Abstract:
A leveling fastener for connecting and aligning boards includes an elongated support member having first and second support portions with first and second coplanar upper surfaces, a connecting portion that extends upward from the support member, and an elongated fastening component that extends from the connecting portion and that has a pointed end that can be driven into a board, thereby securing the leveling fastener to the board. In use, the first coplanar upper surface of the leveling fastener is positioned flush against a first bottom surface of a board, the fastening component is driven into a first side surface of the board, and a second bottom surface of a second board is positioned flush against the second coplanar upper surface of the fastener. Another aspect of the invention relates to the leveling fastener in combination with a device for driving the leveling fastener into a board. The driving device has an alignment structure having an abutment surface on its exterior and a driver slidably connected to a fastener delivery channel defined by the alignment structure.

Description:
TECHNICAL FIELD 
     This invention relates to carpentry, building, and construction, and more particularly to an apparatus and method making a level connection between two or more boards. 
     BACKGROUND 
     In various situations in carpentry, building, and construction work, it is necessary to connect boards, so that the respective upper and lower surfaces of adjacent boards are aligned and level. This need arises, for example, in the construction of decks, particularly when joists are spaced 16 inches apart. This operation has been performed with deck clips described in U.S. Pat. No. 5,027,573. However, the clips described therein require additional fasteners, such as nails, for affixation to boards, because the clips themselves only have short “locator prongs.” Additional fasteners require additional materials and additional procedures, which make construction work slower and more complicated. 
     SUMMARY 
     The invention, in one aspect, relates to a leveling fastener for connecting and aligning boards. The leveling fastener includes an elongated support member, having first and second support portions with first and second coplanar upper surfaces, a connecting portion that extends upward from the support member, and an elongated fastening component that extends from the connecting portion and that has a pointed end that can be driven into a board, thereby securing the leveling fastener to the board. 
     When connecting boards, the first coplanar upper surface of the leveling fastener is positioned flush against a first bottom surface of a first board, the fastening component is driven into a first side surface of the board, and a second bottom surface of a second board is positioned flush against the second coplanar upper surface of the fastener. 
     In another aspect, the invention relates to a combination of a leveling fastener and a device for driving the leveling fastener into a board. The driving device has an alignment structure having an abutment surface on its exterior and a driver slidably connected to a fastener delivery channel defined by the alignment structure. A leveling fastener is disposed within the fastener delivery channel so that movement of the driver down the fastener delivery channel can move the fastener from a first position to a second position. 
     Preferably, the leveling fastener is constructed as a unitary device. It may be constructed of a single piece of material or multiple pieces that are connected together. The leveling fastener can have more than one connecting portion, each of which may have more than one pointed end. The pointed ends may be directed in the same direction, in opposing directions, or in any desired orientation. The connecting portion may have any suitable shape or configuration, for example a pointed prong or a thin plate. Any part of the leveling fastener may have a rough surface (for example, a surface that is jagged, grooved, or barbed), which permits the fasteners to have a more secure connection to boards. 
     The driving device may also include an alignment plate connected to the alignment structure. The alignment plate may include a cutout portion, thereby permitting any part of the support members that protrude outside the alignment structure to remain in flush contact with a board, throughout the driving operation. Alternately, the alignment plate may be positioned so that it abuts a side of a board opposite the side that is in contact with a support surface of the leveling fastener. The driving device may also include a magazine for retaining a plurality of leveling fasteners, springs for returning the driver to a position for driving subsequent fasteners, after a fastener has been driven. 
     The force required to activate the driver may be supplied manually, or by a pneumatic, hydraulic, elastic, electrical, electromagnetic, electrostatic, magnetic, combustion, or explosive device. For example, the force may be provided by a hammer blow, gunpowder, a spring, an electric motor, an internal combustion engine, or a compressed air device. The force required to activate the driver may be supplied from an offset orientation, for example, with cams, rollers, or linkages. 
     Embodiments of the invention may include one or more of the following advantages. Leveling fasteners may be constructed as a single, unitary piece and may be connected to boards without the need for additional devices to hold the fastener in place (for example, nails, screws, adhesives). Unitary leveling fasteners are easy to use. The invention may reduce workers&#39; time and labor in building, construction, and carpentry work. Leveling fasteners according to the invention can be securely attached to boards. Leveling fasteners may employ rough surfaces to make connections to boards more secure. Leveling fasteners may employ multiple connecting portions or multiple pointed members for making secure attachments to boards. The invention can be used to align, stiffen, and/or level boards that are connected together. Leveling fasteners can be installed easily with a driving device or gun. Leveling fasteners may be made from materials that have any cross-sectional shape, including round or rectangular cross-sections. Leveling fasteners may be made from any suitable material, including metal, plastic, fiberglass, and carbon fiber. Leveling fasteners may be made, for example, from wire or stamping metal. Leveling fasteners may be manufactured in any suitable manner, for example they may be molded, cast, cut, machined, and/or bent. Leveling fasteners may have any suitable overall size. The invention may be used to connect boards without nails or other fasteners that protrude through the exposed upper surfaces of the boards, as in a deck. The invention may be used with boards of wood, foam, plastic, fiberglass, or any suitable material. 
     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
    
    
     DESCRIPTION OF DRAWINGS 
     FIG. 1 is a perspective view of a leveling fastener. 
     FIG. 2 is a side view of the leveling fastener of FIG. 1 connecting two boards. 
     FIG. 3 is a perspective view of a leveling fastener. 
     FIG. 4 is a perspective view of a leveling fastener. 
     FIG. 5 is a top view of the leveling fastener of FIG.  4 . 
     FIG. 6 is a front view of the leveling fastener of FIG.  4 . 
     FIG. 7 is a bottom horizontal sectional view of a driving device. 
     FIG.  8 . is a side vertical sectional view of the driving device of FIG.  7 . 
     FIG.  9 . is a top horizontal sectional view of a the driving device of FIG. 7, showing an alternate disposition of the magazine. 
     FIG. 10 is a side vertical sectional view of an alternate driving device. 
     FIG. 11 is a side view of a leveling fastener connecting two boards. 
     FIG. 12 is a top view of the leveling fastener of FIG.  11 . 
     FIG. 13 is a side view of a leveling fastener. 
     FIG. 14 is a perspective view of a leveling fastener. 
     FIG. 15 is a front view of the leveling fastener of FIG.  14 . 
     FIG. 16 is a front view of a leveling fastener. 
     FIG. 17 is a top view of the leveling fastener of FIG.  16 . 
     FIG. 18 is a perspective view of a leveling fastener. 
     FIG. 19 is a side view of the leveling fastener of FIG. 18 connecting two boards. 
     FIG. 20 is a tope view of the leveling fastener of FIG.  18 . 
     FIG. 21 is a perspective view of a leveling fastener. 
     FIG. 22 is a perspective view of a leveling fastener. 
     Like reference symbols in the various drawings indicate like elements. 
    
    
     DETAILED DESCRIPTION 
     Referring to FIGS. 1-2 there is shown leveling fastener  600  having support member  610  with first support portion  612  and second support portion  614 , a connecting portion  616  that extends upward from support member  610  to fastening component  618 , which is elongated and is generally parallel to support member  610 . Fastening component  618  has forward-facing pointed prong  620 . Forward-facing prong  620  has a pointed end and an elongated shaft portion that is sufficient to hold fastener  600  securely in a board without the need for any other fastening structure. FIG. 2 shows the leveling fastener in use for making a leveling connection between first board  110  and second board  120 . First support surface  613  of first support portion  612  is flush against first contact surface  112  of first board  110  and prong  620  (in phantom) is driven through first end surface  114  of first board  110 . Second support surface  615  of second support portion  614  is flush against second contact surface  122  of second board  120 . 
     Leveling fasteners may also be designed to be attached to boards on either side of the fastener. For example, referring to FIG. 3 there is shown leveling fastener  600 A having support member  610 A with first support portion  612 A, second support portion  614 A, and connecting portion  616 A that extends upward from support member  610 A to fastening component  618 A, which is elongated and is approximately parallel to support member  610 A. Fastening component  618 A has forward-facing pointed prong  620 A and rearward-facing pointed prong  622 A. In use, rearward-facing prong  622 A could be driven into a board that is set against second support portion  614 A. For example, rearward-facing prong  622 A could be driven into second end surface  124  of second board  120 , shown in FIG. 2, by hammering board  120  against prong  622 A, after prong  620 A has been driven into first board  110 . 
     Leveling fasteners may be designed to have only one pointed prong, or to have any desired number of pointed prongs, which may be oriented for driving into the same board or into different boards, and at any suitable angle. 
     Preferably, the height of leveling fasteners (for example, the distance from the bottom of support member to the top of fastening component  618 ) is from ¼ inch to 3 inches and the length of support portions (for example either first support portion  612  or second support portion  614 ) is from ¼ inch to 3 inches. Preferably, the pointed prongs (for example, forward-facing pointed prong  620 ) are from ¼ inch to 3 inches long and have a cross-sectional thickness of from {fraction (1/16)} inch to ½ inch. Leveling fasteners may also employ a variety of pointed elements on fastening components, in addition to prongs, and may employ simultaneously various types of pointed elements, each of which may have any desired dimensions. 
     Referring to FIGS. 4-6, there is shown leveling fastener  600 B, which is made of stamping metal that has been cut and then bent in half along fold  611 B. Fastening component  618 B has two forward-facing pointed prongs  620 B, which enhance the attachment of leveling fastener  600 B to boards. 
     Leveling fasteners may be used with a driving device for driving the fasteners into boards. FIGS. 7-10 show driving devices for use with leveling fasteners similar to those shown in FIGS. 4-6, although any of the leveling fasteners described herein may be used with driving devices. Driving devices may be used to make construction, building, and carpentry work more easy and efficient. For example, driving devices for driving two-pointed staples into a deck board and a joist below it are described in my U.S. patent application Ser. No. 00/137,012, filed Aug. 20, 1998, which is incorporated herein by reference. 
     Referring to FIGS. 7-9, there is shown a device for driving leveling fasteners into boards. The driving device has alignment structure  1010 , driver  1012 , and alignment plate  1018 . 
     Alignment structure  1010  has abutment surface  1024  which is adapted to abut first board end surface  114 B of first board  110 B. Alignment structure  1010  defines fastener delivery channel  1044 . Fastener  600 B is positioned within fastener delivery channel  1044 . When abutment surface  1024  is positioned against board end surface  114 B, first support surface  614 B is flush against first board contact surface  112 B and pointed prongs  620 B are directed toward board end surface  114 B, so that the device is positioned to drive pointed prongs  620 B into board end surface  114 B. Driver  1012  has striking portion  1050  with broadened striking head  1052 , stock  1054 , and driving portion  1056 . Driver  1012  is slidably and movably fitted within fastener delivery channel  1044 . Driver  1012  is capable of moving toward abutment surface  1024 , in response to an external force, for example a hammer blow on striking head  1052 . Such movement causes driving portion  1056  to move down fastener delivery channel and to contact connecting portion  616 B, in order to move leveling fastener  600 B from a first position to a second position, thus driving pointed prongs  620 B into board end surface  114 B. 
     The driving device has two internal springs  1068  disposed within driving channel  1062  so that, when driver  1012  is driven forward, internal springs  1068  are compressed between stock  1054  of driver  1012  and compression surface  1070  that bounds driving channel  1062  within alignment structure  1010 . After the forward motion of driver  1012  ceases, internal springs  1068  expand, so as to push driver  1012  back to its initial position. External springs  1072 , connected between striking head  1052  and alignment structure  1010 , may be used alternately or in conjunction with internal springs  1068 , in order to return driver  1012  to its initial position, when the driving motion is completed. 
     Alignment plate  1018  is fastened to alignment structure  1010  so that it can abut first board contact surface  112 B. Alignment plate  1018  defines alignment cutout  1071 , which provides clearance for support member  610 B of leveling fastener  600 B, so that support surface  613 B can remain flush against first contact surface  112 B, while pointed prongs  620 B are driven forward into board end surface  114 B by driver  1012  as it progresses down fastener delivery channel  1044 . 
     Magazine  1016 , which holds a plurality of leveling fasteners for subsequent delivery to fastener delivery channel  1044 , is fitted partially within alignment structure  1010 . Magazine  1016  defines fastener supply channel  1048  which joins fastener delivery channel  1044 , so that fasteners which are retained within supply channel  1048  may pass into fastener delivery channel  1044 . FIGS. 8 and 9 show alternative dispositions of magazine  1016 . In FIG.  8 , magazine  1016  is connected to the top of alignment structure  1010 , so that the leveling fasteners are stored vertically. In FIG. 9, magazine  1016  is connected to a side of alignment structure, so that the fasteners are stored horizontally. 
     FIG. 9 also shows the connection of boards  110 B′,  120 B′ by leveling fastener  600 B′ (in phantom). 
     Referring to FIG. 10, there is shown an alternate configuration of the driving device, in which first support surface  613 B of leveling fastener  600 B is flush against first contact surface  112 B of first board  110 B and alignment plate  1018 ′ abuts opposing board surface  116 B. The position of alignment plate  1018 ′ relative to alignment structure may be adjusted on adjustment member  1074 ′, so that first support surface  613 B may be flush against first contact surface  112 B, for any thickness of board  110 B. Adjustment member  1074 ′ may also include magazine  1016 ′ for holding a plurality of leveling fasteners. 
     Leveling fasteners may be made from a variety of different materials and in a variety of configurations. Making leveling fasteners from stamping metal allows for efficient and inexpensive manufacturing. Designs in which the cut metal has been folded also gives additional thickness, rigidity, and strength to the fasteners. Preferably, 13 gauge metal is used, however either heavier or lighter materials may also be used, depending on the intended purpose of the leveling fastener. 
     Referring to FIGS. 11-12, there is shown a leveling fastener that is made from thinner 16 gauge metal, which has been folded laterally along folds  622 C, in order to create broad support surfaces  613 C,  615 C on support portions  612 C,  614 C. In addition to breadth of support surfaces  613 C,  615 C, multiple folds provide additional strength and rigidity, which is helpful when thinner materials, such as  16  gauge wire, are used. In FIG. 11, boards  110 C,  120 C are set in alignment against support portions  612 C and  614 C, respectively, and prong  620 C has been driven into board  110 C. 
     Referring to FIG. 13, there is shown a leveling fastener similar to that in FIGS. 11-12, however the embodiment of FIG. 13 has barbs  624 D on support surfaces  613 D,  615 D of first and second support portions  612 D,  614 D. Barbs  624 D allow support surfaces  613 D,  615 D to grip boards more strongly. Any part of the leveling fasteners can have a rough surface, for example a surface that is jagged, grooved, or barbed, which permits the fasteners to have a more secure connection to boards. Further, connecting portions  616 D and  617 D have different lengths. 
     Leveling fasteners may employ multiple fastening components and combine different types of fastening components, for example pointed prongs and flat protrusions. Thus, referring to FIGS. 14-15, there is shown a leveling fastener made of metal that is folded laterally along folds  622 E. This embodiment has first and second connecting members  616 E,  617 E, and first and second fastening components  618 E,  619 E. First fastening component  618 E has first forward-facing pointed prong  620 E and second rearward-facing pointed prong  623 E. Second fastening component  619 E has a first rearward-facing pointed prong  622 F. Referring to FIGS. 16-17, there is shown a leveling fastener having rearward-facing flat triangular fastening component  636 J and rearward-facing pointed prong  622 J. Support member  610 J has been bent into an elongated U-shape at end fold  638 J, so that individual support elements  640 J are spaced apart, thereby creating effectively a broad support member  610 J. 
     Referring to FIGS. 18-22, there are shown additional varieties of leveling fasteners made from sheets of stamping metal. The embodiment shown in FIGS. 18-20 is doubled in thickness at connecting portion  616 F and fastening component  618 F, thus enhancing the strength and rigidity of these elements. Lateral panels  626 F are folded downwardly away from support surfaces  613 F,  615 F, thereby providing additional rigidity and strength. The embodiment of FIG. 21 is made from stamping metal that has been cut and bent, so that connecting portion  616 G and fastening component  618 G are formed by bending metal pieces upward, leaving first and second cutouts  628 G,  629 G on support member  610 G. T-shaped support  630 G and tabs  632 G provide additional strength and rigidity to connecting portion  616 G. Support member  610 G defines punched holes  632 G punched there through. Punching roughens support surface  613 G, in the vicinity of holes  632 G, so that it can grip boards more strongly. 
     The embodiment of FIG. 22 is made from stamping metal that has been cut and bent, so that forward-facing prong  620 H is bent away from connecting portion  616 H, which thereby defines prong cutout  634 H. 
     A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, magazine  1016  may be orientated at any suitable angle relative to alignment structure  1010 . Accordingly, other embodiments are within the scope of the following claims.