Patent Publication Number: US-6902366-B2

Title: Sealable fastener with circumferential sealant channel and sealant delivery groove for delivering sealant into the circumferential sealant channel

Description:
FILING HISTORY 
   This application is a based in part upon the disclosure contained within disclosure document number 495,287 filed on Jun. 13, 2001, and a continuation-in-part of application Ser. No. 09/931,697, filed on Aug. 15, 2001, now abandoned, and a divisional of application Ser. No. 09/982,400 filed on Oct. 18, 2001, and issuing into U.S. Pat. No. 6,604,899 on Aug. 12, 2003. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to the field of fasteners such as bolts, screws, rivets and nails. More specifically the present invention relates to a sealable fastener including a fastener shank having a shank first end for engagement by a fastener insertion tool and having a shank second end for embedding into a receiving structure, the shank first end having a shank first end wall and the shank second end having a shank second end wall; a longitudinal shank side wall and a continuous, fully circumferential channel recessed into the shank side wall; and including a longitudinally extending sealant delivery groove in the shank side wall for delivering sealant into the circumferential channel. For applications in which the fastener bore in a receiving structure terminates within a solid portion of the receiving structure, such as a boat hull, a first embodiment is provided in which the sealant delivery groove has a groove entry port in the shank second end and extending longitudinally to a groove exit port opening into the circumferential channel. A seal confirmation passageway which may be in the form of a groove is optionally provided which extends from a confirmation passageway enter port in the circumferential channel to the shank first end where it opens out of a confirmation passageway exit port. 
   Sealant is first injected into a fastener bore. Then the fastener shank is screwed, driven or slid into the fastener bore so that the shank second end bears against and compresses the sealant within the fastener bore so that the sealant is forced into the sealant delivery groove and flows through the sealant delivery groove and into and around the circumferential channel, creating a circumferential seal between the fastener shank and the receiving structure so that water or other liquid cannot flow around the fastener shank and through the receiving structure. 
   Where absolute confirmation of a complete seal is required, the seal confirmation passageway, which is in the form of a bore or a groove, is provided. After sealant flows from the sealant delivery passageway and around the circumferential channel, the s alant flows out of the circumferential channel into the confirmation passageway entry port and along the seal confirmation passageway until the sealant is exposed at or exits from a confirmation passageway exit port in the shank first end. 
   2. Description of the Prior Art 
   There have long been fasteners having fastener shanks for extending into and interconnecting multiple discrete fastener receiving structures. These prior fasteners have included bolts, screws, rivets, pins and nails. A problem with these prior fasteners has been that no truly effective means has been provided for creating a seal between the shank of the fastener and the receiving structure to reliably prevent liquid from flowing along the shank from one side of the receiving structure to the other. This problem is particularly noteworthy in the marine industry and is probably the most common cause of leakage in boat hulls. 
   It is thus an object of the present invention to provide a fastener which includes a shank for passing into a receiving structure including means in the form of a longitudinal sealant delivery groove in the shank side wall for reliably delivering flowable sealant circumferentially around the shank, preferably into a circumferential channel, creating a circumferential seal between the shank and the receiving structure, thereby preventing flow of liquid along the shank and through the receiving structure. 
   It is another object of the present invention to provide such a fastener which may take any conventional form, such as a bolt, screw, rivet, pin or nail. 
   It is still another object of the present invention to provide such a fastener which is inserted into a receiving structure in the same way and with the same tool or tools used to insert an otherwise similar fastener, and through which a flowable sealant can be rapidly, easily and reliably delivered. 
   It is finally an object of the present invention to provide such a fastener which is relatively inexpensive to manufacture and to install in a receiving structure. 
   SUMMARY OF THE INVENTION 
   The present invention accomplishes the above-stated objectives, as well as others, as may be determined by a fair reading and interpretation of the entire specification. 
   A sealable fastener is provided for insertion into an fastener opening in a receiving structure, the sealable fastener including a fastener shank including a shank first end having a shank first end wall and a shank second end having a shank second end wall, a shank side wall extending between the shank first end wall and the shank second end wall and a circumferential channel recessed into the shank side wall; and a sealant delivery groove in the shank side wall having a delivery groove entry port in the shank second end and extending to a delivery groove exit port opening into the circumferential channel; so that a flowable sealant placed in the fastener opening is drivable into the delivery groove entry port as the fastener shank is inserted into the fastener opening, so that the sealant flows through the sealant delivery groove and exits through the delivery groove exit port and flows into and around the circumferential channel, creating a circumferential seal between the fastener shank and the fastener opening in the receiving structure. 
   A sealable fastener is additionally provided for insertion into an opening in a receiving structure, the sealable fastener including a fastener shank including a shank first end having a fastener head and a shank first end wall, and a shank second end having a shank second end wall, a shank side wall extending between the shank first end and the shank second end and a circumferential channel in the shank side wall extending to one of the fastener head and the shank second end; a sealant delivery groove in th shank side wall having a delivery groove entry port in the shank second end and extending to a delivery groove exit port opening into the circumferential channel; and a seal confirmation groove including one of a radial notch and a confirmation passageway in the fastener head opening out of the shank first end; so that a flowable sealant placed in the fastener opening is drivable into the delivery groove entry port as the fastener shank is inserted into the fastener opening, and so that the sealant flows through the sealant delivery groove and exits through the delivery groove exit port and flows into and around the circumferential channel, creating a circumferential seal between the fastener shank and the opening in the receiving structure, and then flows to the shank first end through the seal configuration groove to become visible at the shank first end and thus to indicate that a complete seal has been achieved. 
   A sealable fastener is still additionally provided for insertion into an fastener opening in a receiving structure, the sealable fastener including a fastener shank including a shank first end having a shank first end wall and a shank second end having a shank second end wall, a shank side wall extending between the shank first end wall and the shank second end wall and a circumferential channel recessed into the shank side wall; and a sealant delivery groove in the shank side wall having a delivery groove entry port in the shank first end and extending to a delivery groove exit port opening into the circumferential channel; so that a flowable sealant is injectable into the delivery groove entry port, so that the sealant flows through the sealant delivery groove and exits through the delivery groove exit port and flows into and around the circumferential channel, creating a circumferential seal between the fastener shank and the opening in the receiving structure. 
   A sealable fastener is yet additionally provided for insertion into an opening in a receiving structure, the sealable fastener including a fastener shank including a shank first end having a fastener head and a shank first end wall and a shank second end having a shank second end wall, a shank side wall extending between the shank first end wall and the shank second end wall and a circumferential channel in the shank side wall extending to one of the fastener head and the shank second end; a sealant delivery groove in the shank side wall having a delivery groove entry port in the shank first end and extending to a delivery groove exit port opening into the circumferential channel; and a seal confirmation groove having a confirmation groove entry port in the circumferential channel and extending to a confirmation groove exit port in the shank first end; so that a flowable sealant is injectable into the delivery groove entry port, so that the sealant flows through the sealant delivery groove and exits through the delivery groove exit port and flows into and around the circumferential channel, creating a circumferential seal between the fastener shank and the opening in the receiving structure; and so that the sealant flows from the circumferential channel into the confirmation groove entry port, and then flows to the shank first end through the seal confirmation groove to become visible at the shank first end and thus to indicate that a complete seal has been achieved. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion taken in conjunction with the following drawings, in which: 
       FIG. 1  is a side view of a fastener having the sealant channel and shank second end delivery passageway and the seal confirmation passageway of the first embodiment. 
       FIG. 2  is a cross-sectional side view of the fastener of  FIG. 1 , revealing the sealant delivery passageway and seal confirmation passageway.  FIG. 2   a  is a cross-sectional view of the shank of the fastener of  FIG. 2 , taken along line  2   a — 2   a.    
       FIG. 3  is a side view as in  FIG. 1  of a double channel embodiment of the fastener. 
       FIG. 4  is a cross-sectional side view of the fastener of  FIG. 3 , revealing the sealant delivery and seal confirmation passageways. 
       FIG. 5  is a cross-sectional side view of the open ended channel embodiment of the inventive fastener fit through bores in two abutting receiving structures, showing flowable sealant being injected by the nozzle of an adhesive gun and circumferentially filling the open ended channel to create a seal. 
       FIG. 6  is a side view of a fastener having the sealant circumferential channel and shank second end delivery groove and the seal confirmation groove and passageway of the first embodiment. 
       FIG. 7  is a cross-sectional side view of the fastener of  FIG. 6 , revealing the sealant delivery groove and seal confirmation groove and passageway.  FIG. 7   a  is a cross-sectional view of the shank of the fastener of  FIG. 7  taken along line  7   a — 7   a,  showing the sealant delivery groove.  FIG. 7   b  is a cross-sectional view of the shank of the fastener of  FIG. 7  taken along line  7   b — 7   b,  showing the groove portion of the seal confirmation groove-passageway.  FIG. 7   c  is a cross-sectional view of the shank of the fastener of  FIG. 7  taken along line  7   c — 7   c,  showing the bore portion of the seal confirmation groove-passageway. 
       FIG. 8  is a side view as in  FIG. 6  of a double channel embodiment of the fastener. 
       FIG. 9  is a cross-sectional side view of the fastener of  FIG. 8 , revealing the segmented sealant delivery groove and seal confirmation groove and passageway. 
       FIG. 10  is a cross-sectional side view of the open ended channel, extending from the passageway exit port to the fastener head. 
       FIG. 11  is a cross-sectional side view of the second embodiment, in which sealant is delivered from the shank first end and in which most of the sealant delivery passageway is replaced with a longitudinal sealant delivery groove, the sealant delivery groove being broken at the first circumferential channel into a diametrically opposed segment.  FIG. 11   a  is a view as in  FIG. 11  showing the fastener with the optional confirmation passageway and showing the fastener screwed into a fastener opening in a receiving structure. 
       FIG. 12  is a cross-sectional side view of the open ended channel, extending from the shank second end to a point beyond the interface between two receiving structures being interconnected by the inventive fastener. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
   Reference is now made to the drawings, wherein like characteristics and features of the present invention shown in the various FIGURES are designated by the same reference numerals. 
   First Preferred Embodiment 
   A first embodiment is provided primarily for applications in which a fastener bore B in a receiving structure terminates within the receiving structure, such as a boat hull. The receiving structure may be a composite receiving structure including a proximal receiving structure R 1  through which a segment of fastener bore B passes completely and a distal receiving structure R in which the remainder of fastener bore B penetrates and then terminates. Referring to  FIGS. 1-4 , a sealable fastener  10  is disclosed including a fastener shank  20  having a shank first end  22  for engagement by a fastener insertion tool and having a shank second end  26  for embedding into a receiving structure R, the shank first end  22  having a shank first end wall  24  and the shank second end  26  having a shank second end wall  28 ; a longitudinal shank side wall  32  and a continuous; fully circumferential channel  40  recessed into the shank side wall  32 ; and including a sealant delivery passageway  50  in the form of a groove in the shank side wall  32  having a delivery passageway entry port  52  in the shank second end  26  and extending longitudinally to a delivery passageway exit port  54  opening into the circumferential channel  40 . A seal confirmation passageway  70  is optionally provided which extends from a confirmation passageway entry port  72  in the circumferential channel to the shank first end  22  where it opens out of a confirmation passageway exit port  74 . 
   Method 
   Sealant S is first injected into the fastener bore B. Then the fastener shank  20  is screwed, driven or slid into the fastener bore so that the shank second end  26  bears against and compresses the sealant S within the fastener bore B so that the sealant S is forced into the sealant delivery passageway  50  and flows through the sealant delivery passageway  50  and into and around the circumferential channel  40 , creating a circumferential seal between the fastener shank  20  and the receiving structure R so that water or other liquid cannot flow around the fastener shank  20  and through the receiving structure R. See FIG.  5 . 
   Where absolute confirmation of a complete seal is required, a seal confirmation passageway  70  as described above is provided. After sealant S flows from the sealant delivery passageway  50  and around the circumferential channel  40 , the sealant S flows out of the circumferential channel  40  into the confirmation passageway entry port  72  and along the seal confirmation passageway  70  until the sealant S is exposed at or exits from the confirmation passageway exit port  74  in the shank first end  22 . The sealant delivery passageway exit port  54  and the seal confirmation passageway entry port  72  preferably open into the circumferential channel  40  at diametrically opposing points so that sealant S from the sealant delivery passageway  50  has to flow all the way around the circumferential channel  40  before entering the seal confirmation passageway  70 , to completely assure that the circumferential channel  40  is filled around the entire shank  20  circumference before sealant S is exposed at the confirmation passageway exit port  74  to indicate a complete seal. 
   The seal confirmation passageway  70  can be either a longitudinal bore in fastener shank  20  as shown in  FIGS. 2 ,  4 ,  5  and  6  or can be a longitudinal groove along shank side wall  32  as shown in  FIGS. 6-9  extending from shank second end  26  to circumferential channel  40 , or a combination of groove and passageway. This is also true for the passageway configurations disclosed in the parent application, Ser. No. 09/931,697 the contents of which are incorporated by herein reference. 
   For the first embodiment of the present application, where the sealant delivery passageway  50  is a longitudinal bore, it can either include a longitudinal segment only which extends directly into a side of the circumferential channel  40 , or it can include an axial segment  56  which connects to a radial segment  58  which extends into the bottom of the circumferential channel  40 , as shown in  FIGS. 2 ,  4  and  5 . Where multiple circumferential channels  140 - 142  are provided, and where the sealant delivery passageway  50  has only the longitudinal segment which enters a side of a given circumferential channel, the sealant delivery passageway  50  is broken into passageway or groove segments extending between circumferential channels as shown in FIG.  9 . Where the seal confirmation passageway  70  is a longitudinal bore, it can either include a rectilinear longitudinal segment only which extends directly from a side of the circumferential channel  40 , or it can have an axial segment  76  which connects to a radial segment  78  which extends into the bottom of the circumferential channel  40 , as shown in  FIGS. 2 ,  4  and  5 . For the embodiments shown in  FIGS. 2 ,  4 ,  7 , and  9 , or other variations in which the sealant delivery passageway  50  opens out of the shank second end  26  and the seal confirmation passageway opens out of the shank first end  22 , and where the fastener  10  is inserted through one or more receiving structures R until the shank second end  26  protrudes through the receiving structures R and R 1 , the user has the option of injecting sealant with a sealant injection tool or gun into the seal delivery passageway  50 , or into the seal confirmation passageway  70 , as may be desired and convenient. 
   Second Preferred Embodiment 
   A second embodiment of the sealable fastener  10  is disclosed including a fastener shank  20  having a shank first end  22  having a shank first end wall  24  and a shank second end  26  having a shank second end wall  28 , a shank side wall  32  extending between shank first end  22  and shank second end  26 , a continuous, fully circumferential channel  40  recessed into shank side wall  32 , and including a longitudinal sealant delivery groove  50  in shank side wall  32  having a delivery groove entry port  52  in the shank first end  22  and extending longitudinally to a delivery groove exit port  54  opening into circumferential channel  40 . A seal confirmation passageway  70  including a longitudinal groove optionally is provided and extends from a confirmation passageway entry port  72  in circumferential channel  40  to a confirmation passageway exit port  74  in shank first end  22 . See  FIG. 11   a  Shank first end  22  preferably includes a fastener head  60 . Sealant is injected into the delivery groove entry port  52  and flows along the sealant delivery groove  50  to the circumferential channel  40 , flows entirely around the circumferential channel  40  and then enters the confirmation groove entry port  72  and flows along the confirmation groove and exits through the confirmation groove exit port  74 . This embodiment is analogous to that disclosed in parent application Ser. No. 09/931,697, except that longitudinal grooves replace the bored passageways. 
   Method 
   When fastener  10  is to be used, the fastener shank  20  is inserted into a fastener bore B in a receiving structure R such as a boat hull or a nut N. Then a flowable sealant S is injected into delivery groove entry port  52  so that the sealant S flows through sealant delivery groove  50  and exits through delivery groove exit port  54  and flows into and around circumferential channel  40 , creating a circumferential seal between fastener shank  20  and the receiving structure R so that water or other liquid cannot flow around the fastener shank  20  and through the receiving structure R. Sealant S injection is preferably preformed by an adhesive dispensing gun, structured much like a conventional caulking gun, examples of which are found in the existing art. 
   Design Variations of Second Embodiment 
   The fastener first end  22  has a first head radial notch  62  which registers with the delivery groove  50  and optionally a second head radial notch which registers with confirmation groove  70 . Alternatively, fastener first end  22  does not have a fastener head  60 . 
   Circumferential channel  40  preferably is located midway between the shank first and second end walls  24  and  28 , respectively, but can be located at virtually any point along shank  20  accessible by delivery groove  50 . Various channel  40  widths and depths may be provided, depending upon the type of sealant S used and upon the durability of sealing required for the specific application. Circumferential channel  40  is preferably deeper than any fastener threads  12  on the shank  20 . Channel  40  optionally follows an irregular or skewed path around the shank  20 . 
   Where the delivery groove  50  is provided rather than a bore passageway, and multiple circumferential channels are provided, it is preferred that the delivery grooves be staggered on diametrically opposing sides of the shank  20  between circumferential channels  140 ,  142  and  144  so that one circumferential channel must fill before sealant enters the next channel. 
   Where multiple circumferential channels  140  and  142  are provided, seal confirmation groove entry port  72  opens out of the most distal channel  142 , which is preferably a deeper channel than channel  140  so that seal confirmation groove  70  can extend substantially parallel to the shank axis and yet not intersect or enter channel  140 . Since sealant S reaches circumferential channel  140  first, and only then reaches circumferential channel  142  second, the discharge of sealant S through groove  70  indicating that second circumferential channel  142  is filled also indicates that sealant S has filled circumferential channel  140  as well. 
   Examples of flowable sealants are, but are not limited to, FUSOR SELF-LEVELING SEAM SEALER™, company reference number 122EZ, and LORD™ Urethane Adhesive, company reference numbers 7542A/B and 7545A/B. Fastener  10  is preferably configured as a bolt, but also may be configured as a screw, a pin, or a nail or a rivet (see FIG.  11 ). While virtually all existing fasteners are circular in cross-section, this sealant S delivery feature is understood to be suited for incorporation into fasteners of other cross-sectional shapes, and thus the term “fastener” is understood to include fasteners of all cross-sectional shapes. 
   Once again, it is preferred that the first passageway radial segment  58  be wider than the second passageway radial segment  58  and that the first circumferential channel  142  be wider than second circumferential channel  140  and that first circumferential channel  140  be wider than second circumferential channel  142 . The reason for these proximally progressive increments in passageway radial segment  58  diameters is that sealant S pressure diminishes as it flows distally, and a wider passageway radial segment  58  helps compensate for this loss in sealant S pressure. 
   Additional Embodiments 
   An open end channel  240  may extend from virtually any given point along shank side wall  32  all the way to shank first end  22 , where channel  240  is either open, or contained behind a fastener head  60 . For this embodiment, sealant S can be delivered either through a delivery passageway  50 , or through a delivery groove  50  extending from shank second end  26  or through a radial notch  62  in fastener head  60 . See FIG.  10 . The depth of open end channel  240  may be equal to and preferably is greater than the depth of the troughs of threads  12 . 
   A seal confirmation groove  70  is optionally provided for indicating when the circumferential channel  40  is filled with sealant S and forms a circumferential seal around the bolt shank  20 . A seal confirmation groove entry port  72  opens out of circumferential channel  40  into confirmation groove  70  which extends generally axially along shank side wall  32  to a seal confirmation groove exit port  74  in shank first end  22 . Seal confirmation groove entry port  72  preferably opens out of circumferential channel  40  opposite groove  50  so that sealant S only enters groove  70  after flowing all the way around circumferential channel  40  and creating a complete seal. 
   Still alternatively, an open end channel  240  may extend from virtually any given point along shank side wall  32  all the way to shank second end  24 , where channel  240  is open. For this embodiment, sealant S is injected into the fastener bore B first and then the fastener  10  is inserted and sealant S is compressed and flows proximally toward the shank first end  22 . See FIG.  12 . 
   While the invention has been described, disclosed, illustrated and shown in various terms or certain embodiments or modifications which it has assumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.