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.

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

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 1-⅝ trim head wood screws. The present clips were secured in the test rig using #7-10 1-⅝ fillister head wood screws. The tests were conducted at a temperature of 24° C. (75.2 ° 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.