U.S. patent application number 17/578908 was filed with the patent office on 2022-07-21 for hidden deck fastener.
The applicant listed for this patent is Pan American Screw LLC. Invention is credited to Jeffery M. Bent, Phillip R. Lail.
Application Number | 20220228373 17/578908 |
Document ID | / |
Family ID | |
Filed Date | 2022-07-21 |
United States Patent
Application |
20220228373 |
Kind Code |
A1 |
Lail; Phillip R. ; et
al. |
July 21, 2022 |
HIDDEN DECK FASTENER
Abstract
A hidden deck fastener or clip has a H-shaped body having a top
portion having a thickness, a top surface and a bottom surface, and
an integrally formed leg extending downwardly from the bottom
surface, the leg defines channels in opposing sides thereof. A
stepped fastener receiving opening is formed in the top portion and
the leg. The opening has a first region formed into a part of the
thickness of the top portion and a second region aligned and
contiguous with the first region extending through the leg. The
first region is a counterbore having a flat bottom. The fastener
has a pull-out force resistance at least 50 percent greater than a
comparable fastener having a countersink fastener receiving
opening.
Inventors: |
Lail; Phillip R.;
(Statesville, NC) ; Bent; Jeffery M.; (Burlington,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pan American Screw LLC |
Conover |
NC |
US |
|
|
Appl. No.: |
17/578908 |
Filed: |
January 19, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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63139355 |
Jan 20, 2021 |
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International
Class: |
E04F 15/02 20060101
E04F015/02 |
Claims
1. A hidden deck fastener, comprising: a II-shaped body having a
top portion having a thickness, a top surface and a bottom surface,
an integrally formed leg extending transversely, downwardly from
the bottom surface, the leg spaced inwardly from sides of the top
portion, the leg defining channels formed in opposing sides
thereof, a stepped fastener receiving opening formed in the top
portion and the leg, the stepped fastener opening having a first
region formed into a least a part of the thickness of the top
portion and a second region aligned and contiguous with the first
region extending through the leg, wherein the first region is a
counterbore having straight sides terminating at a flat bottom
surface at the second region, wherein the channels in the legs
extend toward and are spaced from the fastener receiving opening
second region, and wherein the fastener has a pull-out force
resistance at least 50 percent greater than a comparable fastener
having a countersink fastener receiving opening.
2. The fastener of claim 1, further including ridges formed on the
top surface and/or the bottom surface of the top portion.
3. The fastener of claim 2, wherein the ridges are formed on the
bottom surface of the top portion.
4. The fastener of claim 1, wherein the fastener receiving opening
first region has a diameter about 2 times a diameter of the second
region.
5. The fastener of claim 1, wherein the first region is formed in
the top portion less than the thickness of the top portion.
6. The fastener of claim 1, wherein the channels have enlarged
regions inwardly of an end thereof.
7. The fastener of claim 1, further including a threaded fastener
having a shank and a head, wherein the head has a flat bottom
surface to engage the flat bottom surface of the fastener receiving
opening first region.
8. In combination: a hidden deck fastener and a threaded fastener,
the hidden deck fastener having a II-shaped body having a top
portion having a thickness, a top surface and a bottom surface, an
integrally formed leg extending transversely, downwardly from the
bottom surface, the leg spaced inwardly from sides of the top
portion, the leg defining channels formed in opposing sides
thereof, a stepped fastener receiving opening formed in the top
portion and the leg, the stepped fastener opening having a first
region formed into a least a part of the thickness of the top
portion and a second region aligned and contiguous with the first
region extending through the leg, the first region being a
counterbore having straight sides terminating at a flat bottom
surface at the second region, wherein the channels in the legs
extend toward and are spaced from the fastener receiving opening
second region; and the threaded fastener having a shank and a head,
wherein the head has a flat bottom surface to engage the flat
bottom surface of the fastener receiving opening first region,
wherein the fastener has a pull-out force resistance at least 50
percent greater than a comparable fastener having a countersink
fastener receiving opening.
9. The combination of claim 8, wherein the fastener receiving
opening first region has a diameter about 2 times a diameter of the
second region.
10. The combination of claim 8, wherein the first region is formed
in the top portion less than the thickness of the top portion.
11. A decking and fastener system, comprising: a decking member
having an upper surface, a lower surface, and a side wall extending
between the upper and lower surfaces, the side wall having a groove
formed therein, a hidden deck fastener having a H-shaped body
having a top portion having a thickness, a top surface and a bottom
surface, an integrally formed leg extending transversely,
downwardly from the bottom surface, the leg spaced inwardly from
sides of the top portion defining wings in the top surface, the leg
defining channels formed in opposing sides thereof, a stepped
fastener receiving opening formed in the top portion and the leg,
the stepped fastener opening having a first region formed into a
least a part of the thickness of the top portion and a second
region aligned and contiguous with the first region extending
through the leg, the first region being a counterbore having
straight sides terminating at a flat bottom surface at the second
region, wherein the channels in the legs extend toward and are
spaced from the fastener receiving opening second region, wherein
the hidden deck fastener is positioned adjacent the decking member
with a wing positioned in the decking member groove, and wherein a
threaded fastener having a shank and a head having a flat bottom
surface is driven into the hidden deck fastener such that the flat
bottom surface of the head engages the flat bottom surface of the
fastener receiving opening first region, wherein the fastener has a
pull-out force resistance at least 50 percent greater than a
comparable fastener having a countersink fastener receiving
opening.
12. The system of claim 11, wherein the fastener receiving opening
first region has a diameter about 2 times a diameter of the second
region.
13. The system of claim 11, wherein the first region is formed in
the top portion less than the thickness of the top portion.
14. The system of claim 11, wherein the hidden deck fastener
further includes ridges formed on the upper and/or lower surface of
the top portion.
15. The system of claim 14, wherein the ridges are formed on the
lower surface.
Description
CROSS-REFERENCE TO RELATED APPLICATION DATA
[0001] This application claims the benefit of and priority to
Provisional U.S. Patent Application Ser. No. 63/139,355 filed Jan.
20, 2021, titled, IMPROVED HIDDEN DECK FASTENER, the disclosure of
which is incorporated herein in its entirety.
BACKGROUND
[0002] The present disclosure relates to deck fasteners, and more
particularly to hidden deck fasteners having improved/greater pull
out resistance.
[0003] Composite materials have become a mainstay of today's
decking systems. These decking systems use fasteners to attach the
decking to underlying structural members or joists. Fasteners can
include screws, nails, staples or clips. Screws, nails and staples
are typically installed directly through the top face of the
structural members to the joist below.
[0004] Securing the decking members to the joists by direct
fastening through the top face of the decking has many drawbacks.
For example, the fasteners are visible, unattractive and take away
from the facade or look of the decking. Fasteners may corrode and
discolor the decking members. Fasteners may also become loose. In
addition, in installing screws, nails and staples hammer blows to
the decking surface may cause damage and/or depressions in the
decking.
[0005] Clips for securing the decking to the underlying joists are
also known. In such a system, the decking members have longitudinal
grooves or channels formed along sides of the members.
[0006] Once such clip, referred to as a fastener, disclosed in
Orchard, U.S. Pat. No. 9,181,715, and commonly assigned with the
present application, includes a pi (II) shaped body having a top
horizontal portion and a pair of integrally formed spaced apart
vertical legs that extend downwardly from the horizontal portion. A
space is defined between the legs, and the legs are inwardly
compressible (toward each other) in response to a side force. The
top portion has raised ribs for frictionally engaging the decking
members. The clip has a bore through the top portion about mid-way
along the length and width that aligns with the space between the
legs. The bore has a countersink in the top surface.
[0007] The clip is inserted into the grooves of adjacent decking
members and is secured to the underlying joist by a
countersink-headed fastener to secure the fastener and the decking
to the underlying joist. Such clips are advantageous in that they
are hidden--positioned between decking members--and as such,
fasteners are not installed in the surface of the decking
members.
[0008] While such clips function well, it has been found that a
clip can pull out of the fastener. That is, the fastener remains in
the underlying joist, but the clip pulls out, over the head of the
fastener. As such, the clip no longer functions to secure the
decking to the underlying joist.
[0009] Accordingly, there is a need for a clip to secure decking
that is hidden on installation. Desirably, such a clip has a high
pull-out strength. Ore desirably still, such a clip grips the
adjacent decking members preventing transverse movement, but
allowing longitudinal movement for expansion and contraction of the
members.
SUMMARY
[0010] In one aspect an embodiment of a hidden deck fastener has a
II-shaped body having a top portion having a thickness, a top
surface and a bottom surface, and an integrally formed leg
extending transversely, downwardly from the bottom surface. The leg
is spaced inwardly from sides of the top portion and defines
channels formed in opposing sides or edges thereof. The channels
can be formed having enlarged regions inwardly of ends thereof.
[0011] A stepped fastener receiving opening is formed in the top
portion and the leg. The opening has a first region formed into a
least a part of the thickness of the top portion and a second
region aligned and contiguous with the first region extending
through the leg. The first region is a counterbore having straight
sides terminating at a flat bottom surface at the second
region.
[0012] The channels in the legs extend toward and are spaced from
the fastener receiving opening second region. The fastener has a
pull-out force resistance at least 50 percent greater than a
comparable fastener having a countersink fastener receiving
opening.
[0013] In embodiments, the fastener further includes ridges formed
on the top surface and/or the bottom surface of the top portion. In
a current embodiment the ridges are formed on the bottom surface of
the top portion.
[0014] In embodiments, the fastener receiving opening first region
has a diameter about 2 times a diameter of the second region. The
first region can be is formed in the top portion less than the
thickness of the top portion.
[0015] In an aspect, the fastener includes a threaded fastener
having a shank and a head. The head has a flat bottom surface to
engage the flat bottom surface of the fastener receiving opening
first region.
[0016] In another aspect, in combination is a hidden deck fastener
and a threaded fastener. The hidden deck fastener has a H-shaped
body having a top portion having a thickness, a top surface and a
bottom surface, and an integrally formed leg extending
transversely, downwardly from the bottom surface.
[0017] The leg is spaced inwardly from sides of the top portion and
defines channels formed in opposing sides or edges thereof.
[0018] A stepped fastener receiving opening is formed in the top
portion and the leg. The stepped fastener opening has a first
region formed into a least a part of the thickness of the top
portion and a second region aligned and contiguous with the first
region extending through the leg. The first region is a counterbore
having straight sides terminating at a flat bottom surface at the
second region.
[0019] The channels in the legs extend toward and are spaced from
the fastener receiving opening second region.
[0020] The threaded fastener has a shank and a head. The head has a
flat bottom surface to engage the flat bottom surface of the
fastener receiving opening first region.
[0021] The fastener has a pull-out force resistance at least 50
percent greater than a comparable fastener having a countersink
fastener receiving opening.
[0022] In an embodiment, the fastener receiving opening first
region has a diameter about 2 times a diameter of the second
region. The first region is formed in the top portion less than the
thickness of the top portion.
[0023] In yet another aspect a decking and fastener system includes
a decking member having an upper surface, a lower surface, and a
side wall extending between the upper and lower surfaces. The side
wall has a groove formed therein.
[0024] A hidden deck fastener has a H-shaped body having a top
portion having a thickness, a top surface and a bottom surface, and
an integrally formed leg extending transversely, downwardly from
the bottom surface. The leg is spaced inwardly from sides of the
top portion defining wings in the top surface. The leg defines
channels formed in opposing sides or edges thereof.
[0025] A stepped fastener receiving opening is formed in the top
portion and the leg. The stepped fastener opening has a first
region formed into a least a part of the thickness of the top
portion and a second region aligned and contiguous with the first
region extending through the leg. The first region is a counterbore
having straight sides terminating at a flat bottom surface at the
second region.
[0026] The channels in the legs extend toward and are spaced from
the fastener receiving opening second region.
[0027] The hidden deck fastener is positioned adjacent the decking
member with a wing positioned in the decking member groove and a
threaded fastener having a shank and a head having a flat bottom
surface is driven into the hidden deck fastener such that the flat
bottom surface of the head engages the flat bottom surface of the
fastener receiving opening first region.
[0028] The fastener has a pull-out force resistance at least 50
percent greater than a comparable fastener having a countersink
fastener receiving opening.
[0029] In an embodiment, the fastener receiving opening first
region has a diameter about 2 times a diameter of the second
region. The first region is formed in the top portion and can
extend less than the thickness of the top portion.
[0030] In embodiments, the hidden deck fastener further includes
ridges formed on the upper and/or lower surface of the top portion.
In an embodiment, the ridges are formed on the lower surface.
[0031] Further understanding of the present disclosure can be
obtained by reference to the following detailed description in
conjunction with the associated drawings, which are described
briefly below.
DESCRIPTION OF THE DRAWINGS
[0032] An embodiment of a hidden deck fastener or clip is disclosed
as an example and is not limited by the figures of the accompanying
drawings, in which like references may indicate similar elements
and in which:
[0033] FIG. 1 is a top perspective view of an embodiment of a
hidden deck fastener of the present disclosure;
[0034] FIG. 2 is a bottom perspective view of the fastener;
[0035] FIG. 3 is a top view of the fastener;
[0036] FIG. 4 is a bottom view of the fastener;
[0037] FIG. 5 is a side view of the fastener;
[0038] FIG. 6 is a sectional view of the fastener taken along line
6--6 of FIG. 5;
[0039] FIG. 7 is an end view of the fastener installed between a
pair of panels and into a joist;
[0040] FIGS. 8A and 8B are force versus time curves from pull-out
testing of the known clips (FIG. 8A) and the present clips (FIG.
8B);
[0041] FIGS. 9A and 9B are illustrations reproducing photographs of
the known clips (FIG. 9A) and the present clips (FIG. 9B) following
pull-out testing; and
[0042] FIG. 10 is an example of a fillister head wood screw for use
with the fastener.
DETAILED DESCRIPTION
[0043] While the present disclosure is susceptible of embodiments
in various forms, there is shown in the drawings and will
hereinafter be described a presently preferred embodiment with the
understanding that the present disclosure is to be considered an
exemplification and is not intended to limit the disclosure to the
specific embodiment illustrated.
[0044] Referring now to FIGS. 1 and 2, there is shown a top
perspective view embodiment of an embodiment of a hidden deck
fastener or clip 10 (referred to herein as "clip"). The clip 10 has
a pi (II) shaped body 12, and includes a top portion 14 having
wings 16 and a centrally located fastener receiving hole 18. In the
illustrated embodiment the top portion 14 is rectangular in shape
in which the wings 16 are configured for insertion and retention in
groove(s) 22 of decking member(s) 24. Cut-outs 26 are formed in the
short sides 28 of the top portion 14 that are angular in shape. In
an embodiment, the cut-26 outs extend through the top portion 14.
It will be appreciated that the top portion 14 may be of any of a
variety of suitable shapes, such as a circle, oval, biscuit or the
like.
[0045] The fastener receiving hole 18 is located in the top portion
14, and in an embodiment, the receiving hole 18 is located in a
longitudinal and transverse center of the top portion 14.
[0046] A leg 30 extends downwardly and depends from a lower surface
32 of the top portion 14. In an embodiment, the leg 30 is located
in a transverse center of the top portion 14, and the fastener
receiving hole 18 extends into and through the leg 30. On either
side of the hole 18, the leg 30 include channels 34. The channels
34 extend inwardly from ends 36 of the legs 30, toward by not into
the fastener receiving hole 18, and form bifurcations 38 in each
end 36 of the leg 30. A portion of each channel 34 is enlarged as
indicated at 40. The channels 34 extend up to about the lower
surface 32 of the top portion 14.
[0047] In embodiments, the lower surface 32 of the top portion 14
includes a series of ribs or ridges 42 that extend downwardly from
the lower surface 32. The ridges 42 facilitate securing the clips
10 to the decking members 24 as will be described below.
[0048] In a current embodiment, the fastener receiving hole 18 is a
stepped hole having first or upper region 18a and a second or lower
region 18b. In an embodiment, the first region 18a is formed into a
portion of the top portion 14. That is, the first region 18a is
formed into a portion of the thickness of the top portion 14. The
second region 18b is aligned and contiguous with the first region
18a and in an embodiment extends through a portion of the top
portion 14 and through the leg 30.
[0049] As seen in FIGS. 1, 3 and 6, the first region 18a has a
cylindrical bore profile, or is a counterbore into a portion of the
top portion 14. The second region 18b is a continuation of a
portion of the diameter d.sub.18a of the first region 18a (the
counterbore).
[0050] The present deck fastener or clip 10 can be formed from a
wide variety of materials. Suitable materials include polymeric
material such as polypropylene and the like. Other suitable
materials will be recognized by those skilled in the art.
[0051] In an embodiment, the clip 10 has a top portion length
l.sub.14 of about 1.5 inches, a width W.sub.14 of about 0.75 inches
and a depth or thickness t.sub.14 of about 0.135 inches. The depth
or thickness corresponds to the height h.sub.22 of the longitudinal
grooves or channels 22 formed in the sides of the decking members
24.
[0052] The ridges 42 on the top portion lower surface 32 extend
from the lower surface 32 about 0.025 inches. The leg 30 has a
length l.sub.130 of about 1.0 inches, a height h.sub.30 of about
0.39 inches and a width W.sub.30 of about 0.163 inches. The
fastener receiving hole first region 18 a has a diameter d.sub.18a
of about 0.25 inches and a depth t.sub.18a into the top portion 14
of about 0.095 inches. The second region 18b has a diameter
d.sub.18b of about 0.125 inches.
[0053] The clip 10 is secured in place using a fastener 46 having a
head 48 having a flat bottom 50, such as the illustrated filister
head wood screw (see, FIG. 10), a cap head, a hex washer head or
the like.
[0054] In use, referring to FIG. 7, the clip 10 is positioned
between two decking members 24 with the top portion wings 16
positioned in the side wall grooves 22 of adjacent members 24. It
is anticipated that the bottom of the leg 30 will rest on a
supporting structure, such as a floor joist 52. The ridges 42 on
the lower surface 32 of the top portion 14 will hold the clip 10 in
place. The fastener 46 is positioned in the fastener receiving hole
18 and is driven into the structure or joist 52 to fasten the clip
10 and decking member(s) 24 to the structure or joist 52.
[0055] After installation the decking members 24 may expand and
contract across their widths as a result of changes in the weather
(temperature, humidity and precipitation) and as such, exert
transverse or sideway forces on the leg 30. The channels 34 allow
for inward movement or compression of portions of the leg 30 to
accommodate expansion of the members 24. As the decking members 24
contract, the leg 30 returns to its initial shape.
[0056] The decking members 24 may also expand and contract along
their lengths. To prevent excessive longitudinal movement of the
members 24, an embodiment of the clip 10 includes the ribs or
ridges 42 that serve as frictional elements to allow but limit
longitudinal (lengthwise) movement of the decking members 24. While
the ridges 42 are shown on the lower surface 32 of the clip 10,
they can be on the lower or upper, or both surfaces of the clip 10.
These frictional elements can be ribs or ridges 42 as shown,
fingers, raised protrusions or like elements.
[0057] Tests were conducted to compare the pullout force required
to pull clips from their fasteners and the decking members. The
tests compared the present clips to known clips such as those
disclosed in the aforementioned patent to Orchard. Ten samples of
each the present clip and the known clip were tested to determine
the pull-out required to pull the clip from a fastener.
[0058] The known clips were secured in a test rig using #7-10 1-5/8
trim head wood screws. The present clips were secured in the test
rig using #7-10 1-5/8 fillister head wood screws. The tests were
conducted at a temperature of 24.degree. C. (75.2 .degree. F.). The
pull-out force was measured in kilo-newtons (KN) and pounds-force
(lbf). The results of the test are shown in Table 1 below.
TABLE-US-00001 TABLE 1 Comparison of Pull-Out Force for Known Clips
and Present Clips Sample # Sample # (known Pull-out force (present
Pull-out force clips, K#) (KN/lbf) clips, P#) (KN) K1 1.027
KN/230.87 lbf P1 1.625 KN/365.3 lbf.sup. K2 1.047/235.37 P2
1.652/371.37 K3 0.987/221.88 P3 1.562/351.14 K4 1.107/248.9 P4
1.615/363.05 K5 0.856/192.43 P5 1.686/379.01 K6 1.007/226.37 P6
1.717/385.98 K7 1.029/231.32 P7 1.670/375.42 K8 1.010/227.05 P8
1.411/317.19 K9 1.072/240.99 P9 1.724/387.56 K10 1.035/232.67 P10
1.627/365.75 Max. 1.107/232.67 Max. 1.724/387.56 Min. 0.856/192.43
Min. 1.411/317.19 Avg. 1.018/228.78 Avg. 1.629/366.18
[0059] As can be seen from Table 1, the resistance to pull-out of
the present clips (represented by the pull-out force required) is
significantly greater than the known clips. In every instance, the
present clips required a greater pull-out force (showed greater
resistance to pull-out) than the known clips. That is, the lowest
pull-out force for the present clips (1.411 KN) was greater than
the greatest pull-out force for the known clips (1.104 KN).
[0060] The average pull-out force required for the present clips
(1.6291 KN) was 60 percent greater than the average pull-out force
required for the known clips (1.018 KN), calculated as
((1.629-1.018)/1.018), and the lowest pull-out force for the
present clips (1.411 KN) was almost 34 percent greater than the
greatest pull-out force for the known clips (1.104 KN), calculated
as ((1.411-1.104)/1.104).
[0061] FIGS. 8A and 8B are force vs. time curves generated during
the testing, in which FIG. 8A is the curve for the known clips and
FIG. 8B is the curve for the present clips. As can be seen from the
figures, there is an almost immediate failure (pull-out) of the
known clips at about 5-10 seconds whereas the present clips go well
beyond 30 seconds, and over 36 seconds before failure. Again, the
curves also show that at about the average failure force of the
known clips, all of the present clip samples, were well within
their functional range.
[0062] FIGS. 9A and 9B are illustrations reproducing photographs of
the samples following testing in which FIG. 9A is an illustration
reproducing a photograph of the known clips and FIG. 9B is an
illustration reproducing a photograph of the present clips. As can
be seen from FIG. 9A, failure of the known clips was due to
pull-out, whereas as seen in FIG. 9B, failure of the present clips
10 was not due to pull-out; rather, failure of the clips 10 was due
to breakage of the clips themselves.
[0063] Accordingly, it will be appreciated that the present hidden
deck fasteners 10 (again, referred to as clips) provide improved
securement of decking members 24, are hidden on installation, and
have substantially increased high pull-out strength compared to
known decking fasteners. The present clips 10 are easy to install
and grip adjacent decking member(s) 24 preventing transverse
movement, but allow for limited transverse and longitudinal
movement for expansion and contraction of the member(s) 24.
[0064] In the present disclosure, the words "a" or "an" are to be
taken to include both the singular and the plural. Conversely, any
reference to plural items shall, where appropriate, include the
singular. All patents and published applications referred to herein
are incorporated by reference in their entirety, whether or not
specifically done so within the text of this disclosure.
[0065] It will also be appreciated by those skilled in the art that
any relative directional terms such as side(s), upper, lower, top,
bottom, rearward, inboard, forward, outboard and the like may be
for explanatory purposes only and may not be intended to limit the
scope of the disclosure.
[0066] From the foregoing it will be observed that numerous
modifications and variations can be made without departing from the
true spirit and scope of the novel concepts of the present
disclosure. It is to be understood that no limitation with respect
to the specific embodiments illustrated is intended or should be
inferred.
* * * * *