A staple apparatus can comprise a staple head movable in a first staple direction from a head retracted position to a head extended position. The staple apparatus can further comprise an indexing apparatus comprising an index biasing member and an indexing member. The indexing member can be positioned at least partially within an indexing area and biased with the index biasing member toward a member extended position relative to the indexing area. The indexing member can define a rung travel path and can further comprise an indexing tab comprising a ramp surface positioned to taper the rung travel path in the first indexing direction. The indexing tab can further comprise a shoulder positioned past at least a portion of the ramp surface in the first indexing direction. In further embodiments, a staple chain positioning apparatus can comprise a push member movable in an extension direction.

An apparatus for reinforcing stapling connections created by an elastic stapling apparatus with a plurality of individual reinforcing elements. The apparatus constructs and deploys the plurality of individual reinforcing elements simultaneously with the elastic stapling apparatus generating a plurality of plastic fasteners. The apparatus manufactures the plurality of individual reinforcing elements from a pair of oppositely disposed rolls of reinforcing stock material. The individual reinforcing elements provide additional structural integrity to articles that are deformable in construction.

A device for dispensing an individual plastic fastener from a supply of fastener stock includes a motor-driven head assembly adapted to receive the supply of fastener stock, sever an individual fastener from the supply and in turn eject the severed fastener. The head assembly includes a pair of needle block assemblies that retain corresponding hollow needles, each needle block assembly being shaped to define a feed channel that transitions a side rail for the fastener stock into axial alignment behind its corresponding needle. In addition, at least one needle block assembly includes a rearward shelf and a forward bowing plate. In use, the lowermost cross-links of the fastener stock fittingly align between the shelf and the bowing plate. In this manner, the lowermost cross-links are limited to distort uniformly upward within the single plane defined by the pair of feed channels, thereby optimizing feed reliability of the device.

A reactor plate assembly for a fastener dispensing device includes a metal reactor plate mounted onto the distal end of a fixed support arm for the device, the reactor plate including a flattened top surface shaped to define a pair of elliptical, needle-receiving holes. The reactor plate assembly additionally includes a brush anvil removably secured to the underside of the support arm. The brush anvil includes four separate bristle clusters that are retained within associated bores in a block, with a first pair of bristle clusters projecting into one needle-receiving hole and a second pair of bristle clusters projecting into the other needle-receiving hole. Each bristle cluster includes a group of individual nylon bristles, the free ends of the bristles lying flush with the top surface of the reactor plate to provide a planar support surface which can be penetrated by the needles of the device during the dispensing process.

A plastic fastener is rendered tacky so as to adhere to the items which it couples, thereby enhancing securement. The plastic fastener is constructed as an H-shaped staple that includes a pair of parallel cross-bars interconnected by a flexible filament. In one embodiment, the plastic fastener includes an inner plastic core constructed using at least one flexible plastic material and an adhesive-based outer coating constructed using at least one of a pressure-sensitive adhesive and a heat-activatable adhesive. In another embodiment, the plastic fastener is constructed using a mixture of at least one flexible plastic material and at least one adhesive material. In lieu of incorporating an adhesive material into the plastic fastener, a novel item coupling process achieves fastener tackiness by applying heat onto the plastic fastener either prior to, during, or after being dispensed into the desired items.

A fastener assembly for coupling together two or more articles includes a plastic fastener and an anchoring member. The plastic fastener includes a pair of parallel cross-bars that are interconnected by a transverse filament. The anchoring member is constructed as a unitary, solid, plastic disc with opposing flattened surfaces. In use, the anchoring member is disposed against an outer surface of the articles to be coupled together. During the fastener dispensing process, the ejected cross-bar penetrates through the articles as well as the anchoring member. Upon completion, the ejected cross-bar lies directly upon the exposed surface of the anchoring member. As such, the stiffened anchoring member provides structural integrity to articles that are deformable in construction. In this manner, the anchoring member prevents intact removal of a dispensed fastener by either intentional or unintentional widening of the hole in the articles through which the fastener extends.

A method for penetrating a material with a fastener dispensing needle includes the steps of partially penetrating the material using a first penetration stroke, partially withdrawing the needle from the material using a first withdrawal stroke and, in turn, fully penetrating the material using a second penetration stroke. Once fully penetrated, a plastic fastener is dispensed from the fastener dispensing needle. Thereafter, the fastener dispensing needle is fully withdrawn from the material. Additional partial penetration and withdrawal strokes could be incorporated into the needle penetration cycle in a repeating pattern, as needed, with each penetration stroke preferably having a stroke length which is twice the length of each withdrawal stroke. The use of an oscillating, back-and-forth, linear needle penetration cycle serves to minimize the risk of lateral needle deflection which can result in bending or breakage of the needle as well as damage to the penetrated material.

An apparatus for reinforcing stapling connections created by an elastic stapling apparatus with a plurality of individual reinforcing elements. The apparatus constructs and deploys the plurality of individual reinforcing elements simultaneously with the elastic stapling apparatus generating a plurality of plastic fasteners. The apparatus manufactures the plurality of individual reinforcing elements from a pair of oppositely disposed rolls of reinforcing stock material. The individual reinforcing elements provide additional structural integrity to articles that are deformable in construction.

A plastic fastener is rendered tacky so as to adhere to the items which it couples, thereby enhancing securement. The plastic fastener is constructed as an H-shaped staple that includes a pair of parallel cross-bars interconnected by a flexible filament. In one embodiment, the plastic fastener includes an inner plastic core constructed using at least one flexible plastic material and an adhesive-based outer coating constructed using at least one of a pressure-sensitive adhesive and a heat-activatable adhesive. In another embodiment, the plastic fastener is constructed using a mixture of at least one flexible plastic material and at least one adhesive material. In lieu of incorporating an adhesive material into the plastic fastener, a novel item coupling process achieves fastener tackiness by applying heat onto the plastic fastener either prior to, during, or after being dispensed into the desired items.

A method for penetrating a material with a fastener dispensing needle includes the steps of partially penetrating the material using a first penetration stroke, partially withdrawing the needle from the material using a first withdrawal stroke and, in turn, fully penetrating the material using a second penetration stroke. Once fully penetrated, a plastic fastener is dispensed from the fastener dispensing needle. Thereafter, the fastener dispensing needle is fully withdrawn from the material. Additional partial penetration and withdrawal strokes could be incorporated into the needle penetration cycle in a repeating pattern, as needed, with each penetration stroke preferably having a stroke length which is twice the length of each withdrawal stroke. The use of an oscillating, back-and-forth, linear needle penetration cycle serves to minimize the risk of lateral needle deflection which can result in bending or breakage of the needle as well as damage to the penetrated material.