Micro-fastener driving tool with a gas spring

Abstract

A portable linear fastener driving tool for driving staples, nails, pins, or other linearly driven fasteners is provided. The tool uses a gas spring principle in which a cylinder filled with compressed gas is used to quickly push a piston through a drive stroke while a driver also drives the fastener into a workpiece. Next, the piston / driver is returned to its starting position by using a rotary-linear lifter, and the piston further compresses the gas above the piston, thereby preparing the tool for another drive stroke. In the illustrated embodiment, the tool exhibits an inverted U-shaped three-chamber design for a central cylinder, a left pressure chamber, and a right pressure chamber. In one illustrated embodiment, the lifter motor is configured to have its longitudinal axis substantially parallel to the longitudinal axis of the actuating cylinder, thereby making this tool more compact. Other embodiments show angles ranging from 0 to 90 degrees.

Description

Cross - reference to related applications

[0001] This application claims the priority of Provisional Patent Application No. 63 / 389,527, entitled "MICROFASTENER DRIVING TOOL WITH GAS SPRING", filed on July 15, 2022, and Provisional Patent Application No. 63 / 461,961, entitled "MICROFASTENER DRIVING TOOL WITH GAS SPRING", filed on April 26, 2023.

Technical Field

[0002] The technology disclosed herein generally relates to fastener driving tools, and more specifically to micropinners of the type that fire small pins into a substrate material. Embodiments include a sealed pressure chamber containing compressed gas, an actuating cylinder including a piston with a connecting driver, a removable battery pack, and an electric lifter sub - assembly, and are specifically disclosed as fastener driving tools that provide a reusable gas spring for driving small pins into a substrate during operation. The upper chamber of the actuating cylinder (the "variable displacement volume section") is in fluid communication with the pressure chamber, thereby sharing the compressed gas. This compressed gas is not released to the atmosphere during the drive stroke, but instead is reused many times over thousands of drive strokes.

[0003] The fastener driving tool includes an internal pressurized gas stored within a sealed pressure chamber. Actuating a trigger on the tool rotates a rotary - linear lifter that holds the piston and driver in a "ready position". The compressed gas then pushes the piston and driver towards the exit end of the tool with sufficient force to drive a small fastener (such as a pin) into the substrate, and this operating procedure may be referred to herein as the "drive stroke".

[0004] After the drive stroke, the lifter subassembly is automatically actuated. The lifter subassembly includes a plurality of lifter pins disposed around at least one lifter disk. The driver includes a plurality of lifter "teeth" or protrusions that the lifter pins "catch" during the "return stroke". During the return stroke, the lifter disk rotates, thereby causing the lifter pins to "catch" a first driver protrusion and initiate "lifting". The lifter disk continues to rotate and successive lifter pins catch and lift successive driver protrusions. The return stroke ends when the piston and driver are returned to their ready positions. The same compressed gas is used to initiate the drive stroke again. As described above, the compressed gas is generally reusable over hundreds or thousands of drive strokes.

[0005] The fastener driving tool is generally a portable cordless tool for driving staples, nails, pins, or other linearly driven fasteners. The tool is also specifically disclosed as a gas spring linear fastener driving tool that uses a compressed gas filled actuating cylinder to quickly push its piston through the movement of the drive stroke while also driving the fastener into the workpiece. Next, the piston is returned to its starting position by using a rotary-linear lifter, thereby further compressing the gas above the piston and thereby preparing the tool for another drive stroke. The driver is typically (at least during the drive stroke) attached to the piston and has a protrusion along one of its surfaces for use in contacting the lifter, thereby lifting the driver (and piston) during the return stroke.

[0006] Statement Regarding Federally Sponsored Research and Development None.

Background Art

[0007] Microfastener tools for driving nails, staples, or pins are common. Typically, such tools are used with an external pressurized gas source, such as a pneumatic compressor having a hose, and do not include a removable battery pack. The tool also typically includes a housing, a firing valve, and a cylinder including a piston and a driver blade, and the driver blade is used to sequentially drive staples, nails, or pins into a substrate.

[0008] A problem common to these types of tools is the need for an external pressurized gas source to operate the tool. To operate the tool, the user must typically carry around a heavy and cumbersome compressed gas unit with an air hose, along with a typically small and lightweight microfastener tool. In addition, during actual operation, the user must be mindful of the hose connecting the external compressed gas unit to the microfastener tool. This is because if the hose is damaged or cut, the tool will no longer operate.

[0009] Another aspect of conventional FUSION-type tools currently on the market is that the lifter motor and its drive train to the actual lifter are oriented at an angle perpendicular to the longitudinal axis of the actuating cylinder. (FUSION® is a hybrid fastener driving tool first invented by Senco Products, Inc., which uses a pressurized gas spring to power the drive stroke, but uses electricity to lift and return the driver and piston to their "ready position") The vertical lifter motor limits (extends) the profile of the tool at its side near the front of the conventional FUSION-type tool, which results in a larger working space problem when the motor housing is somewhat offset to the side of the main centerline of the tool. SUMMARY OF THE INVENTION

[0010] Accordingly, it is advantageous to provide a fastener driving tool that operates based on the gas spring principle, wherein a cylinder including a moving piston and a driver is at least partially surrounded by at least one pressure vessel (as a main storage chamber) to increase the storage space for the pressurized gas required for the gas spring effect.

[0011] Another advantage is to provide a fastener driving tool that uses the gas spring principle to provide a rapid downward driving stroke and uses a plurality of lifter pins that contact the driver and the piston and lift and return them to their ready positions, an electric rotary-linear lifter.

[0012] It is a further advantage to provide a fastener driving tool that operates based on the gas spring principle and includes a "working storage volume" that comprises a combination of two physically separated storage chambers and a variable displacement portion of the working cylinder.

[0013] It is yet another advantage to provide a fastener driving tool that operates based on the gas spring principle, wherein the lifter motor and its drive train to the actual lifter mechanism are mechanically arranged to be substantially parallel to the longitudinal axis of the working cylinder, thereby providing a more compact tool for most of its working parts.

[0014] It is also a further advantage to provide a fastener driving tool that operates based on the gas spring principle, wherein the lifter motor and its drive train to the actual lifter mechanism are mechanically arranged at an angle that is neither parallel nor perpendicular to the longitudinal axis of the working cylinder, thereby being able to help cool the lifter motor and / or help adjust the center of mass of the entire tool.

[0015] Additional advantages and other novel features will be described in part in the following description, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the techniques disclosed herein.

[0016] To achieve the above and other advantages, according to one aspect, a pressurized gas system for a portable fastener driving tool is provided, the pressurized gas system including a pressure chamber including a first side storage chamber and a second side storage chamber, and an actuating cylinder including a movable piston having a first end and an opposite second end, and a longitudinal axis extending at least between the first end and the second end, the pressure chamber extending along the longitudinal axis of the actuating cylinder and presenting an inverted U-shaped cross-section with a top bent portion, a first extended leg portion, and a second extended leg portion, the actuating cylinder being located proximal to the top bent portion of the inverted U-shape, the first side storage chamber being located in the first extended leg portion of the inverted U-shape and extending longitudinally along the first side of the actuating cylinder, the second side storage chamber being located in the second extended leg portion of the inverted U-shape and extending longitudinally along the second side of the actuating cylinder, the first side storage chamber and the second side storage chamber being operable to be in fluid communication with at least a portion of the actuating cylinder, and the pressure chamber being operable to contain a pressurized gas.

[0017] According to another aspect, a portable fastener driving tool is provided, including a pressure chamber containing a pressurized gas, an actuating cylinder including a movable piston having a first end and an opposite second end, and a first longitudinal axis extending at least between the first end and the second end, a movable driver in communication with the piston at least during a driving stroke, a lifter in communication with the driver at least during a return stroke, and a motor powering the lifter and having a second longitudinal axis, the first longitudinal axis being substantially parallel to the second longitudinal axis.

[0018] According to yet another aspect, there is provided a portable fastener driving tool comprising a pressure chamber for containing pressurized gas, an actuating cylinder including a movable piston having a first end portion and an opposite second end portion, and a first longitudinal axis extending at least between the first end portion and the second end portion, an actuating cylinder, a movable driver in communication with the piston at least during a driving stroke, a lifter in communication with the driver at least during a return stroke, and a motor supplying power to the lifter and having a second longitudinal axis, wherein the first longitudinal axis is oriented at an angle within a range of about 1 degree to about 15 degrees with respect to the second longitudinal axis.

[0019] According to yet another aspect, there is provided a portable fastener driving tool comprising a pressure chamber including a first side storage chamber and a second side storage chamber, an actuating cylinder including a movable piston having a first end portion and an opposite second end portion, and a longitudinal axis extending at least between the first end portion and the second end portion, an actuating cylinder, a movable driver in communication with the piston at least during a driving stroke, a lifter in communication with the driver at least during a return stroke, a guide body having a linear passage for the driver and positioned proximal to the first end of the actuating cylinder, a motor, and a three-chamber seal having a central O-ring portion seated around the actuating cylinder, a left ear-shaped seal portion seated around the first side storage chamber, and a right ear-shaped seal portion seated around the second side storage chamber, the three-chamber seal being positioned proximal to the first end.

[0020] According to a further aspect, there is provided a portable fastener driving tool comprising a pressure chamber for containing a pressurized gas, an actuating cylinder including a movable piston having a first end and an opposite second end, and a first longitudinal axis extending at least between the first end and the second end, a movable driver in communication with the piston at least during a driving stroke, a lifter in communication with the driver at least during a return stroke, a motor and a gear train for powering the lifter, wherein at least one of the motor and the gear train has a second longitudinal axis, and wherein the first longitudinal axis is oriented at an angle other than 90 degrees with respect to the second longitudinal axis.

[0021] Further advantages will become apparent to those skilled in the art from the following description and drawings, which illustrate and describe a preferred embodiment in one of the best modes contemplated for carrying out the technology. As will be understood, the technology disclosed herein is capable of other different embodiments and some of the details thereof are capable of modification in various obvious respects without departing from the principles thereof. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.

Brief Description of the Drawings

[0022] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the technology disclosed herein and, together with the description and claims, serve to explain the principles of the technology. In the drawings,

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DETAILED DESCRIPTION OF THE INVENTION

[0053] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, and like numerals refer to like elements throughout the drawings.

[0054] It should be understood that the technology disclosed in this specification is not limited, in its application, to the details of the construction and arrangement of components described in the following description or shown in the drawings. The technology disclosed in this specification allows for other embodiments and can be implemented or executed in various ways. It should also be understood that the expressions and terms used in this specification are for the purpose of description and should not be regarded as limiting. The use of "including", "comprising", or "having" and their variants in this specification means including the items listed hereinafter, their equivalents, and additional items. Unless otherwise specifically limited, the terms "connected", "coupled", or "mounted" and their variants used in this specification are widely used and include direct and indirect connections, couplings, or mountings. Furthermore, the terms "connected" or "coupled" and their variants are not limited to physical or mechanical connections or couplings. Additionally, the terms "communicating with" or "in a communication state with" mean that two different physical or virtual elements transfer signals or information to each other in some form, regardless of whether the transmission of their signals or information is direct or whether there are additional physical or virtual elements involved in the transmission of signals or information between them. Moreover, the term "in a communicating state with" can also refer to a mechanical, hydraulic, or pneumatic system where one end of the "communication" (the "first end") can be the "cause" of a certain motive force (mechanical movement, or a change in hydraulic or pneumatic state), and the other end of the "communication" (the "second end") can be affected by the movement / state change, regardless of whether there are intermediate components between the "first end" and the "second end".If a product has moving parts that depend on a magnetic field, or detects a change in a magnetic field in some way, or data is transferred from one electronic device to another by use of a magnetic field, those situations can be referred to as "magnetically communicating" with each other, where one end of the "communication" can induce a magnetic field and the other end can receive that magnetic field and be acted upon (or otherwise affected) by it.

[0055] For terms such as "first" or "second" that precede element names, such as a first inlet, a second inlet, etc., they are used for identification purposes to distinguish similar or related elements, results, or concepts and are not necessarily intended to imply an order, and the terms "first" or "second" are not intended to exclude the inclusion of additional similar or related elements, results, or concepts unless otherwise indicated.

[0056] Referring now to FIG. 1, a fastener driving tool is generally indicated by reference numeral 10. The tool 10 has a magazine 20 for holding a plurality of fasteners, a guide body 24 near the front end, an outlet end 22, and a first longitudinal axis 150. The outer front wall 26, the left pressure chamber outer wall 36, and the right pressure chamber wall 38 (see FIG. 2) are arranged in an inverted "U-shape" in cross-section (see FIG. 3) and are partially wound around the motor 30, the motor housing 31, the gearbox housing 32, and the chassis 34. The motor 30, the motor housing 31, the gearbox housing 32, and the chassis 34 are somewhat disposed within the inverted "U-shaped" "bend" portion of the "U". The chassis 34 is part of a chassis subassembly (subassembly, "S / A") 40 that will be described in more detail below. The motor 30 includes a rotating part and a stationary part.

[0057] The upper pressure chamber end (sometimes referred to as the "end cap" in this specification) 50 is fixed to the ends of the outer front wall 26, the left pressure chamber outer wall 36, and the right pressure chamber outer wall 38 (not shown in this figure) via a plurality of fasteners 28. The end cap 50 and the chassis S / A 40 provide an airtight seal at the outer walls 26, 36, and 38.

[0058] Next, referring to FIG. 2, a bottom view of the tool 10 is shown. In this figure, the left pressure chamber outer wall 36 and the right pressure chamber outer wall 38 are shown as being partially "wrapped around" the motor 30 in an inverted U shape. Note that the outer front wall 26 (not shown in this figure) is above the motor 30 and forms the "top" of the inverted U shape. The outer front wall 26 and the pressure chamber inner wall 25 constitute a cylinder chamber 56 (sometimes referred to as a "hollow cylinder" or an "actuating cylinder" in this specification) including a piston 60 and a driver 62 (see FIG. 5). The actuating cylinder 56 extends between a first end opposite to the second end of the longitudinal axis 150. The first end is proximal to the guide body 24, and the second end is proximal to the end cap 50.

[0059] The movable piston 60 exhibits a reciprocating motion having a first end movement position and a second end movement position opposite thereto. The movement of the piston 60 between the first end movement position and the second end movement position defines a variable ventilation volume portion 142 on the first side of the piston 60 proximal to the first end of the actuating cylinder 56 and a variable displacement volume portion 166 on the second side of the piston 60 proximal to the second end of the actuating cylinder 56. The variable displacement volume portion 166 is pneumatically separated from the variable ventilation volume portion 142 by the piston 60.

[0060] The left pressure chamber outer wall 36 houses the left pressure chamber 42 (see FIG. 3), and the right pressure chamber outer wall 38 houses the right pressure chamber 44 (see FIG. 3). The left pressure chamber 42 may be referred to herein as the "first side storage chamber," and the right pressure chamber 44 may be referred to herein as the "second side storage chamber." Each pressure chamber 42 and 44 is filled with a pressurized gas during the manufacture of the tool. The inverted U-shape has a cylinder chamber 56 at the "bend" or "top" of the inverted U-shape and the left pressure chamber 42 and the right pressure chamber 44 as the "ends" or "straight portions" of the inverted U-shape, a "three-chamber" design. The "straight portion" of the inverted U-shape may be referred to herein as the "extended leg portion." The right pressure chamber 44 and the left pressure chamber 42 extend between a first end and a second end opposite the first end of the longitudinal axis 150. The left pressure chamber 42 extends along a first side of the actuating cylinder 56, and the right pressure chamber 44 extends along a second side of the actuating cylinder 56.

[0061] The end cap 50 presents mating surfaces for the first side storage chamber 42, the second side storage chamber 44, and the actuating cylinder 56. It will be understood that the first side storage chamber 42 and the second side storage chamber 44 are not operable to be in fluid communication with each other except for the space proximal to the second end of the actuating cylinder 56. The first side storage chamber 42, the second side storage chamber 44, and the actuating cylinder 56 are all attached to the guide body 24.

[0062] Referring now to FIG. 3, the inverted U-shaped three-chamber design is shown in a rear cross-sectional view along the cut line 3-3 of FIG. 2 and is also shown in a cross-sectional view of the end cap 50 along the cut line 25-25 of FIG. 2. In FIG. 3, the outer front wall 26 has an inner cylinder wall 27 that, together with the pressure chamber inner wall 25, forms the cylinder chamber 56. The upper portion 61 of the piston 60 is shown disposed within the cylinder chamber 56.

[0063] The left pressure chamber outer wall 36 has a left pressure chamber inner wall 37, and together with the left pressure chamber inner wall 23, constitutes the left pressure chamber 42. Similarly, the right pressure chamber outer wall 38 has a right pressure chamber inner wall 39, and together with the right pressure chamber inner wall 25, constitutes the right pressure chamber 44. A plurality of fastener receptacles 29 engage with a plurality of fasteners 28 to fix the end cap 50 to the tool 10.

[0064] It will be appreciated that the left pressure chamber 42, the right pressure chamber 44, and the end cap 50 form a "single chamber" for storing pressurized gas. This single chamber is referred to herein as the "main pressure storage chamber" 156 and also includes the variable displacement volume portion 166 and the internal volume portion 140 (described below) of the end cap 50. The volume portion below the piston 60 is referred to as the variable vent volume portion 142, and the gas below the piston 60 is discharged from the tool 10 during the drive stroke and then refilled (from the external environment) during the lift stroke. The gas in the variable vent volume portion 142 is typically at atmospheric pressure (unless the tool is used in space).

[0065] Furthermore, it will be appreciated that the main pressure storage chamber 156 and the variable displacement volume portion 166 (see FIG. 11) are always pressurized during the operating cycle of the tool 10. In other words, the pressurized gas initially stored in the main pressure storage chamber 156 is not released to the atmosphere at the end of the drive stroke, but instead is reused over many operating cycles of the tool 10. This is quite different from a typical "air tool" that is connected to a compressed air hose (or a pressurized air or gas cylinder) and requires a new filling of compressed air or compressed gas for each new drive stroke.

[0066] Rather than operating like a typical "air tool", the pressurized gas system used in the fastener driving tool 10 disclosed herein functions similarly to a Senco FUSION® tool, which uses power supplied by a battery pack to "lift" the driver back towards its "ready" position, but uses gas pressure to "drive" the driver towards the substrate (i.e., towards its "driven" position) when driving a fastener into the target substrate. The pressurized gas system disclosed herein is designed to maintain its pressure over thousands of operating cycles before the tool may need to be refilled with additional pressurized gas. This is a feature that the tool 10 shares in common with the Senco product line of FUSION tools.

[0067] In view of the above, it will be further understood that after the tool 10 is filled with pressurized gas, the combination of the main pressure reservoir chamber 156 (which is always in fluid communication) and the variable displacement volume portion 166 of the actuating cylinder 154 always applies gas pressure to the "upper" surface 61 of the piston 60, including during the lift stroke. When the piston 60 is at its "bottom" end movement position (i.e., proximal to or at its "driven" position), the system gas pressure is at its minimum magnitude, yet is still a significant pressure so that the fastener can be fully driven into the target substrate during the drive stroke. As the driver 62 is lifted (during the "return" stroke), the "upward" movement of the piston 60 (in some of the figures herein) compresses the gas molecules within the combined space of the main pressure reservoir chamber 156 and the variable displacement volume portion 166 until the piston 60 reaches its "upper" end movement position (i.e., proximal to or at its "ready" position), at which point the system gas pressure will be at its maximum magnitude.

[0068] Since the pressurized gas system of this tool 10 is always under pressure, if any type of repair is necessary, care must be taken when disassembling the tool 10. Since the pressurized gas system may contain pressures in excess of 100 PSI, the tool 10 cannot simply be "popped open". This is true even if the gas pressure slowly decreases to the point where the tool 10 does not drive the fastener properly, and in that situation, there will still be significant pressure contained within this tool 10. Therefore, before attempting to "open" the tool to expose its moving parts within the area of the actuating cylinder 154, disassembly procedures must be carried out to depressurize the tool 10, and further, an authorized service center may need to perform any such disassembly procedures.

[0069] In Figure 3, the upper surface 61 of the piston 60 is the bottom of the variable displacement volume portion 166 bounded on each side by the left pressure chamber 42 and the right pressure chamber 44. These three volume portions constitute the inverted U-shaped three-chamber design of the tool 10. This inverted U-shaped three-chamber design is unique compared to conventional gas spring tool designs. For example, U.S. Patent No. 8,011,547 owned by Kyocera Senco Industrial Tools, Inc. discloses a fastener driving tool having a cylinder chamber and a piston essentially surrounded by an annular-shaped pressure chamber.

[0070] The inner wall 25 of the pressure chamber does not extend to the inner walls of the left pressure chamber 42 and the right pressure chamber 44. By design, this allows the pressurized gas stored in the left pressure chamber 42 and the right pressure chamber 44 to flow into the cylinder chamber 56 during the drive stroke. The pressurized gas pushes the piston 60 and the driver 62 towards the outlet end 22 and then drives the fastener into the substrate.

[0071] It will be appreciated that the cylinder chamber 56, the left pressure chamber 42, and the right pressure chamber 44 are in fluid communication with each other via the end cap 50. It will also be appreciated that a portion of the inner cylinder wall 27 and the pressure chamber inner wall 25 (which is also the outer wall of the actuating cylinder) forms a displacement volume created by the stroke of the piston 60. In other words, the gas pressure chamber 56 is not a fixed volume, but rather the volume of this chamber changes as the piston 60 moves up and down. This type of mechanical configuration is often referred to as a variable displacement volume 166, and this term is used primarily herein with respect to this non-fixed volume.

[0072] The left pressure chamber 42 and the right pressure chamber 44 preferably constitute fixed volumes, which will typically make manufacturing less expensive. However, it will be further appreciated that it is not an absolute requirement that the left and right pressure chambers actually be fixed volumes. Without departing from the principles of the present invention, it is possible to deform the size and / or shape of a portion of either chamber 42 or 44 such that the volume thereof actually changes during operation of the present invention.

[0073] Referring now to FIG. 4, the end cap 50 is shown as being fully fixed to the tool 10. In FIG. 4, the end cap 50 is clearly shown as having an inverted U-shape that conforms to the three-chamber design of the tool 10. The fastener 28 secures the end cap 50 to the tool 10. It will be appreciated that the internal volume 140 of the end cap 50 is a portion of the main pressure storage chamber 156 of the fastener driving tool 10. In other words, the end cap internal chamber 140 is in fluid communication with the left pressure chamber 42 and the right pressure chamber 44, and their combined volumes form a fixed volume storage space for compressed gas.

[0074] Next, referring to FIG. 5, tool 10 is shown in a left side cross-sectional view along cutting line 5-5 of FIG. 4. Piston 60 includes a seal 64, an upper form piece 68, and a lower form piece 69. Driver 62 is screwed to piston 60. Driver 62 moves through piston stop or bumper 54 and guide body 52 when driving a fastener into a workpiece. Guide body 52 has a straight passage for driver 62. Driver 62 has a plurality of spaced protrusions 63 (see FIG. 12), which may also be referred to herein as "teeth".

[0075] Generally speaking, the internal space of end cap 50 includes an "upper pressure chamber" referred to herein as 140. A land 58 for one of end cap fasteners 28 is shown. Upper pressure chamber end seal 57 is located where end cap 50 is attached to tool 10. End cap 50 has an inner wall 51. The gas in upper pressure chamber portion 140 generally mixes with a portion of the pressurized gas stored in left pressure chamber 42 and right pressure chamber 44. As described above, the operating cylinder outer wall 25 does not extend to the upper pressure chamber inner wall 51. This allows pressurized gas to flow from left pressure chamber 42 and right pressure chamber 44 into upper pressure chamber 140, and this combined gas can push piston 60 and driver 62 towards outlet end 22 during the drive stroke.

[0076] Proximal to piston stop 54 is an O-ring portion 100, which is part of a three-chamber seal (or gasket) 80 (see FIG. 8). Proximal and outside of cylinder chamber 56 is a rotatable lifter sub-assembly ("S / A") 70. A gear train sub-assembly ("S / A") 86 is mechanically connected to motor 30, and gearbox 86 includes an output shaft having a pinion gear 47 (see FIGS. 6 and 9).

[0077] Next, referring to FIG. 6, the chassis S / A40 is shown in an enlarged view. The drive spur gear 48 is mechanically connected to the pinion gear 47 (see FIG. 9) via a first spur gear 108 having an integral shaft. FIG. 6 shows a bevel gear 108 with an integral shaft. The driven spur gear 49 is mechanically connected to the pinion gear 47, and the driven spur gear 49 rotates the lifter shaft 79 during the return stroke. The pinion gear 47 is mechanically connected to the bevel gear 108. The bevel gear 108, the drive spur gear 48, and the driven spur gear 49 are at an angle of 90° with respect to the pinion gear 47. In other words, the direction of the pinion gear 47 is perpendicular to the first spur gear 108 and the lifter gear 49.

[0078] During the return stroke, the motor 30 is energized to rotate the gear train S / A86, thereby rotating the pinion gear 47. The pinion gear 47 rotates the gear / shaft 108, thereby driving the gear 48 via a key connection. Next, the drive spur gear 48 drives the driven spur gear 49. Thereby, the drive spur gear 48 and the driven spur gear 49 rotate together with the pinion gear 47. At the same time, the lifter shaft 79 rotates, thereby rotating the lifter cover plate 76 and the lifter base 74 (see FIG. 9). The lifter base 74 and the lifter cover plate 76 hold a plurality of lifter pins or extensions 72. The plurality of lifter pins 72 sequentially engage (or "capture") and "lift" the driver teeth 63 so as to lift and return the driver 62 to its preparation position. A shuttle return spring 78 is disposed on the lifter shaft 79 between the lifter cover plate 76 and the lifter base 74.

[0079] Now referring to FIG. 7, the tool 10 is shown in a partial right side view without the outer housing. The spring of the lifter S / A70 and a part of the gear train can be seen in this figure.

[0080] Next, referring to FIG. 8, the chassis S / A40 is shown in an exploded view. Together with the end cap 50, the chassis S / A40 seals and houses the pressurized gas while the tool is operating at the work site. At the bottom of the chassis S / A40 (in this figure), there is a chassis 34 for attaching the gearbox housing 32. Directly above the chassis 34, there is a pinion gear opening 87 for the pinion gear 47. A plurality of fasteners 96 fix the bearing block 98 proximal to the pinion gear opening 87.

[0081] Directly above the pinion gear opening 87, there is an intermediate annular seal seat 101. On the left side of the seat 101 (in this figure), there is a left seal seat 103, and on the right side (in this figure), there is a right seal seat 105. The left seal seat 103 has upper corner portions 111 and lower corner portions 113. The right seal seat 105 has upper corner portions 115 and lower corner portions 117. At the center of the seat 101, there is a driver opening 88.

[0082] The chassis S / A40 has a left pressure chamber cap 82, a right pressure chamber cap 84, and a cylinder chamber cap 81. These three caps 81, 82, and 84, together with the three-chamber seal 80 (also sometimes referred to as the "lower seal" in this specification), act to seal the cylinder chamber 56, the left pressure chamber 42, and the right pressure chamber 44. The end cap 50 and the chassis S / A40 are at both ends of the pressurized gas system of the tool 10.

[0083] The lower seal 80 has a central O-ring portion 100, a left seal portion 102, and a right seal portion 104. The left seal portion 102 and the right seal portion 104 may also be referred to as "ear-shaped" portions in this specification. The left seal portion 102 has upper corner portions 110 and lower corner portions 112. The right seal portion 104 has upper corner portions 114 and lower corner portions 116.

[0084] The lower seal 80 seats on the plurality of seating portions described above. The central O-ring portion 100 is designed to seat on the seating portion 101. The left seal portion 102 is designed to seat on the left seal seating portion 103, the upper corner portion 110 seats on the upper corner portion 111, and the lower corner portion 112 seats on the lower corner portion 113. The right seal portion 104 is designed to seat on the right seal seating portion 105, the upper corner portion 114 seats on the upper corner portion 115, and the lower corner portion 116 seats on the lower corner portion 117.

[0085] The seating portion of the power transmission sub-assembly (“S / A”) 90 is located on the opposite side of the chassis S / A 40 from the lower seal 80. The power transmission S / A 90 includes a lifter bearing opening 95, a lower solenoid opening 94, and a drive spur gear bearing opening 92. The entire lower power transmission S / A 90 is part of the chassis S / A 40, and the chassis S / A 40 is firmly attached to the tool 10 via a plurality of fasteners 97 that hold the guide body to the chassis S / A 40.

[0086] Next, referring to FIG. 9, the lifter S / A 70, the chassis S / A 40, the gear train S / A 86, the power transmission S / A 90, and the motor 30 are shown in an exploded view. In FIG. 9, a plurality of positioning pins 91 are shown together with the bevel gear 108 mechanically connected to the drive spur gear 48. The cover 109 covers the bevel gear 108 and the spur gear 48. The lifter shaft 79 has a key portion 73 and passes through the solenoid 75. The solenoid 75 is proximal to the driven spur gear 49.

[0087] The gear train S / A86 includes a mounting adapter 120 that is mechanically connected to the motor 30. The mounting adapter 120 is part of a first gear set subassembly (「S / A」) 144. The first gear set S / A144 includes the mounting adapter 120, a first ring gear 122, a first separator plate 124, a pinion 126, a first planetary gear set 128, a first set of planetary shafts 130, a first spacer / ring 127, a second separator plate 125, a first output disk 145, and a spur gear 149 (integrated with the disk 145). Note that the first ring 127 and the first output disk 145 are preferably configured to have a 「reverse prevention」 function, that is, the gear train S / A86 can only rotate in one direction. (Refer to the rotation pins on the first output disk 145 in FIGS. 23 and 24).

[0088] A second gear set subassembly (「S / A」) 146 is mechanically connected to the first gear set S / A144. The second gear set S / A146 includes a third separator plate 121, a second ring gear 134, a second planetary gear set 136, a second set of planetary shafts 138, a fourth separator plate 123, a pair of spacer rings 137, a second output disk 148, a deep groove 143 (sometimes referred to herein as a 「deep groove ball bearing S / A」), and a pinion gear 47. The integrated spur gear 149 of the stage 1 output disk 145 functions as the sun gear of the second gear set S / A146.

[0089] Note that in FIG. 9, the second spacer 137 is shown as having multiple rings, while in FIGS. 23 and 24, the second spacer 137 is shown as a single ring. It will be understood that the number of spacers within the gear train S / A86 can be varied according to the wishes of the system designer.

[0090] In FIG. 9, the motor 30 has an output pinion 126 that is mechanically (press - fit) attached to the pinion shaft 160. The pinion 126 engages with the planet gears 128 of the first gear set S / A144 and thus drives the entire gear train S / A86. The pinion gear 126 functions as the sun gear of the first gear set S / A144. The second gear set S / A146 is mechanically attached to the power transmission S / A90 via a shaft with a pinion gear 47, thereby driving a lifter S / A70 attached to the power transmission S / A90.

[0091] Next, referring to FIG. 10, an enlarged view of the 3 - chamber seal 80 is shown, showing the central O - ring portion 100 along with its left “ear - shaped” portion 102 and right “ear - shaped” portion 104. As can be seen in FIG. 10, the intermediate annular portion of the seal 80 is designed to maintain the gas pressure within the actuating cylinder 154, and the left portion 102 and right portion 104 are designed to seal the gas pressure within their corresponding pressurized gas chambers.

[0092] Next, referring to FIG. 11, a portion of the back of the tool is shown in an enlarged rear cross - sectional view along the cutting line 3 - 3 of FIG. 2. Note that the pressure chamber inner wall / cylinder sleeve 25 does not extend to contact the inner surface 51 of the end cap 50. As described above, this feature allows the pressurized gas to fill a volume portion called the main pressure storage chamber 156.

[0093] Here, referring to FIG. 12, the piston 60 is shown in its ready position. Note that when the piston 60 is moved to its driven position, the driver teeth 63 can be sequentially contacted by the lifter pin 72 to raise the driver 62 and the piston 90 back to the ready position.

[0094] Next, referring to FIG. 13, a rear view of the tool 10 is shown. This figure also shows the inverted U - shape of the pressure chamber of which the end cap 50 is a part.

[0095] Next, referring to FIG. 14, a right side sectional view taken along the cutting line 14-14 of FIG. 13 is shown. A part of the mechanical drive components is shown from the side opposite to that shown in FIG. 5.

[0096] Next, referring to FIG. 15, a rear view of the tool is shown, with the r-side pressure chamber 42 and the right-side pressure chamber 44 each shown by a dashed line. It will be understood that the exact size and shape of the pressure chambers 42 and 44 can be changed without departing from the principles of the technology disclosed herein. Also, for example, the overall "U-shape" of the entire pressure chamber shown in the illustrated embodiment is merely one desirable shape that can be achieved with this device.

[0097] In other words, other overall shapes may be configured instead for the pressure chamber, and the lifter motor may be at least partially "nested" within a pressure chamber having a different overall shape. For example, the pressure chamber can have an overall "J-shape", and the lifter motor may be at least partially nested within the "curved" portion of that J-shape, thereby still providing a compact overall cross-sectional profile for the tool. As a further example, the pressure chamber can have something like an overall "H-shape", and the lifter motor may be at least partially nested within one portion between the "bottom legs" of the H-shape, and the actuating cylinder may, in some cases, be nested within a second portion between the "upper legs" of the H-shape. Many different specific shapes are possible while still nesting the lifter motor within a portion of the overall pressure chamber shape.

[0098] Next, referring to FIG. 16, a right side sectional view taken along cutting line 16-16 of FIG. 15 is shown. In this figure, the right pressure chamber 44 is shown. One of the fasteners 28 is shown fully fixed within the chassis S / A 40, noting that this holds the end cap 50 onto the outer walls 26, 36, and 38. In FIGS. 15 and 16, it can be seen that a portion of the pressure chamber 44 is fully on the side of the actuating cylinder 154. In this embodiment, the opposite pressure chamber 42 is essentially symmetric to the pressure chamber 44 and thus has the same size and shape characteristics.

[0099] Next, referring to FIG. 17, a front perspective view of the tool 10 is shown. This figure shows the full length of the pressure chamber and actuating cylinder, the guide body 24, and also shows the attachment portion of the power transmission S / A 90. The end cap 50 is shown including its overall U-shaped profile.

[0100] Next, referring to FIG. 18, a rear perspective view of the tool 10 is shown. This figure shows the full length of the actuating cylinder and pressure chamber, and the outer portion of the motor and power train. In particular, this figure shows the overall U-shaped form of the end cap 50 and how its shape conforms to the overall shape of the pressure chamber with the motor 30 "pushed in" inside the outer portion of the pressure chamber. Further, an alternative cover 209 which is part of the power transmission S / A 90 is shown. FIG. 18 also clearly shows the features of the bottom of the magazine 20.

[0101] Now referring to FIG. 19, the tool 10 is shown having the alternative cover 209. When disposed on the tool 10, this cover 209 has an opening which helps to hold the shafts for the drive spur gear 49 and the bevel gear 108 (which have an integral shaft).

[0102] Referring now to FIG. 20, tool 10 is shown with alternative cover 209 with end cap 50 removed. The top of cylinder 56 can be seen at reference numeral 158. This top portion 56 does not extend to outer front wall 26, left outer wall 36, or right outer wall 38. The top surface (in this figure) of the pressure chamber will be covered by a seal 57 (see FIG. 22) to provide an airtight attachment to end cap 50.

[0103] Referring now to FIG. 21, tool 10 is shown with an exploded view of alternative cover 209 and power transmission S / A 90. This figure shows two different gear trains. The left gear train (in this figure) is driven by motor 30 and the right gear train drives lifter S / A 70. The left gear train has an upper shaft (i.e., the one closest to the viewer of this drawing) that extends through the large opening on the left side of cover 209, and the lifter shaft 78 of the right gear train extends through the large opening on the right side of cover 209. As will be described below, when fully assembled, drive gear 48 drives driven gear 49.

[0104] Referring now to FIG. 22, tool 10 is shown in an exploded view. In this embodiment, an additional special piston stop retaining ring 152 is disposed between lower seal 80 and piston stop 54. An upper seal 57 is shown that seals the joint between end cap 50 and main pressure storage chamber 156. Pressure chamber seal 57 is disposed proximal to the second end and has an inverted U shape. The "U shape" configuration of right pressure chamber outer wall 38 and left pressure chamber outer wall 36 can be seen in FIG. 22. This "U shape" assembly fits over and around motor 30 and motor housing 31 and is fixed to chassis S / A 40 by fastener 28. Note that fairly long fastener 28 passes through end cap 50, upper seal 57, completely through main storage pressure chamber 156, bottom seal 80, and is fixed to chassis S / A 40.

[0105] Next, referring to FIG. 23, a rear exploded view of the gear train S / A86 is shown. The motor 30 is mechanically attached to the first gear set S / A144, and the second gear set S / A146 is mechanically attached to the first gear set S / A144, thereby outputting power to the power transmission device 90 via the pinion gear 47. The operations of these components will be described in more detail below. The first gear set S / A144 includes a first planetary gear set 162 that includes a first ring gear 122 and four planetary gears 128 attached to a positioning pin or shaft 130. The sun gear of this first planetary gear set is not shown in this figure. The second gear set S / A146 includes a second planetary gear set 164 that includes a second ring gear 134, four planetary gears 136, and a positioning pin or shaft 138.

[0106] Next, referring to FIG. 24, a front exploded view of the gear train S / A86 is shown. The motor 30 rotates at a relatively high speed, for example, 19100 RPM (revolutions per minute). The gear train S / A86 reduces its speed and increases torque in order to operate the lifter S / A70.

[0107] In operation, the motor 30 is activated and begins to rotate the output pinion 160 (for example, at about 19100 RPM). The output pinion 160 is inserted into the first gear set S / A144 and engages the first planetary gear 128. The first planetary gear 128 transmits the load to the first ring gear 122, and this configuration may be referred to as the first planetary gear assembly 162. The reduction calculation of the first gear set S / A144 is obtained by dividing the number of teeth on the first ring gear 122 by the number of teeth on the "sun gear" (i.e., the output pinion 160) and adding 1. Thus, if the number of teeth on the first ring gear 122 is equal to, for example, 52, and the number of teeth on the output pinion 160 is equal to, for example, 16, the reduction calculation is 52÷16 + 1, or approximately 4.25:1.

[0108] Next, the second gear set S / A146 engages with the first gear set S / A144, and the second planetary gear 136 transmits the load to the second ring gear 134, and this configuration may be referred to as the second planetary gear assembly 164. The reduction calculation is the same as above, but the "sun gear" in the second gear set S / A146 is a combination of the first output disk 145 connected to the spur gear 149. For example, using the same numbers as above, the reduction calculation of the second gear set S / A146 is again approximately 4.25:1. The second planetary gear assembly 164 includes a sun gear (i.e., the spur gear 149), the second planetary gear 136, and the second ring gear 134. At this stage, the two reduction ratios are multiplied, i.e., 4.25×4.25, which is equal to a reduction ratio of 18.0625:1 to the gear train S / A86.

[0109] Next, the pinion gear 47 outputs to the bevel gear 108 with an integral shaft. These two gears 47 and 108 generate another reduction, and the reduction calculation is as follows. If the pinion gear 47 has, for example, 13 teeth and the bevel gear 108 with an integral shaft has, for example, 32 teeth, this is equal to a ratio of 2.462:1. Here too, when the result is multiplied by the total cumulative reduction ratio, it is equal to 44.47:1.

[0110] The bevel gear 108 with an integral shaft is keyed to the drive spur gear 48, and the drive spur gear 48 meshes mechanically with the driven spur gear 49 on the lifter shaft 79. Dividing the number of teeth of the driven spur gear 49 by the drive spur gear 48, if the drive spur gear 48 has, for example, 16 teeth and the driven spur gear 49 has, for example, 32 teeth, it is equal to a ratio of approximately 2:1. Combining this reduction ratio with the previous total reduction ratio gives a final total reduction ratio of approximately 89:1, or equal to approximately 215 RPM, for example, during the lift stroke.

[0111] It will be understood that the exact number of teeth on the gears on each part of the gear train S / A86 and the lifter S / A70 is a decision made by the system designer. The number of teeth on the gears used depends on the power and torque required between the output of the motor 30 and the rotation of the lifter S / A70, as determined by the designer. In the example described above, the reduction ratio is very significant due to the fact that the lifter S / A70 must overcome the force of the pressurized gas stored in the main pressure storage chamber 156. It will also be understood that the force required to overcome the drive mechanism of the tool varies depending on the type of tool.

[0112] It will be understood that the lifter motor and any sensors used in this tool communicate with a system controller (not shown). The printed circuit board including the system controller can be arranged within the handle portion (not shown). In a typical fastener driving tool, the trigger switch is actuated by a trigger actuator. In such a tool, the handle portion is designed to be gripped by a human hand, and the trigger actuator is designed to be actuated linearly by a human finger while gripping the handle portion. The trigger switch typically provides an input to the control system. In the FUSION type tool, there are several types of sensors and output indicators, and those types of input and output devices are likely to be used in the design of this tool.

[0113] The system controller typically includes a microprocessor or microcomputer device that functions as a processing circuit. Also, at least one memory circuit including random access memory (RAM) and read only memory (ROM) devices typically forms part of the system controller. A non-volatile memory device such as an EEPROM, NVRAM, or flash memory device is typically included to store user input information (when applicable to a specific tool model).

[0114] Operation of the tool

[0115] The "ready position" of tool 10 is when piston 60 is proximal to end cap 50 (see FIG. 5). The "driven position" of the tool is when piston 60 is distal from end cap 50 and proximal to piston stop 54. The tool enters the "driving stroke" when piston 60 is released from lifter S / A 70, at which time gas pressure moves piston 60 toward the driven position.

[0116] The driving stroke typically occurs when the trigger is actuated by a human user and the outlet end 22 is pressed against the workpiece. Virtually all commercially used fastener driving tools include a safety contact element that is actuated when the outlet end of the tool is pressed against the workpiece. When the trigger is pulled, lifter S / A 70 rotates, thereby releasing driver 62 from contact with the lifter, and then the force of the compressed gas in end cap 50 and in left pressure chamber 42 and right pressure chamber 44 presses piston 60 and driver 62 toward outlet end 22. Fasteners from fastener magazine 20 are pushed out through guide body 24 by driver 62 from outlet end 22.

[0117] The pressure of the gas in end cap 50, left pressure chamber 42, and right pressure chamber 44 (i.e., pressure chamber 156 as a whole) is high enough to quickly push driver 62 downward to properly seat the fastener in the substrate.

[0118] As driver 62 moves downward, piston 60 and piston stop 54 push air (or possibly some other gas) out of variable vent volume 142 below piston 60. The air in this volume is moved to the atmosphere (not shown) through an exhaust port, which desirably provides a low resistance path so as not to further impede the downward stroke of piston 60 and driver 62. The pressurized gas above piston 60 is not released to the atmosphere but instead remains within the combination of pressure chamber 156 and variable displacement volume 140.

[0119] One aspect of the present invention is to provide a rather large storage space volume for holding pressurized gas that is also used to drive the piston 60 downward during the driving stroke of the driver 62. The internal volume of the end cap 50 is a completely open space and communicates with the left pressure chamber 42 and the right pressure chamber 44. The volumes of the end cap 50 and the left storage chamber 42 and the right storage chamber 44 are preferably larger than the total volume of the cylinder operating space. This enables a powerful and rapid stroke.

[0120] At this stage, the lifter S / A 70 is engaged to "lift" and return the driver 62 and the piston 60 to the ready position (via the "return stroke"). When the motor 30 is energized, the gear train S / A 86, the pinion gear 47, the bevel gear 108, the driving spur gear 48, and the driven spur gear 49 rotate mechanically. When the driven spur gear 49 begins to rotate, the lifter shaft 79 also begins to rotate. The lifter base 74 and the lifter cover plate 76 are mechanically connected to the lifter shaft 79 and rotate simultaneously with the lifter shaft 79, and then the lifter shaft 79 rotates the lifter pins 72. The lifter pins 72 mechanically engage the driver teeth 63 one by one at a time when the lifter shaft 79 rotates during the return stroke. Each individual lifter pin 72 engages a single driver protrusion 63 until the driver 62 is completely "lifted" and returned to the ready position.

[0121] The illustrated embodiment enables both a rapid firing (or driving) stroke time and a rather rapid "lifting" time to return the driver 62 to its upper position to prepare for the next firing (driving) stroke. Both of these pneumatic and mechanical actions can occur continuously and rapidly, enabling the user to quickly place the fastener on the surface, in some cases at a speed of about two operating cycles per second.

[0122] The operating pressure within the system may preferably be about 120 PSIG and, in the case of a rapid-fire tool, should probably be at least 100 PSIG. By the term "operating pressure", the inventors mean the pressure within the end cap 50 as well as the left pressure chamber 42 and the right pressure chamber 44 when the piston 60 is in its ready position (or proximal thereto), i.e., when the piston 60 is at its uppermost moving position.

[0123] It should be noted that other gases than air can be used for the main pressure storage chamber 156 and the variable displacement volume section 140 if desired. Dry and clean air functions well in many or most applications, but alternative gases such as nitrogen gas can be used as the "charge gas". In practice, bottled nitrogen gas is preferred.

[0124] Referring next to FIG. 25, the interior of the end cap 50 is shown as a cross-sectional view along the cutting line 25-25 of FIG. 2. The inner surface 51 forms an open space bounded by a bottom wall 220, an upper wall 226, a left wall 224, and a right wall 222. These four "boundaries" of the inner surface 51 constitute the end cap volume section 140. The end cap volume section 140 is in fluid communication with the right pressure chamber 42 and the left pressure chamber 44, and the right pressure chamber 42 and the left pressure chamber 44 reach the end cap in the regions indicated by the arrows 42 and 44 in FIG. 25.

[0125] Next, referring to FIG. 26, as described above, the longitudinal axis of the actuating cylinder is indicated by reference numeral 150. (This axis 150 may be referred to herein as the "first longitudinal axis.") In this figure, the longitudinal axis of the motor 30 is also indicated by reference numeral 250. This "second longitudinal axis" 250 extends along the centerline of the rotating part of the motor 30 and is substantially parallel to the first longitudinal axis 150. It will be understood that the centerline of the rotating part of the motor 30 defines the second longitudinal axis 250. Also, it will be understood that the rotational output part of the motor 30 drives the gear train and the rotational output part of the gear train can also define the second longitudinal axis 250. Further, in the present embodiment, the first longitudinal axis and the second longitudinal axis are in the same plane.

[0126] As can be seen from the figures, (as clearly shown in FIGS. 13, 15, and 18, for example) with the motor 30 "pushed in" within the region of the U-shaped pressure chamber 156, these two longitudinal axes are substantially parallel to each other. This provides a very compact fastener driving tool, providing more space for the hands of a human user when operating the tool compared to conventional FUSION-type tools, providing a smaller cross-sectional area near the front part of the tool, thereby allowing more "open" space in a narrow working space such as a furniture or other similar location. As described above, conventional FUSION-type tools have a longitudinal axis of a lifter motor perpendicular to the longitudinal axis of the actuating cylinder, thereby restricting the profile of the tool at its side near the front part of the tool, thereby causing a larger working space problem when the motor housing is somewhat offset to the side of the main centerline of the tool.

[0127] Alternative configuration

[0128] FIG. 26 also shows possible alternative positions for the motor and the mechanical drive train, as may be required. In this figure, the alternative motor is shown in phantom lines at reference numeral 270. When the longitudinal axis of motor 270 is angled at an "inclination" of approximately 15 degrees compared to longitudinal axis 250, thereby providing a tool having an approximate appearance as illustrated by these phantom lines for the motor position, the longitudinal axis of this alternative position motor 270 is shown at reference numeral 260. Thus, the approximate angle between line 250 and line 260 is approximately 15 degrees. It should be noted that the plane of the inclination angle need not necessarily be in the vertical direction (as shown in FIG. 26).

[0129] One reason for designing a tool with an inclination angle other than 0 degrees may be to provide more space, which in some cases may allow for more cooling for the motor. Both the motor and the electronics (not shown) are heat sources when the fastening tool is in use, and providing more space between them may be necessary for larger and more powerful tools such as framing nailers. Additionally, the battery pack (also not shown) is another heat source, especially when the tool is used rapidly over many drive cycles in a short period of time. Thus, depending on the ultimate design of all these heat source components, it may be desirable to "tilt" the "second" longitudinal axis of the motor relative to the "first" longitudinal axis 150 of the actuating cylinder.

[0130] Referring now to Figure 27, again as an alternative possible configuration, a tool similar to that shown in Figure 26 is shown having an inclination angle of about 15 degrees with respect to the motor and the mechanical drive train. In Figure 27, the entire tool is generally designated by reference numeral 210 and has an outer front wall 26 and a left side pressure chamber outer wall 236 (essentially the same as the tool 10 of the first embodiment of Figure 1). This tool 210 includes a fastener magazine 245 having a profile slightly different from that of the magazine 20 of the tool 10 of the first embodiment, and includes a trigger handle 280 not shown in the drawings of the first embodiment. However, the entire trigger handle is not shown in Figure 27 and typically includes a lowermost portion that extends to a battery pack (also not shown). Further, the details of the actual movable trigger installed in this type of tool are not shown in order to clarify the figures of Figures 26 - 30.

[0131] The outer housing of the entire tool is not shown in these figures for clarity, but it should also be noted that it is typical for the outer housing to be included in a "complete" tool. At a minimum, high - temperature components such as the motor and the electronics that make up the system controller (not shown) should almost certainly be covered by the outer housing.

[0132] The tool 210 of Figure 27 includes a motor 270 having a motor housing 231 and a gearbox 232 having a housing. The output portion of the gearbox 232 enters at an angle into a lifter sub - assembly 240 similar to the lifter sub - assembly 70 of the tool 10 of the first embodiment. At least one of the centerlines of the rotating portion of the motor 270 and / or the centerline of the rotating output portion of the gear train defines an "inclined" longitudinal axis 260, similar to that shown in Figure 26.

[0133] The longitudinal axis of the actuating cylinder is designated by reference numeral 150 as described above. (This axis 150 may be referred to herein as the "first longitudinal axis". The "inclined" longitudinal axis 260 may be referred to herein as the "second longitudinal axis").

[0134] As can be seen by referring to FIG. 27, the approximate angle between line 250 and line 260 is about 15 degrees. Also, as described above, the plane of the inclination angle (between lines 250 and 260) does not necessarily have to be in the vertical direction. In other words, the motor 270 and its gearbox 232 can extend not only "downward" in this view of FIG. 27, but also extend somewhat away to the left side of the tool 210. In summary, the angle between the first longitudinal axis and the second longitudinal axis is about 15 degrees on FIG. 27.

[0135] Referring now to FIG. 28, this time, as another possible alternative configuration, a tool similar to that shown in FIG. 27 is shown having an inclination angle of about 30 degrees for the motor and the mechanical drive train. In FIG. 28, the entire tool is generally designated by reference numeral 310 and has an outer front wall 326 and a left side pressure chamber outer wall 336 (substantially the same as the tool 10 of the first embodiment of FIG. 1). This tool 310 includes a fastener magazine 320 similar to the magazine 245 shown in FIG. 27 and includes a trigger handle 380 similar to the trigger handle 280. However, the entire trigger handle is not shown in FIG. 28 either and typically includes a lowermost portion that extends to a battery pack (also not shown).

[0136] The outer housing for the entire tool is also not shown in FIG. 28, again for clarity. However, the fastener exit ends of the tool in the guide bodies 324 and 322 are shown just above the magazine 320.

[0137] The tool 310 of FIG. 28 includes a motor 370 having a motor housing 331 and a gearbox 332 having a housing. The output portion of the gearbox 332 enters at an angle into a lifter subassembly 340 that is similar to the lifter subassembly 70 of the tool 10 of the first embodiment. At least one of the centerline of the rotating portion of the motor 370 and / or the centerline of the rotational output portion of the gear train defines an "inclined" longitudinal axis 360 somewhat similar to the axis 260 shown in FIG. 27.

[0138] The longitudinal axis of the actuating cylinder is indicated by reference numeral 350. (This axis 350 may be referred to herein as the "first longitudinal axis". The "tilted" longitudinal axis 360 may be referred to herein as the "second longitudinal axis")

[0139] As can be seen in FIG. 28, the approximate angle between line 350 and line 360 is about 30 degrees. Also, as described above, the plane of the tilt angle (between lines 350 and 360) does not necessarily have to be in the vertical direction. In other words, the motor 370 and its gearbox 332 can extend not only "downward" in this view of FIG. 28, but also extend somewhat away to the left side of the tool 310. In summary, the angle between the first longitudinal axis and the second longitudinal axis is about 30 degrees on FIG. 28.

[0140] Referring now to FIG. 29, as another possible alternative configuration, a tool similar to that shown in FIG. 28 is shown having a tilt angle of about 60 degrees for the motor and mechanical drive train. In FIG. 29, the entire tool is shown generally by reference numeral 410 and has an outer front wall 426 and a left side pressure chamber outer wall 436 (essentially the same as the tool 10 of the first embodiment of FIG. 1). This tool 410 includes a fastener magazine 420 similar to the magazine 245 shown in FIG. 27 and includes a trigger handle 480 similar to the trigger handle 280. However, the entire trigger handle is not shown in FIG. 29 either and typically includes the lowermost portion that extends to a battery pack (also not shown).

[0141] The outer housing for the entire tool is also not shown in FIG. 29 for clarity. However, the fastener exit ends of the tool at the guide bodies 424 and 422 are shown just above the magazine 420.

[0142] The tool 410 of FIG. 29 includes a motor 470 having a motor housing 431 and a gearbox 432 having a housing. The output portion of the gearbox 432 enters at an angle into a lifter subassembly 440 that is similar to the lifter subassembly 70 of the tool 10 of the first embodiment. At least one of the center line of the rotating portion of the motor 470 and / or the center line of the rotational output portion of the gear train defines an “inclined” longitudinal axis 460 that is somewhat similar to the axis 260 shown in FIG. 27.

[0143] The longitudinal axis of the actuating cylinder is indicated by reference numeral 450. (This axis 450 may sometimes be referred to herein as the “first longitudinal axis.” The “inclined” longitudinal axis 460 may sometimes be referred to herein as the “second longitudinal axis.”)

[0144] As can be seen in FIG. 29, the approximate angle between line 450 and line 460 is about 60 degrees. Also, as described above, the plane of the inclination angle (between lines 450 and 460) need not necessarily be in the vertical direction. In other words, the motor 470 and its gearbox 432 can extend not only “downward” in this view of FIG. 29, but also somewhat away to the left side of the tool 410. In summary, the angle between the first longitudinal axis and the second longitudinal axis is about 60 degrees on FIG. 29.

[0145] Referring now to FIG. 30, this time, as another possible alternative configuration, a tool similar to that shown in FIG. 29 having an inclination angle of about 85 degrees for the motor and mechanical drive train is shown. In FIG. 30, the entire tool is shown generally by reference numeral 510 and has an outer front wall 526 and a left side pressure chamber outer wall 536 (essentially the same as the tool 10 of the first embodiment of FIG. 1). This tool 510 includes a fastener magazine 520 similar to the magazine 245 shown in FIG. 27 and includes a trigger handle 580 similar to the trigger handle 280. However, the entire trigger handle is not shown here (again) in FIG. 30 and typically includes a lowermost portion that extends to a battery pack (also not shown).

[0146] The outer housing for the entire tool is not shown in FIG. 30 either, again for clarity. However, the fastening tool exit ends of the guides 524 and 522 are shown just above the magazine 520.

[0147] The tool 510 in FIG. 30 includes a motor 570 having a motor housing 531 and a gearbox 532 having a housing. The output portion of the gearbox 532 enters at an angle into a lifter subassembly 540 that is similar to the lifter subassembly 70 of the tool 10 of the first embodiment. At least one of the centerline of the rotating portion of the motor 570 and / or the centerline of the rotating output portion of the gear train defines an "inclined" longitudinal axis 560 that is somewhat similar to the axis 260 shown in FIG. 27.

[0148] The longitudinal axis of the actuating cylinder is indicated by reference numeral 550. (This axis 550 may be referred to herein as the "first longitudinal axis". The "inclined" longitudinal axis 560 may be referred to herein as the "second longitudinal axis")

[0149] As can be seen by looking at FIG. 30, the approximate angle between line 550 and line 560 is about 85 degrees. Also, as described above, the plane of the inclination angle (between lines 550 and 560) does not necessarily have to be in the vertical direction. In other words, the motor 570 and its gearbox 532 can extend not only "downward" in this view of FIG. 30, but also somewhat away from the left side of the tool 510. In summary, the angle between the first longitudinal axis and the second longitudinal axis is about 85 degrees on FIG. 30.

[0150] As described above, one reason for separating the combination of the motor and the gearbox somewhat from the pressure chamber is to enhance the potential cooling of the relatively "hot" motor during operation. Another possible reason is that it can move the center of mass of the entire tool, if that is desirable. For example, the use of high-strength (and potentially high-mass) nails, or in some cases, the weight of magazines or pressure chambers or lifter sub-assemblies or motors and gearboxes or electronic devices such as battery packs and system controllers, etc. Depending on the overall power requirements of this type of fastener driving tool, any of these components can potentially vary significantly in weight and do not necessarily have to vary proportionally at the same rate as the required power can be increased for a given tool size.

[0151] The exemplary embodiments shown in FIGS. 27 - 30 generally show various angles that can be provided between the centerline of the actuating cylinder, i.e., one of the lines 150, 350, 450, or 550, and the centerline of the rotation of the motor, i.e., one of the lines 260, 360, 460, or 560. Further, the centerline of the motor rotation in FIG. 27 is also shown as possibly being on a line 250 that is parallel to the centerline 150 of the actuating cylinder in that figure, i.e., the angle between lines 150 and 250 is 0 degrees, but geometrically speaking, even if these lines are in the same plane, they never intersect. All of these alternative motor / cylinder orientations are different from any of the conventional FUSION-type tools, which all have a 90-degree angle between their motors and actuating cylinders, i.e., these conventional tools are all in a vertical orientation. (Note: Their exact centerlines may not intersect if they are in different planes, but when viewed from one side of the tool, as in the figures of FIGS. 27 - 30, these lines appear to intersect at right angles.)

[0152] Note that the 0-degree angle between the centerline of the actuating cylinder and the rotating part of the motor and / or its gearbox is the most preferred angle for most purposes, as in the tools shown in, for example, FIGS. 6, 14, and 16. However, as described above, for some purposes, such as cooling the motor and / or changing the center of gravity of the entire tool, some alternative angles to approximately 90 degrees can provide advantages. For the purposes of the present technical disclosure, it is assumed that the closer this angle is to 0 degrees, the better (or more preferred) it is. However, this cannot be truly determined until the tool designer selects the exact materials used in the tool's construction, and further, the final shape and size of the tool's outer housing (or housing such as a clam shell housing) must be determined before making the final decision regarding what the "best" (or most preferred) angle will ultimately be. In addition, the size of the fasteners (e.g., nails) should also be considered, although the mass of such fasteners typically varies as the magazine empties during tool use.

[0153] As used herein, the term "proximal" can mean positioning one physical object in proximity to a second physical object such that the two objects may in some cases be adjacent to each other, but does not necessarily require the absence of a third object disposed between them. In the technologies disclosed herein, a "male positioning structure" may be disposed "proximal" to a "female positioning structure". Generally, this may mean that the two male and female structures are physically abutting each other, or this may mean that, regardless of whether the two male and female structures are actually in contact with each other along a continuous surface, due to their particular size and shape, one structure is oriented with respect to the other in a given direction and is essentially held in an X-Y (e.g., horizontal and vertical) position such that they are "fitted" to each other. Or, two structures of any size and shape (whether male, female, or other) may be positioned somewhat close to each other regardless of whether they are physically abutting each other, and such a relationship can still be referred to as "proximal". Or, more than one possible position relative to a particular point can be specified in relation to the exact attributes of a physical object, such as "near" or "at" the end of a rod, and all of those possible near / at positions can be considered "proximal" to the end of that rod. Further, the term "proximal" can also have a meaning strictly related to a single object, where a single object may have two ends, a "distal end" is the end disposed somewhat farther away from a reference point (or region) of interest, and a "proximal end" is the other end that would be disposed somewhat closer to that same reference point (or region) of interest.

[0154] The various components described and / or illustrated in this specification can be manufactured in various ways, including manufacturing them in multiple parts or manufacturing each of these components as an integral part, without departing from the principles of the technology disclosed in this specification. For example, the components included as the recited elements in the following claims may be manufactured as an integral part, or the components may be manufactured as a combined structure of several individual parts that are assembled together. However, the "components of multiple parts" are still included within the scope of the recited elements claimed for the purpose of claim interpretation, even if the recited elements claimed are thought to be described and illustrated only as an integral structure in this specification.

[0155] Note that some of the embodiments illustrated in this specification do not have all of those components included in some of the drawings of this specification for purposes of clarity. In particular, with respect to prior designs, readers are referred to other U.S. patents and applications owned by Kyocera Senco to view examples of such outer housings and other components. Similarly, information on "how" an electronic controller operates to control the functions of the tool can be found in other U.S. patents and applications owned by Kyocera Senco. Furthermore, other aspects of the tool technology of the present invention may exist in conventional fastener driving tools sold by assignee Kyocera Senco Industrial Tools, Inc., including information disclosed in prior U.S. patents and published applications. Examples of such publications are U.S. Patent Nos. 6,431,425, 5,927,585, 5,918,788, 5,732,870, 4,986,164, 4,679,719, 8,011,547, 8,267,296, 8,267,297, 8,011,441, 8,387,718, 8,286,722, 8,230,941, 8,602,282, 9,676,088, 10,478,954, 9,993,913, 10,549,412, 10,898,994, 10,821,585, and 8,763,874, and U.S. Patent Application Publications 2020 / 0156228, 2021 / 0016424, 2020 / 0070330, 2020 / 0122308, and U.S. Provisional Patent Application No. 63 / 331993 filed on April 18, 2022. These documents are hereby incorporated by reference in their entirety.

[0156] All documents cited in the "Background Art" and "Detailed Description of the Invention" are hereby incorporated by reference in their relevant parts, but the citation of any document should not be construed as an admission that it is prior art to the technology disclosed in this specification.

[0157] The foregoing description of the preferred embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the technology disclosed herein to the precise forms disclosed, and the technology disclosed herein may be further modified within the spirit and scope of the present disclosure. Any example described or illustrated herein is intended as a non-limiting example, and many modifications or variations of those examples or preferred embodiments are possible without departing from the spirit and scope of the technology disclosed herein, taking into account the above teachings. The embodiments have been selected and described to illustrate the principles of the technology disclosed herein and its practical application, thereby enabling one of ordinary skill in the art to utilize the technology disclosed herein in various embodiments and with various modifications suitable for the particular uses contemplated. Therefore, this application is intended to cover any variations, uses, or adaptations of the technology disclosed herein using its general principles. Furthermore, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this technology pertains and that are within the scope of the appended claims.

Claims

1. A pressurized gas system for a portable fastener driving tool (10), comprising: A pressure chamber (156) including a first side storage chamber (42) and a second side storage chamber (44); An actuating cylinder (56, 154) including a movable piston (60), having a first end and an opposite second end, and a longitudinal axis (150) extending at least between the first end and the second end; Comprising: The pressure chamber (156) extends along the longitudinal axis (150) of the actuating cylinder (56, 154), has an inverted U-shaped cross-section, with a top bent portion, a first extended leg, and a second extended leg; The actuating cylinder (56, 154) is located proximal to the top bent portion of the inverted U-shape; The first side storage chamber (42) is located in the first extended leg of the inverted U-shape and extends along the first side of the actuating cylinder; The second side storage chamber (44) is located in the second extended leg of the inverted U-shape and extends along the second side of the actuating cylinder; The first side storage chamber (42) and the second side storage chamber (44) are operable to be in fluid communication with at least a portion of the actuating cylinder; The pressure chamber (156) is operable to contain pressurized gas. Pressurized gas system.

2. The tool (10) according to claim 1, wherein the pressure chamber (156) always contains pressurized gas during operation.

3. Further comprising an end cap (50) attached proximal to the second end of the actuating cylinder (56, 154), the end cap having an open space, and the first side storage chamber (42), the second side storage chamber (44), and the open space of the end cap are all in fluid communication.

4. During operation, the movable piston (60) exhibits a reciprocating motion having a first end movement position and an opposite second end movement position, and the movement of the movable piston between the first end movement position and the second end movement position is A variable ventilation volume portion (142) on the first side of the movable piston proximal to the first end of the actuating cylinder (56, 154); The variable displacement volume portion (166) on the second side of the movable piston proximal to the second end of the actuating cylinder (56, 154), is configured to define, wherein the variable displacement volume portion is always in fluid communication with both the first side storage chamber (42) and the second side storage chamber (44) during operation, The tool (10) according to claim 1.

5. The tool (10) according to claim 4, further comprising an end cap (50) attached proximal to the second end of the actuating cylinder (54, 154), the end cap having an open space, and the first side storage chamber (42), the second side storage chamber (44), the variable displacement volume portion (166), and the open space of the end cap being always in fluid communication with each other during operation.

6. The tool (10) according to claim 5, wherein the end cap (50) presents mating surfaces (220, 222, 224, 226) for at least the first side storage chamber (42) and the second side storage chamber (44), and further comprises a seal (57) on the mating surfaces to prevent pressurized gas from escaping.

7. The tool (10) according to claim 1, wherein the first side storage chamber (42) and the second side storage chamber (44) are not operable to be in fluid communication with each other except for the space proximal to the second end of the actuating cylinder (54, 154).

8. The guide body (24) proximal to the first end of the actuating cylinder (54, 154), a movable driver (62) that communicates with the movable piston (60) at least during the driving stroke, further comprising, wherein the guide body (24) includes a linear space that allows the movable driver (62) to pass through for driving a fastener from the outlet end (22) of the guide body, wherein the actuating cylinder (54, 154), the first side storage chamber (42), and the second side storage chamber (44) are all attached to the guide body. The tool (10) according to claim 1.

9. The tool (10) according to claim 8, further comprising at least one fastener (28) that holds the end cap (50) to the pressure chamber (156) and holds the guide body (24) to the pressure chamber.

10. A portable fastener driving tool (10, 210), a pressure chamber (156) containing pressurized gas; an actuation cylinder (54, 154) including a movable piston (60), the actuation cylinder (54, 154) having a first end and an opposite second end and a first longitudinal axis (150) extending at least between said first end and said second end; a movable driver (62) in communication with said movable piston during at least a drive stroke; a lifter (70) in communication with the movable driver during at least the return stroke; a motor (30) for powering the lifter, the motor (30) having a second longitudinal axis (250); Equipped with the first longitudinal axis (150) is substantially parallel to the second longitudinal axis (250); Tool (10, 210).

11. The tool (10, 210) of claim 10, wherein the motor (30) includes a rotating portion and a stationary portion, a centerline of the rotating portion defining the second longitudinal axis (250).

12. The tool (10, 210) of claim 10, wherein the motor (30) includes a rotational output portion that drives a gear train, and at least one of the gear train and the motor rotational output portion defines the second longitudinal axis (250).

13. the pressure chamber (156) extends along the first longitudinal axis (150) and has an inverted U-shape in transverse cross-section, the inverted U-shape including an apex bend portion, a first extension leg, and a second extension leg; the actuating cylinder (54, 154) is located proximal to the apex bend of the inverted U-shape; a first side storage chamber (42) of the pressure chamber located in the first extension leg of the inverted U-shape and extending longitudinally along a first side of the actuating cylinder; a second side storage chamber (44) of the pressure chamber located in the second extension leg of the inverted U-shape and extending longitudinally along a second side of the actuating cylinder; the first side storage chamber and the second side storage chamber are operable to be in fluid communication with at least a portion of the actuation cylinder; the pressure chamber contains pressurized gas at all times during operation; The tool (10, 210) of claim 10.

14. A three-chamber seal (80) located proximal to the first end and having a central O-ring portion (100), a left ear-shaped portion (102), and a right ear-shaped portion (104); A pressure chamber seal (57) arranged proximal to the second end and having an inverted U-shape; The tool (10, 210) according to claim 13, further comprising.

15. The actuating cylinder (54, 154) includes a variable ventilation volume portion (142) below the movable piston (60); The actuating cylinder includes a variable displacement volume portion (166) above the movable piston; The variable displacement volume portion (166) is pneumatically separated from the variable ventilation volume portion (142) by the movable piston (60); The tool (10, 210) according to claim 14, further comprising this.

16. A gearbox mechanically connected to the motor (30), the gearbox including an output shaft (160) having pinion gears (47, 126); A first spur gear (108) mechanically connected to the pinion gear; A lifter gear (49) mechanically connected to the first spur gear; A lifter shaft (79) key-coupled to the lifter gear; Further comprising, The directions of the pinion gears (47, 126) are perpendicular to the first spur gear (108) and the lifter gear (49); The tool (10, 210) according to claim 10.

17. The tool (10, 210) according to claim 10, wherein the first longitudinal axis (150) and the second longitudinal axis (250) are in the same plane.

18. A portable fastener driving tool (10), A pressure chamber (156) for containing pressurized gas; An actuating cylinder (54, 154) including a movable piston (60), the actuating cylinder having a first end and an opposite second end, and a first longitudinal axis (150) extending at least between the first end and the second end; A movable driver (62) communicating with the movable piston at least during the driving stroke; A lifter (70) communicating with the movable driver at least during the return stroke; A motor (270) for supplying power to the lifter, the motor (270) having a second longitudinal axis (260); Comprising The first longitudinal axis (150) is oriented at an angle within a range of about 1 degree to about 15 degrees with respect to the second longitudinal axis (260). Tool (10). [

19. ] The tool (10) according to claim 18, wherein the motor (270) includes a rotating part and a stationary part, and a center line of the rotating part defines the second longitudinal axis (260). [

20. ] The tool (10) according to claim 18, wherein the motor (270) includes a rotational output part that drives a gear train, and at least one of the gear train and the rotational output part of the motor defines the second longitudinal axis (260). [

21. ] The pressure chamber (156) extends along the first longitudinal axis (150) and has an inverted U-shaped cross-section, and the inverted U-shape includes a top bending part, a first extended leg part, and a second extended leg part. The actuating cylinder (54, 154) is located proximal to the top bending part of the inverted U-shape. The first side storage chamber (42) of the pressure chamber is located in the first extended leg part of the inverted U-shape and extends longitudinally along a first side of the actuating cylinder. The second side storage chamber (44) of the pressure chamber is located in the second extended leg part of the inverted U-shape and extends longitudinally along a second side of the actuating cylinder. The first side storage chamber and the second side storage chamber are operable to be in fluid communication with at least a part of the actuating cylinder. The pressure chamber always contains pressurized gas during operation. The tool (10) according to claim 18. [

22. ] A portable fastener driving tool (10), A pressure chamber (156) including a first side storage chamber (42) and a second side storage chamber (44), An actuating cylinder (54, 154) including a movable piston (60), having a first end and an opposite second end, and a longitudinal axis (150) that extends at least between the first end and the second end, the actuating cylinder (54, 154), A movable driver (62) that communicates with the movable piston at least during a driving stroke, A lifter (70) that communicates with the movable driver at least during a return stroke, A guide body (24) having a linear passage for the movable driver, and the guide body (24) is located proximal to the first end of the actuating cylinder. A motor (30), A three-chamber seal (80) having a central O-ring portion (100) seated around the actuator cylinder, a left ear-shaped seal portion (102) seated around the first side storage chamber, and a right ear-shaped seal portion (104) seated around the second side storage chamber, The three-chamber seal (80) located proximal to the first end, A tool (10) comprising:

23. Further comprising a pressure chamber seal (57) seated at the second end, The actuator cylinder (54, 154), the first storage chamber (42), and the second side storage chamber (44) contain pressurized gas, The three-chamber seal (80) and the pressure chamber seal (57) prevent the pressurized gas from leaking to the atmosphere, The tool (10) according to claim 22.

24. A gearbox mechanically connected to the motor (30), the gearbox including an output shaft (160) having pinion gears (47, 126), A first spur gear (108) mechanically connected to the pinion gear, A lifter gear (49) mechanically connected to the first spur gear, A lifter shaft (79) key-coupled to the lifter gear, Further comprising: The direction of the pinion gear is perpendicular to the first spur gear and the lifter gear, The tool (10) according to claim 22.

25. The movable driver (62) includes at least one protrusion (63), The lifter (70) includes at least one extension (72), The lifter is rotatable and mechanically connected to the lifter shaft (79), When the lifter shaft rotates, the lifter mechanically engages at least one extension of the lifter with at least one protrusion of the movable driver during the return stroke, The tool (10) according to claim 24.

26. The cylinder (54, 154) and the movable piston (60) act as a gas spring during the drive stroke, and the lifter (70) does not mechanically engage the movable driver (62) during the drive stroke, The tool (10) according to claim 25.

27. A portable fastener driving tool (10, 210, 310, 410, 510), A pressure chamber (156) for containing pressurized gas, An actuating cylinder (54, 154) including a movable piston (60), having a first end and an opposite second end, and a first longitudinal axis (150) extending at least between the first end and the second end, the actuating cylinder (54, 154); A movable driver (62) in communication with the movable piston at least during a driving stroke; A lifter (70) in communication with the movable driver at least during a return stroke; A motor (30, 270, 370, 470, 570) and a gear train for supplying power to the lifter, wherein at least one of the motor and the gear train has a second longitudinal axis (250, 260, 360, 460, 560), the motor (30, 270, 370, 470, 570) and the gear train; Comprising; The first longitudinal axis is oriented at an angle other than 90 degrees with respect to the second longitudinal axis; A tool (10, 210, 310, 410, 510).

28. The tool (10, 210, 310, 410, 510) according to claim 27, wherein the motor (30, 270, 370, 470, 570) includes a rotating part and a stationary part, and a center line of the rotating part defines the second longitudinal axis (250, 260, 360, 460, 560).

29. The tool (10, 210, 310, 410, 510) according to claim 27, wherein the motor (30, 270, 370, 470, 570) includes a rotational output part for driving a gear train, and at least one of the gear train and the rotational output part of the motor defines the second longitudinal axis (250, 260, 360, 460, 560).

30. The tool (10, 510) according to claim 27, wherein the first longitudinal axis (150) is oriented at an angle within a preferred range of about 0 degrees to about 85 degrees with respect to the second longitudinal axis (570).

31. The tool (10, 410) according to claim 30, wherein the first longitudinal axis (150) is oriented at an angle within a more preferred range of about 0 degrees to about 60 degrees with respect to the second longitudinal axis (470).

32. The tool (10, 310) according to claim 31, wherein the first longitudinal axis (150) is oriented at an angle within an even more preferred range of about 0 degrees to about 30 degrees with respect to the second longitudinal axis (370).

33. The tool (10, 210) according to claim 32, wherein the first longitudinal axis (150) is oriented at an angle within a further more preferred range of from about 0 degrees to about 15 degrees with respect to the second longitudinal axis (270).

34. The tool (10) according to claim 27, wherein the first longitudinal axis (150) is parallel to the second longitudinal axis (250).

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