Patent Publication Number: US-2022228373-A1

Title: Hidden deck fastener

Description:
CROSS-REFERENCE TO RELATED APPLICATION DATA 
     This application claims the benefit of and priority to Provisional U.S. Patent Application Ser. No. 63/139,355 filed Jan. 20, 2021, titled, IMPROVED HIDDEN DECK FASTENER, the disclosure of which is incorporated herein in its entirety. 
    
    
     BACKGROUND 
     The present disclosure relates to deck fasteners, and more particularly to hidden deck fasteners having improved/greater pull out resistance. 
     Composite materials have become a mainstay of today&#39;s decking systems. These decking systems use fasteners to attach the decking to underlying structural members or joists. Fasteners can include screws, nails, staples or clips. Screws, nails and staples are typically installed directly through the top face of the structural members to the joist below. 
     Securing the decking members to the joists by direct fastening through the top face of the decking has many drawbacks. For example, the fasteners are visible, unattractive and take away from the facade or look of the decking. Fasteners may corrode and discolor the decking members. Fasteners may also become loose. In addition, in installing screws, nails and staples hammer blows to the decking surface may cause damage and/or depressions in the decking. 
     Clips for securing the decking to the underlying joists are also known. In such a system, the decking members have longitudinal grooves or channels formed along sides of the members. 
     Once such clip, referred to as a fastener, disclosed in Orchard, U.S. Pat. No. 9,181,715, and commonly assigned with the present application, includes a pi (II) shaped body having a top horizontal portion and a pair of integrally formed spaced apart vertical legs that extend downwardly from the horizontal portion. A space is defined between the legs, and the legs are inwardly compressible (toward each other) in response to a side force. The top portion has raised ribs for frictionally engaging the decking members. The clip has a bore through the top portion about mid-way along the length and width that aligns with the space between the legs. The bore has a countersink in the top surface. 
     The clip is inserted into the grooves of adjacent decking members and is secured to the underlying joist by a countersink-headed fastener to secure the fastener and the decking to the underlying joist. Such clips are advantageous in that they are hidden—positioned between decking members—and as such, fasteners are not installed in the surface of the decking members. 
     While such clips function well, it has been found that a clip can pull out of the fastener. That is, the fastener remains in the underlying joist, but the clip pulls out, over the head of the fastener. As such, the clip no longer functions to secure the decking to the underlying joist. 
     Accordingly, there is a need for a clip to secure decking that is hidden on installation. Desirably, such a clip has a high pull-out strength. Ore desirably still, such a clip grips the adjacent decking members preventing transverse movement, but allowing longitudinal movement for expansion and contraction of the members. 
     SUMMARY 
     In one aspect an embodiment of a hidden deck fastener has a II-shaped body having a top portion having a thickness, a top surface and a bottom surface, and an integrally formed leg extending transversely, downwardly from the bottom surface. The leg is spaced inwardly from sides of the top portion and defines channels formed in opposing sides or edges thereof. The channels can be formed having enlarged regions inwardly of ends thereof. 
     A stepped fastener receiving opening is formed in the top portion and the leg. The opening has a first region formed into a least a part of the thickness of the top portion and a second region aligned and contiguous with the first region extending through the leg. The first region is a counterbore having straight sides terminating at a flat bottom surface at the second region. 
     The channels in the legs extend toward and are spaced from the fastener receiving opening second region. The fastener has a pull-out force resistance at least 50 percent greater than a comparable fastener having a countersink fastener receiving opening. 
     In embodiments, the fastener further includes ridges formed on the top surface and/or the bottom surface of the top portion. In a current embodiment the ridges are formed on the bottom surface of the top portion. 
     In embodiments, the fastener receiving opening first region has a diameter about 2 times a diameter of the second region. The first region can be is formed in the top portion less than the thickness of the top portion. 
     In an aspect, the fastener includes a threaded fastener having a shank and a head. The head has a flat bottom surface to engage the flat bottom surface of the fastener receiving opening first region. 
     In another aspect, in combination is a hidden deck fastener and a threaded fastener. The hidden deck fastener has a H-shaped body having a top portion having a thickness, a top surface and a bottom surface, and an integrally formed leg extending transversely, downwardly from the bottom surface. 
     The leg is spaced inwardly from sides of the top portion and defines channels formed in opposing sides or edges thereof. 
     A stepped fastener receiving opening is formed in the top portion and the leg. The stepped fastener opening has a first region formed into a least a part of the thickness of the top portion and a second region aligned and contiguous with the first region extending through the leg. The first region is a counterbore having straight sides terminating at a flat bottom surface at the second region. 
     The channels in the legs extend toward and are spaced from the fastener receiving opening second region. 
     The threaded fastener has a shank and a head. The head has a flat bottom surface to engage the flat bottom surface of the fastener receiving opening first region. 
     The fastener has a pull-out force resistance at least 50 percent greater than a comparable fastener having a countersink fastener receiving opening. 
     In an embodiment, the fastener receiving opening first region has a diameter about 2 times a diameter of the second region. The first region is formed in the top portion less than the thickness of the top portion. 
     In yet another aspect a decking and fastener system includes a decking member having an upper surface, a lower surface, and a side wall extending between the upper and lower surfaces. The side wall has a groove formed therein. 
     A hidden deck fastener has a H-shaped body having a top portion having a thickness, a top surface and a bottom surface, and an integrally formed leg extending transversely, downwardly from the bottom surface. The leg is spaced inwardly from sides of the top portion defining wings in the top surface. The leg defines channels formed in opposing sides or edges thereof. 
     A stepped fastener receiving opening is formed in the top portion and the leg. The stepped fastener opening has a first region formed into a least a part of the thickness of the top portion and a second region aligned and contiguous with the first region extending through the leg. The first region is a counterbore having straight sides terminating at a flat bottom surface at the second region. 
     The channels in the legs extend toward and are spaced from the fastener receiving opening second region. 
     The hidden deck fastener is positioned adjacent the decking member with a wing positioned in the decking member groove and a threaded fastener having a shank and a head having a flat bottom surface is driven into the hidden deck fastener such that the flat bottom surface of the head engages the flat bottom surface of the fastener receiving opening first region. 
     The fastener has a pull-out force resistance at least 50 percent greater than a comparable fastener having a countersink fastener receiving opening. 
     In an embodiment, the fastener receiving opening first region has a diameter about 2 times a diameter of the second region. The first region is formed in the top portion and can extend less than the thickness of the top portion. 
     In embodiments, the hidden deck fastener further includes ridges formed on the upper and/or lower surface of the top portion. In an embodiment, the ridges are formed on the lower surface. 
     Further understanding of the present disclosure can be obtained by reference to the following detailed description in conjunction with the associated drawings, which are described briefly below. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       An embodiment of a hidden deck fastener or clip is disclosed as an example and is not limited by the figures of the accompanying drawings, in which like references may indicate similar elements and in which: 
         FIG. 1  is a top perspective view of an embodiment of a hidden deck fastener of the present disclosure; 
         FIG. 2  is a bottom perspective view of the fastener; 
         FIG. 3  is a top view of the fastener; 
         FIG. 4  is a bottom view of the fastener; 
         FIG. 5  is a side view of the fastener; 
         FIG. 6  is a sectional view of the fastener taken along line  6 -- 6  of  FIG. 5 ; 
         FIG. 7  is an end view of the fastener installed between a pair of panels and into a joist; 
         FIGS. 8A and 8B  are force versus time curves from pull-out testing of the known clips ( FIG. 8A ) and the present clips ( FIG. 8B ); 
         FIGS. 9A and 9B  are illustrations reproducing photographs of the known clips ( FIG. 9A ) and the present clips ( FIG. 9B ) following pull-out testing; and 
         FIG. 10  is an example of a fillister head wood screw for use with the fastener. 
     
    
    
     DETAILED DESCRIPTION 
     While the present disclosure is susceptible of embodiments in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification and is not intended to limit the disclosure to the specific embodiment illustrated. 
     Referring now to  FIGS. 1 and 2 , there is shown a top perspective view embodiment of an embodiment of a hidden deck fastener or clip  10  (referred to herein as “clip”). The clip  10  has a pi (II) shaped body  12 , and includes a top portion  14  having wings  16  and a centrally located fastener receiving hole  18 . In the illustrated embodiment the top portion  14  is rectangular in shape in which the wings  16  are configured for insertion and retention in groove(s)  22  of decking member(s)  24 . Cut-outs  26  are formed in the short sides  28  of the top portion  14  that are angular in shape. In an embodiment, the cut- 26  outs extend through the top portion  14 . It will be appreciated that the top portion  14  may be of any of a variety of suitable shapes, such as a circle, oval, biscuit or the like. 
     The fastener receiving hole  18  is located in the top portion  14 , and in an embodiment, the receiving hole  18  is located in a longitudinal and transverse center of the top portion  14 . 
     A leg  30  extends downwardly and depends from a lower surface  32  of the top portion  14 . In an embodiment, the leg  30  is located in a transverse center of the top portion  14 , and the fastener receiving hole  18  extends into and through the leg  30 . On either side of the hole  18 , the leg  30  include channels  34 . The channels  34  extend inwardly from ends  36  of the legs  30 , toward by not into the fastener receiving hole  18 , and form bifurcations  38  in each end  36  of the leg  30 . A portion of each channel  34  is enlarged as indicated at  40 . The channels  34  extend up to about the lower surface  32  of the top portion  14 . 
     In embodiments, the lower surface  32  of the top portion  14  includes a series of ribs or ridges  42  that extend downwardly from the lower surface  32 . The ridges  42  facilitate securing the clips  10  to the decking members  24  as will be described below. 
     In a current embodiment, the fastener receiving hole  18  is a stepped hole having first or upper region  18   a  and a second or lower region  18   b . In an embodiment, the first region  18   a  is formed into a portion of the top portion  14 . That is, the first region  18   a  is formed into a portion of the thickness of the top portion  14 . The second region  18   b  is aligned and contiguous with the first region  18   a  and in an embodiment extends through a portion of the top portion  14  and through the leg  30 . 
     As seen in  FIGS. 1, 3 and 6 , the first region  18   a  has a cylindrical bore profile, or is a counterbore into a portion of the top portion  14 . The second region  18   b  is a continuation of a portion of the diameter d 18a  of the first region  18   a  (the counterbore). 
     The present deck fastener or clip  10  can be formed from a wide variety of materials. Suitable materials include polymeric material such as polypropylene and the like. Other suitable materials will be recognized by those skilled in the art. 
     In an embodiment, the clip  10  has a top portion length l 14  of about 1.5 inches, a width W 14  of about 0.75 inches and a depth or thickness t 14  of about 0.135 inches. The depth or thickness corresponds to the height h 22  of the longitudinal grooves or channels  22  formed in the sides of the decking members  24 . 
     The ridges  42  on the top portion lower surface  32  extend from the lower surface  32  about 0.025 inches. The leg  30  has a length l 130  of about 1.0 inches, a height h 30  of about 0.39 inches and a width W 30  of about 0.163 inches. The fastener receiving hole first region  18  a has a diameter d 18a  of about 0.25 inches and a depth t 18a  into the top portion  14  of about 0.095 inches. The second region  18   b  has a diameter d 18b  of about 0.125 inches. 
     The clip  10  is secured in place using a fastener  46  having a head  48  having a flat bottom  50 , such as the illustrated filister head wood screw (see,  FIG. 10 ), a cap head, a hex washer head or the like. 
     In use, referring to  FIG. 7 , the clip  10  is positioned between two decking members  24  with the top portion wings  16  positioned in the side wall grooves  22  of adjacent members  24 . It is anticipated that the bottom of the leg  30  will rest on a supporting structure, such as a floor joist  52 . The ridges  42  on the lower surface  32  of the top portion  14  will hold the clip  10  in place. The fastener  46  is positioned in the fastener receiving hole  18  and is driven into the structure or joist  52  to fasten the clip  10  and decking member(s)  24  to the structure or joist  52 . 
     After installation the decking members  24  may expand and contract across their widths as a result of changes in the weather (temperature, humidity and precipitation) and as such, exert transverse or sideway forces on the leg  30 . The channels  34  allow for inward movement or compression of portions of the leg  30  to accommodate expansion of the members  24 . As the decking members  24  contract, the leg  30  returns to its initial shape. 
     The decking members  24  may also expand and contract along their lengths. To prevent excessive longitudinal movement of the members  24 , an embodiment of the clip  10  includes the ribs or ridges  42  that serve as frictional elements to allow but limit longitudinal (lengthwise) movement of the decking members  24 . While the ridges  42  are shown on the lower surface  32  of the clip  10 , they can be on the lower or upper, or both surfaces of the clip  10 . These frictional elements can be ribs or ridges  42  as shown, fingers, raised protrusions or like elements. 
     Tests were conducted to compare the pullout force required to pull clips from their fasteners and the decking members. The tests compared the present clips to known clips such as those disclosed in the aforementioned patent to Orchard. Ten samples of each the present clip and the known clip were tested to determine the pull-out required to pull the clip from a fastener. 
     The known clips were secured in a test rig using #7-10 1-⅝ trim head wood screws. The present clips were secured in the test rig using #7-10 1-⅝ fillister head wood screws. The tests were conducted at a temperature of 24° C. (75.2 ° F.). The pull-out force was measured in kilo-newtons (KN) and pounds-force (lbf). The results of the test are shown in Table 1 below. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Comparison of Pull-Out Force for Known Clips and Present Clips 
               
            
           
           
               
               
               
               
            
               
                 Sample # 
                   
                 Sample # 
                   
               
               
                 (known 
                 Pull-out force 
                 (present 
                 Pull-out force 
               
               
                 clips, K#) 
                 (KN/lbf) 
                 clips, P#) 
                 (KN) 
               
               
                   
               
               
                 K1 
                 1.027 KN/230.87 lbf  
                 P1 
                 1.625 KN/365.3 lbf     
               
               
                 K2 
                 1.047/235.37 
                 P2 
                 1.652/371.37 
               
               
                 K3 
                 0.987/221.88 
                 P3 
                 1.562/351.14 
               
               
                 K4 
                 1.107/248.9  
                 P4 
                 1.615/363.05 
               
               
                 K5 
                 0.856/192.43 
                 P5 
                 1.686/379.01 
               
               
                 K6 
                 1.007/226.37 
                 P6 
                 1.717/385.98 
               
               
                 K7 
                 1.029/231.32 
                 P7 
                 1.670/375.42 
               
               
                 K8 
                 1.010/227.05 
                 P8 
                 1.411/317.19 
               
               
                 K9 
                 1.072/240.99 
                 P9 
                 1.724/387.56 
               
               
                 K10 
                 1.035/232.67 
                 P10 
                 1.627/365.75 
               
               
                 Max. 
                 1.107/232.67 
                 Max. 
                 1.724/387.56 
               
               
                 Min. 
                 0.856/192.43 
                 Min. 
                 1.411/317.19 
               
               
                 Avg. 
                 1.018/228.78 
                 Avg. 
                 1.629/366.18 
               
               
                   
               
            
           
         
       
     
     As can be seen from Table 1, the resistance to pull-out of the present clips (represented by the pull-out force required) is significantly greater than the known clips. In every instance, the present clips required a greater pull-out force (showed greater resistance to pull-out) than the known clips. That is, the lowest pull-out force for the present clips (1.411 KN) was greater than the greatest pull-out force for the known clips (1.104 KN). 
     The average pull-out force required for the present clips (1.6291 KN) was 60 percent greater than the average pull-out force required for the known clips (1.018 KN), calculated as ((1.629-1.018)/1.018), and the lowest pull-out force for the present clips (1.411 KN) was almost 34 percent greater than the greatest pull-out force for the known clips (1.104 KN), calculated as ((1.411-1.104)/1.104). 
       FIGS. 8A  and 8B are force vs. time curves generated during the testing, in which  FIG. 8A  is the curve for the known clips and  FIG. 8B  is the curve for the present clips. As can be seen from the figures, there is an almost immediate failure (pull-out) of the known clips at about 5-10 seconds whereas the present clips go well beyond 30 seconds, and over 36 seconds before failure. Again, the curves also show that at about the average failure force of the known clips, all of the present clip samples, were well within their functional range. 
       FIGS. 9A  and 9B are illustrations reproducing photographs of the samples following testing in which  FIG. 9A  is an illustration reproducing a photograph of the known clips and  FIG. 9B  is an illustration reproducing a photograph of the present clips. As can be seen from  FIG. 9A , failure of the known clips was due to pull-out, whereas as seen in  FIG. 9B , failure of the present clips  10  was not due to pull-out; rather, failure of the clips  10  was due to breakage of the clips themselves. 
     Accordingly, it will be appreciated that the present hidden deck fasteners  10  (again, referred to as clips) provide improved securement of decking members  24 , are hidden on installation, and have substantially increased high pull-out strength compared to known decking fasteners. The present clips  10  are easy to install and grip adjacent decking member(s)  24  preventing transverse movement, but allow for limited transverse and longitudinal movement for expansion and contraction of the member(s)  24 . 
     In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. All patents and published applications referred to herein are incorporated by reference in their entirety, whether or not specifically done so within the text of this disclosure. 
     It will also be appreciated by those skilled in the art that any relative directional terms such as side(s), upper, lower, top, bottom, rearward, inboard, forward, outboard and the like may be for explanatory purposes only and may not be intended to limit the scope of the disclosure. 
     From the foregoing it will be observed that numerous modifications and variations can be made without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred.