Patent Publication Number: US-2009217495-A1

Title: Hidden deck fastener

Description:
This is a continuation of Provisional U.S. Patent Application Ser. No. 61/033,217, filed Mar. 3, 2008, the contents of which are incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to devices for adhering a surface structure, usually boards, to underlying sub-structures, such as an apparatus for securing adjacent boards to a large sub-structure consisting of various joists. 
     BACKGROUND OF THE INVENTION 
     Structures, including but not limited to decks, docks, steps, roof decks, ramps, gazebos, pool decks, and platforms can and do use the same substructure technique for the purpose of adhering the surface boards. The technique has many elements, including but not limited to, a substructure made up of posts, beams, joist hangers, joists, header, and fascia boards. The purpose of the substructure is to provide a base to which the horizontal surface, made up typically of boards, is laid down and adhered to. Typically, the boards of a horizontal surface are arranged adjacent to one another, and transversely lay across the joists at an angle sufficient to allow them to rest securely and provide an area to fasten them to the joists. 
     Historically, the surface boards are fastened to the joists using nails or screws. More recently, some surface boards have been fastened to the substructure using hidden fastening devices, sometimes called clips or just hidden fasteners. 
     Screws and nails as a way to adhere surface boards to the substructure have proven to yield several disadvantages when used in the construction of decks. There is a general dislike of the appearance of the resulting pattern of the head portion of fasteners showing across the surface of the deck. In addition, many fasteners are coated in a color that is not consistent with the color of the deck surface boards, creating yet another unappealing aesthetic result. In many cases, regardless of the fastener used, the result of attempting to drive a fastener through the deck surface board and into the substructure results in the head of the fastener not being completely buried or recessed into the wood. Similarly, the inherent shrinkage of wood deck boards due to moisture loss can cause the board to shrink away from the head, causing the same situation. This is not only aesthetically unattractive, etc., it creates a safety hazard and usually results in the necessity to remove the protruding fastener and re-install it, or another fastener in its place, thus requiring additional installation time and costs. 
     Other aesthetic issues that may arise during installation are the marring of the surface when setting the head, mushrooming or splintering of displaced material when driving the fastener into the deck board surface, and creating a large hole when removing an installed or partially installed fastener, the head of which has failed to set below the board&#39;s surface, or failed when one has to install a fastener through the deck surface board and into a knot present in the substructure. Once installed, many fasteners eventually rust, creating discoloration or bleeding onto the deck surface boards. 
     While some current existing hidden fastening devices have been designed in an attempt to solve many of these objections to driven fastener installations, existing designs have other limitations, leaving installers with an unsatisfactory solution. For example, some of these devices require installation from the underside of the deck, which is not always possible depending on the space available under the deck. Some devices are two piece/two step installations which are first attached to the bottom of the deck surface board and then require a subsequent precision placement, resulting in increased difficulty and slower installation. Some devices affix to the top of the joists between the boards and into grooves in a predetermined location on the side of the deck surface boards, thus limiting the flexibility to use the same device in different and multiple manufacturer board profiles. The same limited use drawback presents itself more dramatically in the installation of various pre-grooved boards of varying thickness, such as ¾ inch, 1 inch, 1¼ inch or 1½ inch. Many of these devices which affix to the top of the joists between the boards have, by design, smaller scaled parts and fasteners requiring more effort, precision and patience to accomplish installations. Most devices which affix to the top of joists between the boards require additional surface area for clip placement when two deck surface boards meet end-to-end over one joist. These require an extra “nailer block” effectively doubling the joist surface to allow the use of multiple devices and/or fasteners, increasing project costs and requiring additional installation time. Some hidden fasteners have a pre-determined “built-in” spacer used to force spacing between parallel deck surface boards, and can create spacing which conflicts with the manufacturers&#39; specifications or recommendations. This spacer can create a solid width of multiple deck boards which can buckle when the deck boards thermally expand or when the joists shrink due to moisture loss. Many devices which affix to the top of the joists between the boards limit the size of the fastener available for use, due to the spacing available between parallel deck surface boards. The inability to access and remove these clip fastening screws makes it nearly impossible to replace a deck board without damage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is perspective view of a clip fastener made in accordance with one embodiment of the present invention; 
         FIG. 2  is an edge view of the clip fastener of  FIG. 1 ; 
         FIG. 3  is a side view of the clip fastener of  FIG. 1 ; 
         FIG. 4  is an edge view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 5  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 6  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 7  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 8  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 9  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 10  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 11  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 12  is an edge view of another alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 13  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 14  is another perspective view of the clip fastener of  FIG. 1 ; 
         FIG. 15  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 16  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 17  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 18  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 19  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 20  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 21  is a perspective view of an alternate embodiment of the clip fastener of  FIG. 1 ; 
         FIG. 22  is a plan view of a deck in which the present invention can be used; 
         FIG. 23  is a diagram showing how a clip fastener of the present invention is installed; 
         FIG. 24A  and  FIG. 24B  are elevational and side views, respectively, showing how a clip fastener of the present invention is used; 
         FIG. 25  is another diagram showing how a clip fastener of the present invention is installed; 
         FIG. 26  is a diagram showing where the clip fastener of the present invention might be installed in a deck; 
         FIG. 27  is a diagram showing how a deck is made using the clip fastener of the present invention; and 
         FIG. 28  is another diagram showing the placement of the clip fasteners of the present invention when used at end-to-end deck board joining locations. 
     
    
    
     DETAILED DESCRIPTION 
     As seen in  FIG. 1 , a clip fastener  10  includes a top section  12  having two opposed wings  14 ,  16 , a center section  18  having a vertical spine designed to be installed against the vertical surface of a joist member, and a bottom section  20  with an attachment device such as a barrel that creates an opening  22  to accommodate a fastener (not shown). Spikes  24  can be provided in the center section  18 , if desired, and weep hole(s)  23  can be provided in the bottom section  20 , as shown in  FIG. 3 . 
     As seen in  FIG. 2 , the wings  14 ,  16  can each have a first portion  26  connected at the ends of dual center section spines  28 ,  30 , and second portions  32  extending from the ends of the first portions  26 . The first and second portions  26 ,  32  can have the zigzag configuration shown in  FIG. 2 , or various other configurations, as will be seen. The first and second portions  26 ,  32  and the joint between them are preferably flexible, providing a spring-loaded fit when installed in a groove of a board, which can be made of wood or composite material. 
     In  FIG. 2 , the first portions  26  both extend from respective ends of the spines  28 , 30  towards the bottom section  20 , and the second portions  32  extend from the distal ends of the first portions at an angle to the first portions away from the bottom section  20 . In  FIG. 4 , a left wing  34  includes a first portion  36  that extends from a distal end of the spine  28  towards the bottom section  20 , and a second section  38  that extends from the distal end of the first portion  36  at an angle to the first portion  36  and away from the center section  20 . A second wing  40  on the opposite side of the clip fastener includes a first portion  42  that extends away from a distal end of the spine  30  and away from the bottom section  20 , and a second section  44  that extends from the distal end of the first portion  42  downwardly from the first section  42  at an angle to the first portion  42 , generally towards the bottom section  20 . 
     Similarly, in  FIG. 5 , a left wing  46  includes a first portion  48  extending away from the bottom section  20 , and a second section  50  extending towards the bottom section  20 . A right wing  52  includes a first section  54  extending away from the bottom section  20 , and a second section  56  extending back towards the bottom section  20 . 
     In  FIG. 6 , a left wing  58  includes a first portion  60  extending towards the bottom section  20 , and a second section  62  extending generally away from the bottom section  20 . A right wing  64  has a first portion  66  extending towards the bottom section  20  and a second portion  68  extending away from the bottom section  20 . 
     In  FIG. 7 , a left wing  70  has a first portion  72  extending perpendicularly away from the end of the center section  18  opposite the bottom section  20 , and a second section  74  which extends towards the bottom section  20 , and is curved to then extend towards the first section  72 . A right wing  76  includes a first section  78  that extends away from the end of the center section  18  in a generally perpendicular direction, and a second section  80  which extends away from the distal end of the first section  78  at an oblique angle to the center section  18 , curves and then extends back towards the first section  78 . 
     In  FIG. 8 , a left wing  82  extends outwardly from the center section  18  and away from the bottom section  20 , and curves downwardly away from the center section  18 , but generally towards the bottom section  20 . A right wing  84  is a mirror image of the left wing  82 . 
     In  FIG. 9 , a left wing  86  extends away from the distal end of the center section  18  generally downwardly towards the bottom section  20 , and then curves upwardly away from the bottom section  20 , still extending away from the center section  18 . A right wing  88  is a mirror image of the wing  86 . 
     In  FIG. 10 , a left wing  90  includes a first section  92  that extends in a generally perpendicular direction away from the distal end of the center section  18 . A second portion  94  extends generally perpendicular to the first section  92 , and a third section  96  extends generally perpendicular to the second section  94 , towards the center axis of the center section  18 . A right wing  98  is a mirror image of the left wing  90 , and includes a first portion  100 , a second portion  102  and a third portion  104 . 
     In  FIG. 11 , the center section  18 A has a single spine, not the double spines of the center portions  18  in the other figures. An end portion  106  has a continuous piece extending from an end of the center section  18 A which is distal from the bottom section  20 . The end section  106  includes a first wing  108  having a first portion  110  extending perpendicularly from the distal end of the center section  18 A to the left, a second portion  112  and a third portion  114  which form the left wing  108 . A fourth portion  116 , a fifth portion  118 , a sixth portion  120  and a seventh portion  122  from the right wing. The seventh portion  122  is bent, as shown. The left and right wings are continuous with each other. 
     In  FIG. 12 , a left wing  124  has a first portion  126  extending from the distal end of the spine  28  away from the center section generally perpendicular to the center section. A second portion  128  extends from the distal end of the first portion  126  back towards the spine  28 . A third portion  130  extends from the distal end of the distal end of the second portion  128 . A second wing  132  includes a first portion  134 , second portion  136  and a third portion  138 , and is a mirror image of the left wing  124 . 
     The clip fasteners of the present invention can be fabricated in several ways, as seen in  FIGS. 13-21 . 
     The clip fastener in  FIG. 13  is similar to the clip fasteners in  FIGS. 1 and 6 . The clip fastener is formed of a single piece of metal or other suitable material, the center section  18  having two parallel spines  28 ,  30 , and a substantial width W. The opening  22  is oriented in the direction of the width W of the center section  18 , and generally perpendicular to outward edges  12 A and  12 B of the wings. The wings extend out generally perpendicular to the center of the opening  22  and generally perpendicular in a direction B to a center axis A of the center section ( FIG. 2 ). The clip fastener in  FIG. 14  is similar to the clip fastener in  FIG. 13 , but has spikes in the center section. In  FIG. 15 , the bottom section  20  and part of the center section  18  are formed of molded plastic, and metal wings or wings made of other material are placed in the plastic. 
     In  FIG. 16 , the clip fastener is made of wire, not sheet metal, as in the other figures. In  FIG. 17 , the clip fastener is made of wire, but the wings have a depth similar to the wings in  FIG. 13 , for example. Also, the clip fastener in  FIG. 17  has a spike or nail  140  which can be hammered into a joist during installation. In  FIG. 18 , the fastener is similar to the fastener in  FIG. 15 , but the wings are made of wires, and part of the center section is solid. 
     In  FIG. 19 , the center section is made from sheet metal, and is of one piece construction with a single spine in the center section. The center section runs generally perpendicular to the wings. In  FIG. 20 , a spike  142  is provided in place of the fastener opening seen in  FIG. 19 . In  FIG. 21 , the bottom and center sections are made of plastic or other suitable material, and sheet metal wings are inserted in the sides of the plastic. 
     The manner in which the fasteners of the present invention are installed in decks and used to secure deck boards to joists will now be described. 
     The clip fasteners of the present invention can be used for outdoor decks, as shown in  FIG. 22 . In  FIG. 22 , a deck  200  located adjacent a home  202  has a plurality of spaced joists  204 . Deck boards  206  (two shown in  FIG. 22 ) run generally parallel to the long dimension of the deck, and preferably begin at a long edge  208 . Additional boards  206  are installed adjacent one another across the joists  204 , typically using a gapping device. 
     The boards have grooves  210  spaced along their inside edges, as seen in  FIG. 23 . The grooves  210  can be made by the factory, or at the work site. Any suitable vertical groove location may be used, but a groove of ⅛ inch to 3/16 inch thickness in a minimum groove depth of about ⅜ inch is preferable to insure proper installation. 
     The first board  206  is installed with screws  207  on one side ( FIG. 22 ), with a wing edge  212  of a clip fastener  214  placed in the groove  210 , as shown in  FIG. 23 . If the fastener has spikes, the spiked side of the clip should face the joist. The clip is then pushed downward in the direction of arrow  215  and toward the deck board until it is aligned with its center section in a generally vertical position adjacent a vertical surface  217 , as seen in  FIGS. 24A and 24B . 
     The wing of the clip are shaped to insure a snug fit between the top and bottom of the board&#39;s groove. However, some bending of the clip, at the wing or backbone structure, is normal. 
     After the right wing  212  in  FIG. 23  is inserted in the groove  210  in  FIG. 24A , the clip is rotated in the direction of arrow  218  until the clip  214  is aligned generally perpendicular to the top surface of joist  204 . A suitable screw  216  or other fastening device is then driven through the opening of the clip, as seen in  FIG. 24B  and  FIG. 25 . The spiked side of the clip should imbed itself slightly into the side of the joist  204  when the screw is secured. 
     One clip  214  is then secured at selected (preferably all) inner joist groove locations, as seen in  FIG. 26 , on either side of the joists, insuring that maximum fastener spans, as applicable by building codes, are not exceeded. After installation of the fasteners, a gapping tool (not shown) can be used between the installed board  206  and the next board  206  to be installed. The next board  206  can be held at a slight upward angle and positioned with its grooved side over the protruding left wing of the installed clips, as shown in  FIG. 27 . The deck board is pushed toward the clip (arrow  218 ) and down (arrow  220 ), onto the joist structure. This process is repeated until the entire deck is surfaced. The last board is installed with screws, through its face at the outer edge, as with the first board. Screws  207  can also be used at the ends of the boards, as seen in  FIG. 26 . 
     Boards ( 222 ,  224 ) that do not extend across the entire surface of the deck can be butt-jointed, as seen in  FIG. 28 , by placing a clip ( 214 ) on either side of the joist ( 204 ) over which the two deck boards overlap. The deck boards can be placed at a 45° angle to the framing structure, if desired, by cutting a small triangular piece of decking to fit in a corner of the deck framing structure, with its grooved side providing the desired angle. 
     While the principles of the invention have been described above in connection with specific apparatus and applications, it is to be understood that this description is made only by way of example and not as a limitation on the scope of the invention.