180 which in turn allows that pressurized air at the reduced second level into the air storage tank 200. It should be appreciated that in various embodiments the drop down air regulator 160 has an adjustable setting assembly that enables the operator to set the reduced second pressure level from a plurality of different pressure levels. The air storage tank 200 holds a sufficient amount of that pressurized air at the reduced second level (such as at about 80 psi) until such pressurized air is needed by the tool 50. When the pressurized air is needed by the tool 50, the pressurized air at the reduced second level flows from the storage tank 200 to and through the second check valve, if employed, to and through the second air supply hose 240, to and through the coupler 260, to and through the coupler 58 of the tool 50, and into power supply of the tool 50.

In various example embodiments, even though the tool 50 is configured to optimally drive nails at about 90 psi to about 120 psi, the tool 50 will still operate at a sub-optimal pressure (for the driving process and/or for the return process) to drive nails at reduced air pressures lower than about 90 psi (such as at about 80 psi). At such reduced air pressures, the tool 50 will drive each nail with relatively less force applied to the head of the nail. The pneumatically powered fastener driving apparatus 40 of the present disclosure thus intentionally uses the pressurized air supply apparatus 100 to supply pressurized air at a desired sub-optimal reduced pressure level to cause the pneumatically powered fastener driving tool 50 to drive the nail with sufficient amount of force to still drive the nail into the object and the substrate but not to drive the nail too far into the object and the substrate, as further explained below. Thus, in certain embodiments of the present disclosure, counter to conventional thinking regarding making such pneumatic fastener driving tools operate in optimal manners, the present disclosure contemplates making such pneumatic fastener driving tools operate in the described sub-optimal manner(s) to drive the nails at more desired force levels and to appropriately drive certain nails into certain objects and substrates. It should be appreciated that such sub-optimal operation is not required by various embodiments of the present disclosure.

Additionally, it should be appreciated that at the reduced pressure level, the pneumatically powered fastener driving tool 50 will engage the head of the nail to drive the nail with sufficient amount of force without damaging a coating on the head of the nail, as further explained below.

More specifically, the air compressor 120 can be any suitable air compressor that is configured to produce and output a continuous supply of pressurized air at a first air pressure level (such as and industry standard level of about 90 psi to about 120 psi). The air compressor 120 in this illustrated example embodiment is electrically powered, although it can be powered by other suitable energy sources. The air compressor 120 includes at least one air inlet port (not shown or labeled) and at least one air outlet port. This example air compressor 120 is shown with three outlet ports 130a, 130b, and 130c. The air compressor 120 can include one or more outlet couplers (such as outlet coupler 132) suitably connected to the respective air outlet port 130a. It should be appreciated that while the air compressor 120 can in certain circumstances be employed to only supply the tool 50 with pressurized air, in many circumstances the air compressor 120 will be employed for supplying pressurize air to one or more various other tools and apparatus. Due to the potential or actual need to supply such other tools and apparatus, the air compressor 120 may need to be set to supply air pressure at the first pressure level (such as the industry standard level of about 90 psi to about 120 psi).

The first air supply hose 140 can be any suitable air supply hose configured to communicate pressurized air in accordance with the present disclosure. In this example embodiment, the first air supply hose 140 is an elongated rubber hose having a ⅜ inch (0.953 cm) diameter and a length of 100 feet (30.48 meters). It should be appreciated that, in various alternative embodiments, the first air supply hose 140 can be any suitable size, diameter, and length. The first air supply hose 140 includes a first hose coupler 144 at a first end 142 of the first air supply hose 140. The first hose coupler 144 is configured to be removably securely attached to the outlet coupler 132 of the air compressor 120. The first air supply hose 140 also includes a second hose coupler 148 at an opposite second end 146 of the first air supply hose 140. The second hose coupler 148 is configured to be removably securely attached to the inlet coupler 164 of the drop down air regular 160. In various embodiments, either one or both of these couplers 144 and 148 can be quick disconnect couplers.

The drop down air regulator 160 can be any suitable air pressure regulator that is configured to receive pressurized air at a first level and output pressurized air at a desired reduced second level. The drop down air regulator 160 includes a housing 162 and a suitable adjustable setting assembly (not shown) supported by the housing and that enables the operator to set the reduced second pressure level that the drop down air regulator 160 will output. The housing 162 of the drop down air regulator 160 includes an air inlet port (not shown or labeled) and an air outlet port (not shown or labeled). The drop down air regulator 160 includes an air inlet coupler 164 connected to the air inlet port on one side of the housing 162. The drop down air regulator 160 includes an air outlet coupler 166 connected to the air outlet port on an opposite side of the housing 162. The drop down air regulator 160 is configured to receive from the air compressor 120 the pressurized air supply at the first level (such as about 90 psi to about 120 psi) and reduce the pressure level of the pressurized air to a reduced second level (such as about 60 psi to about 100 psi). It should be appreciated that the drop down air regulator 160 can reduce the pressurized air supply to a reduced second pressure level within such a suitable range, and that the exact amount of the reduction can vary in accordance with the present disclosure. It should be appreciated that the amount of the reduced second pressure level can be based on various characteristics of the air compressor, the tool, the nail, the object, and the substrate, as well as the desired amount of buffer pressure (which is the desired difference between the first pressure level and the second pressure level).

The first check valve 180 can be any suitable check valve configured to allow pressurized air to flow through the check valve 180 in only one direction in accordance with the present disclosure. The first check valve 180 includes an air inlet coupler (not labeled) connected to the air outlet coupler 166 of the drop down air regulator 160. The first check valve 180 also includes and an air outlet coupler (not labeled) connected to the air inlet coupler 204 of the air storage tank 200. The check valve 180 allows pressurized air at the reduced pressure level to be communicated to the air storage tank 200 from the drop down regulator 160 and prevents the pressurized air from re-entering the drop down regulator 160 from the air storage tank 200.

The air storage tank 200 can be any suitable air storage tank configured to store pressurized air for a period of time in accordance with the present disclosure. In this illustrated example embodiment, the air storage tank includes 200 a partially cylindrical housing 202 that defines one or more internal pressurized air storage chambers (not shown). The housing 202 includes an air inlet port 210 and a plurality of air outlet ports 212a, 212b, and 212c. The air storage tank 200 includes an air inlet coupler 204 connected to the air inlet port 210. The example air storage tank 200 also includes one or more air outlet couplers 206a, 206b, and 206c respectively connected to the air outlet ports 212a, 212b, and 212c. It should be appreciated that the quantity of air outlet ports can vary in accordance with the present disclosure.

In this example embodiment, the example air storage tank 200 has a ten gallon air capacity. It should be appreciated, that the air storage tank can be any suitable size and have any suitable capacity. In this example embodiment air storage tank 200 includes a handle 203 for transporting the air storage tank. In this example embodiment, the air storage tank includes supports 205a and 205b to enable the air storage tank 200 to be positioned on an suitable surface adjacent to the location at which the tool is being used. The air storage tank 200 includes a safety relief valve (not shown) for releasing excess pressure that builds up within the air storage tank 200 and a drain (not shown) for releasing moisture and water that may accumulate inside of the air storage tank 200 during use. In this example embodiment, the air storage tank receives the pressurized air at the reduced second pressure level and stores that pressurized air at that reduced second pressure level to supply that pressurized air at that reduced second pressure level to the pneumatic fastening tool 50.

As mentioned above, a second check valve (not shown) can be employed on the outlet side of the air storage tank 200.

The second air supply hose 240 can be any suitable air supply hose configured to communicate pressurized air in accordance with the present disclosure. In this example embodiment, the second air supply hose 240 is an elongated rubber hose having a ¼ inch (0.635 cm) diameter and a length of 100 feet (30.49 meters). In various embodiments, the second air hose 240 is substantially shorter such as 10 feet (3.048 meters), and in certain embodiments particularly minimized to be as close to the fastener driving site as possible. It should be appreciated that, in various alternative embodiments, the second air supply hose 240 can be any suitable size, diameter, and length. The second air supply hose 240 includes a first hose coupler 242 at a first end 244 of the second air supply hose 240. The first hose coupler 242 is configured to be removably securely attached to an outlet coupler of the air supply tank 200. The second air supply hose 240 also includes a second hose coupler 248 at an opposite second end 246 of the second air supply hose 240. The second hose coupler 248 is configured to be removably connected to the pneumatic air connection coupler 58 of the tool 50. In various embodiments, either one or both of these couplers 244 and 148 can be quick disconnect couplers.

Having described the various structural components of this example embodiment of the fastener driving apparatus 40, a brief description of one example method of operating the fastener driving apparatus 40 is now provided. The compressor 120 intakes air and creates pressurized air at a first pressure level of about 90 psi to about 120 psi. The compressor 120 communicates this pressurized air at the first pressure level to the first air supply hose 140. The compressor 120 can also communicate pressurized air at this first pressure level to one or more other pneumatic devices (not shown) via one or more additional air supply hoses (not shown). The first air supply hose 140 communicates this pressurized air at the first pressure level of about 120 psi to the drop down air regulator 160. The drop down air regulator 160 reduces the pressure level of the received pressurized air from the first pressure level (such as from about 90 psi to about 120 psi) to a reduced second pressure level (such as from about 60 psi to about 100 psi). It should be appreciated that this reduced second pressure level can vary in such the range in accordance with the present disclosure. The drop down air regulator 160 communicates the pressurized air at the reduced second pressure level to the first check valve 180. The first check valve 180 communicates or allows this pressurized air to be communicated into the air storage tank 200 without returning to the drop down air regulator 160. The air storage tank 200 holds a sufficient amount of this pressurized air at the reduced second pressure level until such pressurized air is needed by the tool 50. When the pressurized air is needed by the tool 50, the pressurized air at the reduced second pressure level flows from the storage tank 200 through the coupler 260 to the second air supply hose 240. The pressurized air at the reduced second pressure level flows through the second air supply hose 240 though the coupler 58 of the tool 50 and into power supply of the tool 50.

For each actuation of the pneumatic fastener driving tool 50 supplied with this reduced second pressure level, the pneumatic fastener driving tool 50 generates a suitable reduced driving force for driving each fastener due to this received pressurized air at the reduced second pressure level. For example, based on the received pressurized air at the reduced second pressure level of about 80 psi, the pneumatic fastener driving tool 50 can generate enough driving force for driving each nail. This reduced driving force can be lower than the optimal driving force that the pneumatic fastener driving tool 50 would normally generate when it receives pressurized air at the first pressure level such as of about 120 psi. This reduced driving force that the pneumatic fastener driving tool 50 applies to the nail enables the nail to be driven into the object and the substrate as shown in FIG. 1D. This driving of the nail at the reduced driving force reduces the likelihood of occurrence of the sets of issues described above in relation to FIGS. 1A and 1B (i.e., the force does applied does not drive the nail too far into the object and the substrate). This driving of the nail at the reduced driving force also is also sufficient enough to reduce the likelihood of occurrence of the set of issues described above in relation to FIG. 1C (i.e., the force is sufficient enough to drive the nail into the object and the substrate). It should also be appreciated that the reduced second air pressure level will be much more constant because it is below the pressure ranges provided by the air compressor and thus accounts for leaky air compressor and other fluctuations of air pressure in the entire apparatus.

In various embodiments of this method, the tool is positioned at about 90 degrees (about perpendicular) relative to object.

It should be appreciated that the reduced pressure level can be different for different nails, different objects, different substrates, and different combinations thereof in accordance with the present disclosure. Below is a table showing example reduced pressure level ranges that can be employed with these example different nails, objects, substrates, and combinations thereof.

Application
Substrate
Fastener
Pressure Range

Sheathing
OSB into
2-⅜″× .113″
80-110 psi

Framing lumber

Trim
Pine casing into
16 ga × 1-½″ Trim
60-75 psi

Framing lumber

Trim
Pine casing into
16 ga × 2″ Trim
70-85 psi

Framing lumber

Siding
Fiber cement, OSB,
16 ga × 1-½″ Trim
60-70 psi

Framing lumber

Siding
Fiber cement, OSB,
16 ga × 2″ Trim
70-80 psi

Framing lumber

In the above examples, the framing lumber may include for example the most common species which are: (1) SPF—Spruce Pine Fir; (2) DF—Douglas Fir; and (3) SYP—Southern Yellow Pine. In the above example for sheathing, the air compressor first pressure level can be in a higher range such as about 115 psi to about 145 psi and the second reduced pressure level can be in a range such as about 80 psi to about 110 psi. It should be appreciated from this example that the sets of first and second ranges can vary in accordance with the present disclosure, and the compressor air pressure level may need to be set above the industry standards as discussed above.

The reduced driving force generated by the pneumatic fastener driving tool 50 due to this received pressurized air at the reduced pressure level also facilitates the use of coatings on the heads of nails. As mentioned above, the fourth set of issues occur even when the pneumatically powered fastener driving tool drives the nail into the object and the substrate at the correct distance or position, but the color of the head of the nail does not match the color of the outer surface of the object. The apparatus and method of the present disclosure enables nails with coated heads to be employed. Specifically, the coatings on the heads can be the same color as the outer surface of the substrate. This is shown in FIGS. 4 and 5, which show a nail 12 having a head 13 and a coating 14 on the outer surface of the head 13. FIG. 5 also illustrates of the nail 12 of FIG. 4 driven into the object 4. As shown in FIG. 5, the outer surface of the coating 14 is substantially aligned with the outer surface of the object 4 after the nail is driven into the substrate using the apparatus or method of the present disclosure. The coating 14 can be of the same or substantially the same color of the object 4. It should be appreciated that the thickness of the coating 14 on the head 13 of the nail 12 is enlarged and not drawn to scale in FIGS. 4 and 5 for illustration purposes only and that the coating is expected to be much thinner relative to the thickness of the head 13 of the nail 12. The driving of the nail 10 at the reduced driving force, as mentioned above, is also low enough to reduce the likelihood of occurrence of the fastener driver blade damaging the coating 14 on the outer surface of the head 13 of the nail 12. Thus, the apparatus and method of the present disclosure addresses the fourth set of issues described above.

It should be appreciated that if there is a drop in the air pressure supplied by the compressor 120 due to the length of the first air supply hose 140 or other reason, this drop is expected to be inconsequential because the drop down regulator 162 is configured to reduce the air pressure.

It should be appreciated that the sequential fire mode of the tool in various embodiments will produce more consistent results than the bump fire mode of the tools and thus various embodiments include only using the sequential fire mode.

It should also be appreciated that for certain tools, the reduced air pressure described above can be combined with an appropriate setting of the tool depth setting device to obtain desired nail positioning.

It should be appreciated that for certain embodiments, test firing using test reduced pressure levels and various settings may need to be done before the actual firing of the nails.

FIG. 3 illustrates an alternative embodiment of the pressurized air supply apparatus of the present disclosure generally indicated by numeral 1100. This pressurized air supply apparatus 1100 includes: (1) an air compressor 1120; (2) a first air supply hose 1140; (3) a drop down air regulator 1160; (4) a first check valve 1180; (5) an air storage tank 1200; (6) a second air supply hose 1240; and (7) a coupler 1260 connectable to a fastener driving tool such as tool 50 described above. In this alternative example embodiment, all of the components are the same as described above, except that the drop down air regulator 1160 is connected to an outlet coupler of the air storage tank 1200. The drop down air regulator 1160 reduces the level of the air pressure received from the storage tank 1200 before that air pressure at a reduced second pressure level is communicated to the tool 50. This provides the same benefits as described above.

FIG. 3A illustrates a further alternative embodiment of the pressurized air supply apparatus of the present disclosure generally indicated by numeral 2100. The pressurized air supply apparatus 2100 is configured to supply pressurized air at a desired reduced air pressure level to the pneumatically powered fastener driving tool 50 (as part of the pneumatically powered fastener driving apparatus of the present disclosure). The pressurized air supply apparatus 2100 includes: (1) an air compressor 2120; (2) a first air supply hose 2140; (3) a drop down air regulator 2160; (4) a second air supply hose 2240; and (5) a coupler 2260 connectable to a fastener driving tool such as tool 50 described above. The drop down air regulator 2160 is removably mechanically and fluidly connectable to the first air hose 2140. The second air supply hose 2240 is removably mechanically and fluidly connected to the drop down air regulator 2160. The coupler 2260 is removably mechanically and fluidly connected to the second air hose 2240 and the pneumatic air connection coupler 58 of the tool 50. In this alternative example embodiment, all of the components are thus the same as described above, except that the air storage tank has been removed and the drop down air regulator 2160 is directly connected to the first air hose 2140. The drop down air regulator 2160 reduces the level of the air pressure received from the air compressor 2120 through the first hose 2140 before that air pressure at a reduced second pressure level is communicated through the second air hose 2240 to the tool 50.

Generally, in this example embodiment, the air compressor 2120 in configured to create pressurized air at a set first pressure level (such as set from about 90 psi to about 120 psi) and to supply that pressurized air through the first air supply hose 2140 to the drop down air regulator 2160. The drop down air regulator 2160 is configured to reduce the pressure level of that supplied pressurized air from the set first pressure level (such as from about 90 psi to about 120 psi) to a reduced second pressure level (such as from about 60 psi to about 100 psi). For example, if the first air pressure level is set at 100 psi, the reduced second pressure level can be about 80 psi. In various embodiments, the reduction of the pressure level is about 20 psi. In various other embodiments, the reduction of pressure level ranges from about 8 psi to about 10 psi. In various other embodiments, the reduction of pressure level ranges from about 8 psi to about 20 psi. The reduction can depend on various factors such as, but not limited to, characteristics of the air compressor and the first and second hoses, the tool, the nails driven by the tools, the object, and/or the substrate. The drop down air regulator 2160 is configured to supply the pressurized air at the set reduced second level to the second hose 2240. The pressurized air at the reduced second level flows through the second hose 2240 to and through the coupler 2260, to and through the coupler 58 of the tool 50, and into power supply of the tool 50.

In this example embodiment, even though the tool 50 is configured to optimally drive nails at about 90 psi to about 120 psi, the tool 50 will still operate at a sub-optimal pressure (for driving process and/or for the return process) to drive nails at reduced air pressures lower than about 90 psi (such as at about 80 psi). At such reduced air pressures, the tool 50 will drive each nail with relatively less force applied to the head of the nail. The pneumatically powered fastener driving apparatus of the present disclosure thus intentionally uses the pressurized air supply apparatus 2100 to supply pressurized air at a desired sub-optimal reduced pressure level to cause the pneumatically powered fastener driving tool 50 to drive the nail with sufficient amount of force to still drive the nail into the object and the substrate but not to drive the nail too far into the object and the substrate. Thus, again in this embodiment of the present disclosure, counter to conventional thinking regarding making such pneumatic fastener driving tools operate in optimal manners, the present disclosure contemplates making such pneumatic fastener driving tool operate in the described sub-optimal manner(s) to drive the nails at more desired force levels and to appropriately drive certain nails into certain objects and substrates. It should be appreciated that such sub-optimal operation is not required by various embodiments of the present disclosure. Additionally, it should be appreciated that at the reduced pressure level, the pneumatically powered fastener driving tool 50 will engage the head of the nail to drive the nail with sufficient amount of force without damaging a coating on the head of the nail as explained herein.

In this example embodiment, the air compressor 2120 can be any suitable air compressor that is configured to produce and output a continuous supply of pressurized air at a first air pressure level (such as and industry standard level of about 90 psi to about 120 psi). The air compressor 2120 in this illustrated example embodiment is electrically powered, although it can be powered by other suitable energy sources. The air compressor 2120 includes at least one air inlet port (not shown or labeled) and at least one air outlet port. This example air compressor 2120 is shown with three outlet ports 2130a, 2130b, and 2130c. The air compressor 2120 can include one or more outlet couplers (such as outlet coupler 2132) suitably connected to the respective air outlet port 2130a. It should be appreciated that while the air compressor 2120 can in certain circumstances be employed to only supply the tool 50 with pressurized air, in many circumstances the air compressor 2120 will be employed for supplying pressurize air to one or more various other tools and apparatus. Due to the potential or actual need to supply such other tools and apparatus, the air compressor 2120 may need to be set to supply air pressure at the first pressure level (such as the industry standard level of about 90 psi to about 120 psi).

The first air supply hose 2140 can be any suitable air supply hose configured to communicate pressurized air in accordance with the present disclosure. In this example embodiment, the first air supply hose 2140 is an elongated rubber hose having an ¼ or ⅜ inch (0.635 or 0.9525 cm) inner diameter and a length of 100 to 300 feet (30.48 to 91.44 meters). It should be appreciated that, in various alternative embodiments, the first air supply hose 2140 can be any suitable size, diameter, and length. The first air supply hose 2140 includes a first hose coupler 2144 at a first end 2142 of the first air supply hose 2140. The first hose coupler 2144 is configured to be removably securely attached to the outlet coupler 2132 of the air compressor 2120. The first air supply hose 2140 also includes a second hose coupler 2148 at an opposite second end 2146 of the first air supply hose 2140. The second hose coupler 2148 is configured to be removably securely attached to the drop down regulator 2160. In various embodiments, either one or both of these couplers 2144 and 2148 can be quick disconnect couplers.

In various embodiments, the first hose 2140 (that is upstream of the drop down air regulator 2160) can have a relatively large volume, and to a certain extent can function as an air storage device.

The drop down air regulator 2160 can be any suitable air pressure regulator that is configured to receive pressurized air at a first level and output pressurized air at a desired reduced second level. The drop down air regulator 2160 includes a housing 2162 and a suitable adjustable setting assembly (not shown) supported by the housing and that enables the operator to set the reduced second pressure level that the drop down air regulator 2160 will output. The drop down air regulator 2160 includes a housing 2162 and a suitable adjustable setting assembly (not shown) supported by the housing and that enables the operator to set the reduced second pressure level that the drop down air regulator