Abstract:
A fastener for fixedly connecting two members in spaced relation to one another includes a substantially cylindrical shaft having two opposed ends and a central collar portion positioned between the ends. At least one outwardly extending cylindrical ridge is positioned adjacent the central collar portion on either side thereof. Each end of the shaft is inserted longitudinally into apertures defined in the members. The at least one ridge assists in retaining the respective shaft in a respective aperture. A connecting system and a method for connecting two elongated members with the fasteners is also provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/231,537, filed Aug. 5, 2009, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The installation of decking for such structures as decks and docks is time consuming. It is desirable to provide a fastener and system for improving the efficiency of decking installation. It is also desirable to improve the efficiency of other installations that involve the side-by-side installation of boards or the like. 
         [0003]    Nail holes in boards can result in splitters, dimpling, or puckering. Nail and screw pops are also common. It is desirable to fasten together boards in a decking or other system without having to nail or screw through the faces of the boards in order to connect them to an underlying support structure. It is also desirable to provide a mechanism for evenly spacing boards. It is further desirable to be able to prefabricate a panel structure so that it can be transported and installed as a single panel that includes multiple boards. 
       SUMMARY OF THE INVENTION 
       [0004]    In accordance with the teachings described herein, an example fastener for fixedly connecting two members in spaced relation to one another comprises a substantially cylindrical shaft having two opposed ends and a central collar portion. At least one outwardly extending cylindrical ridge is positioned adjacent the central collar portion on either side thereof. Each end of the shaft is configured to be inserted longitudinally into apertures defined in the members. The at least one ridge assists in retaining the respective shaft in the respective aperture. 
         [0005]    In another example, a connecting system comprises at least two elongated members having opposing apertures and at least one fastener positioned between the at least two elongated members for fixedly coupling the elongated members together in spaced relation via the opposing apertures. The fastener has a substantially cylindrical shaft with two opposed ends and a central collar portion. At least one outwardly extending cylindrical ridge is positioned adjacent the central collar portion on either side thereof. The at least one ridge assists in retaining the respective shaft in the respective aperture. 
         [0006]    In another example, a method of fixedly connecting two or more elongated members together comprises providing a first elongated member and a second elongated member, with each elongated member having an aperture disposed in opposing sides thereof. The method further comprises inserting one end of a fastener into the aperture in the first elongated member. The fastener has a substantially cylindrical shaft with two opposed ends and a central collar portion, with at least one outwardly extending, cylindrical ridge positioned adjacent the central collar portion on either side thereof. When the shaft is inserted longitudinally into the aperture, the at least one ridge assists in retaining the shaft in the aperture. The method further comprises hammering the fastener into the aperture until the central collar portion abuts the side of the first elongated member. Then the other end of the fastener is inserted into the aperture disposed in the side of the second elongated member. The other end of the fastener is then hammered into the second elongated member until the central collar portion abuts the side of the second elongated member. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The present invention will hereinafter be described in conjunction with the appended drawing figures wherein like numerals denote like elements. 
           [0008]      FIG. 1  is a top view of an example fastener; 
           [0009]      FIG. 2  is an end view of the example fastener of  FIG. 1 ; 
           [0010]      FIG. 3  is a cross-sectional view of the example fastener of  FIG. 1 , taken along line  3 - 3 ; 
           [0011]      FIG. 4  is a cross-sectional view of a central portion of the example fastener of  FIG. 1 , taken along line  4 - 4 ; 
           [0012]      FIG. 5  is a perspective view of an example connecting system with a cut-away of the interior of two hollow-core boards with the example fastener of  FIG. 1  installed in apertures defined in the sides of the boards; 
           [0013]      FIG. 6  is a cross-sectional view of the example connecting system of  FIG. 5 , taken along line  6 - 6 ; 
           [0014]      FIG. 7  is another example fastener; 
           [0015]      FIG. 8  is an end view of the fastener shown in  FIG. 7 ; 
           [0016]      FIG. 9  is a cross-sectional view of the fastener of  FIG. 7  taken along line  9 - 9 ; 
           [0017]      FIG. 10  is a perspective view of another example connecting system with a cut-away of the interior of two solid-core boards, with the example fastener of  FIG. 7  installed in apertures defined on the sides of the boards; and 
           [0018]      FIG. 11  is a cross-sectional view of the example connecting system of  FIG. 10 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    The ensuing detailed description provides preferred exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the ensuing detailed description of the preferred exemplary embodiments will provide those skilled in the art with an enabling description for implementing the preferred exemplary embodiments of the invention. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention, as set forth in the appended claims. 
         [0020]    To aid in describing the invention, directional terms may be used in the specification and claims to describe portions of the present invention (e.g., upper, lower, left, right, etc.). These directional definitions are merely intended to assist in describing and claiming the invention and are not intended to limit the invention in any way. In addition, reference numerals that are introduced in the specification in association with a drawing figure may be repeated in one or more subsequent figures without additional description in the specification in order to provide context for other features. 
         [0021]    An example fastener  10 ,  110  is shown in  FIGS. 1 and 7 . The fastener  10 ,  110  is used to connect elongated members  12 , such as boards, decking, fencing, and the like, to form a rigid panel system. The example fastener  10 ,  110  is an independent, hidden fastener that may be used to connect different types of elongated members, or to connect similar types of elongated members. The fastener  10 ,  110  can be used in both residential and commercial applications. 
         [0022]    While reference herein is primarily made in the context of decking, such as in connection with decks or docks, it should be understood that these references equally apply in other applications, such as fencing, stair treads, stair landings, animal kennel floors, boardwalks, handicap ramps, gangways, piers, and floating docks, among other applications. The example fastener  10 ,  110  provides consistent spacing between boards  12 . It can be used to connect any species of wood or composite lumber, including both solid and hollow-core composite lumber. 
         [0023]    An example connecting system  14 ,  114  is also described that includes the example fastener  10 ,  110 . The example connecting system  14 ,  114  provides a rigid connection between elongated members  12 , such as boards, decking, fencing materials, and the like, and the underlying supporting structure (not shown). The underlying supporting structure may be joists or other supports. Typically, the joists will be spaced apart from one another. The example fasteners  10 ,  110  may be connected directly to the supporting joists instead of having to nail or drill through the elongated members  12 . The fasteners  10 ,  110  also provide consistent spacing between adjacent elongated members  12 . 
         [0024]    A first embodiment of the example fastener  10  and connecting system  14  is shown in  FIGS. 1-6 . A second embodiment of the example fastener  110  and connecting system  114  is shown in  FIGS. 7-11 . Elements of the second embodiment that are similar to elements of the first embodiment are represented by reference numerals increased by factors of 100. For example, the fastener  10  in  FIGS. 1-6  corresponds to the fastener  110  in  FIGS. 7-11 . 
         [0025]    Referring now to  FIG. 1 , an example fastener  10  includes a substantially cylindrical shaft  16  having two opposed ends  18 . A central collar portion  20  is positioned between the two ends  18 . As shown, the portions of the shaft  16  on either side of the central collar portion are substantially the same length. Alternatively, and not shown, the portions of the shaft  16  on either side of the central collar could have different lengths. The shaft  16  has a diameter D 1  that is dimensioned to fit snugly inside an aperture or hole  22  having a diameter D 2  such that force must be applied to insert the shaft  16  into an aperture  22 . 
         [0026]    A plurality of outwardly extending cylindrical ridges  24  are positioned adjacent the central collar portion  20  on either side thereof. The ridges  24  extend along part of the length of the shaft  16 . The raised ridges  24  have a diameter D 3  that is greater than the diameter D 1  of the shaft  16 . The ridges  24  provide a frictional locking action against the interior of an aperture  22  for assisting in holding the fastener  10  inside an aperture  22 . The ridges  24  could extend along more or less of the length of the shaft  16 , if desired. The opposed ends  18  of the shaft  16  may be co-linear, as shown. 
         [0027]    The ends  18  of the shaft  16  include outwardly flared portions  26 , such as outwardly extending tabs. The outwardly flared portions  26  provide a spring-like action for holding the shaft  16  in an aperture  22 . A slot  28  is cut into each end  18  of the shaft  16  in the vicinity of the tabs  26  in order to allow the tabs to flex inwardly when inserted into an aperture  22 . The slot  28  is shown best in  FIGS. 1 and 2 . The outwardly flared portions  26  provide a spring-like action against the interior of an aperture  22  once installed. This spring-like action provides locking power for locking the shaft  16  inside an aperture  22 . One type of tab that may be utilized has a radiused end  30  for assisting in insertion into an aperture  22 . The tab preferably has a lip  32 , which may be utilized in some examples for snapping behind an internal rib  34  defined inside a hollow-core board. Other mechanisms for flaring the ends outwardly to create a spring action may also be utilized with equal success, the invention not being limited to the shape of the tabs shown. 
         [0028]    The central collar portion  20  has a centrally disposed bore  36  that extends therethrough. The bore  36  may be a cylindrical hole, a tapered hole, or a combination of cylindrical and tapered. A cylindrical bore  38  is shown in  FIGS. 3 and 4  that has a tapered opening  40 . The bore  36  of the central collar portion  20  preferably faces upwardly during installation. Since the fastener  10  is a mirror image of itself in both the vertical and horizontal directions, the bore  36  can either face upwardly or downwardly with equal success. 
         [0029]    Embodiments are also envisioned where the fastener is not a mirror image of itself in either or both of the vertical and horizontal directions. The bore  36  is preferably sized for accepting a second fastener, such as a screw or a nail (not shown) that is used to secure the fastener to a joint. 
         [0030]    The central collar portion  20  may be cylindrical, square, or a different cross-sectional shape, and has a height H 1  or diameter D 4  (depending upon the shape thereof) that is greater than the diameter D 1  of the shaft  16 . The central collar portion  20  shown in  FIG. 2  is cylindrical. The central collar portion  20  also has a width W 1  that is utilized to space the elongated members  12  by a fixed spacing that is equal to the width W 1  of the collar portion  20 . 
         [0031]    The collar  20  provides at least two functions. First, it provides a standard spacing between adjacent boards  12 . One example of a residential fastener includes a collar  20  having a width of ⅛″, 3/16″, or ¼″ spacing between boards  12 . One example of a commercial fastener includes a collar  20  having a width of ⅜″, 7/16″, ½″, 9/16″, or ⅝″ spacing between boards  12 . Other sizes may also be utilized. Secondly, the collar  20  provides the ability to attach the fastener directly to a supporting structure, such as a supporting joist or cross-beam. This connection is made through the bore  36  that is located in the center of the collar  20 . A coated or stainless steel screw may be inserted into the bore  36  and then the screw driven into the underlying joist or support structure (not shown). Other types of screws, nails, or fasteners may also be utilized for attaching the fastener to a support structure. 
         [0032]    Depressions  42  may be disposed on the side of the shaft  16  along the length thereof. Multiple depressions  42  may be utilized, such as shown in  FIGS. 1 and 3 . The depressions  42  are used to save material during the molding process and to provide additional flared portions  44  that assist in creating a frictional connection with an aperture  22 . The flared portions  44  are shown best in  FIG. 3 . 
         [0033]    Referring to  FIGS. 5 and 6 , an example connecting system  14  is depicted that utilizes the example fastener  10  of  FIGS. 1-4  in connection with two side-by-side, hollow-core composite boards  12 . The hollow-core composite boards  12  have opposing exterior faces  46  and exterior side walls  48 . The hollow-core composite boards  12  also include an internal rib  34 . As shown in  FIG. 6 , each board  12  has two internal ribs  34  that are equally spaced from the side walls  48  thereof. 
         [0034]    Apertures  22  are defined on opposing side walls  48  of the boards  12  for accepting the ends  18  of the example fastener  10 . The fastener  10  shown in  FIG. 5  includes two flared tabs  26  at either end  18  of the shaft  16 . These tabs  26  are inserted through an aperture in the internal rib  34  of the boards  12  and the lip  32  of the tab  26  snaps into place behind the internal rib  34 . 
         [0035]    The fastener  10  is shown inserted into apertures  22  that are disposed on the side walls  48  of the boards. Alternatively, apertures could be defined on the face or ends of the boards to provide a different structure. The central collar portion  20  provides a fixed spacing between the side walls  48  of the boards  12  and is recessed relative to the faces  46  of the boards  12 . 
         [0036]    The example connecting system  14  may be utilized to create pre-assembled panels that consist of multiple boards  12  that are joined by the fasteners  10 . One proposed use for the pre-assembled panels is for docks. Use of the fasteners  10  in connection with decking installation resulted in a 60% or greater reduction in installation time. In some instances, it resulted in a 75% or greater reduction in installation time. 
         [0037]      FIGS. 7-11  depict another example fastener  110 . Fastener  110  is similar to fastener  10  in many respects. In this example, the fastener  110  has a rectangular central collar portion  120  that has a height H 1  and a width W 1 . The height H 1  of the central collar portion  120  is greater than a diameter D 1  of the shaft  116 . As with the prior example fastener  110 , the fastener  110  shown in  FIGS. 7-11  includes a substantially cylindrical shaft  116  having two opposed ends  118 . The central collar portion  120  is positioned between the two ends  118 . As shown, the portions of the shaft  116  on either side of the central collar portion  120  are substantially the same length, but could be different lengths. The shaft  116  has a diameter D 1  that is dimensioned to fit snugly inside an aperture  22  such that force must be applied to insert the shaft  120  into an aperture  22 . 
         [0038]    A plurality of outwardly extending cylindrical ridges  124  are positioned adjacent the central collar portion  120  on either side thereof. The ridges  124  extend along part of the length of the shaft  116 . The raised ridges  124  have a diameter D 3  that is greater than the diameter D 1  of the shaft  116 . The ridges  124  provide a frictional locking action against the interior of an aperture  22  for assisting in holding the fastener  110  inside an aperture  22 . The opposed ends  118  of the shaft  116  may be co-linear, as shown. 
         [0039]    The ends  118  of the shaft  116  include outwardly flared portions  126 , such as outwardly extending tabs. The outwardly flared portions  126  provide a spring-like action for holding the shaft  116  in an aperture  22 . A slot  128  may be cut into each end of the shaft  116  in the vicinity of the tabs  126  in order to allow the tabs  126  to flex inwardly when inserted into an aperture  22 . The slot  128  is shown best in  FIG. 8 . The outwardly flared portions  126  provide a spring-like action against the interior of an aperture  22  once installed. This spring-like action provides locking power for locking the shaft  116  inside an aperture  22 . The tab preferably has a lip  132 , which may be utilized in some examples for snapping behind an internal rib  34  defined inside a hollow-core board  12 . Other mechanisms for flaring the ends outwardly to create a spring action may also be utilized with equal success. 
         [0040]    The central collar portion  120  has a centrally disposed bore  136  that extends therethrough. The bore  136  may be a cylindrical hole, a tapered hole, or a combination of cylindrical and tapered. A cylindrical bore  138  is shown in  FIG. 9  that has a tapered opening  140 . The bore  138  is sized for accepting a second fastener, such as a screw or a nail (not shown). 
         [0041]      FIGS. 10 and 11  depict the example fastener  110  installed in a solid core board  12 . The aperture  22  is shown in this example extending all the way through the width W 2  of the board  12 . Alternatively, the apertures  22  may extend only partially through the board  12 . Since the boards  12  shown do not have an internal rib  34 , the tabs  126  and ridges  124  on the shaft  116  of the fastener  110  press against the internal sides of the aperture  22  to create a frictional connection therewith. This helps to deter removal of the fastener  110  from the apertures  22  such that force must be utilized to remove the fastener  110  from the aperture  22  (such as a pry bar). The central collar portion  120  shown has a rectangular shape, with a height H 1  that is greater than the diameter of the shaft D 1 , but less than the height H 2  of the boards  12  such that the central collar portion  120  is recessed relative to the faces  46  of the boards  12 . 
         [0042]    The fastener  10 ,  110  may be utilized in the following manner. In order to install the fastener  10 ,  110  to couple boards  12  together, opposing holes or apertures  22  are defined in the side walls  48  of the boards  12 . These holes  22  are preferably pre-formed but could alternatively be drilled at the construction site. The drill diameter may vary based upon the diameter D 1  of the shaft  16 ,  116  of the fastener  10 ,  110 . The holes  22  may have a diameter D 2  that is equal to or less than the diameter D 1  of the shaft  16 ,  116  in order to provide a press-fit into the apertures  22 . 
         [0043]    With decking installations, joists are typically 16 or 24 inches on center. Thus, the holes  22  are drilled along the lengths of the boards  12  to match up with the spacing of the underlying support structure. Hole locations can be drilled to accommodate the spacing of existing framing, even if it&#39;s not a standard spacing. 
         [0044]    Once the holes  22  are drilled, one end  18 ,  118  of a fastener  10 ,  110  is inserted into each hole  22  in a board  12 . The fastener  10 ,  110  is then driven into place. Then an adjacent board  12  is aligned with and installed on the other end  18 ,  118  of the fasteners  10 ,  110  in order to couple two boards  12  together. A mallet may be utilized to pound the side wall  48  of the board  12  onto the other end  18 ,  118  of the fasteners  10 ,  110 . Once inserted, the fasteners  10 ,  110  cannot typically be removed without the use of a tool, such as a pry bar. 
         [0045]    Once the boards  12  are connected together, the connection is complete and additional boards  12  may be added to the free sides of the boards  12 . The process may be repeated until multiple boards are coupled together to form a panel of boards. The system can be used to form panels for later installation or to join individual boards at the construction site. 
         [0046]    Once the boards  12  or panels are placed over a support structure, such as a joist, a fastener, such as a screw, may be inserted into the bore  36 ,  136  in the central collar portion  20 ,  120  of the fastener  10 ,  110  and screwed to the joist below. This process is repeated until all of the fasteners  10 ,  110  are attached to the underlying support structure. 
         [0047]    When hollow-core boards are utilized, an internal rib  34  may be spaced from the side walls  48  a distance that is substantially equal to the length L 1  of each portion of the shaft  16 ,  116  minus the length L 2  of the tabs  26 ,  126 . When the fastener shaft  16 ,  116  is inserted into the aperture  22  in the side wall  48 , the tabs  26 ,  126  enter the aperture in the internal rib  34  and snap behind the internal rib  34 . This helps to secure the fastener  10 ,  110  in place inside the hollow-core board. The fastener  10 ,  110  can then only be removed with a tool, such as a pry bar. 
         [0048]    The fastener  10 ,  110  can be constructed from plastic, aluminum, stainless, steel, brass, fiberglass, or other known materials. The fastener  10 ,  110  may be formed by molding or other manufacturing techniques. The term “substantially,” as used herein, is a term of estimation. 
         [0049]    While the principles of the invention have been described above in connection with preferred embodiments, it is to be clearly understood that this description is made only by way of example and not as a limitation of the scope of the invention.