WO2006127491A1 - Combustion nailer with a temperature sensor - Google Patents

Abstract

A combustion nailer (10) includes a housing (12) substantially enclosing a combustion engine (14) having a cylinder head (42) , a control unit (62) associated with the housing (12) for controlling operation of the tool, at least one printed circuit board (66) electrically connected to the control unit (62) for maintaining tool operation, and at least one temperature sensor (60) mounted on the at least one printed circuit board (66) for monitoring tool temperature and for signaling sensed temperature to the control unit (62) .

Description

COMBUSTION NAILER WITH A TEMPERATURE SENSOR

RELATED APPLICATION

The present application claims priority under 35 USC § 120 from US

Serial No. 60/684,088 filed May 23, 2005.

BACKGROUND

The present invention relates generally to fastener-driving tools used

for driving fasteners -into workpieces, and specifically to combustion-powered

fastener-driving tools, also referred to as combustion tools or combustion nailers.

Combustion-powered tools are known in the art for use in driving

fasteners into workpieces, and examples are described in commonly assigned

patents to Nikolicli U.S. Pat. Re. No. 32,452, and U.S. Pat. Nos. 4,522,162;

4,483,473; 4,483,474; 4,403,722; 5,197,646; 5,263,439 and 5,713,313, all of

which are incorporated by reference herein. Similar combustion-powered nail and

staple driving tools are available commercially from ITW-Paslode of Vernon

Hills, Illinois under the IMPULSE® and PASLODE® brands.

Such tools incorporate a tool housing enclosing a small internal

combustion engine or power source. The engine is powered by a canister of

pressurized fuel gas, also called a fuel cell. A battery-powered electronic power

distribution unit produces a spark for ignition, and a fan located in a combustion

chamber provides for both an efficient combustion within the chamber, while facilitating processes ancillary to the combustion operation of the device. Such

ancillary processes include: mixing the fuel and air within the chamber; turbulence

to increase the combustion process; scavenging combustion by-products with fresh

air; and cooling the engine. The engine includes a reciprocating piston with an

elongated, rigid driver blade disposed within a cylinder body.

A valve sleeve is axially reciprocable about the cylinder and,

through a linkage, moves to close the combustion chamber when a work contact

element at the end of the linkage is pressed against a workpiece. This pressing

action also triggers a fuel-metering valve to introduce a specified volume of fuel

into the closed combustion chamber.

Upon the pulling of a trigger switch, which causes the spark to ignite

a charge of gas in the combustion chamber of the engine, the combined piston and

driver blade is forced downward to impact a positioned fastener and drive it into

the workpiece. The piston then returns to its original or pre-firing position,

through differential gas pressures created by cooling of residual combustion gases

within the cylinder. Fasteners are fed magazine-style into the nosepiece, where

they are held in a properly positioned orientation for receiving the impact of the

driver blade.

The above-identified combustion tools incorporate a fan in the

combustion chamber. This fan performs many functions, one of which is cooling.

The fan performs cooling by drawing air though the tool between firing cycles.

This fan is driven by power supplied by an onboard battery and, to prolong battery life, it is common practice to minimize the run time of the motor. Also, short fan

run time reduces fan motor wear (bearings and brushes), limits sound emitting

from the tool due to air flow, and most importantly limits dirt infiltration into the

tool. To manage fan 'on time', combustion tools typically incorporate a control

program that limits fan 'on time' to 10 seconds or less.

Combustion tool applications that demand high cycle rates or require

the tool to operate in elevated ambient temperatures often cause tool component

temperatures to rise. This leads to a number of performance issues. The most

common is an overheated condition that is evidenced by the tool firing but no

fastener driven. This is often referred to as a "skip" or "blank fire." As previously

discussed, the vacuum return function of a piston is dependent on the rate of

cooling of the residual combustion gases. As component temperatures rise, the

differential temperature between the combustion gas and the engine walls is

reduced. This increases the duration for the piston return cycle to such an extent

that the user can open the combustion chamber before the piston has returned,

even with a lockout mechanism installed. The result is the driver blade remains in

the nosepiece of the tool and prevents advancement of the fasteners.

Consequently, a subsequent firing event of the tool does not drive a fastener.

Another disadvantage of high tool operating temperature is that there

are heat-related stresses on tool components. Among other things, battery life is

reduced, and internal lubricating oil has been found to have reduced lubricating capacity with extended high temperature tool operation. Accordingly, elevated

operational temperatures often require more frequent tool maintenance,

necessitating unwanted tool downtime.

It is known to place a temperature sensing element in close

proximity to the engine or combustion power source and manage the cooling

function of the fan to regulate engine temperatures and achieve desirable tool

operation. However, due to the significant shock and heat associated with a

combustion nailer, design consideration must be given to the construction and/or

assembly of the sensing element within the tool to yield reliable operation.

Thus, there is a need for an improved combustion-powered fastener-

driving tool which regulates tool operating temperatures within accepted limits to

prolong performance and maintain relatively fast piston return to pre-firing

position. In addition, there is a need for an improved combustion-powered

fastener-driving tool which manages tool functions in accordance with engine

temperatures, and provides a temperature sensor that offers reliable operational

life

BRIEF SUMMARY OF THE INVENTION

The above-listed needs are met or exceeded by the present

temperature sensor for a combustion nailer which features a disposition in close

proximity to the tool's engine compartment, but yet is sufficiently distant and/or protected that the severe vibrational and temperature stresses inherent with tool

operation are reduced. The present sensing element is mounted to a circuit board

with connectors for promoting ease of assembly in manufacturing.

In an area adjacent to the circuit board, a heat exchange profile or a

cavity in the cylinder head, in which the sensor will be positioned, will expose the

sensor to tool operational temperature. At least one mounting screw will provide

positive retention of the circuit board to the cylinder head, and a conductor pad on

the circuit board will provide circuit ground with the head. The present sensor

provides convenient and effective construction that will promote long operational

life and relatively accurate temperature readings.

More specifically, a combustion nailer includes a housing

substantially enclosing a combustion engine having a cylinder head, a control unit

associated with the housing for controlling operation of the tool, at least one

printed circuit board electrically connected to the control unit for maintaining tool

operation, and at least one temperature sensor mounted on the at least one printed

circuit board for monitoring tool temperature and for signaling sensed temperature

to the control unit.

In another embodiment, a combustion nailer includes a housing

substantially enclosing a combustion engine having a cylinder head, a control unit

associated with the housing for controlling operation of the tool, at least one

printed circuit board electrically connected to the control unit for maintaining tool

operation, and at least one temperature sensor mounted on an underside of the at least one printed circuit board for monitoring tool temperature and for signaling

sensed temperature to the control unit, the cylinder head including a pocket

projecting from the cylinder head for substantially enclosing the at least one

temperature sensor.

In still another embodiment, a combustion nailer includes a housing

substantially enclosing a combustion engine having a cylinder head, a control unit

associated with the housing for controlling operation of the tool, at least one

printed circuit board electrically connected to the control unit for maintaining tool

operation, and at least one temperature sensor mounted on the at least one printed

circuit board for monitoring tool temperature and for signaling sensed temperature

to the control unit, the at least one printed circuit board being connected to the

control unit, and the at least one temperature sensor being disposed on the at least

one printed circuit board between a trigger and the combustion engine and

constructed and arranged to extend through an opening in the housing to be in

operational access to the combustion engine.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a front perspective view of a fastener-driving tool

incorporating the present temperature control system;

FIG. 2 is a fragmentary vertical cross-section of the tool of FIG. 1

shown in the rest position; FIG. 3 is a fragmentary top perspective view of the cylinder head of

the tool of FIG. 1 depicting the present temperature control sensor;

FIG. 4 is an exploded side view of the sensor of FIG. 3;

FIG. 5 is a fragmentary, partially exploded side elevation of the tool

of FIG. 1 equipped with another temperature sensor; and

FIG. 6 is a fragmentary reverse side elevation of the sensor of FIG.

5.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGs. 1 and 2, a combustion-powered fastener-

driving tool, also known as a combustion nailer, incorporating the present control

system is generally designated 10 and preferably is of the general type described

in detail in the patents listed above and incorporated by reference in the present

application. A housing 12 of the tool 10 encloses a self-contained internal power

source 14 (FIG. 2) within a housing main chamber 16. As in conventional

combustion tools, the power source or combustion engine 14 is powered by

internal combustion and includes a combustion chamber 18 that communicates

with a cylinder 20. A piston 22 reciprocally disposed within the cylinder 20 is

connected to the upper end of a driver blade 24. As shown in FIG. 2, an upper

limit of the reciprocal travel of the piston 22 is referred to as a top dead center or

pre-firing position, which occurs just prior to firing, or the ignition of the combustion gases which initiates the downward driving of the driver blade 24 to

impact a fastener (not shown) to drive it into a workpiece.

Through depression of a trigger 26 associated with a trigger switch

(not shown), an operator induces combustion within the combustion chamber 18,

causing the driver blade 24 to be forcefully driven downward through a nosepiece

28 (FIG. 1). The nosepiece 28 guides the driver blade 24 to strike a fastener that

had been delivered into the nosepiece via a fastener magazine 30.

Included in the nosepiece 28 is a workpiece contact element 32,

which is connected, through a linkage 34 to a reciprocating valve sleeve 36, an

upper end of which partially defines the combustion chamber 18. Depression of

the tool housing 12 against the workpiece contact element 32 in a downward

direction as seen in FIG. 1 (other operational orientations are contemplated as are

known in the art), causes the workpiece contact element to move from a rest

position to a pre-iϊring position. This movement overcomes the normally

downward biased orientation of the workpiece contact element 32 caused by a

spring 38 (shown hidden in FIG. 1). Other locations for the spring 38 are

contemplated.

Through the linkage 34, the workpiece contact element 32 is

connected to and reciprocally moves with, the valve sleeve 36. In the rest position

(FIG. 2), the combustion chamber 18 is not sealed, since there is an annular gap 40

including an upper gap 4OU separating the valve sleeve 36 and a cylinder head 42, which accommodates a spark plug 46, and a lower gap 4OL separating the valve

sleeve 36 and the cylinder 20. A chamber switch 44 is located in proximity to the

valve sleeve 36 to monitor its positioning. In the preferred embodiment of the

present tool 10, the cylinder head 42 also is the mounting point for at least one

cooling fan 48 and an associated fan motor 49 which extends into the combustion

chamber 18 as is known in the art and described in the patents which have been

incorporated by reference above. In addition, US Patent No. 5,713,313 also

incorporated by reference, discloses the use of multiple cooling fans in a

combustion-powered tool. In the rest position depicted in FIG. 2, the tool 10 is

disabled from firing because the combustion chamber 18 is not sealed at the top

with the cylinder head 42 and the chamber switch 44 is open.

Firing is enabled when an operator presses the workpiece contact

element 32 against a workpiece. This action overcomes the biasing force of the

spring 38, causes the valve sleeve 36 to move upward relative to the housing 12,

closing the gaps 40U and 4OL, sealing the combustion chamber 18 and activating

the chamber switch 44. This action also induces a measured amount of fuel to be

released into the combustion chamber 18 from a fuel canister 50 (shown in

fragment).

In a mode of operation known as sequential operation, upon a

pulling of the trigger 26, the spark plug 46 is energized, igniting the fuel and air

mixture in the combustion chamber 18 and sending the piston 22 and the driver

blade 24 downward toward the waiting fastener for entry into the workpiece. In an alternative mode of operation known as repetitive firing, ignition is initiated by

the closing of the chamber switch 44, since the trigger 26 has already been pulled

and the corresponding switch closed. As the piston 22 travels down the cylinder

20, it pushes a rush of air which is exhausted through at least one petal, reed or

check valve 52 and at least one vent hole 53 located beyond the piston

displacement (FIG. X). At the bottom of the piston stroke or the maximum piston

travel distance, the piston 22 impacts a resilient bumper 54 as is known in the art.

With the piston 22 beyond the exhaust check valve 52, high pressure gasses vent

from the cylinder 20. Due to cooling of the residual gases, internal pressure

differentials created in the cylinder 20 cause the piston 22 to be forced back to the

pre-firing position shown in FIG. 2.

To manage those cases where extended tool cycling and/or elevated

ambient temperatures induce high tool temperature, at least one temperature

sensing device 60 such as a thermistor (shown hidden in FIG. 2) is preferably

located on or close to the cylinder head 42. Other types of temperature sensing

devices are contemplated besides the thermistor. Also, other locations on the tool

10 are contemplated depending on the application. The temperature sensing

device 60 is connected to a control program "P" (not shown) and described in

commonly assigned, copending US Patent application serial no. 11/028,020 filed

January 3, 2005, which is incorporated by reference. The program is associated

with a control unit 62(shown hidden in FIG. 1), which includes a microproces'sor,

and is configured to extend 'on time' of the at least one cooling fan 48 until the temperature of the power source 14 is lowered to the preferred "normal" operating

range. Alternately, the program is configured to run the fan 48 "on" for a fixed

time, for example 90 seconds, which is long enough to assure that the combustion

chamber temperature has returned to the "normal" operating range. In the

preferred embodiment, the program "P" and the control unit 62 are located in a

handle portion 64 of the tool 10. Also, it is contemplated that the microprocessor-

based program "P" may be replaced in the control unit 62 by a circuit using

discrete components.

The temperature threshold is selected based upon the proximity of

the temperature sensing device 60 to the components of the power source 14, the

internal forced convection flow stream, and desired cooling effects to avoid

nuisance fan operation. Excessive fan run time unnecessarily draws contaminants

into the tool 10 and depletes battery power. Other drawbacks of excessive fan run

time include premature failure of fan components and less fan-induced operational

noise of the tool 10. For demanding high cycle rate applications and/or when

elevated ambient temperatures present overheating issues, temperature controlled

forced convection will yield more reliable combustion-powered nail performance

and will also reduce thermal stress on the tool.

Referring now to FIGs. 3 and 4, a feature of the present tool 10 is

that the temperature sensing device, preferably the temperature sensor 60

(however other known temperature sensing devices are contemplated) is located on a printed circuit board (PCB) 66 associated with, and preferably attached to an

upper end 68 of the cylinder head 42 for monitoring tool temperature and for

signaling sensed temperature to the control unit 62. As is known in the art, the

PCB 66 is electrically connected to the control unit 62 for maintaining tool

operation. While other connections are contemplated, the present PCB 66 is

shown connecting the temperature sensor 60 and the fan motor 49 with the control

unit 62 using push-on connectors 69. Also, the PCB 66 is shown secured to the

cylinder head 42 by a threaded fastener 70; however other suitable attachment

technologies known in the art such as adhesives, rivets, etc. are contemplated.

To provide accurate combustion engine temperature readings, while

protecting the temperature sensor 60 from the harsh operational environment of

the combustion engine 14, the temperature sensor is preferably located on an

underside 72 of the PCB 66. In addition, the cylinder head 42 is provided with a

pocket 74 for accommodating the temperature sensor 60. In the preferred

embodiment, the pocket 74 projects vertically from the cylinder head 42 and is

integrally cast into the cylinder head, however other orientations, and separate

fabrication and attachment is contemplated, but perceived to be less desirable.

The pocket 74 is dimensioned to substantially enclose the temperature sensor 60

so that, upon assembly, the temperature sensor is enclosed by the PCB 66 and the

pocket 74. As is known in the art, thermal conductive material is placed between

the pocket walls and the sensor 60 to promote accurate engine temperature

sensing. Electronically, the PCB 66 has a conductor pad (not shown) on the underside 72 that electrically connects with cylinder head 42. This provides a

common connection for the fan motor 49, ignition ground, and the temperature

sensor 60 to improve manufacturability.

Referring now to FIG. 2, it is also contemplated that the temperature

sensor 60, referred to as 60' for purposes of clarity only, is locatable in an alternate

location, as depicted in FIG. 1. However, multiple temperature sensors 60, 60' are

contemplated in the tool 10. More specifically, the location of the temperature

sensor 60' is inside the housing 12 between the trigger 26 and the combustion

engine 14, and in the path of the internal forced convection flow stream induced

by the fan 48.

Referring now to FIGs. 2, 5 and 6, placing the temperature sensor

60' between the trigger 26 and the combustion engine 14 is preferably achieved by

locating the temperature sensor on a circuitry PCB 76 associated with, and

preferably electrically connected with the control unit 62. As is known in the art,

the PCB 76 electrically connects the control unit 62 control unit to the cylinder

head 42. While in the preferred embodiment, the circuitry PCB 76 is a separate

circuit board from a control unit PCB 77 (shown hidden in FIG. 1), it is

contemplated that the temperature sensor 60' is mountable on a PCB which is

unitary with the control unit PCB. Also, the electrical connection of the

temperature sensor 60, 60' to the control unit 62 enables the control unit to apply

the sensed temperature signals to various tool functions, including but not limited to fan ran time, combustion chamber lockout mechanisms, spark generation and

fuel delivery.

To accommodate the temperature sensor 60', the housing 12 is

provided with at least one aperture 78 dimensioned to tightly engage the

temperature sensor and the associated portion of the circuitry PCB 76 to minimize

air leakage. A portion 80 of the PCB 76, bearing the temperature sensor 60', is

attached and projects normally from the associated PCB 76. A formation 82 on

the extension 80 is laterally enlarged to create a flange or otherwise dimensioned

to tightly engage the aperture 78. Also, in the preferred embodiment, a

supplemental aperture 84 is provided on the handle portion 64 to accept extension

80 and is in registry with the aperture 78 in the housing 12. The aperture 78 is

disposed in the housing 12 such that, upon being engaged therein, the temperature

sensor 60' is adjacent an exterior 86 of the cylinder 20 and in the path of the

internal forced convection flow stream.

It will be seen that the present temperature sensor for a combustion

nailer provides for placement of temperature sensors 60, 60' on and/or in close

proximity to the combustion engine 14 while also protecting the sensors from the

harsh working environment of combustion nailers. The presently described sensor

mounting arrangements reduce wiring to the sensor and reduce manufacturing

costs.

While particular embodiments of the present temperature sensor for

a combustion nailer has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without

departing from the invention in its broader aspects and as set forth in the following

claims.

Claims

CLAIMS:

1. A combustion nailer, comprising:

a housing substantially enclosing a combustion engine having a

cylinder head;

a control unit associated with said housing for controlling operation

of the tool;

at least one printed circuit board electrically connected to said

control unit for maintaining tool operation;

at least one temperature sensor mounted on said at least one printed

circuit board for monitoring tool temperature and for signaling sensed temperature

to said control unit.

2. The combustion nailer of claim 1 wherein said at least one

circuit board having said at least one temperature sensor is disposed upon said

cylinder head.

3. The combustion nailer of claim 2 further including a pocket

in said cylinder head for accommodating said at least one temperature sensor.

4. The combustion nailer of claim 3 wherein said temperature

sensor is disposed upon an underside of said circuit board and, upon insertion into said pocket, said at least one temperature sensor is enclosed by said pocket and

said circuit board.

5. The combustion nailer of claim 1 wherein said circuit board is

provided with push-on connectors for connecting said temperature sensor to said

control unit.

6. The combustion nailer of claim 1 wherein said at least one

circuit board having said at least one temperature sensor is located in said housing

between a trigger and said combustion engine.

7. The combustion nailer of claim 6 wherein said at least one

circuit board is an extension of a circuit board connecting said temperature sensor

to said control unit.

8. The combustion nailer of claim 7 wherein said extension is on

a circuit board which is separate from a control unit circuit board supporting said

control unit.

9. The combustion nailer of claim 7 wherein said extension

projects generally normally from said circuit board.

10. The combustion nailer of claim 6 wherein said temperature

sensor is received in an aperture in said housing configured to tightly engage said

sensor and an associated circuit board formation.

11. The combustion nailer of claim 9 wherein said extension

projects from a handle portion of the housing through a supplemental aperture

which is in registry with said aperture in said housing.

12. The combustion nailer of claim 9 wherein said aperture is

disposed in said housing such that, upon being engaged therein, said sensor is

adjacent an exterior of a cylinder of a combustion engine in said tool.

13. A combustion nailer, comprising:

a housing substantially enclosing a combustion engine having a

cylinder head;

a control unit associated with said housing for controlling operation

of the tool;

at least one printed circuit board electrically connected to said

control unit for maintaining tool operation;

at least one temperature sensor mounted on an underside of said at

least one printed circuit board for monitoring tool temperature and for signaling

sensed temperature to said control unit; said cylinder head including a pocket for substantially enclosing said

at least one temperature sensor.

14. The combustion nailer of claim 13 wherein said at least one

printed circuit board is accommodated upon said pocket.

15. A combustion nailer, comprising:

a housing substantially enclosing a combustion engine having a

cylinder head;

a control unit associated with said housing for controlling operation

of the tool;

at least one printed circuit board electrically connected to said

control unit for maintaining tool operation;

at least one temperature sensor mounted on said at least one printed

circuit board for monitoring tool temperature and for signaling sensed temperature

to said control unit;

said at least one printed circuit board being connected to said control

unit, and said at least one temperature sensor being disposed on said at least one

printed circuit board between a trigger and said combustion engine and

constructed and arranged to extend through a corresponding opening in said

housing to be in operational access to said combustion engine .

16. The combustion nailer of claim 15 wherein said temperature

sensor is received in an aperture in said housing configured to tightly engage said

sensor and an associated circuit board formation.

17. The combustion nailer of claim 16 wherein said circuit board

formation projects normally from said printed circuit board.