Adhesive Plastic Collar for Debris-Free Nail Fastening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing collated nail strips made from plastic materials tend to shatter and separate from the nail shank when driven into a workpiece, generating debris and causing housekeeping issues, while also being prone to corrugation and flexing in the tool magazine.
Innovation Solution
A collation system using a molded plastic material with a collar portion that encircles the fastener shank and a connecting portion between adjacent collars, formulated from adhesive polymers like polyolefin blends, which is preheated before molding to enhance adhesion, reducing debris generation and improving rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic material is used to collate nails in a strip, then ease of manufacture and structural integrity are improved, but the plastic shatters and separates from the nail shank when driven into the workpiece, generating debris
Solution Approach 1:
The patent changes the physical and chemical parameters of the plastic material by using a blend of polypropylene and maleic anhydride modified polypropylene, and by controlling the molding temperature (450°F to 600°F), to achieve both ease of manufacture and reduced debris generation while maintaining adhesion to the nail shank
Solution Approach 2:
The patent uses a composite plastic material consisting of a blend of polypropylene and maleic anhydride modified polypropylene, which combines the ease of processing of polypropylene with the enhanced adhesion properties of the modified component, resolving the contradiction between manufacturability and debris generation
2Strength
If plastic material is molded onto fasteners, then adhesion and holding power are improved, but the plastic tends to corrugate or advance on itself in the tool magazine
Solution Approach 1:
The patent applies different properties to different parts of the plastic collation: the collar portion has high adhesion to the nail shank, while the connecting portion has a specific geometry (bridge and rib structure) that provides rigidity and prevents corrugation, resolving the contradiction between adhesion and strip stability
3Object-generated harmful factors
If the plastic collation system is designed to maximize adhesion to the nail shank, then debris generation is reduced, but the strip becomes more prone to flexing in the tool magazine
Solution Approach 1:
The patent segments the plastic collation into distinct functional portions: the collar portion that adheres to the nail shank to prevent debris generation, and the connecting portion with bridge and rib structures that provide the rigidity needed to prevent flexing, while maintaining the necessary adhesion strength
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces debris generation, enhances adhesion of the plastic to the nail shank, and increases the holding power of the nails in the substrate by embedding the plastic into the wood, resulting in improved performance and reduced housekeeping issues.
Implementation Method 1
The plastic material is formulated from an adhesive polymer such as a polyolefin, a polyolefin blend, an epoxy or the like. When the fastener is driven from the driving tool, the collar portion remains adhered to the fastener such that the collar portion penetrates the substrate with the fastener. In a present strip, the polymer is a blend of polypropylene and a maleic anhydride modified polypropylene and adhesion is effected by preheating the fasteners prior to molding the plastic material to the fasteners.
Data Source
AI summary
A fastener assembly is configured for use in an associated fastener driving tool for driving a fastener from the assembly into an associated substrate. The assembly includes a row of fasteners, each having a shank, arranged substantially parallel to each other. A collation system is formed from a plastic material that is molded onto and adhered to the fasteners. The plastic material is molded to define a collar portion substantially encircling the fastener shank and a connecting portion extending between and connecting adjacent collar potions. The plastic material is formulated from an adhesive polymer. When the fastener is driven from the driving tool, the collar portion remains adhered to the fastener such that the collar portion penetrates the substrate with the fastener.