Patent Abstract:
A self-sealing attachment assembly, includes a base portion defining a receptacle having an opening at one end and a surface with a through-hole at an opposite end, a sealant material in the receptacle, and a cover secured to the base portion and enclosing the opening, wherein the cover is configured to receive a driving force from a fastener and dispenses the sealant material via the through-hole by displacement through the receptacle when actuated by the driving force. A method is disclosed for installing a building material to a framing that includes mounting a self-sealing attachment assembly onto a fastening member and driving the fastening member through the sealing assembly and the building material toward the framing to dispense a sealant material to seal the penetration hole formed by the fastening member in the building material to form a watertight seal.

Full Description:
BACKGROUND 
     1. Field 
     The present disclosure relates generally to sealing products, and more particularly, to a self-sealing attachment assembly configured to provide a watertight seal to components used by the building industry for attaching building materials to the framing of a structure. 
     2. Background 
     In the building industry, sealing out water from penetrating to the interior surfaces of a structure is always desirable. Making structures watertight against rainwater, irrigation water, and any other moisture is a concern. Creating this seal against the effects of water may be accomplished, for example, by wrapping the exterior surfaces of a home in a building paper and fastening the paper to the framing of a home or other structure, or by providing an exterior surface, such as siding, roofing, or plaster lath, to protect the interior structure of the home. The point at which a building material, such as building paper or plaster lath, is fastened to the framing presents an opportunity for moisture to penetrate through the hole where the fastener, such as a nail, screw or bolt, extends into the framing. Penetration of moisture into the structural framing may mold, mildew, freeze, thaw, rot the wood, or cause other problems associated with waterproof exterior systems. 
     SUMMARY 
     One aspect of the disclosure, a self-sealing attachment assembly, includes a base portion defining a receptacle having an opening at one end and a surface with a through-hole at an opposite end, a sealant material in the receptacle, and a cover secured to the base portion and enclosing the opening, wherein the cover is configured to receive a driving force from a fastener and dispenses the sealant material via the through-hole by displacement through the receptacle when actuated by the driving force. 
     Another aspect of the disclosure, a self-sealing attachment assembly, includes a sealing assembly that includes a base portion defining a receptacle having an opening at one end and a surface with a through-hole at an opposite end, a sealant material in the receptacle, and a cover secured to the base portion and enclosing the opening, and a fastener having a head portion and a shank portion, the shank portion extending through the through-hole. 
     Another aspect of the disclosure, a self-sealing attachment assembly, includes a base portion comprising a retaining ring coupled to a containment structure, a fastener having a head and a shank portion, the fastener positioned in the base portion with the head abutting the retaining ring to define a receptacle having an opening at one end through which the shank portion extends, a sealant material in the receptacle, and a cover comprising an exit aperture, wherein the cover is secured to the base portion to enclose the receptacle opening with the shank extending through the exit aperture. 
     In another aspect of the disclosure, a self-sealing attachment assembly for a structure includes a building material mounted on framing for the structure, a sealing assembly, and a fastening member, wherein a cover of the sealing member is compressed by a head of the fastening member into a base portion of the sealing member to dispense the sealant material through a through-hole to seal a hole formed by the shank of the fastening member in the building material. 
     A method is disclosed for installing a building material to a framing that includes mounting a self-sealing attachment assembly onto a fastening member and driving the fastening member through the attachment assembly and the building material toward the framing so that a cover of the attachment assembly moves through a receptacle to dispense a sealant material to seal the penetration hole formed by the fastening member in the building material to form a watertight seal. 
     A method is disclosed for installing a building material to a framing that includes placing a self-sealing attachment assembly against the building material in a location aligned with a member of the framing and driving a fastening member toward the framing so that the head of the fastening member moves within a base portion to dispense the sealant material via an exit aperture in a cover to form a watertight seal surrounding a penetration hole formed by the fastening member in the building material. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Various aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein: 
         FIG. 1  illustrates a perspective view of a self-sealing attachment assembly in a preassembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 2  illustrates a side sectional view of the self-sealing attachment assembly of  FIG. 1 , in accordance with certain aspects of the present invention; 
         FIG. 3  illustrates another perspective view of the self-sealing attachment assembly of  FIG. 1 , wherein a sealant is provided in a base portion of the assembly, in accordance with certain aspects of the present invention; 
         FIG. 4  illustrates a side sectional view of the self-sealing attachment assembly of  FIG. 3 , in accordance with certain aspects of the present invention; 
         FIG. 5  illustrates a perspective view of the self-sealing attachment assembly of  FIG. 1  in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 6  illustrates a side sectional view of the self-sealing attachment assembly of  FIG. 1  in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 7  illustrates a perspective view of a fastening member and a self-sealing attachment assembly, in accordance with certain aspects of the present invention; 
         FIG. 8  illustrates a side sectional view of a self-sealing attachment assembly mounted on a fastening member, in accordance with certain aspects of the present invention; 
         FIG. 9  illustrates a side view of a structural system with a self-sealing attachment assembly shown in various configurations, in accordance with certain aspects of the present invention; 
         FIG. 10  illustrates a bottom view of a self-sealing attachment assembly, wherein expansion slits are provided, in accordance with certain aspects of the present invention; 
         FIG. 11  illustrates a bottom view of a self-sealing attachment assembly, wherein exit apertures are provided, in accordance with certain aspects of the present invention; 
         FIG. 12  illustrates a side view of a structural system with a self-sealing attachment assembly shown in various configurations, in accordance with certain aspects of the present invention; 
         FIG. 13  illustrates a bottom view of a self-sealing attachment assembly, in accordance with certain aspects of the present invention; 
         FIG. 14  illustrates a perspective view of a self-sealing attachment assembly in a preassembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 15  illustrates another perspective view of the self-sealing attachment assembly of  FIG. 14 , wherein a sealant is provided in a receptacle of the assembly, in accordance with certain aspects of the present invention; 
         FIG. 16  illustrates a perspective view of the self-sealing attachment assembly of  FIG. 15  in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 17  illustrates a bottom view of the self-sealing attachment assembly of  FIG. 16 , in accordance with certain aspects of the present invention; 
         FIG. 18  illustrates a side view of a structural system with a self-sealing attachment assembly shown in various configurations, in accordance with certain aspects of the present invention; 
         FIG. 19  illustrates a perspective view of a self-sealing attachment assembly in a preassembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 20  illustrates a bottom view of a base portion of the self-sealing attachment assembly, in accordance with certain aspects of the present invention; 
         FIG. 21  illustrates another perspective view of the self-sealing attachment assembly of  FIG. 19 , wherein a sealant is provided in a receptacle of the assembly, in accordance with certain aspects of the present invention; 
         FIG. 22  illustrates a perspective view of the base portion of the self-sealing attachment assembly of  FIG. 19 , wherein a sealant is provided in a receptacle of the assembly, in accordance with certain aspects of the present invention; 
         FIG. 23  illustrates a perspective view of the self-sealing attachment assembly of  FIG. 19  in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 24  illustrates a side view of a structural system with a self-sealing attachment assembly shown in various configurations, in accordance with certain aspects of the present invention; 
         FIG. 25  illustrates a perspective view of a self-sealing attachment assembly in a preassembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 26  illustrates another perspective view of the self-sealing attachment assembly of  FIG. 25 , wherein a sealant is provided in a receptacle of the assembly, in accordance with certain aspects of the present invention; 
         FIG. 27  illustrates a perspective view of the self-sealing attachment assembly of  FIG. 25  in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 28  is a top view of an exemplary base portion of the self-sealing attachment assembly of  FIG. 25 , in accordance with certain aspects of the present invention 
         FIG. 29  is a bottom view of the base portion of  FIG. 28 , in accordance with certain aspects of the present invention; 
         FIG. 30  is a sectional view taken along line A-A of the base portion of  FIG. 28 , in accordance with certain aspects of the present invention; 
         FIG. 31  is a top view of an exemplary piston member of the self-sealing attachment assembly of  FIG. 25 , in accordance with certain aspects of the present invention 
         FIG. 32  is a bottom view of the piston member of  FIG. 31 , in accordance with certain aspects of the present invention; 
         FIG. 33  is a sectional view taken along line A-A of the piston member of  FIG. 31 , in accordance with certain aspects of the present invention; 
         FIG. 34  illustrates a side view of a structural system with the self-sealing attachment assembly of  FIG. 25  shown in various configurations, in accordance with certain aspects of the present invention; 
         FIG. 35  illustrates a perspective view of a self-sealing attachment assembly in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 36  illustrates a partial cutaway of a top perspective view of a self-sealing attachment assembly in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 37  illustrates a partial cutaway view of a bottom perspective view of a self-sealing attachment assembly in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 38  illustrates a partial cutaway of a close-up perspective view of a portion of a self-sealing attachment assembly in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 39  illustrates a bottom perspective view of a self-sealing attachment assembly in an assembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 40  illustrates a perspective view of a self-sealing assembly in a preassembled configuration, in accordance with certain aspects of the present invention; 
         FIG. 41  illustrates a perspective view of the self-sealing attachment assembly of  FIG. 40  in an assembled configuration, in accordance with certain aspects of the present invention; and 
         FIG. 42  illustrates a perspective view of the self-sealing attachment assembly of  FIG. 41  in an actuated configuration, in accordance with certain aspects of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Various aspects of a self-sealing attachment assembly may be illustrated by describing components that are coupled, attached, and/or joined together. As used herein, the terms “coupled”, “attached”, and/or “joined” are used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled”, “directly attached”, and/or “directly joined” to another component, there are no intervening elements present. 
     Relative terms such as “lower” or “bottom” and “upper” or “top” may be used herein to describe one element&#39;s relationship to another element illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of a self-sealing attachment assembly in addition to the orientation depicted in the drawings. By way of example, if a self-sealing attachment assembly in the drawings is turned over, elements described as being on the “bottom” side of the other elements would then be oriented on the “top” side of the other elements. The term “bottom” can therefore encompass both an orientation of “bottom” and “top” depending on the particular orientation of the apparatus. 
     Various aspects of a self-sealing attachment assembly may be illustrated with reference to one or more exemplary embodiments. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments of a self-sealing attachment assembly disclosed herein. 
     The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. 
       FIGS. 1-6  illustrate the configuration of an exemplary self-sealing attachment assembly  1  in various stages of assembly. As shown in  FIGS. 1 and 2 , the assembly  1  may include a base portion  10  and a cover  50 . The base portion  10  and the cover  50  may individually be composed of a plastic, such as a high-density polyethylene (HDPE) or high-density polypropylene (HDPP), or any other suitable material, including nylon, rubber, fiberglass, wood, or metal. The base portion  10  may be formed with a lower plate  12  coupled to a containment structure  14 , which may be an integrally formed annular side wall, for example. A through-hole  20  may be provided in the lower plate  12 . The lower plate  12  and containment structure  14  define a receptacle  25  for containment of a sealant material  40 . As shown in  FIGS. 3 and 4 , the sealant material  40 , which may be a caulking material such as a silicone or urethane caulking, butyl rubber, tar, or some other suitable waterproofing material, may be loaded directly into the receptacle  25 . The through-hole  20  may be formed with dimensions that, in combination with the viscosity of the sealant material, prevent the unintended release of the sealant material  40  from the receptacle  25  unless an applied force actuates the release. In another aspect according to the present invention, the sealant  40  may be provided in a sealant casing, which, for example, may be a thin, flexible, rupturable material like that of plastic wrap or a plastic bag. 
     With the sealant material  40  provided in the receptacle  25 , the cover  50  may be securely coupled with the base portion  10  to enclose an open side of the receptacle  25 . For example, the containment structure  14  may be interference fit or co-molded in a manner to encompass the cover  50  with zero clearance between the cover  50  and the inner side surfaces of the containment structure  14 . In another variation in accordance with aspects of the present invention, a securing mechanism, such as an adhesive, or a tongue and groove feature, for example, may secure the cover  50  in a position to effectively enclose the receptacle  25  while preventing unintentional actuation of the assembly during transport and/or storage. 
       FIGS. 5 and 6  illustrate an assembled self-sealing attachment assembly  1 . The cover  50  is securely coupled to the base portion  10 , preferably enclosing the sealant material  40  in that portion of the receptacle  25  not occupied by the cover  50 . An access hole  54  may be provided in the cover  50  to enhance the alignment and access of a fastener to be used with the assembly  1 . The dimensions of the assembly  1  may be varied in many ways to accommodate different configurations and sizes of fasteners, as well as to provide for different types and/or amounts of caulking in accordance with sealing requirements for differing fastening conditions. For example, although depicted as round, the assembly may be manufactured to be any shape. Furthermore, the depth and dimensions of the receptacle  25 , thickness of the cover  50 , thickness of the containment structure  14 , and the thickness of the lower plate  12 , for example, may be varied in accordance with the material comprising the base portion  10  and/or cover  50  in order to provide the desired strength and/or rigidity of the individual components to ensure the effective release of the sealant material  40  as intended (e.g., without unintended rupture). In accordance with another aspect of the present invention, the base portion  10  and/or the cover  50  may be made pliable to intentionally enable collapse, depending upon the application. In accordance with yet another aspect of the present invention, a releasable liner (not shown) may be provided on an upper surface  56  of the cover  50  and/or the lower surface of the lower plate  12  to seal respectively the access hole  54  and/or through-hole  20 . 
     In use, as shown in  FIGS. 7-8 , the self-sealing attachment assembly  1  may be installed over a fastener  70  of any type, such as a screw, nail, and/or bolt (self-tapping or other), by extending the fastener through the access hole  54  and through-hole  20 . As shown in  FIG. 9  in various degrees of insertion, with an assembly  1  mounted thereon, a fastener  70  may be driven (or tightened in the case of a nut and bolt) into a structural member  80  to attach a building material  90 , such as a waterproof building paper, plywood, or a plaster lath, for example, to the structure of a home. The structural member  80  may be a stud or a plywood member, for example. The fastener  70  may be driven or tightened to wedge the assembly  1  against the building material  90  with the head of the fastener  70  abutting the upper surface  56  of the cover  50 . Continued driving or tightening of the fastener  70  applies a distributed force from the head of the fastener to the upper surface  56  of the cover  50 . The distributed force, in turn, drives the cover  50  further into the receptacle  25 . As discussed previously, the cover  50  may be designed with a uniform bottom surface  52  having dimensions to prevent escape of the sealant material  40  from the receptacle  25  other than through features provided in the lower plate  12 , such as the through-hole  20  (see also  FIGS. 10 and 11 , which show respectively expansion slits  21  and exit apertures  22  as exemplary features that may be provided to direct and/or control the escape of the sealant material  40  from the receptacle  25  through the lower plate  12 ). Thus, driving the cover  50  into the receptacle  25  forces a displacement of the enclosed sealant material  40  out of the through-hole  20  and into the area surrounding the penetration hole formed by the fastener  70  entering the building material  90 . The sealant material  40  will cover effectively around the hole to also provide a seal against enlargements of the hole as a result of movement of the construction material  90  during installation, for example, or due to an oversized hole initially provided compared to the size of the fastener  70  being used. 
     As shown in  FIGS. 12 and 13 , the self-sealing attachment assembly  1  may be formed without a through-hole  20  in the lower plate  12  and/or an access hole  54  in the cover  50 . For example, a fastener  70  that is self-tapping may be driven directly through the cover  50  and/or directly through the lower plate  12 . When actuated as described above, the sealant material  40  may be forced out through the hole in the lower plate  12  created by the self-tapping fastener  70 . And although  FIG. 9  illustrates fastening a building material  90  between the fastener sealing assembly  70  and a structural member  80 , as shown in  FIG. 12  the fastener  70  may be used directly against a structural member for fastening to another structural member or for fastening a building material to the opposite side of the stud  80 . 
       FIGS. 14-18  illustrate another exemplary self-sealing attachment assembly. As shown in  FIG. 14 , the assembly  100  may include a base portion  110 , a cover  150 , and an integrated fastening member  170 . The base portion  110  and the cover  150  may individually be composed of a plastic, such as a high-density polyethylene (HDPE) or high-density polypropylene (HDPP), or any other suitable material, including nylon, rubber, fiberglass, wood, or metal. The fastener member  170  may be a fastener of any type, such as a screw, nail, and/or bolt (self-tapping or other), for example. 
     The base portion  110  may be formed with a retaining ring  112  coupled to a containment structure  114 , which may be an integrally formed annular side wall, for example. The fastener member  170  may slide into the base portion  110  so that a head  172  abuts the retaining ring  112  with the shank portion of the fastener member extending out through an opening in the containment structure  114 . The containment structure  114  may be interference fit, for example, to encompass the head  172  with zero clearance between the head  172  and the inner side surfaces of the containment structure  114 . With the fastening member  172  thus seated in the base portion  110 , the head  172  effectively seals an access hole  113  formed at the center of the retaining ring  112  and prevents fluid communication through the access hole  122  from a receptacle  125  defined by the interior of the containment structure  140  and the head  172  of the fastener member  170 . A washer may be provided to further enhance the seal. 
     As shown in  FIG. 15 , a sealant material  140 , which may be a caulking material such as a silicone or urethane caulking, butyl rubber, tar, or some other suitable waterproofing material, may be loaded directly into the receptacle  125 . In another aspect according to the present invention, the sealant  140  may be provided in a sealant casing, which, for example, may be a thin, flexible, rupturable material like that of plastic wrap or a plastic bag. With the sealant material  140  provided in the receptacle  125 , the cover  150  may be securely coupled with the base portion  110  by sliding an exit aperture  154  in the cover  150  over the shank of the fastener member  170  until the cover  150  seats against an annular lip  115  provided in the base portion  110 . The cover  150  may be secured to the containment structure by interference fit or via a securing mechanism, such as an adhesive, for example, effectively enclosing the receptacle  125 . 
       FIG. 16  illustrates an assembled self-sealing attachment assembly  100 . The cover  150  is securely coupled to the base portion  110 , enclosing the sealant material  140  in the receptacle  125 . The dimensions of the assembly  100  may be varied in many ways to accommodate different configurations and sizes of fastener members, as well as to provide for different types and/or amounts of caulking in accordance with sealing requirements for differing fastening conditions. In use, as shown in  FIG. 17 , access to the head of the fastener member  170  may be provided through the access hole  113  in the center of the retaining ring  112 . Thus, as shown in  FIG. 18 , the self-sealing fastening assembly  100  may be driven (or tightened in the case of a nut and bolt) into a structural member  180  to attach a construction material  190 , such as a waterproof building paper, plywood, or a plaster lath, for example, to a structure. The structural member  180  may be a stud or a plywood member, for example. The fastener  170  may be driven or tightened until an upper surface of the cover  150  of the assembly  100  abuts against the construction material  190 . Continued driving or tightening of the fastener  170  causes the head of the fastener to continue to displace through the receptacle  125 , forcing a displacement of the enclosed sealant material  140  out of the exit aperture  154  and into the area surrounding the penetration hole formed by the fastener  170  entering the construction material  190 . The sealant material  140  will cover effectively around the hole to also provide a seal against enlargements of the hole as a result of movement of the construction material  190  during installation, for example, or due to an oversized hole initially provided compared to the size of the fastener  170  being used. 
       FIGS. 19-24  illustrate yet another exemplary self-sealing attachment assembly. As shown in  FIG. 19 , the assembly  200  may include a base portion  210  and a fastening member  270 . The base portion  210  may be composed of a plastic, such as a high-density polyethylene (HDPE) or high-density polypropylene (HDPP), or any other suitable material, including nylon, rubber, fiberglass, wood, or metal. The fastener member  270  may be a fastener of any type, such as a screw, nail, and/or bolt (self-tapping or other), for example. 
     The base portion  210  may be formed with a lower plate  212  coupled to a containment structure  214 , which may be an integrally formed annular side wall, for example. Accordingly, the lower plate  212  and containment structure  214  define a receptacle  225  for containment of a sealant material  240 . A recessed channel  215  may be provided on an inner surface of the containment structure  214  for coupling the fastener member  270  to the base portion  210 . For example, the fastener member  270  may be formed with a head structure that includes a head plate  272 , and the containment structure  214  may be interference fit, for example, to encompass the head plate  272  with zero clearance between the head plate  272  and the inner side surfaces of the containment structure  214 . A through-hole  220 , as shown in  FIG. 20 , may be provided in the lower plate  212 . As shown in  FIGS. 21 and 22 , the sealant material  240 , which may be a caulking material such as a silicone or urethane caulking, butyl rubber, tar, or some other suitable waterproofing material, may be loaded directly into the receptacle  225 . In another aspect according to the present invention, the sealant  240  may be provided in a sealant casing, which, for example, may be a thin, flexible, rupturable material like that of plastic wrap or a plastic bag. 
     With the sealant material  240  provided in the receptacle  225 , the fastener member  270  may be securely coupled with the base portion  110  by sliding the shank of the fastener member  270  through the receptacle  225  and the through-hole  220  until the head plate  272  is press fit, for example, into the recessed channel  215 , as shown in  FIGS. 23 and 24 . With the head plate  272  thus secured, the sealant material  240  is effectively enclosed and secured in the receptacle  225 , and the integrated self-sealing attachment assembly  200  is ready for use. Additionally, the through-hole  220  may be formed with dimensions that, in combination with the viscosity of the sealant material and the shank of the fastener member  270 , prevent the unintended release of the sealant material  240  from the receptacle  225  unless an applied force actuates the release by unseating the head plate  272  from the recessed channel  215 . 
       FIG. 23  illustrates an assembled self-sealing attachment assembly  200 . The fastener member  270  is securely coupled to the base portion  210 , enclosing the sealant material  240  in the receptacle  225 . The dimensions of the assembly  200  may be varied in many ways to accommodate different configurations and sizes of fastener members, as well as to provide for different types and/or amounts of caulking in accordance with sealing requirements for differing fastening conditions. 
     In use, as shown in  FIG. 24 , the self-sealing attachment assembly  200  may be driven (or tightened in the case of a nut and bolt) into a structural member  280  to attach a construction material, for example, such as a waterproof building paper, plywood, or a plaster lath, to a structure or to attach various structural components directly to one another. The structural member  280  may be a stud or a plywood member, for example. The fastener member  270  may be driven or tightened so that the head plate  272  disengages from the recessed channel  215  and slides through the receptacle  225 , forcing a displacement of the enclosed sealant material  140  out of the through-hole  220  and into the area surrounding the penetration hole formed by the fastener  270  entering the structural member  280 , for example. The head plate  272  is preferably designed with a uniform bottom surface having dimensions to prevent escape of the sealant material  240  from the receptacle  225  other than through features provided in the lower plate  212 , such as the through-hole  220 . The sealant material  240  will cover effectively around the hole to also provide a seal against enlargements of the hole as a result of movement of the structural member  280  during installation, for example, or due to an oversized hole initially provided compared to the size of the fastener  270  being used. Additional exemplary features, including expansion slits, exit apertures, depressions or channels may be provided on a lower surface of the lower plate  212  to direct and/or control the escape of the sealant material  240  from the receptacle  225  while providing increased surface area, for example, for increasing the strength of the bond between the attachment assembly  200  and the structural member  280 . 
       FIGS. 25-39  illustrate another exemplary self-sealing attachment assembly, in accordance with aspects of the present invention. As shown in  FIGS. 25-27 , the assembly  300  may include a base portion  310 , a piston member  350 , and a fastener member  370 . The base portion  310  and the piston member  350  may be composed of a plastic, such as a high-density polyethylene (HDPE) or high-density polypropylene (HDPP), or any other suitable material, including nylon, rubber, fiberglass, wood, or metal. The fastener member  370  may be a fastener of any type, such as a screw, nail, and/or bolt (self-tapping or other), for example. A sealant material  340 , which may be a caulking material such as a silicone or urethane caulking, butyl rubber, tar, or some other suitable waterproofing material, may be loaded directly into the base portion  310  and secured therein by the piston member  350  until released by an applied force on the piston member  350  through actuation of the fastener member  370 . 
     As shown in isolation in  FIGS. 28-30 , the base portion  310  may be integrally formed with an annular lower plate  312  that concentrically joins a cylindrical outer wall  314  and a cylindrical inner wall  316 . The cylindrical inner wall  316  may be formed to have a shorter height dimension than that of the cylindrical outer wall  314 . Accordingly, an annular receptacle  325  for containment of a sealant material  340  may be defined by the space between the annular lower plate  312  and the concentric outer and inner walls,  314  and  316 . A through-hole  320  may be provided in the lower plate  312  to provide communication between an exterior of the base  310  and a piston retaining space  326  via the interior of the inner wall  316 , the piston retaining space  326  being defined by an area interior to the outer wall  314  and above the upper surface of the inner wall  316 . A securing means, such as a recessed channel  318  on an inner surface of the outer wall  314 , may be provided in the piston retaining space  326  for coupling the piston member  350  to the base portion  310 . Exit channels  330  may be provided at intervals along portions of the inner wall  316  that extend through the base plate  312  and provide communication from the receptacle  325  to the exterior of the base portion  310 . For example, as shown in  FIGS. 28-30 , each exit channel  330  may be formed along a 30 degree arc of the inner wall  316  and spaced apart from neighboring exit channels by a 30 degree arc of the inner wall on each side. In another aspect according to the present invention, the inner wall  316  may be a solid cylinder and exit apertures, for example, may be formed through the lower plate  312  to provide communication between the receptacle  325  and the exterior of the base portion  310 . As illustrated in  FIG. 30 , for example, edges of the inner and outer walls,  314  and  316 , may be provided with chamfers  335  to, for example, allow easier manipulation of sliding parts, prevent damage of assembled parts, and/or prevent ripping or tearing of materials that may be placed in contact with the assembly  300  during or after application. 
     As shown in  FIG. 26 , with the sealant material  340  provided in the receptacle  325 , the piston member  350  may be securely coupled with the base portion  310  to enclose an open side of the receptacle  325 . For example, as shown in isolation in  FIGS. 31-33 , the piston member  350  may be formed with a uniform, annular lower surface  352  that joins concentric inner and outer piston walls,  354  and  356 , respectively. Support members  360  may extend between the walls  354  and  356  to provide a more consistent and distributed load bearing structure in order to maintain the integrity of the piston member  350  during actuation. Configuring the piston member  350  to be substantially hollow provides for a lighter design. In another aspect in accordance with the present invention, the piston member  350  may be a solid annular piston. The piston member  350  may be formed with an annular bead  358  to engage the recessed channel  318  in the base portion  310  for securing the piston member  350  to the base portion  310  while enclosing the sealant material  340  in the receptacle  325 . 
     As shown in  FIG. 34 , an outer surface of the outer piston wall  356  is configured to slidably engage an inner surface of the outer wall  314  of the base portion  310 , and an inner surface of the inner piston wall  354  forms a piston cylinder  365  configured to slidably engage an outer surface of the inner wall  316  of the base portion  310 . Thus, the base portion  310  may be interference fit, for example, to encompass the piston member  350  with zero clearance between the outer surface of the outer piston wall  356  and the inner surface of the outer wall  314 . 
     With the sealant material  340  provided in the receptacle  325 , the piston member  350  may be securely coupled with the base portion  310  by press fitting the piston member  350  into the piston retaining space  326  of the base portion  310  until the annular bead  358  engages the recessed channel  318 . With the piston member  350  thus securely coupled to the base portion  310 , the self-sealing fastening assembly  300  may be installed with a fastener member  370 . In other aspects in accordance with the present invention, the fastener member  370  may be provided as an integral element of the assembly  300 . 
     As shown in  FIGS. 34-39 , the shank of the fastener member  370  may be extended through the piston cylinder  365  of the piston member  350  nested in the base portion  310  and the through-hole  320  of the base portion  310  until a head  372  of the fastener member engages an upper surface of the outer piston wall  356  and upper surfaces of the support members  360  of the piston member  350 . The self-sealing attachment assembly  300  may be driven (or tightened in the case of a nut and bolt) into a structural member  380  to attach a construction material, for example, such as a waterproof building paper, plywood, or a plaster lath, to a structure or to attach various structural components directly to one another. The fastener member  370  may be driven or tightened so that the annular bead  358  disengages from the recessed channel  318  and the annular piston member  350  slides through the receptacle  325 , forcing a displacement of the enclosed sealant material  340  out of the exit channels  330  and into the area surrounding the penetration hole formed by the fastener member  370  entering the structural member  380 , for example. In this manner, the piston cylinder  365  slidably engages the outer surface of the inner wall  316  so that the uniform annular lower surface  352  displaces the sealant material  340  while preventing escape of the sealant material  340  from the receptacle  325  other than through features provided for communicating through the lower plate  312 , such as exit channels  330 . The sealant material  340  will cover effectively around the hole to also provide a seal against enlargements of the hole as a result of movement of the structural member  380  during installation, for example, or due to an oversized hole initially provided compared to the size of the fastener  370  being used. Additional exemplary features, including expansion slits, exit apertures, depressions or channels may be provided on a lower surface of the lower plate  312  to direct and/or control the escape of the sealant material  340  from the receptacle  325  while providing increased surface area, for example, for increasing the strength of the bond between the attachment assembly  300  and the structural member  380 . 
     Although the self-sealing attachment assembly described above is shown as having a piston member  350  nested entirely in the base portion  310 , a variety of configurations of a piston member and base portion may define, with or without a separate fastener, a suitable means for providing an assembly for attachment to a construction material. For example,  FIGS. 40-42  illustrate a self-sealing assembly  400  in accordance with certain aspects of the present invention that functions in most respects similar to the self-sealing attachment assembly  300 , and, as such, a majority of the structure and functional aspects of the applicator assembly  400  are not repeated here. The assembly  400  may include a base portion  410  and a piston member  450 . The base portion  410  and the piston member  450  may be composed of a plastic, such as a high-density polyethylene (HDPE) or high-density polypropylene (HDPP), or any other suitable material, including nylon, rubber, fiberglass, wood, or metal. A material  440 , which may be a sealant material or a high-strength bonding material, for example, may be loaded directly into the base portion  410  and secured therein by the piston member  450  until released by an applied force on the piston member  450 . A securing means, such as a recessed channel  418  may be provided in the base portion  410  to couple with a securing mechanism, such as an annular lip  452 , provided on the piston member  450  for coupling the piston member  450  to the base portion  410 . 
     As shown in  FIGS. 40-42 , the piston member  450  may be formed to slideably engage the base portion  410  and occupy a substantial portion of the interior receptacle area of the base portion  410 , thereby releasing the material  440  through exit apertures or a through-hole, for example, provided in the base portion  410 . Any suitable means for actuating the piston member  450  to displace through the interior receptacle portion of the base portion  410  may be used. For example, the piston member  450  may be formed with external threads on a sidewall that mate with an internally threaded sidewall of the base portion  410 , wherein the piston member  450  is screwed down into the base portion  410 , displacing the material  440  and leaving the assembly  400  bonded to a construction material, for example. Alternatively, a separate fastener may be used to drive the piston member  450  into the base portion  410 , as described above, for example, with respect to assembly  300 . As shown in  FIG. 42 , the piston member  450  may be formed to have a depth dimension greater than the depth dimension of the base portion  410  when fully engaged. In this manner, the depth of the piston member  450  may be varied, for example, to provide varying final elevations of the assembly  400  when installed. The piston member  450  may be hollow or solid, for example, depending on the structural needs of the installation. For example, where the assembly  400  may be used as a hanger or spacer between construction materials, a solid configuration of the piston member  450  may be used to provide enhanced structural stability to the installation. 
     The previous description is provided to enable any person skilled in the art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments. For example, although disclosed above for use with a sealant material in a structural building environment, the self-sealing fastening assembly may be used to contain and release a variety of materials in any variety of environments, including lubricants such as grease and oil, for example. Thus, the claims are not intended to be limited to the embodiments shown herein, but is to be accorded the full scope consistent with the language claims, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”

Technology Classification (CPC): 5