Fastener

An improved fastener comprising: a screw element (1) and a cover member (11). The screw element (1) comprising a shank member (2) having comprising a piercing tip (6) at a first end of the shank member and a head (7) at a second end of the shank member. The head of the screw comprising a first recess (9) for releasably engaging an instrument of rotation and a second recess (10) extending from the first recess into the shank member for releasably engaging a shank portion (14) of a cover member (11). The cover member (11) comprising a capping portion (12) having a first face (13), a second face (17) and a shank portion (14) extending substantially orthogonally from the first face (13) of the capping portion (12), the shank portion (14) being releasably engagable with the second recess (10) of the screw element (1).

FIELD OF THE INVENTION

The present invention relates to fasteners and in particular to fasteners suitable for use with budding products.

The invention has been developed primarily for use as fastener for building cladding sheets and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

BACKGROUND OF THE INVENTION

Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.

Fasteners, such as screws have been used for many years to permanently or temporarily fasten two or more materials together. When fastening materials together with screws, the face of the head of the screw usually remains visible to the end user. In many instances, this is not aesthetically pleasing for the end user. Accordingly, it often desired to hide screw heads by various means. Most commonly this can be achieved by filling over the screw head with wall filler, or similar compound specifically designed for this purpose, allowing the filler to dry and then sanding the area. Usually the filled area and surrounding area are painted after filling the screw heads. Unfortunately once the area has been painted, location of screw fasteners and/or removal of screws to unfasten materials is not easily possible, particularly if the fastener head has been obscured or hidden by means of filler material and/or paint. Furthermore, removal of screws in such installations generally cannot be achieved without damage to the area and possibly the installation.

Whilst the above procedure is effective in hiding screw heads used to secure unfinished building materials, it is generally not effective in hiding screw heads fastened into prefinished material, for example, pre painted materials. In some instances, it is known to colour match screw heads to surrounding colour. However, for a manufacturer, this means that large stock holdings in a large variety of colours are required to be able to meet consumer demands.

Location of screw fasteners is easier for prefinished screws than for filled and over coated installations, but removal of prefinished fasteners risks damaging the finish and does not allow for location of fastening points or removal of the fasteners.

OBJECT OF THE INVENTION

It is an object of the present invention to provide an improved fastening system that is easy to install, can be colour matched to its surroundings and may be easily located and removed if required.

SUMMARY OF THE INVENTION

According to the invention there is provided an improved fastening system suitable for use with building elements comprising;

a screw element comprising a shank member having a first end, a second end and a thread positioned along at least a portion of the shank member intermediate the first and second ends, the screw element further comprising a piercing tip at the first end of the shank member and a head at the second end of the shank member, the head of the screw comprising a first recess for releasably engaging an instrument of rotation and a second recess extending from the first recess into the shank member for releasably engaging a shank portion of a cover member; and

the cover member comprising a capping portion having a first face, a second face and an edge member intermediate the first face and second face, the cover member further comprising a shank portion extending substantially orthogonally from the first face of the capping portion remote from the second face, the shank portion being releasably engagable with the second recess of the screw element.

According to the invention there is further provided a screw element comprising a shank member having a first end, a second end and a thread positioned along at least a portion of the shank member intermediate the first and second ends, the screw further comprising a piercing tip at the first end of the shank member and a head at the second end of the shank member, the head of the screw element comprising a first recess for releasably engaging an instrument of rotation and a second recess extending from the first recess into the shank member for releasably engaging a shank portion of a cover member.

According to the invention there is further provided a cover member comprising a capping portion having a first face, a second face and an edge member intermediate the first face and second face, the cover member further comprising a shank portion extending substantially orthogonally from the first face of the capping portion remote from the second face, the shank portion being releasably engagable with the second recess of the screw element.

The advantage of the fastening system of the present invention is that the exposed face of the head of the screw element is disguised to the end user by means of the cover member. The cover member minimises access of weather elements, such as rain, to the interface between the fastening means and the building materials.

It is acknowledged that the term ‘comprise’ may, under varying jurisdictions be provided with either an exclusive or inclusive meaning. For the purpose of this specification, the term comprise shall have an inclusive meaning that it should be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components. Accordingly, the term ‘comprise’ is to be attributed with as broad an interpretation as possible within any given jurisdiction and this rationale should also be used when the terms ‘comprised’ and/or ‘comprising’ are used.

It is to be understood that the terms ‘cover member’ and ‘capped pin’ are used interchangeably throughout the specification to describe the ‘cover member’ of the invention which inserts through the first into the second recess of the screw element of the invention.

In a further embodiment of the invention, the second recess is sized and shaped to securely hold the shank portion of the cover member in place. In one embodiment of the invention the second recess extends a sufficient distance into the interior of the shank member of the screw element to securely hold the cover member in place. It is preferable that the cover member is held in the shank portion such that an external force is applied to the cover member to release the cover member from engagement with the second recess of the screw element The advantage of this is that accidental dislodgement of the cover member from the screw element is prevented.

In a further embodiment of the invention the second recess extends into the interior of the shank member of the screw element. In one embodiment of the invention the second recess is in the form of a cylindrical recess within the shank member, wherein the cylindrical recess has a continuous interior surface within the shank member and a closed end remote from the first recess. It is to be understood that the second recess can adopt any suitable shape known to the person skilled in the art which allows the second recess to accommodate the shank portion of the cover member. Optionally in a further embodiment of the invention the second recess extends within the shank element approximately one quarter of the overall distance from the face of the screw element to the tip of the screw element.

In a further embodiment of the invention, each of the first and second recess have an opening at one end of the recess and a base at the opposing end of the recess remote from the opening, the first and second recess being formed adjacent to each other wherein at least a portion of the base of the first recess is contiguously formed with the opening of the second recess.

In a further embodiment of the invention the screw element comprises a cylindrical shank member.

In a further embodiment of the invention the screw element comprises a tapered shank member.

In a further embodiment of the invention the screw element comprises a threaded portion on at least a portion of the shank member. In one embodiment the threaded portion comprises a helical ridge threaded portion. In a further embodiment of the invention, the threaded portion comprises a pitched threaded portion.

In a further embodiment of the invention, the capping member is sized and shaped such that it covers the exposed face of the screw element. In one embodiment of the invention, the second face of the capping portion has a convex shape such that the second face is curved outwards relative to the shank portion of the cover member.

In a further embodiment of the invention, the shank portion further comprises an angled portion remote from the capping portion. Conveniently the angled portion extends from the shank portion at a predetermined angle relative to the shank portion. In this embodiment of the invention the angled portion extends from the shank portion at an angle such that the lineal distance between any pair of opposing points on a pair of spaced apart parallel longitudinal axes is greater than the diameter of the second recess of the screw element, wherein the first longitudinal axis extends from the capping member to the section of the angled portion closest to the edge member of the capping portion and the second longitudinal axis extends from the capping portion to the edge of the shank portion remote from the tip of the angled portion.

Thus, when the cover member is in use, the angled portion is inserted into the second recess of screw element and pressure is applied to the cover member to urge the angled portion into the second recess. Due to the larger diameter, the angle between the shank portion and the angled portion is altered such that the angled portion is forced into engagement with the interior surface of the second recess of the screw element, thereby forming a resilient bias within the second recess and retaining the cover member within the screw element.

In one embodiment of the invention, the shank portion and/or angled portion further comprise at least one retaining means. In a further embodiment of the invention, the retaining means are removeably attached to the screw element. In an alternative embodiment the retaining means are integrally formed with the screw element. Optionally, in a further embodiment of the invention, the retaining means are made of the same material as the screw element. In an alternative embodiment of the invention the retaining means are made from any suitable material known to the person skilled in the art that will provide the necessary properties to achieve the functional requirements of the retaining means.

In a further embodiment of the invention, the retaining means is in the form of at least one protrusion or appendage attached to the end of the shank portion or angled portion remote from the capping portion. Conveniently, where a plurality of retaining means are provided the protrusions or appendages are spaced apart from each other. In some instances, it is understood that it is preferable for the protrusions or appendages to be equally spaced apart from each other.

In a further embodiment of the invention the shaped protrusion or appendage is in the form of a curved or angular projection. Preferably, the retaining means are shaped such that the shank portion of the cover member is secured within the second recess of the screw element by means of a friction fit or a resiliently biased fit.

In a further embodiment of the invention, the retaining means or protrusion is disposed axially on or about the shank portion.

Optionally, in a further embodiment of the invention, the retaining means or at least one protrusion is disposed circumferentially on or about the shank portion.

In a further embodiment of the invention, the shank portion of the cover member comprises a weakened or friable section intermediate the shank portion and the capping portion. Conveniently the weakened area or section allows for the capping portion of the cover member to become separated from the shank portion when an external force is applied to remove the cover member from the screw element. The advantage of this is that the cover member further acts as a securing means to prevent unwanted removal of the screw element when in being used to secure a building material to a building substructure.

In a further embodiment of the invention, the second face of the capping member is surface treated, for forming a decorative coating. Conveniently the surface treatment is selected from at least one of the group comprising etching, abrading, anodizing, galvanizing, irradiating, polishing, and embossing.

In a further embodiment of the invention, the surface treatment comprises a surface coating. In another embodiment of the invention, the surface coating is applied as paint.

According to the invention, there is provided a method for installing an improved fastener comprising the steps of;(a) providing at least a first and a second material to be releasably fastened together;(b) positioning a first material in a user selected position, the first material at least partially covering at least a section of the second material;(c) providing a screw element comprising a shank member having a first end, a second end and a thread positioned along at least a portion of the shank member intermediate the first and second ends, the screw further comprising a piercing tip at the first end of the shank member and a head at the second end of the shank member, the head of the screw comprising a first recess for releasably engaging an instrument of rotation and a second recess extending from the first recess into the shank member for releasably engaging a shank portion of a cover member;(d) providing a cover member comprising a capping portion having a first face, a second face and an edge member intermediate the first face and second face, the cover member further comprising a shank portion extending substantially orthogonally from the first face of the capping portion remote from the second face, the shank portion being releasably engagable with the second recess of the screw element;(e) releasably engaging the instrument of rotation with the first recess;(f) driving the screw through the at least two materials to be releasably engaged until the face of the screw is co-planar with a first surface of the first material; and(g) placing the cover member in position by inserting the shank portion of the cover member into the second recess in the head of the screw and applying pressure to urge the edge member of the capping portion into physical contact with the first surface of the first material.

In a further embodiment of the invention, at least one of the first and second materials is a façade panel. In a further embodiment of the invention the façade panel is a fibre cement panel.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings and specificallyFIGS. 1(a) to 1(d), 3(a) to 3(d) and 4(a) to 4(d), there is shown three embodiments of an improved fastening system according to the invention. It is to be understood that throughout the detailed description of the invention, the features of the invention that are common to each embodiment have substantially the same reference numeral. The reference numerals are prefixed with one or more further digits to indicate the embodiment of the invention being referred to.

Screw element1comprises a shank member2having a first end3and a second end4. In the embodiments shown the first end3is provided with a piercing tip6and the second end4is provided with a screw head7. Screw head7has an exterior face8positioned remote from the shank member2. Exterior face8is provided with a first recess9for releasably engaging an instrument of rotation such as a screwdriver and a second recess10for releasably engaging shank portion14of cover member11. The second recess10extends from the first recess9into the interior section of shank member2. A screw thread5is positioned on the external surface of the shank member2intermediate the first and second ends3and4. In the embodiment shown the first recess has a cruciform shape, which accommodates a Philips™ head type screwdriver. The second recess10is in the shape of a cylindrical recess which has a continuous internal wall and a closed end remote from opening extending from the first recess9.

Cover member11comprises a capping portion12and a shank portion14. The capping portion12has a first face13, second face17and an edge member18intermediate the first face13and second face17such that the first face13is spaced apart and separate to the second face17. The shank portion14extends substantially orthogonally from the first face13of capping portion12. The shank portion14of the cover member11is sized and shaped such that it is releasably engagable with the second recess10of the screw element1. In use, the second face17comprises the outermost portion of the cover member11which is visible when the cover member11is engaged with the screw element1.

Referring now specifically to the cover member11shown inFIG. 1(a), shank portion14is further provided with an angled portion15remote from the capping portion12. The angled portion15extends from the shank portion14at a predetermined angle16relative to the shank portion14. In this embodiment of the invention the angled portion15is angled such that the lineal distance A between any pair of opposing points on the longitudinal axes (shown in dotted lines onFIG. 1(a)) extending from (a) the capping member12to the section of the angled portion15aclosest to the edge member18of the capping portion12and (b) the capping portion12to the edge of the shank portion16aremote from the tip of the angled portion is greater than the diameter of the second recess10of the screw element.

In use, the angled portion15is inserted into the second recess10. Pressure is then applied to the second face17of the cover member11to urge the angled portion15into the second recess10. In performing this action, angle16between the shank portion14and the angled portion15is altered such that the angled portion15is biased towards the interior surface of the second recess10. When the angled portion15is biased into this position, an external force must be applied to overcome the bias in order to remove the cover member11from the screw element1.

Referring now specifically toFIG. 3(a), there is shown a second embodiment of the cover member311. In the embodiment shown, the shank portion314is provided with a plurality of projections or protrusion attached to or projecting from the end of the shank portion314remote from the capping portion312. In the embodiment shown, the projections are axially aligned with the shank portion314. Referring toFIG. 4(a), there is shown a third embodiment of the cover member411. In this embodiment of the invention, the projections or protrusions are equally spaced apart from each other and circumferentially disposed on or about the shank portion414. In both the second and third embodiments of the cover member311,411, the projections are shaped such that the shank portions314,414of cover members311,411are secured within the second recess310,410of the screw element301,401by means of a friction or resiliently biased fit.

Referring now toFIG. 3(c), the second surface317of cover member311has been finished with a decorative surface finish. It is understood that the second surface of the cover member may require some kind of pre-treatment, for example, etching, abrading, irradiating, and the like surface treatment prior to finishing in order to provide a suitable surface to enable adequate adhesion of an applied decorative finish such as a paint or transfer print.

In some instances, the shank portion14of the cover member11is designed with a weakened or friable section where the shank portion14projects from the capping portion12of the cover member11. In the instance where the shank portion14is retained within the second recess10of the screw element1, the weakened area or section allows for the capping portion12of the cover member11to become separated from the shank portion14in the event an external force is applied to remove the cover member11from the screw element1. The advantage of this is that the cover member11further acts as a securing means to prevent unwanted removal of the screw element1when in being used to secure a building material to a building substructure.

Referring now toFIGS. 2(a) to 2(c), the use of the improved fastener to fasten a building material to a building substructure is shown. Optionally all surfaces are prepared by cleaning or similar prior to installation. The piercing tip206of the screw element is positioned on a desired fastening location220on building material230. An instrument of rotation such as a screwdriver is positioned so that the blade240releasably engages at least a portion of first recess209in screw head207. Rotational energy is applied to screwdriver blade240causing piercing tip206to penetrate building material230at or adjacent the desired fastening location220. As force is continually applied to the screwdriver blade, the shank member202of the screw element of the invention is progressively driven into building sheet230.

Referring now toFIG. 2(b), building sheet230is fastened to the building substructure232via the screw element of the invention. Shank member202of the screw element has been driven in until face208of screw head207is level or co-planar with surface231of building material230. At this stage, the fastening location is easily identified because face208is visible and unprotected. In many instances the colour of the screw element will contrast with that of surface231of building material230. InFIG. 2(b)cover member211is shown adjacent face208, ready to be installed. In order to install the cover member211, the angled portion215of the shank is inserted into the second recess210of the screw. Pressure is applied to second surface212of cover member211, which forces the angled portion215of the shank portion214further into the second recess210. The angled and shank portions215,214respectively of cover member211are forced into the second recess210of the screw element until edge member218is brought into physical contact with surface231of building material230. As the shank portion214of the cover member211is forced into second recess210, the angle of bend216between shank portion214and angled portion215is altered and results in the formation of a resiliently biased spring. The cover member211is held in position because of the resistance fit of the resiliently biased spring within second recess210.

Referring now toFIG. 2(c), there is shown a completed installation, with cover member211installed and in place. Once installed, the diameter of the capping member212is sized and shaped to completely cover the screw face208. Edge member218of cover member211is in close physical contact with surface231of building material230and further acts to minimize contact of environmental agents with the screw200. Once installed, the capped pin covers face208of screw200and serves to obscure or hide the fixing locations.

The exterior surface of cover member211may be surface treated by one or more surface treatment processes to provide an aesthetic decorative finish. The surface treatment may be one or more of etching, abrading, anodizing, galvanizing, irradiating, polishing, and embossing. In some cases, the surface treatment may include a decorative paint finish that is matched to a paint colour and other features, such as gloss level and texture, of a prefinished building material.

Referring now toFIGS. 5(a) and 5(b), there is shown a further embodiment of the screw element500of the invention. As before, screw element500comprises a shank member502having a first end and a second end. The first end of screw element500is provided with a piercing tip506and the second end is provided with a screw head507. Screw head507is provided with a first recess509for releasably engaging an instrument of rotation, in this instance a square key and a second recess510for releasably engaging a shank portion of a cover member of the invention. The second recess510extends from the first recess509into the interior section of shank member502. The diameter of second recess510is much smaller than that of first recess509. A screw thread505is positioned on the external surface of the shank member502intermediate the first and second ends. The shank member502is also provided with wings520which act to further secure the screw element500in place when in use, particularly when being used with composite building material.

FIG. 6shows an improved fastener system6according to the invention in an installed position, where at least one building material601is shown fastened to a building substructure602. Cover members have been installed to complete the wall construction at that fastening location. Also shown inFIG. 6, are partially completed fastening locations604,605where the screws have been installed but each has not yet had its respective cover member (unshown) installed. If, for any reason, fasteners need to be removed from a completed wall installation, the capped pins can be removed by levering the cap away from the building material surface. Levering action will overcome the resiliently biased retaining means or angled portion on the shank portion and allow the shank portion to be withdrawn from second recess of the screw element. This can be done with substantially no damage to any surface finish on the building material, which is important if the building material has an expensive or high quality surface finish factory applied, which cannot be easily repaired on site.

It will be appreciated that the illustrated improved fastener is easy to install, can be colour matched to its surroundings to minimize visibility and may be easily located and removed if required.

It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the invention as defined in the appended claims.