Collating strip for plug and plug installation method

A collating strip for holding plugs prior to insertion of the plugs into a hole such as a screw hole or nail hole after the screw or nail has been driven. The collating strip comprises an elongated strip having a plurality of perforations spaced along its length; and a plug positioned in each of the perforations, each plug having an insertion end and an external end, the insertion ends projecting from said strip. The strips may be in sheet form of a plurality of strips side by side with an individual strip being separable from the remaining strips of the sheet.

FIELD OF THE INVENTION

The invention relates to plugs for filling recesses left by attachment openings in a surface, such as a screw or nail hole in trim, sheathing or a like item. More particularly, the invention relates to a collating strip to hold a plurality of plugs, a sheet of multiple collating strips and an automatic or semi-automatic method of installing plugs from the strip.

BACKGROUND

Plugs are commonly used to conceal holes formed for attaching trim or a similar building material with attachment holes (decking, sheathing, furniture, etc.). Numerous loose plugs are packaged together in a bag for individual handling and insertion into an attachment hole. This known method of packaging and handling carries numerous drawbacks. For example, the relatively small sized plugs are easily dropped and/or lost, attract dirt from one's fingertips, are challenging to position into a flush hole with one's fingertips, are difficult to isolate prior to use and are often difficult to position with proper grain orientation in the trim material. It would be useful to have a storage and delivery system that allows a quick and facile positioning, orientation and insertion of plugs with minimal or no direct handling of the individual plugs.

SUMMARY

In one embodiment, a strip of plugs configured for insertion into a hole in a surface includes a substrate and a plurality of plugs. The substrate defines a first side and an opposite second side and has a plurality of perforations longitudinally spaced apart from one another extending between the first side and second side. Each of the plurality of plugs extends axially from an external end to an insertion end with an axially extending outer surface therebetween. The outer surface is non-uniform in diameter in the axial direction and has a substantially cylindrical portion proximate the external end. Each plug is maintained by the substrate in a perforation via friction fit between the substrate and the substantially cylindrical portion with the external end and a portion of the outer surface exposed from the first side of the substrate. The insertion end and a portion of the outer surface is exposed from the second side of the substrate.

In another embodiment, a strip of plugs configured for insertion into a hole in a surface includes a substrate having a plurality of perforations spaced apart from one another in a substantially longitudinal row. Each plug of a plurality of plugs is maintained by a perforation in the substrate. Each plug has an upper portion with a substantially cylindrical outer surface of a first diameter and a lower portion with a reduced diameter smaller than the first diameter. Each plug is maintained by the substrate via friction fit between the substantially cylindrical outer surface of the respective upper portion and the substrate with the reduced diameter of the lower portion exposed from the substrate.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the drawings wherein like numerals represent like parts throughout the Figures, a collated strip of plugs for use in concealing holes in trim or like structures and a corresponding method of installation is disclosed.

FIG. 1shows one currently employed method of trim installation, including the step of concealing the recess left by the screw hole with a loose plug10(typically having a matching surface to the surrounding trim3or like surface). The screw or nail1is installed by driving the screw or nail into the trim3leaving a bore5above its head. A plug12is placed into the bore and tapped in until its outer end face is flush with the outer surface of the exterior member such as trim3.

FIG. 2shows an embodiment of the disclosed collating plug strip10with a plurality of associated plugs12engaged with an elongate strip14. The strip has an upper surface11and bottom surface13. This embodiment of the plug strip10includes pre-punched perforations16at predetermined positions along the length of the elongate strip14. Each perforation16is configured to rigidly or semi-rigidly engage a plug12, as shown most clearly in the middle strip inFIG. 2. In a preferred embodiment, the strip14is a polymeric material that has a relatively translucent or clear appearance and is somewhat flexible (i.e. not a rigid plastic). However, additional strips may be made from paper, cardboard, cloth, or the like.

The plugs12have an insertion end15that is adapted to be inserted in the screw hole and an external end17having a finished end surface which is exposed when the plug12is inserted. The plugs12are inserted into the perforations16finished end surface first. The perforations16have their inner side edges19turned downward and inward as shown inFIG. 2to frictionally grasp the plugs12.

As shown best in the middle strip10ofFIG. 2, the strip14and plugs12are engaged with at least a portion of the “insertion end”15of the plugs projecting from the bottom surface13of the strip14. As shown in the bottom strip10ofFIG. 2, the plugs12can be positioned in the strip14with the respective grains on the surface of the exposed end17being in alignment.

The collating strip10allows easy handling of numerous plugs12without the drawbacks discussed above. After attachment of a trim board or like member with a screw, a user can grip the strip14and position a plug12within the fastener recess/hole (with surface grains aligned). In the embodiment depicted inFIG. 2, a user can tap or otherwise push the plug12into the hole and then dislodge the strip14. The separated plug12can be tapped additionally to effect a flush mating with the surface of the trim.

Embodiments of the disclosed strips10may be provided wherein the engaged plugs12are positioned at predetermined lengths along the strip14that substantially correspond to the positions of pre-cut holes or recesses in the trim surface. This configuration allows a user to align the plug strip10with numerous individual plugs12aligned with a separate recess, and then install the plugs12in a single step, without having to access or move the strips numerous times for the same trim surface.

FIGS. 3 and 4depict an additional embodiment of a strip24. As shown, this embodiment includes a plurality of spaced registry notches28spaced along each longitudinal edge of the strip24. As will be discussed in further detail below, the registry notches28can assist alignment of the strip with a trim surface, and also assist in engagement with an automatic or semiautomatic feeding and attachment tool.FIGS. 3 and 4also show numerous embodiments of perforations, indentations or holes in the substrate24that can be used to engage and maintain standard shaped plugs therewith. The perforations can also be shaped to adapt to numerous different shapes of plugs, if desired.

FIG. 5shows the bottom side of another plug strip130, which includes a plurality of plugs132engaged within perforations126in a notched strip134. Typically, each registry notch138is positioned on a longitudinal edge of the strip134opposite a registry notch138on the opposite edge of the strip. The registry notches138are also typically spaced longitudinally a uniform distance from each other along the respective edges. In this embodiment, the strip134extends longitudinally with the perforations136and associated plugs132being positioned longitudinally between the registry notches138. This relationship assists a more facile alignment and/or longitudinal advancement of the strip130on a surface or through an automatic feeding and attachment tool. The perforations136are preferably oval as shown particularly inFIG. 7although other shapes may be used.

As shown particularly inFIGS. 5, 6, 10 and 11, the plug132,232may include an upper enlarged cylindrical portion133,233, a lower reduced cylindrical portion135,235and a tapered transition portion137,237between the upper enlarged cylindrical portion133,233and the lower reduced cylindrical portion135,235. The lower reduced cylindrical portion135,235may have a taper139,239at its end portion. The outer face of the enlarged cylindrical portion135,235is the external end having a finished end surface141and the end of the lower cylindrical portion137,237is the insertion end143. See U.S. Pat. No. 8,104,248, the entire disclosure of which is incorporated by referral herein in its entirety, for a disclosure of various types of plugs that may be used.

FIG. 5shows the insertion end43of each plug132projecting above the bottom surface145of the strip134, which allows easy insertion into a recess or bore in trim or a similar surface material.FIG. 6depicts the reverse or top side of theFIG. 5view, showing the “finished” end surface141of the plugs132. As shown, the finished end141may project very slightly beyond the surface of the strip134, but this is not a necessary relationship. The individual plugs132can be inserted into a trim recess and the strip134can be dislodged without contact with the finished end of the plug132. An embodiment may be provided wherein a removable covering or wrapper extending along the side of the substrate with the finished ends of the plugs to protect the finish.

TheFIGS. 5 and 6embodiment features engagement of the plugs132with the strip134via a relatively light frictional engagement within the strip perforations. The perforations126engage the upper enlarged cylindrical portion133of the plug130. Additional embodiments may be provided which employ a mild adhesive either alone or in combination with frictional forces to engage or assist engagement of the plugs with the substrate.

FIG. 7shows a plan view of the notched strip ofFIGS. 5 and 6. This view shows a spacing distance of approximately 1.0 inch between the centers of each successive plug132along the strip134. However, the spacing can be varied as desired for different sized plugs and different configurations of substrate. A preferred range of distances is 0.20 inches to 2.0 inches, with a particularly preferable distance of approximately 0.5 inches. As shown and discussed above, the registry notches138are disposed along each longitudinal edge of the substrate134in an opposing configuration. These registry notches138each have substantially the same size and shape, but these characteristics may vary, for instance, for different configurations of attachment and feeding tools. The strip130may come wrapped in a coil configuration for advantageous packaging, storage and use.

FIG. 8depicts an embodiment of a semi-automatic installation device or tool150for use with the disclosed strip, like that depicted as reference numeral130. The installation device150includes an elongated track152that defines a front opening154extending the entire length of the track. Also defined by the track152are a lower opening156and an upper opening157, each sized and shaped to allow an end of the strip130to pass through. The track152is preferably a rigid material such as a metal or a hard plastic. The track152is configured to receive and slidably maintain the strip130with the insertion ends115of the plugs132within the front opening154, as shown in the lower exploded window inFIG. 8.

The installation device150also includes an advancement and attachment mechanism, positioned within the housing portion shown generally as reference numeral158inFIG. 8. The attachment mechanism includes a plunger or similar item (not shown) that reciprocates generally perpendicular to the strip portion in front of the plunger. One embodiment of the device150may include an advancement mechanism with a toothed-wheel configuration. The teeth of the wheel are sized, shaped and positioned generally to engage with the notches138on the strip substrate134.

A user typically feeds the strip130upward through the track152until the teeth engage with a front set of the notches138. When a plug132is advanced in front of the plunger, a user can position the plug132within a trim recess or bore, and then pull the device trigger160which effects reciprocation of the plunger outward, thereby dislodging the plug132from the substrate134and installing it within the recess. Thereafter, the toothed wheel rotates upward (clockwise in the view ofFIG. 8) a predetermined angle, advancing the strip130upward into position with the next plug132in front of the plunger ready for the next installation. As shown in the upper exploded circle inFIG. 8, the empty strip134material exits the upper end of the track152. The described toothed wheel and plunger is a non-limiting example of an advancement and attachment mechanism that is suited for use with the disclosed strip130.

FIG. 9shows a plurality of collating plug strips230joined at adjacent longitudinal edges to form a sheet240. Here, the sheet240includes four parallel longitudinally extending strips230joined in an alternating offset alignment (i.e., a “quad sheet”). It is to be understood that any number of rows may be provided. Each strip230is attached to an adjacent strip230with the plugs232of each respective adjacent strip longitudinally aligned with the intermediate portion of strip234between plugs232of the adjacent strip. This described configuration likewise results in the registry notches238and relief notches242in the strip234being longitudinally offset from the corresponding notches of the adjacent strip(s). As shown, alternating strips230in the sheet240are substantially longitudinally aligned.FIG. 9also shows a non-limiting example of the dimensions of an embodiment of the sheet240(in inches).

The side elevation view of the sheet240shown inFIG. 10depicts the alternating arrangement of adjacent strips230. The end strip plugs232aare longitudinally offset from the adjacent (rear) strip plugs232b. The enlarged portion of a plug232(detail B) shows preferred dimensions and a plastic retaining element246which may be included for assisting securement of a plug232within a perforation in the substrate234.

The registry notches238are positioned to facilitate incremental and consistent longitudinal feeding of a strip230with an automatic or semi-automatic attachment tool. The relief notches242are positioned between each successive plug232in a strip230to improve flexibility of the strip and/or sheet240.

As shown in the enlarged end view ofFIG. 11(detail A), the sheet240can be manufactured with a V-notch244or similar notch in the substrate234at the joined interface between longitudinal edges of adjacent strips230in the sheet240. The V-notch244assists in facile detachment of adjacent strips by tearing or peeling off.FIG. 11also indicates a preferred geometry and dimensions.

With reference toFIG. 12, prior to use of a collated strip, an end strip230is typically be detached (by “peeling” or “tearing”) from the adjacent strip in the sheet240and fed into an installation device (like that depicted previously as reference numeral150) or used for hand installation.

The four-strip configuration of the sheet240depicted inFIGS. 9 and 12is particularly advantageous for manufacturing, packaging, transporting, pre-use handling and strip detachment.

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.