Patent Publication Number: US-11655628-B2

Title: Deck ledger board spacing system with keyed center bushing, coupling spacers, reinforcing coupler, and reinforced shim

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Patent Application No. 63/264,235, filed Nov. 17, 2021 and 63/201,241, filed Apr. 20, 2021. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates most generally to building construction materials and, more particularly, to spacers used to secure a ledger board to a structural framing member of a structure to which the deck is attached, and still more particularly to a deck ledger board spacer of the same kind having an exchangeable and selectively-sized keyed center bushing that accommodates fasteners of differing diameters, differentially-sized countersinks on opposing sides of the spacer to accommodate secondary fasteners of differing sizes and shapes, and a plurality of sealant or adhesive recesses on each side of the spacer to accept and constrain a flowable sealant and to receive shear transfer accessories, such as couplers, reinforcing chips, and coupling spacers. 
     Background Discussion 
     Prior to the recent adoption of deck building code requirements, deck ledgers were frequently installed with nails. Nails were eventually found to be structurally inadequate for the ledger connection and a major cause for structural failure in decks. Eventually, nails were effectively prohibited by most building codes, which typically require ½″ bolts and lag screws at deck ledger connections. 
     In addition to fastening standards, the current building codes typically call for methods to prevent decay at the connection, as it too is often a contributing cause or factor in ledger failure. Flashing and spacers are known devices employed to prevent wood decay in ledgers and other supporting structures. 
     The bolts and lags required by building codes provide a secure connection, but they are costly and somewhat cumbersome to install. Because of this, fastener manufacturers developed structural wood screws approved for ledger installations. These structural screws are proprietary, smaller in diameter than the larger bolts and lags, easier to install because they often obviate the need for pilot holes, and drive with light duty battery-operated drivers. Structural screws are tested to capacities rivaling larger commodity fasteners. Typically, structural screws range from about ¼″-⅜″ in diameter, and they are better sized than the ½″ and ⅝″ lag screws for conditions requiring attachment into the 1½ face of a stud or framing member. 
     The present invention improves on a known deck spacer also invented by, and patents issued to, the present inventor, viz., the spacer shown in U.S. Pat. Nos. 8,087,207 and 6,945,004, each of which is incorporated in its entirety by reference herein. 
     The foregoing patents each teach a spacer directed for use in the same manner as the present invention, but each also lack structure making the spacer suitable for use with a variety of primary and secondary fasteners, as well as use with sealants and/or adhesives adding strength and preventing water and debris intrusion. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is an improved board spacer, typically employed as a deck spacer, used to secure and space a ledger board to a structure while maintaining the ledger a predetermined distance from the structure. 
     Among the many objects of the invention, it is a principal object to provide a board spacer that can be sold individually, yet still be suited for use with a variety of primary (center) and secondary (circumferential) fasteners. 
     The improved board spacer of the present invention accommodates a wide range of proprietary structural wood screws and commodity fasteners that vary by diameter. It does so by including a hole in the center of the spacer that accepts keyed bushings with a variety of cylindrical hole diameters. The new spacer design also provides opposing conical and cylindrical countersink profiles to accept common wood screws and newly developed, structurally rated hexagonal head screws which are approved for installing joist hangers and other structural connectors. Additionally, the new design has sealant wells to constrain sealant on both sides of the spacer. 
     The inventive board spacer benefits retailers, users, and material specifiers. Retailers can rely on a single spacer to be compatible with their selection of deck ledger fasteners, simplifying ordering, inventory, and reducing required shelf space. Users will benefit from increased selection of fastener choices. Engineers and other materials specifiers can select their preferred fasteners based on test data and availability, for both primary and secondary fasteners to ensure reliable connections and local availability. 
     The present invention further provides multiple solutions to increasing the spacing width between a ledger and a deck board by providing several spacing accessories for use in conjunction with the deck spacer that enable the user to widen the space between the deck ledger and structural framing member. 
     In achieving the principal object of the invention, a second, corollary object is also achieved, namely that of being economical in manufacture, marketing, and sale. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
       The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
         FIG.  1    is an upper front perspective view of the deck spacer of the present invention; 
         FIG.  2    is a front view in elevation thereof; 
         FIG.  3    is a side view in elevation thereof; 
         FIG.  4    is an inverted rear view in elevation thereof; 
         FIG.  5    is a cross sectional side view taken along section line  5 - 5  of  FIG.  4   ; 
         FIG.  6    is a front view in elevation showing an alternative embodiment with bushing retention structure; 
         FIG.  7    is a cross-sectional side view in elevation showing the deck spacer installed in a stacked configuration; 
         FIG.  8    is an upper front perspective view showing an alternative embodiment of the deck spacer of the present invention, in this instance showing a coupling spacer; 
         FIG.  9    is a rear view in elevation thereof; 
         FIG.  10    is a side view in elevation thereof; 
         FIG.  11    is an upper front perspective view of a reinforced shim as used in the present invention; 
         FIG.  12    is a top plan view thereof; 
         FIG.  13    is a side view in elevation thereof; 
         FIG.  14    is a lower rear perspective view thereof; 
         FIG.  15    is an upper front perspective view of a reinforcing coupler as used in the present invention; 
         FIG.  16    is a top plan view thereof; 
         FIG.  17    is a side view in elevation thereof; 
         FIG.  18    is a lower rear side perspective view thereof; 
         FIG.  19    is a cross-section side view in elevation showing a deck spacer being coupled with a coupling spacer; 
         FIG.  20    is a cross-sectional side view in elevation of a reinforced shim being coupled with a coupling spacer; and 
         FIG.  21    is a cross-sectional side view in elevation showing a reinforcing coupler connecting with a coupling spacer. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring first to  FIGS.  1  through  7   , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved deck board spacer, and more broadly useful as a board spacer generally, which is generally denominated  10  herein. The views, collectively, show that in an embodiment the deck board spacer (“deck spacer” or “board spacer” herein) includes a generally cylindrical low-profile, generally solid disc body  12  having a generally circular circumferential outer side  14 . The disc body is typically manufactured in a plastic injection molding process and is thus a unitary piece of polymeric material. Alternatively, the disc body may be made using plastic or metal blocks for CNC machining. 
     The cylindrical/circular geometry, while preferable, is not essential, and the disc body may be configured in any of a number of suitable geometries. The thickness of the disc is typically less than an inch (2.54 cm) and is selected to provide spacing for air circulation while maintaining the essential structural integrity of the connection between a ledger board and the attached structure. 
     Each of the front side  16  and the back (rear) side  18  are substantially planar, though each side is characterized in having several substantially mirror image depressions, recesses, wells, and through holes. For instance, and most importantly, the spacer includes a center hole  20  having at least one—and in embodiments, a plurality of—evenly-spaced radially-extending voids or spokes  22  that function as the female elements for a keyed bushing (to be described more fully below). In embodiments, a single spoke may be employed, as it alone may be sufficient when cooperating with a male bushing element to prevent rotation and translation of the bushing, or a plurality of spokes may be provided in an evenly spaced arrangement, e.g., three spokes at roughly 120 degrees apart, as shown in the view. However, this selection of the number and placement of the “negative” keying element is non-limiting, as any number of elements, one or greater, might be employed, and spacing needn&#39;t be entirely even or consistent. 
     The disc front and rear sides next include through holes  24  for secondary fasteners, i.e., those secondary to a bolt adapted for passage through the through hole of one or any of a number of keyed bushings that may be inserted into the center hole  20 , as more fully described below. These holes are generally substantially smaller (i.e., have a substantially smaller inner diameter) than the center hole and the keyed bushing through holes, and on each side they include countersunk or a counterbored holes comprising a recess shaped (cylindrical or conical) and sized to fit the head of a fastener such that the surface of the fastener head sits flush with the front or rear surfaces,  16   s ,  18   s , respectively, of the disc when fully tightened (see  FIG.  5   ). Advantageously, the countersinks/counterbores may be of different sizes and configurations,  26   a ,  26   b ,  26   c ,  26   d , adapted to fit most commonly used deck screws, hex head screws, and other fasteners. 
     Next, the deck spacer of the present invention includes adhesive/sealant cavities or wells— 28   a ,  28   b ,  28   c  on the front side—and  28   a N,  28   b N,  28   c N on the rear side. The wells on the front side are of the same dimensions, as are those on the rear side; however, the wells on the rear side are slightly smaller in their perimeter dimension than those on the front side. These wells provide a pocket for containing a volume of flowable sealant or adhesive with bonding surfaces at the bases of the wells  30   a ,  30   b ,  30   c ,  30   a N,  30   b N,  30   c N and sides  32   a ,  32   b ,  32   c ,  32   a N,  32   b N,  32   c N to contain and constrain the adhesive such that it does not migrate between the front or rear surfaces  34 ,  36  of the spacer and the structural element to which the spacer is attached. Again, the sealant wells will also serve to receive element and features of shear transfer accessories. 
     In embodiments, the deck spacer may include three distinct center keyed bushings  40 ,  42 ,  44 , having variously sized through holes  40   a ,  42   a ,  44   a , and a plurality of radiating male spokes sized and spaced for complementary insertion into the center hole  20  and the female voids  22  disposed around the peripheral of the center hole. Each keyed bushing has a thickness substantially, if not precisely, matching the thickness of the disc body immediately surrounding the keyed bushing when inserted in the center hole. 
     The figures show the bushings coupled to the outer side  14  (the periphery) of the disc body  12 , typically though injection molding at the time of manufacture. Such an evenly spaced configuration is somewhat arbitrary and intended for packaging economy and to promote product recognition; it is not a structural feature essential to the spacer when in use. For the same purposes, the bushings could be spaced in any of a number of ways or sold entirely separately from the disc body itself. Further, while three bushings are shown, the only limits to the number possible are set by what is commercially practical—that is, there are only so many different sizes of fasteners used in construction for connecting the structural members of decks to structural framing members. 
     When in use, the builder simply selects a keyed bushing adapted to fit the primary and secondary fasteners of his or her choice, installs the appropriate center keyed bushing, and orients the disc body with the countersink/counterbore on the outboard side of the spacer (the side facing away from the member to which the spacer will first be secured). 
     Referring next to  FIG.  6   , there is shown in a front elevational view an alternative embodiment  60  of the inventive apparatus, here showing that the swappable keyed bushing can be provided with an integral surface feature structure that cooperates with a complementary surface feature  62  on the interior wall  64  of the center hole  66  (the latter surface feature not shown). For instance, each of the variable bushings  68 ,  70 ,  72  may include a low profile circumferential (equatorial) ridge  68   a ,  70   a ,  72   a  disposed about the surfaces of each of the annular bushing body portions  68   b ,  70   b ,  72   b . The ridge dimensions are sized for a snap-fit coupling with a female channel or groove  64  circumferentially disposed around the interior wall of the center hole and sized to fit all of the variably sized bushings. 
     Note should be made that because the deck spacer is screwed to the ledger, the spacer engages the primary fastener as the ledger deflects from vertical loads placed on the deck. The spacer, being harder than the wood, increases the load capacity of the connection by effectively increasing the side member thicknesses and dowel bearing strengths of the side members. For this reason, it is critical that the center hole of the bushing be properly sized to the diameter of the fastener and thus why having a selection of center hole bushings is particularly advantageous. 
       FIG.  7    is a cross-sectional side view showing the inventive deck spacer installed in a stacked configuration  80 . This constitutes a new method for stacking spacers while maximizing load bearing capacity, which is accomplished by: (1) temporarily attaching the ledger in the desired location; (2) drilling pilot holes through ledger and into supporting structure; (3) centering one (or more) spacers over the pilot holes on the ledger and installing secondary fasteners through spacer(s) and into the ledger as typically installed; (4) centering one or more spacers over pilot holes in the supporting structure and installing with secondary fasteners through the spacer(s) and into the supporting structure. The connection is then completed with a primary fastener. When completed, this combination features first and second stacked spacers  82 ,  84 , the first  82  screwed directly to the ledger L with suitably sized secondary fasteners  86 , the second  84  attached to the building framing member FM through siding S (shown generically to cover the myriad kinds contemplated), also using suitably sized secondary fasteners  88 . A primary fastener  90 , such as a lag screw or bolt is employed to complete this stacked spacer assembly. As will be appreciated, sealant is advantageously employed between each spacer and the wood structure to which it is attached. 
     This method doubles the penetration of the secondary fasteners and effectively increases the thickness and dowel bearing strength of the mains and side members. This also minimizes primary fastener deflection and increases the load bearing capacity of the connection. This is useful in stucco and exterior foam sheathing applications where extra distance is needed for clearance between the ledger and the supporting structure framing. 
     Referring next to  FIGS.  8  through  10   , there is illustrated another embodiment of the inventive deck spacer described above. It may be referred to herein as a “coupling spacer,” and it may be used either instead of, or in conjunction with, the earlier described embodiment of the deck spacer, as it is provided with surface features that enhance coupling strength and improved resistance to sheer forces when installed. The coupling spacer is generally denominated  110  herein. 
     As with the earlier described embodiment, this alternative embodiment includes a generally cylindrical low-profile disc body  112  having a circular circumferential outer side  114 . Again, the cylindrical/circular geometry is not essential, and the disc body could take other shapes. Dimensions are essentially identical to the deck spacer. 
     Each of the front side  116  and the back (rear) side  118  are substantially planar, though each side is characterized in having nearly mirror image pluralities of depressions, recesses, wells, and through holes, and as will be discussed more fully below, the front side includes elevated perimeter rims around the adhesive/sealant cavities. 
     The coupling spacer includes a center hole  120  having one or more radially-extending voids or spokes  122  which function as the female elements for a keyed bushing (to be described more fully below). In embodiments, a single spoke may be employed, as it alone may be sufficient when cooperating with a male bushing element to prevent rotation and translation of the bushing, or a plurality of spokes may be provided in an evenly spaced arrangement, e.g., three spokes at roughly 120 degrees apart, as shown in the view. The selection of the number and placement of the “negative” keying element is non-limiting. 
     The disc front and rear sides next include through holes  124  for secondary fasteners. These holes have a substantially smaller inner diameter than the center hole, and on each side they include countersunk or a counterbored holes comprising a recess which is shaped and sized to fit the head of a fastener such that the surface of the fastener head sits flush with the front or rear surfaces,  116   s ,  118   s , respectively, of the disc when fully tightened. 
     Advantageously, the countersinks/counterbores may be of different sizes and configurations,  126   a ,  126   b ,  126   c ,  126   d , adapted to fit most commonly used deck screws, hex head bolts, and other fasteners. 
     Next, the coupling spacer includes adhesive/sealant cavities or wells— 128   a ,  128   b ,  128   c  on the front side—and  128   a N,  128   b N,  128   c N on the rear side. The purpose and function, as described above, is to provide a recess for containing a flowable sealant or adhesive. The bonding surfaces are at the bases of the wells  130   a ,  130   b ,  130   c ,  130   a N,  130   b N,  130   c N and sides  132   a ,  132   b ,  132   c ,  132   a N,  132   b N,  132   c N to contain and constrain the adhesive such that it does not migrate between the front or rear surfaces  134 ,  136  of the spacer and thereby get between the spacer and the structural element to which the spacer is attached. 
     In embodiments, the coupling spacer includes three distinct center keyed bushings  140 ,  142 ,  144 , having variously sized through holes  140   a ,  142   a ,  144   a , and a plurality of radiating male spokes sized and spaced for complementary insertion into the center hole  120  and the female voids  122  disposed around the peripheral of the center hole. 
     As noted,  FIGS.  8 - 10    show an alternative embodiment of the deck spacer, i.e., a coupling spacer, and in this embodiment the coupling features relate to male elements  150   a ,  150   b ,  150   c , which comprise elevated perimeters (raised projections) that extend upwardly from the coupling spacer surface  116   s  and are sized to insert snugly but readily into the larger well openings  28   a ,  28   b ,  28   c  on the front side  16  of the deck spacer  10  or a complementary coupling spacer. When coupling to the deck spacer, the front side of the coupling spacer is approximated to the front side of the deck spacer and the male elements inserted into the well openings of the deck spacer. When the lag bolt and secondary fasteners are installed, the compression of the two spacer bodies effectively locks the coupling spacer in its mated connection to the deck spacer. Further, the wells on the coupling spacer also accept adhesive/sealant compound, and thereby contribute to unifying the deck spacer and coupling spacer, whereby shear strength is substantially increased. 
       FIGS.  8 - 10    also show the keyed bushings coupled to the outer side  114  (the periphery) of the disc body  112 . Three bushings are once again shown, but there is no specific number of bushings essential to the inventive apparatus, and commercial practicality will inform manufacture and sales. 
     Referring now to  FIGS.  11 - 14   , there is shown a reinforced shim  160 , which cooperates with the deck spacer or coupling spacer to provide a spacing system or an options kit for increasing spacing between a ledger board and a structural member. Some deck installations call for slight increases in the ledger board gap, and the reinforcing shim includes male projections,  160   a ,  160   b ,  160   c , on its front side  162 , which insert into the larger wells on either the deck spacer  10  or the coupling spacer  110 . When so inserted, the reinforced shim increases the spacing between the ledger board and structural member and provides a planar rear surface  164  to engage either. It further includes through holes  166  that align with the through holes  24  on the deck spacer or the through holes  124  on the coupling spacer so as to pass secondary fasteners selected according to the countersink provided. Likewise, the center hole  168  aligns with the center holes  20 ,  120  of either apparatus. Again, the wells formed and defined within the raised projections accommodate adhesive/sealant and thus contribute to unifying the reinforced shim with the spacers and to increasing shear strength when installed. 
     Finally, the board spacing options kit next includes selective use of a reinforcing coupler  180 , which essentially duplicates the features of the reinforced shim, but for the inclusion of male elements  180   a ,  180   b ,  180   c  on the front side and slightly smaller male elements  190   a ,  190   b ,  190   c  on the rear side  184  of the shim. It further includes through holes  186  for passing secondary fasteners, a center hole  188 . 
     System elements provide flexibility and options in selecting spacer components best fitted for the installation and other construction materials at hand while never compromising structural integrity. 
     The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like. 
     Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims.