U.S. patent application number 10/060411 was filed with the patent office on 2003-08-07 for packaged nails suitable for sheathing having enlarged diameter heads for enhanced retention.
This patent application is currently assigned to STANLEY FASTENING SYSTEMS, L.P.. Invention is credited to Sutt, Edward G. JR..
Application Number | 20030146121 10/060411 |
Document ID | / |
Family ID | 27658314 |
Filed Date | 2003-08-07 |
United States Patent
Application |
20030146121 |
Kind Code |
A1 |
Sutt, Edward G. JR. |
August 7, 2003 |
Packaged nails suitable for sheathing having enlarged diameter
heads for enhanced retention
Abstract
The present invention provides a nail suitable for sheathing
which provides an enhanced resistance to failure. The nail includes
an enlarged head as well as a shank having surface deformations.
Sheathing panels are secured to a framing structure through the use
of the nail. The enlarged head provides a first clamping surface
that is seated against an exterior surface of the sheathing panel.
The framing structure within which the shank is secured is a second
clamping surface. Through the provision of an enlarged head and a
shank having surface deformations, the ability of the nail to
maintain the securement of the sheathing panel to the framing
structure element is enhanced. A plurality of the nails are
disposed within a package suitable for use with mechanical
drivers.
Inventors: |
Sutt, Edward G. JR.;
(Jamestown, RI) |
Correspondence
Address: |
PILLSBURY WINTHROP, LLP
P.O. BOX 10500
MCLEAN
VA
22102
US
|
Assignee: |
STANLEY FASTENING SYSTEMS,
L.P.
EAST GREENWICH
RI
|
Family ID: |
27658314 |
Appl. No.: |
10/060411 |
Filed: |
February 1, 2002 |
Current U.S.
Class: |
206/338 |
Current CPC
Class: |
F16B 15/06 20130101;
F16B 15/08 20130101 |
Class at
Publication: |
206/338 |
International
Class: |
B65D 085/24 |
Claims
What is claimed is:
1. A package of collated nails suitable for sheathing comprising: a
plurality of nails suitable for sheathing, each nail comprising: a
substantially round head having a flat top surface suitable for
being driven into a flush relationship with an exterior surface of
a sheathing panel and a bottom surface, the head further having a
head diameter; a single elongate shank integral with the head and
extending from the head bottom surface, the elongate shank further
including a point opposite the head, and a plurality of surface
deformations formed on the shank, the surface deformations being
configured to provide an enhanced resistance to panel separation by
withdrawal of the nail shank from a framing structure, the shank
further having a substantially round cross-section having a shank
diameter between 0.092 and 0.148 in.; wherein: each nail is
manufactured from steel wire; each nail has a length defining the
distance from the head to the shank point, the length being between
1.625 inches and 3.00 inches; for the nail length, the shank
diameter of each nail generally corresponds to a shank diameter as
specified by ASTM F1667-95 for common nails of that nail length
specified for use with mechanical drivers, the head diameter
providing an enlarged bottom head surface area for engaging the
exterior surface of the sheathing panel to enhance resistance to
panel separation by head pull through; and the ratio of the head
diameter to shank diameter of each nail is between 2.70 and 3.37;
and at least one attachment element constructed to temporarily
attach the plurality of nails into a package.
2. The package of collated nails of claim 1, wherein the surface
deformations of each nail comprise a plurality of longitudinally
spaced apart rings extending radially outwardly from the shank.
3. The package of collated nails of claim 1, wherein the length of
each nail is approximately 2 inches, the shaft diameter is
approximately 0.113 in., the head diameter is approximately 0.320
in., and the ratio of head diameter to shaft diameter is
approximately 2.83.
4. The package of collated nails of claim 1, wherein the length of
each nail is approximately 2.5 inches, the shaft diameter is
approximately 0.113 in., the head diameter is approximately 0.320
in., and the ratio of head diameter to shaft diameter is
approximately 2.83.
5. The package of collated nails of claim 1, wherein the head of
each nail has a circular shape.
6. The package of collated nails of claim 1, wherein the surface
deformations are disposed at least between a middle position on the
shank, halfway between the point and the head, and the point.
7. The package of collated nails of claim 1, wherein the shank has
a circular cross-section.
8. The package of collated nails of claim 1, wherein the attachment
element comprises a frangible plastic binding element attached to
each nail of the package.
9. The package of collated nails of claim 1, wherein the attachment
element comprises a frangible wire welded to each nail of the
package.
10. The package of collated nails of claim 1, wherein the
attachment element comprises frangible paper attached to each nail
of the package.
Description
[0001] Reference is made to co-pending applications DKT SFS-178
REG2 and DKT SFS-178 REG3, both entitled "Power Driven Nails for
Sheathing Having Enlarged Diameter Heads for Enhanced Retention and
Method," and both filed on the same day as the present application
and hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Wooden structural elements can be fastened together by
driven fasteners such as common nails. Nails have a head and a
shank. The head provides an impact surface onto which a force is
applied to drive the fastener. The shank typically includes a
pointed end opposite the head. The pointed end pierces the wooden
structural elements, thus diminishing the force required to drive
the nail into the structural element.
[0003] Nails are typically used to fasten an outer structural
element to an inner structural element. The fastening of an outer
and inner wooden structural elements is complete when the head is
flush with the outer structural element and the shank has been
driven entirely through the outer structural element into the inner
structural element.
[0004] One specific use of nails is the securement of structural
elements such as panelized structural sheathing (plywood, oriented
strand board (OSB), etc.) to inner structural framing elements
(e.g., joists, 2.times.4's, and roof rafters). Structural
sheathing, as defined by the 1999 APA Panel Handbook & Grade
Glossary, which is incorporated herein by reference, is the
"structural covering, usually of wood panels or boards, on the
outside surfaces of framing. It provides support for construction,
snow and wind loads and backing for attaching exterior facing
materials such as wall siding, roof shingles or underlayment in
double layer floors."
[0005] Structural sheathing is typically vulnerable to uplift in a
large wind event such as a tornado or hurricane. Structural
sheathing is also vulnerable to earthquake loads where large
deflections of structural elements, to which the sheathing is
secured, may occur. In highly stressed situations, of which high
winds and earthquakes are but two examples, the retention of the
sheathing is necessary to minimize property damage.
[0006] There are three types of loading conditions that can occur
to cause a nail to fail: an axial force (a load parallel to the
nail shank), a shear force (a load perpendicular to the nail
shank), and a combination of these two loading conditions. In a
situation where a nail is axially loaded the nail can typically
fail in one of two modes. A first failure mode is a withdrawal
failure. A withdrawal failure occurs when the nail shank withdraws
from the inner structural element allowing the outer structural
element to separate from the inner structural element. A second
failure mode is known as a "pull through" failure. A pull through
failure occurs when the nail head is pulled through the outer
structural element allowing the outer structural element to
separate from the inner structural element. In a situation where
the nail is loaded in a shear condition, there are numerous failure
modes that can occur: withdrawal, pull through, wood crushing, and
nail shank bending.
[0007] ASTM F1667-95 is the standard specification that covers
driven fasteners including common nails. Head sizes for nails such
as common nails are specified within this standard. Head size has
typically been set for nails such as common nails based on the
shank diameter and shank length.
[0008] ASTM F1667-95 includes a Table 16, which is the standard
specification for nails for use mechanical drivers. The nails
listed in this table are denoted as common nails. The nails listed
in this table have a length and a shank diameter. However, nail
head sizes are not listed in this specification. In Table 15 of the
ASTM F1667-95 Standard Specification, the head sizes for common
nails which are not mechanically driven are provided. Additionally,
it should be noted that nails other than those listed in Table 16
(i.e., Tables 3-15 and 17-55) are typically not specifically
specified for use with mechanical drivers and would typically be
sold in bulk. However, some of the these other nails are available
in a packaged form for use with a mechanical driver.
[0009] Head sizes for nails mechanically driven are typically
smaller than those which are not mechanically driven (i.e.,
manually driven). Smaller head sizes are needed for mechanically
driven nails because mechanically driven nails are more typically
sold in a packaged collated form and there is often a requirement
that the nail package be as dense as possible. In particular,
packaged nails sold in a stick form typically require a minimum of
spacing separating the nail shanks of adjacent nails. For this
reason, large head sizes have typically not been used for nails
sold in a packaged form. Additionally, small nail head sizes have
been used for mechanically driven nails, because larger nail head
sizes have been considered detrimental to easily passing through
the mechanical driver. Consequently, smaller head sizes have been
used for nails which are sold in package form to be driven by
mechanical drivers than would be used for manually driven nails
sold in bulk. Mechanical drivers also typically have a maximum nail
head size that is usable with the mechanism.
[0010] NER-272 is the document that governs the design capacities
allowed for power driver nails in wood framed construction.
Additionally, it is the document that allows the power driven
fastener to be utilized in lieu of a hand driven fastener in the
major building codes (BOCA, ICBO, and SBCCI). The tables in
NER-272(5-22 and 28-37) specify the nail diameter, length and
spacing for use in the attachment of structural sheathing to a
framing member for a floor, wall or roof. The nails specified for
these structural applications have a length between 15/8 and 3
inches with a diameter between 0.092 and 0.148 in. Basically, it
can be determined that a conventionally acceptable nail for
sheathing is:
[0011] 1. Manufactured from a form of steel wire;
[0012] 2. Has a single round shank;
[0013] 3. Has a shank diameter between 0.092 and 0.148 in.; and
[0014] 4. Has a length between 15/8 and 3 inches.
[0015] In addition to the four criteria listed above, it is also
recognized that nails suitable for sheathing preferably have
surface deformations, which are typically barbs, to provide a
resistance to pull out.
[0016] There exists a need for a package of collated nails that is
more cost effective than existing nails that achieve the desired
functional characteristics for sheathing nails. There particularly
exists a need for such sheathing nails that can be used for high
uplift applications, such as roof sheathing.
SUMMARY OF THE INVENTION
[0017] The present invention comprises a package of collated nails.
Each nail of the plurality of nails is preferably manufactured from
steel wire. Each nail preferably comprises a full round head having
a flat top surface suitable for being driven into a flush
relationship with an exterior surface of a sheathing panel and a
bottom surface. A single elongate shank that is integral with the
head extends from the head bottom surface. The elongate shank
further includes a point opposite the head and a plurality of
surface deformations disposed on the shank. The surface
deformations are configured to provide an enhanced resistance to
panel separation by withdrawal of the nail shank from a framing
structure. The shank has a substantially round cross-section having
a shank diameter between 0.092 and 0.148 in. Each nail further has
a length between 1.625 inches and 3.00 inches. For the nail length,
the shank diameter generally corresponds to a shank diameter as
specified by ASTM F1667 95 for common nails of that nail length
specified for use with mechanical drivers. The head diameter
provides an enlarged bottom head surface area for engaging the
exterior surface of a sheathing panel to enhance resistance to
panel separation by head pull through. The ratio of the head
diameter to shank diameter is between 2.70 and 3.37. The package
further includes at least one attachment element constructed to
temporarily attach the plurality of nails into a package. The
attachment element comprises in one embodiment of the invention a
frangible plastic binding element attached to each nail of the
package. The attachment element in another embodiment of the
invention comprises a frangible wire welded to each nail of the
package.
[0018] An outer structural element is secured to an inner
structural element through the use of the nail of the present
invention. The nail of the present invention has particular
benefits in applications such as the securement of outer structural
elements such as panelized structural sheathing (plywood,
orientated strand board (OSB), etc.) to inner structural framing
elements such as joists, 2.times.4's, and roof rafters, which are
typically used in framing structures.
[0019] The enlarged head provides a first clamping surface that is
seated against an exterior surface of the sheathing panel into
which the nail is first driven. The framing structure within which
the deformed shank is disposed, is the second clamping surface.
Through the provision of an enlarged head and a deformed shank, the
ability of the nail to maintain the securement of the sheathing
panel to the framing structure is enhanced. The nail of the present
invention provides a nail head clamping surface of the necessary
size to clamp a sheathing panel between the nail head and a framing
structure, within which the deformed shank is disposed.
[0020] The shank of the present invention nail includes surface
deformations such as rings to resist withdrawal. Accordingly, the
deformed shank increases the force required to withdraw the nail
shank from the framing structure (i.e. the withdrawal
capacity).
[0021] The enlarged head of the present invention nail increases
the surface area in contact with the exterior surface of a
sheathing panel. The enlarged surface area subsequently ensures
that a larger area of the sheathing panel would have to be pulled
though the nail head for a pull through failure to occur.
Accordingly, the pull through capacity of the sheathing panel is
correspondingly increased through the use of the nail of the
present invention.
[0022] The pull through capacity of a sheathing panel may be
determined experimentally. The withdrawal capacity of the nail
shank may also be determined experimentally. Accordingly, the nails
of the present invention may be designed such the withdrawal
capacity exceeds the pull through capacity.
[0023] One embodiment of a nail manufactured in accordance with the
present invention has been shown in experiments to provide up to a
20-97 percent increase in panel uplift capacity as compared to 8d
common nails with similar nail spacing. Additionally, the nail of
the present invention has been shown in experiments to provide a 14
percent increase in shear capacity and similar energy dissipation
as compared to 8d common nails. The enlarged nail head has been
shown in experiments to provide a 10 percent increase in pull
through capacity as compared to 8d common nails.
[0024] The nail of the present invention also has particular
benefits in applications such as the securement of outer structural
elements such as structural sheathing used in sub-flooring to floor
joists or other load bearing structural elements in the
sub-flooring. If the nails used to secure the sheathing to the
sub-flooring loosen, the floor will squeak. Squeaking floors
present a nuisance and source of irritation for home dwellers where
this phenomenon occurs. The nail of the present invention provides
a clamping force on the sub-floor sheathing. This clamping force
minimizes the possibility that nails used to fasten the sub-floor
sheathing will loosen and that floors secured by the nails will be
less likely to squeak.
[0025] Other advantages of the nail of the present invention are
also derived from the enlarged diameter nail head. Nails should be
driven until the nail head is flush with exterior surface of the
sheathing. If the nail is power driven, there is an opportunity to
drive a nail beyond the flush position, to a position beneath the
exterior surface of the sheathing. The nail head compresses and
damages the cellular structure of the sheathing as it is driven
past the flush position. The strength of the sheathing is
correspondingly lowered as a result of an over driven nail. The
enlarged head of the nail of the present invention provides a large
surface area that is more easily driven to a position where the
head is contacting the exterior surface of the sheathing and is
substantially flush with the sheathing surface. The large surface
area of the enlarged nail head distributes the driving impact
forces over a greater area, thus minimizing the possibility that
the nail can be over driven. And, as the structural damage caused
by overdriving the nail head is less likely to occur through the
use of the nail of the present invention, pull through failures are
correspondingly decreased.
[0026] These and other aspects and advantages of the invention can
be realized by the embodiments of the nail of the invention. Other
objects, aspects, and advantages of the embodiments of the
invention will become apparent from the detailed description taken
in conjunction with the drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0027] FIG. 1 is a side view of a plurality of nails of an
embodiment of the present invention disposed in a collated
package.
[0028] FIG. 2A is a side view of a plurality of nails of another
embodiment of the present invention disposed in a collated stick
package.
[0029] FIG. 2B is a side view of a plurality of nails of yet
another embodiment of the present invention disposed in a collated
stick package.
[0030] FIG. 3 is a cross-sectional side new of the embodiment of
the nail of the present invention shown in FIG. 1 taken along line
3-3.
[0031] FIG. 3A is a top view of the embodiment of the nail of the
present invention shown in FIG. 3 taken along line A-A.
[0032] FIG. 4 is a side view of the embodiment of the present
invention shown in FIG. 3 used to secure a sheathing panel to a
framing structure.
[0033] FIG. 5 is an enlarged side view, in cross-section of the
embodiment of the present invention in FIG. 3 showing a portion of
the deformed shank.
DETAILED DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 shows a plurality of nails 10 disposed in a collated
package 100. Frangible wires 102 and 104 are welded to the shanks
of each nail so as to attach the plurality of nails 10 together
into the collated package 100. Although the collated nail package
100 shown is in a flattened configuration, it is understood that
the frangible wires are flexible and would allow the collated
package to be disposed in a coiled configuration.
[0035] FIG. 2A shows a plurality of nails 10 disposed in a collated
package 200. A plastic binding element 202 is used to attach the
plurality of nails together into the collated package.
[0036] FIG. 2B shows a plurality of nails 10 disposed in a collated
package 300. A paper binding element 302 is used to attach the
plurality of nails together into the collated package.
[0037] FIG. 3 shows an embodiment of the nail 10 of the present
invention of FIG. 1. The nail 10 is preferably manufactured from a
form of steel wire. The nail 10 includes a enlarged round head 20
having a substantially planar, flat top surface 21 and a bottom
surface 22. The flatness of the top surface enables it to be driven
into a flush relationship with the exterior surface of a sheathing
panel. The enlarged head top surface 21 is adapted for receiving a
driving impact force, and is particularly suited to be driven by a
power driving tool, such as (but not limited to) a pneumatically
operated driving tool. The head bottom surface 22 is adapted for
contact with an exterior surface of a wooden structural element. As
is shown in FIG. 3A, the enlarged head 20 has a full round,
preferably circular shape.
[0038] The nail 10 also includes a single elongate shank 24 which
is integral with the head and extends from the enlarged head bottom
surface 22. As is shown in FIG. 3, the shank 24 is preferably
centered with respect to the head 20. The shank 24 includes a point
26 opposite the head and a middle position half way between the
point 26 and the head 20. The shank 24 preferably has a
substantially round, preferably circular cross-sectional shape. The
shank 24 preferably includes a plurality of surface deformations,
which as shown are preferably spaced apart pointed rings 28. The
rings 28 are preferably disposed between the middle position of the
shank and the point 26. Each of the rings 28 preferably have a
tapered configuration with a larger diameter toward the nail head
and a smaller diameter toward the nail point 26, with the shank 24
being substantially smooth above the rings 28. The rings 28 are
preferably not more than halfway up the shank 24 from the point 26,
but may be less than halfway up the shank. Accordingly, the rings
28 function as a barb and easily penetrate into structural elements
but are difficult to extract. The embodiment of the nail 10 shown
in FIG. 3 is suitable for wooden structural applications.
[0039] The nail 10 has specific application in the securement of an
exterior panelized structural element, such as panelized sheathing,
to inner structural framing elements, such as joists, 2.times.4's
and roof rafters, which are commonly used in framing structures.
FIG. 4 shows a structural configuration of an outer sheathing panel
40 (in one set of examples the panels 40 may have dimensions in a
range of 4' wide .times.8' long .times.1/4"-11/8" thick) attached
to an inner structural framing element 42 (e.g., a "two-by-four")
of a framing structure. As can be seen in this figure, the nail
head 20 has been driven until the head 20 is substantially flush
with the exterior surface 41 of the sheathing panel 40. The shank
24 is driven entirely through the sheathing panel 40 into the inner
structural framing element 42. The shank rings 28 are disposed
within the inner structural framing element 42.
[0040] The nail 10 provides a clamping force on the sheathing panel
40 securing the sheathing panel 40 to the inner structural framing
element 42. Specifically, the nail 10 clamps the sheathing panel 40
between the enlarged head 20 and the inner structural framing
element 42, within which the shank 24 is secured.
[0041] The enlarged head 20 engages the exterior surface 41 of the
sheathing panel 42 with a contact surface having a large area. The
large contact surface provided by the enlarged head 20 results in a
situation where forces that would potentially loosen the sheathing
panel 40 are distributed over the large surface area of the
enlarged head. Accordingly, the large contact surface diminishes
the chance that the sheathing panel can pull through the nail head
20. The shank rings 28 firmly engage the inner structural framing
element 42, thus diminishing the likelihood that the shank can
loosen or be pulled from the inner structural element 42. The large
surface area of the enlarged head 20 and the secure retention of
the shank 24 results in the sheathing panel 40 essentially being
clamped between the enlarged head 20 and the inner structural
framing element 42.
[0042] FIG. 5 is an enlarged cross-sectional side view of the
embodiment of the present invention in FIGS. 1-4 showing a portion
of the shank 24, having the surface deformations. The deformations
preferably include the aforementioned spaced apart rings 28, which
are disposed along the lower portions of the shank 24, specifically
between the middle position of the shank and the nail point 26.
[0043] Two specific, non-limiting examples of preferred embodiments
of the nail of the present invention are as follows. The first
specific embodiment includes a length of about 2 inches and a shank
diameter of about 0.113 in. The head diameter is about 0.320 in.
The ratio of the head diameter to the shank diameter is about 2.83.
The shank length to shank diameter is about 17.70, and the shank
length to head diameter is about 6.25. The second embodiment
includes a length of about 21/2 inches and a shank diameter of
about 0.113 in. The head diameter is about 0.320 in. The ratio of
the head diameter to the shank diameter is about 2.83. The shank
length to shank diameter is about 22.12, and the shank length to
head diameter is about 7.81.
[0044] In accordance with one aspect of the present invention, a
maximum head size of 0.320 in. is employed, as this corresponds to
the maximum head size that can be used with certain existing
commercially available mechanical nail drivers.
[0045] The specific embodiments of the present invention described
above have particular utility in structural applications where a
high resistance to pull through failures is required. For example,
the specific embodiments of the present invention described above
have particular utility in areas where high uplift forces are
present. Accordingly, the nails of the present invention would
provide a significant benefits to the attachment of structural roof
sheathing to roof trusses or other wooden framing elements used in
a roof structure. The specific embodiments of the present invention
described above would also provide both strength and stiffness
benefits in high shear situations.
[0046] It is to be understood that the two embodiments described
above are only two out of many different possible preferred
embodiments of the nail of the present invention. The various
preferred embodiments of the present invention include a length
between 1.625 and 3.00 inches, a substantially round, preferably
circular cross-section shank having a diameter between 0.092 and
0.148 in. and a head diameter sized such that the ratio of the head
diameter to the shank diameter is between 2.70 and 3.37. A more
preferred range of the ratio of the head diameter to the shank
diameter for the invention would be between 2.70 and 3.00. A ratio
of the head diameter to the shank diameter over 3.00 typically is
more difficult to manufacture than a ratio below 3.00. Nails having
a ratio above 3.00 typically require two blows to manufacture the
nail head from the steel wire from which the nail is constructed.
Nails having a ratio below 3.00 typically require only a single
blow to manufacture the nail head.
[0047] It is also to be understood that a nail having a ratio of
the head diameter to the shank diameter less than 2.70 would not
provide the resistance to pull through failures to the extent that
is provided by the preferred embodiments of the invention, while
providing a resistance to withdrawal and to shear failure. It is
also understood that a nail having a ratio of the head diameter to
the shank diameter greater than 3.37 would be more suitable for the
securement of shingles than for sheathing.
[0048] In accordance with NER-272 Section 3.3.2, the shank of the
nails of the present invention preferably have a minimum average
bending yield strength of 100 KSI (689 MPa) for nails having a
nominal diameter of 0.135 in. or less. In addition, nails with
diameters greater than 0.135 in. shall have a minimum average
bending yield strength of 90 KSI (620 MPa). It must be noted,
however, that the present invention includes nails that do not meet
the minimum bend yield strength noted above, as not meeting this
strength requirement increases ductility and resistance to cyclic
shear.
[0049] The various preferred embodiments of the invention are
preferably provided either in a bulk form or in a packaged collated
form that is suitable for use with mechanical drivers such as
pneumatic nail guns. Preferred embodiments of packaged collated
nails of the present invention were shown in FIGS. 1, 2A and 2B. It
is understood that collated nail packages having configurations
other than what is shown in FIGS. 1, 2A and 2B, such as what are
commonly known as "stick" packages, are also possible within the
scope of the invention.
[0050] The various preferred embodiments of the invention
preferably include a plurality of surface deformations such as
rings. The plurality of surface deformations are disposed on the
lower portion of the shank, preferably at least between the middle
position of the shank and the point. In another embodiment of the
invention, the entirety of the shank between the middle position
and the point could include surface deformations. Shank rings of
shapes other than what is shown in the preferred embodiment are
also possible within the scope of the invention. Additionally,
shank deformations other than rings are also possible within the
scope of the invention.
[0051] In the embodiments shown in FIGS. 1 through 5, nails
suitable for sheathing are configured to provide high retention. It
is preferable that the nail head diameter, and the corresponding
surface area, are sized so that the benefits of the invention are
achieved.
[0052] While advantageous embodiments have been chosen to
illustrate the invention, it will be understood by those skilled in
the art that various changes and modifications can be made therein
without departing from the scope of the invention.
* * * * *