U.S. patent application number 11/744939 was filed with the patent office on 2008-11-13 for hidden deck fastener and method of use.
This patent application is currently assigned to RES-Q-JACK, INC., DBA CEPCO TOOL COMPANY. Invention is credited to Michael Deschamps.
Application Number | 20080279654 11/744939 |
Document ID | / |
Family ID | 39969675 |
Filed Date | 2008-11-13 |
United States Patent
Application |
20080279654 |
Kind Code |
A1 |
Deschamps; Michael |
November 13, 2008 |
HIDDEN DECK FASTENER AND METHOD OF USE
Abstract
A hidden deck fastener for joining adjacent deck boards and
securing the boards to an underlying joist includes a biscuit core
having an upper face and a lower face, two supporting leg members
attached to the lower face, arranged on opposite sides of a central
region of the biscuit core and extending downwardly, a screw well
located in the central region, the screw well having a central
cavity within the upper face and a controlled flash continuous with
the lower face, the controlled flash defining the bottom of the
well, a ridge defining a central beam extending through a least a
lower portion of the screw well, the central beam extending between
the leg members through the central region of the biscuit core, and
foot members connected to the lower end of the legs, defined by a
living hinge groove at the lower end of the legs.
Inventors: |
Deschamps; Michael; (Elmira,
NY) |
Correspondence
Address: |
AQUILLA PATENTS & MARKS, PLLC
221 COE HILL ROAD
CENTER HARBOR
NH
03226-3605
US
|
Assignee: |
RES-Q-JACK, INC., DBA CEPCO TOOL
COMPANY
Elmira
NY
|
Family ID: |
39969675 |
Appl. No.: |
11/744939 |
Filed: |
May 7, 2007 |
Current U.S.
Class: |
411/457 |
Current CPC
Class: |
E04F 15/02 20130101;
E04F 2201/05 20130101; E04F 2019/0427 20130101; E04F 2015/02094
20130101 |
Class at
Publication: |
411/457 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Claims
1. A fastening device, comprising: a) a biscuit core having an
upper face and a lower face; b) two supporting leg members
extending downwardly from the lower face, arranged on opposite
sides of a central region of the biscuit core; c) a screw well
located in the central region, the screw well comprising a central
cavity within the upper face and a controlled flash continuous with
the lower face, the controlled flash defining the bottom of the
well.
2. The device of claim 1, further comprising: d) a ridge defining a
central beam extending through a least a lower portion of the screw
well, the central beam extending between the leg members through
the central region of the biscuit core.
3. The device of claim 2, further comprising: e) a foot member
connected to a lower end of at least one of the leg members, the
foot member being defined by a living hinge groove formed within
the lower end of the leg member.
4. The device of claim 1, wherein the central cavity of the screw
well has a beveled edge.
5. The device of claim 4, wherein the central cavity of the screw
well is non-circular and elongated.
6. The device of claim 1, wherein the biscuit core and the
supporting leg members are unitarily formed.
7. The device of claim 6, wherein the device comprises a polyolefin
or a thermoplastic material.
8. The device of claim 7, wherein the material is polypropylene,
polyethylene or high density polyethylene.
9. The device of claim 8, wherein the device is manufactured by
injection molding.
10. A fastening device, comprising: a) a biscuit core having an
upper face and a lower face; b) two supporting leg members
extending downwardly from the lower face, arranged on opposite
sides of a central region of the biscuit core; c) a screw well
located in the central region, the screw well comprising a central
cavity within the upper face and a controlled flash continuous with
the lower face, the controlled flash defining the bottom of the
well; d) a ridge defining a central beam extending through a least
a lower portion of the screw well, the central beam extending
between the leg members through the central region of the biscuit
core; and e) a foot member connected to a lower end of at least one
of the leg members, the foot member being defined by a living hinge
groove formed within the lower end of the leg member.
11. The device of claim 10, wherein the central cavity of the screw
well has a beveled edge.
12. The device of claim 10, wherein the central cavity of the screw
well is non-circular and elongated.
13. The device of claim 10, wherein the biscuit core and the
supporting leg members are unitarily formed.
14. The device of claim 13, wherein the device comprises a
polyolefin or a thermoplastic material.
15. The device of claim 14, wherein the material is polypropylene,
polyethylene or high density polyethylene.
16. The device of claim 15, wherein the device is manufactured by
injection molding.
17. A method for joining boards, comprising the steps of: a)
providing one or more two boards to be joined and a supporting
joist therefore; b) providing a fastener according to claim 1; and
c) inserting the fastener into a receiving slot of the board and
driving a nail or screw through the controlled flash and into the
joist.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention pertains to the field of joining and
connecting systems. More particularly, the invention pertains to a
fastener for joining adjacent boards and for securing the boards to
an underlying support, such as a joist, being particularly
well-suited for outdoor platform deck construction.
[0003] 2. Description of Related Art
[0004] Outdoor spaced board platforms, generally referred to as
decks, are becoming increasingly popular additions to homes,
offices, restaurants and the like. They generally are made from a
plurality of elongate, flat laid, closely spaced boards, connected
to and supported on their bottom surfaces by framing with spaced
joists, stringers, beams or the like, forming a secure floor.
[0005] Deck boards traditionally are cut from natural wood or
pressure-treated lumber, but have been increasingly manufactured
from various composites made from wood and/or other cellulosic
materials mixed with various resins, or even plastics and various
metals. It is now common for decks to be constructed of hard woods
or weatherproof composite materials.
[0006] In constructing conventional wood decks, for example, the
standard method is to nail directly through the deck boards into
the supporting joist members. The problems associated with this
method are well known and include: (1) nails backing out with
seasonal swelling and shrinkage of the wood, (2) rusting of the
nails and staining of the deck boards, (3) wood bruises of the deck
boards by hammer marks, and (4) loosening of the boards due to nail
pull out.
[0007] Unlike conventional treated lumber decks, which typically
are nailed or screwed to underlying joists, hardwood deck boards
and composite deck boards typically are secured with hidden
fasteners or clips to provide a more finished appearance free of
visible nail and screw holes. Numerous examples of various
fastening devices have been proposed for the purpose of fastening
adjacent deck boards to one another and/or securing deck boards to
the supporting joists. In some cases, hidden fasteners are inserted
into pre-cut slots or biscuit jointer slots formed in the deck
boards, and then screwed to the underlying deck joists to hold the
deck boards against the joist.
[0008] U.S. Pat. No. 6,851,884 discloses an anchoring biscuit
device for joining three boards, wherein the biscuit-shaped device
includes sidewalls that are not opposite arcs. It includes, (a) a
first substantially flat horizontal top element having a generally
biscuit-shaped configuration, with opposite sidewalls, at least one
of said sidewalls having a flat edge, and at least a portion of
said sidewalls being non-parallel with respect to one another; (b)
at least one substantially vertical support member attached to the
underside of the top element and extending downwardly therefrom for
a predetermined length for joinder of two adjacent boards which
have been pre-cut with biscuit receiving slots, and, (c) an
attachment orifice located at least on the top element for
attachment of the anchoring biscuit device to a support board for
anchoring and support of the two adjacent boards.
[0009] U.S. Pat. No. 6,402,415 discloses an anchoring biscuit
device for joining three boards. It includes, (a) a first
substantially flat horizontal top element having a generally
biscuit-shaped configuration, (b) at least one substantially
vertical support member attached to the underside of the top
element and extending downwardly therefrom for a predetermined
length for joinder of two adjacent boards which have been pre-cut
with biscuit receiving slots, and, (c) an attachment orifice
located at least on the top element for attachment of the anchoring
biscuit device to a support board for anchoring and support of the
two adjacent boards.
[0010] U.S. Pat. No. 5,738,473 discloses a fastener for securing
boards to joists, having first and second sharp, pointed prongs.
The first prong has a driving portion for driving the prong at an
angle through a first board and a joist thereunder. The second
prong extends from the first prong at an angle in the range of
about 30 to 60 degrees and acts to secure an adjacent board to the
first board. In another aspect, a fastener for securing boards to
joists thereunder includes a first member having two parallel
sharp, pointed prongs, and a third sharp, pointed prong extending
from the first member at an angle in the range of about 35-55
degrees. One of the prongs of the first member is driven into a
first board and the other of the prongs is driven into the joist.
The third prong secures an adjacent board to the first board.
[0011] U.S. Pat. No. 5,027,573 discloses an attachment system,
method and connector connection for constructing a structure having
supporting members and supported members, as most commonly found in
house and patio wood decks, board walks, stair systems, wood
benches and trellis systems. The structures are characterized by
the apparent absence of nails or other fasteners, however, the
structures are securely fastened by nails or screw fasteners in
combination with a connector, which is not directly connected to
the supporting members.
[0012] U.S. Pat. No. 4,925,141 discloses a relatively simple, one
nail deck bracket that includes a planar body with prongs extending
outwardly from each side thereof for uniformly spacing and
interconnecting adjacent planks, and a planar arm extending
downwardly from the bottom edge of the body in a plane
perpendicular to or otherwise angled with respect to the plane of
the body for bearing against one side of the joist, the arm having
a hole for receiving a nail for connecting the bracket to the
joist. Two arms can be provided at opposite ends of the body for,
in effect, straddling the joist.
[0013] U.S. Pat. No. 4,620,403 discloses a nailing anchor for use
in fixedly attaching a series of parallel wooden boards to a
transverse joist. The member has two flat, horizontal tabs each
positionable between one of a pair of adjacent boards and the
joist. The tabs are fixedly attached to a flat spacer body and
extend perpendicularly therefrom in opposite directions. A hole in
the one tab allows the anchor to be nailed to the joist. An
elongated slot in the spacer body allows the anchor to be
toe-nailed through the one adjacent board into the joist. A flat,
triangular point depends perpendicularly from an upper edge of the
spacer for fastening the one board to the spacer body.
[0014] U.S. Pat. Nos. D485,160, D488,373, and D470,039 disclose
various ornamental designs for hidden fastening biscuit
devices.
[0015] U.S. Publication No. 20060107612 discloses an anchoring
device comprising a generally horizontal top element having an
elongate, generally vertical, collapsible element extending
downwardly from the underside thereof, the horizontal top element
comprising a metallic plate reinforced plastic.
[0016] U.S. Publication No. 20060059822 discloses a deck clip
comprising a generally vertically extending leg, and a pair of arms
extending from an upper edge of the leg. Each arm is configured for
insertion into a slot of a deck board and presents an enlarged
lobe. When the deck clip is screwed to a deck joist, the lobes grip
the deck boards and hold them tight against the joist. The shape of
the lobes increases the gripping force between the lobes and the
deck boards as adjacent boards are hammered or otherwise pushed
together. The lobes facilitate the gripping of the boards and help
maintain the desired gap between adjacent boards for the life of
the deck.
[0017] Other deck fasteners are known as well. Although there are
numerous known devices that are intended to aid in fastening
adjacent deck boards to one another and/or securing deck boards to
the supporting joists, unfortunately, prior art deck clips suffer
from several problems, which limit their utility. For example, many
prior art deck clips don't provide substantial holding force,
resulting in loose deck boards. Many prior art deck clips also are
difficult to install or do not effectively grip the deck boards,
often causing the boards to shift. Thus, there is a need in the art
for an improved hidden deck fastener that is easy to install and
effectively grips the deck boards and secures them to the
joists.
SUMMARY OF THE INVENTION
[0018] The present invention provides a fastener for fastening
adjacent deck boards to one another and securing the deck boards to
the supporting joist. Briefly stated, the apparatus according to
the invention provides a hidden deck fastener including a biscuit
core having an upper face and a lower face, two supporting leg
members attached to the lower face, arranged on opposite sides of a
central region of the biscuit core and extending downwardly, a
screw well located in the central region, the screw well having a
central cavity within the upper face and a controlled flash
continuous with the lower face, the controlled flash defining the
bottom of the well.
[0019] In the preferred embodiment, the invention provides a hidden
deck fastener including a biscuit core having an upper face and a
lower face, two supporting leg members attached to the lower face,
arranged on opposite sides of a central region of the biscuit core
and extending downwardly, a screw well located in the central
region, the screw well having a central cavity within the upper
face and a controlled flash continuous with the lower face, the
controlled flash defining the bottom of the well, a ridge defining
a central beam extending through a least a lower portion of the
screw well, the central beam extending between the leg members
through the central region of the biscuit core, and foot members
connected to the lower end of the legs, defined by a living hinge
groove at the lower end of the legs.
[0020] The invention provides an improved fastener for fastening
adjacent deck boards to one another and securing the deck boards to
the supporting joist, that is stronger, easier to install, more
effective at securing boards to an underlying joist, and more
effective at preventing relative movement between adjacent boards.
These and other features and advantages will become readily
apparent from the following detailed description, which should be
read in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING
[0021] FIG. 1 shows a perspective view of a deck fastener according
to an embodiment of the present invention.
[0022] FIG. 2 shows a top view of a deck fastener according to an
embodiment of the present invention.
[0023] FIG. 3 shows a side view of a deck fastener according to an
embodiment of the present invention.
[0024] FIG. 4 shows a front side elevation view of a deck fastener
according to an embodiment of the present invention.
[0025] FIG. 5 shows a side view of a deck fastener with folding
legs, according to an embodiment of the present invention.
[0026] FIG. 6 shows a bottom side view of a deck fastener according
to an embodiment of the present invention.
[0027] FIG. 7 shows a side view of nail placement into a deck
fastener according to an embodiment of the present invention.
[0028] FIG. 8 shows deck boards fastened using a deck fastener
according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The following description relates to certain preferred
embodiments of a hidden deck fastener for fastening adjacent deck
boards to one another and securing the deck boards to the
supporting joist. It is understood that numerous variations and
modifications, other than those specifically indicated herein, will
be readily apparent to those of sufficient skill in the art. In
addition, certain terms are used throughout the discussion in order
to provide a convenient frame of reference with regard to the
accompanying drawings, such as "upper", "lower", "top", "bottom",
"side", and the like. Such terms are not intended to be
specifically limiting of the invention, except where so indicated
in the claims. Obviously, numerous modifications and variations of
the present invention are possible in light of the teachings
herein. It is therefore understood that within the scope of the
appended claims, the invention may be practiced otherwise than as
specifically described herein.
[0030] The present invention solves various problems and provides a
distinct advance in the art of deck fasteners. More particularly,
the present invention provides an improved fastener for fastening
adjacent deck boards to one another and securing the deck boards to
the supporting joist, that is stronger, easier to install, more
effective at securing boards to an underlying joist, and more
effective at preventing relative movement between adjacent boards.
The apparatus according to the invention provides a hidden deck
fastener including a biscuit core having an upper face and a lower
face, two supporting leg members attached to the lower face and
extending downwardly therefrom, arranged on opposite sides of a
central region of the biscuit core, a screw well located in the
central region, the screw well having a central cavity within the
upper face and a controlled flash continuous with the lower face,
the controlled flash defining the bottom of the well.
[0031] In the preferred embodiment, the invention provides a hidden
deck fastener including a biscuit core having an upper face and a
lower face, two supporting leg members attached to the lower face
and extending downwardly therefrom, arranged on opposite sides of a
central region of the biscuit core, a screw well located in the
central region, the screw well having a central cavity within the
upper face and a controlled flash continuous with the lower face,
the controlled flash defining the bottom of the well, a ridge
defining a central beam extending through a least a lower portion
of the screw well, the central beam extending between the leg
members through the central region of the biscuit core, and foot
members connected to the lower end of the legs, defined by a living
hinge groove at the lower end of the legs.
[0032] Referring now to FIGS. 1-6, a deck fastener 100 constructed
in accordance with one embodiment of the present invention broadly
comprises a biscuit core 10 having an upper face 205 and a lower
face 210, and two supporting leg members 20a,b perpendicular to the
plane of the biscuit core 10, extending downwardly from the lower
face 210 thereof. The supporting leg members 20a,b are arranged on
opposite sides of the central region of the biscuit core, leaving
space for a nail or screw to pass between the legs into a joist or
support board. The supporting leg members 20a,b have a
predetermined height, so as to rest on a joist in such a way as to
establish biscuit core 10 at a predetermined height from the joist
for attachment of two adjacent boards thereto, which have
corresponding pre-cut biscuit slots.
[0033] The upper surface of the biscuit core also includes a screw
well 30 located on center. This enables the user to nail or screw
the deck fastener 100 into a joist, as more fully described in
conjunction with FIGS. 7-8. The screw well 30 is located within the
central region of the biscuit core 10, the bottom of the well being
defined by controlled flash 40, which forms a thin layer of
material over the bottom of the central cavity 30, thus defining
the bottom of the well. The central cavity of screw well 30 marks
the location for the screw, but the cavity does not extend through
the biscuit core 10. Rather, the controlled flash 40 at the bottom
provides a thin (preferably 0.025'' thick) layer of material
covering the bottom of the screw well. The controlled flash forms a
continuous smooth surface with the lower face of the biscuit core,
such that there are no holes penetrating through the biscuit core.
The controlled flash thus covers the bottom of the screw well, but
allows the screw to penetrate.
[0034] In the preferred embodiment, a central beam 80 runs through
the center at the bottom of the screw well, providing additional
structure to the screw well. Central beam 80 extends through the
plane of the biscuit core 10 between the legs 20a,b through the
screw well 30, thus providing additional integrity to the
installation and aiding to prevent screw pull-out. Preferably the
central beam 80 is formed as a triangular ridge, on which the screw
shank rests when set at a 45 degree angle. Preferably, the central
cavity of screw well 30 also has a beveled edge 70 and is formed as
an elongated oval, to facilitate the screws better. The screw is
placed into the screw well and driven through the controlled flash
at the bottom of the well. The center beam provides added support
at the base of the screw, which helps to prevent pull-outs and
shifting of the deck boards.
[0035] Additionally, in the preferred embodiment, foot members
60a,b, defined by living hinge 50, are activated upon pushing the
fastener 100 down against a joist. The deck fastener is inserted
into the slot or groove and centered on the joist. When the deck
fastener is inserted into the slot and pushed down against the
joist, the living hinge is activated and the feet move into place.
The tapered foot slides under the deck board, lifting the deck
board off the joist, thereby allowing air to circulate between the
deck boards and the joists. This helps to prevent moisture
accumulation and premature decay. The fastener is screwed to a deck
joist to hold the deck board tight against the joist, and the
adjoining board is fitted over the biscuit core and up against the
first board, repeating the steps as necessary to extend the
structure.
[0036] The biscuit core is configured to fit into a pre-milled slot
or groove, or a biscuit-cutter machined slot formed in the edges of
the deck boards. Each leg is configured to hold the biscuit core up
and in position, while also providing consistent spacing between
adjacent boards. When the deck fastener is pushed down against the
joist, the feet are activated and each foot points in the opposite
direction, sliding under the adjacent deck boards. In the example
shown herein, the biscuit core is in the form of a rectangle having
rounded corners, however, this shape is not critical to the
invention and other shapes are suitable. The deck fastener can be
made from practically any material, but preferably is made from a
thermoplastic material, such as polypropylene or polyethylene (more
preferably HDPE) by injection molding. Other suitable materials may
include wood or wood composites, metal alloys or composites,
styrene polymers and copolymers, ABS, acrylics, cellulosics,
vinyls, nylons, polycarbonate, PVC and various fluorocarbon
materials.
EXAMPLE 1
[0037] An example of the present invention was manufactured from
high density polyethylene (HDPE) using a sixteen (16) cavity mold
in a 150 ton Engel injection molding machine. The example is
essentially as shown in FIGS. 1-8. In this example, the biscuit
core 10 is about 1/8'' thick, and the supporting legs 20a,b are
about 3/32'' thick and 1/8'' apart. The feet 60a,b are defined by
living hinges 50a,b at the lower end of the legs, and are activated
by pushing the deck fastener 100 down against the joist. With the
living hinged feet activated, the distance between the lower face
of the biscuit core and the top side of the feet is 3/8''. In this
example, the controlled flash is 0.025'' thick and the center beam
is 0.05'' tall (at center of ridge). The deck fastener can be used
with pre-grooved deck boards, or a 1/8'' router bit or a #20
biscuit cutter can be used to cut the slots, where needed. When
cutting the slots, the slot should be cut in each board 3/8'' from
the bottom surface. The deck fastener preferably is secured with a
#721/4'' stainless steel screw on a 45 degree angle to the joist,
as shown in FIGS. 7-8. Pre-drilling the hole with a 1/8'' drill is
recommended.
* * * * *