Note: Descriptions are shown in the official language in which they were submitted.
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STAPLE TOOL
TECHNICAL FIELD
This disclosure relates tools for driving staples into a workpiece and in
particular,
staples of the type that comprise barbs that may provide increased retention
in a workpiece.
The disclosure also relates to methods of driving staples into a workpiece and
to staple
assemblies.
BACKGROUND
1 0 Traditionally, staples have been used to attach items to workpieces
(e.g. rural posts,
wire livestock fences, power poles etc.). Often, such staples are hand driven
into the
workpiece using a manual tool.
Power tools for driving staples into a workpiece are also known in the art.
These
generally comprise a driver blade for driving the staple into the workpiece
and a nosepiece
1 5 comprising a passage to guide the staple as it is driven into the
workpiece. These power tools
can also comprise a magazine which is able to hold an arrangement of collated
staples that
may be fed into the firing chamber of the nosepiece.
Barbed staples, which comprise barbs extending from the legs of the staples,
are also
known in the art. The barbs on the staples can allow stronger retainment (i.e.
when compared
2 0 to traditional non-barbed staples) of the staple in a workpiece.
The barbs on such staples meant that they are not suitable for power tools
known in
the art that are configured for use with non-barbed staples. As such, only
manual (i.e. hand
driven) tools are presently used for such staples.
The above references to the background art do not constitute an admission that
the art
25 forms part of the common general knowledge of a person of ordinary skill
in the art. The
above references are also not intended to limit the application of the staple
tool as disclosed
herein.
2
SUMMARY
Disclosed is a tool for driving a barbed staple into a workpiece, the tool
includes a
housing enclosing a power delivery source and a driver blade driven by the
power delivery
=source and comprising an engagement portion configured for engagement with
the staple.
The tool further includes a nosepiece comprising an aperture providing access
for loading a
staple into the nosepiece and a passage configured for slidable mounting of
the driver blade.
In use, the driver blade may be driven along a longitudinal axis of the
passage by the power
delivery source to engage and drive a staple into a workpiece. The nosepiece
further
comprises at least one space configured to provide clearance in the passage
for a barb of the
staple when driven by the driver blade.
Also disclosed is a tool for driving a barbed staple into a workpiece, the
tool includes
a housing enclosing a power delivery source and a driver blade driven by the
power delivery
source and comprising an engagement portion configured for engagement with the
staple.
The tool further includes a nosepiece comprising an aperture providing access
for loading a
staple into the nosepiece and a passage for slidable mounting of the driver
blade. In use, the
driver blade may be driven along a longitudinal axis of the passage by the
power delivery
source to engage and drive a staple into a workpiece. The engagement portion
of the driver
blade is configured to provide lateral support to the staple as it is driven
along the longitudinal
axis of the passage.
In a broad aspect, the invention pertains to a tool for driving a barbed
staple into a
workpiece, the barbed staple including a crown, two legs extending from the
crown, and a
barb extending outwardly from each leg such that a width of the barbed staple
is greater than
a width of the crown. The tool comprises a housing enclosing a power delivery
source, a
driver blade drivable by the power delivery source and comprising an
engagement portion
configured for engagement with the barbed staple, and a nosepiece defining an
aperture
providing access for loading the barbed staple into the nosepiece. The
aperture includes two
opposing lateral passages arranged to provide clearance for the outwardly
extending barbs on
the respective legs of the barbed staple. The nosepiece further defines a
passage in which the
driver blade is slidably mounted such that, in use, the driver blade is
drivable along a
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=
2a
longitudinal axis of the passage by the power delivery source, to engage and
drive the barbed
staple into the workpiece. The nosepiece defines two spaced-apart
longitudinally extending
channels sized to enable passage for the barbs of the barbed staple when the
barbed staple is
driven by the driver blade.
In a further aspect, the invention provides a tool for driving a barbed staple
into a
workpiece, the barbed staple including a crown, two legs extending from the
crown, and a
barb extending outwardly from each leg such that a width of the barbed staple
is greater than
a width of the crown. The tool comprises a housing enclosing a power delivery
source, a
driver blade drivable by the power delivery source and comprising an
engagement portion
configured for engagement with the barbed staple, and a nosepiece defining an
aperture
providing access for loading the barbed staple into the nosepiece further
defining a passage in
which the driver blade is slidably mounted such that, in use, the driver blade
is drivable along
a longitudinal axis of the passage by the power delivery source, to engage and
drive the
barbed staple into the workpiece. The nosepiece defines two spaced-apart
longitudinally
extending channels sized to enable passage for the barbs of the barbed staple
when the barbed
staple is driven by the driver blade, the channels extending from the aperture
to a workpiece
contact element slidably mounted on the nosepiece.
Still further, the invention embodies a tool for driving a barbed staple into
a
workpiece, the tool comprising a housing enclosing a power delivery source. A
driver blade
is drivable by the power delivery source and comprises an engagement portion
configured for
engagement with the barbed staple. A nosepiece defines an aperture providing
access for
loading the barbed staple into the nosepiece. The nosepiece further defines a
passage in
which the driver blade is slidably mounted such that, in use, the driver blade
is drivable along
a longitudinal axis of the passage by the power deliver source, to engage and
drive the barbed
staple into the workpiece. The driver blade comprises a ridge formed along a
longitudinal
axis of the driver blade, the ridge being slidably engaged with a
corresponding recess defined
in the nosepiece. The ridge is configured to resist lateral movement of the
driver blade with
respect to the longitudinal axis of the passage. The engagement portion of the
driver blade
includes opposing ends, and a portion between and recessed relative to the
ends such that the
engagement portion can provide lateral support to the barbed staple as it is
driven along the
longitudinal axis of the passage.
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2b
Embodiments will now be described by way of example only, with reference to
the
accompanying drawings in which
Figs. la and lb are side views of an embodiment of a powered staple tool;
Fig. 2 is a section view of a nosepiece assembly of the tool of Figs. 1 and
lb;
Figs. 3a and 3b are a front and side view respectively of a driver assembly of
the
tool of Figs. la and lb; and
Fig. 4 is a perspective view of an assembly of collated staples that may be
suitable for
use with an embodiment of the tool.
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DETAILED DESCRIPTION
In the following detailed description, reference is made to accompanying
drawings
which form a part of the detailed description. The illustrative embodiments
described in the
detailed description, depicted in the drawings and defined in the claims, are
not intended to
be limiting. Other embodiments may be utilised and other changes may be made
without
departing from the spirit or scope of the subject matter presented. It will be
readily
understood that the aspects of the present disclosure, as generally described
herein and
illustrated in the drawings can be arranged, substituted, combined, separated
and designed in
a wide variety of different configurations, all of which are contemplated in
this disclosure.
Disclosed is a tool for driving a barbed staple into a workpiece, the tool
comprising: a
housing enclosing a power delivery source; a driver blade driven by the power
delivery
source and comprising an engagement portion configured for engagement with the
staple; a
nosepiece comprising an aperture providing access for loading a staple into
the nosepiece, the
nosepiece further comprising a passage configured for slidable mounting of the
driver blade;
such that, in use, the driver blade may be driven along a longitudinal axis of
the passage by
the power delivery source to engage and drive a staple into a workpiece;
wherein, the
nosepiece further comprises at least one space configured to provide clearance
in the passage
for a barb of the staple when driven by the driver blade.
In some forms, the nosepiece comprises two opposing spaces, the spaces being
configured to provide clearance for outwardly facing barbs on respective legs
of the staple.
In some forms, the nosepiece comprises at least one lateral passage arranged
to
provide clearance for a barb of the staple when the staple is being loaded
into the nosepiece.
In some forms, the nosepiece comprises two opposing lateral passages arranged
to provide
clearance for outwardly facing barbs on respective legs of the staple.
In some forms, the at least one space is in the form of a channel that extends
from the
at least one lateral passage to a distal end of the nosepiece.
In some forms, the nosepiece includes wall portions that define a proximal
portion of
the passage and which are arranged to be in facing relation with an upper
portion of
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respective legs of the staple so as to assist in maintaining correct alignment
of the staple in
the nosepiece.
In some forms, the engagement portion of the driver blade is configured to
provide
lateral support to the staple as it is driven along the longitudinal axis of
the passage.
Also disclosed is a tool for driving a barbed staple into a workpiece, the
tool
comprising: a housing enclosing a power delivery source; a driver blade driven
by the power
delivery source and comprising an engagement portion configured for engagement
with the
staple; a nosepiece comprising an aperture providing access for loading a
staple into the
nosepiece, the nosepiece further comprising a passage configured for slidable
mounting of
the driver blade; such that, in use, the driver blade may be driven along a
longitudinal axis of
the passage by the power delivery source to engage and drive a staple into a
workpiece;
wherein the engagement portion of the driver blade is configured to provide
lateral support to
the staple as it is driven along the longitudinal axis of the passage.
In some forms, the engagement portion of the driver blade is formed such that
its
profile conforms to the crown of the staple.
In some forms, the driver blade further comprises a guide element configured
to resist
lateral movement of the driver blade with respect to the longitudinal axis of
the passage.
In some forms, the guide element is a ridge formed along the longitudinal axis
of the
driver blade, the ridge configured for slidable engagement with a
corresponding recess in the
nosepiece.
In some forms, a workpiece contact element slidably mounted on the nosepiece
and
configured to retract upon the tool being pressed against a workpiece.
In some forms, the workpiece contact element comprises a groove, the groove
aligned
such that, in use, when the staple is driven into the workpiece, the legs the
staple will be
located either side of the groove.
In some forms, the groove is configured for receipt of a fence wire.
In some forms, the power delivery source is pneumatically powered. In an
alternative
form, the power delivery source is powered by a gas fuel cell. The power
delivery source
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may be in other forms, such as electrically driven for example a cordless
battery powered
tool.
In some forms, the tool further comprises a staple supply mechanism for
supplying
staples into the nosepiece through the aperture.
In some forms, the staple supply mechanism is arranged to receive a plurality
of
collated staples. In some forms, the inside crown of the staples rest and
slide along a
magazine rail into the nose.
In some forms, the staple supply mechanism comprises a guard arranged to
protect a
user from contact with the barbs of the staples stored therein.
1 0 Also disclosed is a system for driving a barbed staple into a
workpiece, the system
comprising: a plurality of staples, each staple comprising a crown having two
legs extending
therefrom, at least one of the staples comprising a barb; and a tool according
to any form
described above, the tool being arranged to receive individual ones of the
plurality of staples
into the nosepiece through the aperture to be driven into the workpiece under
movement of
the driver blade.
In some forms, the plurality of staples is collated when stored in a staple
supply
mechanism of the tool.
In some forms, the staple assembly comprises at least one strip of collation
tape
secured to the legs of the staples
2 0 In some forms, the at least one strip of collation tape is secured at a
location on at
least one leg of respective ones of the staples between the crowns and barb of
the staple.
In some forms, the at least one strip of collation tape is frangible such that
upon
driving of a staple by the driver blade, the at least one strip of collation
tape is broken and the
staple separated from the remaining collated staples.
In some forms, the at least one strip of collation tape is broken during
driving of the
staple, a portion of the at least one strip of collation tape remains on the
staple.
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In some forms, the portion of the at least one strip of collation tape
inhibits lateral
movement of the staple with respect to the longitudinal axis of the passage,
when the staple is
driven along the passage.
Also disclosed is an assembly of staples, the staples comprising a crown
portion
having at least two legs extending therefrom and one or more barbs protruding
from at least
one of the legs, the assembly further comprising at least one strip of
collation tape, wherein
the staples are collated and connected by way of the at least one strip of
collation tape
secured to the staples.
In some forms, the at least one strip of collation tape is secured to legs of
the staples
at a location between the respective crowns and the one or more barbs of the
staples.
In some forms, each of the legs of the plurality of staples includes one or
more barbs
which project outwardly from the legs.
In some forms, the barbs may have a flat, square or round tip.
Also disclosed is a barbed staple comprising: a crown; two legs extending from
the
crown; and one or more barbs protruding from the legs; wherein the staple
further comprises
at least one guiding element secured to at least one of the legs at a location
between the
respective barb of the leg and the crown.
In some forms, the at least one guiding element is a portion of collation
tape.
Also disclosed is a method of driving a barbed staple into a workpiece, the
method
comprising: locating a barbed staple in a nosepiece of a powered tool; and
driving the staple
along a longitudinal axis of the nosepiece and into the workpiece under
operation of a driver
blade of the powered tool; wherein an engagement portion of the driver blade
is configured to
provide lateral support to the staple as it is driven along the longitudinal
axis of the
nosepiece.
Also disclosed is a method of driving a barbed staple into a workpiece, the
method
comprising: locating a barbed staple in a nosepiece of a powered tool, the
barbed staple being
in the form having a crown; two legs extending from the crown; and one or more
barbs
protruding from the legs; wherein the staple further comprises at least one
guiding element
secured to at least one of the legs at a location between the respective barb
of the leg and the
7
crown.; and driving the staple along a longitudinal axis of the nosepiece and
into the
workpiece under operation of a driver blade of the powered tool; wherein the
guiding element
inhibits lateral movement of the staple with respect to the longitudinal axis
when it is being
driven..
When compared to manual methods, the use of a power tool for driving a staple
into a
workpiece (e.g. a post, bench, wall etc.) can be both quicker and easier. This
can be
especially true with regards to barbed staples, which can offer more
resistance against
insertion into a workpiece. Moreover, a power tool may provide greater
precision and control
over the placement and depth of a staple in a workpicce. For example, a power
tool may
provide the precision required when driving a staple across a fence wire in
order to avoid
damage to the fence wire. Additionally, use of a power tool instead of a
manual method
reduces the manual labour required by a user, which may in turn reduce
repetitive strain
injuries and operator fatigue.
To accommodate for the barbs in the staple legs, adequate clearances need to
be
provided in the nosepiece of the tool for both loading and passage of the
staple through the
nosepiece. These clearances increase the likelihood that the staple may twist
or move
laterally in the nosepiece which may result in jamming of the staple in the
nosepiece. To
compensate for this, the tool may include arrangements to maintain the staple
alignment.
These may include modification of the engagement portion of the driver blade
to laterally
support the staple, including a guide arrangement for maintain alignment of
the driver blade
and maintaining close support of the staple in the proximal portion of the
nosepiece, and
using guiding elements on the legs of the staples to assist in maintaining
this close support.
Figs. la and lb show an embodiment of a tool 10 for driving a barbed staple
into a
workpiece. The tool 10 comprises a housing 12 containing a power delivery
source (not
shown). In the illustrated form, the tool is pneumatic (i.e. powered
pneumatically). In other
embodiments the tool may be, for example, gas powered. A person of ordinary
skill in the art
would understand that other means for powering a tool would also be suitable.
The tool 10 further comprises a nosepiece assembly 14 extending from a lower
end of
the housing 12. A staple supply assembly, in the form of a magazine 16,
extends laterally
from the nosepiece assembly 14. Fig. la shows the magazine 16 holding staples
18, 'while in
Fig. la, the magazine 16 is empty. The magazine 16 supplies collated staples
18 to a loading
chamber of the nosepiece assembly 14. In the illustrated form of Fig. lb, the
staples 18 arc
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collated by way of collation tape 20. In other forms, the staples 18 may be
collated by way of
adhesive, or alternatively may not be collated (i.e. they may be provided
individually).
A hand grip 22 extends from the housing 12 and is configured such that a user
may
comfortably handle the tool 10. Adjacent the hand grip 22 is a trigger 24,
which when
pressed, activates the power delivery source such that a staple (loaded in the
nosepiece
assembly 14) may be driven into a workpiece by the tool 10. As a safety
measure a lower
workpiece contact 48 disposed at a distal end of the nosepiece assembly 14 may
need to be
retracted to allow activation of the power delivery source.
Referring to Fig. 2, a section of the nosepiece assembly 14 is shown. The
nosepiece
assembly 14 comprises a nosepiece 26 having a passage 28 along which a driver
blade 30 is
arranged to travel. In Fig. 2, a staple 18 is located partway down the passage
28 in the
nosepiece 26 and is in contact with the driver blade 30 which is designed to
push the staple
through the nosepiece passage 28.
The tool further comprises a power delivery source (not shown) that is
arranged to
drive the driver blade 30 down the passage 28 (i.e. towards the distal end of
the nosepiece 26
that is located at the workpiece). The driver blade 30 (which is described in
more detail
below with reference to Fig. 3A and 3B) comprises an engagement portion 32
that engages
the crown 34 of a staple 18 that has been loaded into the passage 28, to drive
the staple 18
down the passage 28. In this way, the staple 18 may be driven into and secured
in a
workpiece.
The staple 18 comprises barbs 40 extending outwardly from the staple legs 42,
thereby increasing the overall width of the staple 18. The barbs 40 of the
staple 18 as shown
comprise a truncated point such that the tips of the barbs 40 are flat (i.e.
square) so that they
are less likely to come in contact, or sustain damage from contact, with the
nosepiece when
the staple 18 is driven in the passage 28.
Typically the staple 18 comprises a hot dip galvanization coating, which may
provide
the staple 18 with rust resistance. A person of ordinary skill in the art
would understand that
other, or additional, coating or treatment may be applied to the staple such
as e.g. electro-
galvanization, heat treatment, phosphate etc.
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The staple 18 further comprises tape 44 attached to each of its legs 42. The
thickness
of the tape 44 may be such that it assists in positioning and/or guiding the
staple in the
nosepiece as will be explained in more detail below.
The tape 44 may, for example, be a portion of collation tape that remains on
the staple
when it is broken away from a collated staple arrangement. Such a collated
arrangement is
shown in Fig. 4. In this way, the tape would be 'dual purpose', in that it
would first provide
for collating the assembly of staples, and secondly provide stability of a
staple 18 in the
passage 28 when driven by forming a wadding barrier. The tape may
alternatively be applied
individually to the staple (i.e. such that it is not a portion of collation
tape applied to an
assembly of collated staples). In one form the tape 44 may be formed of paper,
however a
person of ordinary skill in the art would understand that the tape may be
formed of other
suitable materials such as plastic. In addition, the collation tape may
protect the staple leg and
wire coating and barb from damage.
In the illustrated form the collated staple arrangement is loaded in the
magazine 16
and supplies staples 18 to the loading chamber of the nosepiece 26 via an
access aperture in
the nosepiece 26. The aperture comprises means to provide access for the barbs
40 of the
staple 18. In the illustrated form, the means is in the form of lateral
passages 46, which
provide clearance for the barbs 40 on the staples 18 when loaded from the
magazine 16.
Furthermore to allow for passage of the staple 18 through the nosepiece 26,
clearance spaces
.. in the form of channels 38 are provided along the walls defining the
passage 28. These
channels extend from the lateral passages 46 to the distal end of the
nosepiece 26.
The workpiece contact element 48, in the form of a foot, is located at the
lower end of
the nosepiece 26. The foot 48 is configured to retract, in use, as it contacts
the workpiece.
That is, the foot 48 will retract back up the nosepiece 26 when a user pushes
the end of the
tool 10 against a workpiece in order to allow the power delivery source of the
tool 10 to be
activated for driving of a staple into 18 the workpiece (under operation of
the tool trigger). A
slot 50 is located in the base of the foot 48 and aligned such that it is
perpendicular to the
longitudinal axis of the crown 34 of the staple 18, and such that it is
located between the legs
42 of the staple in use. Thus in use, a user can align, for example, a fence
wire in the slot 50
.. in order to ensure that the legs of a staple 18 will be driven into the
workpiece either side of
the wire. This helps to prevent a user from accidentally aligning the tool 10
such that a leg 42
of the staple 18 is driven into the wire, which could cause damage to the wire
or any surface
10
treatment applied to the wire. Thus, the slot 50 may help to ensure that the
durability of the
wire being attached to a workpiece is not compromised (e.g. due to rust).
Because of the existence of the channels 38 and the lateral passages 46 (both
of which
are provided to cater for the barbs 40 on the staples18), the tool 10 includes
various means to
support and/or maintain alignment of the staple in the nosepiece. As mentioned
above, the
outer surface of the tape is in contact, or close to being in contact, with
the surface of the
passage 54 disposed proximal of the lateral passages 46. Such an arrangement
may provide a
closer fit of the upper portion of the staple 18 in the passage 28. This may
help to correctly
position the staple in the nosepiece to receive the driver blade and to
stabilise the motion (i.e.
by limiting motion of the staple to the longitudinal axis of the passage 28)
of the staple 18
when it is initially driven by the driver blade 30 down the passage 28.
To further assist in maintaining the position of the staple 18 in the
nosepiece, the drive
blade 36 may be modified to provide lateral support for the staple.
Figures 3A and 3B provide front and side views respectively of the driver
assembly
of the embodiment of the tool 10. The driver assembly comprises a driver blade
30 having an
engagement portion 32 and ridge 36.
The engagement portion 32 is crescent shaped, such that it conforms to the
form of
the crown 34 of the staple 18. Such a configuration may allow the engagement
portion 32 to
guide the staple 18 in the passage 28 and prevent movement of the staple 18
away from the
longitudinal axis of the passage 28 (e.g. rotation or lateral movement of the
staple 18 in the
passage 28). In other words, receipt of the crown 34 of the staple 18 in the
concave
engagement portion 32 helps to self-centre the staple 18 whilst it is being
driven. In use, the
power delivery source can be configured such that the driver blade 30 is
accelerated as it
engages the staple 18 and drives the staple 18 into the workpiece. In this
respect, the staple
will be held in the crescent (i.e. in continuous contact) throughout the
driving action of the
driver blade 30 (i.e. from engagement with the driver blade to the staple
being embedded in a
workpiece).
The crescent shaped engagement portion 32 may also reduce or eliminate damage
to
any coating that may be applied to the staple 18. This may especially be the
case when
compared to manual methods of driving a staple 18 into a workpiece (e.g. hand
hammer
driven).
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The driver blade 30 also comprises a ridge 36. This ridge 36 is arranged to
align and
engage with a corresponding slot (not shown) located on the nosepiece 26. This
engagement
aligns the driver blade 30 in the passage 28, such that when it is driven, it
is substantially
restricted to motion along the longitudinal axis of the passage. In the
absence of complete
side support (i.e. due to the passage 28 comprising channels 38) the ridge 36
may provide
partial or full stability to the driver blade 30 during driving action.
Now referring to Fig. 4, the assembly of staples 18 for use with the
embodiment of the
tool is shown. Each staple comprises a crown 34, two legs 42 and a barb 40 on
each leg 42.
The staples 18 are collated and connected by paper collation tape 44 applied
to the legs 42 of
the staples 18. Each staple 18 comprises diverging points 52, which have
opposing angled
faces such that when a staple 18 is driven into a workpiece, the legs 42 are
caused to diverge.
As discussed above, the collation tape 44 not only secures the collated
staples together but
can assist in maintaining alignment of the staple 18 in the nosepiece 26 by
providing a closer
fit of the upper portion of the staple 18 in the passage 28.
To allow for reliable operation of the staple tool, the dimensions of the
staples 18 and
their alignment in the collated assembly need to be within relative tight
tolerances which may
be in the order of 5mm. Also the adhesion of the collation tape and its
properties influence
the operation of the tool. In one form, the staples are manufactured and
collated to meet the
desired criteria using a process whereby the staples are made using a pressing
operation
including a 3 stage bending process. During this pressing operation the barbs
are formed on
the staple legs. The staples then pass onto a staple collation rail where the
stables are heated
to approximately 300 C. The collation tape (which in one form may be a paper
based tape
supplied under the trade name PASLODE PRO-STRIP EQ98) is applied to the heated
staples
where a bond is formed between the collation tape and the metal surface of the
staples.
Accordingly a powered staple tool 10 is provided that uses barbed staples 18
which
may be in supplied in a collated assembly. This allows for rapid and effective
fixing of the
staples and is ideal for applications such as fencing. To accommodate for the
barbs in the
staple legs, adequate clearances are provided in the nosepiece of the tool for
both loading and
passage of the staple through the nosepiece. As these clearances increase the
likelihood of
the staple twisting or moving laterally in the nosepiece (which may result in
jamming of the
staple in the nosepiece), support arrangements are provided to maintain
correct positioning of
the staple in the nosepiece.
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In the claims which follow and in the preceding summary except where the
context
requires otherwise due to express language or necessary implication, the word -
comprising"
is used in the sense of -including", that is, the features as above may be
associated with
further features in various embodiments.
Variations and modifications may be made to the parts previously described
without
departing from the spirit or ambit of the disclosure.
