Interface for fuel delivery system for combustion fastener driver

Abstract

A fuel delivery system for use with a combustion fastener driver including a cylinder head frame, the system includes a fuel cell with an outer shell having a closed lower end and an open upper end, a closure crimped over the upper end and defining an opening for accommodating a reciprocating valve stem, a fuel cell adapter frictionally engaging the closure and including a flange configured for suspending the fuel cell in a tool fuel cell chamber. The adapter includes a collar configured for receiving the valve stem and being suspended for restricted vertical movement relative to the flange. A stem receiver block is connectable to the cylinder head frame and includes a stem engagement portion configured for directly and sealingly engaging an end of the valve stem, the stem engagement portion being in fluid communication with an internal receiver passage constructed and arranged for delivering fuel to a combustion chamber.

Claims

1. A fuel delivery system constructed and arranged for use with a combustion fastener driver including a cylinder head frame, a combustion chamber, and a housing defining a fuel cell chamber, said fuel delivery system comprising: a fuel cell with an outer shell having a closed lower end and an open upper end; a closure crimped over said upper end and defining an opening sized to accommodate a reciprocatable valve stem; a fuel cell adapter frictionally engaged to said closure and including a flange configured to suspend said fuel cell in the fuel cell chamber, said fuel cell adapter including a collar defining an opening sized to receive said valve stem, wherein the collar is suspended for restricted vertical movement relative to said flange; and a stem receiver block connectable to the cylinder head frame and including a stem engagement portion configured to directly and sealingly engage an end of said valve stem, said stem engagement portion being in fluid communication with an internal receiver passage constructed and arranged to deliver fuel to the combustion chamber.

2. The fuel delivery system of claim 1, wherein said stem receiver block includes a body defining said internal fuel passage, and wherein said stem engagement portion depends from said body and defines a stem chamber.

3. The fuel delivery system of claim 2, wherein said stem chamber includes a stem stop defining a generally horizontal surface configured to engage an upper end of the valve stem.

4. The fuel delivery system of claim 2, wherein said collar is dimensioned to slidingly accommodate reciprocal movement of said stem engagement portion.

5. The fuel delivery system of claim 1, wherein said flange on said fuel cell adapter defines a main opening in which said collar is suspended, wherein said collar is dimensioned to slidingly accommodate a stem engagement portion of said stem receiver block and to guide said stem engagement portion as it engages said valve stem.

6. The fuel delivery system of claim 5, wherein said collar is suspended relative to said flange to enable vertical movement relative to the flange in the general range of 0.020 inch and to restrict non-vertical movement of said collar relative to the flange.

7. The fuel delivery system of claim 5, wherein said collar is suspended relative to said flange by a plurality of arms, each arm connected at one end to said collar and at an opposite end to a ring on said flange, the ring defining said main opening.

8. The fuel delivery system of claim 7, wherein said plurality of arms includes four arms constructed and arranged to generally surround said collar.

9. The fuel delivery system of claim 7, wherein said plurality of arms includes four arms suspended from two main support points on the ring.

10. The fuel delivery system of claim 7, wherein said plurality of arms each include a ring portion, a mid portion, and a collar portion.

11. The fuel delivery system of claim 1, wherein said stem receiver block is made of metal.

12. The fuel delivery system of claim 1 wherein said collar has an upper end extending above an upper stem end when said valve stem is in a rest position.

13. The fuel delivery system of claim 1 wherein said collar includes a radially inwardly tapering internal chamfer that facilitates locating said stem receiver block upon the valve stem.

14. The fuel delivery system of claim 1 wherein said collar is dimensioned to define a stroke of the stem receiver block and the valve stem.

15. A fuel cell adapter for use with a fuel cell, said adapter comprising: a generally planar flange including a ring defining a main opening; and a collar suspended in said main opening by a suspension connected to said collar and to the ring, said suspension including a plurality of support arms each connected at one end to said collar and at an opposite end to said ring such that said collar is connected to said flange only by said suspension.

16. The adapter of claim 15 wherein each of the support arms is constructed to enable vertical movement of the collar relative to the flange in the range of 0.020 inch and to restrict non-vertical movement of the collar relative to the flange.

17. The adapter of claim 15 wherein said plurality of support arms include four support arms, each generally “S”-shaped and including a mid portion generally arcuate and generally following a curve of a perimeter of said collar.

18. The adapter of claim 17 wherein said support arms have ends attached to said ring such that two pairs of such support arms each have said ends closely attached at said ring, so that said collar is suspended in said main opening at two generally diametrically opposed support points.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front perspective view of a combustion tool equipped with the present fuel delivery system;

(2) FIG. 2 is a fragmentary top perspective view of the tool of FIG. 1 showing an upper end of the fuel cell chamber open and ready for accommodating a fuel cell;

(3) FIG. 3 is a fragmentary vertical section of the tool of FIG. 1 showing the present fuel delivery system;

(4) FIG. 4 is a fragmentary bottom perspective view of a fuel cell shown suspended from the cylinder head frame;

(5) FIG. 5 is a top perspective view of a fuel cell equipped with the present fuel cell adapter;

(6) FIG. 6 is an enlarged fragmentary vertical section of the system of FIG. 3;

(7) FIG. 7 is a top perspective view of an alternate embodiment of the fuel cell and adapter of FIG. 5;

(8) FIG. 8 is a front elevation of the fuel cell of FIG. 7;

(9) FIG. 9 is a vertical cross-section taken along the line 9-9 of FIG. 8 and in the direction generally indicated;

(10) FIG. 10 is a top perspective view of the adapter of FIG. 7;

(11) FIG. 11 is a bottom perspective view of the adapter of FIG. 10;

(12) FIG. 12 is an overhead plan view of the adapter of FIG. 10;

(13) FIG. 13 is a front elevation of the adapter of FIG. 12;

(14) FIG. 14 is a cross-section taken along the line 14-14 of FIG. 13 and in the direction generally indicated;

(15) FIG. 15 is a fragmentary vertical section of a nailer equipped with the fuel cell of FIG. 7 in the rest position; and

(16) FIG. 16 is a fragmentary vertical section of the nailer of FIG. 14 shown in the fuel dispensing position.

DETAILED DESCRIPTION

(17) Referring now to FIGS. 1-3, a combustion nailer is depicted, generally designated 10. As is known in the art, a main tool housing 12 encloses a power source or engine 14 (FIG. 3) and a fuel cell chamber 16. A fuel cell door 18 is pivotally engaged on the housing 12 and is configured to close off the fuel cell chamber 16 during tool operation. The construction and arrangement of such doors 18 is well known in the art.

(18) The power source 14 includes a reciprocating piston 20 (FIG. 3) having a driver blade 22 secured thereto for common movement relative to the power source and within a cylinder 24. A nosepiece 26 (FIG. 1) is secured to a lower end of the power source 14 as is known in the art and provides an attachment point for a fastener magazine 28, here shown as a coil magazine, however other types of magazines such as strip magazines are considered suitable. Fasteners are fed sequentially from the magazine 28 into the nosepiece 26 where they are engaged by the driver blade 22 traveling down a fastener passageway in the nosepiece.

(19) The fasteners are driven into a workpiece or substrate after initiation of a power cycle, initiated in some tools by the operator actuating a trigger 30. A workpiece contact element 32 reciprocates relative to the nosepiece 26 to control tool functions as is known in the art, but is not relevant to the present discussion.

(20) Also provided to the housing 12 is a handle 34 which serves as the mounting point for the trigger 30. A battery chamber 36 (FIG. 1) is also provided to the housing 12 for accommodating at least one battery 38 for powering electronic tool functions such as spark generation, cooling fan operation, electronic fuel injection and/or tool condition sensing as known in the art. The location of the battery chamber 36 may vary depending on the particular nailer configuration.

(21) Referring now to FIGS. 2-4, an upper end of the power source 14 is defined by a cylinder head 40, serving as the mounting point for a fan motor 42 powering a fan 44 projecting into a combustion chamber 46, and also being the mounting point for a spark generator or spark plug 48. Also included on the cylinder head 40 are two spaced, parallel arms 50 included as part of a cylinder head frame, each having a recessed shelf 52 defined on an inner surface 54 (FIG. 2). A space 56 between the inner surfaces 54 defines an entrance to the fuel cell chamber 16. The entrance 56 is considered part of the fuel cell chamber 16. Ends of the arms 50 have pivot openings 57 for receiving corresponding lugs 58 of the fuel cell door 18.

(22) Referring now to FIGS. 3-6, as described in U.S. Pat. No. 5,263,439, incorporated by reference, inserted into the fuel cell chamber 16 is a fuel cell, generally designated 60, the general construction of which is well known in the art pertaining to combustion tools, and which is configured for removable engagement in the fuel cell chamber 16. The particular construction of the present fuel cell 60, having an internal fuel metering valve 62 (FIGS. 3 and 6) is described in copending U.S. Pat. No. 7,392,922 which has been incorporated by reference. Generally speaking, a fuel valve stem 64 is biased to a closed position, as by a spring (not shown), but when axially depressed, a measured dose of fuel is dispensed. Upon withdrawal of the axial force, the stem 64 resumes its rest position, and a subsequent dose of fuel flows into a metering chamber 66 for the next firing cycle.

(23) Other major components of the fuel cell 60 include a generally cylindrical, close bottomed outer shell 68, and a closure 70 crimped over an open upper end 72 of the shell. As a result of this crimping action, the closure 70 includes a peripheral annular ring 74. Included on the closure 70 is an opening 76 for accommodating the reciprocating valve stem 64.

(24) Referring now to FIGS. 3-6, an important feature of the present fuel cell 60 is an adapter, generally designated 80. A main portion of the adapter 80 is the adapter body 82 including a depending ring 84 which is retained on the fuel cell 60 through engagement with the fuel cell closure 70. A tight friction fit of the adapter 80 with the closure 70 is achieved by at least one radially extending gripping formation 86 which tightly engages an interior surface of the peripheral closure ring 74. The gripping formation 86 defines an annular concave recess or groove 88 which accommodates an inner curved portion of the closure ring and preferably is dimensioned for a looser engagement on the closure ring 74 compared to the formation 86, to accommodate manufacturing variations. In addition, an upper end of the gripping formation 86 includes a radially extending lip 89 configured for engaging an upper surface of the closure ring 74. The depending ring 84 and the formation 86 can be provided in a single closed ring or a series of spaced protrusions.

(25) To reduce the possibility of a user accidentally using a fuel cell not suitable for the present tool 10, the adapter 80 is designed to be extremely difficult to remove from the closure 70. This is accomplished by dimensioning the gripping formation 86 and the radially extending lip to have an extremely tight friction fit with the closure 70. In addition, in that the adapter 80 is preferably molded of a plastic material, a material is selected for stiffness, as well as for fuel resistance, moldability and durability. It is contemplated that acetyl, commonly sold under the trademark Celcon® by Hoechst Celanese, Charlotte N.C., is a preferred material, however other acetyls, polyamids or other fuel resistant plastics may be suitable.

(26) The other main portion of the adapter 80 is a generally planar, disk-shaped flange 90 that is configured for engaging the locating shelves 52 for suspending the fuel cell 60 in the fuel cell chamber 16. It will be seen that the generally planar flange 90 extends beyond an exterior of the fuel cell outer shell 68. In fact, the flange 90 is dimensioned so that once engaged in the locating shelves 52, it is the sole support for the fuel cell 60 in the fuel cell chamber 16. More specifically, once suspended on the shelves 52, a bottom 92 of the fuel cell 60 is disposed above and free of a floor 94 of the fuel cell chamber 16 (FIG. 3). While the particular engagement of the flange 90 on the shelves 52 is described here, it will be appreciated that the adapter 80 may be provided with alternate structures configured for suspending the fuel cell 60 from the cylinder head 40.

(27) Preferably, the flange 90 has a vertically projecting collar 96. The collar is tubular in shape, defining an inner area 98 that surrounds the valve stem 64. Also, the collar 96 projects from the flange 90 a sufficient distance to protect the valve stem 64 from damage or impact. Another feature of the collar 96 is that it is dimensioned for slidingly accommodating reciprocal movement of a stem receiver block 100. More specifically, an upper end 102 of the collar 96, which extends above an uppermost point of the valve stem 64 when the stem is in its uppermost rest position, also defines an end of an inwardly tapering, annular internal chamfer area 104 that facilitates location of a depending stem engagement portion 106 of the stem receiver block 100 upon the valve stem.

(28) Referring now to FIGS. 3 and 6, the stem receiver block 100 includes a block-like body 108 defining an internal fuel passage 110 connected at one end to the stem engagement portion 106, and at an opposite end to a fuel port 112, preferably taking the form of a barbed nozzle. Depending from the body 108, the stem engagement portion 106 defines a stem chamber 114 dimensioned to accommodate an upper end 116 of the stem 64. A counterbored stem stop 118 defines an annular flat or horizontal sealing surface for sealingly receiving the upper stem end 116. It has been found that the horizontal stem stop 118 provides a more positive seal with the upper stem end 116 than provided by conventional fuel cell engagement structures.

(29) Another feature of the present stem receiver block 100 is that a shoulder 120 is defined where an underside of the body 108 meets an upper end of the stem engagement portion 106. This shoulder 120 impacts the upper end 102 of the collar 96 to limit the downward movement of the stem receiver block, and accordingly the valve stem 64. In other words, the shoulder 120 is positioned on the body 108 to define a lowermost point of the stroke of the stem receiver block 100 and the valve stem 64. Due to the construction of the internal metering valve 62, the downward travel of the stem receiver block 100 is sufficient to release a dose of fuel from the metering valve.

(30) In one embodiment, the stem receiver block 100 is made of metal, and more preferably aluminum. It has been found that the aluminum is more resistant to flow variations and the resultant dosage variations over a wider range of ambient temperatures resulting in improved performance in lower temperature environments than conventional plastic stem receiver blocks.

(31) It is contemplated that the adapter body 82 may be provided in two alternative configurations. In one, as shown in FIGS. 3, 5 and 6, the adapter body 82 has two main components: an outer portion 82a including the gripping formation 86, the groove 88 and the lip 89; and an inner portion 82b, which includes the collar 96 and the flange 90 and engages the outer portion by a screw-and-twist engagement, where lugs 121 on the inner portion 82b engage helical grooves 122 on the outer portion 82a. In the other configuration, the adapter body 82 is provided as a single, integral piece.

(32) To complete the connection between the fuel cell valve stem 64 and the combustion chamber 46, a flexible hose or conduit 123 is matingly engaged on the end of the fuel port 112 at one end, and at an opposite end is matingly engaged on a cylinder head inlet fitting 124. Fluid communication between the inlet fitting 124 and the combustion chamber 46 is achieved by a fuel passage 126 in the cylinder head 40.

(33) An advantage of the present adapter 80 is that the combination of the tight frictional engagement between the gripping formation 86 and the radially extending lip 89, the suspension of the fuel cell 60 in the tool using the flange 90 engaging the shelves 52, and the direct engagement of the stem receiver block 100 upon the fuel cell has been found to significantly improve fuel cell efficiency. More specifically, a more consistent fuel dosing is obtained, and performance in colder temperatures has been improved.

(34) Referring now to FIG. 5, an upper surface 128 of the flange 90 is preferably provided with integrally formed depressions 130 and grooves 132 for enhancing gripping and handling by a user. This enhanced gripping is useful when the adapter 80 is provided in two portions 82a, 82b as described above. In addition, openings 134 are provided for facilitating molding. The specific shapes and dimensions of the depressions 130, the grooves 132 and the openings 134 may vary to suit the particular application, and in some cases may be optionally eliminated.

(35) Referring again to FIGS. 3 and 6, another feature of the present adapter 80 is that the flange 90 defines a stem opening 136 for reciprocally and slidingly accommodating the valve stem 64. It is preferred that the stem opening 136 is dimensioned for defining a tight, sliding engagement with the valve stem such that there is minimal clearance between the opening and the valve stem outer surface. Such tight, sliding engagement reduces the chances for dirt to become lodged in the fuel cell metering valve 62. In addition, the relatively small diameter opening 136 prevents the adapter 80 from being used with incompatible fuel cells, which have larger diameter stems that will not fit through the opening 136. As is known in the art, there are different fuel cell fuel mixtures, and some mixtures are formulated for specific types of tools, and will be less effective if used with incompatible tools.

(36) Referring now to FIGS. 2 and 3, as is known in the art, to dispense a dose of fuel from the fuel cell 60 through the flexible hose 122, a fuel cell actuator assembly is provided and is generally designated 138 which is in operational relationship with fuel cell chamber 16 and is constructed and arranged for exerting an axial force on the valve stem 64. A main component of the actuator 138 is a generally elongate actuator element 140 configured for exerting an axial force on the stem 64, releasing the dose of fuel. In one embodiment, the element 140 is associated with the fuel cell door 18 and is in actual contact with the stem receiver block 100.

(37) As seen in FIGS. 2 and 3, the fuel cell door 18 is pivotally engaged with the pivot points 57 on the cylinder head arms 50. As is well known in the combustion tool art, vertical projections 142 on the reciprocating valve sleeve 144 (which largely defines the combustion chamber 46) engage ends 146 of the actuator element 140 and cause it to rock relative to the fuel cell door 18, thus exerting the periodic axial force on the stem receiver block 100, which in turn axially depresses the valve stem 64. Also shown in FIG. 2 is the pivoting nature of the stem receiver block 100, which is connected to a pivoting arm 148 connected to the cylinder head 40 at points 150. Once the tool 10 is pressed against a workpiece, the workpiece contact element 32 is retracted relative to the cylinder 24, ultimately causing the depression of the valve stem 64, releasing a dose of fuel into the combustion chamber 46 and a resulting combustion or firing of the tool 10.

(38) Referring now to FIGS. 7-14, an alternate embodiment of the adapter 80 is generally designated 160. Components of the adapter 160 shared with the adapter 80 are designated with identical reference numbers. A main difference between the adapters 80 and 160 is that the latter is provided with a flexible suspension for the collar 96. Instead of a solid connection rigidly supporting the collar 96 upon the flange 90, as seen in FIG. 5, the collar in the adapter 160 is suspended relative the flange 90. The suspension, generally designated 162, is defined by a plurality, and preferably four support arms 164, each connected at one end 166 to a ring 168 defined in the flange 90. The ring 168 defines a main opening 170. In one embodiment, the ring 168 projects generally vertically, or in the direction of the longitudinal axis of the fuel cell 60, relative to the flange 90. Other ring configurations are contemplated.

(39) As best seen in FIGS. 10 and 12, the collar 96 is located generally centrally in the main opening 170, and is connected to the flange 90 only through the support arms 164, which are each connected to the collar at an end 172 opposite the end 166. The arms 164 are generally “S”-shaped, relatively stiff, and are constructed to permit the collar 96 only a limited vertical travel generally no more than 0.020 inch, with small tolerances contemplated for this value. At the same time, the collar 96 is restricted to allow even less non-vertical movement, including pivoting, rotating or laterally relative to the orientation depicted in FIG. 13.

(40) This relatively stiff suspension is achieved by the arms 164 having a generally rectangular vertical cross-section, and including three main portions: a first or ring portion 174 projecting generally parallel to a diameter of the opening 170; a second or mid portion 176 being gently arcuate and generally following a curve of the generally cylindrical perimeter of the collar 96 in spaced orientation; and a third or collar portion 178 curving abruptly from the mid portion and contacting the collar in a direction generally parallel to a diameter of the collar.

(41) Referring now to FIG. 12, it will be seen that the ring portion 174 and the collar portion 178 are oriented at generally 90° from each other. Further, the arms 164 generally surround the collar 90, and the ring ends 166 of adjacent support arms 164a and 164b are closely adjacent each other, as are the ring ends 166 of adjacent support arms 164c and 164d. As a result, the collar 96 can be said to be suspended from mainly two, generally diametrically-opposed support points 180, 182. Also, the arms 164a, 164b are oriented to be mirror-images of arms 164c, 164d.

(42) Referring now to FIGS. 15 and 16, it will be seen that the present adapter 160 promotes positive, sliding engagement between the stem receiver block 100 and the valve stem 64. It has been found that the relatively stiff suspension 162, featuring the design incorporating limited vertical movement of the collar 96 relative to the flange 90, and even further restricted non-vertical movement, improves the efficiency of the actuation of the valve stem 64 for obtaining more consistent fuel delivery.

(43) While a particular embodiment of the present interface for a fuel delivery system for a combustion nailer has been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.