Note: Descriptions are shown in the official language in which they were submitted.
CA 02759114 2011-11-25
PAPER TOOL CONSTRUCTION
BACKGROUND
[0001] This application is a divisional of Canadian Patent Application No.
2,746,472 filed on
December 20, 2007.
10001a] The present invention relates to paper tools and, more particularly,
to constructions of
paper tools for reduced force input requirements.
[0002] Staplers are commonly used to impart a staple through one or more
sheets to bind the
sheets together. Typically, a stapler includes a base, a magazine pivotally
mounted to the base,
and a drive arm including a driver that can force a staple from the magazine
through the sheets.
The drive arm is pivotally mounted to either the magazine or the base and is
usually directly
engaged by a user to drive the staple. Other paper tools, such as punches and
trimmers/cutters,
can include similar components constructed in a similar manner to staplers.
SUMMARY
[0003] In one embodiment, the invention provides a paper tool including a base
having a
front end and a rear end and a drive arm pivotally coupled to the base about a
first pivot axis.
The drive arm includes a front portion proximate the front end of the base and
a rear portion
proximate the rear end of the base. The paper tool also includes a handle
pivotally coupled to the
base and a drive member supported by the handle rearwardly of the first pivot
axis such that,
when the handle pivots relative to the base, the drive member engages the rear
portion of the
drive arm to pivot the drive arm about a first pivot axis.
[0004] In some embodiments, the paper tool can be a stapler including a
magazine pivotally
coupled to the base and a driver coupled to the drive arm. The driver is
operable to drive a staple
from the magazine.
[0005] In other embodiments, the paper tool can be a punch including a punch
pin coupled to
the drive arm. The punch pin is operable to punch a sheet.
[0006] In further embodiments, the paper tool can be a trimmer including a
cutting blade
coupled to the drive arm. The cutting blade is operable to cut a sheet.
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[0007] Other aspects of the invention will become apparent by consideration of
the detailed
description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Fig. I is a perspective view of a stapler embodying the present
invention.
[0009] Fig. 2 is a side view of the stapler of Fig. I shown without a housing
assembly and in
a rest or raised static position.
[0010] Fig. 3 is an exploded rear perspective view of the stapler of Fig. 1.
[0011] Fig. 4A is a cross-sectional view of the stapler of Fig. 1 shown in the
rest position.
[0012] Fig. 4B is a cross-sectional view of the stapler of Fig. 1 shown in a
stapling or
lowered operating position.
[0013] Fig. 4C is a cross-sectional view of the stapler of Fig. 1 shown in an
open position.
[0014] Fig. 5 is a perspective view of a slider for use with the stapler shown
in Fig. 1.
[0015] Fig. 6 is a perspective view of a hole punch according to a second
embodiment of the
invention.
[0016] Fig. 7 is a side view of a paper cutter according to a third embodiment
of the
invention.
[0017] Fig. 8 is a perspective view of a stapler according to a fourth
embodiment of the
invention.
[0018] Fig. 9 is an exploded perspective view of the stapler of Fig. 8.
DETAILED DESCRIPTION
[0019]
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[00201 Although references are made below to direction, such as "top,"
"bottom," "front,"
"rear," "upper," "lower," or the like, the references are made relative to the
drawings (as
normally viewed) for convenience. These directions are not intended to be
taken literally or to
limit the present invention in any form.
[00211 Fig. I illustrates a paper tool 10 embodying the present invention. In
the illustrated
embodiment, the paper tool 10 is a stapler operable to bind (i.e., staple) two
or more sheets of
paper or other material. In other embodiments, the paper tool may be, for
example, a hole punch
(Fig. 6) operable to punch a hole in one or more sheets of paper, a paper
cutter (Fig. 7) operable
to cut one or more sheets of paper, or the like. In some embodiments, the
stapler 10 may be a
heavy duty stapler operable to staple up to about sixty sheets of paper.
[00221 As shown in Figs. 1-4C, the illustrated stapler 10 includes a base 14,
a magazine 18, a
case 20, a drive arm 22, a handle 26, and a housing assembly 30. The
illustrated base 14
includes a front end 34, a rear end 38, two flanges 42 extending upwardly from
the rear end 38,
and an anvil 46 configured to engage and bend a staple. Each flange 42
includes two apertures
50, 54 (Fig. 3) and is positioned adjacent to one side of the magazine 18 and
the drive arm 22.
An upper surface 58 of each flange 42, or hip, includes a notch 62 to provide
clearance for a
drive member 66, as further discussed below. The first apertures 50 receive a
first pin 70
defining a first pivot axis 74 to pivotally couple the magazine 18 and the
drive arm 22 to the base
14. The second apertures 54 receive a second pin 78 defining a second pivot
axis 82 to pivotally
couple the handle 26 to the base 14. As shown in Figs. 3 and 4A, the second
pin 78 is disposed
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rearwardly of the first pin 70 (i.e., closer to the rear end 38 of the base
14), but at substantially
the same height, or elevation, as the first pin 70. In some embodiments, the
second pin 78 may
be positioned at a different height than the first pin 70.
[0023] In the illustrated embodiment, each flange 42 also includes a generally
square
window 86 (Fig. 2) configured to receive a magazine pin 90. The illustrated
magazine pin 90
moves within the windows 86 and limits the pivoting range of the magazine 18
relative to (e.g.,
away from) the base 14.
[0024] The illustrated magazine 18 is pivotally coupled to the base 14 about
the first pivot
axis 74 by the first pin 70. As shown in Figs. 4A-4C, the magazine 18 is
biased away from the
base 14 by a biasing member 92. In the illustrated embodiment, the biasing
member 92 is a coil
spring, although other suitable biasing members may also be employed.
[0025] The illustrated magazine 18 defines a chamber 94 configured to retain
staples and
includes two downwardly extending tabs 98. The illustrated tabs 98 correspond
to the windows
86 in the flanges 42 of the base 14 and support the magazine pin 90. A slot
102 at the front of
the magazine 18 is configured to pass a staple out of the chamber 94.
[0026] In the illustrated embodiment, the magazine 18 also includes an
elongated opening
106 on each sidewall 110 of the magazine 18. The openings 106 receive
corresponding
protrusions 114, or detents, of the case 20 to limit the pivotal movement of
the case 20 and the
drive arm 22 away from the magazine 18. However, the illustrated protrusions
114 extend only
partially into the openings 106 such that the protrusions 114 may be manually
released out of the
openings 106 to open the case 20 and the drive arm 22 relative to the magazine
18, facilitating
refilling of the chamber 94 with staples.
[0027] The illustrated case 20 is also pivotally coupled to the base 14 by the
first pin 70. As
shown in Figs. 2 and 4A, the case 20 is partially received within the magazine
18 to help define
the chamber 94. The case 20 includes two shoulders 115 (Fig. 3) that engage an
upper surface of
the magazine 18 to pivot the magazine 18 about the first pivot axis 74 toward
the base 14 when
the case 20 pivots toward the base 14.
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[00281 As shown in Figs. 4A-4C, a pusher assembly 116 is supported between the
magazine
18 and the case 20 in the chamber 94. The illustrated pusher assembly 116
includes a slide
member 117 and a biasing member (e.g., a coil spring) (not shown). The biasing
member is not
shown in the figures to help clarify other portions of the stapler 10. The
biasing member is
coupled between a rear portion of the case 20, wraps around a boss 119
extending from the case
20 into the chamber 94, and couples to the slide member 117. When the case 20
is closed
relative to the magazine 18 (as shown in Figs. 4A and 4B), the biasing member
pulls the slide
member 117 to bias the staples toward the slot 102. When the case 20 is opened
relative to the
magazine 18 (as shown in Fig. 4C), the biasing member pulls the slide member
117 away from
the slot 102.
[0029] In the illustrated embodiment, the drive arm 22 is pivotally coupled to
the base 14 and
the magazine 18 about the first pivot axis 74 by the first pin 70 and includes
a driver 120 (Figs.
4A-4C) coupled to a front portion 122 of the drive arm 22. In other
embodiments, the drive arm
22 may be coupled to the base 14 about a different pivot axis. A biasing
member 123 (e.g., a coil
spring) is coupled to a seat 124 formed on the case 20 to bias the drive arm
22, and thereby the
handle 26, away from the case 20 and the magazine 18. When the drive arm 22 is
pivoted
downwardly, as shown in Fig. 4B, the illustrated driver 120 is operable to
force (i.e., drive or
push) a staple from the chamber 94 of the magazine through the slot 102 toward
the anvil 46.
When the drive arm 22 is pivoted upwardly, as shown in Fig. 4C, flanges 125
(Fig. 3) on the
drive member 120 engage the shoulders 115 of the case 20 to pivot the case 20
to the open
position relative to the magazine 18.
[00301 The illustrated drive arm 22 also includes a generally T-shaped slot
126 formed in
each rear portion 130, or wing, of the drive arm 22. The slots 126 provide
clearance to allow the
drive member 66 and the second pin 78 to move relative to the drive arm 22
when the handle 26
is pivoted. As shown in Fig. 3, a generally linear portion 134 of each T-
shaped slot 126 allows
lateral movement of the drive member 66 relative to the drive arm 22, while an
arcuate portion
138 of each slot 126 allows the drive arm 22 to open relative to the magazine
18 (as shown in
Fig. 4C). In the illustrated embodiment, the linear portion 134 and the
arcuate portion 138 are in
communication to form a single slot. In other embodiments, the linear portion
134 and the
arcuate portion 138 may be formed as two separate slots.
CA 02759114 2011-11-25
[00311 The illustrated handle 26 is pivotally coupled to the base 14 about the
second pivot
axis 82 by the second pin 78. As shown in Fig. 3, the handle 26 includes two
flanges 142
extending downwardly from a rear portion 146 of the handle 26. The illustrated
flanges 142
generally correspond to the upwardly extending flanges 42 of the base 14 and
are positioned to
the outside of the upwardly extending flanges 42. In the illustrated
embodiment, each flange 142
of the handle 26 includes two apertures 150, 154. The first apertures 150
receive the second pin
78 to pivotally couple the handle 26 to the base 14, while the second
apertures 154 receive and
support the drive member 66. As shown in Figs. 3 and 4A, the drive member 66
is disposed
rearwardly of and substantially higher than (i.e., further from the base 14)
the first pin 70 and the
second pin 78 when in the rest, or static, position. As a front portion 158 of
the handle 26 pivots
downwardly about the second pivot axis 82, the handle 26 lifts the drive
member 66 away from
the base 14 such that the drive member 66 engages and exerts an upward force
on a lower
surface 162 of the drive arm 22, pivoting the drive arm 22 about the first
pivot axis 74. In other
embodiments, the drive member 66 may exert an upward force on a upper surface
of each slot
126.
[00321 As shown in Figs. I and 4A-4C, the illustrated housing assembly 30
includes a lower
housing portion 166 substantially surrounding the base 14 and an upper housing
portion 170
substantially surrounding the handle 26. The illustrated upper housing 170 is
fixed to the handle
26 with fasteners 171 (e.g., screws, rivets, or the like) for movement with
the handle 26. In the
illustrated embodiment, the upper housing portion 170 receives a portion of
the lower housing
portion 166 such that the upper housing portion 170 is pivotally coupled to
the lower housing
portion 166. As such, when the handle 26 pivots relative to the base 14, the
upper housing
portion 170 pivots in a similar manner relative to the lower housing portion
166. The illustrated
housing assembly 30 increases the aesthetic appearance of the stapler 10 in
addition to providing
contours for improved gripping of the stapler 10 during operation. The slight
additional length
provided by the housing assembly 30 accommodates the drive member 66 rearward
of the pins
70, 78.
[00331 Referring to Figs. 4A-4C, the lower housing portion 166 includes a rear
flange 172
that extends upwardly from the lower housing portion 166. When the handle 26
is pivoted about
the second pivot axis 82 toward the base 14 (as shown in Fig. 4B), the rear
flange 172 helps bias
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the handle 26 away from the base 14. When the handle 26, and thereby the drive
arm 22 and the
case 20, is pivoted about the second pivot axis 82 away from the base 14 (as
shown in Fig. 4C),
the rear flange 172 engages the drive arm 22 to limit the pivoting range of
the drive arm 22 and
the case 20.
[00341 In the illustrated embodiment, the drive member 66 includes a shaft 173
and a roller
174 surrounding a portion of the shaft 173. When the roller 174 contacts the
lower surface 162
of the drive arm 22, the roller 174 rotates relative to the shaft 173 to roll
along the lower surface
162. In some embodiments, an alternative drive member 66' may include a slider
178 (Fig. 5)
that surrounds a portion of the shaft 173 and slides along the lower surface
162. In such
embodiments, the slider 178 may be made from or covered with a low friction
material. In other
embodiments, the drive member 66, 66' may be split into two pieces, or tabs,
that extend
downwardly from the handle 26 to engage the lower surface 162 of the drive arm
22, but do not
extend entirely across the lower surface 162. Additionally or alternatively,
in some
embodiments, the drive member 66, 66' may be integrally formed as a single
piece with the
handle 26.
[00351 Referring to Fig. 4A, the distal end of the front portion 122 of the
drive arm 22 is
spaced a first distance A from the first pivot axis 74 and a longitudinal axis
182 of the drive
member 66 is spaced a second distance B from the first pivot axis 74. In
addition, the first pivot
axis 74 is spaced a third distance C from a bottom surface of the base 14 and
the longitudinal
axis 182 of the drive member 66 is spaced a fourth distance D from the bottom
surface of the
base 14. In the illustrated embodiment, the first distance A is greater than
the second distance B,
and the fourth distance D is greater than the third distance C. In other
embodiments, the first
distance A and the fourth distance D may be greater than the second distance B
and the third
distance C, respectively, by a greater or lesser amount than that illustrated.
Furthermore, the first
pivot axis 74 is spaced a fifth distance E from the second pivot axis 82 and
is spaced a sixth
distance F from the longitudinal axis 182. In some embodiments, a ratio of the
fifth distance E to
the sixth distance F is between about 0.35 and about 0.55. In the illustrated
embodiment, the
ratio is approximately 0.47.
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(00361 As shown in Figs. 4A and 4B, the front portion 122 of the drive arm 22
(e.g., a point
approximately above the driver 120 when the stapler 10 is in an actuated, or
operating, position)
moves a first pivot distance relative to the base 14 (i.e., from a first
distance G, to a second
distance G2) as the drive arm 22 pivots about the first pivot axis 74 from the
rest position to the
stapling position, and the front portion 158 of the handle 26 moves a second
pivot distance
relative to the base 14 (i.e., from a first distance H1 to a second distance
H2) as the handle 26
pivots about the second pivot axis 82 from the rest position to the stapling
position. In some
embodiments, the ratio of the second pivot distance to the first pivot
distance (i.e., the ratio of the
handle travel to the driver travel) is between about 1.5 and about 2.3. In the
illustrated
embodiment, the first pivot distance is about 15 millimeters (mm), the second
pivot distance is
about 29 mm, and the ratio is about 1.9.
[00371 As shown in Fig. 4A, the magazine 18 is spaced an opening distance 0
from the base
14 when the stapler 10 is in a rest position. In such an arrangement, each of
the first and second
pivot distances includes an active travel comppnent and a free travel
component. When the
handle 26 is pivoted from the rest position about the second pivot axis 82
relative to the base 14,
the magazine 18, the drive arm 22, and the driver 120 pivot together about the
first pivot axis 74
until the magazine 18 contacts two or more sheets S (Fig. 4B) positioned on
the base 14 (i.e., the
free travel component). As such, in the illustrated embodiment, the free
travel component is
approximately equal to the opening distance 0 minus the height of the sheets
S. After the
magazine 18 contacts the sheets S, the handle 26 continues to pivot about the
second pivot axis
82, thereby pivoting the drive arm 22 and the driver 120 about the first pivot
axis 74 relative to
the magazine 18 (i.e., the active travel component). In some embodiments, the
ratio of the active
travel component of the handle 26 to the active travel component of the drive
arm 22 or driver
120 is between about 1.7 and about 2.5. In the illustrated embodiment, the
ratio is about 2.1.
[00381 The illustrated arrangement creates a "see-saw" type movement of the
drive arm 22 to
drive a staple from the magazine 18. When an operator presses the upper
housing portion 170
toward the base 14 against the bias of the rear flange 172, the handle 26 is
pivoted about the
second pivot axis 82 (e.g., from a rest position shown in Fig. 4A to an
operating position shown
in Fig. 4B) such that the front portion 154 of the handle 26 is pivoted toward
the base 14 and the
rear portion 146 of the handle 26, and thereby the drive member 66, is pivoted
away from the
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base 14. As the drive member 66 pivots away from the base 14, the drive member
66 exerts an
upward force on the lower surface 162 of the drive arm 22, pivoting the rear
portion 130 of the
drive arm 22 away from the base 14 and the front portion 122 of the drive arm
22, and thereby
the driver 120, toward the base 14 about the first pivot axis 74.
[00391 Initially, as the front portion 122 of the drive arm 22 pivots toward
the base 14, the
biasing member 123 exerts a force on the case 20 to pivot the case 20 and the
magazine 18 about
the first pivot axis 74 against the bias of the biasing member 92. Once the
magazine 18 contacts
two or more sheets S positioned on the base 14 (as shown in Fig. 4B), the
magazine 18 and the
case 20 stop pivoting relative to the base 14, but the handle 22 begins to
pivot relative to the
magazine 18 and the case 20 against the bias of the biasing member 123. When
the handle 22
pivots relative to the magazine 18 and the case 20, the driver 120 passes
through the chamber 94
of the magazine 18 and pushes a staple through the slot 102 in the magazine 18
toward the anvil
46, binding the sheets S clamped between the base 14 and the magazine 18.
After this stapling
operation, the operator releases the pressure on the upper housing portion
170, allowing the
biasing members 92, 123 and the rear flange 172 to return the stapler 10 to
the rest position
shown in Fig. 4A.
[00401 Fig. 6 illustrates a paper tool 210 according to another embodiment of
the invention.
The illustrated paper tool 210 is similar to the paper tool 10 shown in Figs.
1-4, and like parts
have been given the same reference numbers plus 200.
[00411 In the illustrated embodiment, the paper tool 210 is a one-hole punch.
The illustrated
punch 210 includes a punch pin 384 coupled to the front portion of a punch
housing 386 to
punch a hole in one or more sheets of paper. In other embodiments, the hole
punch 210 may
include fewer or more punch pins (e.g., a two-hole punch, a three-hole punch,
etc.) to
simultaneously punch more holes in the sheets. A biasing member 388 (e.g., a
coil spring)
surrounds a portion of the punch pin 384 within the punch housing 386 to bias
the punch pin 384
away from the base 214.
100421 When the upper housing portion 370 is pivoted toward the base 214, the
front portion
322 of the drive arm 222 is pivoted toward the base 214 by lifting the lower
surface of the drive
arm 222 with the drive member (not shown). The front portion 322 thereby
engages the punch
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pin 384 to push the punch pin 384 against the bias of the biasing member 388
toward the base
214, punching a hole in the sheets.
[0043] Fig. 7 illustrates a paper tool 410 according to still another
embodiment of the
invention. The illustrated paper tool 410 is similar to the paper tool 10
shown in Figs. 1-4, and
like parts have been given the same reference numbers plus 400.
[0044] In the illustrated embodiment, the paper tool 410 is a paper cutter or
trimmer. The
illustrated paper cutter 410 includes a blade 592 coupled to the drive arm 422
to cut one or more
sheets of paper. When the front portion 558 of the handle 426 is pivoted
toward the base 414,
the drive member 466 engages the lower surface (not shown) of the drive arm
422 to pivot the
drive arm 422, and thereby the blade 592, about the second pivot pin 478
toward the base 414,
cutting the sheets.
[0045] Figs. 8 and 9 illustrate a paper tool 610 according to yet another
embodiment of the
invention. The illustrated paper tool 610 is similar to the paper tool 10
shown in Figs. 1-4, and
like parts have been given the same reference numbers plus 600.
[0046] In the illustrated embodiment, the paper tool 610 is a stapler. The
illustrated stapler
610 includes a flat clinch mechanism 788 to engage and bend a staple. However,
it should be
readily apparent to one skilled in the art that in other embodiments the
stapler 610 may include a
stationary anvil to bend a staple. In addition, the stapler 610 includes a
release lever 790 to
facilitate refilling of the magazine 618 with staples. The illustrated release
lever 790 is
actuatable against a biasing member 794 to unlock an inner portion 798 of the
magazine 618,
allowing the inner portion 798 to slide forward relative to an outer portion
802 and be refilled
with staples. In the illustrated embodiments, a biasing member (not shown)
biases the inner
portion 798 forward when the release lever 790 is actuated.
[0047] The magazine 618 and the drive arm 622 are pivotally coupled to the
base 614 about
the first pivot axis 674 by the first pin 670. As shown in Fig. 9, the first
pin 670 includes a
spacer 806 adjacent to each end of the first pin 670 to maintain proper
spacing between the drive
arm 622 and the flanges 642, or hips, of the base 614. The illustrated drive
arm 622 includes a
generally horizontal slot 810 formed in each rear portion 730 of the drive arm
622, similar to the
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generally linear portions 134 of the T-shaped slots 126 discussed above with
reference to Fig. 3.
The horizontal slots 810 provide clearance to allow the drive member 666 to
move laterally
relative to the drive arm 622 when the handle 626 is pivoted.
[00481 The handle 626 is pivotally coupled to the base 614 about the second
pivot axis 682
by the second pin 678. In the illustrated embodiment, the second pin 678 is
split into two pin
portions 678A, 678B such that the second pin 678 does not extend through the
magazine 618 or
the drive arm 622, allowing the pin portions 678A, 678B to translate relative
to the magazine 618
and the drive arm 622. The illustrated handle 626 supports the drive member
666 such that, as
the front portion 758 of the handle 626 pivots downwardly about the second
pivot axis 682, the
handle 626 lifts the drive member 666 away from the base 614. Similar to the
drive member 66
discussed above with reference to Figs. 3 and 4A, the drive member 666 engages
and exerts
upward force on the lower surface 762 of the drive arm 622 to pivot the drive
arm 622 about the
first axis 674.
(00491 As shown in Fig. 8, the first pivot axis 674 is spaced a fifth distance
E' from the
second pivot axis 682 and is spaced a sixth distance F' from the longitudinal
axis 782 of the
drive member 666. In some embodiments, the ratio of the fifth distance E' to
the sixth distance
F' is between about 0.45 and 0.65. In the illustrated embodiment, the ratio is
approximately
0.55.
[00501 Similar to the stapler 10 discussed above with reference to Figs. 4A
and 4B, the front
portion 722 of the drive arm 622 may move a first pivot distance relative to
the base 614 (i.e.,
from a first distance G1' to a second distance) as the drive arm 622 pivots
about the first pivot
axis 674 from the rest position to the stapling position, and the front
portion 758 of the handle
626 may move a second pivot distance relative to the base 614 (i.e., from the
a first distance H1'
to a second distance) as the handle 626 pivots about the second pivot axis 682
from the rest
position to the stapling position. In some embodiments, the ratio of the
second pivot distance to
the first pivot distance (i.e., the ratio of the handle travel to the driver
travel) is between about 2.0
and about 4Ø In the illustrated embodiment, the first pivot distance is
about 29 mm, the second
pivot distance is about 85 mm, and the ratio is about 3Ø
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[0051] As shown in Fig. 8, similar to the magazine 18 discussed above, the
magazine 618 is
spaced an opening distance 0' from the base 614 when the stapler 610 is in a
rest position.
Accordingly, each of the first and second pivot distances includes an active
travel component
and a free travel component. In some embodiments, the ratio of the active
travel component of
the handle 626 to the active travel component of the drive arm 622 or driver
720 is between
about 2.8 and about 3.6. In the illustrated embodiment, the ratio is about
3.2.
[0052] In operation, the stapler 610 functions similar to the stapler 10
discussed above.
When an operator presses the front portion 758 of the handle 626 toward the
base 614, the handle
626 is pivoted about the second pivot axis 682 such that the rear portion 746
of the handle 626,
and thereby the drive member 666, is pivoted away from the base 614. As the
drive member 666
pivots away from the base 614, the drive member 666 exerts an upward force on
the lower
surface 762 of the drive arm 622, pivoting the rear portion 730 of the drive
arm 622 away from
the base 614 and the front portion 722 of the drive arm 622, and thereby the
driver 720, toward
the base 614. In the illustrated embodiment, when the driver 720 pushes a
staple out of the
magazine 618 toward the base 614, the staple is bent with the flat clinch
mechanism 788, rather
than by a stationary anvil.
[00531 Various features and advantages of the invention are set forth in the
following claims.
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