Patent Abstract:
A fastener assembly of fastening members formed from connected and collated fasteners mounted in non-contacting clips, for feeding into a fastening tool. The fastening members are driven by a powered fastening tool into deck boards and joists for building a deck or driven into alternate workpieces for building other structures.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates, in general, to the field of fasteners. In particular, the present invention relates to a fastener assembly including a plurality of clips and fasteners. The clips and fasteners can be used in construction applications such as deck board installation. 
     2. Description of the Related Art 
     The use of fastening tools, such as pneumatic or electrically powered fastening tools, is commonplace in the construction industry. Devices, such as nails employed with fastening tools are often provided in collated assemblies. However, in the field of deck construction, current deck board installation requires the user to manually and separately connect a clip and fastener, position the clip and fastener together in the correct location on the deck boards for installation, and align a drill or hammer with the clip and fastener to install the clip and fastener. The aforementioned steps are repeated hundreds or thousands of times for each deck installation. 
     Existing fasteners, such as those disclosed in U.S. Pat. No. 8,256,614, include multiple clips that are individually joined to each other, or interconnected after release from a fastening tool. However, U.S. Pat. No. 8,256,614 has the disadvantage of requiring two modes of installation for feeding the fastening components: an apparatus of installation tool for feeding deck clips, and an apparatus of installation tool for allowing a screw/nail of each deck clip to be positioned in an associated deck clip. Accordingly, there is a need in the art for an improved fastener assembly, such as the fastener assembly disclosed herein, that reduces the number of steps for fastening tool loading, thereby saving deck construction time. 
     SUMMARY OF THE INVENTION 
     To facilitate the use of nails by pneumatic or electrically powered fastening tools, in deck construction, nails can be serially collated using, for example, adhesively applied tape or other known collating media to form strips that can be easily inserted into and used by such fastening tools. 
     The present invention allows the user to load a plurality of serially arranged clips with connected nails or fasteners into a fastening tool and drive the clip and fastener simultaneously from the tool into the deck boards. Subsequent fasteners in the fastener assembly are fed to the nosepiece of the fastening tool for the next clip and fastener installation. 
     Combining the clip and fastener to form a single fastening member in a fastener assembly reduces the number of steps required to construct a deck or other structure. As a result, the time required for feeding clips and fasteners into a fastening tool and thereby constructing a deck can be significantly reduced. Accordingly, the fastener assembly of the present invention provides time saving construction of deck boards or other structures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying Figures. In the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  illustrates a section of a fastener assembly according to an embodiment of the invention; 
         FIG. 2  illustrates an expanded section of a fastener assembly according to the embodiment of  FIG. 1 ; 
         FIG. 3  illustrates a perspective view of fastener assembly clip according to the embodiment of  FIG. 1 ; 
         FIG. 4  illustrates a cross sectional view of the fastener assembly clip according to the embodiment of  FIG. 1 ; 
         FIG. 5  illustrates a side view of the fastener assembly clip according to the embodiment of  FIG. 1 ; and 
         FIG. 6  illustrates a top view of the fastener assembly clip according to the embodiment of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The inventive fastener assembly disclosed herein can be used under a broad variety of conditions and for numerous applications. The inventive fastener assembly can be used as feed to a variety of nailers and/or other fastening tools. In operation, the fastener assembly disclosed herein, can be stored in the housing and magazine of a fastening tool (not shown). 
     Individual fastening members form the fastener assembly. The fastening members are sequentially fed forward into a nosepiece of the fastening tool by a pusher in the magazine. Under pneumatic, electrical or other source of power, a fastening tool driver blade translates to impact the forwardmost fastening member of the fastener assembly that resides in the nosepiece so that the fastening member may be driven into a joist or workpiece (not shown). 
     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. 
     In accordance with an embodiment of the invention,  FIGS. 1 and 2  illustrate a fastener assembly for use in securing adjacent deck boards to an underlying joist. In the Figures, the fastener assembly  10  includes a plurality of fastening members  22 . The individual fastening members  22  include a first component, such as a fastener  12 , in the form of a nail, having an elongated body, a head portion  11  at one end of the elongated body, a tip portion  20  at an opposite end, and a shank portion  18  therebetween, 
     Individual fastening members  22  are connected by the fasteners  12  being collated. The fastener assembly  10  is formed by bonding the individual fasteners  12  with the collation member  14  at each shank  18 , and inserting the fastener  12  into a second component mounted to the lower portion of the fastener  12  above the tip portion  20 . 
     The second component can be a clip  16  that effectively maintains the spacing between the adjacent deck boards on the joist. Manufacturing the fastening member  22  of the fastener assembly  10  includes the nails  12  being connected to each other by the collation member  14 , and inserted into the clip  16 . As shown in  FIGS. 1 and 2 , the fastener  12  is also located substantially in the center of the clip  16 . The clip  16  is separately attached to the fastener shank  18  above the tip portion  20  of each fastener  12  in the fastening member. The clip  16  is attached in the fastener assembly  10  by contact with only the fastener  12 . Each clip  16  is physically separate from adjacent clips in the fastener assembly  10 . 
       FIG. 3  illustrates a perspective view of the clip  16  and  FIG. 4  illustrates a cross-sectional view of the clip. The clip  16  has an aperture  24  that defines a longitudinal axis A, as shown in  FIG. 4 , for receiving the fastener  12 . The longitudinal axis of the fastener  12  is coaxial with the longitudinal axis A of the clip. 
     In an embodiment, the shank portion  18  of the fastener  12  is substantially the same diameter as the aperture  24  in the clip  16 . As such, the fastener  12  is inserted into the clip  16  in an interference fit. Therefore, no further elements are required to hold the fastener  12  in position in the clip  16  before the fastening member  22  is driven into the joist or workpiece. 
     The diameter of the head portion  11  of the fastener  12  is larger than the diameter of the aperture  24  in the clip  16 . The larger head portion  11  prevents the fastener head from passing through the clip  16  or being recessed below an upper surface of the clip when the fastening member  22  is struck by the driver blade of the fastening tool. When driven into the joist, the larger head portion  11  of the fastener  12  allows the fastener to securely hold the clip  16  to the joist. 
     The clip  16  of the fastening member  22  can be a unitary member formed of a base portion  26  and a crosspiece  28  extending perpendicularly across an upper surface of the base portion. See for example,  FIG. 3 . In an embodiment, the clip  16  has a substantially T-shaped cross section as shown in  FIG. 4 . The aperture  24  in the clip extends from an upper surface  30  of the clip  16  through the clip body and can have a uniform diameter throughout its length. The aperture can pass through substantially the center of the base portion  26  and the crosspiece  28 . 
     As shown in  FIG. 5 , for example, the base portion  26  of the clip  16  is contiguous around the perimeter, and rectangular in cross section. The contiguity of the base portion  26  keeps dust and debris from entering the clip  16  from the sides. The rectangularity of the base portion  26  serves to align the deck boards during the deck assembly. The base portion  26  also has an outer surface that is planar throughout. 
     The crosspiece  28  of the clip  16  can be substantially a cross in shape, as shown in the top view of  FIG. 6 . In an embodiment, the crosspiece  28  includes, on the same plane, a pair of flanges  46 ,  48  that project over the base portion  26  and a pair of shoulders  34  at right angles to the flanges and coplanar with a perimeter P of the base. See, for example,  FIG. 3 . When the fastening member  22  is installed in the decking assembly, the flanges  46 ,  48  are positioned within grooves in the sides of the adjacent deck boards. The flanges  46 ,  48  have a height  32  that matches the grooves in the sides of the deck boards to ensure a secure fit. 
     As shown in  FIG. 3 , the outer edges of the flanges  46 ,  48  are curved. Also, as shown in  FIGS. 3 and 4 , the crosspiece  28  has a planar upper surface  30  and planar lower surfaces  36  that are formed by the flanges  46 ,  48 . The planar upper  30  and lower  36  surfaces are perpendicular to the base  26 . The outer surfaces  40  of the crosspiece flanges are parallel to the shank portion  18  of the fastener  12  and the outer surfaces of the base  26 . 
     The crosspiece  28  is substantially uniform about the longitudinal axis A, thereby forming a substantially symmetrical clip. 
     The clip  16  can be of any material including metal or plastic or a combination of metal and plastic. In an embodiment, the clip can be injection molded plastic. The clip can be formed such that it has rigidity. In an embodiment, the entire body of the clip is a rigid plastic. 
       FIG. 2  illustrates an expanded fastener assembly  10  in which the fasteners  12  are connected to each other with the collation member  14  applied to the parallely arranged fasteners  12  at their respective shanks  18 . The clips  16  are disposed around a lower portion of the fastener  12  above the tip portion  20 . 
     The fastener assembly  10  includes a plurality of fastening members  22  arranged adjacent to each other. The fastening members  22  include the nail or fastener  12  interference fit into the clip  16 . 
     Adjacent fasteners are attached to each other by the collation member  14 . The collation member  14  is attached to the shank portions  18  of the fasteners  12 , between the fastener head portions  11  and fastener tip portions  20 . The collation member  14  can be formed from paper having an adhesive, such as glue, on a side facing the fastener  12 . In an embodiment, the collation member  14  is in the form a strip that extends from the forwardmost fastener to the last fastener in the fastener assembly  10 . While, the fasteners  12  are spaced apart from each other, the collation member  14  serves to connect the fasteners  12  for the fastening members together. However, the clips  16  of the fastening members  22  are not connected. Namely, the clips  16  are separated from each other by a gap and are non-contacting. 
     In an embodiment a plurality of fastening members  22  form the fastener assembly  10 . The plurality of fastening. members  22  include a forward fastening member, which is at the front of the fastener assembly, and would be fed to the nosepiece of the fastening tool before a next or rear fastening member. The forward fastening member has a forward face  42  on the nosepiece side of the magazine and a rear face  44  radially opposing the forward face, on the pusher side of the magazine. The rear face  44  of the forward fastening member faces a forward face  42  of the next or rear fastening member. 
     In the fastener assembly  10 , the forward face of the clip  16  includes a forward flange  46 . The rear face of the clip  16  includes a rear flange  48 . The rear flange  48  is disposed on a radially opposing side of the aperture from the forward flange  46 . The upper surface of the forward flange  46  and the upper surface of the rear flange  48  form the upper surface  30  of the clip  16 . 
     The rear flange  48  of the clip  16  in the forward fastening member is spaced apart, by a gap  50 . The gap  50  is defined between the base portion  26  on the forward face  42  of the clip  16  in the rear fastening member and the rear flange  48  on the rear face  44  of the forward fastening member. In order to ensure a dense array of fastening members, it is preferred to provide the maximum number of nails in the least amount of space. Accordingly, the gap  50  is designed to be as small as possible. 
     In an embodiment, the forward flange  46  of the rear fastening member is positioned vertically between the collation member  14  and the rear flange  48  of the forward fastening member. The forward flange  46  of the rear fastening member partially and non-contactingly, overlaps the rear flange  48  of the forward fastening member in a horizontal direction. 
     In an embodiment, the rear flange  48  of the fastening member has a greater length than the forward flange  46 . The size differential accommodates the head portion  11  of the fastener  12 , so that the head portion of each forward fastening member can effectively clear the forward flange  46  of the rear fastening member when the fastening member  22  is struck by the driver blade. 
     The distance between the forward flange  46  of the rear fastening member and the shank portion  18  of the forward fastening member can be greater than the distance between the base portion  26  of the rear fastening member and the rear flange  48  of the forward fastening member. Alternatively, distance between the forward flange  46  of the rear fastening member and the shank portion  18  of the forward fastening member can be equal to the distance between the base portion  26  of the rear fastening member and the rear flange of the forward fastening member. 
     In an embodiment, the shank portion  18  of the forward fastening member is positioned parallel and adjacent to the shank portion  18  of the rear fastening member and connected by the collation member  14 . The clip  16  of the forward fastening member being spaced apart from the clip  16  of the rear fastening member. 
     As an example, the fastening tool includes a magazine connected to a tool housing and a nosepiece. The nosepiece is mounted to the housing. The magazine is coupled to the nosepiece at one end thereof and is mounted to the tool handle at an opposite end thereof. 
     In operation, the fastener assembly is loaded into the fastening tool through a fastener loading assembly, often identified as the fastening tool magazine. The fastening tool magazine provides storage capabilities for the fastener assembly  10  as well as the ability to present the fastening members  22  to a fastening member driving assembly. The fastening member driving assembly of a pneumatic or electrically powered fastening tool uses air pressure or a solenoid, respectively, to drive a driver blade through a channel disposed within the nosepiece. The nosepiece is coupled with the fastening tool magazine and is where an individual fastening member  22  is presented. 
     The inside of the fastening tool magazine typically includes a mechanism for providing a pushing force to the fastening members. The pushing force pushes the fastening member  22  down the length of the fastening tool magazine to the nosepiece. The pushing force keeps a constant pressure on the fastening members  22  so that as one fastening member is driven by the driver blade the next fastening member is forced into the nosepiece to replace it. 
     When the fastening tool drives the fastening member from the tool and into the joist, the shank portion  18  of the fastener  12  slides through the aperture  24  of clip  16 . As the head portion  11  of the fastener  12  is larger in diameter than the aperture  24 , the fastener comes to a stop when the head portion reaches the upper surface  30  of the clip  16 . Manufactured deck boards have pre-machined grooves on laterally adjacent sides into which the flanges  46 ,  48 , having a predetermined thickness  32 , are inserted. 
     Once installed between the adjacent boards and installed in the joist, the fastening member  22  is hidden from view. 
     While aspects of the present invention are described herein and illustrated in the accompanying drawings in the context of a pneumatic fastening tool, those of ordinary skill in the art will appreciate that the invention, in its broadest aspects, has further applicability. 
     It will be appreciated that the above description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. While specific examples have been described in the specification and illustrated in the drawings, it will be understood by those of ordinary skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. Furthermore, the mixing and matching of features, elements and/or functions between various examples is expressly contemplated herein, even if not specifically shown or described, so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise, above. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular examples illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of the present disclosure, but that the scope of the present disclosure will include any embodiments falling within the foregoing description.

Technology Classification (CPC): 5