HIDDEN FASTENER FOR ABUTTING BOARDS

Abstract

In an exemplary embodiment, a hidden fastener may include a constraining member configured to support a plurality of boards, and a base member extending below the constraining member. The base member includes a pair of leg portions, each leg portion includes an opening at an inclined angle for receiving a fastener at an inclined position. The pair of leg portions is attached to a structural member via a spacing formed between the pair of leg portions, the spacing corresponding to a size of a top surface of a structural element.

Claims

1. A hidden fastener, comprising: a constraining member configured to support a plurality of boards; and a base member extending below the constraining member, the base member including a pair of leg portions, each leg portion includes an opening at an inclined angle for receiving a fastener at an inclined position, wherein the pair of leg portions is attached to a structural member via a spacing formed between the pair of leg portions, the spacing corresponding to a size of a top surface of a structural element.

2. The hidden fastener of claim 1, wherein the constraining member includes a top surface where a portion of at least one board is supported thereof.

3. The hidden fastener of claim 2, further comprising a first tab member and a second tab member form on the top surface of the constraining member, wherein the first tab member is located at a first side portion of the constraining member and the second tab member is located at a second side portion that runs parallel to the first side portion.

4. The hidden fastener of claim 3, wherein the first and second tab members extend in an upward direction with respect to the top surface of the constraining member.

5. The hidden fastener of claim 3, wherein the first and second tab members extend in a downward direction with respect to the top surface of the constraining member.

6. The hidden fastener of claim 3, wherein the first and second tab members extend in a side direction with respect to the top surface of the constraining member.

7. The hidden fastener of claim 3, wherein the first tab member has a first size and the second tab member has a second size different than the first size.

8. The hidden fastener of claim 3, wherein the first tab member has a first size and the second tab member has a second size same than the first size.

9. The hidden fastener of claim 1, wherein the pair of leg portions extend from the base member at an angle.

10. The hidden fastener of claim 9, wherein the angle is approximately between 30? to 60?.

11. The hidden fastener of claim 1, wherein each leg portion includes a flat portion that extends from the base member and a curved portion for receiving and engaging with a side portion of the board.

12. The hidden fastener of claim 1, wherein the constraining member includes a side extending member that cooperatively engages with a groove formed at a side portion of the board.

13. The hidden fastener of claim 1, wherein the constraining member and the base member are integrally formed.

14. A method of installing a hidden fastener to a butt end of a board, comprising: attaching a first hidden fastener to a structural member, the first hidden fastener includes a pair of leg portions that correspondingly engages to a top surface of the structural member; engaging a first side of a first board to the first hidden fastener; engaging a first side of a second board to the first hidden fastener; attaching a second hidden fastener to the structural member opposite to the first hidden fastener, the second hidden fastener includes a pair of leg portions that correspondingly engages to the top surface of the structural member; engaging a second side of the first board to the second hidden fastener; and engaging a second side of the second board to the second hidden fastener.

15. The method of claim 14, wherein attaching the first hidden fastener to the structural member includes fastening a fastener to the structural member at an angle.

16. The method of claim 14, wherein attaching the second hidden fastener to the structural member includes fastening a fastener to the structural member at an angle.

17. The method of claim 14, wherein engaging the first side of the first board to the first hidden fastener includes inserting a side portion of the first hidden fastener into a groove formed at the first side of the first board.

18. The method of claim 14, wherein engaging the first side of the second board to the first hidden fastener includes inserting a side portion of the first hidden fastener into a groove formed at the first side of the second board.

19. The method of claim 14, wherein engaging the second side of the first board to the second hidden fastener includes inserting a side portion of the second hidden fastener into a groove formed at the second side of the first board.

20. The method of claim 14, wherein engaging the second side of the second board to the second hidden fastener includes inserting a side portion of the second hidden fastener into a groove formed at the second side of the second board.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a perspective view of a hidden fastener according to an example embodiment of the present disclosure.

[0011] FIG. 2 is a plan view of the hidden fastener of FIG. 1.

[0012] FIG. 3 is a front view of the hidden fastener of FIG. 1.

[0013] FIG. 4 is a side view of the hidden fastener of FIG. 1.

[0014] FIGS. 5A and 5B are perspective views of a hidden fastener with different tab members configuration, according to an example embodiment of the present disclosure.

[0015] FIG. 5C is a perspective view of a hidden fastener without any tab members, according to an example embodiment of the present disclosure.

[0016] FIGS. 6-11 are perspective views of the hidden fastener of FIG. 1 in use in a decking system, according to an example embodiment of the present disclosure.

[0017] It should be noted that these Figures are intended to illustrate the general characteristics of methods, structure and/or materials utilized in certain example embodiments and to supplement the written description provided below. These drawings are not, however, to scale and may not precisely reflect the precise structural or performance characteristics of any given embodiment, and should not be interpreted as defining or limiting the range of values or properties encompassed by example embodiments. For example, the relative thicknesses and positioning of layers, regions and/or structural elements may be reduced or exaggerated for clarity. The use of similar or identical reference numbers in the various drawings is intended to indicate the presence of a similar or identical element or feature.

DETAILED DESCRIPTION

[0018] A hidden fastener (e.g., a connector clip) according to the present disclosure is a device for use in conjunction with (deck)boards to abut at least the ends of the boards atop a structural member (e.g., joist). In a conventional approach, a sister joist is generally required next to an existing joist for installing butt joints. However, besides the cost of material for the additional joist, installing sister joists is time consuming and labor intensive requiring installers to possibly work underneath the deck and handle heavy structural members causing possible injuries. Therefore, the hidden fastener disclosed herein requires fewer parts and is easier to install. That is, only two hidden fasteners will be required instead of the conventional four hidden fasteners, fewer fasteners (e.g., screws) to install to the structural member, and no sister joist will be required.

[0019] As described herein, the term connector clip is interchangeable with and/or described as a hidden fastener that is configured to fasten adjacent to or under the ends of the boards, which in effect hides the connector clip from plain sight while constraining the movement of (adjacent) boards. The term fastener assembly described herein includes the connector clip (or hidden fastener) and a fastener (e.g., screw) assembled together prior to or during installation.

[0020] For simplicity, the hidden fastener will be described in simplified fashion with relation to a deck system. It should be noted that the figures exemplify various aspects of the hidden fastener in use but do not illustrate a complete deck system. It should also be noted that the hidden fastener is useful in other environments and using other combinations and assembly sequences and all such uses are part of this invention. It will further be appreciated that in some of the drawings, some boards and/or joists are shown as transparent in order to better illustrate certain features of operation.

[0021] FIGS. 1 to 4 illustrate one example embodiment of a hidden fastener 10 used to join ends of a deck board 50 to a structural member 15 (e.g., a joist). The hidden fastener 10 includes a deck board constraining member 20 for supporting a plurality of deck boards 50 and a base 30 that extends below the constraining member 20. The constraining member 20 is generally rectangular in shape and has a first side 21, a second side 22 opposite the first side 21, a third side 23, and a fourth side 24 opposite the third side 23. In one implementation, the first and second sides 21, 22 correspond to long sides and the third and fourth sides 23, 24 correspond to short sides. The constraining member 20 also includes a top surface 26 where a portion of the board 50 is supported and/or constrained.

[0022] The base 30 includes a base portion 31 that extends below the constraining member 20. The base portion 31 can be integrally formed with the constraining member 20, or alternatively, formed separately from the constraining member 20 using conventional methods. The base portion 31 is substantially rectangular in shape having a similar shape as the constraining member 20. However, the base portion 31 is smaller in size in relation to the constraining member 20. In other words, the base portion 31 is formed smaller than the constraining member 20 such that extending members 56 (at sides 21, 22), as shown in FIG. 4, are formed which are designed to engage with the boards 50. To describe in a different manner, the extending members 56 project out over the base portion 31. Extending at each end side 33 of the base 30 includes a leg portion 35 that projects generally perpendicular in relation to the base portion 31, as shown in FIGS. 2 and 3. The leg portions 35 correspondingly engage the structural member, i.e., joist 15 to firmly support the entire base 30 against the joist 15. Further, due to the extended design of a pair of leg portions 35, an opening or space 39 is formed between the leg portions 35 to engage with the joist 15. That is, the space 39 matches a dimension of a top surface 17 of the joist 15 to securely attach the hidden fastener 10 against a single joist 15, as shown in FIG. 6. In one implementation, a typical width dimension of a single joist is approximately 1.5-2.0 inches, and hence, the space 39 separating the pair of leg portions 35 should correspondingly be approximately 1.5-2.0 inches. Further, each leg portion 35 includes an inner planar surface 37 (shown in FIG. 3) that is configured to engage (i.e., contact) a planar side surface 19 of the joist 15 forming the same shape and size as the joist 15, i.e., a generally rectangular shape. It should be appreciated that a distance between the two inner planar surface 37 corresponds to the distance of the space 39. Unlike conventional hidden fasteners, a sister joist is not required or installed as the present hidden fastener 10 is directly installed to a single joist for butt jointing two adjacent boards 50. As a result, this provides cost savings in materials and saves considerable labor time for installation. Moreover, the joists can be damaged on the top and corners thereof making them uneven. As a result, the present hidden fastener 10 can be installed (even on the damaged joist) because the present hidden fastener 10 and screws engage with vertical sides of the joist.

[0023] Each leg portion 35 includes an opening 36 in a thick portion 38 thereof for receiving a fastener, e.g., screw 45. As shown in FIG. 9, the screw 45 securely attaches the hidden fastener 10 to the structural member 15 that enters from a topside of the hidden fastener 10 via the opening 36. Advantageously, fastening the screw 45 from the topside requires less effort and provides greater structural connectivity. In addition, there is no need for attaching the screws at two planes, i.e., vertically and horizontally. That is, attaching screws on the top surface and/or the side surfaces of the structural member 15. Moreover, the present hidden fastener 10 prevents and/or reduces the installer from working underneath the decking system, which may cause bodily injuries or harm.

[0024] In some implementations, the thick portion 38 of the leg portion 35 can include a countersink for receiving the screw 45 designed for this purpose. For instance, the countersink allows a head of the screw 45 to sit flush with or below the surface of the surrounding material, i.e., thick portion 38.

[0025] The openings 36 and screws 45 are oriented at a skewed angle (i.e., inclined) relative to a plane of the top surface 17 of the structural member 15. Accordingly, unlike conventional hidden fasteners, the mounted screws 45 are not oriented perpendicular to the top surface 17 of the structural member 15 and/or perpendicular to a planar surface (i.e., side surface 19) of structural member 15. In some implementations, the angled screw opening 36 is approximately 30-60 degrees, preferably approximately 45 degrees in relation to the structural member 15. Mounting the screw 45 in an angled screw opening 36 results in a better securement to the structural member 15 as each screw 45 extends into a center portion of the structural member 15 at an angle, which creates a tighter securement and/or a greater pull-out resistance. As such, the hidden fastener 10 is less likely to detach from the structural member 15 due to the screws 45 being secured at an angle. The hidden fastener 10, in addition to being less likely to pull out, is also more likely to resist any rotational (mostly downward shear) forces applied from having more load on one side or an uneven installation surface via the shape of the joist. Further, the angled screw 45 tends to draw the hidden fastener 10 sidewardly against the planar side surface 19 of the structural member 15 removing any gaps therebetween for a tight, consistent fit. In addition, the downward driving force of the screw on each side allows the user to modify the inclination of the hidden fastener relative to the incoming boards by tightening or loosening the screws on each side in order to create a more planar transition between the abutting boards.

[0026] In other implementations, only a single screw, rather than the two angled side screws may be employed. For example, the hidden fastener in a middle of the top surface 26 can include an opening for receiving the single screw.

[0027] Referring back to FIG. 2, each leg portion 35 further includes a platform 40 that extends at each side of the thick portion 38, forming a generally T-shaped member. The platform 40 includes a flat portion 41 that is configured to engage (support) a bottom surface portion 52 of the board 50, and a curved portion 42 that is configured to cooperatively engage a lower side edge portion 53 of the board 50, as shown in FIG. 11. The curved portion 42 conforms to and has a similar shape as the lower side edge portion 53 of the board 50. The curved portion 42 also acts to constrain the boards 50 from moving once attached to the hidden fastener 10. That is, the curved portion 42 constrains vertical movement and/or any rotational movements of the boards 50. In other implementations, the curved portion 42 does not specifically engage with the board (due to the boards have different radii and profiles). Hence, in this embodiment, the curved portion 42 is to provide strength (stress relief) and support to the leg portion 35 itself. The primary constraint provided by a central vertical portion of the thick portion 38 is constraint of the board's lateral translation and to function as a rigid connection between the extending member 56 and the flat portion 41 of the leg portion 35. Thus, in conjunction with the board 50 being supported on the flat portion 41 and the curved portion 42 and a portion of the constraining member 20 (i.e., extending member 56) slideably engaging into the groove 55, the boards 50 are securely held by the hidden fastener 10.

[0028] In some implementations, on the top surface 26 of the constraining member 20, a first tab member 44 and a second tab member 46 are formed projecting upwardly therefrom (FIG. 1). Alternatively, the first and second tab members 44, 46 can be formed that project in a downwardly direction (FIG. 5A) or can be formed in a side direction (FIG. 5B) (i.e., extending from a side portion of the top surface 26 in a planar direction). In some implementations, the first and second tab members 44, 46 can be integrally formed approximately at a center portion of sides 22, 21, respectively, of the constraining member 20. In some implementations, the first and second tab members 44, 46 are similar in size and shape. In other implementations, the first and second tab members 44, 46 are different in size and shape. For example, the second tab member 46 is slightly larger than the first tab member 44. In this implementation, due to the different sizes, tab members 44, 46 can act as a reference as to which direction the hidden fastener 10 is attached to the joist 15. By way of example, as shown in FIG. 7, tab member 44 is configured to create spacing (gaps) 48 between ends 58, 59 of boards 50a, 50b, respectively, that are closely adjacent to each other, and tab member 46 is configured to engage underneath of board 50c (i.e., groove (not shown)) which extends across the joist 15 at a non-abutting joint for securement. In other words, the hidden fasteners 10 are arranged in opposite configuration on joist 15 depending on whether a butt joint is needed. In some implementations, the spacing 48 created by the tab member 44 can range between 1/16 inch and ? inch. Additionally, the tab members 44, 46 are different sizes because of the alternative spacing needed between abutting boards based on the environmental temperature, i.e., due to the change in length/spacing caused by a difference between the coefficient of thermal expansion (CTE) of the decking material and the sub-structure. In the embodiment shown, the correct tab (for a given temperature range) is kept in place to provide the desired spacing and the incorrect one may be easily removed (i.e., broken off).

[0029] In some implementations, only one tab member (44 or 46) is needed in any single abutment to provide the correct spacing for the boards. Therefore, in any situation where multiple abutments appear adjacent to one another on the same joist, the tab members 44, 46 on the hidden fastener 10 only need to provide spacing to one board by maintaining the orientation of the hidden fastener 10 relative to each other, such that the correct tab 44 or 46 for a given temperature range engages with only a single side of a board; meaning that a user can have access to proper (CTE) gapping via the tab members 44, 46, no matter the number of adjacent abutments.

[0030] In some implementations, the first tab member 44 and/or the second tab member 46 can be integrally formed with and has the same material as the constraining member 20, or in the alternative, the first tab member 44 and/or the second tab member 46 can be formed with a different material as the constraining member 20. For example, the first tab member 44 and/or the second tab member 46 can be made from plastic materials or polymers having the same material as the constraining member 20. In other implementations, where the tab members 44, 46 are constructed from a different material, the tab members 44, 46 can be made from metal, for example.

[0031] In some implementations, the first and second tab members 44, 46 are generally rectangular shaped. In some implementations, the first and second tab members 44, 46 include a curved top portion so as to reduce damage to the boards. It should be appreciated that the tab members 44, 46 can be designed with other shapes as long as the functionality/purpose of tab members 44, 46 is achieved.

[0032] While the use of the tab members 44, 46 allow for spacing 48 between the boards 50, it should be appreciated that the disclosed hidden fastener 10 may be designed without the tab members 44, 46, as shown in FIG. 5C, removing any spacing effect created by the tab members 44, 46 and permit the ends of the boards 50 to directly contact each other or for the spacing to be accomplished by manual positioning of the boards 50 with respect to one another.

[0033] In the example embodiments disclosed in FIGS. 6 and 8, a decking system 1 includes a pair of hidden fasteners (i.e., a first hidden fastener 10a and a second hidden fastener 10b) that are configured to engage each side 57 of the decking board 50. As such, there are two hidden fasteners 10a, 10b for each butt joint formed in the decking system 1. As described herein, side 57 depicts a side edge of the board 50 extending in a longitudinal direction.

[0034] The first hidden fastener 10a is positioned on the joist 15 where the opening 39 formed by the pair of leg portions 35 cooperatively engages with the joist 15. In other words, the pair of legs portions 35 is typically positioned to cooperatively engage with a width dimension of the top surface 17 of the joist 15 when installed. Once positioned, the first hidden fastener 10a is installed against the joist 15 by fastening screws 45 at each side at an angle. As discussed earlier, the first hidden fastener 10a includes the angled screw openings 36 to enable the screws 45 to penetrate the joist 15 at both sides at approximately 45 degrees, for example. Next, the end portions 58, 59 of respective boards 50a, 50b are positioned on the first hidden fastener 10a, in particular, on the top surface 26 thereof, to form the butt joint on the joist 15. The groove 55 of each board 50a, 50b at the edge sides 57 thereof engages the constraining member 20 of the hidden fastener 10a to properly align and hold the boards 50a, 50b to the hidden fastener 10a. Using the tab member 44 formed on the top surface 26 of the hidden fastener 10a, spacing 48 is formed between end 58 of board 10a and end 59 of board 10b. To complete the installation, the second hidden fastener 10b is installed on the other side edge 57 of boards 50a, 50b (opposite the first hidden fastener 10a). The second hidden fastener 10b similarly slideably engages with the top surface 17 of the joist 15 until the constraining member 20 of the second hidden fastener 10b engages the groove 55 formed on the other edge side 57 of the boards 50a, 50b. At this stage, both tab members 44 on the respective first and second hidden fasteners 10a, 10b are aligned with the respective edge sides 57, i.e., facing each other. The tab member 44 on the second hidden fastener 10b ensures a consistent spacing 48 is formed with respect to the first hidden fastener 10a. Once in position, screws 45 penetrate the joist 15 on each side of the second hidden fastener 10b to completely secure the two ends of the boards, forming the butt joint.

[0035] As shown in FIGS. 7 and 10, a third hidden fastener 10c is installed on the joist 15; however, the third hidden fastener 10c is installed in an opposite configuration in relation to the first or second hidden fasteners 10a, 10b, in that the second tab member 46 engages the board 50c. In other words, at each side 57 of board 50c, the second tab member 46 of the respective hidden fasteners engages underneath the board 50c via a groove (not shown). Because board 50c lays across the joist 15 at a middle portion thereof, there exists no butt joints over this particular portion of the joist 15. In one implementation, hidden fastener 10c would only be installed in this configuration if there were an abutment to the left hidden fastener 10c in FIG. 10; otherwise a more typical fastener could be used. In this implementation, regarding the tab member 44, it would be removed (broken off) from hidden fastener 10a in order to properly engage with board 50c.

[0036] In some implementations, the butt joints are alternating between every other decking board in a longitudinal pattern. That is, butt joints are formed over a single joist in alternating manner.

[0037] In some implementations, the present hidden fastener provides the board improved support due to the support platforms that are under each board adjacent to the joist and allows for some limited adjustment of individual board heights due to the dual screw design.

[0038] The hidden fastener in any embodiment can be manufactured from any number of materials having suitable strength characteristics. For example, the hidden fastener can be constructed from plastic materials or polymers, such as, but not limited to, polyethylene terephthalate (PET), high density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene (PP), and/or polyvinyl chloride (PVC). Due to the inherent and mechanical properties of plastic (e.g., density, toughness, low electrical conductivity, transparency, etc.), the hidden fastener can be light weight and durable to withstand external force (e.g., impact, drops, stress, and the like). By way of example, the hidden fastener is manufactured from molded polycarbonate. This material provides strong members that are corrosion and/or mold resistant and which can be clear, tinted, colored, translucent or opaque as desired and therefore desirably less visible than metal or colored components in a finished deck system. The hidden fastener 10 can be formed of any colors, such as, black, grey, brown, white, etc., in addition, to matching the color of the boards 50. In one example embodiment, the hidden fastener is made from glass-filled Nylon.

[0039] The decking boards are disclosed as composite boards or wooden deck boards. However, the decking boards are also available in many materials including hardwoods, plastics and composites formed from a combination of materials.

[0040] As described herein, the term proximal end relates to an end being closest to the user, and the term distal end relates to an end being farthest from the user.

[0041] The articles a and an, as used herein, mean one or more when applied to any feature in embodiments of the present disclosure described in the specification and claims. The use of a and an does not limit the meaning to a single feature unless such a limit is specifically stated. The article the preceding singular or plural nouns or noun phrases denotes a particular specified feature or particular specified features and may have a singular or plural connotation depending upon the context in which it is used. The adjective any means one, some, or all indiscriminately of whatever quantity.

[0042] At least one, as used herein, means one or more and thus includes individual components as well as mixtures/combinations.

[0043] The transitional terms comprising, consisting essentially of and consisting of, when used in the appended claims, in original and amended form, define the claim scope with respect to what unrecited additional claim elements or steps, if any, are excluded from the scope of the claim(s). The term comprising is intended to be inclusive or open-ended and does not exclude any additional, unrecited element, method, step or material. The term consisting of excludes any element, step or material other than those specified in the claim and, in the latter instance, impurities ordinarily associated with the specified material(s). The term consisting essentially of limits the scope of a claim to the specified elements, steps or material(s) and those that do not materially affect the basic and novel characteristic(s) of the claimed disclosure. All materials and methods described herein that embody the present disclosure can, in alternate embodiments, be more specifically defined by any of the transitional terms comprising, consisting essentially of, and consisting of.

[0044] Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0045] It will be understood that, if an element is referred to as being connected or coupled to another element, it can be directly connected, or coupled, to the other element or intervening elements may be present. In contrast, if an element is referred to as being directly connected or directly coupled to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.).

[0046] Spatially relative terms (e.g., beneath, below, lower, above, upper and the like) may be used herein for ease of description to describe one element or a relationship between a feature and another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, for example, the term below can encompass both an orientation that is above, as well as, below. The device may be otherwise oriented (rotated 90 degrees or viewed or referenced at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.

[0047] Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, may be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing.

[0048] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0049] While the disclosure has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.