Patent Publication Number: US-2020284033-A1

Title: Floating Connection Fastening System

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the priority of U.S. Provisional Patent Application No. 62/815,546 filed on Mar. 8, 2019. 
    
    
     BACKGROUND 
     This disclosure relates generally to devices and techniques for implementing a floating connection. More particularly, this disclosure relates to fastening systems which employ a floating connection to secure a non-load bearing wall to a truss or load bearing structure. 
     In some construction techniques, interior non-load bearing walls are typically framed approximately 1½ inch to ¾ inch below the load bearing components, such as, for example, floor joists, floor trusses, roof trusses, etc. The gap allows the load bearing components to deflect under pre-designed loads. The non-load bearing wall still requires bracing against lateral movement which is the principal objective of fastening between the non-load bearing wall and the truss or load bearing structures. 
     It is a well-known characteristic that if the non-load bearing walls are built flush to the underside of the load bearing components, the walls potentially become load bearing or quasi-load bearing. Such characteristics result in the transfer of load to structural components which, over time, typically result in dips in floors, cracking of finished work and failure of various components. 
     It is also possible that the load bearing structure may deflect upwardly relative to a partition wall. In the latter instance, the wall may be displaced upwardly or otherwise displaced. Consequently, for many installations, it is desired to implement a floating connection between a non-load bearing wall and a load bearing member by both creating a gap between the top of the non-load bearing wall and the underside of the load bearing member and/or creating a gap at the underside of the wall top plate between the head or flange of the fastener and the underside of the top plate so that, upon driving, the fastener sits proud relative to the bottom of the top plate. 
     As used herein, the phrase “floating connection” refers to a connection which accommodates relative vertical movement between connected structures, but limits movement in the lateral and transverse direction. 
     One technique for implementing a floating connection between a generally vertical non-load bearing wall and a generally horizontal load bearing wall involves usage of a specially configured fastener. One such representative fastener has a head with a flange-like tapered underside and a shank which has a non-threaded axially extended portion adjacent the flange. The unthreaded portion has a slip surface or Teflon™-like coating to facilitate sliding along the unthreaded portion. The fastener has an intermediate knurl and a threaded portion at the distal end. The head and flange have a diameter which is greater than the unthreaded portion. Upon driving the fastener in the top plate assembly of the non-load bearing interior wall, the knurl forms a bore which is equal to or slightly greater than the diameter of the unthreaded portion of the fastener. The fastener is driven into the truss or support member so that the thread engages into the support member and the head only engages against the underside of the top plate or projects below the underside of the top plate to form a slight gap which is typically on the order of ½ to ¾ inches. The unthreaded portion of the fastener thus slides in the bore relative to the non-load bearing member. 
     U.S. Pat. No. 9,360,032 discloses a fastener assembly specifically configured to connect a non-load bearing wall to a truss. The fastener assembly comprises a fastener which has a head and an axially extending shank which has an unthreaded shank portion and a threaded shank portion adjacent the distal end. A sleeve is retained on the fastener and disposed about the unthreaded shank portion. The sleeve is axially displaceable or slidable along the unthreaded shank portion. The sleeve is typically a plastic member with one end engageable against the upper end of the threaded portion and the other end engageable against a flange or a tapered neck disposed adjacent the head. 
     The unthreaded shank portion extends an axial length which is greater than the longitudinal length of the sleeve. The disclosed fastener assembly of U.S. Pat. No. 9,360,032 is employed for implementing a floating connection between a non-load bearing wall and a load bearing component. 
     It should be appreciated that the floating connection for all installations is replicated numerous times to complete the installation. 
     The present disclosure involves a fastening system for efficiently implementing a floating connection between a non-load bearing member and a load bearing member to provide a reliable and durable floating connection. 
     SUMMARY 
     Briefly stated, a floating connection installation system employs an installation assembly comprising an adaptor in the form of an offset cap. The cap has a central first axis and a distal reference flange perpendicular to and coaxial with the first axis. The adaptor also has a coaxial coupling recess and defines a proximal opening. A floating bushing comprises a semi-flexible sleeve having a second central axis and a coaxial locating flange disposed about the second axis. The locating flange also has a notch. The locating flange is receivable in the coupling recess. The floating sleeve has a generally cylindrical inside surface interrupted by an axial slot extending from the notch to a floating sleeve terminus. 
     The adaptor opening has a polygonal axially extending shape. A driver bit is received in the adaptor and extends through the opening to define an offset clearance relative to the reference flange. 
     A preferred fastener has a head, an unthreaded portion, a reamer and a distal threaded portion. The floating bushing captures the fastener, and the head is engageable by the driver bit. A driver has a chuck which receives a shank of the bit so that the adaptor and driver are rotatably fixed. The driver bit has a socket which engages the fastener head and the driver is energized to apply a torque to the fastener. 
     The fastener is driven through a non-load bearing member into a load bearing member to provide a floating connection between the non-load bearing member and the load bearing member. During driving, the fastener forms a bore in the non-load bearing member, and the sleeve is entirely received in a portion of the bore. The floating bushing locating flange engages the non-load bearing member. The fastener is driven to a proud position offset or spaced from the non-load bearing member. The offset position is pre-established by the adaptor. 
     In one embodiment, the floating sleeve has an exterior thread and the adaptor has a key engageable in the floating sleeve notch. 
     A method for installing a floating connection comprises engaging an adaptor with a driver bit having a reference flange defining an offset clearance and a received floating bushing with a captured fastener. The method comprises driving the fastener to form a bore in a non-load bearing member and threadably engaging a load bearing member so that the sleeve is received in a portion of the bore. 
     The installation method comprises driving the fastener through a non-load bearing member into a load bearing member so that the sleeve is entirely retained in the load bearing member, and there is an offset clearance of the fastener head. The installation method further comprises engaging a flange of the floating bushing against the underside surface of the non-load bearing member. The installation method comprises ultimately engaging the reference flange of the adaptor against a surface of the non-load bearing member. 
     A floating connection installation assembly comprises an adaptor comprising an offset cap defining a central first axis and having a distal reference flange perpendicular to the first axis. The adaptor has a coaxial coupling recess and a proximal axial opening which receives a driver bit. A floating bushing has a semi-flexible sleeve and a locating flange receivable in the coupling recess. The locating flange has a notch. The floating sleeve has a generally cylindrical inside surface interrupted by an axial slot extending from the notch. A preferred fastener has a head, a shank extending from the head with an unthreaded portion, a threaded terminal portion and an intermediate reamer. The floating bushing captures the fastener. The unthreaded portion of the fastener extends through the sleeve wherein the fastener is rotatably and axially slidable along the unthreaded portion, and the sleeve captures the fastener between the head and the reamer. 
     The driver and the reference flange define an offset clearance. The locating flange has a notch extending to the axial slot. In one embodiment, the adaptor has a key which is engageable in the notch. 
     When the locating flange is received in the coupling recess, the reference flange and the locating flange have coplanar surfaces. The inside surface of the sleeve has a uniform sleeve diameter and the reamer has a maximum diameter greater than the sleeve diameter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a floating connection assembly comprising a fastener, a floating bushing and a driver attachment assembly in engaged relationship; 
         FIG. 2  is a second perspective view of the floating connection assembly of  FIG. 1 ; 
         FIG. 3  is an elevational view of the floating connection assembly of  FIG. 1 ; 
         FIG. 4  is an opposite elevational view of the floating connection assembly of  FIG. 3 ; 
         FIG. 5  is a third perspective view of the floating connection assembly of  FIG. 1 ; 
         FIG. 6  is an exploded perspective view of the floating connection assembly of  FIG. 5 ; 
         FIG. 7  is a central sectional view of the floating connection assembly of  FIG. 1 ; 
         FIG. 8  is an enlarged sectional view of the driver attachment assembly of  FIG. 7 ; 
         FIG. 9  is an enlarged perspective view of the floating bushing of  FIG. 7 ; 
         FIG. 10  is an enlarged perspective view of the fastener of  FIG. 7 ; 
         FIG. 11  is a perspective view, partly broken away and partly representational, of a driver, an attachment assembly, a fastener and a floating bushing in assembled driving relationship; 
         FIG. 12  is a representational sectional view of an installed floating connection; 
         FIG. 13  is a representational elevational view of the installed floating connection of  FIG. 12 ; 
         FIG. 14  is a representational sectional view of the installed floating connection of  FIG. 12  from a 90° perspective thereof; 
         FIG. 15  is a perspective view of the floating connection of  FIG. 12 ; 
         FIG. 16  is a second perspective view of the installed floating connection of  FIG. 15 ; 
         FIG. 17  is an enlarged perspective view of a second embodiment of an offset cap; 
         FIG. 18  is a sectional view through the offset cap of  FIG. 17 ; 
         FIG. 19  is a perspective view of a second embodiment of a floating bushing; and 
         FIG. 20  is a perspective view of a floating connection assembly comprising a second embodiment of the offset cap and the floating bushing of  FIG. 19 . 
     
    
    
     DETAILED DESCRIPTION 
     With reference to the drawings wherein like numerals represent like parts throughout the several figures, a floating connection fastening system employs a fastener  10 , a floating bushing  20  ( FIG. 9 ) or  30  ( FIG. 19 ) mounted to or capturing the fastener, and a driver offset adaptor  50  which mounts a driver bit  60  and receives the fastener/sleeve assembly. A driver  70  ( FIG. 11 ) has a chuck which engages the driver bit and rotatably drives the fastener. The principal innovative components are the floating bushings  20 ,  30  and the cooperating adaptor  50 . As described herein, “upper” and “lower” refer to preferred installation orientations for descriptive purposes and should not be deemed limiting. 
     With additional reference to  FIGS. 6 and 10 , the connection system is described in terms of a representative preferred fastener  10  configured to form a bore and to connect a non-load bearing member to a load bearing member. The fastener  10  preferably has a six inch axial length which includes a hex head  12  and an integral retaining washer or a flange  13  adjacent a tapered frustro-conical neck  14 . Other head, retainer flange/neck configurations are possible. An unthreaded cylindrical shank portion  15  axially extends approximately 4 inches from the neck  14 . A threaded portion  18  extends to a threaded distal tip  19 . The fastener preferably has an intermediate reamer  16  having diametrically protruding bore forming blades. In a preferred embodiment, the maximum diameter of the head  12  and the unthreaded portion  15  are 0.26 inches and 0.020 inches, respectively. The major diameters of the reamer  16  and threaded portion  18  are 0.24 inches and 0.26 inches, respectively. Naturally, other fastener configurations which have an unthreaded shank portion and have different dimensions are possible. 
     A slidable bushing  20  or  30  is configured to mount onto and surround the unthreaded shank portion  15  of the fastener to thereby capture the fastener prior to installation. The bushing  20  or  30  essentially functions to axially slide relative to the unthreaded shank portion  15  which, post installation, may axially move. Each bushing  20 ,  30  is preferably formed from plastic and has a semi-flexible sleeve  21 ,  31  which extends approximately ⅞ to one inch with an outer diameter less than the outside diameter of the head flange  13 . Each sleeve  21 ,  31  in a normal non-flexed condition has an inner diameter greater than the diameter of the unthreaded portion  15  and less than the maximum diameters of the flange  13  and reamer  16 . The bushing  20  or  30  axially retains the fastener by the opposed sleeve ends  23 ,  25  or  33 ,  35 , respectively engaging the reamer  16  and the flange  13  and/or the neck  14 . 
     With additional reference to  FIG. 9 , bushing  20  is a semi-flexible plastic member having a lower quasi-annular flange  22  defining a notch  24  and a generally perpendicularly projecting semi-flexible sleeve  21 . The sleeve  21  has a longitudinal slot  26  extending from the notch to the terminus of the sleeve. The sleeve  21  has a cylindrical inner surface  28  interrupted by the slot  26 . The sleeve  21  is configured so that it can be easily snapped over the unthreaded portion  15  of the fastener and is retained to the fastener by the flange  22  engaging the lower portion of the fastener neck/flange and the upper end  23  engaging an upper projecting portion of the reamer  16  and by the resilience of the sleeve which returns to its normal shape. The notch  24  may also facilitate capturing the fastener. Upon installation, the sleeve  21  is driven into the fastener bore of the non-load bearing member and flange  22  engages the underside surface of the non-load bearing member. 
     With additional reference to  FIG. 19 , semi-flexible bushing  30  is similar in form and function to bushing  20  except that sleeve  31  has an exterior thread  39 . Bushing  30  has a lower flange  32  with a notch  34  and sleeve  31  is traversed by a longitudinal slot  36 . The inner surface  38  substantially cylindrical except for the axial slot. Again, bushing  30  is configured so that sleeve  31  snaps over and slides along and is rotatable about the unthreaded upper portion  15  of the fastener and is also axially slidable along with the unthreaded upper portion. Upon installation, the sleeve  31  is rotatably driven into the fastener formed bore of the non-load bearing member and flange  32  engages the underside surface of the non-load bearing member. 
     The offset adaptor  50  functions to receive a driver bit  60  to form an attachment assembly  65  rotatably couplable with the fastener  10  captured by the receivably mounted bushing  20  or  30 . With reference to  FIG. 11 , upon mounting the assembly  65  to a torque driver  70  and driving the attachment assembly/fastener/bushing, a pre-established proud head position of the fastener is ultimately implemented, as illustrated in  FIGS. 12-16 . 
     With additional reference to  FIGS. 5-8 , the offset adaptor  50  comprises a bell-like enclosure or cap having a central axis A. The enclosure terminates at an annular reference flange  52  normal to and coaxial with the axis A. The enclosure has a quasi-cylindrical portion  54  which upwardly tapers to form a central axial opening  56 . The opening  56  has a polygonal shape complementary to a shank portion of the driver bit. A coupling recess  58  coaxial with axis A is formed at the end of the adaptor. Coupling recess  58  is complementary to the flange  22  or  32  of the bushing  20  or  30 . 
     With reference to  FIGS. 19 and 20 , for adaptor  50 ′, a key  59  projects radially inwardly to interrupt the recess  58 . The key  59  ( FIG. 20 ) is generally complementary with the notch  24  or  34  of the bushing flange  22  or  32  so that upon reception of the coupled flange  22  or  32  by the adaptor  50 ′, the adaptor  50  and bushing  20  or  30  are rotatably locked. In some embodiments wherein the sleeve has no exterior threads (such as sleeve  21 ), the key is omitted and there is no rotational locking between the cap or adaptor  50  and the bushing  20 . Upon driving the fastener, there may be limited rotation of the bushing  20  due to friction between the flange  22  and the adaptor  50 . 
     The driver bit  60  has a socket  62  adapted to engage the hex head  12  of the fastener. Naturally, the bit/fastener head engagement may be configured differently if the fastener torque engagement portion has a different structure. The bit has a polygonal shank portion  64  of uniform polygonal cross-section is closely received in the opening  56 . The bit  60  and adaptor  50  are thus rotatably fixed. The bit shank axially projects from the adaptor and has a proximal engagement end  66 . With reference to  FIG. 11 , the bit shank end  66  is received by the chuck  72  of a torque driver  70  which may be of numerous conventional forms. 
     The driver bit is retained to the housing so that it forms an interior stop with a clearance C as indicated in  FIG. 8 . Because of the pre-established clearance C, when the fastener is driven, the reference flange  52  ultimately engages the underside of the header H or support member, and the fastener head is torqued to drive the fastener  10  (and sleeve) so that the flange  22  or  32  carried by the cap in coupling recess  58  ultimately engages the underside of the non-load bearing member and the head essentially sits proud relative to the non-load bearing member or is offset by clearance C. 
     With reference to  FIGS. 12-16  the bushing  20  and captured fastener  10  are installed as a unit. Upon driving and installing the fastener  10 , the bushing  20  remains mounted to the fastener, and the bushing and fastener function to provide the floating connection installation between a load bearing structure, such as a truss, and a non-load bearing structure, such as a partition or interior wall. The installation is accomplished in a one-step procedure in which the fastener  10  forms a bore B in the header H or non-load bearing member as it is driven into the load bearing member such as truss T. The sleeve  21  of the bushing is forced into the bore B during the driving step via a combination of friction from the fastener and a direct pushing force from the adapter  50 . The sleeve  21  is received along with the adjacent unthreaded portion of the fastener in the fastener bore B of the non-load bearing member. Upon installation, the sleeve  21  or  31  does not extend the entire axial length of the formed bore B. 
     The bushing  30  rotates with the driver and adaptor  50 ′ as the fastener is driven. The exterior surface of sleeve  31  and the thread  39  frictionally engage the non-load bearing member bore B. Sleeve  31  may slightly thread or engage into the structure adjacent the non-load bearing member bore. 
     When installed by the embodiment of the adapter  50  (without a key like element  59  in the adapter  50 ′), the bushing  20 , for the most part, does not rotate or only slightly rotates when the fastener is driven. Once the fastener is threaded into the load bearing member, the unthreaded portion of the fastener is slidable relative to the inner surface of the sleeve  21  or  31 . The attachment assembly  65  comprising adaptor  50  and driver bit  60  is disengaged from the fastener head  12  of the implemented floating connection and is reusable with multiple captured fastener/bushings for multiple subsequent floating connection installations. 
     For preferred embodiments, wherein the floating bushing  20  does not have an exterior thread, it is not required that the bushing rotate with the adaptor. For such embodiments, the described key/notch configuration and engagement is not required. 
     While preferred embodiments of the foregoing floating connection fastening system have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.