CONCRETE NAILER HAVING MAGAZINE CUTOUT FOR DEEP TRACKS

Abstract

A concrete nailer has a cutout defined by a magazine. The cutout is disposed proximate the drive track of the concrete nailer and provides the concrete nailer with sufficient reach to perpendicularly nail a complete range of U-shaped channels or track available to the job site against concrete, even though the magazine accommodates both long and short nails. The concrete nailer has the added ability to nail thick boards like 2×4's to concrete.

Claims

1. A method of nailing a channel to concrete using a concrete nailer having a magazine, the channel having a U-shape of walls arranged vertically and a base connecting the walls, the method comprising: providing a cutout in a bottom portion of the magazine; positioning a nose of the concrete nailer above the channel so that the cutout clears at least one wall of the channel; engaging the base of the channel with a contact trip of the concrete nailer oriented perpendicularly to the base of the channel while the cutout still clears the wall; then pressing the contact trip against the base of the channel so that the contact trip is fully actuated; and firing a nail through the base of the channel and into the concrete.

2. The method claimed in claim 1, wherein the dimensions of the channel range from 30 mm to 100 mm wide and from 20 mm to 70 mm deep.

3. The method claimed in claim 2, wherein the magazine is configured to accept nails having lengths ranging from ½ inch to at least 2¼ inches.

4. The method claimed in claim 1, further comprising: providing a drive system including a drive track configured to guide a nail along the drive axis; and guiding the nail along the drive track so that the orientation of the nail relative to the channel is maintained during travel of the nail along the drive track.

5. The method claimed in claim 4, wherein the cutout is disposed proximate to the drive track.

6. The method claimed in claim 4, wherein the step of guiding includes guiding a portion of a carrier, in which the nail is disposed, along the entire length of the drive track, to maintain the orientation of the nail relative to the channel.

7. The method claimed in claim 2, wherein the channel is 30 mm wide and 70 mm deep.

8. A concrete nailer, comprising: a housing; a drive system configured for driving a nail, the drive system including a drive track configured to guide the nail along a drive axis, and a contact trip; and a magazine connected to the housing, the magazine having a bottom portion defining a cutout, wherein the cutout is disposed proximate to the drive track.

9. The concrete nailer claimed in claim 8, wherein the magazine is configured to accept nails having lengths ranging from 1/2 inch to at least 2¼ inches.

10. The concrete nailer claimed in claim 8, wherein the cutout is configured to accommodate a channel having a U-shape including a base, wherein the cutout is configured so that the contact trip may be fully actuated when the contact trip is pressed against the base of the channel.

11. The concrete nailer claimed in claim 10, wherein the channel has a width ranging from 30 mm to 100 mm and a depth ranging from 20 mm to 70 mm.

12. The concrete nailer claimed in claim 11, wherein the channel has a width of 30 mm and a depth of 70 mm.

13. The concrete nailer claimed in claim 8, further comprising: a system configured to maintain an orientation relative to a work surface of nails as short as ½ inch along the drive axis in the drive track, the system comprising: a magazine interface at one end of the magazine, the magazine interface being disposed proximate to the drive track; and a carrier carrying a plurality of nails, wherein the magazine interface and the drive track are configured to cooperate with the carrier to align each nail and a portion of the carrier along the drive axis and along the drive track until the nail is driven into a workpiece.

14. The concrete nailer claimed in claim 8, wherein the concrete nailer is cordless.

15. A magazine in a concrete nailer having a bottom surface and a contact trip aligned along a drive axis, the magazine comprising: a magazine interface configured to be positioned proximate a drive track of the nailer when the magazine is attached to the nailer bottom surface; and a lower portion defining a cutout disposed proximate the interface, wherein the magazine is configured to accommodate nails having lengths ranging from ½ inch to at least 2¼ inches, and wherein the nails are oriented in the magazine to be parallel to the drive axis.

16. The magazine in a concrete nailer claimed in claim 15, wherein the cutout is configured to clear a vertical wall of a U-shaped channel having a U-shape having a width ranging from 30 mm to 100 mm and a height ranging from 20 mm to 70 mm, when the contact trip is fully actuated against a base of the channel.

17. The magazine in a concrete nailer claimed in claim 16, wherein the channel has a width of 30 mm and a height of 70 mm.

18. The magazine in a concrete nailer claimed in claim 15, wherein the height of the cutout proximate the interface is at least 35 mm.

19. The magazine in a concrete nailer claimed in claim 15, wherein the magazine interface is configured to cooperate with the drive track of the concrete nailer to guide the nails along the drive axis to maintain orientation of the nails in the drive track relative to a work surface.

20. The magazine in a concrete nailer claimed in claim 19, wherein the nails are mounted in a carrier, and wherein the magazine interface is configured to maintain the orientation of both a nail and a portion of the carrier along the drive axis.

21. A method of maximizing the reach of a concrete nailer having a housing, a nose portion and a contact trip, the method comprising: providing a magazine accommodating nails having lengths ranging from ½ inch to at least 2¼ inches; and connecting the magazine to the housing such that an interface of the magazine is proximate to the nose portion and so that, when the contact trip is fully actuated, a distance from a work surface to a portion of the magazine proximate the nose portion is in the range of from 60 mm to 70 mm.

22. The method claimed in claim 21, wherein the distance from the work surface to a portion of the magazine proximate the nose portion is 70 mm.

23. A method of minimizing the height of a concrete nailer having a housing and a contact trip, the height being measured from a work surface to the top of the housing, comprising: connecting a magazine to the housing so that the magazine provides the concrete nailer with a reach ranging from 60 mm to 70 mm into a channel having a U-shape when the contact trip is fully actuated against a bottom of the channel.

24. The method claimed in claim 23, wherein the height of the concrete nailer is less than 17 inches, and the magazine accommodates nails having lengths ranging from ½ inch to at least 2¼ inches.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:

[0023] FIG. 1 is a partial elevational sectional detail view of a conventional concrete nailer using a magazine loaded with short nails, and driving the nails into a track and concrete.

[0024] FIG. 2 is a view similar to that of FIG. 1, with long nails shown superimposed over the short nails for contrast.

[0025] FIG. 3 is a view similar to those of FIGS. 1 and 2, and illustrating the problems encountered by a conventional concrete nailer when attempting to nail a track to concrete using a magazine configured to accept both short and long nails.

[0026] FIG. 4 is a partial elevational detail view of a conventional concrete nailer using a drive system, drive track and contact trip made unusually long to artificially create enough reach to nail many sizes of track to concrete.

[0027] FIG. 5 is a rear perspective view of the conventional nailer of FIG. 4 positioned next to the concrete nailer and magazine of the present invention.

[0028] FIG. 6 is a side-by-side elevational view, taken from the bottom, illustrating the differences in height between the concrete nailers of FIG. 5.

[0029] FIG. 7 is a perspective view of one embodiment of a concrete nailer and magazine according to the present invention, with the contact trip shown in the extended position.

[0030] FIG. 8 is an enlarged partial elevational detail view of the concrete nailer and magazine of FIG. 7, with the actuated position of the contact trip shown in phantom, and illustrating short nails loaded in the magazine.

[0031] FIG. 9 is a view similar to FIG. 8, but showing long nails loaded in the magazine.

[0032] FIG. 10 is an enlarged partial elevational detail view of the concrete nailer and magazine of FIG. 7, illustrating the contact trip of the concrete nailer oriented along a drive axis and fully actuated against the base of a track to be nailed to concrete.

[0033] FIG. 11 is a view similar to FIG. 10, but showing the concrete nailer and magazine of FIG. 7 driving long nails into a 2×4 and concrete.

[0034] FIG. 12 is a partial elevational detail view of the contact trip and drive track subassembly of the concrete nailer of FIG. 7, illustrating what happens when a short nail becomes misaligned along the drive axis.

[0035] FIG. 13 is a side elevational detail view of the magazine of FIG. 7.

[0036] FIG. 14A is an enlarged elevational detail view of the circled portion of the magazine of FIG. 13.

[0037] FIG. 14B is an enlarged elevational detail view of the portion of the magazine shown in FIG. 14A positioned proximate the drive track of the concrete nailer of FIG. 7.

[0038] FIG. 15A is an enlarged elevational detail view of short nails mounted in a carrier of the present invention.

[0039] FIG. 15B is an enlarged perspective detail view of the magazine interface taken along line 15-15 of FIG. 14B, and illustrating a nail mounted in a portion of the carrier.

[0040] FIG. 16 is an exploded perspective detail view of the magazine interface of the magazine of FIG. 7 being positioned proximate the drive track of the concrete nailer of FIG. 7, and showing a system for aligning nails along the drive track of the concrete nailer.

[0041] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the present invention, and such exemplifications are not to be construed as limiting the scope of the present invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

[0042] Referring now to the drawings and particularly to FIG. 7, a cordless concrete nailer 10 in accordance with an embodiment of the present invention includes a housing 12, a motor 14 (shown schematically in phantom) disposed in the housing, a battery pack 16 for providing power to the motor, and a drive system 18 (also shown schematically in phantom) configured for driving a nail and operatively associated with the motor. The drive system 18 includes a drive track 20 disposed parallel to a drive axis 22. The concrete nailer 10 further includes a magazine 24 connected to a bottom surface 25 of the housing 12. A bottom portion 26 of the magazine 24 in turn defines a cutout 28 which is disposed proximate the drive track 20 when the magazine 24 is connected to the concrete nailer housing 12. A contact trip 30 extending from a nose 32 of the housing 12 is operatively associated with the drive system 18, and is coaxial with the drive axis 22. In operation, nails are fed from the magazine 24 and into engagement with the drive track 20. When an operator presses the contact trip 30 against a work surface 34, the contact trip is moved upwards to its actuated position, thus completing an electrical circuit (not shown) which permits the concrete nailer 10 to be fired, thereby driving nails along the drive track 20, out the bottom of the contact trip 30, and into the work surface.

[0043] Although the concrete nailer 10 is described as having an electric drive system 18, the magazine 24 may also be used in conjunction with concrete nailers having other drive systems, including without limitation pneumatic, hydraulic, powder-actuated/explosive, and gas/explosive.

[0044] FIGS. 8 and 9 show the concrete nailer 10 in which the magazine 24 accommodates both short nails 40 (FIG. 8) and long nails 42 (FIG. 9). One embodiment of the magazine 24 accommodates nails ranging in length from a small as ½ inch to at least as long as 21/4 inches, thus providing the concrete nailer 10 with considerable flexibility.

[0045] Still referring to FIGS. 8 and 9, the unique cooperation of components of the concrete nailer 10 and magazine 24 allows the concrete nailer to have considerable “reach” R when the contact trip 30 is moved from an extended position 36 to an actuated position 38 (shown in phantom). This cooperation enables a contractor to use the concrete nailer 10 in constricted spaces and in connection with workpieces having challenging geometries.

[0046] FIG. 10 illustrates how the concrete nailer 10 easily handles one of the most difficult of workpiece geometries likely to be encountered on a job site, namely, when the concrete nailer is required to nail a U-shaped metal channel or “track” 44 to concrete 50. The sizes of track which are likely to be found on a job site have widths W at the base 46 ranging from 30 mm to 100 mm, and depths D of walls 48 ranging from 20 mm to 70 mm. As previously noted, where this gets particularly challenging for a concrete nailer is when the track dimensions approach the narrowest but tallest ends of the range, namely, when the track measures 30 mm wide, but is 70 mm deep. That is because, when nailing concrete, it is very important to maintain the angle A of the drive axis 22 as close to 90° relative to the concrete as possible. However, as shown in FIG. 10, the reach R generated by the concrete nailer 10 is at least 70 mm. Therefore, even though the magazine 24 accommodates both short nails 40, as shown in FIG. 10, and long nails 42 (including nails at least as long as 2¼ inches), as shown in FIG. 11, the path 43 of the tips of the long nails 42 (see FIGS. 10 and 11) is still above the walls 48 of track 44. This enables the concrete nailer 10 using the magazine 24 to maintain the drive axis 22 perpendicular to the concrete 50, thereby successfully tackling workpiece geometries which, to date, have been difficult, if not impossible, for conventional concrete nailers to successfully handle. (It should be noted that, although the optimum orientation of the drive axis 22 to the work surface 34 is 90°, the concrete nailer 10 is capable of maintaining the orientation of the drive axis at any desired angle relative to the work surface.)

[0047] Returning for the moment to FIGS. 5 and 6, the height H1 of the concrete nailer 10 can thus be as short as 16 inches, compared to the height H2 of the second conventional concrete nailer 200, which must be 18½ inches, an increase of more than 12%. Thus the design of the second conventional concrete nailer 200 requires more metal and larger components, and is more unwieldy, heavier and more costly than the concrete nailer 10, and is less able to fit into the constricted space requirements that the concrete nailer 10 easily handles.

[0048] Referring to FIGS. 7, 10 and 11, the magazine cutout 28 is disposed proximate the drive track 20. As shown in greater detail in FIGS. 13, 14A and 14B, the magazine 24 includes a magazine interface 52 that is aligned along drive axis 22 when the magazine is attached to the concrete nailer 10.

[0049] FIG. 14A shows that the cutout 28 of magazine 24 has a length LC and a height HC.

[0050] In one embodiment, the length LC is about 28 mm, and the height HC is about 20 mm. When the magazine 24 is connected to the concrete nailer 10, as shown in FIG. 14B, the magazine interface 52 of magazine 24 is disposed proximate the drive track 20 of the concrete nailer 10, so that the drive axis 22 of the magazine interface shown in FIG. 13 is coincident with the drive axis 22 of the concrete nailer 10. However, at first glance, it is not intuitively apparent how a short nail 40, in particular, can be maintained in a desired orientation along the drive axis 22, in that the travel of the nail 40 along the drive track 20 is exposed to the cutout 28. That is because, as shown in FIG. 12, without support proximate the cutout 28, the nail would likely become skewed from the drive axis 22 and jam the mechanism, as shown at 40′.

[0051] FIGS. 15A, 15B and 16 show a system 53 of the present invention configured to maintain the desired orientation relative to a work surface 34 of nails as short as ½ inch in the drive track 20, notwithstanding the proximity of the nails 40 to the cutout 28.

[0052] As shown in FIGS. 15A and 15B, nails 40, 42 are mounted vertically in a plastic carrier 54, which is angled to match the angle N of the magazine 24. When the concrete nailer 10 is fired, a drive bar (not shown) of the drive system 18 strikes the top of the nail 40 presented to the concrete nailer drive axis 22 by the magazine interface 52, and separates a portion 56 carrying the nail 40 from the rest of the carrier 54. Portion 56 carries the nail 40 all the way along the drive track 20, and moves with the nail even as the nail is driven into a work surface 34. The orientation system 53 is configured to capitalize on this effect: the magazine interface 52 defines respective guide surfaces 58 and 59, and the carrier 54 defines guide surfaces 60 that match the configuration of guide surfaces 58. Furthermore, the drive track 20 of the concrete nailer 10 is also provided with guide surfaces 62. As shown particularly in FIG. 16, the respective guide surfaces 58, 59, 60 and 62 of the orientation system 53 cooperate to maintain the orientation of the nail 10 along the drive axis 22 during its entire travel along the drive track 20.

[0053] To nail the track 44 to concrete, the operator positions the nose 32 of the concrete nailer 10 above the track so that the cutout 28 formed in the bottom 26 of the magazine 24 clears at least one wall 48 of the track. The contact trip 30 of the concrete nailer 10 then engages the base 46 of the track 44 so that the contact trip is oriented perpendicular to the base of the track, while the cutout 28 still clears the wall 48. Then, while maintaining this orientation, the contact trip 30 is pressed against the base 46 of the track 44 so that the contact trip is fully actuated, and the concrete nailer 10 fires a nail 40, 42 through the base of the track and into the concrete 50.

[0054] It can now be seen that the concrete nailer 10 and magazine 14 of the present invention fulfill the long-felt need for a concrete nailer having a magazine which accommodates both short and long nails, has the flexibility to nail 2×4's into concrete, and which also satisfactorily nails to concrete the complete range of track presently available on job sites. While the emphasis has been placed on being able to nail 2×4's into concrete, it should be recognized that the concrete nailer 10, if desired, may nail other sizes of wood with similar thicknesses to concrete as well.

[0055] While the present invention has been described with respect to various embodiments, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the present invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limitations of the appended claims.