Attachment plate

Abstract: An attachment plate (1)is used to attach insulation panels (57) to building substrates (59) using an internal combustion cordless nail setting tool (55) loaded with nails (77) held in collating strips (79) for feeding and holding them in a magazine. The attachment plate (1) has a washer (2) and an annular chamber (51) at a first end. A wall of the annular chamber is defined by a band of fingers. The interior of the attachment plate (1) has a recess (30). The attachment plate (1) second end has flexible tabs. The attachment plate (1) is placed on a pilot (67) and against a flange (65) of a tool adapter (63). The attachment plate (1) is pushed into the insulation panel (57) such that the tool muzzle bends and passes through the fingers (45). When the tool (55) is fired, a nail (77) and nail collating ring (79) are forced into and captured within the recess (30). The tabs (41) bend against the substrate (59) if the insulation panel (57) is of less than nominal thickness.

Description: This invention pertains to building construction, and more particularly to apparatus for attaching insulation panels to structural substrates. Many types of buildings include compressible insulation panels attached to structural substrates. The insulation panels are typically attached in place by mechanical fasteners such as screws or nails in conjunction with specialized attachment devices. The attachment devices are commonly thin plates having relatively large areas. The plates are placed on the insulation panel surface opposite the substrate, and the fasteners are driven through the plates and insulation panel into the substrate. The process of attaching insulation panels to buildings has traditionally been slow and costly. If screws are used as the fasteners, holes must be predrilled into the masonry or other substrate. Self-drilling screws require time for drilling and tapping. Further, the screws must be fed individually into the front of an electric screw gun tool. With powder driven nails as the fasteners, the nails and powder loads must be fed individually or in small numbers, usually by hand, into the power setting tool. Examples of prior insulation panel attachment devices may be seen in U.S. patents 2,307,348; 4,380,413; 4,545,270; 4,606,168; and 4,862,664. The attachment devices of the foregoing patents do not pass completely through an insulation panel from its exposed surface to the substrate. Consequently, it is difficult to consistently apply the correct amount of force to the fasteners. If too little force is applied, the plate portions of the attachment devices will project improperly above the insulation panel exposed surface. In addition, the fasteners will not embed sufficiently into the substrate, so they will have a tendency to work loose. If too much force is applied to the attachment devices, they will penetrate excessively into the insulation panels. U.S. patents 5,054,983 and 5,171,118 show insulation panel attachment devices that pass entirely through insulation panels. Those attachment devices can thus clamp insulation panels to a substrate with a uniform force. On the other hand, the devices of the two foregoing patents suffer the handicap of being unable to accommodate insulation panels having thicknesses that vary from a nominal thickness. Further, the devices of the foregoing patents require installation by power setting tools that have individual feeding of the nails and the powder loads. Consequently, installation times are undesirably high. According to this invention an attachment plate for attaching an insulation panel to a substrate comprises: a) a washer defining a central opening and a longitudinal axis; b) a tubular member joined to the washer and extending concentrically along the longitudinal axis, the tubular member comprising: i) a first section adjacent the washer that defines a first inner portion that merges with the washer central opening, the first portion terminating in a first transverse surface; ii) a second section adjacent the first section and defining a second internal diameter smaller than the first inner portion, the second internal diameter terminating in a second transverse surface that cooperates with the second internal diameter to define a recess; and iii) an end section adjacent the second section and defining a passage therethrough; and characterised by, c) finger means upstanding from the first transverse surface for cooperating with the first inner portion, the washer central opening, and the first transverse surface to form an annular chamber and for defining and bendably closing a central counterbore, so that the attachment plate can penetrate the insulation panel and a power nail setting tool can drive a collating ring into the recess and a nail through the passage and into the substrate to attach the insulation panel to the substrate. In accordance with the present invention, an attachment plate for insulation panels is provided that greatly increases the productivity of attaching insulation panels to buildings. This is accomplished by designing the attachment plate both to be installed using a combustion powered repeating type setting tool and to accommodate insulation panels of varying thickness. It is a feature of the present invention that the attachment plate can accommodate insulation panels having thicknesses different than a nominal thickness. If the insulation panel thickness is slightly less than nominal, the attachment plate second end contacts the substrate before the washer is flush with the panel exposed surface. Upon firing the tool, the nail forces the attachment plate fully into the panel by bending the tabs the amount necessary to assure that the installed attachment plate does not protrude above the panel exposed surface. If the panel has a slightly greater thickness than nominal, the attachment plate second end is spaced from the substrate when the attachment plate washer is flush with the panel exposed surface. When the tool is fired, the nail forces the washer to penetrate the panel a slightly further amount until the attachment plate second end contacts the substrate. In that situation, the tabs do not bend. The apparatus of the invention, using a multi-section attachment plate, thus enables insulation panels to be very rapidly and easily installed on a building using a repeating impulse tool. The attachment plate also enables insulation panels of varying thicknesses to be installed with consistent clamping force. A particular example and modification of the present invention will now be described with reference to the accompanying drawings, in which:- Fig. 1 is a top view of the attachment plate of the present invention, Fig. 2 is a cross sectional view taken along line 2-2 of Fig. 1, Fig. 3 is a bottom view of the attachment plate, Fig. 4 is an exploded view showing a repeating impulse nail setting tool for attaching an insulation panel to a building substrate using the attachment plate of the present invention, Fig. 5 is a partially broken view similar to Fig. 4, but showing the attachment plate partially penetrated into the insulation panel, Figs. 6A-6D are longitudinal cross sectional views of the attachment plate and a portion of the nail setting tool during various stages of the installation of the attachment plate, Fig. 7 is a cross sectional view of the attachment plate installed to a building substrate, Figs. 8 and 8A are views similar to Figs. 6A and 6D, respectively, but showing the attachment plate in conjunction with an insulation panel of greater than nominal thickness, Figs. 9 and 9A are views similar to Figs. 8 and 8A, respectively, but showing the attachment plate in combination with an insulation panel of less than nominal thickness, Fig. 10 is a longitudinal cross sectional view of a modified embodiment of the present invention, and Fig. 11 is a longitudinal cross sectional view of a further modified embodiment of the present invention. Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto. Referring to Figs. 1-3, an attachment plate 1 for insulation panels is illustrated that includes the present invention. The attachment plate 1 is constructed as a tubular piece that is symmetrical about a longitudinal axis 3 and that has first and second ends 2 and 5, respectively. At the plate first end 2 is a washer 7 of relatively large outer diameter 8 and having a central opening 10. A number of openings pass through the washer 7. The openings may be in the form of holes 9 having frusto-conical cross sections, with the holes having their apexes toward the attachment plate first end 2. The holes 9 provide flexibility to the washer. Joined to the washer 7 and extending toward the attachment plate second end 5 is a tubular member 11. In the preferred embodiment, the tubular member 11 has four sections 13, 15, 17, and 19. The first section 13 has an outer diameter 21 that is substantially smaller than the washer outer diameter 8. The first section has an inner diameter 23 that is the same size as the diameter of the washer central opening 10. The inner diameter 23 terminates in a first annular transverse surface 24. The second section 15 of the tubular member 11 has an outer diameter 25 that preferably is less than the outer diameter 21 of the first section 13 and an inner diameter 27 that is less than the first section inner diameter 23. The second section inner diameter 27 blends into the transverse surface 24 of the first section 13 through a dished transition surface 28. The second section inner diameter terminates in a second transverse surface 30. The inner diameter 27 and transverse surface 30 cooperate to define a recess 29 that is sized to accept a nail collating ring, as will be explained presently. The third section 17 has a frusto-conical outer diameter 33. The third section defines a internal passage 31 that is sized to guide a nail. The fourth section 19 has a cylindrical outer diameter 35. The passage 31 continues through the fourth section. The fourth section has a thin wall. Several slots 39, which may be four in number, are cut transversely through the fourth section wall so as to form tabs 41. Upstanding from the transverse surface 24 is a band of double fingers 45. Each double finger has a first finger 47 having a first end joined with a living hinge to the transverse surface 24 and a second end that is approximately coplanar with the attachment plate first end 2. The first fingers 47 converge slightly toward the attachment plate first end. A second finger 49 is bendably joined with a living hinge at a first end thereof to the second end of each respective first finger 47. The second fingers 49 are generally triangular in shape, as best shown in Fig. 1. The second fingers extend radially toward the longitudinal axis 3, and they lie in a transverse plane generally coplanar with the attachment plate first end. The first fingers 47, the washer central opening 10, the inner diameter 23, and the transverse surface 24 cooperate to form an annular chamber 51 having a generally rectangular cross section when viewed from the side. The first fingers also define a central counterbore 53, which is normally closed by the second fingers. For maximum flexibility and resistance to thermal conductivity, the attachment plate 1 is preferably made from a thermoplastic material. Now turning to Figs. 4 and 5, a tool 55 is shown that is used to attach an insulation panel 57 to a building substrate 59 by means of the attachment plate 1. The substrate 59 can be any found in the construction industry, such as concrete, masonry, wood, or steel. A major benefit of the present invention is that the tool 55 is an internal combustion power nail setting tool commonly used to fasten wood and light gauge metal. An exemplary setting tool is manufactured and marketed by Illinois Tool Works of Glenview, Illinois, under the trademarks TrakFast and Impulse. Those tools have collated nail magazines and fuel canisters for providing power. The collating features a plastic strip such as is shown in U.S. patent 5,069,340 used for feeding and holding nails in the tool magazine. The plastic collating material holds a nail as it is fired from the tool and acts as a clamping washer when installing the attachment plate 1 to the substrate 59. The power setting tool enables rapid, continuous, and consistent operation until the nail magazine is empty. Secured to the power setting tool 55 is a plate 61. An adapter 63 is mounted to the plate concentric with the tool muzzle, not shown in Figs. 4 or 5. The adapter 63 is spring loaded by a known mechanism so as to be able to reciprocate relative to the tool along the axis 3. The adapter has a stabilizing flange 65 and a pilot 67. The stabilizing flange 65 preferably has an area greater than the area of the attachment plate washer 7. The adapter pilot 67 has an outer diameter that is sized to fit snugly inside the inner diameter 23 of the adapter plate 1 (Fig. 2). On the end of the plate 61 opposite the adapter is a rest 69. A worker places an attachment plate 1 on the adapter 63 by inserting the adapter pilot 67 into the adapter plate annular chamber 51 until the stabilizing flange 65 abuts the plate washer 7. Also see Fig. 6A. For easy installation, the free end of the pilot is formed with an external chamfer or arcuate surface 71. Friction between the pilot outer diameter and the adapter plate inner diameter 23 holds the attachment plate-in place on the adapter. The worker aligns the attachment plate 1 with the desired location on the insulation panel 57. He then manually pushes the tool 55 and attachment plate such that the attachment plate second end 5 penetrates the insulation panel. The fins 43 cut the insulation panel and aid in the penetration process. Manual pushing continues until the adapter stabilizing flange 65 and the rest 69 contact the insulation panel exposed surface 73, Fig. 6B. At that point, the attachment plate first end 2 is flush with the exposed surface 73 of the insulation panel, and the attachment plate second end 5 is in contact with the building substrate 59. The worker continues to push the tool 55 toward the insulation panel 57. That action causes the tool 55, including its muzzle 75, to move toward the attachment plate 1 relative to the adapter 63, Fig. 6C. The tool muzzle 75 advances to contact the second fingers 49 of the double fingers 45. The muzzle 75 bends the second fingers downwardly into the counterbore 53 and flat against the first fingers 47. Simultaneously, the first fingers 47 bend slightly outwardly. The tool advances until the muzzle free end is close to the adapter plate dished surface 28. At that point, the tool bottoms out relative to the adapter. Simultaneously, the motion of the tool relative to the adapter energizes the tool electronic firing system through the adapter spring loaded mounting system. The workman is then able to fire the tool. A driving ram in the muzzle, not shown in Fig. 6D, passes through the tool muzzle to force a collating ring 79 and a nail 77 into the recess 29 of the attachment plate 1. The collating ring 79 becomes compressed within the recess and locks to the attachment plate around the nail by radial compression and frictional forces of the recess internal diameter 27. The nail 77 passes through the passage 31 and becomes embedded in the substrate 59, thus installing the attachment plate to the substrate and clamping the associated region of the insulation panel 57 to the substrate. The first fingers 47 absorb shock from the tool 55 during firing and lessen any potential damage to the second fingers 49, which are bent over by and in contact with the muzzle 75. When the tool 55 and adapter 63 are removed from the installed attachment plate 1, the fingers 45 bend back to their undeflected positions. See Fig. 7. The worker then places another attachment plate on the adapter pilot 67 of his tool for immediate attachment at another location on the insulation panel. Later, a series of coatings 81 are spread on the insulation panel exposed surface 73 to provide solid wall foundation and texture. The double fingers 45 act to seal the counterbore 53 from excessive coating penetration and adhesion. Any coating 81 that does enter the counterbore 53 serves to anchor the adjacent coating and enable it to resist outward and shear forces. Some coating material also enters the annular chamber 51 and fills the holes 9 in the washer 7 to provide additional adhesion of the coating over the insulation panel. Consequently, the finished surface of the building wall provides a smooth and dimple free appearance as well as a strong bond to the insulation panel. Further in accordance with the present invention, the attachment plate is capable of accommodating insulation panels of varying thicknesses. Looking at Fig. 8, an insulation panel 57A has a thickness greater than the nominal thickness of the insulation panel 57 of Figs. 9-7. Consequently, when the worker has fully penetrated the attachment plate 1 manually into the insulation panel 57A with his tool 55, the second end 5 of the attachment plate does not contact the substrate 59. When the worker fires the tool, the force of the driving ram on the nail will further penetrate the attachment plate into the insulation panel such that the attachment plate second end 5 does contact the substrate 59. As a result, the attachment plate washer 7 comes to rest below the insulation panel exposed surface 73A, Fig. 8A. In Fig. 9, the insulation panel 57B has a thickness less than the nominal thickness of the insulation panel 57 of Figs. 4-7. In that situation, the second end 5 of the attachment plate 1 contacts the substrate 59 before the adapter 63 of the setting tool contacts the insulation panel exposed surface 73B. Upon firing the setting tool, the driving ram forces the attachment plate tabs 41 to bend until the surface of the attachment plate first end 2 is flush with the insulation panel exposed surface 73B, Fig. 9A. In that manner, the surface of the attachment plate first end does not protrude above the insulation panel exposed surface 73B. Rather, the surface of the attachment plate first end is always flush with or slightly below the insulation panel exposed surface. Looking at Fig. 10, a modified attachment plate 83 is depicted that is generally similar to the attachment plate 1 described above in conjunction with Figs. 1-9. However, the attachment plate 83 is fabricated with a solid thin cylindrical band 85 upstanding from the transverse surface 24' at the end of the inner diameter 23' of the first section 13' of the tubular member 11'. At the free end of the solid band 85 are joined several fingers 87. The fingers 87 are bendable by respective living hinges to the band 85. The fingers 87 extend radially toward the longitudinal axis 3' and lie generally coplanar with the attachment plate first end 2'. In all other respects, the attachment plate 83 is identical to the attachment plate 1. Fig. 11 shows a further modified attachment plate 89. The attachment plate 89 has a frusto-conical surface 91 for the central opening of the washer 7' and for the inner diameter 23' of the first section 13' of the tubular member 11'. Accordingly, the cross section of the annular chamber 93 has a generally triangular shape. To interfit with the attachment plate 89, the pilot 95 of the setting tool adapter 63' has a frusto-conical exterior surface 97. Thus, it is apparent that there has been provided, in accordance with the invention, an attachment plate for insulation panels that fully satisfies the aims and advantages set forth above.

Claims: An attachment plate (1) for attaching an insulation panel (57) to a substrate (59) comprising: a) a washer (2) defining a central opening (10) and a longitudinal axis (3); b) a tubular member (11) joined to the washer (2) and extending concentrically along the longitudinal axis (3), the tubular member (11) comprising: i) a first section (13) adjacent the washer (2) that defines a first inner portion (23) that merges with the washer central opening (10), the first portion (23) terminating in a first transverse surface (24); ii) a second section (15) adjacent the first section (13) and defining a second internal diameter (27) smaller than the first inner portion (23) the second internal diameter (27) terminating in a second transverse surface (30) that cooperates with the second internal diameter (27) to define a recess (29); and iii) an end section (17,19) adjacent the second section (15) and defining a passage (31) therethrough; and characterised by , c) finger means (45) upstanding from the first transverse surface (24) for cooperating with the first inner portion (23), the washer central opening (10), and the first transverse surface (24) to form an annular chamber (51) and for defining and bendably closing a central counterbore (53), so that the attachment plate (1) can penetrate the insulation panel (57) and a power nail setting tool (55) can drive a collating ring (79) into the recess (29) and a nail (77) through the passage (31) and into the substrate (59) to attach the insulation panel (57) to the substrate (59). An attachment plate according to claim 1, wherein the finger means (45) comprises: a. a plurality of first fingers (47) having respective first ends bendably joined to the first transverse surface (24) and respective second ends, the first fingers being arranged concentrically around the longitudinal axis (3) to define the central counterbore (53); and b. a plurality of second fingers (49) bendably joined to the second ends of respective first fingers (47), the second fingers (49) extending radially toward the longitudinal axis (3). An attachment plate according to claim 2, wherein the first fingers (47) converge in the direction away from the first transverse surface (24). An attachment plate according to claim 1, wherein the finger means (45) comprises: a. a thin cylindrical band (85) having a first end joined to the first transverse surface (24) and a second end, the cylindrical band being concentric to the longitudinal axis (3) to define the central counterbore (53); and b. a plurality of fingers (87) bendably joined to the second end of the cylindrical band (85), the fingers (87) extending radially toward the longitudinal axis (3). An attachment plate according to any one of the preceding claims, wherein the tubular member end section comprises: a. a third section (17) adjacent the second section (15) and having a frusto-conical outer form; and b. a fourth section (19) adjacent the third section (17), the fourth section (19) having a cylindrical outer form that cooperates with the passage (31) to form a thin wall (35). An attachment plate according to claim 5, wherein the fourth section wall (35) is formed with a plurality of transverse slots (39) to thereby create a plurality of tabs (41) that facilitate bending. An attachment plate according to any one of the preceding claims, wherein the washer central opening (10) and the inner portion (23) of the tubular member first section (13) are formed with a common frusto-conical surface (23') such that the annular chamber (93) has a generally triangular shaped cross section. An apparatus for clamping an insulation panel (57) to a building substrate (59) comprising: a. tool means (55) for firing collated nails (77); b. an adapter (63) having a flange (65) and a pilot (67) mounted to the tool means (55); and c. an attachment plate (1) in accordance with anyone of the preceding claims, the attachment plate (1) receiving the adapter pilot (67) and the washer (2) abutting the adapter flange (65) to enable the attachment plate (1) to be placed on the adapter (63) and the attachment plate to be penetrated into the insulation panel (57) and the tool means (55) to be fired to force a collating ring (79) into the attachment plate (1) and a nail (77) into the substrate (59) thereby to install the attachment plate (1) to the substrate (59) with the insulation panel (57) clamped between the attachment plate washer (2) and the substrate (59). An apparatus according to claim 9, wherein the collating ring (79) becomes compressed and locked to the recess (30) in the attachment plate (1) by radial compression and friction. An apparatus according to claim 8 or 9, wherein the finger means (45) absorb shock from the tool means (55) when the tool means (55) is fired.

Inventors: DILL MICHAEL C, OLVERA GILBERT, DILL, MICHAEL C., OLVERA, GILBERT
Applicants: ILLINOIS TOOL WORKS, ILLINOIS TOOL WORKS INC.
Application year: 1995
Main classification: E04D3
IPC codes: E04F13, B25C1, E04D3