NAIL FOR FASTENING SHEET MATERIALS

Abstract: A nail (10) and a method using the nail (10) for securing two materials together spaced by an interposed resilient material (22). The nail (10) has a shaft (32) having a first end and a second end. The nail has a head extending radially around the shaft (32) at the first end. The second end of the shaft (32) has a point (34). A sleeve (30) has generally a cylindrical shape and a pair of ends (38). The sleeve (30) has a cylindrical center portion (40) and a pair of frusto-conical tapered portions (42). The method comprises the steps of laying the first material against the second material spaced by the resilient material (22), driving the nail (10) through the first material, the resilient material (22) and into the second material with the point (34) of the shaft (32) piercing the resilient material (22) and into the second material with the point (34) of the shaft (32) piercing the resilient material (22) and the second material.

Description: NAIL FOR FASTENING SHEET MATERIALS Field of the Invention This invention relates to a nail for fastening two sheet materials together and precisely spacing the two sheet materials a determined distance apart from each other. More particularly, the invention relates to a nail which includes a sleeve having a cutting edge for cutting through a resilient material sandwiched between the two sheets, the sleeve precisely positioning the one sheet apart from the other sheet. Background of the Invention In building construction it is commonly needed to affix together various sheet materials which must be properly spaced apart from each other to achieve their intended function. For example, it is desirable to ventilate an attic to equalize the attic temperature and pressure with that outside the building. This equalization inhibits moisture from condensing on insulation and wood roof materials, prevents build-up of ice dams, and reduces air-conditioning costs. One ventilating system is a roof ridge vent using a synthetic fiber matting, covered by asphalt cap shingles and fastened to die plywood roof sheathing, as disclosed in U.S. Patent No. 5,167,579. The overlying cap shingles are secured to the sheathing by nails passing through the matting, and a nail should only be driven to a depth where the shingle remains spaced apart from the sheathing sufficiently to prevent the shingle from being dimpled around the nail site and the resilient material from being too greatly compressed. Another example is placing a layer of foam insulation between vinyl or aluminum siding panels and the outer wall sheathing. Nails are received in slots in the siding panels and extend through the insulation material into an underlying sheathing. Similar to the roof venting system, the siding panels must be secured a distance apart from the sheathing to prevent the siding panels from dimpling and the insulation material from being crushed. Nails have previously been developed for installing sheets of drywall to properly space the head of the nail from the stud surface underlying the drywall. These nails have a fluted shank which ensures that the head of the nail does not penetrate too deeply into the drywall. The flute crushes through the drywall until it engages the stud, thus ensuring that the head of the nail does not penetrate too deeply into die drywall. U.S. Patent No. 4,781,508 discloses such a fluted nail. However, fluted nails of diat type are not capable of cutting through resilient materials such as the synthetic fiber matting or the foam insulation described above, and would instead compress or crush the resilient matting or foam material. Furthermore, such nails are not designed to seal over the hole created by the passage of the fluted shank to prevent moisture penetration, nor would they allow the slotted siding panels to slide laterally along the nail. Summary of the Invention The present invention provides a nail, and method, for securing together two sheet materials spaced apart from each other by an interposed resilient material. The nail has a head extending radially around the shaft at one end, a point at the other end, and a generally cylindrical sleeve carried by and surrounding the shaft adjacent the head end. The sleeve has a length in excess of the thickness of the resilient material and less than the length of the shaft. The sleeve has a cylindrical center portion and a pair of frusto-conical tapered portions. The tapered portion facing the point forms a cutting edge. The tapered portion facing and abutting the head end allows the outer sheet material to reseal under die nail head and, in the application with slotted siding panels, allows the panel to slide laterally. The method comprises the steps of laying the first sheet material against and spaced apart from die second material by die resilient material, driving the point of the nail through the first material and d e resilient material and into the second material. The cutting edge of ώe sleeve cuts the resilient material, moving the sleeve through the resilient material by the tapered frusto- conical portion of the sleeve spreading the resilient material, and stops d e nail at a specific location by the sleeve engaging the second sheet material, d e hardness of d e second material and the taper of the frusto-conical portion limiting movement of the sleeve through the second sheet material. Further objects, features and advantages of the present invention will become more apparent to those skilled in the art as d e nature of the inven- tion is better understood from die accompanying drawings and detailed descrip¬ tion. Brief Description of the Drawings For the purpose of illustrating the invention, the drawings show a form which is presently preferred; it being understood, however, that this invention is not limited to die precise arrangements and instrumentalities shown. Figure 1 is a side sectional view of die layers of a built-up roof showing a nail according to the invention; Figure 2 is an enlarged sectional view taken along die line 2-2 shown in Figure 1; Figure 3 is an exploded view of die nail; Figure 4 is an enlarged view of die sleeve with a portion broken away; Figure 5 is a side view taken along the line 5-5 shown in Figure 4; Figure 6 is an alternative embodiment of me nail; Figure 7 is a side view of a nail according to d e invention in relation to a siding installation; and Figure 8 is a sectional view taken along the line 8-8 shown in Figure 7. Description of the Preferred Embodiment Referring to the drawings in detail, wherein like numerals indi¬ cate like elements, and prime numbers (') indicate counterparts of such ele- ments, Figure 1 illustrates a nail 10 according one embodiment of me invention. Two alternative embodiments are later described to highlight me novel features of the nail 10. Referring to Figure 1, a venting system 12 is used to vent hot air from an attic rough an open slot 14 in die ridge of a roof. The slot 14 is formed by cutting a sheeting material, such as an upper row shea ing panel 16, approximately 3 A " short of the ridge crest formed by the rafters 18 in a roof truss, as shown. Roof shingles 20 are laid in overlapping rows in d e conventional manner up to the slot 14. A unitary mat 22 is made of randomly-aligned synd etic fabrics joined by phenolic or latex bonding which is heat cured to provide d e mat 22 with varying mesh. The materials of die mat 22 are des¬ cribed in more detail in U.S. Patent No. 5,167,579 which is incorporated herein by reference, and such mat is commercially available under ie name COBRA * Ridge Vent sold by GAF Materials Corporation. The mat 22 is a continuous strip preferably about 10'/ 2 " wide and % " diick. It runs die lengϋ of the slot 14 extending evenly on each side, and is of such low profile diat it does not attract attention when covered by shingles of die same color and texture as used on d e rest of die roof, such as a cap shingle 24. The mat 22 may easily be laid by unwinding one end of the material from a roll inserting over the slot 14 at one end, then unrolling it in a continuous strip to the other end where it is cut from the roll. Starting from one end and working to the other, each cap shingle 24 is d en laid over die mat 22 and overlaps the edge of d e preceding cap shingle 24, and is secured by driving me nail 10 of the invention through the cap shingle 24, mat 22 and e roof shingle 20 into die underlying sheadiing 16 and rafters 18. Referring to Figure 3, ie nail 10 comprises a roofing nail 28 and a sleeve 30. The roofing nail 28 is of conventional construction having a shaft 32 that is pointed at one end 34 and a head 36 extending radially around d e shaft 32 at the other end. The roofing nail 28 is preferably made of a galvanized material and is conventionally 2! " long. The sleeve 30 has a generally cylindrical shape having a pair of ends 38 that are parallel to each other and lie in planes transverse to die axes of d e cylinder. The sleeve 30 has a cylindrical center portion 40 and a pair of frusto-conical tapered portions 42 extending from d e center portion 40 to each of die ends 38. The ends 38 and the frusto-conical tapered portions 42 form cutting edges. The sleeve 30 has a cylindrical opening 44 extending between the ends 38 for receiving die shaft 32 of die roofing nail 28. Referring to Figures 4 and 5, the frusto-conical portion 42 taper¬ ing down to the end 38 forms the cutting or knife edge at the end which enables die sleeve 30 to cut through the mat 22. The taper, the result of the frusto- conical portion 42, moves e mat 22 in die cap shingle 24 out of the way as die nail 10 enters d e material. Furthermore, the taper prevents the cutting edge at the end 38 from continuing to drive into die sheathing, therein stopping die sleeve 30 and nail 10 at die proper position. In a preferred embodiment for use wi i the roof ridge vent, for a mat 22 of % " thickness, the sleeve 30 is one inch long widi the cylindrical center portion 40 being 14 " long and each frusto-conical portion being 3 /β" long. The cylindrical opening has a diameter of 0.136" and the outer diameter of die sleeve 30 is 0.1875" (3/16"). The frusto-conical portion 42 tapers down to 0.171875" (11/64") diameter. Therefore, the thickness of the sleeve 30 at the end 38 is .0179375", defining a cutting edge in me end 38 of the sleeve 30 capable of cutting through the mat 22. Referring to Figure 2, the sleeve 30 is slipped over the shaft 32 of d e roofing nail 28 prior to installation. The nail 10 may be driven in the conventional manner using a hammer. However, it an advantage d at die nail 10 of diis invention can be used widi a pneumatic gun or o er automated driving means for delivering die nail 10. It is recognized that sleeve 30 could be coated widi a fluoropolymer to ease ie movement of die sleeve 30 past the fibers in mat 22. As the nail 10 is driven dirough the cap shingle 24, the pointed end 34 of the roofing nail 28 makes die first penetration dirough die shingle 24 and punctures die mat 22. The frusto-conical portion 42 of die sleeve 30 enlarges the opening in the shingle 24, widi the end 38 initially cutting the shingle 24, thus allowing the sleeve 32 to pass dirough d e shingle 24. The cap shingle 24 is preferably an asphalt-based material. Asphalt shingles are resilient enough that die shingle 24 will deform to allow the sleeve 30 to pass dirough. The end 38 acts as a cutting or knife edge to cut dirough die mat 22 with d e frusto-conical portion 42 pushing the fibers in mat 22 to the side as it passes dirough mat 22. As ie nail 10 is driven, die sleeve 30 makes contact with d e sheadiing panel 16 and, while penetrating slightly because of the cutting edge of d e end 38, die hardness of the sheadiing panel 16 and d e taper of the frusto-conical portion 42 limits the depdi that the sleeve 30 may enter die panel 16. This depth and die lengdi of sleeve 30 spaces the head 36 of d e roofing nail 28 from ie sheadiing panel 16 d e proper amount to secure the cap shingle 24 and die mat 22. The unitary mat 22 is resilient such mat it flexes back around die upper frusto-conical portion 42 of the sleeve 30 therein sealing d e sleeve 30 within the material. The asphalt shingle is sufficiently pliant in normal temperatures that, shortly after the nail 10 is installed, ambient temperature will cause the cap shingle 24 to melt slightly and conform to me frusto-conical portion 42 of the sleeve 30, creating a greater seal than would be achieved with just die head 36. Referring to Figure 6, an alternative embodiment of e nail 10' is shown. The nail 10' has a integral sleeve 30' with ie roofing nail 28'. The sleeve 30' has a cylindrical center portion 40' and a pair of frusto-conical tapered portions 42' extending from the center portion 40'. The frusto-conical portion 42' tapers down at the end of the sleeve 30' toward die end 34' to form a cutting or knife edge 38'. The upper frusto-conical portion 42', in proximity to the head 36' of die nail 28', allows die resilient materials such as die fibers in mat 22' to close up. Any compression of the mat 22' during driving of the nail 10' will dissipate shortly. Furthermore, the cap shingle 24 of the first embodiment melts slightly and conform to the shape of die shaft 32' above the frusto-conical portion 42' creating a seal. Referring to Figures 7 and 8, an alternate use for nail 10" is shown. A building side 60 has a plywood sheadiing 62, siding 64, and inter¬ posed insulation 66. The siding 64 is conventionally made of a material such as aluminum or vinyl and has a slot 68 through which the nail 10" is inserted. The nail 10" is sized for die diickness of die insulation 66 and die size of the slot 68 in the conventional siding 64. The nail 10" has a sleeve 30" having a cylindrical center portion 40" sized die same as the minor axis of me slot 68. In addition, the sleeve 30" has a pair of frusto-conical tapered portions 42" extending from the center portion 40" to each of its ends 38". As the nail 10" is driven dirough die slot 68 in the siding, me frusto-conical portion 42" and sleeve 30" acts as a cutting or knife edge 38" to cut dirough the resilient insulation 66. As the nail 10" is driven, the sleeve 30" makes contact with the sheathing 62. The knife edge formed by d e end 38' engages and penetrates slightly into d e sheathing 62. The hardness of d e sheathing 62 and the taper of the frusto-conical portion 42" limits the depth the sleeve 30" enters the sheadiing 62, thus positioning the nail 10". The upper frusto-conical portion 42" of die sleeve 30", being smaller man the cylindrical portion 40" of the sleeve 30" is, dius, smaller than the minor axis of slot 68. Therefore, the siding 64 is located between the head 36" of the nail 28" and the cylindrical portion 40" of the sleeve 30". The frusto-conical portion 42" that is in proximity to the slot 68 allows die siding 64 to move laterally relative to the nail 10" between the head 36" and die cylindrical portion 40" of the sleeve 30" upon expansion and contraction. It is recognized d at die nail 10" could be used to secure die insulation 66 having outer shell and not associated widi a siding 64. The present invention may be embodied in odier specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to me appended claims, rather than to the foregoing specification, as indicating d e scope of the invention.

Claims: I claim: 1. A nail comprising: a shaft having a preselected lengdi, a head extending radially around die shaft at one end; and a sleeve carried by die shaft and surrounding the shaft in proximity to the head, die sleeve having a pair of opposite ends, a cylindrical center portion and a pair of frusto-conical tapered portions, each of the frusto- conical tapered portions extending from the center portion to one of me ends, the sleeve having a lengdi less d an the lengdi of the shaft. 2. A nail for securing two sheet materials toge ier spaced by an interposed resilient material, d e nail comprising: a shaft of preselected lengdi having a first end and a second end; a head extending radially around die shaft at die first end; d e second end of d e shaft having a point; and a sleeve carried by die shaft and surrounding die shaft in proximity to the head, die sleeve having a pair of ends, a cylindrical center portion and a pair of frusto-conical tapered portions, each of the frusto-conical tapered portions extending from me center portion to one of the ends forming a cutting edge, and die sleeve having a length in excess of die diickness of the interposed resilient material and less than die lengdi of die shaft. 3. A nail as in claim 2 wherein me sleeve has a cylindrical opening extending between die ends for receiving die shaft of the nail. 4. A nail as in claim 2 wherein the sleeve and die nail are integral. 5. A method of securing a first sheet material to a second sheet material, a resilient material interposed between die sheet materials comprising the following steps: laying die first sheet material against die second sheet material wid d e resilient material sandwiched d erebetween; driving a nail through die first sheet material, the resilient material and into me second sheet material, me nail having a shaft widi a head extending radially around d e shaft at one end and a point at die odier end spaced from the one end in excess of die distance between die first and second sheet materials, the point capable of piercing d e resilient material, and die second sheet material; cutting die resilient material by a sleeve carried by the shaft having a frusto-conical portion taper to a first end forming a cutting edge; moving die sleeve through die resilient material by me tapered frusto-conical portion of the sleeve spreading die resilient material; and stopping ie nail at a specific location by me sleeve engaging the second sheet material, d e hardness of the second sheet material and the taper of the frusto-conical portion limiting movement of the sleeve dirough d e second sheet material. 6. A method of securing a first sheet material to a second sheet material as in claim 5 wherein the step of laying die first sheet material against the second sheet material comprises the following steps: laying the resilient sheet material on the second sheet material; and laying die first sheet material on die resilient material therein spacing the first sheet material from the second sheet material by d e resilient material. 7. A me iod of securing a first sheet material to a second sheet material as in claim 5 wherein die step of laying die first sheet material against the second sheet material comprises the following steps: securing e resilient material to the first sheet material; and laying the first sheet material and resilient material combination on the second sheet material therein spacing die first sheet material from the second sheet material by the resilient material. 8. A mediod of securing a roof vent having an air permeable mat to a roof, comprising me following steps: providing an open slot along substantially die length of a roof ridge permitting ventilation from the interior space under die roof to die exterior; laying die air permeable mat on the roof covering the slot over the length of die slot; laying a capping structure overlying die mat and spaced away from the roof by d e thickness of the mat to provide ventilation dirough the mat in die space between die capping structure and the roof; and driving a nail dirough die first sheet material, the resilient material and into the second sheet material, the nail having a shaft widi a head extending radially around d e shaft at one end and a point at die odier end spaced from the one end and having a lengdi sufficient to pass completely through when fully inserted, die point capable of piercing die resilient material and d e second sheet material; cutting the resilient material by a sleeve carried by the shaft having a frusto-conical taper to a first end forming a cutting edge; moving the sleeve through the resilient material by the tapered frusto-conical portion of the sleeve spreading die resilient material; and stopping the nail at a specific location by the sleeve engaging the second sheet material, the hardness of die second sheet material and the taper of the frusto-conical portion limiting movement of me sleeve through the second sheet material. 9. A method of securing a roof vent as in claim 8 wherein me capping structure is an asphalt shingle and the sleeve having a second frusto- conical taper to a second end in proximity to the head and further comprising the step of sealing die shingle to me nail at ambident temperature. 10. A method of securing a roof vent as in claim 9 wherein die mat is an air permeable and resilient member of randomly aligned synd etic fibers which are open and blended, randomly aligned into a web by an airflow, joined by phenolic or latex binding agents and heat cured to produce a varying mesh, the mat being of unitary sheet construction having no dissimilar sheets laminated or otherwise bonded togedier. 11. In combination, a building having a sheadiing, a siding for covering the sheadiing, a resilient insulation interposed between the siding and the sheadiing for insulating die building, and a plurality of nails for securing d e siding and die insulation to die sheathing, each nail extending dirough a slot in the siding and having a shaft widi a head extending radially around d e shaft at one end for holding the siding, a point at the odier end for piercing die insulation and die sheathing, the shaft having a length sufficient to pass completely dirough the insulation and into die sheadiing when fully inserted, die nail carrying a sleeve having a frusto-conical portion taper to a first end forming a cutting edge for cutting the insulation and stopping the nail at a specific location by engaging the sheathing and a second frusto-conical taper to a second end for allowing the siding to move relative to the nails.

Inventors: ROTTER MARTIN J, ROTTER, MARTIN, J.
Applicants: ROTTER MARTIN J, ROTTER, MARTIN, J.
Application year: 1995
Main classification: E04B7
IPC codes: E04D1, E04D3, E04D5, E04F13, F16B15, F16B19, F16B35