U.S. patent application number 11/473509 was filed with the patent office on 2006-11-09 for method of forming a stacked assembly of roofing caps.
This patent application is currently assigned to PneuTools, Incorporated. Invention is credited to Frederick W. Lamb.
Application Number | 20060251497 11/473509 |
Document ID | / |
Family ID | 33102604 |
Filed Date | 2006-11-09 |
United States Patent
Application |
20060251497 |
Kind Code |
A1 |
Lamb; Frederick W. |
November 9, 2006 |
Method of forming a stacked assembly of roofing caps
Abstract
A staple or nail gun assembly includes a staple or nail gun, a
cap feeding device and a cap having a peripheral rim disposed on
its underside, a marginal edge on its upper side adjacent a central
portion having the shape of a truncated cone. The staple or nail
gun and the cap feeding device are generally disposed at opposite
ends of the handle of the staple or nail gun. The cap feeding
device includes a base, a cap container and a shuttle, and feeds
caps sequentially as they are affixed by the gun. The caps are
coaxially stacked by means of a coaxial plastic cord or wire with
retaining means at the respective ends or in a tubular container
with a flanged end. The caps may also be stacked on a rod or held
together by melting.
Inventors: |
Lamb; Frederick W.;
(McCalla, AL) |
Correspondence
Address: |
Russell H. Walker;Walker, McKenzie & Walker, P.C.
Suite 434
6363 Poplar Avenue
Memphis
TN
38119-4896
US
|
Assignee: |
PneuTools, Incorporated
Memphis
TN
|
Family ID: |
33102604 |
Appl. No.: |
11/473509 |
Filed: |
June 22, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10823436 |
Apr 12, 2004 |
7090455 |
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11473509 |
Jun 22, 2006 |
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10435737 |
May 9, 2003 |
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10823436 |
Apr 12, 2004 |
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09648335 |
Aug 25, 2000 |
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10435737 |
May 9, 2003 |
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|
09438983 |
Nov 12, 1999 |
6302310 |
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09648335 |
Aug 25, 2000 |
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60150534 |
Aug 25, 1999 |
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60160672 |
Oct 21, 1999 |
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60108174 |
Nov 13, 1998 |
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Current U.S.
Class: |
411/531 |
Current CPC
Class: |
B25C 5/1693 20130101;
E04D 15/04 20130101; B25C 1/006 20130101; E04D 2015/045
20130101 |
Class at
Publication: |
411/531 |
International
Class: |
F16B 43/00 20060101
F16B043/00 |
Claims
1: A stacked assembly of roofing caps for use with a cap feeding
device and adapted for use with a fastener having an elongated
shank for securing a roof member to a roof deck, said assembly
comprising a plurality of coaxially stacked said roofing caps, each
said roofing cap having two opposite surfaces, said two opposite
surfaces being an upper surface and a lower surface, wherein each
said roofing cap has a centrally-disposed connecting stud extending
upwardly from said upper surface a distance of less than one-half
the thickness of said roofing cap between said upper and lower
surfaces, and said lower surface has disposed therein a
centrally-disposed complementary hole in said lower surface, said
connecting stud of one of said roofing caps being received in a
frictional fit within said complementary hole of another of said
roofing caps when said one of said roofing caps and said another of
said roofing caps are placed in coaxially stacked relation.
2: A stacked assembly of roofing caps for use with a cap feeding
device and adapted for use with a fastener having an elongated
shank for securing a roof member to a roof deck, said assembly
comprising a plurality of coaxially stacked said roofing caps, each
said roofing cap having two opposite surfaces; and at least one of
the surfaces of each roofing cap being removably glued to one of
said surfaces of another said roofing cap.
3: A stacked assembly of roofing caps for use with a cap feeding
device and adapted for use with a fastener having an elongated
shank for securing a roof member to a roof deck, said assembly
comprising a plurality of coaxially stacked said roofing caps, said
stacked assembly being disposed within a cylindrical tube having a
length at least as long as said stacked assembly, said roofing caps
being selectively retained within said cylindrical tube at one end
of said tube.
4: The stacked assembly as recited in claim 3, wherein said
cylindrical tube includes selectively-deformable inwardly-extending
flanges at said one end of said tube, said flanges being of a
length to secure said caps from exiting said tube at said one end
of said tube prior to an axial force being exerted on said stacked
assembly sufficient to deform said flanges in the direction of said
one end.
5: The stacked assembly as recited in claim 3, wherein said roofing
caps are selectively retained within said cylindrical tube at said
one end by an adhesive label thereat.
6: A stacked assembly of plastic roofing caps for use with a cap
feeding device and adapted for use with a fastener having an
elongated shank for securing a roof member to a roof deck, said
assembly comprising a plurality of coaxially stacked said plastic
roofing caps, wherein adjacent caps are joined together at a melted
outer circumferential portion thereof.
7: A stacked assembly of roofing caps for use with a cap feeding
device and adapted for use with a fastener having an elongated
shank for securing a roof member to a roof deck, said assembly
comprising a plurality of coaxially stacked said roofing caps
having two opposite surfaces, said two opposite surfaces being an
upper surface and a lower surface, each said roofing cap having a
centrally-located orifice extending therethrough from said upper
surface to said lower surface; said stacked assembly of roofing
caps including upper caps and further including a bottommost cap
whose centrally-located orifice has a smaller diameter relative to
that of said centrally-located orifices of said upper caps; said
stacked assembly of roofing caps including a rigid rod being
disposed through said centrally-located orifices of said roofing
caps, said rod having a tip of a larger diameter than said smaller
diameter of said centrally-located orifice of said bottommost cap
and said rod having a neck adjacent said tip and said neck having a
reduced diameter relative to said larger diameter of said tip, said
neck being received within said centrally-located orifice of said
bottommost cap.
8: A method of forming a coaxially-stacked assembly of a plurality
of plastic roofing caps for use with a cap feeding device and
adapted for use with a fastener having an elongated shank for
securing a roof member to a roof deck, wherein adjacent caps are
joined together at a melted outer circumferential portion thereof,
said method comprising the steps of: (a) providing a stacked
assembly of plastic roofing caps; (b) providing a heating means
selected from the group consisting of a flame, a laser, hot air,
and a heating element; and (c) using said heating means to heat
said stacked assembly of plastic roofing caps along a longitudinal
portion thereof such that adjacent caps become meltingly held
together at said melted outer circumferential portion thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of pending U.S.
Non-Provisional application Ser. No. 10/435,737 (filed May 9,
2003), also entitled "Stacked Assembly of Roofing Caps" and fully
included herein by reference, and claims priority benefit thereof
and of the parent applications of said application Ser. No.
10/435,737. Application Ser. No. 10/435,737, in turn, was a
division of pending U.S. Non-Provisional application Ser. No.
09/648,335 (filed Aug. 25, 2000), entitled "Staple or Nail Gun
Assembly, Cap Gun Feeding Device for Staple or Nail Gun, and Cap
Assembly" and fully included herein by reference, and claims
priority benefit thereof and of the parent applications of said
application Ser. No. 09/648,335. Application Ser. No. 09/648,335,
in turn, was a continuation-in-part of U.S. Non-Provisional
application Ser. No. 09/438,983 (filed Nov. 12, 1999), entitled
"Staple or Nail Gun Assembly, Cap Feeding Device for Staple or Nail
Gun, and Cap Assembly" and claimed priority benefit of said
application Ser. No. 09/438,983, which has now issued as U.S. Pat.
No. 6,302,310 (issued Oct. 16, 2001). Application Ser. No.
09/648,335 also claimed priority benefit of U.S. Provisional
Application 60/150,534 (filed Aug. 25, 1999), entitled "Stacked
Felt Caps for the Rapid Feeding Felt Cap Gun," and also claimed
priority benefit of U.S. Provisional Application 60/160,672 (filed
Oct. 21, 1999), entitled "Stacked Feltcaps Held Together with
Plastic Line or Wire or Tube." Application Ser. No. 09/438,983, in
turn, claimed priority of U.S. Provisional Application 60/108,174
(filed Nov. 13, 1998), entitled "Rapid Feeding Felt Cap Gun &
Felt Caps Glued Together."
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO COMPACT DISC(S)
[0003] Not applicable.
FIELD OF THE INVENTION
[0004] This invention relates to a cap feeding device for a staple
or nail gun, as well as a staple or nail gun assembly and a cap
assembly for use with a cap feeding device.
BACKGROUND OF THE INVENTION
[0005] Automatic nail guns, powered by compressed air or
electricity, are used, for example, to attach roofing material,
such as tarpaper, to the roof of a house. A generally flat cap is
often used with each nail. A nail penetrates the cap and the
tarpaper and protrudes into the underlying roof structure,
attaching the roofing material to the roof surface.
[0006] Typically, an operator must manually place and hold a cap
under the nose of a nail gun and then trigger the gun to drive a
nail through the cap into the roof structure. The manual placement
of caps presents a serious safety hazard to the operator because
the operator's hand is close to the nose of the gun when a nail is
driven through the nose of the gun. In addition, manual placement
of caps is time-consuming and inefficient.
[0007] A cap feeding device may be employed to reduce the risk
associated with manual placement of caps and to improve the
efficiency of roofing operation. The cap feeding device
automatically places a cap under the nose of a nail gun, and then
the nail gun drives a nail through the cap and into the underlying
roof structure.
[0008] A conventional cap feeding device generally includes a cap
container and a base having a channel. The base extends between the
cap container and a position under the nose of the nail gun. Caps
are fed into the channel of the base from the cap container and
pushed to the position under the nose of the nail gun. When the
gull is triggered, a nail penetrates and dislodges the cap under
the nose of the nail gun and protrudes into the underlying roof
structure. The feeding of the caps under the nose of the nail gun
is coordinated with the ejection of the nails through the nose of
the nail gun, so that a cap is placed under the nose of the gun
before the gun is triggered to expel a nail.
[0009] Conventional cap feeding devices have a number of drawbacks.
For example, conventional cap feeding devices are generally heavy,
putting additional stress on the operator's hand holding the nail
gun. Also, many conventional cap feeding devices can only be
installed close to the front end of a nail gun, making the nail gun
not only heavy but also unbalanced with most of the weight placed
at the front end of the gun. This makes the nail gun difficult to
handle and may put stress on the operator's hand and wrist. In
addition, with so many components placed near the nose of the gun,
it is difficult to see the position of the nose of the gun, making
a precise placement of a nail difficult.
[0010] The conventional cap feeding devices are installed close to
the front end of the gun because designers need to place a
conventional cap container close to the nose of the gun to reduce
the weight of the cap feeding device. The reason is that in many
devices a cap is pushed directly from the cap container to a
position under the nose of the nail gun. Thus, if the cap container
is far from the nose of the gun, a long shuttle is needed to push a
cap from the container to the position under the nose of the nail
gun through the channel of the base. In addition, an actuator, such
as an air cylinder, with a long displacement is also needed to
drive the shuttle. The displacement of the actuator should be about
the same as the distance between the cap container and the nose of
the nail gun. A long shuttle and actuator increase the weight and
size of the cap feeding device. With the cap feeding device placed
near the nose of the gun, the shuttle and actuator, thus the cap
feeding device can be made lighter, smaller and less expensive.
[0011] Caps for automatic nailing guns are available in a wide
variety of shapes and packaging. Most caps for felt roofing
products are sold in bulk and must be applied singularly with each
nailing operation. Automatic nailers for roofing including
magazines containing caps are available, however, for a variety
of-reasons, have not found wide usage. Most of the disadvantages of
nailers including magazines of roofing caps are related to the
unwieldiness of the apparatus, and somewhat to the lack of
reliability or uniformity of operation. Automatic nailing machines
adapted for installing roofing caps are illustrated in such as U.S.
Pat. No. 5,947,362 to Omli; U.S. Pat. Nos. 5,445,297; 5,184,752;
and 5,042,142. None of these prior automatic roofing nailers
provide the versatility and ease of usage, incorporate the use of
an inventive roofing cap or disclose a convenient packaging of
stacked caps which may be readily inserted into the magazine of an
automatic roofing nailer. Not only does the cap of the present
invention lend itself to convenient packaging, but it also provides
superior reliability in its ability to be routinely fed through the
magazine chamber of the nailing machine for reliable operation, but
the configuration which provides the fit, reliability and
stackability also provides a cap which delivers superior
performance in holding the material to be attached such as roofing
felt to the roof or siding materials.
SUMMARY OF THE INVENTION
[0012] This invention provides a compact, light-weight cap feeding
device that overcomes the problems associated with conventional
nail guns and cap feeding devices.
[0013] In accordance with one aspect of the invention, a device,
which is used to feed, staple or nail caps having a diameter,
includes a base, a container and a shuttle. The base includes cap
feeding and cap holding chambers, and a channel connecting the two
chambers. The distance between the cap feeding and cap holding
chambers is at least twice the diameter of the caps. The container
has a generally cylindrical configuration and is substantially
perpendicular to the base. The container is operatively associated
with the cap feeding chamber and is adapted to feed caps stored in
the container into the cap feeding chamber one cap at a time. The
shuttle is adapted to slide within the channel of the base and is
adapted to move a cap at the cap feeding chamber through the
channel towards the cap holding chamber by a distance equal to a
diameter of the cap.
[0014] In accordance with another aspect of the invention, a staple
or nail gun assembly includes a staple or nail gun and a cap
feeding device. The staple or nail gun has a head portion and a
handle portion. The head portion has an opening through which a
staple or nail is expelled. The handle portion has first and second
ends, the first end being attached to the head portion. The cap
feeding device includes a base, a container and a shuttle. The base
includes cap feeding and cap holding chambers, and a channel
connecting the two chambers. The distance between the cap feeding
and cap holding chambers is at least twice the diameter of the
caps. The container has a generally cylindrical configuration and
is substantially perpendicular to the base, facilitating the
transfer of caps from the container to the cap feeding chamber. The
container is operatively associated with the cap feeding chamber
and is adapted to feed caps stored in the container into the cap
feeding chamber one cap at a time. The shuttle is adapted to slide
within the channel of the base and is adapted to move a cap at the
cap feeding chamber through the channel towards the cap holding
chamber by a distance equal to a diameter of the cap.
[0015] In accordance with a further aspect of the invention, a cap
assembly for use with a cap feeding device includes a plurality of
concentrically stacked staple or nail caps. Each cap has two
opposite surfaces, and at least one of the surfaces of each cap is
attached to one of the surfaces of another cap.
[0016] The cap feeding device and the staple or nail gun assembly
of the present invention are compact and light-weight and thus have
a number of advantages over the prior art. The weight of a staple
or nail gun assembly in accordance to the present invention is
substantially balanced. The weight of the staple or nail gun is
mostly located at the front end of the gun handle, while the weight
of the cap feeding device, especially the weight of the cap
container, is mostly located at the rear end of the gun handle.
Further, although the cap container is not placed near the nose of
the gun, an actuator with a long displacement is not needed because
a cap is not pushed directly from the cap feeding chamber to the
cap holding chamber. The cap in the cap feeding chamber is pushed
by the shuttle towards the cap holding chamber by a distance equal
to the diameter of the cap (if the cap is circular). This cap
pushes the cap in front of it in the channel towards the cap
holding chamber by the same distance. The last cap is pushed into
the cap holding chamber, where a staple or nail penetrates the cap
in the cap holding chamber when the gun is triggered. In other
words, there are at least three caps in the channel of the base,
one at the cap feeding chamber, one at the middle position and one
at the cap holding chamber. Each time after the gun is triggered,
the caps are moved towards the cap holding chamber by a distance
equal to the diameter of the caps. In addition, because most of the
components of the cap feeding device are not located near the nose
of the gun, an operator is able to see the nose of the gun better,
allowing him to more precisely aim the nose of the gun.
[0017] Additional objects of the present invention are roofing caps
having a disk-like circular shape including a peripheral ridge on
the lower surface of the cap and a central portion being in the
shape of a truncated cone exhibiting a flat plateau in the central
portion of the truncated cone. Alternative embodiments of the cap
include a lateral peripheral rim on the upper surface of the cap
providing a complimentary surface for receiving the peripheral
ridge of the adjacent stacked cap.
[0018] In accordance with still further objectives of the present
invention are stacking means by which a plurality of caps may be
stacked in vertical relation and retained for inventory and
shipment and later inserted into the magazine of a nailing machine
with a minimum of effort. Alternative embodiments of such stacking
means include the caps having a hole centrally disposed in the
plateau whereby a plastic cord or wire may be strung through the
adjacent holes of stacked caps in which the lower portion of the
cord or wire is terminated by a releasable fixture and the upper
end may be terminated with such as a loop. Alternative means of
stacking caps within the invention include caps having disposed
thereon a retaining stud on the upper or lower surface of the cap
and the opposite surface having a complementary receiving hole
disposed therein. Additional alternative means of stacking caps
include a skewer rod through the caps or melting the caps together
in a stacked assembly. The inventive caps may similarly be retained
in stacks by means of an adhesive, such as a hot melt adhesive,
disposed between adjacent surfaces of stacked caps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of a staple or nail gun
assembly according to the present invention.
[0020] FIG. 2 is a side view of a cap container of the embodiment
shown in FIG. 1, where the cover is in the open position.
[0021] FIG. 3 is the side view of the cap container shown in FIG.
2, where the cover is in the closed position.
[0022] FIG. 4 is a rear view of the cap container shown in FIGS. 2
and 3.
[0023] FIG. 5 is a top view of a base, a shuttle and a
piston-cylinder arrangement of the embodiment shown in FIG. 1.
[0024] FIG. 6 is an exploded view of a mechanism for holding a cap
in the cap holding chamber of the base.
[0025] FIG. 7 is a top view of the shuttle shown in FIG. 5.
[0026] FIG. 8 is a schematic drawing of the system controlling the
movement of the shuttle.
[0027] FIG. 9a is a top view of a cap of the present invention.
[0028] FIG. 9b is a cross sectional drawing of the cap shown in
FIG. 9a.
[0029] FIG. 9c is a top view of an alternative embodiment of the
cap of the present invention.
[0030] FIG. 9d is a cross sectional drawing of the cap shown in
FIG. 9c.
[0031] FIG. 9e is a top view of an alternative embodiment of the
cap of the present invention.
[0032] FIG. 9f is a cross sectional drawing of the cap shown in
FIG. 9e.
[0033] FIG. 9g is a top view of an alternative embodiment of the
cap of the present invention.
[0034] FIG. 9h is a cross sectional drawing of the cap shown in
FIG. 9g.
[0035] FIG. 10 is an elevational view, partially in section of the
cap shown in FIG. 9f.
[0036] FIG. 11 is an elevational view, partially in section of the
cap shown in FIG. 9d installed on a roof deck.
[0037] FIG. 12 is a partial sectional elevational view of a stack
of caps being fed according to the present invention.
[0038] FIG. 13 is an elevational view of a stack of caps according
to the present invention.
[0039] FIG. 14 is an elevational view of an alternative embodiment
of a stack of caps according to the present invention.
[0040] FIG. 15 is an elevational view of an alternative embodiment
of a stack of caps according to the present invention.
[0041] FIG. 16 is a bottom view of the stack of caps shown in FIG.
15.
[0042] FIGS. 17-19 show a fourth alternative embodiment of
assembling a stack of caps according to the present invention.
[0043] FIG. 17 is a side and partial sectional view of the fourth
alternative embodiment.
[0044] FIG. 18 is an enlarged view of the tip of the retaining rod
of the fourth alternative embodiment.
[0045] FIG. 19 is an enlarged view of the fourth alternative
embodiment showing the piercing of the bottom cap by the tip of the
retaining rod.
[0046] FIGS. 20-24 show a fifth alternative embodiment of
assembling a stack of caps according to the present invention.
[0047] FIG. 20 is a front side view of a stack of caps assembled
according to the fifth alternative embodiment. The view from the
back side is substantially identical.
[0048] FIG. 21 is a top view of the stack of caps of FIG. 20, taken
substantially along the line 21-21 shown in FIG. 20.
[0049] FIG. 22 is an end view of the sled used in making the stack
of caps assembled according to the fifth alternative embodiment,
showing the lid of the sled being opened in dotted outline.
[0050] FIG. 23 is a top view of the sled used in making the stack
of caps assembled according to the fifth alternative embodiment,
showing the lid of the sled opened.
[0051] FIG. 24 is a front view of the sled of the fifth alternative
embodiment shown passing between the laser melting means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] FIGS. 1-8 illustrate one example of the staple or nail gun
assembly 10 of the present invention. The staple or nail gun
assembly 10 includes a staple or nail gun 20 and a cap feeding
device 40. The staple or nail gun 20 has a handle portion 22 and a
head portion 30. The handle portion 22 has front and rear ends 24,
26, the front end 24 being attached to the head portion 30. The cap
feeding device 40 includes a base 50, a cap container 60 and a
shuttle 80. The base 50 includes a cap feeding chamber 52 and a cap
holding chamber 54, and a channel 56 connecting the two chambers
52, 54. The container 60 is used to store staple or nail caps 140
and to feed the caps 140 to the cap feeding chamber 52 of the base
50 one cap at a time. The shuttle 80 is movably disposed in the
channel 56 of the base 50 and is adapted to move a cap at the cap
feeding chamber 52 towards the cap holding chamber 54 through the
channel 56.
[0053] In the preferred embodiment shown in FIG. 1, the staple or
nail gun 20 is an automatic nail gun powered by compressed air,
although any staple or nail gun can be used with an embodiment of
present invention, including a staple or nail gun powered, for
example, by electricity. The head portion 30 of the nail gun 20
includes a nose portion 32 and a barrel having an opening 34 at the
nose portion 32. The nail gun 20 may also include a nail container
36 connected to the head portion 30. The nail container 36 holds a
plurality of nails and feeds the nails into the barrel one nail at
a time. The head portion 30 may also include a piston-cylinder
arrangement, in which a piston is movably disposed in a cylinder
and divides the cylinder into first and second chambers. When the
nail gun 20 is triggered, compressed air is supplied to the first
chamber of the cylinder to push the piston towards the nail in the
barrel. The piston strikes the nail in the barrel to eject the nail
through the opening 34 at the nose portion 32. Then compressed air
can be supplied to the second chamber to return the piston to the
retracted position. Alternatively, the piston may be returned to
the retracted position with any alternative device such as a
spring. Because the head portion 30, which contains most of the
nail gun components, is disposed at the front end 24 of the handle
portion 22, the weight of the staple or nail gun 20 is mostly
placed at the front end 24 of the handle 22.
[0054] As stated above, the cap feeding device 40 includes a base
50, a cap container 60 and a shuttle 80. The base 50 has a cap
feeding chamber 52 and a cap holding chamber 54, and a channel 56
connecting the two chambers 52, 54. The container 60 is used to
store nail caps 140 and to feed the caps 140 to the cap feeding
chamber 52 of the base 50 one cap at a time. The shuttle 80 is
operatively associated with the channel 56 of the base 50 and
pushes a cap at the cap feeding chamber 52 towards the cap holding
chamber 54 through the channel 56.
[0055] As illustrated in FIGS. 2-4, the cap container 60 includes a
hollow tubular portion 62 having first and second open ends 64, 66,
and a cover 68 pivotably connected to the tubular portion 62 at the
first open end 64. The second open end 66 of the tubular portion 62
is aligned with the cap feeding chamber 52 of the base 50, and the
caps 140 in the container 60 are fed to the cap feeding chamber 52
through the second open end 66. In this embodiment, the tubular
portion 62 is attached to the base 50 with a plurality of bolts and
nuts. In the illustrated preferred embodiment, the tubular portion
62 is perpendicular to the base 50. The container 60 also includes
a plunger 70, which may be disposed in the tubular portion 62 or
disposed in the cover 68, and a spring 72, such as a ribbon spring
72 shown in FIGS. 2-4, pulling the plunger 70 towards the second
end 66 of the tubular portion 62. The spring force biases the
plunger 70 against the stack of caps 140 in the direction of the
second end 66 to ensure that the outermost cap at the second end 66
is disposed in the cap feeding chamber 52 of the base 50. In the
embodiment shown in FIGS. 2-4, the tubular portion 62 includes a
longitudinal slot 76 in its wall, and the plunger 70 disposed in
the tubular portion 62 includes a knob 78 extending to the exterior
of the tubular portion 62 through the longitudinal slot 76. The
cover 68 may also include a slot 82 aligned with the slot 76 of the
tubular portion 62 so that the plunger 70 can be lifted into the
cover 68 from the tubular portion 62 by pulling the knob 78 or a
handle 84 attached to the knob 78. When the plunger 70 is in the
cover 68, the cover 68 can be placed in the open position, as shown
in FIG. 2, and the spring force keeps the cover 68 in the open
position. After the cover 68 is placed in the open position, a
coaxial stack of caps 140 can be disposed in the tubular portion
62. Then the plunger 70 is put back in the tubular portion 62 and
the cover 68 is placed in the closed position, as shown in FIG.
3.
[0056] In a preferred embodiment shown in FIGS. 9a and 9b, the caps
140 each have two opposite surfaces 142, 144 with at least one
surface 142, 144 of each cap attached to a surface 142, 144 of
another cap. In a preferred embodiment, the cap is circular, with a
diameter of about 1 inch and a thickness of about 1/16 inch. The
caps 140 can be attached to one another in several ways. For
example, the caps 140 may be glued to each other, or they may be
attached by friction fit. Alternatively, the stack of caps may
include grooves on the opposite sides of the stack, and the caps
may be held together with a string, such as a wax or plastic
string, disposed on the grooves. A stack of caps 140 may include
any number of caps, for example, 100 caps. A stack of caps 140
attached to each other is easier to handle and to load into the cap
container 60.
[0057] The base 50 has a generally flat, elongated rectangular
configuration and is used to transport caps 140 from the cap
feeding chamber 52 to the cap holding chamber 54 under the nose 32
of the nail gun 20. The cap feeding and cap holding chambers 52, 54
are disposed respectively near the first and second ends 86, 88 of
the base 50. The distance between the cap feeding and cap holding
chambers 52, 54 is such that the cap feeding chamber 52 (and thus
the cap container 60) is near the rear end 26 of the handle portion
22, and the cap holding chamber 54 is under the nose 32 of the nail
gun 20. The cap feeding chamber 52 includes an indentation having a
configuration similar to that of the caps 140 for accommodating a
cap. In the illustrated embodiment, for example, the cap feeding
chamber 52 includes an indentation having a circular configuration
which is similar to the flat circular configuration of the caps
140. The cap holding chamber 54 has a generally circular through
hole having a configuration similar to that of caps 140.
[0058] A cap holding mechanism may be provided to hold a cap in the
cap holding chamber 54 and to allow a cap to go through the cap
holding chamber 54 when a nail is ejected through the nose 32 of
the nail gun 20 and strikes the cap. The cap holding mechanism 53
used in the illustrated embodiment is shown in FIG. 6. The cap
holding mechanism 53 includes a feeding pawl 58 and a spring 57.
The feeding pawl 58 and spring 57 are attached to the base 50 by a
bracket 55. The spring 57 presses the feeding pawl 58 against a
ledge 59 which extends from the bottom of the channel 56 into the
circular cap holding chamber 54. As a cap is pushed into the cap
holding chamber 54, the cap passes between the ledge 59 and the
feeding pawl 58. When the cap is placed in the cap holding chamber
54, the feeding pawl 58 presses the cap against the ledge 59 and
holds the cap in the cap holding chamber 54. When a nail is ejected
through the nose 32 of the nail gun 20 and strikes the cap, the
feeding pawl 58 releases the cap and allows the cap to go through
the cap holding chamber 54.
[0059] The channel 56 extends between the cap feeding chamber 52
and the cap holding chamber 54. At the cap feeding chamber 52, the
channel 56 extends beyond the cap feeding chamber 52 and intersects
the first end surface 86 of the base 50 to form an opening 90.
Preferably, the bottom surface of the cap feeding chamber 52 is
flush with the bottom surface of the channel 56 so that a cap
disposed in the cap feeding chamber 52 can be pushed into the
channel 56 towards the cap holding chamber 54. At the cap holding
chamber 54, the channel 56 does not extend beyond the cap holding
chamber 54 so that a cap can only be fed to the cap holding chamber
54 from the channel 56 but not beyond cap holding chamber 54. The
channel 56 has a cross section similar to the cross section of the
caps 140. For example, the channel 56 in the illustrated embodiment
has a rectangular cross section with its width similar to the
diameter of the caps 140 and with its height similar to the height
of the caps 140. In this way, only one cap can be pushed into the
channel 56 from the cap feeding chamber 52, and the channel 56 can
accommodate only one cap at any particular position.
[0060] As illustrated in FIGS. 4, 5, 7 and 8, the shuttle 80 has a
generally flat rectangular configuration. At least a portion of the
shuttle 80 is movably disposed in the channel 56 of the base 50
through the opening 90 of the channel 56. The rest of the shuttle
80 may be outside of the channel 56 or may also be disposed in the
channel 56. Preferably, the cross section of the shuttle 80 is
similar to or slightly smaller than that of the caps 140 and that
of the channel 56. Preferably, the cross section of the shuttle 80
is similar to or slightly smaller than that of the caps 140 and
that of the channel 56. In the illustrated embodiment, the first
end 92 of the shuttle 80 is outside of the channel 56 while the
second end of the shuttle 80 is disposed in the channel 56. The
shuttle 80 is movable within the channel 56 between a forward
position and a back position. At the forward position, the second
end 94 of the shuttle 80 is between the cap feeding chamber 52 and
the cap holding chamber 54. At the back position, the second end 94
is between the cap feeding chamber 52 and the opening 90 of the
channel 56. When the shuttle 80 moves from the back position to the
forward position, the second end 94 of the shuttle 80 pushes a cap
in the cap feeding chamber 52 towards the cap holding chamber 54 by
a distance substantially equal to the diameter of each of the caps
140. Preferably, the second end 94 of the shuttle 80 has a
semicircular configuration that conforms to the side surface of
each of the caps 140.
[0061] As shown in FIGS. 1, 5 and 8, a piston-cylinder arrangement
100, powered by compressed air, is connected to that portion of the
shuttle 80 outside of the channel 56 (or any portion of the shuttle
80) to move the shuttle 80 in the channel 56. Alternatively, any
linear or rotational actuator, such as an electric or hydraulic
motor, may be used to move the shuttle 80 in a desired manner.
Although not shown in the Figures, a shield or guard may be
provided to cover the moving piston and/or the first end 92 of the
shuttle 80 to protect the operator from injury. The cylinder 102
includes a forward chamber 104 and a back chamber 106, which are
separated by the piston 108. Compressed air can be supplied either
to the forward chamber 104 or to the back chamber 106 to move the
piston 108 within the cylinder 102. The supply of compressed air to
the chambers 104, 106 of the cylinder 102 is controlled by a
four-way, two-position valve 110, as shown in FIG. 8. Compressed
air can be supplied to the cylinder 102 from the nail gun 20 or
from another source.
[0062] The positioning of the valve 110, thus the movement of the
piston 108 and the shuttle 80, is coordinated with the relative
movement of the nail gun 20 and the cap feeding device 40. The nail
gun 20 and the cap feeding device 40 are pivotably attached to each
other at a joint 150. A spring 120 disposed between and connected
to the nail gun, 20 and the cap feeding device 40 normally biases
the cap feeding device 40 and the nail gun 20 against each other
and keeps the nose portion 32 of the nail gun 20 apart from the cap
holding chamber 54 of the base 50. When the base 50 is placed on a
roof surface and the nail gun 20 is pressed towards the base 50,
the spring 120 is compressed, allowing the nose portion 32 to be
positioned just above the cap holding chamber 54. In this position,
the nail gun 20 can be triggered to expel a nail through the
opening 34 of the nose 32.
[0063] The coordination between the movement of the shuttle 80 and
the relative movement between the nail gun 20 and the cap feeding
device 40 can be explained while referring to the schematic drawing
in FIG. 8. The four-way, two-position valve 110 includes an air
pressure port 112, an exhaust port 114, and forward and back ports
116, 118 connected respectively to the forward and back chambers
104, 106 of the cylinder 102. At the first valve position 130, the
pressure port 112 is connected to the back port 118, and the
exhaust port 114 is connected to the forward port 116. Compressed
air is supplied to the back chamber 106 of the cylinder 102, and
the forward chamber 104 is connected to the exhaust port 114. At
the second valve position 132, compressed air is supplied to the
forward chamber 104, and the back chamber 106 is connected to the
exhaust port 114. Normally, the nail gun 20 and the cap feeding
device 40 are kept apart by the spring 120, and the valve 110 is in
the first position. At this position, compressed air is supplied to
the back chamber 106, and the shuttle 80 is in the back position.
When the nail gun 20 is pressed towards the base 50 of the cap
feeding device 40, the spring 120 is compressed, and the spring 120
pushes the valve 110 into the second position 132. At this
position, compressed air is supplied to the forward chamber 104 and
the shuttle 80 is moved to the forward position.
[0064] The operation of the nail gun assembly 10, which includes
the cap feeding device 40, can be described while referring to
FIGS. 1-8. If the cap container 60 is empty at the beginning of the
operation, the plunger 70 can be lifted into the cover 68, and the
cover 68 can be placed in the open position. A stack of caps 140
attached to one another is disposed in the cap container 60. The
plunger 70 then is put back into the container 60, and the cover 68
is placed in the closed position. If there are no caps in the
channel 56 of the base 50 at this time, caps 140 can be fed into
the channel 56. To do so, the nail gun assembly 10 is placed on a
surface such as a roof surface, and the nail gun 20 is pressed
towards the base 50 to compress the spring 120. The spring 120 then
presses the valve 110 to put the valve 110 in the second valve
position, and compressed air is supplied to the forward chamber 104
of the cylinder 102 and pushes the piston 108 to the forward
position. The shuttle 80 is pushed to the forward position by the
piston 108, and the shuttle 80 pushes the cap in the cap feeding
chamber 52 towards the cap holding chamber 54 by a distance equal
to the diameter of one of the caps 140. When the nail gun assembly
10 is lifted off the roof surface, the spring 120 pushes the nail
gun 20 and the cap feeding device 40 apart, and the valve 110
returns to the first valve position. The shuttle 80 is moved back
to the back position and a cap is fed into the cap feeding chamber
52. This is repeated until the channel 56 is full of caps but a cap
is not yet fed into the cap holding chamber 54. While doing this,
the nail gun 20 need not be triggered to discharge a nail each time
a cap is advanced in the channel 56. After a cap is loaded into the
cap holding chamber 54, the nail gun assembly 10 is ready for use.
The nail gun assembly 10 can then be placed on a piece of roof
material, such as a piece of tarpaper, placed over a roof surface.
The nail gun 20 is pressed towards the base 50. The shuttle 80
moves to the forward position and pushes the cap in the cap feeding
chamber 52 towards the cap holding chamber 54 by a distance equal
to the diameter of the cap 140. Also, the cap next to the cap
holding chamber 54 is pushed into the cap holding chamber 54. Then,
the nail gun 20 is triggered to eject a nail through the opening 34
on the nose 32. The nail penetrates the cap in the cap holding
chamber 54 and the tarpaper, and protrudes into the roof structure.
The tarpaper is attached to the roof surface by the nail with a cap
disposed between the tarpaper and the head of the nail. When the
nail gun assembly 10 is lifted off the roof surface, the shuttle 80
moves back to the back position, and a cap is fed into the cap
feeding chamber 52. Then, the nail gun assembly 10 is again ready
for use.
[0065] Referring now to FIGS. 9a through 9h, the preferred
embodiments of caps 140 are illustrated. As illustrated in FIGS.
2-4, caps 140 are stored in cap container 60 to be singularly
forwarded by cap feeding device 40 for installation. Caps according
to the present invention have a configuration which facilitates the
separation of an individual cap 140 from a stack and the feeding
through the cap feeding mechanism 40 to ensure uniform supply of
caps 140 and reliable operation of staple gun 20. Upper surface 142
of cap 140 includes a margin 146 disposed around the periphery of
cap 140. Inwardly of margin 146 is a conical section 148 which
slopes upwardly from the rim toward a top plateau 151 of the cap
140 at angle .alpha. of preferably about 20 degrees from the
horizontal plane of cap 140, although angles of from about 10
degrees to about 30 degrees are operable. The periphery of cap 140
is defined by a side wall 154 and a bottom wall 156. Internally of
bottom wall 156 is interior vertical wall 158 which terminates at a
conical section 160 forming generally the undersurface of cap 140,
conical section 160 proceeds centrally to a bottom plateau 162
essentially parallel to top plateau 151 forming the remainder of
the interior relatively concave surface of washer 140. In the
illustrated embodiment of FIGS. 9c and 9d, a hole 164 is centrally
located between top plateau 151 and bottom plateau 162. The
function of hole 164 will be subsequently described. Walls 154, 156
and 158 define a peripheral rim 168 being a circular band, the
function of which will be subsequently described.
[0066] Roofing washer 140 illustrated in varying preferred
embodiments in FIGS. 9a through 9h is specially adapted to be
loaded into a magazine 60 for a roof nailing machine as is
illustrated in the present invention. The inventive washer embodies
several features which facilitate its being prepackaged in a stack
of a convenient number, such as 100 caps for loading in such as
magazine 60 to be singly fed through cap feeding device 40 in a
reliable sequential manner providing the user of staple or nail gun
assembly 10 an uninterrupted supply of caps 140 so long as there
remain caps in magazine 60. Special features of cap 140 which
enable the exemplary service of the present invention are the lower
peripheral rim 168 which is formed by side wall 154, bottom wall
156 and interior wall 158. Peripheral rim 168 provides stability to
a stack of caps 140 such as illustrated in FIG. 3 and facilitates
the individual feeding of the caps 140 by shuttle 80 as illustrated
generally in FIGS. 3-6 and additionally subsequently described. As
previously stated, caps 140 are preferably about one inch in
diameter and exhibit a general thickness of approximately 1/16th
inch and composed of a plastic material well known in the art for
such purposes. However, the vertical extent of cap 140 with the
domed and rimed construction stands approximately 1/8 inch above
baseline B to top line T, because of the downwardly extending rim
168 and the conical dome formed by conical section 148 and top
plateau 151. Upper surface 142 of cap 140 is composed of margin 146
which extends horizontally from side wall 154 toward the center of
cap 140, a distance preferably at least twice the thickness of rim
168, which in the illustrated embodiment is approximately 1/16 inch
in thickness. Margin 146 provides the resting surface for a cap
stacked immediately above it as is illustrated in FIG. 10.
Accordingly, margin 146 extends roughly 1/8th inch radially
inwardly of side wall 154 to form a junction 147 and meets conical
surface 148. As is illustrated in FIG. 9d, conical surface 148
extends upwardly to top plateau 151 which describes a circular area
of approximately 3/8 inch in diameter thereby forming a truncated
cone. Correspondingly, the lower cap surface is preferably defined
by conical section 160 which extends upwardly and inwardly from
side wall 158 to a generally circular bottom plateau. In the
illustrated embodiment, the diameter of bottom plateau 162 is
approximately 7/16th inch. In the embodiment illustrated, it should
be noted that the relative thickness of cap 140 adjacent junction
147 is less than elsewhere in cap 140.
[0067] FIG. 10 illustrates the relationship of adjacent caps when
stacked illustrating that upon stacking, bottom rim 168'' of upper
cap 140'' provides spacing from the lower cap 140' such that the
top plateau of bottom cap 140' is disposed adjacent and touching
the bottom plateau 162'' of upper cap 140 as the rim 168'' of cap
140'' rests firmly on the margin 146' of lower cap 140'. In such
arrangement, the stack of caps 140 provide a stable vertical
orientation so as to be conveniently packaged in a vertical stack
of caps of a convenient number such as 100, the packaging of such a
stack of caps being subsequently described.
[0068] FIG. 11 illustrates the superior holding capacity of cap 140
when disposed on a roof surface 170 holding a layer of felt roofing
paper 172 by means of nail 174. It will be seen that the entry of
nail into the roof surface 170 draws the top and bottom plateaus of
cap 140 downwardly toward roof surface 170 such that bottom plateau
162 engages roof felt 172 holding it firmly against roof surface
170. Concurrently as the general conical surfaces 148 and 160 are
drawn downwardly by nail 174, the peripheral rim 168 also engages
roofing felt 172 firmly because of the resilient nature of cap
material 140. Accordingly, with cap 140 in position as illustrated
in FIG. 11, a secure holding of roofing felt 172 is accomplished on
the roof surface 170. Cap 140 and nail may also be utilized to
secure other building materials such as polyethylene or Styrofoam
sheeting.
[0069] Referring now to FIG. 12, the function of the cooperating
surfaces of cap 140 as a cap is urged off of the bottom of the
stack of caps 140 by shuttle 80 will now be explained. As shuttle
80 advances as indicated in the arrows, it feeds cap 140' laterally
such that the rim 168'' of the cap 140'' immediately above cap 140'
slides along margin 146'. As may be seen in FIG. 12, the stack of
caps 140 being contained within the tubular member 62 of container
60, rim 168' of cap 140' clears the extent of tubular member 62 in
a lateral direction before the rim 168'' of cap 140'' reaches the
innermost extent of margin 146'. The relative dimensions of the
various mentioned structural features of caps 140 enable the cap
140' being fed to clear the tubular member 62 in respect of rim
168' before rim 168'' slides up in the upper conical section 148'
during the feeding process. By allowing leading edge of cap 140' to
clear tubular member 62 prior to the stack of remaining caps 140
within tube 62 having to accommodate the upper conical section 148,
a smooth feeding transition and sliding of the remaining caps
through the upper cap 140'' is accomplished. This combination of
relative movement of rim 168 on margin 146 and the conical surfaces
148 avoids disjointed surfaces to enable the reliable consistent
feeding of caps 140 by shuttle 80.
[0070] Because of the various previously mentioned surface features
of caps 140 enable a smooth, consistent, reliable feeding of a
bottom cap in a stack through a feeding shuttle 80 as illustrated,
caps may be conveniently stacked through several inventive means.
Cap 140 illustrated in FIG. 9c containing hole 164 may be stacked
and bound in a convenient package by such as a line or wire
traversing the stack of caps 140 as illustrated in FIGS. 13 and 14.
In FIG. 13 caps 140 are held together with a thermoplastic cord 180
such as is utilized in plastic rotary lawn trimmers, i.e., of the
type sold under the trademark "Weed Eater" owned by Aktiebolaget
Electrolux. A plastic cord of a thickness of 0.050 to 0.065 inches
in thickness are conveniently utilized. Such plastic cord is
available in hardware suppliers in such sizes. A suitable length of
plastic cord 180 is fed through the stack of caps 140 to a degree
where it exits the bottom of the stack of caps 140. A knob or knot
of material may be formed as at 182 at the lower reach of the stack
of caps 140 to retain the caps on the plastic cord. Preferably the
cord may be touched as with a hot iron to melt the thermoplastic
cord 180 to form an enlarged portion or knob as at 182, the
enlarged portion having a diameter slightly larger than hole 164.
The stack of caps are thus securely retained on cord 180. The cord
may be conveniently terminated at the top of its extent by a
convenient loop 184 as illustrated in FIG. 13. The loop again may
be formed as by tying or melting of the thermoplastic cord, as at
region 186 as illustrated. When the caps are thus installed into
container 60 of nailing machine 10, the cap is directed into tube
62 and the top of the caps are pressed lightly off of the cord 180
into or towards the bottom of tube 62 which is then closed as
described previously.
[0071] FIG. 14 describes an alternative similar embodiment wherein
the stack of caps 140 are held together with a metal wire in a
manner similar to plastic cord in FIG. 13. The wire is fed through
the hole 164 of the stack tack of caps until it exists the bottom
cap of stack of caps 140. A retainer may conveniently be formed at
the bottom end of wire 190, may be terminated as at 192 by creasing
the metal wire into such as a triangular shape as illustrated. Caps
140 are thus securely retained on wire 190 until such time as
inserted into tubular member 62 in a manner as previously
described. Wire 190 is conveniently terminated at the upper portion
of the stack as by twisting or tying the wire forming a loop
194.
[0072] A third alternative of assembling a stack of caps is
illustrated in FIGS. 15 and 16 by means of a cylindrical plastic
tube 200 having a diameter just slightly larger than the diameter
of caps 140. Tube 200 is terminated at its lower end with such as
flanges 202 to catch and retain caps 140 when inserted and stacked
into tube 200. The upper end of tube 200 may be terminated with a
handle 204 such as illustrated or alternatively by a circular
flange or the like similar to that illustrated in the lower portion
of FIGS. 15 and 16, or in continuous circular flange. For added
security, an adhesive label may be added over the top portion of
tube 200 to ensure retention of the caps therein. On insertion of
tube 200 into tube 62, tube 200 is withdrawn while maintaining
pressure with stack of caps 140 such that flanges 202 are deformed
to release caps 140.
[0073] FIGS. 9e and 9f and FIG. 10 illustrate an alternative style
of cap which may be stacked and retained in a stack without
independent means as illustrated in FIGS. 13 through 16. Cap 140 in
FIGS. 9e and 9f include a small stud 210 disposed on the top
plateau 151 of cap 140. Stud 210 is centrally located on the top
plateau 151 and in the illustrated embodiment is approximately 0.04
inches in diameter and extends upwardly from top plateau 151 in an
amount approximately 0.40 inches. Bottom plateau 162 is adapted
with a cooperating hole 212 into which stud 210 will be received
when caps 140 are assembled in stacked relationship. Hole 212 in
the illustrated embodiment is of a diameter slightly smaller than
stud 210 being approximately 0.035 inches in diameter and the hole
extends slightly greater depth than the height of stud 210 which in
the illustrated embodiment is approximately 0.045 inches. Those
skilled in the art will appreciate that the thickness and height of
the described studs and cooperating hole may be varied in dimension
without departing from the scope and spirit of the invention.
Likewise, rather than a single centrally located stud and hole,
other patterns might be selected with similarly suitable results
such as offset pairs of triangularly or other locations about the
center of top plateau 151.
[0074] FIGS. 9g and 9h illustrate further embodiment of caps 140
wherein the region between top plateau 151 and bottom plateau 162
is solid. Stacks of caps 140 may be formed in stacked relationship
with such as the illustrated cap by means of a nominal amount of
adhesive such as a drop of hot melt adhesive placed on the top or
bottom plateau during a stacking operation whereby once the
adhesive has cooled, the caps are retained in stacked relation.
Other adhesives may likewise be employed with the limiting factor
being that the sheer strength of the adhesive when applied to the
caps shouldn't exceed the material strength of the caps such that
the top plateau 151 and bottom plateau 162 are sheared or otherwise
disfigured during the feeding operation. Deterioration of the top
plateau 151 could result in irregular feeding of the caps.
[0075] FIGS. 17-19 show a fourth alternative embodiment of
assembling a stack of caps according to the present invention. A
rigid retaining rod 220 or skewer passes axially through the caps
140, 140a, which are preferably like those shown in FIGS. 9c and
9d, heretofore discussed in detail. Caps 140 have a first diameter
axial hole 160 similarly-sized as the axial diameter of rod 220 so
that rod 220 can be slid through the aligned axial holes 160 of the
stacked caps 140. The tip 222 of rod 220 has a reduced-diameter
neck 224 that is frictionally received into the reduced-diameter
axial hole 160' of the bottom-most cap 140a as the tip 222, having
a larger diameter than reduced-diameter neck 224, is piercingly
inserted through the reduced-diameter hole 160' of the bottom-most
cap 140a. The resilience of bottom-most cap 140a causes the
bottom-most cap 140a to be retained about the reduced-diameter neck
224 of rod 220 as the hole 160' constricts about neck 224 after tip
222 has passed therethrough, thereby holding the stack of caps 140,
140a on the rod 220 until they are to be used.
[0076] Rod 220 further has a grasping loop portion 226. To use this
fourth alternative embodiment, the stacked assembly of caps is
lowered into the feeding tower or container of a cap gun. The user
then grasps the portion 226 while holding the stacked assembly of
caps within the cap gun as by using a finger or thumb, and the user
then pulls the rod 220 from the stacked assembly of caps, thereby
causing the tip 222 and reduced-diameter neck 224 to become
disengaged from bottom cap 140a as the entire rod is withdrawn from
the stacked assembly of caps, which are left in the gun for
subsequent dispensing and nailing by the gun.
[0077] The use of a rigid retaining rod 220 as shown in FIGS. 17-19
has an advantage over the use of thermoplastic cord as disclosed
for the embodiment of FIG. 13, namely, that it is much easier to
feed a rigid rod down through the caps during manufacture of the
stacked assembly of caps than it is to feed a thermoplastic cord
through the stacked assembly, thereby permitting faster assembly of
the stacked caps. Additionally, during loading of the cap gun, the
rigid rod holds the stacked assembly of caps more perfectly axially
aligned because of the rigidity of rod 220 as compared to the
flexibility of thermoplastic cord, thereby facilitating the gun
loading process and reducing loading time. If desired, the
reduced-diameter neck 224 may be formed by cutting a
circumferential groove around the end of rod 220 adjacent the
pointed tip 222.
[0078] FIGS. 20-24 show a fifth alternative embodiment of
assembling a stack of caps according to the present invention. In
this embodiment, the stacked assembly of caps 140 are held together
by adjacent caps 140 being melted together at one or more places.
Preferably the caps are melted together as by heating means such as
a flame, a laser, hot air, or a heating element such as a soldering
iron, preferably by having one or more melted portions 230 that run
longitudinally along the circumferences of the stacked caps 140.
The caps 140, being made of plastic material, melt when heated
along melted portions 230, thereby causing adjacent caps 140 to be
meltingly held together.
[0079] To create this stacked assembly of caps 140, the caps are
preferably stacked within a sled 232 having a hinged lid 234 that
opens for loading as shown in FIG. 23 and as shown in dotted
outline in FIG. 22, with a well-known hinge 236 allowing hinged
movement of lid 234 with respect to sled 232. Longitudinal openings
238, 240 in the sled 232 and/or lid 234 expose portions of the caps
140 to be melted to each other. A latch or hook 242 on the sled 232
engages with a well-known conveyor or chain 244 that transports the
sled 232 carrying the caps 140 past upper and lower lasers 246, 248
during manufacture. Lasers 246, 248 respectively shine through
openings 240, 238 and respectively create melted portions 230 on
the stacked caps 140 within the sled 232.
[0080] The stacked assembly of caps 140 is thus retained together
by the melted portions 230 and can be easily loaded into the
feeding tower or container of a cap gun. As the gun dispenses each
bottom-most cap, as by a reciprocating shuttle or the like, the
plastic material of the melted portion holding the bottommost cap
to the adjacent cap above will become broken, and the bottommost
cap will become separated from the stacked assembly of caps and
will be dispensed.
[0081] An advantage of this embodiment is that the stacked assembly
of caps can be easily removed as a unit from the feeding tower or
container of the cap gun if the gun becomes jammed, so as to permit
unjamming of the gun with subsequent reloading of the remaining
caps of the stacked assembly. Other prior art solutions and other
embodiments do not have this advantage that the caps remain held
together in a stacked assembly when removed from the cap gun. A
further advantage of this embodiment is that no rod or
thermoplastic cord or string is required to hold the stacked
assembly of caps together.
[0082] Various modifications may be made with respect to caps 140
and the stack retaining mechanisms without departing from the scope
and spirit of the invention which is defined by means of the
appendant claims. It is therefore to be understood that within the
scope of the appendant claims the present invention may be
practiced otherwise than as specifically described herein.
* * * * *