Stall release mechanism and debris ingestion mitigation for a fastening tool

Abstract

A driving tool includes a stall release lever, a debris blocking member, and a latch. The stall release lever is configured to be pivotable about a pivot axis between a home position and a release position. When a driver is in a stall position and a follower assembly is in a locked over-center position, pivotal movement of the stall release lever toward the release position forces the follower assembly toward the release over-center position in which the pinch force is released. The pivot axis is substantially parallel to a rotational axis of a flywheel and is substantially perpendicular to a drive axis of a driver. The latch, in an unlatched position, is configured to enable the debris blocking member to move from its first position to its second position to block debris in the nosepiece assembly from entering the drive assembly.

Description

STALL RELEASE MECHANISM AND DEBRIS INGESTION MITIGATION FOR A FASTENING TOOLCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority to U.S. Provisional Patent Application No. 63 / 537,902, filed September 12, 2023, titled "Debris Ingestion Mitigation For a Fastening Tool," which is incorporated herein by reference, in its entirety. This patent application also claims priority to U.S. Provisional Patent Application No. 63 / 538,060, filed September 12, 2023, titled "Stall Release Mechanism For a Fastening Tool," which is incorporated herein by reference, in its entirety.FIELD

[0002] This patent application relates, in general, to the field of power tools. In particular, this patent application relates to a fastening tool or a driving tool, such as a nailer and, more particularly, to improvements in reducing the size and weight of the tool. In particular, this patent application relates to a fastening tool having a stall release mechanism and / or having a debris ingestion mitigation system.BACKGROUND

[0003] Different types of fastening tools are generally known including portable pneumatically actuated devices, electrically actuated devices, hammer actuated devices, manual actuated devices, etc. Fastening tools, such as power nailers and staplers have become relatively common place in the construction industry. Battery-powered nailers are popular in the market.

[0004] A common characteristic of all these types of fastening tools is the provision of a drive track, a fastener driving element mounted in the drive track and a magazine assembly for receiving a supply of fasteners in stick formation and feeding successive leading fasteners in the stick laterally into the drive track to be driven outwardly thereof by the fastener driving element.

[0005] In a fastening tool, for example, fasteners, are driven into a workpiece by a driver blade or driver through a process known as a "drive" or "drive cycle". Generally, a drive cycle involves the driver member striking a fastener head during a drive stroke to an extended position, and returning to a home or returned position during a return stroke.

[0006] In an existing fastening tool, the nosepiece includes a nose portion along which a driver member drives a fastener into a workpiece, and a door portion that covers the nose portion. During the drive cycle, the driver member reciprocates in a space between the nose portion and the door portion.

[0007] Often times, however, during repetitive firing of nails and given user errors like firing into extremely hard surfaces such as on top of an existing nail, nails in the tool may be broken, bent, etc. Bits such as ferrous debris may break off of the nail and potentially fall inside of the tool. Bits of metal inside of the tool may cause tool damage.

[0008] When this type of event (e.g., jam, misfire, stall, etc.) occurs, the user typically opens the door portion of the nosepiece to view inside the tool through the front nose area and clear the debris / bits from the tool.

[0009] Accordingly, there is a need in the art for a fastening tool that blocks the debris created during a drive cycle from entering the tool engine (e.g., including a motor and a flywheel arrangement). There is also a need in the art for a fastening tool that catches and holds ferrous debris so that the user can access and remove the debris from the tool.

[0010] Flywheel-driven fastening tools, such as cordless framing nailers use the flywheel to drive a profile (or driver) in order to fire or propel nails. When a propelled nail strikes an object that is too hard or dense to penetrate, the driver can "stall" in the middle of the drive path.

[0011] In such a stalled position, the driver or profile is subjected to a pinch force between a pinch roller or follower and the flywheel. This pinch force can be quite large. For example, a 400 pounds pinch force or greater can be exerted on the driver between a pinch roller and the flywheel. When the driver profile stops in the middle of the drive (due to the lack of energy needed to drive the nail), the pinch force is still acting on the driver in the stalled position. Thispinch force prevents the driver blade from returning to the start position without intervention. Typically, the user is forced to insert a long screwdriver through the nosepiece of the tool and against the end of the driver and to manually push the blade back to the starting position. The pinch force continues to act on the driver until the driver moves to a position that is adjacent the start of the drive path.

[0012] Accordingly, there is also a need in the art for a fastening tool that, in the event of a stall, provides a way to release the stall to return the tool to an operable state without the need of any external tools that do not wear out or damage any of the fastening tool components.

[0013] FIGS. 26A-26C disclose a prior art stall release lever 2000 that slides along an axis that is parallel to the drive axis of the driver. For example, the stall release lever 2000 may move in the direction SD (that is substantially parallel to the drive axis of the driver) from its home position to its release position to release the stall to return the tool to an operable state. FIGS. 26A-26C also show driver profile ear 2002 and pinch roller shaft 2004.

[0014] FIGS. 27A-27B disclose another prior art stall release lever 3000 that is configured to be rotatable about a vertical axis VA. The vertical axis VA is substantially perpendicular to the drive axis of the driver and is substantially perpendicular to the rotational axis of the flywheel. For example, the stall release lever 3000 may move / rotate about the vertical axis VA and in the direction RD from its home position to its release position to release the stall to return the tool to an operable state. FIGS. 27A-27B also show pinch roller carrier 3002. The details about the stall release lever of FIGS. 27A-B are discussed in detail in commonly assigned U.S. Patent No. 9,399,281 ("the '281 Patent"), filed on March 12, 2013, titled "Stall Release Lever For Fastening Tool", which is incorporated by reference in its entirety.

[0015] Additionally, there needs to be a stall release lever that fits inside the compact housing of the tools without getting in the way of the visual or physical use or the tool in all applications and a stall release lever that is not sticking out the top of the tool at rest.SUMMARY

[0016] In an aspect, a driving tool is provided. The driving tool comprises a housing, a driver, a drive assembly, a nosepiece assembly, a debris blocking member, and a latch. The nosepiece assembly comprises a nose portion along which the driver drives a fastener into a workpiece and a door portion that covers the nose portion. The debris blocking member is configured to be movable between a first position and a second position. The latch has a latched position and an unlatched position. The latch, in the latched position, is configured to latch the door portion of the nosepiece assembly in a closed position. The latch, in the unlatched position, is configured to enable: (a) the debris blocking member to move from its first position to its second position, and (b) the door portion of the nosepiece assembly to move from its closed position to its open position. The debris blocking member, when in the second position, is configured to block debris in the nosepiece assembly from entering the drive assembly.

[0017] Implementations of the foregoing aspects may include one or more of the following features.

[0018] The driving tool may include a frame disposed in the housing. The frame may define a rotational axis and a drive axis.

[0019] The nosepiece assembly may be connected to a forward end of the housing.

[0020] When the latch is moved from its latched position to its unlatched position, the door portion of the nosepiece assembly may be moved from its closed position to its open position and the debris blocking member may be biased from its first position to its second position.

[0021] The door portion of the nosepiece assembly may include a magnetized door that is formed of a magnetic material.

[0022] The door portion of the nosepiece assembly may include one or more magnets.

[0023] At least a portion of the door portion of the nosepiece assembly may be formed of a magnetic material.

[0024] The housing may comprise a drive channel. The fastener may be a lead fastener. The driver may be configured to be moveable, along the drive axis and within the drive channel, from an extended position to drive the lead fastener through the nosepiece assembly and into the workpiece during a drive stroke to a returned position during a return stroke. The driver may include a driver body and a driver blade connected to the driver body. The driver blade may be configured to contact a head portion of the lead fastener. The driver may be within the frame.

[0025] The drive assembly may comprise a motor operably coupled to a flywheel to rotate the flywheel about the rotational axis.

[0026] The debris blocking member may be configured to be movable between its first position and its second position along an axis. The axis of the debris blocking member may be substantially perpendicular to the drive axis of the driver and may be substantially perpendicular to the rotational axis of the flywheel.

[0027] The latch may be configured to be pivotable with respect to the nosepiece assembly and about a pivot axis. The pivot axis of the latch may be substantially parallel to the rotational axis of the flywheel and may be substantially perpendicular to the drive axis of the driver.

[0028] The nosepiece assembly may comprise an opening disposed between the nose portion and the drive assembly. The opening may be formed by cavities in the nosepiece assembly that are configured to allow the driver to be moveable, along the drive axis, between the returned position and the extended position. The debris blocking member may be configured to slide into and out of the opening as the debris blocking member is moved between its first position and its second position.

[0029] The debris blocking member, when in its second position, may be disposed in the opening of the nosepiece assembly.

[0030] In an embodiment of this patent application, a fastening tool may include a debris ingestion mitigation member in the form of a debris blocking member that slides into and out of an opening in the nosepiece between the nosepiece and an engine (e.g., including a flywheel and a motor). The opening may be formed by cavities in the nosepiece that accept the driver profilebody. A latch may be configured to latch the nosepiece in a closed position. The latch may interchangeably be referred to as a latch grip or a latch grip door. The latch may also be configured to control the opening and closing of a nosepiece door. The nosepiece door may be configured to remain closed and cannot be opened until the latch is fully opened. When the latch is fully opened, the nosepiece door can be opened to remove debris. In the open position of the latch, the debris blocking member may be biased by a spring into the opening in the nosepiece, between the nosepiece and the engine. As a result, any debris inside the drive channel formed between the door and the nosepiece is blocked from entering the engine before the debris is released from the drive channel. In the closed position of the nosepiece, the latch may be configured to push the blocking member out of the nosepiece against the bias of the spring. A supplemental debris ingestion mitigation member may be configured to catch ferrous debris. The supplemental debris ingestion mitigation member can include a magnet or a magnetized nosepiece door. In this way, metal bits adhere or stick to the supplemental debris ingestion mitigation member. When the door including magnets or the magnetized door is opened, the bits will not fall into the tool but stick to the underside of the door. By allowing the door to open enough, the user can remove the bits that are stuck to the inside of the door. In an embodiment, the fastening tool may be a nailer or a stapler.

[0031] In another aspect, a driving tool is provided. The driving tool comprises a frame, a motor, a driver, a follower assembly, and a stall release lever. The frame defines a rotational axis and a drive axis. The motor is coupled to the frame and is operably coupled to a flywheel to rotate the flywheel. The driver is configured to be moveable, along the drive axis and with respect to the frame, between a returned position and an extended position through a stall position intermediate the returned position and the extended position. The follower assembly is coupled to the frame and has a locked over-center position in which the driver is pinched between the follower assembly and the flywheel subjecting the driver to a pinch force when the driver is in the stall position. The follower assembly has a release over-center position. The stall release lever is pivotably coupled to the frame. The stall release lever is configured to be pivotable about a pivot axis between a home position allowing the follower assembly to be in thelocked over-center position and a release position. When the driver is in the stall position and the follower assembly is in the locked over-center position, pivotal movement of the stall release lever toward the release position forces the follower assembly out of the locked over-center position toward the release over-center position in which the pinch force is released. The pivot axis of the stall release lever is substantially parallel to the rotational axis of the flywheel and is substantially perpendicular to the drive axis of the driver.

[0032] Implementations of the foregoing aspects may include one or more of the following features.

[0033] The driving tool may include a housing. The stall release lever may include a pivot connection portion that is configured to receive a pivot connection member therein so as to pivotally connect the stall release lever to the frame. The pivot connection portion of the stall release lever may be within the housing.

[0034] The housing may include an opening. A portion of the stall release lever may be configured to extend through the opening in the housing as the stall release lever is pivoted about the pivot axis from the home position to the release position. The portion of the stall release lever includes a user actuatable member.

[0035] The driving tool may further comprise a lever biasing member that is configured to retain the stall release lever in the home position.

[0036] The lever biasing member may be configured to bias the stall release lever into the home position.

[0037] The lever biasing member may include a torsional spring.

[0038] A first end of the lever biasing member may be operatively connected to a portion of the stall release lever and a second end of the lever biasing member may be operatively connected to a portion of the frame.

[0039] The follower assembly may comprise a follower mounted on an axle and the stall release lever may be configured to operably engage the axle to force the follower assembly out of the locked over-center position.

[0040] The housing may include a drive channel. The driving tool may include a nosepiece assembly connected to a forward end of the housing. The driver may be configured for movement within the drive channel from the extended position to drive a lead fastener through the nosepiece assembly and into a workpiece during a drive stroke to the returned position during a return stroke. The driver may include a driver body and a driver blade connected to the driver body. The driver blade may be configured to contact a head portion of the lead fastener. The driver may be within the frame.

[0041] In an embodiment, a fastening tool may include a stall release lever. The stall release lever releases the pinch force on the engine to release a stalled engine. The stall release lever is nested on an outer surface of the tool housing that pivots about an axis on a main component of the engine (e.g., power take off (PTO) carriage or frame) to release the activated part of the tool (PTO pinch roller). A torsion spring may be insert molded into a portion of the lever to retain the lever in the home position. The torsion spring can be located at either a forward portion or a rear portion of the lever. Unlike typical torsion springs that move about a fixed shaft, a rear torsion spring has a pivot point that moves with the lever. A recess in the housing allows for the travel path of the stall release lever to be offset. The stall release lever pivots about a horizontal axis, with a portion of the lever sliding through the opening in the housing as the lever rotates. The stall release lever can be secured to the engine at the PTO carriage / frame with a rivet or shoulder screw. When the stall release lever is actuated, it forces the PTO pinch roller axle towards the rear of the tool to release the pinch force of the stalled engine. Travel limiting stop top tabs are built into the lever and limit the stresses put onto the pivoting connections of the lever. The stall release lever can be formed from plastic injection. The torsion spring may include a hooked end. The torsion spring can be molded into the stall release lever or may be a separate part from the stall release lever. In an embodiment, the fastening tool may be a nailer or a stapler.

[0042] Advantages may include one or more of the following. The impact tools and methods may lead to improved control and speed of fastening operation, while increasing power delivered when needed for impacting and reducing the use of unneeded power, thus saving energy, being more efficient, and protecting tool components from damage. These and other advantages and features will be apparent from the description, the drawings, and the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The numerous advantages of this patent application may be better understood by those skilled in the art by reference to the accompanying Figures. In the drawings, like reference numerals designate corresponding parts throughout the several views.

[0044] FIG. 1 illustrates a fastening tool according to an embodiment of this patent application;

[0045] FIG. 2 illustrates a perspective view of the tool of FIG. 1 with housing of the tool removed to better illustrate internal components of the tool;

[0046] FIGS. 3 and 4 illustrate a perspective view and a partial, perspective view, respectively, of the tool of FIG. 1, wherein one of the two housing portions is removed in FIGS. 3 and 4 to better illustrate internal components of the tool;

[0047] FIG. 5 illustrates a sectional view of the tool of FIG. 1 showing cavities between a nosepiece assembly and an engine in the tool;

[0048] FIG. 6 illustrates a side perspective view of the tool of FIG. 1 showing a debris blocking member, a latch and a nosepiece door in the tool, wherein some portions of the housing are removed to better illustrate internal components of the tool;

[0049] FIG. 7 illustrates a side perspective view of the tool of FIG. 1, wherein the latch is in a closed position and the debris blocking member in a non-blocking / a first position in the tool of FIG. 1, wherein some portions of the housing are removed to better illustrate internal components of the tool;

[0050] FIG. 8 illustrates a side perspective view of the tool of FIG. 1, wherein the latch in a partially opened position and the debris blocking member in a partially blocking / an intermediate position in the tool of FIG. 1, wherein some portions the housing are removed to better illustrate internal components of the tool;

[0051] FIG. 9 illustrates a side perspective view of the tool of FIG. 1, wherein the latch in a fully opened position and the debris blocking member in a fully blocking / a second position in the tool of FIG. 1, wherein some portions the housing are removed to better illustrate internal components of the tool;

[0052] FIG. 10 illustrates a partial front sectional view, taken along an axis Z of FIG. 9, of the tool of FIG. 1;

[0053] FIG. 11 illustrates another partial front sectional view, taken along an axis Y of FIG. 9, of the tool of FIG. 1;

[0054] FIG. 12 illustrates a top perspective view of the nosepiece door in the tool of FIG. 1;

[0055] FIG. 13 illustrates a front sectional view of the nosepiece door in the tool of FIG. 1;

[0056] FIG. 14 illustrates a partial, perspective view of the tool of FIG. 1, wherein some portions of a stall release mechanism / lever are shown;

[0057] FIGS. 15 and 16 illustrate partial, perspective views of the tool of FIG. 1, wherein portions of housing of the tool are not shown to better illustrate the stall release lever, wherein the stall release lever is shown in both its home position and its release position;

[0058] FIG. 17 illustrates a partial, side view of the tool of FIG. 1, wherein portions of housing of the tool are not shown to better illustrate the stall release lever, wherein the stall release lever is shown in both its home position and its release position;

[0059] FIGS. 18 and 19 illustrate a partial, perspective view and a side view, respectively, of the tool of FIG. 1, wherein portions of housing of the tool are not shown to better illustrate the stall release lever, wherein the stall release lever is shown in its home position;

[0060] FIGS. 20 and 21 illustrate a partial, perspective view and a side view, respectively, of the tool of FIG. 1, wherein portions of housing of the tool are not shown to better illustrate the stall release lever, wherein the stall release lever is shown in its release position;

[0061] FIGS. 22A and 22B illustrate a side view and a rear perspective view, respectively, of the stall release lever and its spring according to an embodiment of this patent application;

[0062] FIG. 22C illustrates the stall release lever and its spring installed in the tool of FIG. 1;

[0063] FIGS. 23A and 23B illustrate a side view and a front perspective view, respectively, of the stall release lever and its spring according to another embodiment of this patent application;

[0064] FIG. 23C illustrates the stall release lever and its spring installed in the tool of FIG. 1;

[0065] FIG. 24 illustrates a side-by-side comparison of the tool of FIG. 1 and a prior art tool;

[0066] FIG. 25 illustrates a side view side-by-side comparison and a top view side-by-side comparison, respectively, of the tool of FIG. 1 and the prior art tool showing dimensions of the tool of FIG. 1;

[0067] FIGS. 26A, 26B and 26C illustrate a first perspective view, a side / front view, and a second perspective view, respectively, of a prior art tool and its stall release mechanism; and

[0068] FIGS. 27A and 27B illustrate perspective views of another prior art tool and its stall release mechanism.

[0069] Corresponding reference names and / or numerals indicate corresponding parts throughout the several views of the drawings.DETAILED DESCRIPTION

[0070] With reference to FIGS. 1-4, a fastening tool 10 that is designed to drive a fastener into a workpiece and that is constructed in accordance with the teachings of this patent application is illustrated. The fastening tool 10 may interchangeably be referred to as a driving tool, a fastener driving tool, a nailer, or a stapler tool. According to several aspects, the fastening tool 10 may bea cordless or battery powered nailer or stapler for driving fasteners such as nails or staples into a workpiece. The fastening tool 10 may include a housing 12, a backbone or frame 14, a drive motor assembly 16, a controller (control unit or control module) 18, and a nosepiece assembly 20, a magazine assembly 74, and a battery mount 78.

[0071] In an embodiment, the fastening tool 10 is battery powered. The battery mount 78 may be configured for mounting a battery pack (not shown). The battery mount 78 may be provided for removably mounting the battery pack to the housing 12 of the fastening tool 10.

[0072] While the fastening tool 10 is illustrated as being electrically powered by a suitable power source, such as the battery pack, those skilled in the art will appreciate that this patent application, in its broader aspects, may be constructed somewhat differently and that aspects of this patent application may have applicability to any type of portable or handheld tool including a pneumatic nailer (i.e., pneumatically powered fastening tool). Further, the fastening tool in the embodiment described herein can be powered by a number of other power sources. For example, power sources for the fastening tool can be manual, pneumatic, electric, combustion, solar or use other (or multiple) sources of energy.

[0073] Furthermore, while aspects of this patent application are described herein and illustrated in the accompanying drawings in the context of a nailer, those of ordinary skill in the art will appreciate that this patent application, in its broadest aspects, has further applicability. For example, the drive motor assembly 16 may also be employed in various other mechanisms that use reciprocating motion, including rotary hammers, hole forming tools, such as punches, and riveting tools, such as those that install deformation rivets.

[0074] The nosepiece assembly 20 of the driving tool 10 may be configured to extend forward of the housing 12 and may be configured to be fixed to the housing 12. That is, the nosepiece assembly 20 may be configured to be connected to a forward end of the housing 12. The nosepiece assembly 20 includes a nose portion 22 along which a driver member 30 drives a fastener (e.g., a nail, a staple or other fasteners) into a workpiece. That is, the nose portion 22 of the nosepiece assembly 20 may be placed against the workpiece for driving the fastener into theworkpiece. The nose portion 22 of the nosepiece assembly 20 may interchangeably be referred to nosepiece.

[0075] The nosepiece assembly 20 may also include a door portion 12 that covers the nose portion 22. During the drive cycle, the driver member 30 reciprocates in a space between the nose portion 22 and the door portion 23. The door portion 23 may interchangeably be referred to as door, nose door, nosepiece door, or a nosepiece assembly door. The front of the nosepiece assembly 20 is accessible from the outside of the tool 10. The nose portion 22 and the door portion 23 are disposed in front of the nosepiece assembly 20. The nose door 23 may be provided on the nose portion 22 to trap a portion the driver member 30 between the nose door 23 and the nose portion 22 of the nosepiece assembly 20. The nosepiece assembly 20 may further include a nosepiece aperture or opening 4010 (as shown in FIGS. 6 and 7) that separates the front of the nosepiece assembly 20 from the rear of the nosepiece assembly 20 and an engine (i.e., motor 80 and flywheel 82 together).

[0076] The nosepiece assembly 20 may also define a fastener drive track 24 through which the fasteners are driven during a drive stroke. The fastener drive track 24 may be connected to a drive channel 26. The drive channel 26 may be defined within the interior of the housing 12 and a within which, the driver member 30 is reciprocally mounted on a return mechanism 88 for movement along a fastening tool drive axis A, to drive the fastener. The driver member 30 may be further supported on a driver blade guide fixedly mounted on the nose portion 22. The nosepiece assembly 20 guides the fastener as it is being driven into the workpiece.

[0077] The frame 14 may be configured to be supported within the housing 12. With additional reference to FIG. 2, the frame 14 may be a structural element upon which the drive motor assembly 16, the control module 18, the nosepiece assembly 20 and / or the magazine assembly 74 may be fully or partially mounted.

[0078] With further reference to FIG. 2, the drive motor assembly 16 may include the power source, the driver member 30, a follower assembly, and the return mechanism 88. The powersource may include the motor 80, a flywheel assembly that includes the flywheel 82 and is driven by the motor 80, and an actuator. The motor 80 and the flywheel 82 may together be referred to as an engine. The motor 80 and the flywheel 82 may be coupled to the frame 14. The motor 80 is operably coupled to the flywheel 82 to rotate the flywheel 82. For example, the motor 80 can be an outer rotor brushless motor where the flywheel 82 is an integral part of the outer rotor. Alternatively, the motor 80 can be drivingly coupled to the flywheel 82 via a transmission (not shown).

[0079] The actuator may be coupled to the frame 14. The actuator can be an appropriate type of linear actuator. In an embodiment, the actuator is a solenoid that includes a body, a plunger, which is movable relative to the body, and a plunger spring that biases the plunger into an extended position. The plunger spring may be received in the body. The plunger spring may be received about the plunger between a feature on the plunger and the body.

[0080] As shown in FIG. 1, the drive motor assembly 16 may include the motor 80 and the flywheel 82 that are operable for propelling the driver member 30 in a first direction FD along the drive axis A. In the embodiments herein, the first direction FD is a forward direction toward the nose portion 22 of the tool 10.

[0081] Also, as shown in FIGS. 1-4, mounted to the frame 14 is a carrier 15 that supports a follower assembly 84, including a pinch wheel or follower 86. The follower assembly 84 may be coupled to the frame 14. The follower assembly 84 may include a locked over-center position in which the driver member 30 can be pinched between the follower 86 and the flywheel 82, subjecting the driver member 30 to a pinch force when the driver member 30 is in the stall position.

[0082] The return mechanism 88 of the drive motor assembly 16 may be configured to return the driver member 30 to a returned position. That is, the return mechanism 88 biases the driver member 30 into the returned position. One example return mechanism can include compression return springs (not shown). The return mechanism 88 can include return springs 90 that compress during the drive stroke to absorb the return force applied by the driver member 30. The returnsprings 90 are compressed during the drive stroke and operate to bias the driver member 30 to the returned position during a return stroke.

[0083] Additional details regarding the return mechanism are disclosed in commonly assigned U.S. Patent No. 8,534,527, filed on April 2, 2009 and titled "Cordless Framing Nailer", and U.S. Patent No. 9,216,502, filed March 12, 2013 and titled "Multi-stranded Return Spring For Fastening Tool", which are both hereby incorporated herein by reference in their entireties.

[0084] The drive motor assembly 16 may be actuated by the control module 18 to cause the driver member 30 to translate and impact a fastener in the nosepiece assembly 20 so that the fastener may be driven into the workpiece. Actuation of the power source may use electrical energy from the battery pack to operate the motor 80 and the actuator. The motor 80 is employed to drive the flywheel 82, while the actuator is employed to move the follower 86 that is associated with the follower assembly 84.

[0085] The control module or controller 18 is configured to control a supply of power from the battery pack to the motor 80 to initiate and activate the drive cycle upon receipt of the trigger signal. In an embodiment, the control module 18 moves the follower 86 that is associated with the follower assembly 84, which squeezes the driver member 30 into engagement with the flywheel 82 so that energy may be transferred from the flywheel 82 to the driver member 30 to cause the driver member 30 to translate along the drive axis A. In this way, the control module 18 is arranged to initiate frictional engagement between the outer rim 92 of the flywheel 82 and driver profile to transmit energy from the flywheel 82 to the driver member 30 to accelerate the driver member 30 along the drive axis A for the drive stroke.

[0086] Additional details regarding the drive motor assembly are disclosed in the '281 Patent and also in commonly assigned and U.S. Patent No. 9,126,319, filed December 29, 2011 and titled "Power Take Off For Cordless Nailer", which are both hereby incorporated herein by reference in their entireties.

[0087] A handle portion 64 of the tool 10 extends from the housing 12. The handle 64 may be configured to be received by a user's hand, thereby making the fastening tool portable orhandheld. Additional portability can be achieved by constructing the housing from a lightweight yet durable material, such as magnesium. The handle 64 may include a connecting portion 66 and a housing extension 68 that extends substantially parallel to the handle 64.

[0088] As shown in FIGS. 1 and 3, a trigger assembly 70 is connected to the handle 64. The trigger assembly 70 may be configured to serve as an actuation device or actuator for the fastening tool 10, and is constructed and arranged to actuate a switch assembly 72. The trigger switch can be part of the control module 18 that includes sensors that sense the state of various components, such as the trigger, and generates signals in response thereto.

[0089] The control module 18 may further include a controllerfor receiving various sensor signals and controlling the fastening tool 10 in response thereto.

[0090] The trigger assembly 70 may be coupled to the housing 12 and may be configured to receive an input from the user, typically by way of the user's finger, that may be employed in conjunction with the trigger switch assembly 72 to generate a trigger signal that may be employed in part to initiate the drive cycle of the fastening tool 10 to drive the fastener into the workpiece. The controller 18 may be configured to control a supply of power from the power source to the motor 80 to initiate and activate the drive cycle upon receipt of the trigger signal.

[0091] The magazine assembly 74 may be carried by the housing 12. Fasteners are temporarily contained in the magazine assembly 74, which can be connected to the nosepiece assembly 20. The magazine assembly 74 may be configured to be connected to the nose portion 22 of the nosepiece assembly 20 at one end and is connected to the connecting portion 66 of the housing 12 at an opposite end.

[0092] The magazine assembly 74 may be configured to hold a plurality of fasteners and configured to present a lead fastener of the plurality of fasteners into the drive channel 26. The magazine assembly 74 may be configured for positioning fasteners in line with the driver member 30. The magazine assembly 74 may be constructed and arranged to feed successive leading fasteners along a fastener channel 76 and into the drive track 24. In an embodiment, the supply of fasteners can be collated fasteners. The supply of fasteners may beurged toward the drive track 24 by at least one magazine pusher or a plurality of magazine pushers that are slidably disposed in the magazine assembly 74. The magazine pusher may be configured to travel along the magazine pusher path or the fastener channel 76. The fastener channel 76 may have a width that accommodates the fasteners. The fastener channel 76 extends into the nose portion 22 of the nosepiece assembly 20. The magazine pusher may be biased towards the drive track 24 by a spring or plurality of springs. The magazine pusher may be configured to engage the last fastener in the supply of fasteners to thereby feed individual fasteners from the fastener channel 76 in the magazine assembly 74 to the fastener channel in the nose portion 22.

[0093] In operation, fasteners are stored in the magazine assembly 74, which sequentially feeds the fasteners into the nosepiece assembly 20. The staples or nails are driven by a driver blade 34 through slots in the outward facing portion or bottom of the magazine assembly 74 into a workpiece.

[0094] The driver member 30 may be configured to be moveable, along the drive axis A and within the drive channel 26, from the extended position to drive the lead fastener through the nosepiece assembly 20 and into the workpiece during the drive stroke to the returned position during the return stroke. The driver member 30 is movable within the drive channel 26 relative to the frame 14 between the returned position and the extended position. The returned position may also be referred to as a home position. The driver member 30 includes a driver body 32 at one end and the driver blade 34 for striking the head of a fastener during the drive stroke at an opposite end. The driver blade 34 is connected to the driver body 32 at a proximal end and has a free distal end. The driver blade 34 may be configured to contact a head portion of the lead fastener. The driver member 30 is within the frame 14.

[0095] The driver body 30 may be unitarily formed in an appropriate process, such as investment casting, from a suitable material, such as a ferromagnetic material. In an embodiment, the driver body 30 and the driver blade 34 can be formed of a metal including, but not limited to steel and titanium.

[0096] In addition to the driver member 30 being movable along the drive axis A from the returned position to an extended position to drive a fastener, the driver member 30 may also be configured to be movable in a radial direction relative to the flywheel 82 between an engaged or firing position (FIG. 2) and a home position (FIG. 3). In the firing position, the driver member 30 is drivingly engaged against the flywheel 82. In the home position, the driver member 30 is radially further away from the flywheel 82 than in the firing position.

[0097] The driver body 32 of the driver member 30 may include the driver profile and a cam profile. The driver profile may be disposed on the flywheel side of driver member 30 and is shaped to engage the exterior surface of the outer rim 92 of the flywheel 82, so that the flywheel 82 can deliver kinetic energy to propel the driver member 30. The driver profile forms a lower contour of the driver body 32 and is configured in a manner that is complementary to the exterior surface of outer rim 92 of the flywheel 82. In an embodiment, the driver profile includes a pair of longitudinally extending V-shaped teeth that cooperate to form at least one passage therebetween. The exterior surface of the outer rim 92 of the flywheel 82 has complementary V- shaped teeth and grooves that mesh with the driver profile. As such, the driver profile is configured for engaging grooves on the flywheel 82. The outer rim 92 of the flywheel 82 and the driver body 32, respectively, provide a space into which the V-shaped teeth, respectively, may extend as the exterior surface of the outer rim 92 of the flywheel 82 and / or the driver profile wear away to thereby ensure contact between the exterior surface and the driver profile along a substantial portion of the V-shaped teeth, rather than point contact. To further control wear, a coating may be applied to the driver body 30 at one or more locations, such as over the driver profile and the cam profile. The coating may be a type of carbide, such as titanium carbide, and may be applied via a plasma spray, for example. Alternatively, a ferric nitro carburizing heat treatment or coating can be used. The cam profile of the driver body 32 is located on the follower side of the driver member 30 opposite the driver profile 36. The cam profile includes a raised cam profile and a transition cam profile against which the follower 86 engages. As the follower 86 rides up the transition cam profile, the pinching force acting on the driver member 30 between the follower 86 and the flywheel 82 increases.

[0098] The driver blade 34 itself may include a retaining portion and a blade body. The retaining portion of the driver blade 34 may be configured to secure the driver blade 34 to the driver body 32 and may be configured to inhibit movement of the driver blade 34 relative to the driver body 32 in a direction that is generally transverse to the longitudinal axis A of the driver member 30. The distal end of the driver blade 34 can contact against the head of a fastener and drive the fastener as the driver member 30 moves to its axially extended position. In the axially extended position, portions of the driver member 30 can contact against housing bumper members 104 (as shown in FIG. 2).

[0099] The drive track 24 may be configured to receive a first fastener of a collated strip of fasteners and to guide the fastener out of the nosepiece assembly 20 when the fastener to be driven into a workpiece is struck by the driver member 30.

[0100] In an embodiment, as shown in FIGS. 1-3, a no-mar tip 62 can be attached to the nose portion 22 of the nosepiece assembly 20 to prevent marring of the workpiece when the nose portion 22 is placed against the workpiece for driving the fastener.

[0101] Referring to FIGS. 5-13, a debris ingestion mitigation member 4000 of the fastening tool 10 in accordance with embodiments of this patent application is described. The debris ingestion mitigation member 4000 may be configured to prevent debris created by a fastener during the drive cycle from entering the engine (i.e., the motor 80 and the flywheel 82) of the tool 10. The debris may include ferrous debris.

[0102] In one embodiment, referring to FIGS. 1-13, the driving tool 10 may include the housing 12, the driver 30, the drive assembly 16, the nosepiece assembly 20, the debris blocking member 4000 and a latch 4002. The driver 30 may interchangeably be referred to as the driver member 30. The drive assembly 16 may interchangeably be referred to as the drive motor assembly 16 or the engine (that includes the motor 80 and the flywheel 82). The drive assembly 16 may comprise the motor 80 operably coupled to the flywheel 82 to rotate the flywheel 82 about the rotational axis R (as shown in FIG. 3). The latch 4002 may interchangeably be referred to as door or latch grip.

[0103] Referring to FIGS. 5-13, the debris blocking member 4000 may be configured to be movable between a first position 4000FP (as shown in FIGS. 6 and 7) and a second position 4000SP (as shown in FIG. 9). The debris blocking member 4000 may be configured to be movable between one or more intermediate positions 4000iP(as shown in FIG. 8) that are between the first position 4000FP and the second position 4000sp.

[0104] The debris blocking member 4000 may be configured to be movable between its first position 4000FP and its second position 4000SP along an axis V (as shown in FIG. 6). The axis V may be a vertical axis. As shown in FIG. 6, the axis V of the debris blocking member 4000 may be substantially perpendicular to the drive axis A of the driver 30 and may be substantially perpendicular to the rotational axis R of the flywheel 82.

[0105] The debris blocking member 4000 may be disposed in and movable along a plane that is substantially perpendicular to the drive axis A of the driver 30. The plane may include a horizontal axis H (that is substantially perpendicular to the drive axis A of the driver member 30 and the vertical axis V as shown in FIG. 6) and the vertical axis VA (that is substantially perpendicular to the drive axis A of the driver member 30 and the horizontal axis H as shown in FIG. 6).

[0106] The latch 4002 may be configured to latch the nosepiece assembly 20 in a closed position. The latch 4002 may also be configured to control the opening and closing of the nosepiece door 23. The latch 4002 has a latched position 4002LP (as shown in FIGS. 6 and 7) and an unlatched position4002up (as shown in FIG. 9). The latch 4002 may be configured to be movable between one or more intermediate positions (as shown in FIG. 8) that are between the latched position 4002Lp and the unlatched position 4002up. The latch 4002 may be operatively connected to portions of the housing 12 and / or the nosepiece assembly 20 to maintain the latch 4002 in the latched position 4002Lp.

[0107] For example, the latch 4002 may be configured to be pivotable with respect to the nosepiece assembly 20 and about a pivot axis P (as shown in FIGS. 6-9). The latch 4002 may be configured to be pivotably movable, about the pivot axis P, between its latched position 4002LPand its unlatched position 4002up. A pivot connection 4022 between the portions of the nosepiece assembly 20 and portions of the latch 4002 may define the pivot axis P. For example, a shaft / pin member may be received in aligned openings of the nosepiece assembly 20 and the latch 4002 to provide the pivot connection 4022 therebetween. As would be appreciated by a person skilled in the art, the shaft / pin member or a portion thereof may be integrally formed with one of the nosepiece assembly 20 and the latch 4002 and may be configured to be received in the openings of the other of the nosepiece assembly 20 and the latch 4002 to provide the pivot connection 4022 therebetween. The pivot axis P of the latch 4002 may be substantially parallel to the rotational axis R of the flywheel 82 and may be substantially perpendicular to the drive axis A of the driver 30.

[0108] The latch 4002, in the latched position 4002LP, is configured to latch the door portion 23 of the nosepiece assembly 20 in a closed position. The latch 4002, in the unlatched position 4002UP, is configured to enable: (a) the debris blocking member 4000 to move from its first position 4000FP to its second position 4000SP, and (b) the door portion 233 of the nosepiece assembly 20 to move from its closed position to its open position. The debris blocking member 4000, when in the second position 4000SP, is configured to block / prevent debris in the nosepiece assembly 20 from entering the drive assembly 16.

[0109] Comparing FIGS. 7 and 9, when the latch 4002 is moved from its latched position 4002i.p to its unlatched position 4002UP, the door portion 23 of the nosepiece assembly 20 may be moved from its closed position to its open position and the debris blocking member 4000 may be biased from its first position 4000FP to its second position 4000sp.

[0110] Referring to FIGS. 6-9, the latch 4002 may also include latch portion 4012. In the illustrated embodiment, the latch portion 4012 may include a bent wire shaped configuration or a U-shaped wire configuration. In other embodiments, the latch portion 4012 may include other shaped configurations. One end portion of the latch portion 4012 may be secured to a body 4014 of the latch 4002 and the other end portion 4016 of the latch portion 4012 may be configured to be free and to engage with notches 4018 on portions 4020. The portions 4020 and the corresponding notches 4018 may be disposed on sides MS of the magazine assembly 74. Theportions 4020 and the corresponding notches 4018 may be part of the nosepiece assembly 20. In its latched position 4002LP, the portion 4016 of the latch 4002 may be configured to engage with the notches 4018 on the portions 4020 so as to maintain or keep the nosepiece door 23 in the closed position. In its unlatched position 4002UP, the portion 4016 of the latch 4002 may be configured to disengage from the notches 4018 on the portions 4020 so as to enable the door 23 to move to its open position.

[0111] The nosepiece door 23 may be configured to remain closed and not to open until the latch 4002 is in its fully opened or unlatched position 4002up. When the latch 4002 is fully opened, the nosepiece door 23 can be opened to remove debris in the nosepiece assembly 20. In the open position of the nosepiece door 23, the debris blocking member 4000 is biased by the debris blocking member spring 4001 into the opening 4010 in the nosepiece assembly 20. The opening 4010 in the nosepiece assembly 20 is disposed between the nosepiece assembly 20 and the engine (i.e., the motor 80 and the flywheel 82). As a result, any debris inside the drive channel 26 formed between the door 23 and the nose portion 20 of the nosepiece assembly 20 is blocked from entering the engine before the debris is released from the drive channel 26. In the closed position of the nosepiece assembly 20, the latch 4002 may be configured to push the debris blocking member 4000 out of the nosepiece assembly 20 against the bias of the debris blocking member spring 4001.

[0112] The nosepiece assembly 20 may comprise the opening 4010 (as shown in FIGS. 6 and 7) disposed between the nose portion 22 and the drive assembly 16. The opening 4010 may be formed by cavities 4008 (as shown in FIG. 5) in the nosepiece assembly 20 that are configured to allow the driver 30 to be moveable, along the drive axis A, between the returned position and the extended position. That is, the opening 4010 is formed by cavities 4008 in the nosepiece assembly 20 that accept the driver profile body. The cavities 4008 are disposed between the nose portion 22 and the drive assembly 16 and are arranged on opposite lateral sides of the driver blade 34. The cavity may be formed between the door 23 and either the nose portion 22 or the drive assembly 16. The door 23 of the nosepiece assembly 20 may be the part that opens and thedrive assembly 16. The cavities 4008 are susceptible to ingesting debris created by a struck and / or driven fastener during the drive cycle. The general boundaries of the cavities 4008 are illustrated by the broken lines 4009 in FIG. 5.

[0113] The debris blocking member 4000 may be configured to slide into and out of the opening 4010 as the debris blocking member 4000 is moved between its first position 4000FP and its second position 4000Sp. The debris blocking member 4000, when in its second position 4000SP, may be disposed in the opening 4010 of the nosepiece assembly 20.

[0114] With reference to FIGS. 6-9, the latch 4002 may be configured to control access to the nosepiece assembly 20. The latch 4002 may be arranged between the nosepiece assembly 20 and the housing 12. The latch 4002 may be configured to pivot away from the housing 12 to open the nosepiece assembly 20. The latch 4002 may be configured to apply a force to the debris blocking member 4000 against the bias of the debris blocking member spring 4001 to maintain the debris blocking member 4000 to its first position 4000FP. As such, the debris blocking member 4000 is kept in the non-blocking or first position 4000pp when the latch 4002 is closed or is in its latched position 4002 P. When the latch 4002 is opened or is moved to its unlatched position 4002UP, the debris blocking member 4000 is biased by the debris blocking member spring 4001 into a partially blocking position and then a fully blocking position into the cavity 4008 and closes the cavity 4008 to debris. The debris blocking member 4000 is biased, from its first position 4000pp to the second position 4000SP, upward or through the nosepiece aperture 4010 by the debris blocking member spring 4001. The debris blocking member 4000 of the tool 10 may be configured to pass through the nosepiece aperture 4010.

[0115] FIG. 10 is a cross-sectional view of the tool in FIG. 9 taken along section line Z-Z and FIG. 11 is a cross-sectional view of the tool in FIG. 9 taken along section line Y-Y. The section line Z-Z passes through the door portion 23 of the nosepiece assembly 20. When moving from the front to the rear of the tool 10, the section line Z-Z is located before the section line Y-Y. With reference to FIGS. 10 and 11, the cavity 4008 is shown as closed by the debris blocking member 4000. The debris blocking member 4000 is biased into a fully blocking position by the debris blocking member spring 4001.

[0116] With reference to FIGS. 12 and 13, a further or an additional debris ingestion mitigation member 23M may be provided. That is, a supplemental means of catching ferrous debris FD, 4006 may include a magnet or a magnetized nosepiece door 23M. Ferrous debris FD, 4006 can be captured by the nosepiece assembly 20Mand parts thereof so that the debris FD, 4006 does not enter the engine (i.e., the motor 80 and the flywheel 82). The nosepiece assembly 20Mcan be magnetized by being formed of a magnetic material or by embedding magnets 4004 into the nosepiece door 23M. The door portion 23 of the nosepiece assembly 20 may include the magnetized door 23M that is formed of a magnetic material. The door portion 23 of the nosepiece assembly 20 may include one or more magnets 4004. The magnetic force, generating from the magnet 4004, draws the debris FD, 4006 towards the door 23M, the material of which it is made exhibiting magnet attractable properties resulting in holding the debris FD, 4006 tight against the door 23M. At least a portion of the door portion 23 of the nosepiece assembly 20 may be formed of a magnetic material. When the nosepiece door 23M is opened, the ferrous debris or fastener bits FD, 4006 will not fall into the tool 10 or enter the engine but adhere to the underside of the door 23M. The door 23M can be opened so that the user can remove the debris FD, 4006 which adheres to the inside of the door 23M.

[0117] Referring to FIGS. 14-23A, the fastening tool 10 of this patent application may have a stall release mechanism 1000 that is nested inside the housing 12 of the tool 10. The stall release mechanism 1000 may be configured to pivot about a horizontal axis HA / PA (e.g., as shown in FIGS. 15-21) on a main component of the engine (including the motor 80 and the flywheel 82). Specifically, the fastening tool 10 has the stall release mechanism 1000 in the form of a lever nested inside the housing 12. That is, the stall release mechanism 1000 may interchangeably be referred to as stall release lever 1000. The stall release lever 1000 may be configured to pivot about the horizontal axis HA / PA on the main component of the engine, such as the Power Take Off (PTO) carriage 15 / frame 14, inside the tool 10 to release an activated part (e.g., PTO pinch roller 86) of the tool 10. Because the stall release lever 1000 mounts and pivots about a fixed point on the internal components, the housing 12 of the tool 10 has a curved window that accommodates the travel path of the pivoting stall release lever 1000, which isoffset from the horizontal axis HA / PA. A torsion spring 1010 or 1010' is insert molded into the stall release lever 1000 and retains the stall release lever 1000 in the home position 1000HP. The stall release lever 1000 pivots about the horizontal axis HA / PA, with a portion of the lever 1000 sliding through the window in the housing 12 as the stall release lever 1000 rotates. The stall release lever 1000 can be secured to the engine at the PTO carriage 15 / frame 14 with a rivet or shoulder screw 1004. When the stall release lever 1000 is actuated, the stall release lever 1000 forces the pinch roller axle 1022 towards the rear of the tool 10 to release the pinch force of the stalled engine. Travel limiting stop tabs 1032 may be built into the jam clear arm portion 1030 of the stall release lever 1000 and may be configured to limit the stresses put into the pivoting connections 1004 of the stall release lever 1000.

[0118] In one embodiment, the driving tool 10 comprises the frame 14, the motor 80, the driver 30, the follower assembly 84, and the stall release lever 1000. The driver 30 may interchangeably be referred to as driver member. The frame 14 defines the rotational axis R and the drive axis A. The drive axis A may be drive axis A of the driver 30. The rotational axis R may be rotational axis R of the flywheel 82. The drive axis A of the driver 30 and the rotational axis R of the flywheel 82 are shown, for example, in FIGS. 3 and 4.

[0119] The motor 80 may be coupled to the frame 14 and may be operably coupled to a flywheel 82 to rotate the flywheel 82. The driver 30 may be configured to be moveable, along the drive axis A of the driver 30 and with respect to the frame 14, between the returned position and the extended position through a stall position intermediate the returned position and the extended position. The housing 12 includes the drive channel 26. The driver 30 is configured for movement within the drive channel 26 from the extended position to drive a lead fastener through the nosepiece assembly 20 and into a workpiece during the drive stroke to the returned position during the return stroke.

[0120] The follower assembly 84 may be coupled to the frame 14 and may have a locked over-center position in which the driver 30 is pinched between the follower assembly 84 and the flywheel 82 subjecting the driver 30 to a pinch force when the driver 30 is in the stall position.The follower assembly 84 also has a release over-center position in which the pinch force is released.

[0121] The stall release lever 1000 may be pivotably coupled to the frame 14. The stall release lever 1000 may be configured to be pivotable about the pivot axis HA / PA between the home position IOOOHP allowing the follower assembly 84 to be in the locked over-center position and the release position 1000RP.

[0122] When the driver 30 is in the stall position and the follower assembly 84 is in the locked over-center position, pivotal movement of the stall release lever 1000 toward the release position IOOORP forces the follower assembly 84 out of the locked over-center position toward the release over-center position in which the pinch force is released.

[0123] The pivot axis HA / PA of the stall release lever 1000 may be substantially parallel to the rotational axis R of the flywheel 82 and may be substantially perpendicular to the drive axis A of the driver 30.

[0124] The follower 86 of the follower assembly 84 may be mounted on the axle / shaft 1022 and the stall release lever 1000 may be configured to operably engage the axle 1022 to force the follower assembly 84 out of the locked over-center position.

[0125] Referring to FIGS. 18-19, the stall release lever 1000 may include a body 1024 and a user actuatable member 1006. In the illustrated embodiment, the body 1024 may have Z- shaped configuration. The body 1024 may be disposed in a plane that is defined by the drive axis A of the driver member 30 and a vertical axis (that is substantially perpendicular to the drive axis A of the driver member 30 and the rotational axis R of the flywheel 82). The body 1024 may include a pinch roller engaging portion 1026 and a user actuatable member connector portion 1028. The user actuatable member connector portion 1028 may be configured to connect the user actuatable member 1006 to the body 1024 of the stall release lever 1000. Similar to the travel limiting stop tab 1032, the user actuatable member connector portion 1028 includes a step portion that acts as a stop when the stall release lever 1000 returns to the at-rest position. The stall release lever 1000 can be manually accessible to the user on the exterior of the housing 12via the user actuatable member 1006. The pinch roller engaging portion 1026 of the stall release lever 1000 may include a surface 1036 that is configured to engage against a portion (e.g., outer rim / circumference) 1038 of the pinch roller 86 of the follower assembly 84.

[0126] The stall release lever 1000 may include a pivot connection portion 1002 that is configured to receive a pivot connection member 1004 therein so as to pivotally connect the stall release lever 1000 to the frame 14. The pivot connection portion 1002 of the stall release lever 1000 is within the housing 12. The pivot connection portion 1002 of the stall release lever 1000 may be disposed between the user actuatable member connector portion 1028 and the pinch roller engaging portion 1026. The pivot connection member 1004 of the stall release lever 1000 may be a mounting screw for the stall release lever 1000.

[0127] The housing 12 includes an opening 1008. The portion 1006 of the stall release lever 1000 is configured to extend through the opening 1008 in the housing 12 as the stall release lever 1000 is pivoted about the pivot axis HA / PA from the home position IOOOHP to the release position IOOORP. The portion 1006 of the stall release lever 1000 includes the user actuatable member 1006.

[0128] FIGS. 14-17 show the stall release lever 1000 in both its the home position IOOOHP and the release position IOOORP. FIGS. 18-19 show the stall release lever 1000 in the home position IOOOHP. FIGS. 20-21 show the stall release lever 1000 in the release position IOOORP.

[0129] As shown in FIGS. 17-19, the user actuatable member 1006 of the stall release lever 1000 may be in a substantially horizontal position when the stall release lever 1000 is in its home position IOOOHP. AS shown in FIGS. 17 and 20-21, the user actuatable member 1006 of the stall release lever 1000 may be substantially angled with respect to the frame 14 when the stall release lever 1000 is in its release position IOOORP. Also, when the stall release lever 1000 is in its release position IOOORP, the user actuatable member 1006 of the stall release lever 1000 may be substantially angled with respect to the substantially horizontal home position IOOOHP of the stall release lever 1000.

[0130] FIGS. 22A-22C show a lever biasing member 1010 that may be configured to retain the stall release lever 1000 in the home position lOOOHp in accordance with an embodiment of this patent application. The lever biasing member 1010 may be configured to bias the stall release lever 1000 into the home position 1000Hp. The lever biasing member 1010 may include a spring. The lever biasing member 1010 in FIGS. 22A-22C may be configured to push down on the stall release lever 1000 to return the stall release lever 1000 to the home position IOOOHP, and to bias the stall release lever 1000 in the home position IOOOHP. One end portion 1010L of the spring 1010 may be operatively connected to an elbow portion 1012 of the stall release lever 1000 and the other end portion lOlOpof the spring 1010 may be connected to a portion 1014 of the frame 14 to enable the stall release lever 1000 return to its home position IOOOHP.

[0131] FIGS. 23A-23C show a lever biasing member 1010' that may be configured to retain the stall release lever 1000 in the home position IOOOHP in accordance with another embodiment of this patent application. The lever biasing member 1010' may be configured to bias the stall release lever 1000 into the home position IOOOHP. The lever biasing member 1010' may include a torsional spring. The lever biasing member 1010' in FIGS. 23A-23C may be configured to act torsionally around the pivot connection portion 1002 of the stall release lever 1000. One end portion 1010'i. of the spring 1010' may be operatively connected to a portion 1016 of the stall release lever 1000 and the other end portion 1010'p of the spring 1010' may be connected to a portion 1018 of the frame 14 to enable the stall release lever 1000 return to its home position IOOOHP. The portion 1018 of the frame 14 may include a notch or an opening 1020 that is configured to receive the portions 1010'p of the lever biasing member / spring 1010'.

[0132] FIGS. 22A-22C and FIGS. 23A-23C show two different embodiments of the lever biasing member / spring, each has the same purpose and function. The function of these springs 1010 or 1010' is to return the stall release lever 1000 to the home position IOOOH , and to bias the stall release lever 1000 into the home position IOOOHP SO the stall release lever 1000 does not move unintentionally. The lever biasing member 1010 or 1010' may be configured to rotate the stall release lever 1000 clockwise looking at the side of the tool 10, from the release position IOOORP to the home position IOOOHP.

[0133] When the user presses the user actuatable member 1006, the stall release lever 1000 pivots from its home position IOOOHP to its release / active position IOOORP (overcoming the bias of the spring 1010 or 1010') to release the pinch roller / pinch wheel / follower 86 (by forcing the pinch roller 86 towards the rear of the tool 10 to release the pinch force of the stalled engine). The spring 1010 or 1010'of the stall release lever 1000 returns the stall release lever 1000 to its home position IOOOHP.

[0134] When the follower assembly 84 is in the locked over-center position and the driver member 30 is in a stall position, a user can actuate stall release lever 1000 toward a release position IOOORP. During pivoting of the stall release lever 1000, the surface 1036 pushes against the portion 1038 of the pinch roller 86 of the follower assembly 84 causing the pinch roller 86 to move to a position further from the front of the tool 10 until the locked over-center is released.

[0135] The stall release lever 1000 may include the jam release arm 1034, the jam clear arm 1030 and the linking arm 1033. The jam release arm 1034 may include the pinch roller engaging portion 1026 and the pivot connection portion 1002. The jam clear arm 1030 may include the travel limiting stop tabs 1032. The jam clear arm 1030 may be configured to connect the jam release arm 1034 with the linking arm 1033. The linking arm 1033 may include the user actuatable member connector portion 1028 that connects the linking arm 1033 and the user actuatable member 1006.

[0136] Unlike the prior art stall release lever of the '281 Patent, most of the stall release lever 1000 including the jam release arm 1034, the jam clear arm 1030, and most of the linking arm 1033, is within the housing 12. The user actuatable member connector portion 1028 that connects the linking arm 1033 and the user actuatable member 1006 is outside of the housing so that it can be contacted by the user. This arrangement allows the stall release lever 1000 to fit on one side of the housing 12 of the tool 10. As such, the stall release lever 1000 avoids getting in the way of the user's line of sight of the nosepiece and the operating portions of the drive assembly 16. Also, compared to the prior art stall release lever in FIGS. 26A-26C and FIGS. 27A-27B, the stall release lever 1000 in an at-rest state, is flush with or recessed within the outer surface of the housing 12.

[0137] The tool 10 can become stalled with the follower assembly 84 in the locked overcenter state / position. Thus, the tool 10 can become stalled with the driver member 30 in the intermediate or stall position between the returned position and the extended position of the driver member 30. In this state, a substantial pinching force is exerted on the driver member 30 between the follower assembly 84 and the flywheel 82. In some cases, this pinching force can be about 400 pounds.

[0138] During normal operation, the stall release lever 1000 is biased into the home position IOOOHP. In the home position IOOOHP, the stall release lever 1000 allows the follower assembly 84 to be in the over-center position. When the stall release lever 1000 is in its home position IOOOHP, the follower assembly 84 is allowed to be in its over-center position, which becomes the locked over-center position when it is pinching the driver member 30 against the flywheel 82.

[0139] The driver member 30 can become stalled in an intermediate position with the follower assembly 84 in the locked over-center position. When this occurs, a user can actuate the stall release lever 1000 about the pivot 1004 by applying a force to the portion 1006. As the stall release lever 1000 rotates / pivots, the surface 1036 of the stall release lever 1000 engages the portion (e.g., outer rim / circumference) 1038 of the pinch roller 86 or the follower axle 1022 to move the follower assembly 84 into the release over-center position. The surface 1036 of the stall release lever 1000 may have a concave shape, a straight shape, or an angled shape.

[0140] As noted above, the pinch force between the follower 86 and the flywheel 82 can be about 400 pounds. The amount of direct force on the follower axle 1022 to move the follower assembly 84 from the locked over-center position to the released over-center position can be about A pounds. The stall release lever 1000 provides a mechanical advantage that enables the A pounds necessary to roll the follower or pinch roller 86 backwards with only B pounds (e.g., "B"pounds is four times less than "A" pounds) of actuation force from the user. In one embodiment, A is about 40 pounds and B is about 10 pounds.

[0141] FIG. 24 illustrates a side-by-side comparison of the tool 10 of FIG. 1 and a prior art tool PA10. As can be clearly seen in FIG. 24, the tool 10 of FIG. 1 has a compact configuration compared to the prior art tool PA10.

[0142] FIG. 25 illustrates a side view side-by-side comparison and a top view side-by-side comparison, respectively, of the tool 10 of FIG. 1 and a prior art tool PA10 showing some dimensions of the tool 10. For example, in one embodiment as shown in FIG. 25, the tool 10 may have an overall width of 84 millimeters (mm), and an overall length of 265 mm. Also, as shown in FIG. 25, a distance between the nosepiece assembly 20 and a topmost portion of the stall release lever 1000 (when the stall release lever 1000 is in its active / release position) is 55mm.

[0143] The values / ranges noted above detailed description are exemplary. In an embodiment, the values / ranges are up to 10 percent greater than or up to 10 percent less than the value described above. In another example embodiment, the values / ranges are up to 5 percent greater than or up to 5 percent less than the value described above.

[0144] Example embodiments have been provided so that this disclosure will be thorough, and to fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of this patent application. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. For example, Further, any of the aforementioned modes may be used during forward and / or reverse operation of the motor and may be used for installing or removing fasteners as desired by the user.

[0145] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an,"and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0146] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0147] Terms of degree such as "generally," "substantially," "approximately," and "about" may be used herein when describing the relative positions, sizes, dimensions, or values of various elements, components, regions, layers and / or sections. These terms mean that such relative positions, sizes, dimensions, or values are within the defined range or comparison (e.g., equal or close to equal) with sufficient precision as would be understood by one of ordinary skill in the art in the context of the various elements, components, regions, layers and / or sections being described.

[0148] Numerous modifications may be made to the exemplary implementations described above. These and other implementations are within the scope of this application.

Claims

WHAT IS CLAIMED IS:

1. A driving tool comprising: a housing; a driver; a drive assembly; a nosepiece assembly comprising a nose portion along which the driver drives a fastener into a workpiece and a door portion that covers the nose portion; a debris blocking member configured to be movable between a first position and a second position; and a latch having a latched position and an unlatched position, wherein the latch, in the latched position, is configured to latch the door portion of the nosepiece assembly in a closed position, wherein the latch, in the unlatched position, is configured to enable:(a) the debris blocking member to move from its first position to its second position, and(b) the door portion of the nosepiece assembly to move from its closed position to its open position, and wherein the debris blocking member, when in the second position, is configured to block debris in the nosepiece assembly from entering the drive assembly.

2. The driving tool of claim 1, wherein the driving tool comprising a frame disposed in the housing, wherein the frame defines a rotational axis and a drive axis.

3. The driving tool of claim 1, wherein the nosepiece assembly is connected to a forward end of the housing.

4. The driving tool of claim 1, wherein, when the latch is moved from its latched position to its unlatched position, the door portion of the nosepiece assembly is moved from its closed position to its open position and the debris blocking member is biased from its first position to its second position.

5. The driving tool of claim 1, wherein the door portion of the nosepiece assembly includes a magnetized door that is formed of a magnetic material.

6. The driving tool of claim 1, wherein the door portion of the nosepiece assembly includes one or more magnets.

7. The driving tool of claim 1, wherein at least a portion of the door portion of the nosepiece assembly is formed of a magnetic material.

8. The driving tool of claim 2, wherein the housing comprises a drive channel, wherein the fastener is a lead fastener, wherein the driver is configured to be moveable, along the drive axis and within the drive channel, from an extended position to drive the lead fastener through the nosepiece assembly and into the workpiece during a drive stroke to a returned position during a return stroke, wherein the driver includes a driver body and a driver blade connected to the driver body, wherein the driver blade is configured to contact a head portion of the lead fastener, and wherein the driver is within the frame.

9. The driving tool of claim 2, wherein the drive assembly comprises a motor operably coupled to a flywheel to rotate the flywheel about the rotational axis.

10. The driving tool of claim 2, wherein the debris blocking member is configured to be movable between its first position and its second position along an axis,wherein the axis of the debris blocking member is substantially perpendicular to the drive axis of the driver and is substantially perpendicular to the rotational axis of the flywheel.

11. The driving tool of claim 2, wherein the latch is configured to be pivotable with respect to the nosepiece assembly and about a pivot axis, and wherein the pivot axis of the latch is substantially parallel to the rotational axis of the flywheel and is substantially perpendicular to the drive axis of the driver.

12. The driving tool of claim 8, wherein the nosepiece assembly comprises an opening disposed between the nose portion and the drive assembly, wherein the opening is formed by cavities in the nosepiece assembly that are configured to allow the driver to be moveable, along the drive axis, between the returned position and the extended position, and wherein the debris blocking member is configured to slide into and out of the opening as the debris blocking member is moved between its first position and its second position.

13. The driving tool of claim 12, wherein the debris blocking member, when in its second position, is disposed in the opening of the nosepiece assembly.

14. A driving tool comprising: a frame, the frame defining a rotational axis and a drive axis; a motor coupled to the frame and operably coupled to a flywheel to rotate the flywheel; a driver, the driver configured to be moveable, along the drive axis and with respect to the frame, between a returned position and an extended position through a stall position intermediate the returned position and the extended position; a follower assembly coupled to the frame and having a locked over-center position in which the driver is pinched between the follower assembly and the flywheel subjecting the driverto a pinch force when the driver is in the stall position, and the follower assembly having a release over-center position; a stall release lever pivotably coupled to the frame, the stall release lever configured to be pivotable about a pivot axis between a home position allowing the follower assembly to be in the locked over-center position and a release position, wherein, when the driver is in the stall position and the follower assembly is in the locked over-center position, pivotal movement of the stall release lever toward the release position forces the follower assembly out of the locked over-center position toward the release overcenter position in which the pinch force is released, and wherein the pivot axis of the stall release lever is substantially parallel to the rotational axis of the flywheel and is substantially perpendicular to the drive axis of the driver.

15. The driving tool of claim 14, wherein the driving tool comprises a housing, wherein the stall release lever includes a pivot connection portion that is configured to receive a pivot connection member therein so as to pivotally connect the stall release lever to the frame, and wherein the pivot connection portion of the stall release lever is within the housing.

16. The driving tool of claim 14, wherein the follower assembly comprises a follower mounted on an axle and the stall release lever is configured to operably engage the axle to force the follower assembly out of the locked over-center position.

17. The driving tool of claim 15, wherein the housing includes an opening, wherein a portion of the stall release lever is configured to extend through the opening in the housing as the stall release lever is pivoted about the pivot axis from the home position to the release position, and wherein the portion of the stall release lever includes a user actuatable member.

18. The driving tool of claim 14, further comprising a lever biasing member that is configured to retain the stall release lever in the home position.

19. The driving tool of claim 18, wherein the lever biasing member is configured to bias the stall release lever into the home position.

20. The driving tool of claim 19, wherein the lever biasing member includes a torsional spring.

21. The driving tool of claim 20, wherein a first end of the lever biasing member is operatively connected to a portion of the stall release lever and a second end of the lever biasing member is operatively connected to a portion of the frame.

22. The driving tool of claim 15, wherein the housing includes a drive channel; wherein the driving tool includes a nosepiece assembly connected to a forward end of the housing, wherein the driver is configured for movement within the drive channel from the extended position to drive a lead fastener through the nosepiece assembly and into a workpiece during a drive stroke to the returned position during a return stroke, wherein the driver includes a driver body and a driver blade connected to the driver body, wherein the driver blade is configured to contact a head portion of the lead fastener, and wherein the driver is within the frame.

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