade 128 also includes a crown 272 to reduce potential wear on the tooth 240a and the rotary jack 144. In some cases, the drive blade 128 may rotate or twist about the drive axis A1 in the direction of arrow AA during operation. The crown 272 is formed as a second radius R2 or crown radius in a direction perpendicular to the drive axis A1 and concentric with the arrow AA.The second radius R2 is shaped so that the last tooth 240a can rotate about the drive axis A1 relative to the rotary jack 144. In this way, the drive blade 128 can rotate about the drive axis A1 relative to the rotary jack 144 without excessive wear on the rotary jack 144.

[0022] With further reference to the Fig. 12 and Fig. 13, the cam portions 260 of the roller 256 are shaped to engage the crown 272 of the last tooth 240a. In particular, each cam portion 260 of the illustrated embodiment is rounded in two directions. A first cam portion radius R3 is applied tangentially to the direction of rotation of the roller 256 to form the cup-shaped recess that engages the last lifting tooth 240a. A second cam portion radius R4 is applied perpendicular to the first cam portion radius R3. The second cam portion radius R4 corresponds to the second radius R2 of the last tooth 240a and allows the drive blade 128 to rotate relative to the roller 256 about the drive axis A1 about arrow AA, while simultaneously limiting excessive wear on the roller 256 and / or the last tooth 240a of the drive blade 128 due to rotation about the drive axis A1.

[0023] in the Fig. 16 and Fig. 17, the last tooth 240a of the drive blade 128 and a cam portion 260 of the roller 256 are schematically illustrated. In the illustrated embodiment, the second radius R2 defining the crown 272 of the last tooth 240a is smaller than the second cam portion radius R4. This allows the drive blade 128 to rotate about the drive axis A1 relative to the roller 256 while maintaining contact between the crown 272 and the cam portion 260. Maintaining contact with the crown 272 prevents contact between an edge 276 of the last tooth 240a and the roller 256, which could lead to premature wear of the last tooth 240a and / or the roller 256. In the illustrated embodiment, the second cam portion radius R4 of the roller 256 is 20% larger than the second radius R2 defining the crown 272 of the last tooth 240a. As shown in Fig. 16, the last tooth 240a of the drive blade 128 can rotate two degrees while maintaining contact between the crown 272 and the cam portion 260. Fig. 17 is a detailed view of Fig. 16, which illustrates a contact area between the crown 272 and the cam portion 260. As in Fig. As shown in Figure 17, a gap 280 exists between the edge 276 of the last tooth 240a and the cam portion 260. Without the difference in radii, the two-degree rotation could result in contact between the edge 276 and the roller 256. In other embodiments, the difference in radii can be between 1% and 60%, depending on the desired amount of relative rotation about the drive axis allowed between the drive blade and the roller. In each embodiment, the radius of the cam portion of the roller is larger than the radius of the crown of the last tooth.

[0024] The Fig. Figures 18 to 24 and 26 to 35 show another gas spring-operated fastening drive 300. The gas spring-operated fastening drive 300 has the same features as the gas spring-operated fastening drive 100, with the numerals increased by "200." The gas spring-operated fastening drive 300 operates in a similar manner to the gas spring-operated fastening drive 100 described above.

[0025] With reference to the Fig. 18, 19, and 20-24, the gas spring-operated fastener actuator 300 includes a fill port 500 in fluid communication with the storage chamber 336 (i.e., the pressure vessel) (e.g., defined by the volume within both the inner cylinder 320 behind the piston 324 and within the outer cylinder 332) through which pressurized gas is transferred into the storage chamber 336. The storage chamber 336 is in fluid communication with the cylinder (e.g., the inner cylinder 320 and the outer cylinder 332) in which a pressurized gas is held to exert pressure on the piston 324. The storage chamber 336 may be defined similarly to the compression chamber (i.e., the storage chamber 136) of the gas spring-operated fastener actuator 100. During assembly of the gas spring-operated fastening drive 300, pressurized gas may be supplied from an external fluid supply FS to initially pressurize the storage chamber 336.Gas from the external fluid supply FS can be supplied to the storage chamber 336 via the same filling opening 500 in order to repressurize (i.e., refill) the storage chamber 336 after an accidental leakage of the storage chamber 336 during use of the gas spring-operated fastening drive 300.

[0026] In the embodiment from Fig. 23, the filling opening 500 includes a thread 504 into which a connecting element 508 can engage. The connecting element 508 is connected to the storage chamber 336. The connecting element 508 includes a tool side 508a with a tool-side thread 508b configured to be attached to the thread 504, and an opposite outer side 508c with an external thread 508d. The tool side 508a and the outer side 508c are separated by a shoulder 512. An O-ring 516 is disposed adjacent the shoulder 512 to assist in sealing the connecting element 508 against the pressure chamber 336. The tool-side thread 508b can be connected to the thread 504 to attach the connecting element 508 to the filling opening 500.The connection element 508 further includes a bore 508e, an outer axial end surface 508f, and a radially outer surface 508g on which the tool-side thread 508b and the external thread 508d are disposed. The bore 508e, in the illustrated embodiment, varies in diameter along a length of the connection element 508 along a fill axis FA. The illustrated bore 508e includes a smaller size on the tool side 508a and a larger size on the outer side 508c, with a transition in size axially along the fill axis FA near the shoulder 512. The bore 508e may include an internal thread 508h.

[0027] The external threads 508d of the connecting element 508 are selectively engageable with a plug 520 and an adapter 524 (ie, a first adapter 524). In the embodiment of Fig. 23, the plug 520 is attached to the connector 508. The plug 520 is generally dome-shaped. The plug 520 has internal threads 520a that can be attached to the external threads 508d. The internal threads 520a of the plug 520 are located on an inner surface of the plug 520 that faces radially inward toward the fill axis FA. The plug 520 further includes an end wall 520b that prevents access to the interior of the connector 508 when the plug 520 is attached to the connector 508. The end wall 520b includes a non-circular recess 520c that can be engaged by a tool (not shown) to selectively secure the plug 520 to the connector 508. In the illustrated embodiment, the recess 520c is a hexagonal receptacle in which a hexagonal tool (e.g., an Allen key) is received. The plug 520 further includes an O-ring receptacle 520d (ie,a seal receptacle) that receives a plug O-ring 522 to further assist in sealing the plug 520 with the connector 508. When fully secured to the connector 508, the end wall 520b of the plug 520 abuts the axial surface 508f of the connector 508.

[0028] In other embodiments, the features of the connector 508 may be formed integrally with the compression chamber 336. In such embodiments, the thread 508d, which can be engaged with the plug 520 or the adapter 524, may be formed integrally with the compression chamber 336.

[0029] With reference to Fig. 24, the fill port 500 is further closed by a valve 528 (e.g., a Schrader valve) having a valve stem 532 and a valve body 536. The valve 528 may be disposed within the fill port 500 (and in some cases, more specifically, within the connector 508). The valve body 536 may have a thread 536a that engages the internal thread 508h of the bore 508e. The valve body 536 may be retained relative to the bore 508e by the engagement of the thread 536a and the internal thread 508h or by another engagement (e.g., interference fit, adhesive, etc.). The valve stem 532 can be moved relative to the valve body 536 between an open position in which fluid can flow through the valve 528 and the fill port 500 and a closed position in which the flow of fluid through the valve 528 and the fill port 500 is prevented.The valve 528 can be moved between its open position and its closed position when the adapter 524 is engaged and disengaged from the external thread 508d (i.e., the first connection element). The illustrated valve 528 is a Schrader valve. However, other types of valves 528 are also possible. In other embodiments, the valve 528 can, for example, be a one-piece valve that is held in a closed position by the pressure exerted by the gas in the storage chamber 336 and can be moved to an open position by inserting a tip into the one-piece valve. The illustrated valve stem 532 can be biased in the closed position by a spring within the valve 528.The open position of the valve stem 532 may correspond to a position pushed into the valve body 536, thereby allowing a passage between the valve stem 532 and the valve body 536.

[0030] With continued reference to Fig. 24, the adapter 524 (i.e., a first adapter) is generally annular and includes an internal thread 524a that is attachable to the external thread 508d of the connector 508. The adapter 524 further includes an adapter tip 524b and a radially inwardly extending shoulder 524c. When the adapter 524 is fully attached to the connector 508, the shoulder 524c can abut the outer axial surface 508f of the connector 508, and the adapter tip 524b can depress the valve stem 532 by an amount corresponding to the interference I1. The interference I1 corresponds to movement of the valve stem 532 between its closed and open positions.

[0031] The adapter 524 further includes a primary fill passage 524d and at least one secondary fill passage 524e. In the illustrated embodiment, two secondary fill channels 524e are located on opposite sides of the fill axis FA. The secondary fill channels 524e simply connect the primary fill channel 524d to the bore 508e when the adapter 524 is attached to the connector 508. Once the adapter 524 is connected to the connector 508, fluid (e.g., gas) from an external fluid source FS can be directed from the primary fill passage 524d into the secondary fill passage 524e and through the valve 528 into the storage chamber 336. The adapter 524 further includes an O-ring receptacle 524f (i.e., a seal receptacle) capable of receiving an O-ring 526 (i.e., a seal of the fill adapter). In the illustrated embodiment, the fill adapter O-ring 526 surrounds the fill axis FA and has a generally circular cross-section.In other embodiments, the fill adapter O-ring 526 may be positioned at other locations relative to the fill axis FA and may have one or more flat surfaces (i.e., the fill adapter O-ring 526 may have a non-circular cross-sectional shape). In the illustrated embodiment, the O-ring receptacle 524f (i.e., the seal receptacle) is disposed on a radially inner surface of the adapter 524.

[0032] When the adapter 524 is attached to the connector 508, the fill adapter O-ring 526 acts as a seal between the adapter 524 and the connector 508. Because the fill adapter O-ring 526 is positioned between the radially outer surface 508g and the O-ring receptacle 524f on a radially inner surface of the adapter 524, the fill adapter O-ring 526 can be described as a radially outward seal. In other embodiments, the sealing components between the adapter 524 and the connector 508 can be located at different outward positions. For example, the fill adapter O-ring 526 can be relocated and / or duplicated to an axially outward position between the outer axial surface 508f and the shoulder 524c.In contrast, a position of the fill adapter O-ring 526 between the radial outer surface 508g or another sealing element within the bore 508e can be described as an internal seal within the connector element 508.

[0033] The relative dimensions of the adapter 524 and the connector 508 cause a seal to be formed between the adapter 524 and the connector 508 during connection of the adapter 524 to the connector 508 before the adapter 524 actuates the valve stem 532. More specifically, the axial lengths and positions of the thread 524a, the external thread 508d, the fill adapter O-ring 526 (i.e., the fill adapter seal), and the adapter tip 524b are dimensioned such that the fill adapter O-ring 526 seals against the connector 508 before the adapter tip 524b actuates (e.g., compresses) the valve stem 532.

[0034] The fluid coming from the external fluid supply FS can be led through one or more hoses H (e.g., flexible hoses) to a pressure regulator PR and finally to the adapter 524 and the storage chamber 336. The pressure regulator PR regulates the pressure supplied by the external fluid supply FS to a desired filling pressure. As shown in Fig. 24, the pressure regulator PR may be positioned at an intermediate point in a supply line that receives an external fluid from the external fluid source FS via a hose H and supplies it at a regulated pressure to another hose H and the adapter 524. In other embodiments, the pressure regulator PR may be arranged adjacent to the external fluid source FS (e.g., without a hose H between the external fluid source FS and the pressure regulator PR), immediately adjacent to the adapter 524 (e.g., without a hose H between the pressure regulator PR and the adapter 524), and / or at any location in the supply line between the external fluid source FS and the storage chamber 336.

[0035] The adapter 524, the hose H, and the pressure regulator PR can be considered a first filling adapter FA1 that can be connected to the connecting element 508. The first filling adapter FA1 is connectable to the connecting element 508 (i.e., a first connecting element) and thereby to the filling opening 500 to direct regulated pressurized gas from the external fluid supply FS into the storage chamber 336. Various filling adapters 524 (i.e., second adapters) with different or similar hoses H and pressure regulators PR can be considered second filling adapters (not shown).

[0036] The plug 520 may be attached to the connector 508 during normal operation of the gas spring-operated fastening driver 300, and the adapter 524 may be attached to the connector 508 during a filling or refilling operation. To prevent inadvertent access to the plug 520 during normal operation of the gas spring-operated fastening driver 300, a cap 530 may be attached to the housing 308 with a fastener 534. The fastener 534 may need to be loosened or removed from the housing 308 before the cap 530 can be removed to allow a user to access the recess 520c by inserting a tool (e.g., the Allen wrench) into the housing 308. In the illustrated embodiment, the cap 530 is located on a handle portion 308a of the housing 308.The cap 530 can be selectively connected to the housing 308 to selectively surround the filling opening 500 when the adapter 524 is not connected to the first connection element (the external thread 508d).

[0037] With reference to Fig. 25, a powered fastener drive system 700 may include a plurality of fastener drives 300, 704, 708, 712, 716, 720, 724, 728, 732, 736, 740, 744, 748, 752. The fastener drives 300, 704, 708, 712, 716, 720, 724, 728, 732, 736, 740, 744, 748, 752 may be divided into a first group 758, a second group 762, a third group 766, a fourth group 770, and a fifth group 774, depending on the predetermined inflation pressure requirements of the individual fastener drives, with like fastener drives being grouped together. Each of the fastening drives 704, 708, 712, 716, 720, 724, 728, 732, 736, 740, 744, 748, 752 may have features and functions like the fastening drives 100, 300.

[0038] The adapter 524 (i.e., the first adapter of the first filling adapter FA1) may be connectable to the fastening drive 300 with a connecting element (e.g., the connector 508, the "first connector") on the drive side and / or to the fastening drive 704 with the same connecting element (e.g., the external thread 508d). The same adapter 524 (i.e., the first adapter of the first filling adapter FA1) may be attached to both the fastening drive 300 and the fastening drive 704 to supply pressurized gas from the external fluid supply to either the storage chamber 336 or a similar storage chamber on the drive side of the fastening drive 704. Fastening drives assigned to the same group (e.g., the first group 758) may have similar connecting elements (e.g., the first connecting element, the connecting element 508) for engagement with the same adapter 524 (i.e., the first adapter of the first filling adapter).Different filling adapters (e.g., second filling adapters) with different adapters, i.e., second adapters 524 that are similar to, but different from, adapter 524, e.g., with different internal threads 524a, may be dimensioned as incompatible with the first connection element of the filling port 500. For example, the internal threads 524a of the second adapter 524 may be incompatible with the external thread 508d, thereby preventing the second adapter 524 from delivering pressurized gas from the external fluid supply into the storage chamber 336 on the drive side of the attachment drive 300 or the attachment drive 704.

[0039] Furthermore, different fastening drives (e.g., the fastening drives 708, 712) in different groups (e.g., the second group 762) can have connecting elements 508 (e.g., second connecting elements), for example with external threads 508d, which differ from the external threads 508d of the fastening drives 300, 704, so that second connecting elements (i.e., second connecting elements, connecting elements 524 with different internal threads 524a) can be fastened to the selected fastening drive (708, 712).

[0040] In the illustrated embodiment, the first connection element 508 may have a first thread form (external thread 508d of the fastening drive 300) and the first adapter 524 may have a second thread form (internal thread 524a of the first adapter 524) which is dimensioned to engage the first thread form, while the second adapter (internal thread 524a of the second adapter 524) may be dimensioned to prevent it from engaging the first thread form. The thread forms may differ in one or more of the following characteristics: small diameter, large diameter, depth, pitch, pitch diameter, helix angle, thread width, thread angle, thread root length, etc. In other embodiments, other types of mechanical structures that differ from the dimensions of the threads may be used to selectively establish a connection between the filling opening 500 (e.g.of the fastening drive 300 and the first group 758) with the fill port 500 of other groups (the second through fifth groups 762, 766, 770, 774) to prevent connection. For example, the inner and outer diameters of the fill port 500, the connecting elements 508, and the fill adapter 524 can be dimensioned to selectively allow and / or make incompatible connection between the fill port 500 and the fill adapter 524 compared to the fill ports 500 of other groups (the second through fifth groups 762, 766, 770, 774) to prevent connection.In other embodiments, the type and / or size of a quick connector may selectively allow and / or incompatible connection between the fill port 500 and the fill adapter 524 compared to the fill port 500 of other groups (the second through fifth groups 762, 766, 770, 774) to prevent connection.

[0041] The dimensions or other compatibility features between the fill port 500 and the fill adapters 524 can be selected so that the desired types of fill adapters 524 can be connected to the desired types of fill ports 500. For example, if desired, an adapter 524 typically intended for use with the external threads 508d on the drive side of the fastening drive 708, 712 of the second group 762 can also be connectable (i.e., compatible) with the external thread 508d of the fastening drives 300, 704 of the first group 758, but not with the fastening drives 716, 720, 724 of the third group 766. Various permutations are possible. In each group 758, 762, 766, 770, 774 a different number of fastening drives can be provided (e.g. one, two, three, four, or more than four).The illustrated system 700 includes five groups, but the system 700 may include any number of groups (two, three, four, five, or more than five).

[0042] The Fig. 26 and Fig. 27 show a drive shaft 800 extending along a drive shaft axis A3 that does not intersect (i.e., is non-intersecting) the drive axis A1 defined by the drive blade 328 (i.e., the drive blade axis A1). The drive shaft 800 is connected to and configured to receive torque from the motor 340. In some embodiments, and similar to the attachment drive 100, the attachment drive 300 may include a one-way clutch 348 and a gear train 352, such as a planetary gear train, disposed between the motor 340 and the drive shaft 800. The drive shaft 800 includes an input end 800a connected to the one-way clutch 348, the gear train 352, and the motor 340, and an output end 800b connected to a rotary jack 344. The rotary lifter 344 may have similar features to the rotary lifter 144.

[0043] With reference to the Fig. 27 to 30, the drive shaft 800 includes a pair of flat input sections 800c and a pair of flat output sections 800d, each adjacent to a pair of curved sections 800e near the input end 800a and the output end 800b, respectively. The flat output sections 800c and 800d each form two flat, planar surfaces between pairs of opposing curved sections 800e surrounding the drive shaft axis A3. Any number of flat input sections 800c and flat output sections 800d can be present, as long as the torque from the one-way clutch 348, the gearbox 352, and the motor 340 can be transmitted via the drive shaft 800 to a correspondingly shaped surface 344a of the rotary jack 344. The torque is transmitted to the surface 344a of the rotary jack 344 via each of the flat input sections 800c and the flat output sections 800d.The illustrated rotary jack 344 also includes curved surfaces 344b that mirror the shape of the curved portion 800e. The drive shaft 800 can apply torque to the rotary jack 344 to move the drive blade 328 from the BDC position toward the TDC position.

[0044] The drive shaft 800 further includes a shoulder 800f extending radially outward from the bent portions 800e near the output end 800b. The shoulder 800f projects a distance D1 from the bent portions 800e, measured perpendicular to the drive shaft axis A3. The output end 800b of the drive shaft 800 further includes a cylindrical surface 800g serving as a bearing support. The bearing support surface 800g has a smaller outer diameter than the shoulder 800f. As shown in Fig. As shown in Figure 27, a bearing 804 is secured (e.g., by interference fit) to the bearing surface 800g. The bearing 804 bears against a first side 800f1 of the shoulder 800f.

[0045] A spring 808 (i.e., a biasing member) is disposed between the shoulder 800f and an upper plate 448 (i.e., the upper flange 448, as shown in Fig. 27) of the rotary jack 344. More specifically, the spring 808 is disposed between a second side 800f2 of the shoulder 800f and the plate 448. The spring 808 exerts an axial biasing force along the drive shaft axis A3 on the rotary jack 344 to bias the rotary jack toward an axial home position, thereby positioning the rotary jack 344 at a height along the drive shaft axis A3 that is aligned with the drive blade axis A1 and thus with the drive blade 328, and thereby enabling the drive blade 328 to engage the lift pins 452 of the rotary jack 344. The spring 808 may be a compression spring, a leaf spring, or the like. The spring 808 may be comprised of one or more separate spring elements.

[0046] The Fig. 31 to 34 show a fastener 900 that secures the magazine 304 to the housing 308 and an irregular four-sided gearbox bolt pattern 904 that provides space for the fastener 900 to engage the housing 308. In the illustrated embodiment, the fastener 900 is a threaded fastener, e.g., a bolt or screw. However, other fastening means (e.g., quick-release fingers or snap fasteners) may be used. As shown in Fig. 31, the fastener 900 may extend through a bore 304a in the cartridge 304 at an intermediate position along the cartridge 304 between a proximal end 304b closest to the drive blade axis A1 and a distal end 304c thereof. The proximal end 304b of the cartridge 304 delivers the fasteners into alignment with the drive blade 328.

[0047] As in the Fig. 32 to 34, the bolt pattern 904 includes four bolts 908. Each of the bolts 908 is aligned along a bolt axis BA parallel to the drive shaft axis A3. The bolts 908 connect a clutch housing 348a, in which the one-way clutch 348 is disposed, to a transmission housing 352a, in which the transmission 352 is disposed. The motor housing 348b, in which the motor 340 is disposed, is connected to the clutch housing 348a. The housing 348b and the clutch housing 348a may collectively be referred to as a motor shell 348b. Since the transmission housing 352a contains gears, the transmission housing 352a may also be referred to as a transmission housing 352a. The motor shell 348b may have a generally cylindrical shape and further include projections 348c projecting radially outward from the generally cylindrical motor shell 348b. Each projection 348c may have a bore 348d configured to receive one of the bolts 908.The gear housing 352a may also have a generally cylindrical shape and may further include projections 352b projecting radially outward from the generally cylindrical gear housing 352a. Each projection 352b may have a bore 352c configured to receive one of the bolts 908.

[0048] The Fig. 33 and Fig. 34 show the fastener 900 extending through the bore 304a into the interior of the housing 308. The housing 308 has an inner sidewall surface 310a and a projection 310b extending inwardly into the housing 308 from the inner sidewall surface 310a. The projection 310b includes a magazine fastener receptacle 310c into which the fastener 900 engages to secure the magazine 304 to the housing 308. The magazine fastener receptacle 310c extends inwardly from the inner sidewall surface 310a along the projection 310b. By locating the projection 310b inside the housing 308, the lateral width of the fastener drive 300, including the magazine 304, is reduced compared to prior art fastener drives.

[0049] Fig. Figure 34 illustrates the transmission housing bolt pattern 904 in detail. The transmission housing bolt pattern has an irregular quadrilateral shape in a plane perpendicular to the drive shaft axis A3 (which is itself coaxial with the motor 340 and thus a motor axis). The illustrated irregular quadrilateral shape includes two normally included angles AN1, measured between two adjacent reference lines, each extending from the drive shaft axis A3 and through the bolt axis BA of a corresponding bolt 908. The normally included angles AN1 correspond to 90 degrees. The term "normal" refers to a typical angle expected for the selected number of bolts 908 in the transmission housing bolt pattern 904, which has four bolts 908 for a 360-degree circumference of the transmission housing 352a. A typical angle expected for a four-bolt transmission housing bolt pattern 904 would be 360 degrees / 4 bolts, or 90 degrees.In other embodiments, the angles AN1 may be different, and none of the angles AN1 may be referred to as "normal." The irregular quadrilateral shape includes at least one obtuse angle AN2, measured between two adjacent transmission housing bolts 908 and the drive shaft axis A3, that is greater than 90 degrees. The irregular quadrilateral includes at least one acute angle AN3, measured between two adjacent transmission housing bolts 908 and the drive shaft axis, that is less than 90 degrees. The resulting shape positions at least one of the bolts 908 further inward (closer laterally to the drive shaft axis A3) within the housing 308 to make room for the projection 310b and the fastener 900. It should be noted that the three bolts 908 defining the two normal included angles AN1 are spaced apart by a distance D2.The two bolts 908 defining the obtuse angle AN2 are spaced apart by a distance D3 that is greater than the distance D2. The two bolts 908 defining the obtuse angle AN3 are spaced apart by a distance D4 that is smaller than the distance D2. The distances D2-D4 are shown as straight lines running between the bolt axes BA. Similar relationships can also be established for the arc lengths between the bolts 908, which are represented by the distances D2-D4.

[0050] Other irregular quadrangular shapes for the transmission housing bolt pattern 904 are also possible. Similarly, other irregular, non-quadrangular shapes are also possible for the transmission housing bolt pattern 904. For example, there may be fewer (one, two, three) or more (more than four) bolts 908. For a transmission housing bolt pattern 904 with five bolts, for a regular bolt pattern, the bolts (360 degrees / 5 bolts) would be spaced apart at a normal angle of 72 degrees, resulting in the distance between the bolt axes BA between each of the five bolts 908 being the same (like the distance D2 above, but between each of the five bolts). An irregular bolt pattern is contemplated wherein at least one of the five bolts 908 is spaced at a smaller than normal (i.e., typical, evenly spaced circumferentially) distance (e.g.,less than 72 degrees) and at least one of the bolts is positioned at a greater than typical angular distance (e.g. greater than 72 degrees).

[0051] The Fig. Figure 35 shows an alternative airflow path through the housing 308 of the fastening drive 300, which is defined by a partition wall 1000. The housing 308 includes, as mentioned above, a handle portion 308a, a cylinder portion 308b, a battery receiving portion 308c configured to receive the battery pack B, and a motor housing portion 308d in which the motor 340 is disposed. The battery pack B can be connected to the battery receiving portion 308c to supply electrical power to the motor 340. The housing 308 is divided by the partition wall 1000 into an intake region 309a and an exhaust region 309b. The intake region 309a includes an airflow inlet 408. The illustrated airflow inlet 408 is located at a rear end of the battery receiving portion 308c. The airflow inlet 408 may be an inlet grille with a plurality of separate inlets. The exhaust air area 309b includes an airflow outlet 412.In the illustrated embodiment, two airflow outlets 412 are located on each side of the motor housing portion 308c (e.g., on the left ( . Fig. 31) and the right side ( Fig. 18) of the motor housing portion 308c, which are divided by a forward-backward reference plane passing through the drive axis A3). The airflow outlets 412 may be arranged at an axial height along the drive shaft axis A3 in accordance with the axial height of the fan 380. In other words, the airflow outlet 412 is arranged on the motor housing portion 308c in communication with the exhaust air region 309b. The partition wall 1000 is arranged within the housing 308 between the motor 340 (i.e., the motor housing 388) and the motor housing portion 308c. The partition wall 1000 may be a separate component of the housing 308 and the motor 340. Alternatively, the partition wall 1000 may be formed integrally with the housing 308 or the motor 340. The partition wall can prevent the cooling air flow emitted by the fan 380 in the exhaust air area 309b from re-entering the intake area 309a.In some embodiments, the partition 1000 may be made of a foam material. The partition 1000 may be made of a compliant material that can be deflected. The fan 380 itself may be disposed within the exhaust air area 309b.

[0052] With reference to Fig.35, upon activation of the motor 340, the fan 380 may generate a cooling airflow, as indicated by path AF1, which enters the airflow inlet 408 and cools the controller 384 and optionally the terminals of the battery pack B before entering the cover 396 and cooling the motor 340. In some embodiments, the cover 396 may be removed. After passing the motor 340, the cooling airflow AF1 enters the exhaust region 309b and exits the housing 308 through the airflow outlet 412. However, some air particles may be redirected back to the intake region 309a along a return path AF2. The return path AF2 encounters the partition 1000, which redirects the return path AF2 toward the airflow outlet 412, thereby preventing heated air driven by the fan 380 from flowing back into the motor 340.

[0053] Various features of the invention are set forth in the following claims. 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 63 / 718,005

[0001] US 63 / 620,242

[0001]

Claims

[1] A powered fastener drive comprising: a drive blade movable from a top dead center position to a bottom dead center position for driving a fastener into a workpiece; and a lifting assembly for providing torque to move the drive blade from the bottom dead center position toward the top dead center position, the lifting assembly comprising: a rotary lifter configured to be selectively engaged with the drive blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins, and a motor configured to provide torque to the rotary jack; wherein the roller has a plurality of cam portions defined by cup-shaped recesses having a first radius aligned parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the drive blade has a lifting tooth with a crown disposed thereon, the crown being configured to engage at least one of the plurality of cam portions. [2] The powered fastener driver of claim 1, wherein the crown is defined by a crown radius oriented perpendicular to a drive axis of the drive blade, and wherein the crown radius is less than the second radius of the at least one of the plurality of cam portions. [3] The powered fastener drive according to claim 1, further comprising a pressure vessel in which a pressurized gas is held, a housing in which the pressure vessel and the lifting assembly are arranged, and a damper arranged between the pressure vessel and the housing. [4] The powered fastener driver of claim 3, wherein the damper is a first damper and the powered fastener driver further comprises a second damper disposed between the pressure vessel and the housing, the first damper and the second damper being supported by a first flange and a second flange, respectively, and being arranged asymmetrically relative to each other in a plane containing an axis along which the drive blade is movable. [5] The powered fastener drive of claim 1, wherein the lifting assembly comprises a motor disposed in a motor housing and a gear transmission disposed in a transmission housing, the motor being aligned along a motor axis. [6] The powered fastener drive of claim 5, further comprising a plurality of gear housing bolts connecting the gear housing and the motor housing, the gear housing bolts being arranged in a gear housing bolt pattern having an irregular quadrangular shape as viewed perpendicular to the motor axis. [7] The powered fastener drive of claim 6, wherein the quadrangular shape has at least one obtuse angle, measured between two adjacent gear housing bolts and the motor axis, of greater than 90 degrees and at least one acute angle of less than 90 degrees. [8] The powered fastener drive according to claim 7, wherein the quadrangular shape has at least an angle of 90 degrees. [9] The driven drive for a fastening drive, comprising: a pressure vessel in which a gas under pressure is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; a lift assembly configured to selectively engage the drive blade to move the drive blade from the BDC position toward the TDC position; a housing in which the pressure vessel and the lifting arrangement are arranged; a first damper disposed between the pressure vessel and the housing; and a second damper disposed between the pressure vessel and the housing; wherein the first damper and the second damper are positioned asymmetrically relative to each other in a plane containing an axis along which the drive blade is movable; and wherein the first damper and the second damper are configured to dampen the movement of the pressure vessel relative to the housing. [10] The powered fastener drive of claim 9, further comprising a plurality of gear housing bolts connecting a gear housing to a motor housing, the gear housing bolts being arranged in a gear housing bolt pattern having an irregular quadrangular shape as viewed perpendicular to a motor axis of a motor within the motor housing. [11] The powered fastener drive of claim 10, wherein the quadrangular shape has at least one obtuse included angle, measured between two adjacent gear housing bolts and the motor axis, of greater than 90 degrees and at least one acute included angle of less than 90 degrees. [12] The powered fastener drive of claim 11, wherein the lift assembly comprises a rotary lifter configured to be selectively engaged with the drive blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins, wherein the roller has a plurality of cam portions defined by cup-shaped recesses having a first radius aligned parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius, and wherein the drive blade comprises a lifting tool having a crown disposed thereon, the crown configured to engage at least one of the plurality of cam portions. [13] The powered fastener driver of claim 9, wherein the lift assembly comprises a rotary lifter configured to be selectively engaged with the drive blade, the rotary lifter having a plurality of lift pins and a roller disposed on at least one of the lift pins. [14] The powered fastener drive of claim 13, wherein the roller has a plurality of cam portions defined by cup-shaped recesses having a first radius aligned parallel to a direction of rotation of the roller and a second radius perpendicular to the first radius. [15] The powered fastener driver of claim 14, wherein the drive blade comprises a lifting tool having a crown disposed thereon configured to engage at least one of the plurality of cam portions. [16] A powered fastener drive comprising: a pressure vessel in which a gas under pressure is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; a lift assembly operable to move the drive blade from the BDC position toward the TDC position, the lift assembly comprising a motor positioned within a motor housing and a gear train positioned within a transmission housing, the motor aligned along a motor axis; and a plurality of transmission housing bolts connecting the transmission housing and the engine housing, the transmission housing bolts being arranged in a transmission housing bolt pattern having an irregular quadrangular shape when viewed perpendicular to the engine axis; wherein the quadrangular shape has at least one obtuse angle, measured between two adjacent gearbox bolts and the engine axis, of more than 90 degrees and has at least one acute angle of less than 90 degrees. [17] The powered fastener drive of claim 16, wherein the quadrangular shape has at least an angle of 90 degrees. [18] The powered fastener drive according to claim 16 further comprising: a housing defining an inner surface in which the lifting assembly is positioned, the housing having a projection extending inwardly from the inner surface, and a magazine connected to the housing by a magazine attachment means, which engages a magazine fastener receptacle in the projection. [19] The powered fastener driver of claim 18, wherein the magazine includes a magazine bore receiving the magazine fastener, the magazine bore being located in an intermediate position between a proximal end of the magazine that supplies fastener to the drive blade in alignment with the drive blade and an opposite distal end of the magazine. [20] The powered fastener drive according to claim 18, wherein the magazine is arranged non-perpendicularly inclined to a drive axis along which the drive blade is movable. [21] A powered fastener drive system comprising: a driven fastening drive with a pressure vessel in which a pressurized gas is held; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; and a filling opening in fluid communication with the pressure vessel through which pressurized gas is transferred into the pressure vessel, the filling opening comprising a first connection element; a first filling adapter having a first adapter connectable to the first connection element of the filling opening to supply pressurized gas to the pressure vessel from an external fluid supply; and a second filling adapter having a second adapter different from the first adapter and incompatible with the first connection element of the filling opening, thereby preventing the second filling adapter from delivering pressurized gas from the external fluid supply into the pressure vessel. [22] The powered fastener drive system of claim 21, wherein the first connector has a first thread form, the first adapter has a second thread form dimensioned to engage the first thread form, and the second adapter has a third thread set dimensioned to be incapable of engaging the first thread form. [23] The powered fastener drive system of claim 21, wherein the powered fastener drive is one of a first group of powered drives each having a first connecting member. [24] The powered fastener drive system of claim 23, further comprising a second powered fastener drive having a second pressure vessel defining a second pressure vessel and a second fill port connected to the second pressure vessel, the second fill port communicating with the second pressure vessel, the second fill port including a second connector connectable to the second adapter of the second fill adapter to direct pressurized gas from the external fluid supply into the second pressure vessel. [25] The powered fastener drive system of claim 24, wherein the second powered fastener drive is one of a second group of powered fastener drives each having a second connector. [26] The powered fastener drive system of claim 24, wherein the second connector is incapable of engaging the first adapter of the first fill adapter. [27] The powered fastener drive system of claim 21, further comprising a valve positioned in the fill port and movable between an open position and a closed position when the first fill adapter is engaged or disengaged from the first connector. [28] The powered fastener drive system of claim 27, wherein the fastener drive further comprises a cap engageable with the fill port to selectively enclose the valve when the first fill adapter is not connected to the fill port. [29] The powered fastener drive system of claim 21, wherein the powered fastener drive further comprises a fitting engaging the fill port, the fitting being connected to the pressure vessel and defining a bore, an outer axial end surface, and a radial outer surface. [30] The powered fastener drive system of claim 29, wherein the radially outer surface has a thread defining the first connection element. [31] The powered fastener drive system of claim 29, wherein the first inflation adapter includes a first adapter thread defining the first adapter, a radially inwardly extending shoulder, and an adapter tip, the shoulder adapted to contact the outer axial end surface, and the adapter tip adapted to open a valve within the inflation opening upon engagement between the first adapter and the first connector. [32] The powered fastener drive system of claim 31, further comprising a fill adapter seal disposed between the radially outer surface of the fitting and a seal receptacle on a radially inner surface of the first fill adapter. [33] The powered fastener drive system of claim 21, further comprising a fill adapter seal between the first fill adapter and the fill opening and a valve positioned in the fill opening, wherein the axial lengths of the first adapter and the first connector along a fill axis and an axial position of the fill adapter seal along the fill axis are dimensioned such that, upon attachment of the first fill adapter to the first connector, the fill opening is sealed by the fill adapter seal before the first fill adapter actuates the valve. [34] A powered fastener drive comprising: a housing having an intake area with an airflow inlet, an exhaust area with an airflow outlet, a cylinder part and a motor housing part; a pressure vessel in which a gas under pressure is stored; a piston movable within the pressure vessel by the pressurized gas from a top dead center (TDC) position to a bottom dead center (BDC) position; a drive blade connected to the piston for movement from the TDC position to the BDC position to drive a fastener into a workpiece; a motor positioned within the motor housing portion and configured to to provide torque to move the drive blade from the BDC position toward the TDC position; a fan connected to the engine, the fan being configured to generate a cooling airflow from the airflow inlet to the airflow outlet upon activation of the engine; and a partition disposed within the housing between the motor and the motor housing portion to separate the intake region from the exhaust region and prevent the passage of the cooling air stream expelled by the fan in the exhaust region from re-entering the intake region. [35] The powered fastener drive of claim 34, wherein the partition is made of a foam material. [36] The powered fastener drive according to claim 34, wherein the fan is arranged in the exhaust air area. [37] The powered fastener driver of claim 34, wherein the housing further comprises a battery receiving portion configured to be connected to a power source to supply electrical power to the motor, and wherein the airflow inlet is disposed on the battery receiving portion. [38] The powered fastener drive according to claim 34, wherein the airflow outlet is arranged in communication with the exhaust air area on the motor housing part. [39] The powered fastener drive according to claim 34, wherein the pressure vessel is disposed within the cylinder portion. [40] The powered fastener drive of claim 34, further comprising a cover connected to the motor, the cover configured to direct the cooling airflow generated by the fan into the motor. [41] A powered fastener drive comprising: a drive blade movable along a drive blade axis from a top dead center (TDC) position to a bottom dead center (BDC) position, to drive a fastener into a workpiece; a gas spring mechanism for driving the drive blade towards the BDC position; a rotary jack for returning the drive blade from the BDC position toward the TDC position, the rotary jack having at least one flange and a plurality of jack pins extending from the flange, the rotary jack being movable to an axial home position relative to the drive blade axis, whereby the drive blade is engageable with the jack pins; an engine; a drive shaft extending seamlessly to the drive blade axis along a drive shaft axis, the drive shaft being connected to the motor and is configured to receive torque therefrom, the drive shaft is connected to the rotary jack and configured to transmit torque thereto to return the drive blade from the BDC position toward the TDC position, and wherein the drive shaft has a shoulder; and a spring disposed between the shoulder and the flange along the drive shaft axis, the spring being configured to exert an axial preload force along the drive shaft axis on the rotary jack. [42] The powered fastener drive of claim 41, wherein the drive shaft has a bent portion and a flat portion adjacent to the bent portion through which the torque is transmitted to the rotary jack, the shoulder extending radially outward from the bent portion. [43] The powered fastener drive of claim 42, wherein the spring is disposed between the shoulder and the flange. [44] The powered fastener drive of claim 41, wherein the spring is a leaf spring.

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