Automatic staple loading station

A magazine for use with a fastener driving tool, the magazine comprising:

• a cover portion including a pivotable door;
• a receiving portion that receives a cartridge through the pivotable door in an open position;
• an exit portion that includes an exit opening proximal to a guide body of a fastener driving tool;
• and
• a clamp mounted on the pivotable door, wherein the clamp biases the cartridge toward one side of the magazine that is proximal to the exit opening;
• wherein:
• the cartridge comprises a plurality of fastener strips arranged next to each other, in which the fasteners face in a downward direction;
• the cartridge exhibits a lead strip of fasteners that is positioned so as to be loaded next into the guide body;
• and
• the lead strip of fasteners is biased upward so as to be directed at the exit opening, regardless of the length of the fasteners in that lead strip;
• and
• the pivotable door is controlled by an actuator and remains closed except if a cartridge is being loaded into the receiving portion.

A magazine for use with a fastener driving tool, the magazine comprising:

• a cover portion including a pivotable door;
• a receiving portion that receives a cartridge through the pivotable door in an open position;
• an exit portion that includes an exit opening proximal to a guide body of a fastener driving tool;
• and
• a clamp mounted on the pivotable door, wherein the clamp includes a plurality of removably attachable plates that support the cartridge;
• wherein:
• the cartridge comprises a plurality of fastener strips arranged next to each other, in which the fasteners face in a downward direction;
• the cartridge exhibits a lead strip of fasteners that is positioned so as to be loaded next into the guide body;
• and
• the lead strip of fasteners is biased upward so as to be directed at the exit opening, regardless of the length of the fasteners in that lead strip.

An automatic fastener loader, comprising:

• an outer housing that includes an inlet loading portion, a main holding portion, and a dispensing outlet portion;
• the inlet loading portion comprises a first opening that is sized and shaped to receive at least one cartridge, the at least one cartridge containing a plurality of fasteners;
• the main holding portion is sized and shaped to contain a plurality of the at least one cartridge;
• the dispensing outlet portion comprises a second opening that is sized and shaped to dispense the at least one cartridge;
• a motor that is in mechanical communication with at least one chain drive, in which the at least one chain drive includes a continuous chain;
• and
• a first plurality of movable carriers, and a second, opposite plurality of movable carriers, such that the first and second plurality of movable carriers are positioned so as to not be in contact with each other, and to exhibit an open space therebetween;
• the first and second plurality of movable carriers are connected in pairs to the continuous chain of the at least one chain drive such that each one of the first plurality of movable carriers faces each one of the second plurality of movable carriers, and the chain drive moves the pairs of movable carriers from the inlet loading portion to the dispensing outlet portion, while each of the pairs of movable carriers is operable to carry the at least one cartridge;
• and
• as one of the pairs of movable carriers reaches the dispensing outlet portion, the chain drive allows the at least one cartridge to be moved through the second opening, and thereby unloaded from the automatic fastener loader;
• wherein:
• the outer housing at least partially encloses the first and second plurality of movable carriers, and the at least one chain drive.

A method for dispensing fasteners from an automatic loading station, the method comprising:

• (a) providing an automatic loading station comprising:
• (i) an outer housing that includes an inlet loading portion, a main holding portion, and a dispensing outlet portion;
• the inlet loading portion comprises a first opening that is sized and shaped to receive at least one cartridge, the at least one cartridge containing a plurality of fasteners;
• the main holding portion is sized and shaped to contain a plurality of the at least one cartridge;
• the dispensing outlet portion comprises a second opening that is sized and shaped to dispense the at least one cartridge;
• (ii) a motor that is in mechanical communication with at least one chain drive;
• (iii) a first plurality of movable carriers, and a second, opposite plurality of movable carriers at least partially enclosed by the outer housing;
• the first and second plurality of movable carriers are not in contact with each other, and exhibit an open space therebetween;
• the first and second plurality of movable carriers are connected to the at least one chain drive in pairs such that each one of the first plurality of movable carriers faces each one of the second plurality of movable carriers, and each pair is operable to carry the at least one cartridge;
• (b) moving the pairs of movable carriers, using the chain drive, from the inlet loading portion to the dispensing outlet portion;
• (c) loading the at least one cartridge onto a loading arm from one of the pairs of movable carriers;
• (d) providing an automatic magazine for use with a fastener driving tool, the magazine comprising:
• (i) a cover portion including a pivotable door;
• (ii) a receiving portion that receives the at least one cartridge through the pivotable door in an open position;
• (iii) an exit portion that includes an exit opening proximal to a guide body of a fastener driving tool;
• and
• (iv) a clamp mounted on the pivotable door, wherein the clamp includes a plurality of removably attachable plates that support the at least one cartridge;
• (e) opening the pivotable door of the magazine;
• (f) extending the loading arm from the dispensing outlet portion of the loading station towards the magazine;
• (g) loading the at least one cartridge into the magazine from the automatic loading station;
• (h) retracting the loading arm away from the magazine to the arm's original position;
• (i) closing the pivotable door of the magazine.

The method of claim 245, wherein:

• (a) the first gear system includes:
• a first plurality of planetary gear sets, in which each of the first plurality of planetary gear sets includes a first sun gear, a first plurality of planet gears, and a first ring gear;
• a first plurality of carrier gears that are attached to the first continuous chain;
• the first ring gear is in mechanical communication with the first plurality of carrier gears, which follow along the path of a first continuous chain;
• and
• the first chain drive includes a first plurality of sprockets which drive the first continuous chain;
• (b) the second gear system includes:
• a second plurality of planetary gear sets, in which each of the second plurality of planetary gear sets includes a second sun gear, a second plurality of planet gears, and a second ring gear;
• a second plurality of carrier gears that are attached to the second continuous chain;
• the second ring gear is in mechanical communication with the second plurality of carrier gears, which follow along the path of a second continuous chain;
• and
• the second chain drive includes a second plurality of sprockets which drive the second continuous chain;
• (c) further providing:
• a first plurality of rails that at least partially contain and guide the first continuous chain;
• and
• a second plurality of rails that at least partially contain and guide the second continuous chain;
• (d) wherein:
• the first plurality of rails directing the first plurality of movable carriers in a manner that each first carrier is substantially parallel to the loading arm if the first chain drive is in motion;
• the second plurality of rails directing the second plurality of movable carriers in a manner that each second carrier is substantially parallel to the loading arm if the second chain drive is in motion;
• the first plurality of planet gears working together with the first ring gear to direct the first plurality of movable carriers in a manner that each first carrier is substantially parallel to the loading arm as each one of the first plurality of carriers is moved around the first ring gear;
• and
• the second plurality of planet gears working together with the second ring gear to direct the second plurality of movable carriers in a manner that each second carrier is substantially parallel to the loading arm as each one of the second plurality of carriers is moved around the second ring gear.