Nailer assembly and method of replacing protective support structure thereof

Abstract

A nail gun assembly includes a housing defining a drive section located at a front portion of the nail gun assembly and a grip section located at an upper portion of the nail gun assembly. A fastener cartridge is located below the grip section and includes a feed portion adjacent to the drive section and a distal portion located distal to the drive section. A sacrificial protection support structure is positioned below the distal portion of the fastener cartridge.

Description

[Technical Field]

[0001] This disclosure is a continuation in part of U.S. Application Serial No. 17 / 475,511, filed September 15, 2021, and U.S. Application Serial No. 17 / 475,560, filed September 15, 2021, the disclosures of which are incorporated herein by reference in their entirety. Field of the Invention

[0002] This disclosure relates to a power tool, and more specifically, to a nail gun assembly. [Previous Technology]

[0003] Background of the Invention

[0004] Fasteners such as nails and clips are commonly used in projects ranging from handicrafts to building construction. While manually driving such fasteners into a workpiece is effective, users may quickly become fatigued when projects involve driving a large number of fasteners and / or large fasteners into a workpiece. Furthermore, properly driving large fasteners into a workpiece often requires more than one single impact with a hand tool.

[0005] To address the drawbacks of manual tools, power-assisted devices, such as nail guns (nail gun assemblies), have been developed to drive fasteners into workpieces. Contractors and homeowners typically use such devices to drive fasteners, ranging from headless nails for small projects to regular nails for framing and other construction work. Traditionally, compressed air is used to power these power-assisted (pneumatic) devices. However, other power sources, such as DC motors, are also used.

[0006] The nail gun assembly employs a multi-functional housing, including providing impact protection to internal mechanical and electrical components. The nail gun assembly also includes a linear or circular nail magazine (such as in a roofing nail gun) that feeds fasteners to a drive mechanism that drives the fasteners into the workpiece. The nail magazine also protects consumable fasteners before firing by providing uniform guides that allow the fasteners to enter the drive mechanism in a proper and consistent alignment. The feeding characteristics of features such as linear pack nails or circular coil nails can create a protruding magazine structure that may be easily damaged.

[0007] A key consideration for nail gun assemblies is their weight. When fasteners are relatively large and heavy, to prevent excessively long refill times that could result in significant fastener weight, only a sufficient number of fasteners are accommodated. Therefore, considerable effort is invested in reducing the overall weight of the nail gun assembly. This effort involves incorporating lightweight materials and eliminating unnecessary components.

[0008] Therefore, a typical nail gun assembly uses a molded housing and fastener cartridge to feed consumable fasteners to the drive mechanism. The structural housing surrounding the working mechanism protects the drive mechanism, but the fastener cartridge is susceptible to damage due to functional requirements such as protruding structures. If the fastener cartridge is made of plastic instead of metal extrusion to reduce the weight of the nail gun assembly, its vulnerability increases. The vulnerability of the fastener cartridge is highlighted in drop tests, where the protruding structures of the fastener cartridge are often the first point of impact.

[0009] Therefore, there is a need for a structure for a nail gun assembly that protects the fastener cartridge from damage in the event of a fall. Such a system would be beneficial if it did not significantly increase the weight of the nail gun assembly or significantly alter its operation. [Summary of the Invention]

[0010] Summary of the Invention

[0011] According to this disclosure, a sacrificial protection support structure is provided by a support base that provides vertical alignment between the probe housing and the working surface. Maintaining verticality minimizes nail ricochet and provides the safest and most productive user experience, especially for concrete nail gun assemblies.

[0012] In one embodiment, the support base is a sacrificial structure incorporating a rib structure that produces an intentional deformation and high-stress geometry with predictable impact performance. Through the deformation of the rib structure, the peak impact energy applied to the fastener cartridge is reduced. If the impact event is severe enough, the support base becomes a sacrificial element, thereby protecting the more expensive and difficult-to-replace fastener cartridge.

[0013] In one or more embodiments, the support base is coupled to the housing of the nail gun assembly and pivotable to a position below and adjacent to a distal position of the fastener cartridge. In some embodiments, the support base is coupled to the fastener cartridge. In some embodiments, the coupling is a substantial T-slot or dovetail geometry that creates a considerably large guide surface capable of distributing impact loads and minimizing material stress in the fastener cartridge structure, such that the rib structure deforms before the fastener cartridge or connector suffers any damage.

[0014] In some embodiments, the ribs are configured without filler material and are designed to provide controlled deformation and predictable failure under overstress conditions.

[0015] Advantageously, in some embodiments, the support base is designed to be easily removed by the user and is a sacrificial element. In some embodiments, the support base is configured for tool-free installation and removal.

[0016] In some embodiments of the base system that are asymmetrical, a feature is provided on the support base and / or fastener compartment that allows only one installation orientation.

[0017] According to one embodiment of this disclosure, a nail gun assembly includes a housing that defines a drive section located at a front portion of the nail gun assembly and a grip section located at an upper portion of the nail gun assembly. A fastener cartridge is located below the grip section and includes a feed portion adjacent to the drive section and a distal portion located distal to the drive section. A sacrificial protection support structure is positioned below the distal portion of the fastener cartridge.

[0018] In one or more embodiments, the sacrificial protection support structure includes a first connection portion, and the fastener compartment includes a second connection portion located on a lower housing portion of the fastener compartment, the second connection portion being configured to connect with the first connection portion.

[0019] In one or more embodiments, the sacrifice protection support structure is configured to be removed and / or replaced by a user.

[0020] In one or more embodiments, the sacrificial protection support structure is configured to be removed and / or replaced by a user without tools.

[0021] In one or more embodiments, the sacrificial protection support structure includes a first connecting portion and an energy absorbing portion. The energy absorbing portion is configured to absorb impact forces by deforming before the first connecting portion deforms.

[0022] In one or more embodiments, the energy-absorbing portion includes a plurality of ribs extending downward from the first connecting portion. In some embodiments, a force-absorbing material is located between at least some of the ribs, and / or the ribs are coated with the force-absorbing material. The force-absorbing material includes polyurethane materials, rubber materials, and microporous polyurethane elastomers (MPE).

[0023] In one or more embodiments, the first connection portion includes: an open end portion configured to receive at least a portion of the second connection portion passing through it; a closed end portion opposite to the open end portion; and a sliding arm extending from the open end portion to the closed end portion.

[0024] In one or more embodiments, the sliding arm includes a retaining groove, and the second connecting portion includes a spring-loaded button configured to engage the retaining groove. The second connecting portion further includes a support arm configured to directly contact the sliding arm.

[0025] According to one embodiment of this disclosure, a method is provided for replacing a first sacrificial protection support structure of a nail gun assembly, the nail gun assembly including a housing. The housing defines a drive section located at a front portion of the nail gun assembly and a grip section located at an upper portion of the nail gun assembly. The nail gun assembly further includes a fastener cartridge located below the grip section, the fastener cartridge including a feed portion near the drive section and a distal portion located distal to the drive section. The method includes: uncoupling the first sacrificial protection support structure from the fastener cartridge; and coupling a second sacrificial protection support structure to the fastener cartridge at a location below the distal portion of the fastener cartridge.

[0026] In one or more embodiments, uncoupling the first sacrificial protection support structure from the fastener housing includes: moving the first sacrificial protection support structure in a rearward direction by sliding a sliding surface of a first connecting portion of the first sacrificial protection support structure along a support arm of a second connecting portion of the fastener housing.

[0027] In one or more embodiments, disconnecting the first sacrificial protection support structure from the fastener compartment further includes: using one of the sliding arms of one of the first connection portions to hold one wall of the groove, pushing a spring-biased button toward one of the lower housing portions of the fastener compartment.

[0028] In one or more embodiments, connecting the second sacrificial protection support structure includes: moving the second sacrificial protection support structure in a forward direction while aligning an open end portion of a third connecting portion of the second sacrificial protection support structure with the support arm of the second connecting portion. This movement causes the support arm of the second connecting portion to be inserted into the open end portion of the third connecting portion, and causes a sliding surface of a sliding arm of the third connecting portion to slide along the support arm of the second connecting portion of the fastener housing.

[0029] In one or more embodiments, connecting the second sacrificial protection support structure further includes: using one of the sliding arms of the third connection portion to hold one wall of the groove, pushing a spring-biased button toward one of the lower housing portions of the fastener compartment.

[0030] In one or more embodiments, connecting the second sacrificial protection support structure further includes: abutting the support arm of the second connecting portion against a closed end portion of one of the third connecting portions. Almost simultaneously with the abutment, the spring-biased button is inserted into the retaining groove of the sliding arm of the third connecting portion.

[0031] In one or more embodiments, the first sacrificial protection support structure is disconnected from the fastener compartment by a user without the use of a tool.

Implementation Method

[0040] Detailed Description of Preferred Embodiments

[0041] To facilitate understanding of the principles of this disclosure, reference will now be made to embodiments illustrated in the accompanying drawings and described in the following written description. It should be understood that this is not intended to limit the scope of the disclosure. Furthermore, it should be understood that this disclosure includes any changes and modifications to the illustrated embodiments and includes other applications of the principles of this disclosure, as would normally occur to those skilled in the art to which this disclosure relates.

[0042] Referring to FIG. 1, a power tool 100 in the form of a nail gun assembly is depicted. The nail gun assembly 100 includes a housing 102 defining a drive section 104 and a grip section 106. A trigger 108 is disposed in the grip section 106, and a battery holder 110 is configured to be removably coupled to a battery 112 at the grip section 106. In other embodiments, the power tool is a corded tool or a pneumatic tool. The nail gun assembly 100 further includes a workpiece contact element (WCE) assembly 114 extending from the housing 102. A removable fastener cartridge 116 also extends distally from the drive section 104. The fastener cartridge 116 includes a fastener supply section 118, which includes a lower housing section 120. In some embodiments, the housing section 120 is made of metal, glass fiber filled nylon, or another desired material. The components identified above in the nail gun assembly 100 operate in any known or desired manner, and such operation will not be further described herein.

[0043] Continuing with FIG. 1, the sacrificial protection support structure 122 is disposed below the fastener housing 116 at a position distal to the drive section 104. In some embodiments, the sacrificial protection support structure 122 is made of the same material as the housing portion 120 and / or housing 102 of the fastener housing 116. In some embodiments, the sacrificial protection support structure 122 is supported by the housing 102 and is simply positioned adjacent to or in contact with the lower housing portion 120 at a position distal to the drive section 104. For example, a pivoting connection may be provided.

[0044] In the embodiment of FIG. 1, however, the sacrificial protection support structure 122 is connected to and supported by the fastener housing 116 via and by the coupling portion 130 shown in FIG. 2. The coupling portion 130 extends downward from the lower housing portion 120 and includes a crossbar 132 comprising two support arms 134 and 136. In some embodiments, a dovetail configuration is used instead of the T-shaped geometry of FIG. 2. The coupling portion 130 includes a spring-loaded retaining button 138, which includes a spring member (not shown) that biases the button downward away from the lower housing portion 120.

[0045] As shown in more detail in Figures 3 to 5, the sacrificial protection support structure 122 includes a connecting portion 150 complementary to the connecting portion 130 and an energy absorption portion 152. The connecting portion 150 includes an open end 154 and a closed end 156. A connecting slot 158 ​​extends from the open end 154 to the closed end 156. The connecting slot 158 ​​is sized and shaped to receive the crossbar 132, including support arms 134 and 136. The upper boundary of the connecting slot 158 ​​is defined by sliding arms 160 and 162. The sliding arms 160 / 162 include respective lower sliding surfaces 164 / 166 and retaining grooves 168 / 170, which are defined by wall portions extending downward from the upper surfaces of the sliding arms 160 / 162. The leading edges of the sliding arms 160 / 162 are defined by ramps 172 and 174.

[0046] The energy-absorbing portion 152 includes three ribs 176, 178, and 180. These ribs are spaced apart, with no material between them. In some embodiments, force-absorbing material is disposed between the ribs. Force-absorbing materials include polyurethane materials, rubber materials, and microporous polyurethane elastomers (MPE). In some embodiments, ribs 176, 178, and 180 are formed of the same material as the lower housing portion 120 and / or housing 102. The material, shape, size, and orientation of the ribs and any adjacent structures are selected to provide controlled deformation and predictable failure of the ribs 176, 178, and 180 upon impact, for example.

[0047] Specifically, ribs 176, 178, and 180 are designed to fail before the fastener cartridge 116, including the connecting portion 130, is damaged. This is shown in Figure 6, where the sacrificial protection support structure 122 is shown in a deformed state upon contact with the ground 182 after the nail gun assembly falls. Due to the energy absorbed by the deformation of the energy-absorbing portion 152, the energy transferred to the fastener cartridge 116 is insufficient to damage the fastener cartridge 130.

[0048] In this embodiment, the sacrificial protection support structure 122 is configured to deform inelastically to withstand heavy falls while protecting the fastener housing 116 from damage. Therefore, after some impacts, it is necessary to replace the sacrificial protection support structure 122. Although in some embodiments fasteners such as screws are used to secure the sacrificial protection support structure 122 to, for example, the fastener housing 116, in the embodiment of FIG. 1, the sacrificial protection support structure 122 is configured to be removed by a user without tools. In this embodiment, replacement of the sacrificial protection support structure 122 is achieved according to method 200 shown in FIG. 7.

[0049] Initially, the nailing assembly 100 is in the configuration shown in FIG. 1, with the spring-loaded button 138 inserted into the retaining groove 168 / 170. At block 202, the user holds the nailing assembly 100 while pulling the sacrificial protection support structure 122 backward (to the right as depicted in FIG. 1). When the sacrificial protection support structure 122 is pulled backward, the wall of the retaining groove 168 / 170 defining the sliding arm 160 / 162 is pushed against the spring-loaded retaining button 138 (only one is shown in FIG. 2), thereby pushing the spring-loaded retaining button 138 upward toward the lower housing portion 120, thus allowing the sliding arm 160 / 162 to pass under the spring-loaded retaining button 138. At block 206, the rearward movement of the sacrificial protection support structure 122 continues, causing the sliding surfaces 164 / 166 of the sliding arms 160 / 162 to slide along the support wall 134 / 136 until the connecting parts 130 and 150 are disengaged.

[0050] The user then obtains a replacement sacrificial protection support structure 122 identical to the removed sacrificial protection support structure 122. The connecting portion 150 of the replacement sacrificial protection support structure 122 is then aligned with the connecting portion 130 (block 208), and the crossbar 132, including support arms 134 and 136, is inserted into the open end 154 of the connecting portion 150 (block 210) by moving the replacement sacrificial protection support structure 122 forward (depicted to the left in FIG. 1). Insertion continues, causing the sliding surfaces 164 / 166 of the connecting portion 150 to slide across the support arms 134 / 136 until the ramps 172 / 174 contact the spring-loaded button 138.

[0051] The continued movement of the replacement sacrificial protection support structure 122 causes the ramps 172 / 174 to push the spring-loaded retaining button 138 upward toward the lower housing portion 120, thereby pressing down the spring-loaded retaining button 138 (block 212). Once the ramps 172 / 174 have moved past the pressed spring-loaded retaining button 138, the support arms 134 / 136 abut against the closed end 156 (block 214). Almost simultaneously, the retaining groove 168 / 170 moves to a position below the pressed spring-loaded retaining button 138, thereby releasing the spring-loaded retaining button 138 (block 216) and allowing the spring in the spring-loaded retaining button 138 to push the spring-loaded retaining button 138 into the retaining groove 168 / 170, thereby locking the replacement sacrificial protection support structure 122 in the desired position.

[0052] It should be understood that in different embodiments, some of the actions identified above are not performed in the manner described above. Furthermore, different structural configurations lead to modifications of the method for different embodiments. For example, in some embodiments, the sacrificial protection support structure is configured to be loaded by moving the sacrificial protection support structure backward. In other embodiments, the sacrificial protection support structure is configured to be loaded from the bottom of the connecting portion of the fastener housing. Therefore, the movement of the sacrificial protection support structure is in the upward direction. In some embodiments, a spring-loaded button is not used, and in other embodiments, the two ends of the connecting portion of the sacrificial protection support structure are open. In some of these embodiments, user-operable screws or other types of fasteners are used to secure the sacrificial protection support structure in the desired position.

[0053] Although this disclosure has been illustrated and described in detail in the accompanying drawings and the foregoing description, it should be considered illustrative rather than restrictive in nature. It should be understood that only preferred embodiments are presented, and all changes, modifications, and other applications falling within the spirit of this disclosure are intended to be protected. [Simplified Explanation of the Diagram]

[0032] The above features and advantages, as well as other features and advantages, will be more readily understood by those skilled in the art by referring to the following detailed description and accompanying drawings.

[0033] Figure 1 depicts a side plan view of the power tool disclosed herein, which is in the form of a nail gun assembly including a sacrificial protection support structure;

[0034] Figure 2 depicts a partial side perspective view of the fastener compartment of Figure 1, wherein the sacrificial protection support structure is removed to show the connection portion of the fastener compartment;

[0035] Figure 3 depicts a side perspective view of the sacrificial protection support structure of Figure 1;

[0036] Figure 4 depicts a front perspective view of the sacrificial protection support structure of Figure 1;

[0037] Figure 5 depicts a top perspective view of the sacrificial protection support structure of Figure 1;

[0038] Figure 6 depicts a partial side view of the nail gun assembly in Figure 1 when the sacrificial protective support structure is destructively deformed due to impact; and

[0039] Figure 7 depicts a method for replacing the sacrificial protection support structure of Figure 1.

Claims

1. A nail gun assembly comprising: a housing defining a drive section located at a front portion of the nail gun assembly and a grip section located at an upper portion of the nail gun assembly; a fastener cartridge located below the grip section and including a feed portion adjacent to the drive section and a distal portion located distal to the drive section; and a sacrificial protection support structure positioned below the distal portion of the fastener cartridge.

2. As in request item 1, the nail gun assembly, wherein: The sacrificial protection support structure includes a first connecting portion; and the fastener housing includes a second connecting portion located on a lower housing portion of the fastener housing, the second connecting portion being configured to connect with the first connecting portion.

3. The nail gun assembly as requested in claim 2, wherein the sacrificial protection support structure is configured to be removed by a user.

4. The nail gun assembly as claimed in claim 3, wherein the sacrificial protection support structure is configured to be removed by a user without tools.

5. The nail gun assembly as claimed in claim 1, wherein the sacrificial protection support structure includes: First connecting part; And an energy-absorbing portion configured to absorb impact forces by deforming before the first connecting portion deforms.

6. The nail gun assembly of claim 5, wherein the energy-absorbing portion includes: a plurality of ribs extending downward from the first connecting portion.

7. As in request item 6, the nail gun assembly, wherein: The fastener housing includes a second connecting portion located on a lower housing portion of the fastener housing, the second connecting portion being configured to connect with the first connecting portion.

8. The nail gun assembly of claim 7, wherein the first connecting portion includes: An open end portion located on a first side of one of the sacrificial protection support structures and configured to receive at least a portion of the second connecting portion passing through it; a closed end portion located on a second side of one of the sacrificial protection support structures and opposite to the open end portion; and a sliding arm extending along the top of one of the sacrificial protection support structures from the open end portion to the closed end portion.

9. As in request item 8, the nail gun assembly, wherein: The sliding arm includes a retaining groove; the second connecting portion includes a spring-loaded button configured to engage the retaining groove; and the second connecting portion includes a support arm configured to directly contact the sliding arm.

10. A method for replacing a first sacrificial protection support structure in a nail gun assembly, the nail gun assembly including a housing defining a drive section located at a front portion of the nail gun assembly and a grip section located at an upper portion of the nail gun assembly, the nail gun assembly further including a fastener cartridge located below the grip section, the fastener cartridge including a feed portion near the drive section and a distal portion located distal to the drive section, the method comprising: uncoupling the first sacrificial protection support structure from the fastener cartridge; and coupling a second sacrificial protection support structure to the fastener cartridge at a location below the distal portion of the fastener cartridge.

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