Abstract:
A hidden fastener and associated method for attaching decking members with side grooves to a support member includes a cross member and an elongate anchoring member. The cross member has a body with a front and rear end and defines a hole. The front end has at least one prong and the rear end includes a bent wing. At least one leg extends downward from the body intermediate the front and rear ends. Each of the front and rear ends are configured to engage with the groove of adjacent decking members. The front end is inserted into the groove of a leading decking member and the anchoring member is driven through the hole into the support member. A trailing decking member is placed with the rear end in the groove adjacent the leading decking member.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 14/031,326 filed Sep. 19, 2013, which is a continuation-in-part of U.S. patent application Ser. No. 13/169,175 filed Jun. 27, 2011, which claims priority from U.S. Provisional Application No. 61/358,676 filed Jun. 25, 2010, and claims priority from U.S. Provisional Application No. 61/711,243, filed Oct. 9, 2012, and U.S. Provisional Application No. 61/779,071, filed Mar. 13, 2013, the entire disclosures of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE DISCLOSURE 
       [0002]    The disclosure relates to carpentry and, more particularly, to articles and methods for concealed attachment of grooved surface members to structural members. 
         [0003]    Conventionally, deck planks or other sheathing members have been attached to joists or similar support members by a plurality of fixing or anchoring members, such as nails or screws, driven downward through the top of a plank, such as a wood or composite board, and into the top surface of a supporting beam, such as a joist or ledger board. Although the concept is simple, professional quality installation using this approach requires a high degree of precision, significant time expenditure, and sometimes leads to a flawed result. In particular, planks must be carefully aligned to achieve desirable aesthetic as well as functional results, for example, secure attachment and uniform spacing or parallelism with gaps of proper size for surface drainage and for appearance. Also, the insertion of the nails or screws must be performed carefully to ensure proper penetration of the joist, which will be concealed from view by the overlying wood board at the time of insertion, in order to achieve optimal attachment. This process is time consuming and requires some skill. 
         [0004]    Even if the installation is performed properly, the securing member&#39;s penetration of the upper surface of the plank leaves the plank with a pock-marked appearance and prone to rot and weather damage, which severely decreases the longevity of the deck. In addition, the nail or screws may work loose and protrude from the upper surface of the planks, which poses a risk of injury to users of the deck. Penetration of the top of the plank decreases the integrity of the plank and thus the deck as a whole, and increases the risk of injury. 
         [0005]    These and other problems have spurred on numerous advancements in the field. For instance, an improved deck plank fastening system includes fasteners that attach to a side surface of the plank and a top surface of the joist using nails or screws. Such designs facilitate uniform spacing or parallelism of planks by providing tabs or vertically oriented flanges that engage adjacent planks. The tabs facilitate installation by locating the points of penetration at more readily visible and accessible positions. The fasteners improve the longevity of the resulting deck by repositioning the point of penetration to the side of the plank, which is less prone to weathering. In addition, the tabs reduce the risk of injury to the user of the deck by hiding the nails or screws below the surface. Also, the hidden fasteners improve the aesthetic appeal of the deck. 
         [0006]    Many other improvements and permutations have been conceived in this field, including the provision of deck planks with side grooves for receiving the teeth or tabs of hidden fasteners. Such improvements have specific advantages in specific circumstances, but have not foreclosed innovation in the field. For example, different sizes and types of grooved planks require distinct sizes and configurations of hidden fasteners. The broad variety of possible fasteners to be purchased can make installation of grooved planks both confusing and costly. 
       SUMMARY 
       [0007]    Disclosed herein is a fastener for attaching decking members with side grooves to a support member. The fastener includes a cross member and an elongate anchoring member. The cross member has a body with a top and a bottom and opposite lateral edges extending between a front end and a rear end. The front end has at least one downwardly projecting prong and the second end is bent obliquely upward. The body defines an attachment hole extending from the top to the bottom. A pair of legs is each bent downward from opposite lateral edges of the body intermediate the front end and rear end. Each end of the cross member is configured to engage with the groove of an adjacent decking member. A portion of the anchoring member shank is configured to be driven through the cross member hole into the support member with the front end positioned within the groove of a leading decking member, forming a fastener and rigidly attaching a leading decking member to the support member by engagement between the cross member front end and the leading decking member groove. The legs are positioned between adjacent decking members. 
         [0008]    In another embodiment, a fastener for attaching decking members with side grooves separating a top nub and a bottom nub to a support member has a cross member and an elongate anchoring member. The cross member has a body with a top and a bottom and opposite lateral edges extending between front and rear ends. The front end has at least one downwardly projecting prong and the second end is bent upward. The body defines an attachment hole extending from the top to the bottom. At least one leg projects from the body and has a terminal edge that is below the bottom of the body. The at least one leg defines a front abutment surface on the side of the leg that faces the direction of the body front end. Each end of the cross member is configured to engage the groove of an adjacent decking member and a portion of the anchoring member shank is configured to be driven through the cross member hole into the support member with the front end to rigidly attach a leading decking member to the support member by engagement between the cross member front end with the leading decking member groove with the front abutment surface of the at least one leg against the lower nub. 
         [0009]    In yet another embodiment is disclosed a method of constructing a decking structure by attaching laterally adjacent planks with side grooves separating an upper nub from a lower nub to a support member with hidden fasteners. A cross member having a top and a bottom extending from a front to a rear end is provided. The rear end includes an oblique upward bend and the cross member defines an attachment opening intermediate the front end and rear end extending from the top to the bottom. At least one leg extends in the direction of the bottom. A leading decking plank is positioned substantially flat against the support member and the front end of the cross member is positioned within the groove of the leading decking plank. An elongate anchoring member is driven through the opening in the cross member into the support member with the at least one leg braced against the leading decking plank. The anchoring member and cross member collectively form a hidden fastener. A trailing decking plank is placed substantially flat against the support member adjacent the leading decking plank by inserting the trailing decking plank lower nub between the cross member and support member with the second end of the cross member within the groove of the trailing plank. 
         [0010]    Other features and advantages of the disclosed fastener and method will become apparent in light of the detailed description as illustrated in the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  shows in side view a hidden fastener attaching a sheathing member to a support member, according to an embodiment of the present invention. 
           [0012]      FIG. 2  shows in perspective view a first embodiment of a cross member for use in forming a hidden fastener, according to the present invention. 
           [0013]      FIG. 3  shows in perspective a sectional view of the first embodiment of a hidden fastener attaching a sheathing member to a support member. 
           [0014]      FIG. 4  shows in side view a subsequent sheathing member installed over the hidden fastener shown in  FIGS. 1-3 . 
           [0015]      FIG. 5  shows in perspective view a second embodiment of a cross member for use in forming a hidden fastener, according to the present invention. 
           [0016]      FIG. 6  shows in perspective view the second embodiment of a cross member shown in  FIG. 5 , positioned for attaching a sheathing member to a support member. 
           [0017]      FIG. 7  shows in side view a subsequent hidden fastener being installed and formed to attach the subsequent sheathing member to the support member shown in  FIG. 2 . 
           [0018]      FIG. 8  shows in perspective view a custom barrel and magazines for use with a conventional power driving tool for installing and forming the inventive hidden fastener. 
           [0019]      FIG. 9  shows in side schematic view an exemplary power driving tool for installing and forming the hidden fasteners shown in  FIGS. 1-3 . 
           [0020]      FIG. 10  shows in perspective view an exploded assembly of a conventional power driving tool. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Referring to  FIG. 1 , a sheathing member  2 , such as for example a deck plank, is attached to a support member  4 , such as for example a deck joist, by way of a hidden fastener  6 . The hidden fastener includes a cross member  8 , which has a first end  13   a  engaged into a groove  12  formed on the side of the deck plank  2 . The hidden fastener also includes an anchoring member or fixing member  10 , such as for example a nail or a ballistic screw, which is rigidly attached to the cross member  8  and holds the cross member  8  substantially parallel to the joist when installed. Preferably, the anchoring member  10  is attached to the cross member by a press fit formed when the anchoring member  10  is driven through the cross member  8 . Accordingly, the second end  13   b  of the cross member  8  is supported at a fixed distance from the joist or support member, substantially of equal height with the first end of the cross member. 
         [0022]    Referring to  FIG. 2 , the cross member  8  includes a first end  13   a  formed with downward-curving corners or claws  14  for gripping a lower side of the groove  12  formed in a previously-installed plank or sheathing member  2 . The cross member also includes a second end  13   b  formed with an upward-curving wing  16  that provides for easier assembly of a subsequent plank or sheathing member  2  onto the already-installed cross member. Preferably, the wing  16  forms an angle A with the generally planar body  17  of the cross member  8 , for optimal engagement of the subsequent plank onto the wing  16 . Preferably the angle A is within a range of approximately 10° to approximately 90°; more preferably between 15° and 75°; more preferably between 30° and 60°. In the depicted preferred embodiment, the angle A is approximately 45°. As shown, this embodiment of cross member  8  also has a small dip proximate the apex of the body  13  and wing  16 . 
         [0023]    In this embodiment, the body  17  of the cross member  8  also includes a hole  18  configured for receiving the anchoring member  10  during installation of the fastener. Here, the hole  18  is downwardly sleeved. Preferably, the sleeved hole  18  is carefully dimensioned to provide a press fit on the anchoring member  10 . For example, the sleeved hole  18  may be formed by sequential punch and draw steps to provide an inner diameter within press fit tolerances of a few thousandths of an inch. A press fit between the cross member  8  and the anchoring member  10  permits the anchoring member  10  to support the cross member  8  substantially parallel to the support member  4  after installation of the hidden fastener  6 . This in turn allows quicker and more facile installation of a subsequent plank  2  onto the winged end  16  of the cross member  8 . 
         [0024]    Referring to  FIG. 3 , the nail, ballistic screw, or other anchoring member  10  may be of a conventional shape. Preferably, the nail includes a T-head  20  sized to fit between adjoining deck boards such that no spacer other than the nail is needed in order to obtain adequate drainage from the upper surface of the deck. The anchoring member  10  also may include a collared portion  21 , immediately below the T-head, for properly locating the press fit between the anchoring member  10  and the cross member  8 . In one preferred embodiment, the collared portion  21  of the anchoring member  10  is the only portion that press fits to the sleeved hole  18  of the cross member, with the main shank  23  of the anchoring member  10  being sized to pass freely through the sleeved hole  18 . 
         [0025]    Referring now to  FIG. 4 , when rigidly supported by the anchoring member  10 , the cross member  8  is well positioned for installation of a subsequent sheathing member or deck plank  2   b  onto the winged end  16  of the cross member  8 . As will be appreciated from the phantom lines in  FIG. 4 , the subsequent sheathing member  2   b  first is engaged with the winged end  13   b  of the cross member  8  at an angle to the joist  4 , then is rotated downward onto the joist to fully engage the winged end  16  of the cross member  8  into one of the side grooves  12 . 
         [0026]    Referring to  FIG. 5 , an additional embodiment of a cross member  22  also is suitable for use in forming the hidden fastener  6 . Like the previous embodiment, this cross member  22  includes a first end with downward-curving claws  24 , an opposing second end with an upwardly curved wing  26 , and a sleeved hole  28  for receiving an anchoring member  10 . The cross member  22  also includes at least one downwardly bent spacer legs  30 , which extend outward from lateral edges of the cross member  22 . As shown in  FIG. 5 , this embodiment has two spacer legs  30  positioned to extend from opposite lateral edges of the cross member  22 . 
         [0027]    Referring to  FIG. 6 , the spacer legs  30  can be employed for at least two reasons. First, the legs  30  serve to space a subsequent plank (not depicted) from a plank  2  previously attached to a joist  4  by means of the hidden fastener  6 . Secondly, the legs  30  serve to brace the cross member  22  against the side of a plank  2  with which the claws  24  are engaged, so that the cross member  8  extends from the plank substantially parallel to the underlying joist, for enhanced ease of installing the subsequent plank (not depicted). A cross member,  8  or  22 , and/or legs  30  may cooperate with a positive stopper mechanism within a front end of an automatic feeding system of an installation tool (discussed below) to aid in alignment of the cross member  22  prior to installation via a driven securing member  10 . In other embodiments, the spacer legs may be configured to be driven partially into the support member during installation. 
         [0028]    Referring to  FIG. 7 , the hidden fastener  6  can be installed by means of a power driving tool  32 , shown in phantom lines, specially configured for installing the hidden fastener  6 . For example, as shown in  FIG. 8 , a pneumatic or combustion-powered nail driver may be used with substitution of a suitable barrel  34  including a notch  35 , a generally flat first feeding mechanism  36  (here, a magazine), and a second feeding mechanism  38  (a nail magazine). Alternatively, one or both feeding mechanisms and the barrel may be formed integrally with the power driving tool. Here, the notch  35  of the barrel  34  permits the cross member  8  to be held by the driving tool  32  while being fully inserted into one of the grooves  12  formed on a deck plank  2 , as shown in  FIG. 7 . The notch  35  also permits an upper nose or point  37  of the flat magazine  36  to be engaged into the groove  12 , so that the gun  32  and magazine  36  are held substantially parallel to the joist  4 . As noted above, the power driving tool may include a positive stopper mechanism for aiding alignment of the fixing member and cross member prior to installation. 
         [0029]    Referring also to  FIG. 8 , the notch  35  also exposes a portion of the most forward anchoring member  10  in the second feeding mechanism  38  so that the anchoring member  10  can be positioned directly adjacent the plank  2  to provide proper spacing between adjacent planks. Still referring to  FIGS. 7 and 8 , in some embodiments the first and second feeding mechanisms  36  and  38  are provided integrally with the barrel  34  to provide for quick adaptation of a standard nail driver to other uses. In some embodiments the nail driver also includes a push feed mechanism  54  (shown in  FIG. 9 ) that is customized for installation of the inventive hidden fasteners  6 . 
         [0030]    Referring now to  FIG. 9 , an exemplary power driving tool  32  for use in attaching the disclosed hidden fasteners  6  is shown in schematic outline with key components partly sketched. The barrel  34  and the first and second feeding mechanisms  36  and  38  are sectioned to show a strip of cross members  8  and a stick of anchoring members  10 . In one preferred embodiment, the stick of anchoring members  10  are collated by a wire  40  and are sequentially push-fed into the barrel  34  by a leaf spring  42 . As will be understood, each actuation of the driver  32  makes room for a next anchoring member  10  to be fed from the second feeding mechanism  38  into the barrel  34 . The strip of cross members  8  can be collated on a tape  44 , and can be fed from the first feeding mechanism  36  at least by the pulling action of removing the driver  32  from an already-installed hidden fastener  6 , or by a push feed mechanism. The flat magazine  36  includes a lip or brace  46  for supporting the winged end  16  or  26  of each cross member  8  or  22  during firing of a corresponding anchoring member. 
         [0031]    In addition to the barrel  34  and the feeding mechanisms  36 ,  38 , the depicted embodiment of power driving tool  32  also includes a hammer  48 , which reciprocates within a chamber  50  by means of a spring  52  on a barrel side of the hammer piston and a propulsion fluid  51  on a chamber side of the hammer piston. The tool also may include a push feed mechanism  54 , as discussed above and shown in  FIG. 9  by phantom lines. As known, the nail driver is actuated by a trigger  56  and may be powered at least by compressed air provided through an inlet fitting  58 , or by combustion of butane or other gas provided from a removable flask  60 . The feeding mechanisms  36 ,  38  can be attached to the driver  32  by way of top and bottom braces,  44  and  46 , respectively, or a like means of attachment, or formed integrally with the body of the tool. 
         [0032]    In operation, in preparation for installation and in situ forming of the inventive hidden fastener  6 , the tool  32  is used to position the clawed first end  14  or  24  of a cross member  8  or  22  into a groove  12  of a deck plank  2  resting on a joist  4 . During installation and forming of the hidden fastener  6 , the nose or point  37  of the flat first feeding mechanism  36  is engaged into the groove  12  of the plank, and/or one of the top or bottom braces  62 ,  64  may contact the joist  4  and support the tool  32  with the feeding mechanism  36  substantially parallel to the joist  4 , while the lip  46  formed in the flat magazine  36  supports the winged end  16  or  26  of the cross member  8  or  22  substantially parallel to the joist  4 . Actuating the tool  32  via the trigger  56  causes the hammer  48  to drive an anchoring member  10  through the sleeved hole  18  of the cross member  8  or  22  and into the joist  4 . The collared portion  21  of the anchoring member forms a press fit with the sleeved hole  18  or  28 , thereby rigidly attaching the cross member, anchoring member, joist, and plank. A subsequent plank then can be assembled over the winged end  16  or  26  of the cross member  8  or  22 , as shown in  FIG. 4 . Another fastener can then be attached to the free end of the subsequent plank, and the process repeated as necessary. 
         [0033]    A benefit of the disclosed fastener, method and tool is that they allow various types and sizes of side-grooved sheathing members to be securely yet invisibly attached to underlying support members. Additionally, the secure and hidden attachment can be accomplished for any type of side-grooved sheathing member using identical cross members and anchoring members in combination with a power driving tool specially configured for use with the fasteners, like the disclosed driver. Thus, the disclosed embodiments permit bulk manufacturing and purchasing of a single hidden fastener model for use with many different models of side-grooved deck planking. 
         [0034]    While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage.