Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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FLUSH POSITION INDICATOR FOR
FASTENER INSTALLATION TOOL FOR
ROOF TRUSS FRAMING AND
CONSTRUCTION SYSTEM
BACKGROUND
[0001] The present
disclosure relates to generally fastening systems
employed to connect wood structural members to comply with construction
codes. The present disclosure relates generally to tools and methods for
installing a fastener to secure wood framing components. More particularly,
this
disclosure relates to tools and techniques to precisely install fasteners to
secure
the top plate to roof trusses or rafters.
[0002] Local and
state building codes, which are typically based on
universal codes such as the International Residential Code and the
International
Building Code, set forth various requirements for securing wooden framing
components. Provisions are made in such codes to require that the top plate
and
the rafters, or roof trusses, must be connected to comply with pre-established
connection force standards calculated to resist substantial uplift forces that
may
be experienced throughout the lifetime of the structure. For locations which
are
susceptible to high wind uplift and/or seismic activity, typically, a stronger
force-
resistant connection between the top plate and rafters or trusses is required.
[0003] To satisfy
building code requirements, the use of metal brackets
and a large number of nails are commonly installed using pneumatic nail guns.
Many of the structural locations requiring these robust connections are at the
top
corners of walls and where walls meet roof trusses and the like. These
locations
typically require workers to stand on ladders and employ a hammer or pneumatic
nail guns to nail brackets to roof rafters, roof trusses and the like. A
common
complaint is that the ladders are not a stable platform and maneuvering bulky
nail
guns into cramped locations while standing on a ladder is both difficult and
dangerous.
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[0004] The concept
of a continuous load path (CLP) from the peak of the
roof to the foundation is one that is gaining some popularity in the
construction
industry. Various devices of straps, brackets, cables, threaded rods and bolts
are
currently employed to tie various building components together and create an
integrated unit where stress on any one structural component is transferred to
other components for additional durability.
[0005] There are a
number of techniques, fasteners and hardware items
that are conventionally employed to provide the required connection between
the
top plate and the rafters or roof trusses. Hurricane clips or other forms of
metal
straps or clips are traditionally used and secured by multiple nails or
threaded
fasteners. There is commonly a trade-off between connection integrity and
construction efficiency. For example, hurricane clips, which are effective and
widely used in many locations, may require eight or more nails or threaded
fasteners to meet the requisite code connection standard.
[0006] It is
possible to employ threaded fasteners such as elongated
screws to replace some of the metal brackets and nails currently employed to
meet building codes. However, such screws need to be installed at a particular
angle and position to ensure penetration through several wood members to
engage, for example, a roof truss or rafter. There is a need for a
construction
system that would facilitate the use of threaded fasteners to connect building
components in a manner that meets building codes and allows building
inspectors to visually confirm correct installation of such threaded
fasteners.
[0007] A highly
secure and efficient connection between the top plate and
rafters or roof trusses can be implemented by employing multiple specialty six-
inch threaded fasteners, such as TimberLOK wood screws manufactured and
marketed by OMG, Inc., of Agawam, Massachusetts. To secure the framing
components with the sufficient retentive force, each threaded fastener is
driven
through the top plate and into the rafters or roof trusses at a 22.5 5
optimum
angle with respect to the vertical. Although securing multiple threaded
fasteners
is typically more efficient than attaching a hurricane clip or other strap-
type
connector, it is difficult to consistently implement a 22.5 angle within a
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reasonable range of precision. The usage of protractors, levels and other
similar-type tools to obtain the optimum angle for the threaded fastener has
proven to be clumsy, difficult, time consuming and, at best, only marginally
advantageous over more conventional securement methods.
[0008] The present
disclosure addresses the need for a tool and method
to connect the top plate and rafters or roof trusses by efficiently installing
multiple
threaded fasteners having a consistently precise optimum connection angle.
DEFINITIONS
[0009] As used
herein, the term "roof support member" means any framing
component that provides structural support to a roof of a building, such as a
rafter, a truss or a horizontal ceiling joist.
[0010] As used
herein, the term "top plate" means the horizontal framing
component (which may include two or more members such as two 2x4-inch
members) attached to the topmost portion of the vertical structural members or
studs to which the roof support members are mounted and secured.
SUMMARY
[0011] Briefly
stated, an installation tool is employed to fasten a first
member to a second member. The installation tool comprises a driver assembly
having an elongated tube assembly with a proximal end and a distal end. The
tube assembly is preferably telescopic. A driver, which generates torque, is
mounted adjacent the proximal end. A torque transfer unit is disposed in the
tube for transferring torque produced by the driver to a fastener coupler
adjacent
the distal end. A guide assembly is mounted adjacent the distal end and has an
end and a locating surface and a fastener channel defining an axis disposed at
an angle e to the locating surface. The fastener channel is configured to
receive
a fastener so that when the locating surface is engaged against the first
member
and the locating end is positioned adjacent the second member and the fastener
is received in the channel and the driver is energized, the fastener coupler
engages the fastener and is torqued to drive the fastener through the first
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member at the angle el into the second member. The angle e is preferably
approximately 22 1/2 . A stabilizing piercing edge preferably projects from
the
locating end. The stabilizing edge is the vertex of a square stabilizer plate.
[0012] A guide
head is mountable to an installation tool with a torque
driver having a fastener coupler and comprises a frame and an indicator module
mounted to the frame. The frame has a locating end and a non-coplanar locating
surface and a fastener channel defining an axis disposed at an angle e to the
locating surface and configured to receive a fastener. The indicator module
indicates that the locating surface is flush against the first member. When
the
locating surface is positioned against the first member and the locating end
is
positioned adjacent the second member and the fastener is received in the
channel and the driver is energized, the fastener coupler engages the fastener
and is torqued to drive a fastener through the first member at the angle 8
into the
second member.
[0013] In one
embodiment, the indicator module further comprises a spring
loaded pin which projects through the locating surface and is depressible to
project an indicator from a surface opposed to the locating surface.
[0014] In another
embodiment, the indicator module comprises a
depressible button which projects from the locating surface and an indicator
light
is responsive to the button. The light is preferably an LED.
[0015] In another
embodiment, the indicator module comprises a flag
which is hinged to the frame and is received in the frame in a first position
and at
least partially pivots out of the frame when the locating surface is in a
vertical
position.
[0016] In another
embodiment, the indicator module comprises a
depressible button which projects from the locating surface and an audio
module
is responsive to the button to emit a sound.
[0017] A guide
head is mountable to a fastener installation tool and
comprises a frame having a locating end and a non-coplanar locating surface. A
fastener channel defines an axis disposed at an angle to the locating surface
and
is configured to receive a fastener. When the locating surface is positioned
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against the first member, the fastener is driveable through the member at the
angle. A flush indicator is disposed on the frame to indicate that the
locating
surface is flush against the first member.
[0018] The flush
indicator further comprises a spring loaded pin which
projects through the locating surface and, in one embodiment, is depressible
to
project from a surface opposed to the locating surface. In an
alternate
embodiment, the flush indicator comprises a displaceable actuator which
projects
from the locating surface and an indicator light is responsive to the
actuator. The
light is preferably an LED.
[0019] In another
embodiment, the flush indicator comprises a flag which
is hinged to the frame and is received in the frame in a first position and at
least
partially pivots out of the frame when the locating surface is in a vertical
position
to indicate the flush position.
[0020] The flush
indicator may also comprise an audio module responsive
to a depressible actuator to emit a sound which indicates the flush position.
[0021] The guide
head is mountable to a fastener installation tool having a
torque driver with a fastener coupler. The guide head comprises a frame having
a reference structure and a fastener channel defining an axis disposed at an
acute angle 8 to the reference structure. An indicator module mounted to the
frame indicates that the reference structure is flush against the first
member.
When the locating surface is positioned flush against the first member, the
fastener is received in the channel and the driver is energized, the fastener
coupler engages the fastener and is torqued to drive the fastener through the
first
member at the angle 8.
[0022] A spring
loaded pin which projects through the reference structure
is depressible to actuate various indicators such as a projecting member, an
LED
or an audible signal. In another embodiment, the guide head indicator module
comprises a flag which pivots when the locating surface is in a vertical
position to
indicate the flush position for driving the fastener at the proper angle into
the first
member.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Fig. 1 is a side view, partly broken away, of a fastener
installation
tool for securing a top plate to a roof support member;
[0024] Fig. 2 is a fragmentary top plan view of the installation tool of
Fig. 1;
[0025] Fig. 3 is a fragmentary partially disassembled side view of the
installation tool of Fig. 1;
[0026] Fig. 4 is a representative perspective view, partly in schematic,
of a
structure during its construction phase and illustrating the usage of a
fastener to
connect a top plate to a roof support member;
[0027] Fig. 4A is a fragmentary side sectional view of the structure of
Fig.
4, illustrating a fastener connecting a top plate to a roof support member at
a
location adjacent a vertical stud;
[0028] Fig. 4B is a fragmentary side sectional view of the structure of
Fig.
4, illustrating a fastener connecting a top plate to a roof support member at
a
location between vertical studs;
[0029] Fig. 5 is a side elevational view, portions broken away to show
detail and partly in diagram form, of the installation tool of Fig. 1;
[0030] Fig. 6 is a side elevational view, portions broken away to show
detail and partly in diagram form, of a modified embodiment of the fastener
installation tool of Fig. 1;
[0031] Fig. 7 is a perspective view, partly in diagram form, of a guide
portion of the installation tool of Fig. 1;
[0032] Fig. 8 is a perspective view of the guide portion of Fig. 7,
portions
being shown in phantom and portions being shown to reveal internal detail;
[0033] Fig. 9 is a composite schematic view illustrating the sequential
operation of the installation tool of Fig. 1;
[0034] Fig. 10 is a side elevational view, partly broken away, of a
second
embodiment of a fastener installation tool for connecting a top plate with a
roof
support member;
[0035] Fig. 11 is a fragmentary top plan view of the installation tool
of Fig.
10;
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. I,
[0036] Figs. 12A-12C are side elevational views, partly in
schematic,
illustrating the sequential operation of the installation tool of Fig. 10;
[0037] Fig. 13 is a side elevational view, partly broken away,
of a third
embodiment of a fastener installation tool for connecting a top plate with a
roof
support member;
[0038] Fig. 14 is a fragmentary top plan view of the
installation tool of Fig.
13;
[0039] Figs. 15A-15D are representative side elevational views,
partly in
schematic, illustrating the sequential operation of the installation tool of
Fig. 13;
[0040] Figs. 16A-16B are schematic diagrams illustrating the
usage and
versatility of a representative fastener installation tool for different
structural
heights and wherein the installers have different heights;
[0041] Fig. 17 is a perspective view of a fourth embodiment of
an
installation tool without the power driver assembly wherein certain external
portions are shown as transparent to reveal internal components;
[0042] Fig 18 is an enlarged perspective view of a portion of
the
installation tool of Fig. 17 wherein certain external components are shown as
transparent to reveal internal components;
[0043] Figs. 19A and 19B are top sectional views of portions of
the
installation tool of Fig. 17;
[0044] Fig. 20 is an enlarged end sectional view of the
installation tool of
Fig. 17 and further illustrating a fastener received in the installation tool;
[0045] Fig. 21 is an enlarged generally top plan view of the
guide head
portion of the installation tool of Fig. 17;
[0046] Fig. 22 is an enlarged generally bottom perspective view
of a guide
head portion of Fig. 21;
[0047] Fig. 23 is an enlarged generally opposite side
elevational view,
portions removed, of a handle assembly for the installation tool of Fig. 17;
[0048] Fig. 24 is an enlarged side elevational view, portions
in section and
portions removed, of the handle assembly of Fig. 23;
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[0049] Fig. 25 is an enlarged generally right side view of a portion of
the
handle portion of Fig. 24, taken from the right thereof and partially broken
away
to show detail
100501 Figs. 26A and 26B are side elevational views, partly in phantom,
of
a guide head for a fastener installation tool with a first indicator
illustrating a non-
flush and a flush position, respectively;
100511 Figs. 27A and 27B are side elevational views of a guide head for
a
fastener installation tool with a second indicator illustrating a non-flush
and a
flush position, respectively;
100521 Figs. 28A and 28B are side elevational views, partly in phantom,
of
a guide head for a fastener installation tool with a third indicator
illustrating a non-
flush and a flush position, respectively;
(0053] Figs. 29A and 29B are side elevational views of a guide head for
a
fastener installation tool with a fourth indicator illustrating a non-flush
and a flush
position, respectively;
[0054] Fig. 30 is a schematic view illustrating a flush position
indicator
which employs a light indicator as illustrated in Figs. 28A and 28B; and
100551 Fig. 31 is a schematic view illustrating a flush position
indicator
which employs an audible indicator as illustrated in Figs. 29A and 29B.
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DETAILED DESCRIPTION
[0056] With
reference to the drawings wherein like numerals represent like
parts throughout the several figures, a fastener installation tool is
generally
designated by the numeral 10. The fastener installation tool 10 is a heavy-
duty
hand tool adapted for installing threaded fasteners 12 at a consistent angle
of
approximately 22 1/2 (to the vertical) into a top plate for connection with a
roof
support member.
[0057] As best
illustrated in Figs. 4, 4A and 4B, for a representative
structure 20 for which the installation tool 10 is particularly adapted, a top
plate
22, which may include a single 2x4 or a double 2x4, is mounted at the top of
spaced vertical studs 24. Roof support members 26 of roof trusses 28 are
mounted and supported on the top plate 22. Threaded fasteners 12 are driven
into the top plate at a 22 1/2 angle for engagement with the roof support
member 26. Multiple spaced threaded fasteners 12 are sequentially driven at
pre-established spacings to provide the proper uplift resistance.
[0058] Fig. 4A
illustrates the fastener driven at the upper location of the
stud 24. Fig. 4B illustrates the fastener as driven at the location along the
top
plate between the vertical studs 24. The fasteners 12 are each preferably a
six-
inch fastener having a continuous threaded portion with a pointed tip and a
head
defining a socket or a six-inch TimberLOK fastener manufactured and marketed
by OMG, Inc., of Agawam, Massachusetts. The TimberLOK fastener 12 has a
hex head 14 and a drill tip 16. Alternative configurations for head 14 are
also
possible.
[0059] As will be
further described below, the installation tool 10 is
preferably dimensioned, principally by means of the length of a telescopic
tube
assembly 30, to provide an installation tool which may be effectively used by
installers having a wide range of height and reach for a wide range of
commonly
vertically dimensioned structures. The principal function of the telescopic
tube
assembly 30 is to exert positive forward or upward pressure against the top
plate/roof support interface.
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[0060] With
reference to Figs. 5 and 6, representative tube assembly
lengths are designated by L and t and representative fastener lengths are
designated by D and d which also represents the travel distance to drive the
screws. For one example in Fig. 5, L= 36.14" and D = 8". In Fig. 6, t = 27.4"
and
d = 6". The telescopic tube assembly 30 preferably has a maximum length of
between 27.4 inches and 36.14 inches to accommodate the height and reach of
the installer. For a six-inch fastener 12, the telescopic assembly 30 must
retract
6 inches to drive the fastener, as will be described below.
[0061] The
installation tool 10 dimensions allow for the tool to be
effectively and efficiently used for connecting the top plates 22 to the roof
support
members 26 without requiring the use of a ladder, plafforms or other means for
providing the proper effective height relationship for driving the fasteners
12.
Moreover, the proper fastener angle may be sequentially implemented from
location to location along the top plate 22 to ensure a proper consistent
angle for
each of the multiple fasteners and to provide an integrated composite
connection
having an uplift resistance of high integrity.
[0062] The
installation tool 10 preferably comprises a driver assembly 40
which includes a power driver 42. The driver 42 may be a conventional drill
gun
such as DeWaltTM model or an impact driver. The elongated telescopic tube
assembly 30, which may have a rounded, rectangular or other profile, is
mounted
over and attaches to the forward torque end 44 of the driver 42. The
telescopic
tube assembly 30 comprises a proximal tube 32 which receives and mounts the
driver 42 and a longer tube 34 secured to the tube 32. During fastener
driving,
tube 32 slides relative to tube 34 which essentially remains stationary in
relation
to the components to be connected by the fastener. Tube 34 terminates in a
distal end 36.
[0063] A fastener
guide assembly 50 is mounted at the distal tip 36 of the
tube assembly. The guide assembly 50 provides the proper alignment structure
for implementing the preferred 22 1/2 entry angle for the fastener. The
assembly 50 also engages the support member for stabilizing the installation
tool
during the driving process. The guide
assembly 50 is dimensioned in
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accordance with the dimensions of a given fastener. The guide assembly has a
fastener channel 52 which functions to receive and load the fastener in a
muzzle-
loading fashion. The fastener drill tip 16 is positioned proximate the channel
opening 53. The fastener is inserted head 14 first into the fastener channel
52 of
the guide assembly. The fastener head 14 is engaged by a complementary
torque coupler 43, such as a socket, for a hex thread fastener or a projecting
coupler for a fastening head socket at the applicator end of the torque drive
assembly train 45. The drive train 45, which may include multiple components,
extends through and is housed within the tube assembly 30 and is driven by the
torque driver 42.
[0064] With
reference to Figs. 7 and 8, guide assembly 50 is preferably a
cast or molded member of a lightweight rigid form which is mounted at the
distal
end 36 of the tube assembly. The guide assembly 50 has a frame 60 with a
planar locating or engagement surface 62 disposed at an acute angle with
respect to lower planar mounting surface 64. Mounting surface 64 preferably
engages against the end of the tube assembly and transversely extends across
the end of the tube 34. A planar end plate 66 is preferably perpendicular to
surface 62 and is positioned and configured to closely approach or even
contact
the underside of the roof support member 26 (as will be explained below). The
acute angle is preferably 22 1/2 , although other angles may be provided
depending on the intended application of the installation tool 10.
[0065] The
fastener channel 52, which may be formed by a cylinder, has a
central axis which is perpendicular to the surface 64. The fastener channel
axis
is disposed at an acute angle of preferably 22 1/2 to the surface 62. Surface
62
defines the channel opening 53. The channel 52 receives the fastener 12 so
that
the head 14 is proximate and readily engageable with the torque coupler 43.
[0066] A
transverse slot 65 receives an alignment bracket 68 having a T-
shaped section which protrudes transversely at opposed sides of the
engagement surface 62 and also projects outwardly from the surface 62. The
alignment bracket 68 is positioned and configured to fit or ride below the 2x4
of
the top plate 22 to ensure proper perpendicular alignment with the top plate
22.
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The alignment bracket 68 may be secured in the frame by a friction or
interference fit or may be secured by a fastener (not illustrated) to the
frame and
can be transversely moved. In one embodiment, the bracket C is located
approximately 1 5/8 inches below the end plate 68.
[0067] The upper
portion of the frame is traversed by a slot 69 which
receives a metal stabilizer plate 70. The stabilizer plate is secured in place
by a
threaded adjustment knob 72. The knob 72 connects with a threaded rod 74.
The rod extends through an opening in the plate 70 and threads into a central
threaded opening 75. The
stabilizer plate 70 preferably has a square
configuration with four vertices which form edges 76. The edges 76 are
sharpened. When the plate 70 is mounted in position, one edge 76 or vertex
projects upwardly from the end surface 66 of the frame. Openings 78 are
provided in the plate to provide a height adjustment for vaulted ceilings and
other
configurations. Alternatively, the projecting structure is in the form of a
barb.
[0068] The
function of the stabilizer plate 70 is to provide a stabbing point
to engage into the wood proximate the interface of the top plate 22 and the
roof
support member 26 to thereby stabilize the tool and prevent movement while the
fastener is being torqued by the installation tool. The stabilization is
especially
important at the initial stages of driving the fastener.
[0069] In
addition, the stabilizer plate functions to present a stabbing point
so that upon inspection, an inspector will readily perceive that the fastener
is at
the proper angle.
[0070] The guide
assembly 50 is positioned by the installer at the
intersection of the top plate 22 and the roof support member 26 with the
projecting stabilizer plate edge 76 engaging into the wood and the engagement
surface 62 engaging in surface-to-surface relationship against the vertical
side of
the top plate 22. The end surface 66 is typically positioned proximate the
underside of the roof support member 26, but is slightly offset due to the
less
than complete penetration of the stabilizer edge, and the alignment bracket 68
engages the lower edge portion of the top plate 22.
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[0071] Prior to
engagement of the guide assembly with the top plate/roof
support structure (as previously described), a fastener 12 is dropped into the
fastener channel 52 with the fastener head 14 proximate to or engaging with
the
complementary coupler 43. A portion of the fastener 12 is typically initially
received in a chamber of tube 34 adjacent the distal end 36. The fastener
drill tip
16 is proximate the channel opening 53 in the engagement plate 62. It will be
appreciated that the guide assembly 50 as properly positioned provides the
proper entry point and entry angle for the fastener 12 as the fastener is
driven
through the top plate 22 into the roof support member 26.
[0072] With
reference to Figs. 42 and 43, alternative embodiments of the
guide assembly that mount to the end of the telescopic tube assembly of an
installation tool are generally designated as guide head 150A and guide head
150B, respectively. These guide heads include additional features both for
providing the proper alignment and positioning for the screw and for enhancing
the ability of the operator and/or an inspector to verify that a proper
connection
has been made. Each of the guide heads has a frame 160 with a planar locating
surface 162 disposed at an acute angle with respect to a tube assembly.
Locating surface 162 defines a channel opening for the fastener channel access
of the tube assembly. A planar end plate 166 is configured to engage or
closely
approach the underside of the roof support member 26.
[0073] An L-shaped
bracket preferably extends transversely at opposed
sides of the engagement surface and projects outwardly from the surface to
provide an alignment bracket 168 to engage the vertical support 24. Bracket
168
may be adjustable. A pair of arms 180 and 182 are pivotally mounted at the top
of the frame. One or more of the arms 180 and 182 may be pivoted upwardly to
engage a vertical side of member 26 and provide a proper positioning relative
to
the roof support member 26.
[0074] A stabber
point 170 projects through the end plate 166. In addition,
the upper portion of the frame mounts a linear ink pad 190. In the embodiment
position illustrated in Figs. 42 and 43, the guide heads 160A and 160B have
not
been positioned against the roof support member 26. Upon proper positioning,
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the pivotal arms 180 and 182 would engage against the sides of the support
member 26, and the ink pad would make a linear mark indicated at 191 on the
bottom of the roof support member 26. In addition, the stabber 170 would stab
into the wood and leave a mark 171 as indicated. It should be appreciated that
either the ink mark 191 or the stab mark 171 could be used to identify both
the
proper fastener as well as the proper entry angle of the fastener and
accordingly
indicate that a proper connection has been completed.
[0075] The guide
head 150B illustrated in Fig. 43 has a pair of barbs 176
projecting from the end plate 166. When properly engaged under the roof
support member 26, the pair of barbs would provide two marks 177 which would
again provide a unique marking for indicating the proper connection. Of
course,
the barbs 176 also enhance the stability of the installation tool and the
fastener
during the installation process.
[0076] The
installation tool preferably includes an auxiliary handle (in
addition to the handle on the driver 40) to facilitate two-handed positioning
and
stability during the driving process. Various auxiliary handle configurations
can
be employed.
[0077] With
reference to Figs. 2 and 9, an auxiliary handle 80 is slidably
mounted to the tube and is longitudinally adjustable to provide an auxiliary
handle for the installer. The handle 80 includes a rear grip 82 which radially
projects radially or quasi-radially relative to the longitudinal axis of the
tube
assembly. A forward rod 84 extends from the grip generally parallel to the
tube
assembly. The rod 84 connects to a forward yoke 86 which envelopes the outer
surface of the tube assembly and is slidable along the tube assembly. The
intermediate portion of the rod is received in a cam lock 88 carried by the
fixed
proximal tube 32 that mounts to the forward portion of the driver 42. The rod
locks in place with the cam lock 88.
[0078] The tube 34
telescopes with the proximal tube 32 and is slidably
receivable throughout the driving of the fastener 12 in the installation
process as
the fastener is driven to complete the connection. The changing dynamic
relationships of the fastener 12, the guide assembly 50, the telescopic tube
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assembly 30 and the handle 80 at the various stages of installation are
illustrated
in Fig. 9.
[0079] The
auxiliary handle 80 is selectively adjustable by the installer to
provide maximum stability and comfort to the installer. The handle locks in
place
with a pin 85. The handle 80 is initially adjustable. A button 87 is pressed
to
release the telescoping tube 34 from its fixed relationship with the proximal
tube
32 and drive the threaded fastener. The handle 80 essentially remains
stationary
as the driver moves during the installation progress, as best illustrated in
Fig. 9.
The tube 32 retracts relative to tube 34 to accommodate the progressive
expelling of the fastener 12 from the fastener chamber 52. The telescoping
tubes 32 and 34 only lock when in the fully driven position, at which point,
the
fastener 12 is fully driven.
[0080] It should
be appreciated that approximately six-inch driving link is
required for driving a six-inch fastener.
[0081] With
reference to Figs. 10, 11 and 12A-C, an automatic locking
handle is generally designated by the numeral 90. The handle 90 is generally
configured to radially extend from the proximal tube 32 and slide along the
tube
32 during the driving process until it automatically locks at the full drive
position.
The handle has an orthogonally projecting grip 92 which connects with a yoke
94. The yoke 94 wraps around the tube 32 and is exteriorly slidable
therealong.
[0082] The
automatic locking handle 90 is automatically locked by the use
of balls 96 which are entrapped in a bearing 98. The driving rod 49 has a
varying
diameter along a longitudinal portion. As best illustrated in the sequence of
Figs.
12A-C, as the fastener 12 is driven, the geometry of the driving rod has
reduced
diametric surfaces allowing the balls to slip by and the outer distal tube 34
to fully
telescope. The external handle can be placed anywhere along the proximal tube
32. It will be appreciated that as the fastener 12 is driven, the handle is
rearwardly displaced toward the driver 42 until a fully locked position is
obtained
and the telescoping tube 34 is retracted.
[0083] With
reference to Figs. 13, 14 and 15A-D, another handle which
may be employed for a third embodiment of a fastener installation tool is
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generally designated by the numeral 110. The handle
110 includes a
circumferential grip 112 which extends around the proximal tube 132. The grip
112 may be easily moved along the base tube 32 and tightened in position or
loosened by means of a twisting motion on the grip about the longitudinal axis
of
the tube assembly 30.
[0084] A
protrusion 114 rides within an internal slot 116 which is attached
in fixed relationship to the driver 42. The proximal tube 132 forms the
internal
slot 116, and the sliding tube 134 includes an external rib 147. The internal
slot
116 is not aligned with the rib 147 in the dormant/non-drive state (Fig. 15A).
As
the driver starts to drive, the protrusion 114 starts to ride in the internal
slot 116
until it changes geometry and twists, thereby causing the handle to twist
(Figs.
15B-C). The foregoing continues until the second slot is aligned with the
external
rib, thereby allowing the tube 134 to fully telescope inwardly (Fig. 150).
When
the installer feels the handle 110 rotate slightly, the installer knows that
the
fastener 12 has been sufficiently initially driven, and the installer can
release the
grip 112 on the handle and place both hands on the driver 42.
[0085] Naturally,
other handles are possible. In some embodiments, an
auxiliary handle as such is not required. In such embodiments, the installer
merely grips along the tube assembly at a location that appears to be most
advantageous.
[0086] The
installation tool 10 is preferably battery powered and includes a
chargeable battery power pack. However, in some embodiments, the power
driver (not illustrated) may be directly electrically powered and include a
cord
which connects with the power line.
[0087] With
reference to Figs. 16A and 16B, two different structural
heights of the top plane 22 and two appropriately dimensioned installation
tools
for relatively tall and short installers (shown in silhouette) are
illustrated, it should
be appreciated that the dimensioning of the telescopic tube assembly 30, in
terms of longitudinal length, is established to accommodate the preferred
application in connection with connecting a top plate 22 to a roof support
member
26 without the installer needing a ladder or a platform to obtain the correct
reach
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for driving the fastener. In addition, because the height and reach of an
installer
may significantly vary, the length of the telescopic tube assembly 30 is
preferably
selected to accommodate a wide range of installers' physical dimensions.
[0088] For
applications wherein a fastener greater than 6 inches or even
less than 6 inches may be applicable, an alternative guide assembly may be
employed. For such a guide assembly, the effective depth of the fastener
channel is altered. In addition, the telescopic extremes of the telescopic
tubes 32
and 34 are adjusted to accommodate for the driving length for the fastener.
Naturally, the coupler of the installation tool is adapted to complement the
head
of the fastener.
[0089] It should
also be appreciated that for applications in which an angle
other than 22 1/2 is desired, the guide assembly may also be configured so
that
the fastener channel is at an acute angle relative to the engagement surface
at
the prescribed optimum angle. Naturally, the position of the alignment bracket
68
may also be varied in accordance with a specific project. Multiple guide
assemblies for various installation angles may be provided and attached to the
telescopic tube assembly as desired.
[0090] For some
embodiments, the power driver 40 is easily dismounted
from the telescopic tube assembly 30. The telescopic tube assembly may
employ a receiver configured to receive and functionally attach to a wide
range of
dismountable drill guns without the torque driver being fully integrated with
the
telescopic tube assembly.
[0091] With
reference to Figs. 17-25, another embodiment of an
installation tool (which does not show the power driver assembly) is generally
designated by the numeral 200 (Fig. 17). Installation tool 200 includes a
receiver
202 for the power driver assembly (not illustrated), a telescopic tube
assembly
230 comprising telescopic tubes 232 and 234, and a fastener guide head
assembly 250 which is mounted at the end 236 of tube 234.
[0092] A handle
assembly 210 is disposed in longitudinally fixed
relationship to tube 234 and includes a trigger 212 which is depressible into
one
of essentially two positions. One partially depressed position of the trigger
212
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allows for the handle assembly to be angularly adjusted about the longitudinal
axis of the distal tube 234 at a preset defined angular position. The full
depressed position of the trigger 212 allows for the proximal tube 232 to be
retracted relative to the distal tube 234 when the fastener 12 is driven. The
handle assembly 210 also provides for two-handed support of the tool so that
the
stabilizing edge 276 can be effectively stabbed into the support member. It
should be appreciated that the tubes 232 and 234 do not rotate relative to
each
other with the non-rotatable position being ensured by a longitudinal flat 236
which engages through the handle assembly.
[0093] With
reference to Figs. 19A-B and 23-25, the handle 210 has a grip
portion 214 which carries the trigger 212. The handle assembly 210 is attached
to the distal tube 234 by a yoke 240 which is longitudinally fixed between a
pair
of collars 241 and 243. The trigger 212 moves a ramp 216 which engages
complementary ramp 218 of a plunger 220. The plunger 220 has a radially
acting detent 222 which is biased inwardly into the tube 234.
[0094] A plurality
of (preferably five) recesses 225 are angularly spaced in
fixed relationship to the outer tube 234. The
projectable detent 222 is
longitudinally aligned with the recesses 225 and receivable in a selected
recess
for retention under the plunger bias. Upon depressing the trigger 212, the
detent
222 is retracted from a recess 225. Angularly rotating the grip 214 relative
to the
distal tube 234 allows detent 222 to be angularly engageable into a selected
recess 225 to fix the angular position of the handle assembly 210 as desired
by
the installer. That angular position is further secured by a thumb screw 246
at
the top which is tightened to secure the desired angular position.
[0095] A pair of
internal collar mounts 245 and 247 are respectively fixedly
mounted interiorly of the tubes 232 and 234. The mounts allow rotational and
axial movement of the drive train. A spring 248 bears against the mounts and
essentially biases the tubes 232 and 234 to a maximum extended position which
is limited by a stop 249. The spring 248 may be optional. Stop 249 allows for
replacement of the driver bit 282 to complement the fastener head. The plunger
detent 222 also extends through an opening 223 to prevent movement between
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the distal tube 234 and the proximal tube 232 and thus fix the effective tool
length. When the trigger 212 is fully depressed, the plunger is retracted from
the
opening 223 to allow the proximal tube to move relative to the distal tube
against
the bias of the spring 248 until the fastener is fully driven.
[0096] With
additional reference to Figs. 5, 17 and 20-22, a dual floating
alignment bushing or receiver guide 280 is mounted at the interior of the
distal
tube 234 and has a central opening which receives the output coupler 284 of
the
drive train 282. The guide 280 ensures a concentric alignment between the
fastener and the driver. The dual receiver guide 280 has a double conical or
funnel-like constriction 286 which receives the head 14 of the fastener 12 and
centers it for engagement by the coupler 284 as illustrated.
[0097] A fastener
guide head assembly 250 is mounted at the distal tip
236 of the tube assembly. The guide head assembly 250 has a generally
cylindrical base 251 which is retained to the distal tube 234 by means of one
or
more set screws 239 (Fig. 17). A sleeve 252 extends through the base 251 to
form a channel which receives and guides the fastener 12. Surface 262 defines
the sleeve input opening 253 to sleeve 252 for the fastener as correspondingly
described with respect to guide assembly 50. The sleeve 252 receives the
fastener so that the head 14 is properly positioned to be readily engageable
by
the torque coupler 282. The major thread diameters of the fastener 12 and the
interior diameter of the sleeve 252 are configured so that the interior
diameter of
the sleeve is only slightly larger than the major thread diameters of the
fastener.
Preferably, the maximum diameter of the head 14 is approximately equal to the
major diameter of the threads. It will be appreciated that as the fastener 12
is
loaded into the guide head assembly 250, the head 14 moves through the sleeve
or channel 252 and is convergently directed via the funnel-like constriction
286
(Fig. 20) toward engagement with the torque coupler 284 of the drive train.
The
coupler 284 is also axially centered by the dual receiver guide 280. The dual
receiver guide 280 can axially move or float within the tube. The movement is
inwardly limited by a dimple 281.
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[0098] The guide
head assembly 250 is preferably a cast or molded
member of lightweight rigid form which includes a frame extending from the
base
with a planar engagement surface 262 disposed at an acute angle with respect
to
the lower planar mounting surface 264. Mounting surface 264 preferably
engages against the end of the tube assembly and transversely extends across
the distal end 236 of the tube 234. A planar end plate 266 is parallel to
surface
264 and positioned to engage the underside of the roof support member 26. The
acute angle is preferably 22 1/20, although other angles may be provided
depending on the intended application of the installation tool. The specific
angle
can be provided with a guide head assembly having the required angle of the
sleeve or guide channel relative to the engagement surface 262.
[0099] A
transverse slot 265 receives an L-shaped alignment bracket 268
which protrudes transversely at opposed sides of the engagement surface 262
and also projects outwardly from the surface 262. A set screw 271 secures the
bracket 268 and allows the bracket 268 to be adjusted laterally, for example,
when required at corners. The alignment bracket 268 is positioned and
configured to fit below the 2x4 at the top plate 22 to ensure proper
perpendicular
alignment with the top plate. For corner configurations, the alignment bracket
268 may be moved to an extreme lateral position, either left or right of the
position as shown in Fig. 21.
[00100] The upper
portion of the frame is traversed by a slot 269 which
receives a metal stabilizer plate 270. The stabilizer plate is secured by an
adjustment knob 272 which connects with a threaded rod 274. The rod extends
through an opening in the plate and threads into separate threaded opening
275.
The stabilizer plate 270 preferably has a square configuration with four
vertices
which form edges 276. The edges 276 are sharpened. When the guide head
assembly 250 is properly positioned a sharp edge 276 projects upwardly from
the
edge surface 266 of the frame. The function of the stabilizer plate 270 with
edge
276 is to provide a stabbing structure to engage into the wood proximate the
interface of the top plate 22 and the roof support member 26 to thereby
stabilize
the tool 200 and prevent movement or walking while the fastener 12 is being
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torqued by the installation tool. The stabilization is important at the
initial stages
of driving the fastener.
[00101) With
reference to Figs. 26A-29B, four guide head assemblies 2050,
2150, 2250 and 2350 incorporate indicators for indicating to the installer
that a
flush position is obtained. It should
be appreciated that the guide head
assemblies may take numerous other forms consistent with the various guide
head assemblies previously described in the specification. It will be
appreciated
that the significant factor in obtaining the proper entry angle using a
telescopic
installation tool is ensuring the proper flush position of the locating
surface 2062,
2162, 2262 and 2362, respectively, (or reference structure that may be
interrupted and not be continuously planar).
[00102) With
reference to Figs. 26A and 26B, guide head assembly 2050
incorporates an indicator module 2090. The guide head assembly has a fastener
channel 2052 having a channel opening 2053 which is disposed at an angle 8
with respect to the planar locating surface 2062. It will be appreciated that
the
guide head assembly includes a connecting extension 1070. The extension
mounts to a tube assembly 30. The tube assembly has a drive train 45 for a
fastener coupler 43 (not shown in these particular drawings). The guide head
assembly 2050 also includes an end locating surface 2066 and a
stabber/stabilizer 2076 as well as guide means 2080.
[00103] The
indicator module 2090 employs a transverse channel 2092
which mounts a spring loaded indicator button 2094. In a non-flush position of
Fig. 26A, the button 2094 projects through the locating surface 2062. The
indicator module 2090 may be incorporated into the frame or be mounted
exteriorly of the side of the guide head 2050. When the locating surface 2062
is
flush against another surface, the button 2094 is depressed and forces the
opposing end 2096 of the button to project through the opposing surface. The
projection of end 2096 thus indicates to the installer that a proper flush
position
for the fastener installation has been obtained, as best illustrated in Fig.
26B.
[00104] With
reference to the guide head assembly 2150 in Figs. 27A and
27B, a flush indicator module 2190 shows the non-flush position of Fig. 27A
and
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the proper flush position of Fig. 27B. An indicator flag 2192 is pivotally
mounted
to the frame. When the frame is in the proper flush or vertical position, the
indicator flag 2192 pivots from the frame, as best illustrated in Fig. 27B to
indicate to the installer that the proper flush position has been obtained.
[00105] With
reference to Figs. 28A, 28B and 30, guide head assembly
2250 has an indicator module 2290. An actuator in the form of a spring loaded
button 2260 projects through the locating surface 2262. The button is pre-
loaded
to the position illustrated in Fig. 28A. An indicator light module 2296, which
preferably employs an LED 2298, is illuminated when the button is sufficiently
(wherein the outer end is generally co-planar with the locating surface 2262)
depressed, as best illustrated in Fig. 28B. The LED 2298 may be pulsed or in a
steady state. The depressed condition activates a switch 2264 which closes a
circuit from a battery 2266 to the light module 2296. The illuminated LED
locating surface 2262 is flush against the structure at the proper entry angle
for
driving the fastener at the proper entry angle.
[00106] With
reference to Figs. 29A, 29B and 31, guide head assembly
2350 has an indicator module 2390. An actuator in the form of a spring loaded
button 2360 projects through the locating surface 2362. The button 2360 is pre-
loaded to the position indicated in Fig. 29A. When the button 2360 is
sufficiently
(wherein the outer end is generally co-planar with the locating surface 2362)
depressed, as best illustrated in Fig. 29B, an audio module 2396 is activated
and
emits a sound via speaker 2398. The sound may be steady state or pulsed. The
depressed condition activates a switch 2364 which closes a circuit from a
battery
2366 to the audio module 2396. The audible signal indicates that the locating
surface 2362 is flush against the structure at the proper entry angle for
driving a
fastener at the proper entry angle.
[00107] It will be
appreciated that other flush indicator assemblies may also
be provided for the various guide head assemblies.
[00108] While
preferred embodiments of the foregoing have been set forth
for purposes of describing preferred embodiments, the foregoing descriptions
should not be deemed a limitation of the inventions herein. Accordingly,
various
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modifications, adaptations and alternatives may occur to one skilled in the
art
without departing from the spirit and the scope of the present invention.
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