United States Patent [191
`Zylka et al.
`
`5,067,865
`Ill] Patent Number:
`[45] Date of Patent: Nov. 26, 1991
`
`[54] METHOD AND APPARATUS FOR FEEDING
`TABS OR DISCS TO AN AUTOMATIC
`STAPLE OR NAIL GUN
`
`Primary Exarainer--Neill R. Wilson
`Attorney, Agent, or Firm--Eckert, Seamans, Cherin &
`Mellot
`
`Inventors: Karl H. Zylka, Ft. Lauderdale;
`Augustus M. Buckley, Jr., West Palm
`Beach, both of Fla.
`
`[73] Assignee: Quick-Tab Fasteners, Inc., Pompano
`Beach, Fla.
`
`[21l
`[22I
`1511
`
`1521
`
`[581
`
`[56]
`
`Appl. No.: 429,148
`
`Filed:
`Oct. 30, 1989
`Int. CLs ......................... FI6B 43/00, B27F 7/02;
`B42B 4/00
`U.S. C! ..................................... 411/531; 411/162;
`411/943; 227/48; 227/50
`Field of Search ................ 411/154, 155, 160-164,
`411/480, 531,542, 544, 545,943; 227/39, 48, 50
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`2,069,402 2/1937 Cowlin ................................ 411/162
`3,481,381 12/1969 Black ................................... 411/162
`
`FOREIGN PATENT DOCUMENTS
`
`[57]
`
`ABSTRACT
`
`A method of feeding the discs to the automatic staple or
`nail gun includes the steps of providing a plurality of
`discs stacked atop one another, shuttling a first disc
`from the stack to a position normal to the staple or nail
`expulsion path, and retaining that first disc at that posi-
`tion until the staple or nail is expelled from the gun. The
`apparatus includes a shuttle which is moved from a
`position immediately below the stack of discs to a sec-
`ond position at which the disc, carried by the shuttle
`carriage, is grasped by aclip. The clip retains the disc in
`a position normal to the path of staple or nail expulsion.
`The discs have dimples protruding from both planar
`surfaces of the disc. The dimples are predisposed in a
`predetermined pattern such that the protrusions from
`one surface form a pattern which is non-equivalent to
`the pattern formed by the protrusions extending from
`the other surface of the disc. This dimple pattern is in a
`peripherally spaced band on the disc. The shuttle car-
`riage is configured to carry these discs on planar sur-
`faces beyond the band of dimples.
`
`608080 12/1978 Switzerland ........................ 411/531
`
`13 Claims, 7 Drawing Sheets
`
`FAST FELT 2018, pg. 1
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`Nov. 26, 1991
`
`Sheet 1 of 7
`
`5,067,865
`
`I
`I
`I
`
`FAST FELT 2018, pg. 2
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`IPR2015-00650
`
`

`
`U.S. Patent
`
`Nov. 26, 1991
`
`Sheet 2 of 7
`
`5,067,865
`
`I0
`
`£20 "
`
`FIG. 3A.
`
`72
`
`48
`
`I10
`
`FIG. 3B.
`112
`
`FAST FELT 2018, pg. 3
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`

`
`U.S. Patent
`
`Nov. 26, 1991
`
`Sheet 3 of 7
`
`5,067,865
`
`F/G 4.
`422 414
`BO
`
`410
`
`412
`
`420
`
`416
`
`428
`
`426
`
`FIG. 6.
`
`210
`
`412
`
`2t2
`
`FAST FELT 2018, pg. 4
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`
`

`
`U.S. Patent
`
`Nov. 26, 1991
`
`Sheet 4 of 7
`
`5,067,865
`
`FAST FELT 2018, pg. 5
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`IPR2015-00650
`
`

`
`U.S. Patent
`
`Nov. 26, 1991
`
`Sheet 5 of 7
`
`5,067,865
`
`FIG. 94.
`
`712
`
`/.82
`
`410
`/
`
`416
`
`716
`
`FIG 9B.
`
`FIG 9C.
`
`714
`
`-130
`
`?20
`
`150
`
`FAST FELT 2018, pg. 6
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`IPR2015-00650
`
`

`
`U.S. Patent
`
`~ov. 26, 1991
`
`Sheet 6 of 7
`
`5,067,865
`
`I
`II
`II
`II
`II
`
`I
`
`FAST FELT 2018, pg. 7
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`Nov. 26, 1991
`
`Sheet 7 of 7
`
`5,067,865
`
`¸810
`
`,820
`
`822
`
`910
`
`E
`
`916
`/
`
`914
`
`82
`
`FAST FELT 2018, pg. 8
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`
`

`
`5,067,865
`
`2
`It is another object of the present invention to pro-
`vide discs or tabs which include a plurality of dimples
`protruding from the planar surfaces of the tabs or discs
`wherein the dimples are predisposed in non-equivalent
`5 patterns on opposing planar surfaces thereof.
`It is a further object of the present invention to pro-
`vide a compact container for holding the discs or tabs
`which is removable from the staple or nail gun.
`
`METHOD AND APPARATUS FOR FEEDING TABS
`OR DISCS TO AN AUTOMATIC STAPLE OR NAIL
`GUN
`
`BACKGROUND OF THE INVENTION
`
`The present invention relates to a method for feeding
`tabs or discs to a pneumatically or electrically powered
`staple or nail gun and an apparatus for accomplishing
`the same. The particular configuration of the tabs or
`discs is also part of the invention.
`Automatic staple or nail guns, powered by electricity
`or air pressure, are utilized to staple or nail tar paper or
`other roofing material onto the roofs of homes and
`buildings. Local building codes now permit the use of
`wide crown staples and pneumatically driven nails to
`attach the tar paper or roofing material to the plywood
`structure of the roof. However, the staples or nails must
`be used in conjunction with very thin, metallic (usually
`tin) tabs or discs. Essentially, the staples and nails are
`driven through these tabs or discs such that the upper
`part of the inverted U-shaped staple, or the head of the
`nail, contact the top of the disc or tab surface while the
`legs of the staple or the shank of the nail protrude
`through the tab, through the tar paper or other gener-
`ally waterproof building cover, and into the underlying
`plywood or other type of solid roof structure In order
`to affix the staples or nails and discs to the roof, roofers
`typically grasp a single disc, place the disc in the appro-
`priate location on the roof, position the powered auto-
`matic staple or nail gun above the disc, and then trigger
`the gun which then expels the staple or nail. The staple
`or nail, driven by a significantly large force, penetrates
`the tab or disc and the tar paper and is injected into the
`underlying solid roof structure. This procedure can be
`dangerous in that the roofers must manually handle the
`discs and accurately place the gun atop the disc before
`firing the gun. There is a possibility that the roofer may
`be injured by not withdrawing his or her hand from the
`disc prior to firing the staple or nail. Misplacement of
`the gun or staple or nail on top of the disc or tab re-
`quires that the roofer repeat the procedure to properly
`place the staple or nail in the central region of the tab or
`disc. Typically, several thousand staples or nails and
`discs are utilized on a single residential roof.
`
`OBJECTS OF THE INVENTION
`
`It is an object of the present invention to provide a
`method for automatically feeding the tabs or discs and
`eliminating the manual placement of the discs beneath
`the staple or nail to be fired from the gun.
`It is another object of the present invention to pro-
`vide a disc or tab feeding system wherein the planar
`surfaces of the successive discs do not contact each
`other.
`It is a further object of the present invention to pro-
`vide the quick loading of the discs or tabs into the line
`of firing of the staple or nail expulsion path of the auto-
`matic staple or nail gun such that the gun can be rapidly
`operated.
`It is another object of the present invention to pro-
`vide a feeding mechanism for the tabs or discs which
`utilizes a disc shuttle or carriage.
`It is an additional object of the present invention to
`link the trigger safety of the automatic staple or nail gun
`with the loading of the tab or disc in the staple or nail
`expulsion path.
`
`10
`
`SUMMARY OF THE INVENTION
`The method of feeding the discs to the automatic
`staple or nail gun includes the steps of providing a plu-
`rality of discs stacked atop one another, shuttling a first
`disc from the stack to a position normal to the staple or
`15 nail expulsion path, and retaining that first disc at that
`position until the staple is expelled from the gun. The
`apparatus includes a shuttle which is moved from a
`position immediately below the stack of discs to a sec-
`ond position at which the disc, carried by the shuttle
`20 carriage, is grasped by a clip. The clip retains the disc in
`a position normal to the path of expulsion. The discs
`have dimples protruding from both planar surfaces of
`the disc. The dimples are predisposed in a predeter-
`mined pattern such that the protrusions from one sur-
`25 face form a pattern which is nonequivalent to the pat-
`tern formed by the protrusions extending from the other
`surface of the disc. This dimple pattern is in a peripher.
`ally spaced band on the disc. The shuttle carriage is
`configured to carry these discs on planar surfaces be-
`30 yond the band of dimples.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`40
`
`45
`
`Further objects and advantages of the present inven-
`tion can be found in the detailed description of the
`35 preferred embodiments when taken in conjunction with
`the accompanying drawings in which:
`FIG. 1A is a partial, schematic illustration of an auto-
`matic staple gun with the disc feeding apparatus
`mounted on the gun;
`FIG. 1B is a partial, detail schematic illustration of
`the mounting mechanism of the disc feeder;
`FIG. 3 is a partial, broken away, schematic illustra-
`tion of the staple gun hammer channel guide and the tab
`retention clip;
`FIGS. 3A and 3B schematically illustrate the power
`source switch for the automatic disc feeding mechanism
`in an open state and in a closed state, respectively;
`FIG. 4 illustrates a top view of the shuttle carriage;
`FIG. $ illustrates a cross-sectional view of the shuttle
`50 carriage from the perspective of section line 5’--$" in
`FIG. 4;
`FIG. 6 illustrates one embodiment of the disc having
`dimples;
`FIG. 7 schematically illustrates the shuttle carriage in
`55 an intermediate position and carrying one disc to the
`retention clip while maintaining the static position of
`the successive disc in the stack of discs;
`FIG. 8 schematically illustrates a bottom view of the
`automatic feeding mechanism and the staple gun with a
`60 disc retained by the retention clip and the shuttle car-
`riage loaded with the next successive disc from the
`stack;
`FIGS. 9A, 9B and 9C respectively illustrate the shut-
`tle carriage in a disc loading position, an intermediate
`65 position where the shuttle carriage maintains the suc-
`cessive disc in a static position relative to the stack of
`discs, and in a disc retention position wherein the first
`disc is peripherally grasped by the retention clip;
`
`FAST FELT 2018, pg. 9
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`
`

`
`5,067,865
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`FIG. 10 schematically illustrates a removable con-
`tainer for the discs and, the mounting system for such a
`container;
`FIG. 11 is a detailed, cross-sectional view of the re-
`movable container for the stack of discs; and
`FIG. 12 illustrates a drive system for moving the
`shuttle carriage which is aligned with the shuttle car-
`riage itself.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`
`The present invention relates to a method for auto-
`matically feeding tabs or discs to an automatic staple
`gun or automatic nail gun, an apparatus for accomplish-
`ing the same, and discs that are uniquely designed for
`such operation.
`FIG. 1A schematically illustrates a partial view of an
`automatic staple gun and the apparatus for automati-
`cally feeding the tabs or discs. As used herein the word
`"tab" is interchangeable with the "disc" and both refer
`to very thin, circular or other shaped pieces through
`which a wide crown staple can be expelled. Wide
`crown .staplers can be used for shingles, roofing and
`siding felt~ furniture frame butt joints, ease goods, cor-
`rugated to wood packaging, floor installation and belt
`lines. In addition, these staplers could be used for lath-
`ing and insulation.
`FIG. 1A illustrates a pneumatically powered, wide
`crown stapler 10 manufactured by Senco of Cincinnati,
`Ohio and sold as Model PW. The add on, automatic
`disc feeding apparatus 12 is mounted onto the front end
`14 of the automatic staple gun. Although a pneumati-
`cally driven wide crown stapler and a pneumatically
`driven tab feeder are discussed herein, the stapler and
`feeder could be electrically powered. It is within the
`skill of a person of ordinary skill in the an to alter the
`feeder to include an electrical drive if the automatic
`stapler is electrically driven. The automatic disc feeder
`is powered from the same power source as the auto-
`matic stapler.
`Automatic stapler 10 includes handle 16, trigger 18,
`and staple holder 20. Staple holder 20 holds a string of
`staples 21 which feed individual staples to a hammer
`that expels the staple from hammer channel guide 22 of
`gun 10. Gun 10 also includes a safety trigger actuator
`arm 24 which, when the stapler is not depressed (not in
`a firing position) disables the trigger mechanism inter-
`nally connected to trigger 18. Gun 10 also includes a
`spring 26 that has its upper coil attached to the front end
`14 of the gun and its lower coil attached to a movable
`member 28 that is pan of the safety mechanism of the
`gun. Member 28 moves with respect to the balance of
`the gun.
`FIG. :~ illustrates a partial, broken away, schematic
`view of the gun and the rear portion 30 of the automatic
`disc feeding mechanism 12. Hammer or staple channel
`guide 22 channels the staples are expelled along the
`staple expulsion path identified by arrow A. Most of
`gun 10 and particularly staple hammer guide 22 move
`with respect to mount 28 and safety guide 32.
`In the disabled mode (FIG. 1A), a staple will not be
`expelled upon depression of trigger 18 because safety
`trigger actuator arm 24 has not released .the internal
`safety mechanism of gun 10. In the enabled mode (FIG.
`2), coil spring 26 is depressed by the major portions of
`gun 10 moving vertically downward with respect to
`mount 28 and guide 32. Particularly, staple hammer
`guide 22 is in a raised position in the disabled mode
`
`4
`(FIG. 1A) and is a lowered or operative position in the
`enabled mode shown in FIG. 2. By depressing the front
`top end 34 (FIG. IA) of gun 10, coil spring 26 is de-
`pressed, and safety trigger actuator 24 causes the inter-
`5 hal safety mechanism to move. Upon release of the gun
`safety, trigger 18 is enabled such that upon depression
`of the trigger, a staple will be expelled along staple
`expulsion path A out of staple hammer channel guide
`22. The surface to be stapled is adjacent lower surface
`10 36 of automatic disc feeder 12.
`FIG. 1B is a broken away, partial schematic view of
`the mounting mechanism for disc feeder 12. Essentially,
`gun 10 has a laterally protruding tab 40 onto which is
`mounted a C-shaped mount 42 which is complementary
`15 to tab 40. Bolt 44 attaches C-shaped mount 42 to tab 40.
`Safety trigger actuator 24 is attached by bolt 44. C-
`shaped mount 42 is attached by bolt 46 to shuttle guide
`mount 48. The automatic disc feeder 12 can be mounted
`to staple gun 10 by other mechanisms. A person of
`20 ordinary skill in the an could easily construct other
`mounting systems for the feeder.
`Returning to FIG. 1A, automatic feeder 12 includes a
`disc canister or container 50, a shuttle guide mount 48,
`a shuttle 52 and a shuttle drive 54. Shuttle 52 moves fore
`25 and aft with respect to, among other things, staple ham-
`mer channel guide 22. In the illustrated embodiment,
`shuttle 52 is moved by shuttle actuator arm 56 as guided
`by rail 58. A pair of rails pass through shuttle 52 on
`either side of the shuttle. Shuttle actuator arm 56 is
`30 moved from a shuttle disc loading position, shown in
`FIG. IA, to a disc retention position shown in the figure
`as phantom lines. Lower arm region 60 of actuator arm
`56 is rotatably connected to shuttle 52. Upper arm re-
`gion 62 is rotatably attached to plunger end 64. Plunger
`35 end 64 is attached to a plunger which is driven by a
`pneumatic drive 66. The plunger rides on a rail 68 from
`position B to position C. Position C is shown in phan-
`tom lines. In position C, actuator arm 56 is lowered,
`thereby forcing shuttle 52 from the fore position illus-
`40 trated in FIG. IA to the aft position shown in phantom
`lines in that figure. Although a single chamber pneu-
`matic drive system is shown herein, a double chamber
`pneumatic drive could be substituted therefor. Pneu-
`matic supply lines 70 and 72 provide power to the pneu-
`45 matic driver 66. Disc container or canister 50, in this
`illustrated embodiment, is a rigid canister into which is
`placed ¯ plurality of stacked discs. At the top of canister
`50 is a cap 74. The cap and canister top are locked
`together by a key 78 and keyway 76 system. The bottom
`50 of canister $0 is attached to shuttle guide mount 48. The
`bottom 80 of canister 50 is in very close proximity to the
`disc carriage that will be discussed in detail hereinafter.
`To retain the disc in a position normal to staple expul-
`sion path A, a retention clip 82 is provided. Retention
`55 clip 82 is mounted at an interior position 84 to the inte-
`rior wall of mount 48 near aft end 30 thereof.
`Since the staples and discs must be placed relatively
`close together on the roof, about one foot apart, a pair
`of wheels, one of which is wheel 116, or a curved surface
`60 88 are mounted near fore end 90 of automatic disc
`feeder 12. Wheel 86 could be eliminated and the auto-
`matic feeder and staple gun combination could be
`moved simply by pushing the staple gun combination
`forward on curved surface 88.
`FIG. 2 is a detail view of the mechanism with the
`retention clip 82 partially broken away to expose staple
`hammer channel guide 22. When gun 10 is depressed
`and in an enabled mode, as shown in FIG. 2, the gun
`
`65
`
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`5,067,865
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`5
`bears down further on automatic disc feeder 12. In
`other words, the disc feeder is fixedly mounted to the
`safety mechanisms of the safety gun since the gun
`proper, represented by staple hammer channel guide 22,
`moves up and down with respect to the automatic disc
`feeder. Compare, for example, the position of staple
`string 21 in FIG. IA to the position of staple string 21
`with respect to shuttle guide mount 48 in FIG. 2.
`FIG. 3A schematically illustrates the right-hand side
`of the staple gun in detail, showing the power switch
`mechanism for the automatic disc feeder. Pressurized
`air supply hose 110 has one end connected to the pneu-
`matic supply hose (not shown) of the staple gun. The
`other end of supply hose 110 is attached to pneumatic
`switch 112. Feeder hoses 70 and 72 are connected at the
`output of pneumatic switch 112. Switch 112 is actuated
`by plunger 114. In the stapler disabled mode, that is, in
`the mode illustrated in FIG. 1A, plunger 114 is fully
`extended beyond lower surface 36 of shuttle guide
`mount 48. In the enabled mode, shown in FIG. 3B,
`plunger 114 is depressed and its lower surface is co-pla-
`nar with surface 36. FIG. 3A also illustrates the right
`side guide rail 59 and the right side safety trigger actua-
`tor arm 25.
`When plunger 114 is fully extended, shown in FIG.
`3A, shuttle 52 is in the disc retention position adjacent
`retention clip 82. This position is shown in phantom
`lines in FIG. 1A. When switch plunger 114 is depressed,
`as shown in FIG. 3B, shuttle 52 is in the disc loading
`position, shown by the solid lines in FIG. IA.
`FIG. 4 illustrates a top view of disc carrier or car-
`riage 130. FIG. $ is a cross-sectional view of disc car-
`riage 130 from the perspective of section line 5’--5" in
`FIG. 4. The disc cardage is part of the shuttle which
`moves fore and aft in the automatic disc feeder. FIG. 7
`illustrates a schematic top view of carriage 130 with a
`first disc 210 loaded into the carriage and a second disc
`212, which is the next or successive disc in the stack of
`discs held by the canister, on the fore end planar regions
`of carriage 130. FIG. 6 illustrates a disc or tab 310 hav-
`ing a plurality of hubs or dimples or that protrude from
`the top and bottom planar surfaces of the disc. As illus-
`trated, disc 310 has dimples 312, 314 and 316 protruding
`upward from the top surface of the disc. These dimples
`are represented by open circles in this figure. Disc 310
`also has dimples 318, 320 and 322 protruding from the
`opposing or b~attom planar surface of the disc. These
`dimples are represented by solid or filled-in circles. The
`dimples are placed in a peripherally spaced band about
`central region 322 of the disc. Therefore, in the illus-
`trated circular disc, the band of dimples begins at, for
`example, about ~" from the periphery of disc 310. The
`width of the band depends upon the pattern selected for
`the dimples. The pattern of upwardly protruding dim-
`pies formed by dimples 318, 320 and 322 is a equilateral
`triangle having legs of a certain distance. The down-
`wardly protruding dimples 312, 314 and 316 also form
`an equilateral triangle. However, the size of the equilat-
`eral triangle formed by the downwardly protruding
`dimples is different from the size of the equilateral trian-
`gle formed by the upwardly protruding dimples. There-
`fore, the dimples or hubs are predisposed in non-equiva-
`lent, opposing patterns in a peripherally spaced band on
`either planar surface of the tab or disc.
`This feature of the disc enables the discs, when
`stacked in the disc canister or container, to be separated
`from one another. Such separation ensures that there is
`no planar contact between adjacent discs. Without pla-
`
`6
`nat contact, the discs can be more easily withdrawn
`from the stack. However, it has been found that discs
`having dimples protruding in only one direction may be
`sufficient. Also, if the discs or tabs are thick enough or
`5 have a low coefficient of friction on their planar sur-
`faces, the dimples may not be necessary for the proper
`operation of the automatic disc feeding apparatus. The
`current best mode of the invention is to utilize discs
`having opposing dimples in nonequivalent banded pat-
`IO terns.
`The discs are carried by cardage 130 on planar sur-
`faces located beyond the band of hubs or dimples. Car-
`riage 30 has a top planar surface 410 which keeps the
`next successive disc 212 in a static position relative to
`15 the disc container and the stack discs above it. There-
`fore, the downwardly protruding dimples of disc 212
`are not held or affected by top surface 410. Only planar
`disc regions beyond the band of protrusions are carried
`or held by surface 410. To accomplish this, carriage 130
`20 has a second surface 412 that is below top surface 410.
`In one embodiment, the depth of second surface 412 is
`0.02" and the discs have a thickness of 0.01". To load
`the disc onto carriage 130, the carriage has a third pla-
`nar surface 414. Planar surface 414 supports loaded disc
`25 210 by affecting the lower surface of that disc at periph-
`eral planar regions beyond the band of dimples which
`are downwardly protruding from the disc. Carriage 130
`has a fourth planar surface 416 which provides a space
`for those downwardly protruding dimples. Edge 418
`30 linking the second surface 412 to the third surface 414 is
`a pushing surface which forces loaded disc 210 from the
`stack of discs into the retention clip, as will be discussed
`¯ in detail hereinafter. In a currently preferred embodi-
`ment, carriage 130 is made of aluminum. Pushing sur-
`35 face 418 may be reinforced by steel or other harder
`metal such that that the edge will not deteriorate upon
`repetitive, multiple uses of carriage 130.
`Carriage 130 also includes a guide channel420 such
`that the carriage and its associated shuttle mount (dis-
`40 cussed later with reference to FIG. g) move fore and aft
`smoothly. A key depends downward from the canister
`50 into channel 420 to guide the carriage. Carriage 130
`also includes forwardly protruding arms 422 and 424
`which provide additional stability to the device. A bore
`45 426 is defined by tongue region 428. It has been found
`that some operators trigger the staple gun very rapidly
`and that, upon occasion, carriage 130 has not been with-
`drawn from the staple expulsion path before the staple
`has been expelled from the gun. If the staple is expelled
`50 from the gun while carriage 130 is in the disc retention
`position, the aft position, the staple will penetrate the
`loaded disc 210 and protrude through bore 426 thereby
`preventing significant damage to the carriage.
`FIG. 7 illustrates loaded disc 210 with a peripheral
`55 edge region adjacent push edge 41 of carriage 130.
`FIG. 8 is a schematic view of the bottom of staple
`gun 1[} and automatic disc feeder 12. FIG. 8 clearly
`shows guide rails 58 and 59 for shuttle 52. Shuttle 52
`includes carriage 130 and the carriage slide mounts 510
`60 and 512 through which pass guide rails 58 and 59, re-
`spectively. As shown in FIG. 8, disc 610 is retained or
`held by retention clip 682. The successive disc, disc 612,
`is loaded onto planar surface 414 (FIGS. 4 and 5) of
`carriage 130. In this position, the stack of discs are
`65 aligned on top of the successive, carriage loaded disc
`612. Upon actuation of trigger 18 (FIG. IA), a staple
`would be expelled along the staple expulsion path
`through central disc region 322 of retained disc 610.
`
`FAST FELT 2018, pg. 11
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`Disc 610 is retained by retention clip 82 in a position
`normal to the staple expulsion path. The staple would
`penetrate the disc and then attach itself to the roof or
`other structure in its path. As best shown in FIG. 8, the
`U-shaped channels between carriage legs 422 and 424
`and tongue 428 enable carriage 130 to be partially in-
`serted into retention clip 82. In other words, the U-
`shaped retention clip 82 has legs 620 and 622 which
`protrude into the U-shaped channels of carriage 130
`when the carriage is in the disc retention position.
`FIGS. 9A, 9B and 9C schematically illustrate the
`loading position for carriage 130, an intermediate posi-
`tion, and a disc retention position, respectively. FIG.
`9A illustrates canister 50 holding a plurality of discs,
`one of which is disc 710. A coil spring 712 forces the
`disc down since the staple gun and feeding mechanism
`is subjected to considerable jostling and movement
`during its operation. Disc 714 has been loaded onto
`carriage 130 in FIG. 9A. Dimples "/16 and 718 are
`spaced from surface 416 of the disc, thereby enabling
`smooth operation of the shuttle.
`In FIG. 9B, carriage 130 is intermediate the disc
`loading position (FIG. 9A) and the disc retention posi-
`tion (FIG. 9C). In FIG. 9B, the next or successive disc
`720 is held in a static position with respect to the re-
`maining discs because that disc rides on top surface 410
`of carriage 130. This feature ensures that the stacked
`discs do not jump up and down during the shuttling
`step.
`In FIG. 9C, loaded disc 714 is inserted into retention
`clip 82. Again, successive disc 720 is maintained in a
`static position relative to the other discs in the stack. As
`used herein "static position" refers to a condition
`whereby the discs do not move up and down when the
`carriage moves back and forth due to the space pro-
`vided for the depending dimples. The loaded disc 417 is
`inserted into retention clip 82 and the clip 82 grasps the
`periphery of that disc. When carriage 130 is withdrawn
`or moved to the right in FIG. 9C and disc 714 remains
`within retention clip 82. Thereafter, when carriage 130
`reaches it foremost position, as shown in FIG. 9A, the
`successive disc is loaded onto the carriage. At that time,
`the operator of the staple gun can fire the gun thereby
`stapling the disc or tab to the surface to be stapled.
`FIG. 10 illustrates another embodiment of the present
`invention wherein a removable canister or container
`$10 is held b vertical mounts consisting of legs 812 and
`814 and collar 816. Cap 818 locks removable container
`810 to the mount in a way similar to cap 74 and canister
`50 in FIG. IA. A lower collar 820 holds the lower
`region of removable canister 810.
`FIG. 11 schematically illustrates the lower region of
`removable canister 810. Collar 820 retains the lower
`edge of the canister such that the stacked discs 822 are
`not affected by the transition between removable canis-
`ter 810 and collar 820.
`In the currently preferred embodiment, most of the
`elements of the automatic feeder are made of aluminum
`in order to reduce the weight of the feeder. In the first
`illustrated embodiment beginning with FIG. IA, canis-
`ter $0 is a thin walled aluminum container. In the sec-
`ond embodiment illustrated in FIGS. 10 and 11, the
`removable canister 810 is a cardboard container. There-
`fore, the discs can be specially manufactured and loaded
`into a lightweight cardboard container 810 and the
`removable container can be loaded into the vertical
`mounting mechanism illustrated in FIG. 10 above.
`
`8
`FIG. 12 schematically illustrates a longitudinally
`aligned drive for the shuttle. The container holding the
`stacked discs or tabs is illustrated as column 910. The
`shuttle 912 has laterally protruding tongues which co-
`5 act with a channel 914 defined by mount 916. Mount
`916 corresponds in general to guide rail mount 48 in
`FIG. 1A. However, instead of having the shuttle ride
`back and forth on rails, the shuttle has a tongue which
`laterally protrudes into open channel 914 in mount 916.
`10 A tongue and channel is also provided on the other
`lateral side of the shuttle.
`Shuttle 912 could be moved fore and aft, as shown by
`double headed arrow E, by an aligned drive 918. As
`illustrated in FIG. 12, aligned drive 918 has actuator
`15 arm 920 which is mounted or attached to shuttle 912.
`If the staple gun were electrically driven, aligned
`drive 918 could be a solenoid wherein drive rod 920
`moves in direction E thereby moving shuttle 912 fore
`and aft.
`20 Rather than use a retention clip, the clip may be re-
`placed with a permanent magnet that retains the disc in
`a position normal to the expulsion path of the staple or
`nail. Further, although a staple gun has been described
`in detail herein, the automatic disc feeder could be
`25 mounted on an automatic nail gun. The claims ap-
`pended hereto are meant to cover these embodiments of
`the invention.
`To summarize the operation of the automatic feeder,
`upon first usage, the operator would depress front end
`30 34 of gun 10 down on the surface to be stapled. Such an
`action would compress switch plunger 114 and shuttle
`$2 would move forward from the aftmost position or
`the disc retention position to a foremost position or a
`disc loading position. The first disc would then be
`35 loaded onto the carriage. The operator would then lift
`the gun and switch plunger 114 would be extended.
`This would cause the carriage and shuttle to move
`rearward to the disc retention position. The first disc
`would then be grasped by the retention clip. Upon a
`40 second depression of the gun and switch actuator, the
`shuttle moves forward, leaving the first disc in the re-
`tention clip. The next disc is then loaded, by spring
`action, onto the carriagd. The operator then depresses
`the trigger and fires the staple through the disc and into
`45 the roof. By repeatedly lifting the gun, discs are fed to
`the retention clip and staples are fired therethrough.
`This mechanism ensures that the staples are always fired
`through the center of the disc.
`The claims appended hereto are meant to cover mod-
`50 ifications and changes within the spirit and scope of the
`present invention.
`What is claimed is:
`1. A disc for use in an automated disc feeding, pow-
`dered staple or nail gun, said disc having two opposing,
`55 substantially flat, solid planar surfaces and a plurality of
`raised surfaces protruding from at least one of said pla-
`nar surfaces such that when a plurality of said discs are
`stacked on top of each other, no planar surfaces contact,
`said disc being penetrable by nails and staples.
`2. The disc according to claim 1, wherein a plurality
`of raised surfaces protrude from both of said planar
`surfaces of said disc in opposing patterns, the pattern of
`said raised surfaces protruding from one of said planar
`surfaces being non-equivalent to the opposing pattern of
`65 raised surfaces protruding from the other of said planar
`surfaces.
`3. The disc according to claim 2, wherein said pat-
`terns are equilateral triangles and the size of the triangle
`
`60
`
`FAST FELT 2018, pg. 12
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`5,067,865
`
`of raised surfaces protruding from one of said planar
`surfaces is different than the size of the triangle of raised
`surfaces protruding from the other of said planar sur-
`faces.
`4. The disc according to claim 3, wherein three dim-
`ples protrude from each of said planar surfaces.
`5. A stack of discs f