Patent Description:
Generally, known post-to-beam fastening operations use several separate assemblies for enabling the insertion of a bolt into a wood deck post and/or wood deck beam. More specifically, certain known post-to-beam fastening operations start with a <NUM>/<NUM> inch (<NUM> cms) drill bit inserted into the chuck of a power drill. The power drill and the drill bit from a predrilled hole in the wood and the drill bit is removed from the hole. A <NUM>/<NUM> inch (<NUM> cms) bolt with a washer is hammered into the hole, and a washer and nut are affixed to the opposite end of the bolt. The nut is tightened until the bolt is locked into place. The <NUM>/<NUM> inch (<NUM> cms) diameter bolt can have a carriage head or a hex head. The carriage head bolt includes a square shoulder that, when hammered into the hole in the wood, will lock into place, providing enough torque to facilitate tightening the nut as needed. The hex head bolt enables the user to use a wrench to hold the head of the bolt while another wrench is used to tighten the nut. Both hex head bolts and carriage head bolt such as shown in <FIG> have been utilized in this manner. An example of a drilling device is described in patent document <CIT>. The drilling device includes a platelet-like cutting tool that is form-fitter and/or force-fitted manner to shaft. The device has thread-cutting screws.

There exists a need for an improved post-to-beam fastener and method of post-to-beam fastening that are faster and more efficient.

Various embodiments of the present disclosure provide an improved post-to-beam fastener and an improved method of post-to-beam fastening that are faster and more efficient. These embodiments solve the above problems in part by providing a fastener that combines the pre-drilling and bolt installation steps of post-to-beam fastening into one step (i.e., a single step). The invention is a fastener with the features of claim <NUM> and a method in accordance with claim <NUM>.

Various embodiments of the present disclosure provide a fastener including a head and a tip connected by a threaded shank with a longitudinal axis extending from the head to the tip. The tip includes a recess operable to removably receive and facilitate attachment of a drill bit to the tip end of the fastener.

Various embodiments of the present disclosure provide a method of fastening in which a fastener is attached to a drill by a retaining feature operable to removably secure the fastener to the drill and enable forward and backward movement along a longitudinal axis. The fastener is drilled through a deck post and a deck beam. The fastener is detached from the drill. A nut is installed and tightened on the fastener to press and connect the deck post and deck beam adjacent to each other along the longitudinal axis.

Various embodiments of the present disclosure provide a method of fastening in which a drill bit is removably attached to a fastener in a recess proximate a tip of the fastener. The drill bit and the fastener are drilled through a deck post and a deck beam. The drill bit is detached from the fastener. A nut is installed and tightened on the fastener to press and connect the deck post and deck beam adjacent to each other along the longitudinal axis.

Having thus described embodiments of the present disclosure in general terms, reference will now be made to the accompanying drawings of which only <FIG> show embodiments in accordance with the claims and which are not necessarily drawn to scale, and wherein:.

While the devices and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the scope of the claims. Unless otherwise indicated, any directions and/or order referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

<FIG> illustrate example known hex head fastener <NUM> and an example known carriage head fastener <NUM>. The example known hex head fastener <NUM> includes: (<NUM>) a shank <NUM>; and (<NUM>) a head <NUM> integrally connected to an end of the shank <NUM>. The example known carriage head fastener <NUM> includes: (<NUM>) a shank <NUM>; and (<NUM>) a head <NUM> integrally connected to an end of the shank <NUM>.

Various embodiments of the present disclosure are used for post-to-beam fastening applications. Additionally, these embodiments may be adapted for other decking construction processes. When installing a deck post to a deck beam, the International Code Council (ICC) presently requires <NUM><NUM>/<NUM> inch (<NUM> cms) pre-drilled through-bolts per connection. <FIG> show the American Wood Council (AWC) and International Residential Code (IRC) requirements for post-to-beam fastening.

<FIG>, <FIG>, <FIG>, and <FIG> illustrate one example embodiment of the post-to-beam fastener of the present disclosure that is generally indicated by numeral <NUM>. This illustrated example embodiment shows selected components of the post-to-beam fastener <NUM>, and other components of the post-to-beam fastener <NUM> not discussed herein will be readily understood by those skilled in the art.

The illustrated example post-to-beam fastener <NUM>, sometimes referred to as a "<NUM> Piece Fastener Concept," includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; and (<NUM>) a tip <NUM> integrally connected to the shank <NUM> at a second end <NUM> of the shank <NUM>. In this illustrated example, the post-to-beam fastener <NUM> (i.e., the <NUM> Piece Concept) is configured as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt (i.e., fastener <NUM>) with a tip <NUM> and a head <NUM> opposite of the tip <NUM>. It should be appreciated that while the post-to-beam fastener <NUM> is described as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head <NUM> has a hexagonal shape and includes a retaining feature. More specifically, the head includes surfaces that define: (<NUM>) a recess <NUM> defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a recess indent <NUM> defined in at least one sidewall (not labeled) of the recess <NUM>. In this illustrated example, the surfaces of the head <NUM> that define the recess <NUM> are configured to engage with a fastener driving tool adapter <NUM> during driving and/or insertion of the fastener <NUM> into a workpiece (e.g., the beam or the post) (not shown). In this illustrated example, the surfaces that define the recess indent <NUM> are configured to positively retain the fastener driving tool adapter <NUM> in the recess <NUM> of the fastener <NUM> while a driving tool (not shown) drives the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter <NUM> within the recess <NUM> while the fastener <NUM> is moved axially forward and backward within the workpiece during driving and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the shank <NUM> includes a plurality of thread formations <NUM> extending outwardly from the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> has the tip <NUM> at the second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the tip <NUM> of the fastener <NUM> is configured as a drill tip, which may be milled or forged. In this illustrated example, the head <NUM> includes a feature to positively retain the fastener <NUM> to be moved forward and backward axially. In this illustrated example, the head <NUM>, the shank <NUM>, and the drill tip of tip <NUM> form a unitary structure that enables a user to drill and install the fastener <NUM> in one operation. That is, the fastener <NUM> including the tip <NUM> (i.e., the drill tip) drills, drives and/or inserts the fastener <NUM> into the workpiece without having to use a separate drill bit to first drill or otherwise form a hole through the workpiece. In this illustrated example, the tip <NUM> of the fastener <NUM> includes a flute <NUM> formed in the tip <NUM> of the fastener <NUM>. In this illustrated example, the flute <NUM> is positioned proximate to the end of the tip <NUM>; however other positions of the flute <NUM> are possible in accordance with the present disclosure. As such, the flute <NUM> is configured to collect wood chips generated by drilling (i.e., the cutting action) of the drill tip on the workpiece (e.g., the deck post and the deck beam). During operation, to improve the efficiency of the drill tip, wood chips can be removed periodically during drilling, driving and/or insertion of the fastener <NUM> through the workpiece (e.g., the deck post and the deck beam).

In this illustrated example, removal of the wood chips generated by drilling through the workpiece and collected in the flute <NUM>, is facilitated by movement of the fastener <NUM> forward and backward axially. For example, as best seen in <FIG>, <FIG>, and <FIG>, the head <NUM> of the fastener <NUM> includes a square shaped recess <NUM> including the recess indent <NUM> (or hole) which enables the head to lock an adapter into the recess <NUM> of the head <NUM> (and positively retain the fastener). This permits the fastener <NUM> to be pulled out of the hole being generated in the workpiece, clearing out the wood chips collected from the flutes <NUM> of the tip <NUM>. This method of drilling is known by a person skilled in the art as "peck-drilling.

<FIG> and <FIG> illustrate another example embodiment of the post-to-beam fastener of the present disclosure that is generally indicated by numeral <NUM>. This illustrated example embodiment of the post-to-beam fastener <NUM> is similar to fastener <NUM>, as discussed above. This illustrated example embodiment shows selected components of the post-to-beam fastener <NUM>, and other components of the post-to-beam fastener <NUM> not discussed herein will be readily understood by those skilled in the art.

The illustrated example post-to-beam fastener <NUM>, also referred to as a "<NUM> Piece Fastener Concept," includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; and (<NUM>) a tip <NUM> suitably connected to the shank <NUM> at a second end <NUM> of the shank <NUM>. In this illustrated example, the post-to-beam fastener <NUM> (i.e., the <NUM> Piece Fastener Concept) is configured as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt (i.e., fastener <NUM>) with the tip <NUM> and the head <NUM> opposite of the tip <NUM>. It should be appreciated that while the post-to-beam fastener <NUM> is described as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head <NUM> is configured as a carriage bolt head and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess <NUM> defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a recess indent <NUM> defined in at least one sidewall (not labeled) of the recess <NUM>. In this illustrated example, the surfaces that define the recess <NUM> are configured to engage with the fastener driving tool adapter <NUM> (shown in <FIG> and <FIG>) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., the beam or the post) (not shown). In this illustrated example, the surfaces that define the recess indent <NUM> are configured to positively retain the fastener driving tool adapter <NUM> in the recess <NUM> of the fastener <NUM> while a fastener driving tool (not shown) drives the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter <NUM> within the recess <NUM> while the fastener <NUM> is moved axially forward and backward within the workpiece during drilling, driving and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the shank <NUM> includes: (<NUM>) a square shoulder <NUM> adjacent to the first end <NUM> of the shank <NUM>; and (<NUM>) a plurality of thread formations <NUM> extending outwardly from the shank <NUM> to form a threaded shank that connects to the head <NUM> at the square shoulder <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> has a tip <NUM> at second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the tip <NUM> of the fastener <NUM> is configured as a drill tip, which may be milled or forged. In this illustrated example, the head <NUM> includes a feature to positively retain the fastener <NUM> to be moved forward and backward axially. In this illustrated example, the head <NUM>, the shank <NUM>, and the drill tip of tip <NUM> form a unitary structure that enables a user to drill and install the fastener <NUM> in one operation. That is, the fastener <NUM> including the tip <NUM> (i.e., the drill tip) drills, drives and/or inserts the fastener <NUM> into the workpiece without having to use a separate drill bit to first drill or otherwise form a hole through the workpiece. In this illustrated example, the tip <NUM> of the fastener <NUM> includes a flute <NUM> formed in the tip <NUM> of the fastener <NUM>. In this illustrated example, the flute <NUM> is positioned proximate to the end of the tip <NUM>, however other positions of the flute <NUM> are possible. As such, the flute <NUM> is configured to collect wood chips generated by drilling (i.e., the cutting action) of the drill tip on the workpiece (e.g., the deck post and the deck beam). During operation, to improve the efficiency of the drill tip, wood chips can be removed periodically during drilling, driving and/or insertion of the fastener <NUM> through the workpiece.

In this illustrated example, removal of the wood chips generated by drilling through the workpiece and collected in the flute <NUM>, is facilitated by movement of the fastener <NUM> forward and backward axially. For example, as best seen in <FIG>, and <FIG> the head <NUM> of the fastener <NUM> includes surfaces that define a square shaped recess <NUM> including the recess indent <NUM> (or hole) and that lock an adapter into the recess <NUM> of the head <NUM> (i.e., positively retains the fastener). This permits the fastener <NUM> to be pulled out of the hole being generated in the workpiece, clearing out the woodchips collected from the flute <NUM> of the tip <NUM>.

Referring to fasteners associated with the <NUM> Piece Fastener Concept, several different variations of the drill tip on the end of the fastener are possible in accordance with the present disclosure. As discussed above, the drill tip (i.e., drill point) enables the user to drill, drive and/or install the fastener using a singular, complete assembly including a fastener and a drill tip. As such, there is no need for the user to carry separate drill bits. In various embodiments, the flutes (e.g., drill flutes or cutting flutes) of the drill tip are formed or otherwise defined into the fastener itself. In various embodiments, the flutes of the drill tip are approximately <NUM> inches (<NUM> cms) long. Peck-drilling is typically used with flutes of such a length (e.g., <NUM> inches (<NUM> cms) long). However, it will be appreciated that the flutes can vary in size, shape and number flutes that are defined on the tip of the fastener. As such, in various other embodiments, longer drill flutes could be used, which may reduce the amount of backward and forward drilling (i.e., peck-drilling) used but may require the fastener to be longer overall.

<FIG>, <FIG>, <FIG>, and <FIG> illustrate several different drill tip and/or flute configurations. In some embodiments, the drill tip may be broken, or knocked off of the end of the shank of the fastener by a hammer, or other such tool. In some embodiments, the fastener includes a breakaway tip including the drill tip, and at least a portion of the flute. In these embodiments, the breakaway tip is broken off at a breakaway line or breakaway joint. In these embodiments, the breakaway tip is broken off from the fastener at the breakaway line or breakaway joint after a nut is installed on the fastener and tightened against the workpiece (e.g., the deck post and/or the deck beam).

In particular, <FIG>, illustrate selected components of another example embodiment of a post-to-beam fastener generally indicated by numeral <NUM>. Post-to-beam fastener <NUM> is similar to fastener <NUM> discussed above and includes a milled drill tip and flute formed or otherwise defined in the tip of the post-to-beam fastener <NUM>.

The illustrated example post-to-beam fastener <NUM> includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; and (<NUM>) a tip <NUM> removably connected to the shank <NUM> at a second end <NUM> of the shank <NUM>. In this illustrated example, the post-to-beam fastener <NUM> is configured as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt (i.e., fastener) with the head <NUM> opposite of the tip <NUM>. It should be appreciated that while the post-to-beam fastener <NUM> is described as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head <NUM> is configured with a hexagonal shape and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess (not shown) defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a recess indent (not shown) defined in at least one sidewall (not labeled) of the recess. In this illustrated example, the surfaces that define the recess are configured to engage with a fastener driving tool adapter (not shown) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., the beam or the post) (not shown). In this illustrated example, the surfaces that define the recess indent are configured to positively retain the fastener driving tool adapter in the recess of the fastener <NUM> while a fastener driving tool (not shown) drills, drives, and/or inserts the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter within the recess while the fastener <NUM> is moved axially forward and backward within the workpiece during drilling, driving and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the shank <NUM> includes: (<NUM>) a plurality of thread formations <NUM> extending outwardly from the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>; and (<NUM>) a breakaway line or breakaway joint <NUM> defined between the second end <NUM> of the shank <NUM> and the tip <NUM> of the fastener <NUM>. In this illustrated example, the threaded shank (i.e., shank <NUM>) connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> has a the tip <NUM> at second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the drill tip of tip <NUM> includes a flute <NUM> formed in the tip <NUM> of the fastener <NUM>. More specifically, the flute <NUM> is formed on the tip <NUM> and positioned between the breakaway line or breakaway joint <NUM> and the end of the tip <NUM>, however other positions of the flute <NUM> are possible. As such, the flute <NUM> helps to collect wood chips generated by drilling (i.e., the cutting action) of the drill tip on the workpiece (e.g., the deck post and the deck beam). In this illustrated example, the tip <NUM> of the fastener <NUM> is configured as a breakaway drill tip, which is removed from the shank <NUM> of the fastener <NUM> once the drilling, driving, and/or insertion of the fastener <NUM> is complete. More specifically, the breakaway drill tip of tip <NUM> enables a user to remove the drill tip from the fastener <NUM> once the hole is drilled through the workpiece and a nut (not shown) is installed around the thread formations <NUM> of the shank <NUM> and suitably tightened against the workpiece. As such, the fastener <NUM> including the tip <NUM> drills, drives and/or inserts the fastener <NUM> into the workpiece without having to use a separate drill bit to first drill or otherwise form a hole through the workpiece.

<FIG>, <FIG> illustrate selected components of another example embodiment of a post-to-beam fastener generally indicated by numeral <NUM>. Post-to-beam fastener <NUM> is similar to fastener <NUM> discussed above. Post-to-beam fastener <NUM> includes a forged drill tip (i.e., forged drill point). While the forged drill tip is similar to the milled drill tip and flute discussed above, the process to manufacture forged drilling tips is less expensive. In this illustrated example embodiment, an ending diameter of the forged drill tip of the fastener <NUM> is slightly larger than the <NUM>/<NUM> inch (<NUM> cms) major diameter of threads of the fastener <NUM>. The slightly larger ending diameter of the forged drill tip produces a hole in the workpiece that is slightly larger than the fastener <NUM>. This increased diameter of the hole in the workpiece makes installation of the fastener <NUM> easier. In this illustrated example, the fastener <NUM> includes a breakaway tip that is removed or otherwise broken off before a nut is suitably installed on the fastener and suitably tightened against the workpiece because the ending diameter of the forged drill tip is larger than the threads of the fastener <NUM>. In this illustrated example, the breakaway tip (see <FIG>) is used and knocked off by a hammer or other such tool before installation of the nut( not shown) onto the fastener <NUM>.

The illustrated example post-to-beam fastener <NUM> includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; and (<NUM>) a tip <NUM> suitably connected to the shank <NUM> at a second end <NUM> of the shank <NUM>. In this illustrated example, the post-to-beam fastener <NUM> is configured as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt (i.e., fastener <NUM>) with the head <NUM> opposite of the tip <NUM>. It should be appreciated that while the post-to-beam fastener <NUM> is described as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head <NUM> is configured with a hexagonal shape and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess (not shown) defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a recess indent (not shown) defined in at least one sidewall (not labeled) of the recess. In this illustrated example, the surfaces that define the recess are configured to engage with a fastener driving tool adapter (not shown) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., beam or post) (not shown). In this illustrated example, the surfaces that define the recess indent are configured to positively retain the fastener driving tool adapter in the recess of the fastener <NUM> while a fastener driving tool (not shown) drills, drives and/or inserts the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter within the recess while the fastener <NUM> is moved axially forward and backward within the workpiece during drilling, driving and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the shank <NUM> includes: (<NUM>) a plurality of thread formations <NUM> extending outwardly from the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>; and (<NUM>) a breakaway line or breakaway joint <NUM> disposed between the second end <NUM> of the shank <NUM> and the tip <NUM> of the fastener <NUM>. In this illustrated example, the threaded shank (i.e., shank <NUM>) connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> forms the tip <NUM> at second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the tip <NUM> includes: (<NUM>) a first outer diameter <NUM> at a first end of the tip <NUM> adjacent to the breakaway line or breakaway joint <NUM>; and (<NUM>) a second outer diameter <NUM> at a second end of the tip <NUM> opposite the first end. In this illustrated example, the second outer diameter <NUM> of the tip <NUM> is slightly larger than the major diameter of the thread formations <NUM> of the shank <NUM>. As such, the tip <NUM> of the fastener <NUM> produces a hole in the workpiece that is slightly larger than the major diameter of the thread formations <NUM> of the shank <NUM>. In this illustrated example, the tip <NUM> of the fastener <NUM> is configured as a breakaway drill tip, which is removed from the shank <NUM> of the fastener <NUM> once a hole is drilled through the workpiece. As such, the fastener <NUM> including the tip <NUM>, drills a hole into the workpiece without having to use a separate drill bit to drill or otherwise form a hole through the workpiece. In this illustrated example, once the hole is drilled through the workpiece, the tip <NUM> is removed from the fastener <NUM> at the breakaway line or breakaway joint <NUM> such that a nut (not shown) is suitably installed around the thread formations <NUM> of the shank <NUM> and suitably tightened against the workpiece.

<FIG> illustrates selected components of an additional example embodiment of a post-to-beam fastener generally indicated by numeral <NUM>. The post-to-beam fastener <NUM> is similar to fastener <NUM> discussed above and includes a winged drill tip (i.e., winged cutting tip) formed or otherwise defined in the tip of the post-to-beam fastener <NUM>. In this illustrated example embodiment, the winged drill tip of the fastener <NUM> is used to cut, drill, or otherwise form a proper hole diameter in a workpiece for the installation of the fastener <NUM>. In certain embodiments, the winged cutting tip of the fastener <NUM> is a breakaway tip. In certain other embodiments, only the wings of the winged cutting tip breakaway from the fastener. For example, the wings break off of the winged cutting tip when a specialized nut is installed on the fastener and suitably tightened against the deck post and deck beam.

The illustrated example post-to-beam fastener <NUM> includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; and (<NUM>) a tip <NUM> suitably connected to the shank <NUM> at a second end <NUM> of the shank <NUM>. In this illustrated example, the post-to-beam fastener <NUM> is configured as ½ inch (<NUM> cms) diameter bolt (i.e., fastener <NUM>) with the head <NUM> opposite of the tip <NUM>. It should be appreciated that while the post-to-beam fastener <NUM> is described as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head <NUM> is configured with a hexagonal shape and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess (not shown) defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a recess indent (not shown) defined in at least one sidewall (not labeled) of the recess. In this illustrated example, the surfaces that define the recess are configured to engage with a fastener driving tool adapter (not shown) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., beam or post) (not shown). In this illustrated example, the surfaces that define the recess indent are configured to positively retain the fastener driving tool adapter in the recess of the fastener <NUM> while a fastener driving tool (not shown) drills, drives and/or inserts the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter within the recess while the fastener <NUM> is moved axially forward and backward within the workpiece during drilling, driving and/or insertion of the fastener <NUM>.

In this illustrated example, the shank <NUM> includes: (<NUM>) a plurality of thread formations <NUM> extending outwardly from the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>; and (<NUM>) a breakaway line breakaway joint <NUM> disposed between the second end <NUM> of the shank <NUM> and the tip <NUM> of the fastener <NUM>. In this illustrated example, the threaded shank (i.e., shank <NUM>) connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> has the tip <NUM> at second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the drill tip of the tip <NUM> includes: (<NUM>) a first wing formation 674a extending radially from an outer surface of the tip <NUM>; and (<NUM>) a second wing formation 674b extending radially from the outer surface of the tip <NUM>. In this illustrated example, the first and second wing formations 674a and 674b define a wing formation diameter that is slightly larger than an outer diameter of the tip <NUM>. In this illustrated example, the wing formation diameter of the first and second wing formations 674a and 674b is slightly larger than the major diameter of the thread formations <NUM> of the shank <NUM>. As such, the tip <NUM> and the first and second wing formations 674a and 674b of the fastener <NUM> produce a hole in the workpiece that is slightly larger than the than the major diameter of the thread formations <NUM> of the shank <NUM>. In this illustrated example, the tip <NUM> of the fastener <NUM> is configured as a breakaway drill tip, which is removed from the shank <NUM> of the fastener <NUM> once a hole is drilled through the workpiece. As such, the fastener <NUM> including the tip <NUM>, drills a hole into the workpiece without having to use a separate drill bit to drill or otherwise form a hole through the workpiece. In this illustrated example, once the hole is drilled through the workpiece, the tip <NUM> including the first and second wing formations 674a and 674b is removed from the fastener <NUM> at the breakaway line or breakaway joint <NUM> such that a nut (not shown) is suitably installed around the thread formations <NUM> of the shank <NUM> and suitably tightened against the workpiece.

In one example embodiment, only the wings break away from the tip of the fastener. More specifically, the first and second wing formations are configured to break away or otherwise be removed from the tip of the fastener following the drilling of the hole in the workpiece. For example, the wings break off when a specialized nut is installed on the bolt and tightened against the deck post and deck beam. As such, the nut is configured to break off or otherwise remove the first and second wing formations as the nut is suitably installed on the fastener and suitably tightened against the workpiece. As such, in this example embodiment, the tip remains suitably connected to the fastener following the drilling, driving, and/or insertion of the fastener into the workpiece.

<FIG>, 13A, and 13B illustrate another example embodiment of the post-to-beam fastener of the present disclosure that is generally indicated by numeral <NUM>. This illustrated example embodiment shows selected components of the post-to-beam fastener <NUM>, and other components of the post-to-beam fastener <NUM> not discussed herein will be readily understood by those skilled in the art.

The illustrated example post-to-beam fastener <NUM>, includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; (<NUM>) a tip <NUM> integrally connected to the shank <NUM> at a second end <NUM> of the shank <NUM>; and (<NUM>) a drill bit <NUM> removably attached to the tip <NUM> of the fastener <NUM>. In this illustrated embodiment, the post-to-beam fastener <NUM> is referred to as a "<NUM> Piece Fastener Concept. " that includes a <NUM>/<NUM> inch ( <NUM> cms) diameter bolt (i.e., fastener <NUM>) with a recess in an end (i.e., the tip <NUM>) of the bolt to removably attach the drill bit <NUM>. During operation, the drill bit <NUM> is attached to the tip <NUM> of the post-to-beam fastener <NUM> and the user drills a hole through a workpiece (e.g., the deck post and the deck beam). After drilling is complete, the drill bit <NUM> is removed from the fastener <NUM>. In this illustrated example, utilizing a drill bit produces efficient drilling and/or cutting action of the <NUM> Piece Fastener Concept. It should be appreciated that while the post-to-beam fastener <NUM> is described as a ½ inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In various embodiments of the <NUM> Piece Fastener Concept, known drill bits are used. For example, in one such embodiment a drill bit with a hex shank can be received in a hex recess of the end of the fastener (e.g., a <NUM>/<NUM> inch (. <NUM> cms) hex recess accommodating a <NUM>/<NUM> inch (. <NUM> cms) hex shank spade bit). In another such embodiment, customized drill bits are created to optimize attachment to the recess in the end of the fastener. By utilizing drill bits, efficient cutting action can be achieved with the <NUM> Piece Fastener Concept.

In various embodiments, combining the predrilling and installation according to the present disclosure, the <NUM> Piece Fastener Concept provides a faster user experience. During operation, the <NUM> Piece Fastener Concept operation begins with connecting the bolt (i.e., fastener) to the drill driver. This can be done using a socket, star, or square drive adapter. Next, a drill bit is inserted into the recess on the tip end of the fastener. The recess at the end of the fastener enables the user to install various common drill bits. The drill bit is used to drill the fastener through the workpiece (e.g., the deck post and/or the deck beam). Once the cutting operation has been completed, the drill bit can be removed from the other side of the post (and used with subsequent <NUM> Piece Fastener Concept fasteners, or any other operation). A washer and nut are installed and tightened.

In this illustrated example, the head <NUM> is configured with a hexagonal shape and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess (not shown) defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a recess indent (not shown) defined in at least one sidewall (not shown) of the recess. In this illustrated example, the surface that define the recess are configured to engage with a fastener driving tool adapter (not shown) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., the beam or the post) (not shown). In this illustrated example, the surfaces that define the recess indent are configured to positively retain the fastener driving tool adapter in the recess of the fastener <NUM> while a driving tool (not shown) drives the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter within the recess while the fastener <NUM> is moved axially forward and backward within the workpiece during driving and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the shank <NUM> includes a plurality of thread formations <NUM> extending outwardly from the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the threaded shank (i.e., shank <NUM>) connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> forms the tip <NUM> at second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the tip <NUM> of the fastener <NUM> includes surfaces that define a recess <NUM> in the tip <NUM> to removably attach the drill bit <NUM> to the fastener <NUM>. As best seen in FIGS. 13A and 13B, the recess <NUM> is configured as a hex recess (e.g., a <NUM>/<NUM> inch (. <NUM> cms) hex recess) that accepts any standard hex shank drill bits (e.g., <NUM>/<NUM> inch (. <NUM> cms) hex shank drill bits) In this illustrated example embodiment, the recess <NUM> does not provide any positive engagement of the drill bit <NUM>. That is, there is nothing securing (i.e., locking) the drill bit <NUM> in place within the recess <NUM>, besides the force from the operator while drilling. As such, in this illustrated example, the drill bit <NUM> is easily removed from the recess <NUM> of the fastener <NUM> after drilling and/or cutting a hole through a workpiece.

In another example embodiment, the recess of the fastener includes an additional positive retaining feature (not shown) (e.g., similar to the indent described in <FIG> with respect to the head <NUM> of the <NUM> Piece Fastener Concept fastener <NUM>) to removably secure the drill bit in the end of the fastener. As such, the positive retaining feature secures the drill bit in place within the recess, along with the force from the operator while drilling.

<FIG> and <FIG> illustrate another example embodiment of the post-to-beam fastener of the present disclosure that is generally indicated by numeral <NUM>. The post-to-beam fastener <NUM> is similar to fastener <NUM>, discussed above. This illustrated example embodiment shows selected components of the post-to-beam fastener <NUM>, and other components of the post-to-beam fastener <NUM> not discussed herein will be readily understood by those skilled in the art.

The illustrated example post-to-beam fastener <NUM>, includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; (<NUM>) a tip <NUM> integrally connected to the shank <NUM> at a second end <NUM> of the shank <NUM>; and (<NUM>) a drill bit 1280a removably attached to the tip <NUM> of the fastener <NUM>. In this illustrated embodiment, the post-to-beam fastener <NUM> is referred to as a "<NUM> Piece Fastener Concept. " that includes a <NUM>/<NUM> inch (<NUM> cms) diameter bolt (i.e., fastener <NUM>) with a recess in an end (i.e., the tip <NUM>) of the fastener to removably attach the drill bit to the fastener. During operation, the drill bit <NUM> is attached to the tip <NUM> of the post-to-beam fastener <NUM> and the user drills a hole through a workpiece (e.g., the deck post and the deck beam). After drilling is complete, the drill bit 1280a is removed from the fastener <NUM>. In this illustrated example, utilizing a drill bit produces efficient drilling and/or cutting action of the <NUM> Piece Fastener Concept fastener. It should be appreciated that while the post-to-beam fastener <NUM> is described as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head <NUM> is configured with a hexagonal shape and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess (not shown) defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a recess indent (not shown) defined in at least one sidewall (not shown) of the recess. In this illustrated example, the surfaces that define the recess are configured to engage with a fastener driving tool adapter (not shown) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., the beam or the post) (not shown). In this illustrated example, the surfaces that define the recess indent are configured to positively retain the fastener driving tool adapter in the recess of the fastener <NUM> while a driving tool (not shown) drives the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter within the recess while the fastener <NUM> is moved axially forward and backward within the workpiece during drilling, driving and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the tip <NUM> of the fastener <NUM> includes surfaces that define a threaded recess <NUM> in the tip <NUM> to removably attach to one of a plurality of different drill bits such as drill bits 1280a, 1280b, or 1280c. For example, as best seen in <FIG> and <FIG>, the threaded recess <NUM> includes an internal thread formation (not labeled) (e.g., a <NUM>/<NUM>-<NUM> internal thread) extending from a surface of the threaded recess <NUM> of the tip <NUM> of the fastener <NUM>. In this example embodiment, the internal thread formation is configured to mate or otherwise accept a drill bit having a complimentary external thread formation (e.g., external <NUM>/<NUM>-<NUM> threads). In this example embodiment, the threaded recess <NUM> including the internal thread formation has an advantage in that the threads of the threaded recess <NUM> positively engage the threads of the drill bit so it stays locked into place while drilling. Once the operation is finished, the drill bit is unscrewed and reused.

In various embodiments, users (such as contractors or deck builders) prefer carriage bolts that have a low-profile head compared to hex bolts or other such bolts. The low-profile head of carriage bolts may be perceived to look cleaner and more professional than hex bolts by homeowners (customers of the deck builders). Carriage bolts have no sharp edges that may interfere with homeowners using the deck.

Known carriage bolts have a square shoulder that locks the bolt into the wood when driven with a hammer. To attach a nut to the bolt at the end of the post-to-beam fastening process, the bolt must be rotatably held in place by the wood. In some instances, however, the square shoulder reams a hole in the wood, allowing the bolt to rotate freely. Then, the bolt cannot be rotatably held in place by the wood, thus removing the ability to fasten the connection with a nut.

<FIG> illustrate another example embodiment of the post-to-beam fastener of the present disclosure that is generally indicated by numeral <NUM>. In this illustrated example embodiment, the post-to-beam fastener <NUM> is a bolt (i.e., fastener <NUM>) for use in the <NUM> Piece Fastener Concept for post-to-beam fastening. More specifically, the fastener <NUM> is a carriage bolt with a locking rib pattern replacing the square shoulder. The locking rib pattern, consisting of a plurality of ribs extending radially from the shank to the edge of the head, resists rotation and rotatably holds the fastener <NUM> in place by engagement with the workpiece (e.g., the deck post and/or the deck beam). Each of the plurality of ribs is angled such that the fastener <NUM> can spin freely in a clockwise direction but dig in when the fastener <NUM> tries to rotate counterclockwise. Tightening a nut onto the fastener <NUM> after drilling through the workpiece induces a counterclockwise rotation in the fastener, so if the ribs prevent this rotation, the fastener can be tightened fully.

The illustrated example post-to-beam fastener <NUM> includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; (<NUM>) a tip <NUM> integrally connected to the shank <NUM> at a second end <NUM> of the shank <NUM>; and (<NUM>) a drill bit (not shown) removably attached to the tip <NUM> of the fastener <NUM>.

In this illustrated example, the head <NUM> is configured as a carriage bolt head and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess <NUM> defined in a top surface (not labeled) of the head <NUM>; and (<NUM>) a locking rib pattern <NUM> including a plurality of ribs <NUM> extending outwardly from a bottom surface (not labeled) of the head <NUM>. In this illustrated example, the surfaces that define the recess <NUM> are configured to engage with a fastener driving tool adapter (not shown) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., the beam or the post) (not shown). In this illustrated example, the plurality of ribs <NUM> of the rib locking pattern <NUM> engages with the workpiece such that the fastener <NUM> does not freely spin when a nut (not shown) is suitably tightened around the fastener <NUM>. It should be appreciated that while recess <NUM> is shown as a star-shaped recess, other recesses may be used, such as a socket recess (engageable by a socket), and a square recess (engageable by a square drive adapter).

In this illustrated example, each rib <NUM> of the locking rib pattern <NUM> includes a leading face 1318a and a trailing face 1318b that meet at an apex 1318c of the rib <NUM>. The leading face 1318a forms an angle (not labeled) with respect to the bottom surface of the head <NUM>. Similarly, the trailing face 1318b forms an angle (not labeled) with respect to the bottom surface of the head <NUM>. In this illustrated example embodiment, the angle formed between the leading face 1318a and the bottom surface of the head <NUM> is greater than the angle formed between the trailing face 1318b and the bottom surface of the head <NUM>. As such the leading face 1318a is at a sharper angle with respect to the workpiece (not shown), and the trailing face 1318b is at a shallower angle with respect to the workpiece.

In this illustrated example, the shank <NUM> includes a plurality of thread formations <NUM> extending outwardly from the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>.

In this illustrated example, the thread formations <NUM> of the shank <NUM> are configured such that tightening a nut onto the fastener <NUM> induces a counter-clockwise rotation of the fastener <NUM>, and loosening the nut from the fastener <NUM> induces a clockwise rotation of the fastener <NUM>. As such, when the nut is tightened onto the thread formations <NUM>, the fastener <NUM> is tightened against the workpiece, causing the locking rib pattern <NUM> to come into contact with the workpiece. When the nut is loosened from the thread formations <NUM>, the fastener <NUM> is loosened or backed away from the workpiece, causing the locking rib pattern <NUM> to come out of contact with the workpiece.

In this illustrated example, as the nut is tightened onto the thread formations <NUM>, the tightening of the nut induces a counter-clockwise rotation of the fastener <NUM>, and the apex 1318c and leading edges 1318a of the ribs <NUM> come into contact with the workpiece, Thus, the sharper angle of the leading edges 1318a contact the workpiece during the tightening process, creating a rotational resistance with respect to the workpiece by "biting" into the surface of the workpiece. As such, the interaction between the ribs <NUM> and the workpiece prevent the fastener from spinning while the nut is being tightened. Conversely, when the nut is loosened from the thread formations <NUM>, the loosening of the nut induces a clockwise rotation of the fastener, and the apex 1318c and leading edges 1318a of the ribs <NUM> come out of contact with the workpiece. Thus the shallower angle of the trailing edges 1318b reduce the rotational resistance with respect to the workpiece to allow the fastener <NUM> to spin freely.

In this illustrated example, the tip <NUM> of the fastener <NUM> includes surfaces that define a recess <NUM> in the tip <NUM> to removably attach the drill bit (not shown) to the fastener <NUM>. In this illustrated example embodiment, the recess <NUM> is configured as a hex recess (e.g., a <NUM>/<NUM> inch (. <NUM> cms) hex recess) that accepts any standard hex shank drill bits (e.g., <NUM>/<NUM> inch (. <NUM> cms) hex shank drill bits). In this illustrated example embodiment, the recess <NUM> does not provide any positive engagement of the drill bit. That is, there is nothing securing (i.e., locking) the drill bit in place within the recess <NUM>, besides the force from the operator while drilling. As such, in this illustrated example, the drill bit is easily removed from the recess <NUM> of the fastener <NUM> after drilling and/or cutting a hole through a workpiece.

In this example embodiment, as illustrated in <FIG> and <FIG>, a washer <NUM> is integrated with the head <NUM> of the fastener <NUM>. An integrated washer further reduces the number of pieces that users have to handle during installation (though some users may not presently use washers with known carriage bolts). The integrated washer also increases the bearing surface area of the head of the fastener. A larger bearing surface may provider a tighter post-to-beam connection, resulting in peace of mind for users and their customers. In this illustrated example embodiment, the head <NUM> of the fastener <NUM> has a diameter similar to a standard fender washer. Other diameters between a known carriage bolt and standard fender washer, or greater than the standard fender washer, are also possible.

<FIG>, <FIG> illustrate another example embodiment of the post-to-beam fastener of the present disclosure that is generally indicated by numeral <NUM>. The post-to-beam fastener <NUM> is similar to fastener <NUM>, discussed above. This illustrated example embodiment shows selected components of the post-to-beam fastener <NUM>, and other components of the post-to-beam fastener <NUM> not discussed herein will be readily understood by those skilled in the art.

The illustrated example post-to-beam fastener <NUM>, includes: (<NUM>) a head <NUM>; (<NUM>) a shank <NUM> integrally connected to the head <NUM> at a first end <NUM> of the shank <NUM>; (<NUM>) a tip <NUM> integrally connected to the shank <NUM> at a second end <NUM> of the shank <NUM>; and (<NUM>) a drill bit <NUM> removably attached to the tip <NUM> of the fastener <NUM>. In this illustrated embodiment, the post-to-beam fastener <NUM> is referred to as a "<NUM> Piece Fastener Concept. " that includes a <NUM>/<NUM> inch ( <NUM> cms) diameter bolt (i.e., fastener <NUM>) with a recess in an end (i.e., the tip <NUM>) of the fastener to removably attach the drill bit to the fastener. During operation, the drill bit <NUM> is attached to the tip <NUM> of the post-to-beam fastener <NUM> and the user drills a hole through a workpiece (e.g., the deck post and the deck beam). After drilling is complete, the drill bit <NUM> is removed from the fastener <NUM>. In this illustrated example, utilizing a drill bit produces efficient drilling and/or cutting action of the <NUM> Piece Fastener Concept fastener. It should be appreciated that while the post-to-beam fastener <NUM> is described as a <NUM>/<NUM> inch (<NUM> cms) diameter bolt, any suitable different type of fastener and any suitable different size of fastener may be used in accordance with the present disclosure.

In this illustrated example, the head <NUM> is configured with a hexagonal shape and includes a retaining feature. More specifically, the head <NUM> includes surfaces that define: (<NUM>) a recess (not shown) defined in a top surface (not labeled) of the head <NUM>; (<NUM>) a recess indent (not shown) defined in at least one sidewall (not shown) of the recess; and (<NUM>) a washer <NUM> is integrated with the head <NUM> of the fastener <NUM>. In this illustrated example, the surfaces that define the recess are configured to engage with a fastener driving tool adapter (not shown) during drilling, driving and/or insertion of the fastener <NUM> into a workpiece (e.g., the beam or the post) (not shown). In this illustrated example, the surfaces that define the recess indent are configured to positively retain the fastener driving tool adapter in the recess of the fastener <NUM> while a driving tool (not shown) drives the fastener <NUM> into a workpiece. As such, the head <NUM> retains the fastener driving tool adapter within the recess while the fastener <NUM> is moved axially forward and backward within the workpiece during drilling, driving and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the shank <NUM> includes: (<NUM>) a plurality of thread formations <NUM> extending outwardly from at least a portion of the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>; and (<NUM>) one or more v-grooves <NUM> defined in and by the thread formations <NUM>. In this illustrated example, the threaded shank (i.e., shank <NUM>) connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> forms the tip <NUM> at second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the one or more v-grooves <NUM> defined in the thread formations <NUM> extend along a portion of the thread formations <NUM> (e.g., <NUM>/<NUM> of an inch (<NUM> cms) of the thread formations <NUM>). In this illustrated example, the one or more v-grooves <NUM> cause a reduction of the friction generated by the cutting action of the thread formations <NUM> into the workpiece during drilling, driving, and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the tip <NUM> of the fastener <NUM> includes surfaces that define a recess <NUM> in the tip <NUM> to removably attach to the drill bit <NUM>. As best seen in <FIG>, the recess <NUM> is configured as a hex recess (e.g., a <NUM>/<NUM> inch (. <NUM> cms) hex recess) that accepts any standard hex shank drill bits (e.g., <NUM>/<NUM> inch (. <NUM> cms) hex shank drill bits). In this illustrated example embodiment, the recess <NUM> does not provide any positive engagement of the drill bit <NUM>. That is, there is nothing securing the drill bit <NUM> in place within the recess <NUM>, besides the force from the operator while drilling. As such, in this illustrated example, the drill bit <NUM> is easily removed from the recess <NUM> of the fastener <NUM> after drilling and/or cutting a hole through a workpiece.

<FIG>, <FIG> illustrate various alternative further example embodiments of the post-to-beam fastener of the present disclosure that are generally indicated by numeral <NUM>. The post-to-beam fastener <NUM> shown in <FIG>, and <FIG> is similar to fastener <NUM>, discussed above. This illustrated example embodiment shows selected components of the post-to-beam fastener <NUM>, and other components of the post-to-beam fastener <NUM> not discussed herein will be readily understood by those skilled in the art.

In this illustrated example, the head <NUM> is configured with a hexagonal shape and includes: (<NUM>) a washer <NUM> integrated with the head <NUM> of the fastener <NUM>; and (<NUM>) a locking rib pattern <NUM> including a plurality of ribs <NUM> extending outwardly from a bottom surface (not labeled) of the washer <NUM> integrated with the head <NUM>.

In one example, the washer <NUM> is configured as a standard washer having a diameter of substantially <NUM> inches (<NUM> cms). In another example, the washer (not shown) is configured as a larger fender-type washer having a diameter of substantially <NUM> inches (<NUM> cms). It should be appreciated that while two washers having different dimensions are discussed, other suitable integrated washers having other suitable dimensions may be used in accordance with the present disclosure.

In this illustrated example, each rib <NUM> of the locking rib pattern <NUM> includes a leading face 1518a and a trailing face 1518b that meet at an apex 1518c of the rib <NUM>. The leading face 1518a forms an angle (not labeled) with respect to the bottom surface of the washer <NUM> integrated with the head <NUM>. Similarly, the trailing face 1518b forms an angle (not labeled) with respect to the bottom surface of the washer <NUM> integrated with the head <NUM>. In this illustrated example embodiment, the angle formed between the leading face 1518a and the bottom surface of the washer <NUM> is greater than the angle formed between the trailing face 1518b and the bottom surface of the washer <NUM>. As such the leading face 1518a is at a sharper angle with respect to the workpiece (not shown), and the trailing face 1518b is at a shallower angle with respect to the workpiece.

In one illustrated example, best seen in <FIG> and <FIG>, the plurality of ribs <NUM> of rib pattern <NUM> include partial ribs configured to radially extend from a location along the outer circumference of the washer <NUM> to an interior location spaced a specified distance from the shank <NUM>. As such, the ribs <NUM> radially extend along the surface of the washer <NUM> a partial distance between the outer circumference of the washer and the shank <NUM>.

In this illustrated example, the shank <NUM> includes: (<NUM>) a plurality of thread formations <NUM> extending outwardly from at least a portion of the shank <NUM> to form a threaded shank that connects to the head <NUM> at the first end <NUM> of the shank <NUM>; and (<NUM>) one or more v-grooves <NUM> defined in the thread formations <NUM>. In this illustrated example, the threaded shank (i.e., shank <NUM>) connects to the head <NUM> at the first end <NUM> of the shank <NUM>. In this illustrated example, the fastener <NUM> forms the tip <NUM> at second end <NUM> of the shank <NUM>, and the shank <NUM> has a longitudinal axis extending from the head <NUM> to the tip <NUM>.

In this illustrated example, the one or more v-grooves <NUM> defined in the thread formations <NUM> extend along a portion of the thread formations <NUM> (e.g., <NUM>/<NUM> of an inch (<NUM>) of the thread formations <NUM>). In this illustrated example, the one or more v-grooves <NUM> cause a reduction of the friction generated by the cutting action of the thread formations <NUM> into the workpiece during drilling, driving, and/or insertion of the fastener <NUM> into the workpiece.

In this illustrated example, the tip <NUM> of the fastener <NUM> includes surfaces that define a recess <NUM> in the tip <NUM> to removably attach to a drill bit (not shown). As best seen in <FIG>, the recess <NUM> is configured as a hex recess (e.g., a <NUM>/<NUM> inch (. <NUM> cms) hex recess) that accepts any standard hex shank drill bits (e.g., <NUM>/<NUM> inch (. <NUM> cms) hex shank drill bits). In this illustrated example embodiment, the recess <NUM> does not provide any positive engagement of the drill bit. That is, there is nothing securing the drill bit in place within the recess <NUM>, besides the force from the operator while drilling. As such, in this illustrated example, the drill bit is easily removed from the recess <NUM> of the fastener <NUM> after drilling and/or cutting a hole through a workpiece.

In another illustrated example, best seen in <FIG>, the fastener <NUM> includes a plurality of ribs <NUM> of rib pattern <NUM> that include full ribs configured to radially extend from a location along the outer circumference of the washer <NUM> to an interior location adjacent to the shank <NUM>. As such, the ribs <NUM> radially extend along the surface of the washer <NUM> the entire distance between the outer circumference of the washer <NUM> and the shank <NUM>.

In various embodiments, of the <NUM> Piece Fastener Concept, several variations of the feature (e.g., the recess in the head) to positively retain the bolt to be moved forward and backward axially are possible. As the drill tip drives into the wood workpiece, small wood chips are created within the hole. For the drill to operate efficiently, these chips should be cleared to allow for more chips to be created. If these chips are not cleared the drill tip will get clogged with chips, thus impeding advancement of the drill tip and heating the drill tip due to excessive friction. A positive engagement head clears the wood chips by allowing the bolt to be pulled back and forth out of the hole.

In one such embodiment, <FIG> illustrate a <NUM>/<NUM> inch (. <NUM> cms) Hex to <NUM>/<NUM> inch (. <NUM> cms) Square Adapter. This adapter includes a ball detent which locks into the indent (or hole) defined surfaces of the square recess defined in surfaces of the head of the bolt. As such, the positive engagement provided by the <NUM>/<NUM> inch (. <NUM>) Hex to <NUM>/<NUM> inch (. <NUM> cms) Square Adapter enables the bolt to be pulled back and forth out of the hole to clear the wood chips generated while drilling the hole.

In another such embodiment, <FIG>, <FIG> illustrate an integrated driving tool adapter integrated with the head of the bolt allowing for direct attachment of the integrated driving tool adapter to the drill chuck. This direct attachment is a form of positive engagement, as the drill chuck locks into the integrated driving tool adapter. As such, the positive engagement provided by the integrated driving tool adapter enables the bolt to be pulled back and forth out of the hole to clear the wood chips generated while drilling the hole.

In various embodiments of the <NUM> Piece Fastener Concept, the recess at the end of the bolt enables the user to install various common drill bits for use in the post-to-beam fastener installation methods of the present disclosure. The drill bit is inserted into the end of the bolt and used to drill the bolt through the post. Once the cutting operation has been completed, the drill bit can be removed (and used with subsequent <NUM> Piece Concept bolts, or any other operation).

<FIG> illustrates a comparison between methods of post-to-beam fastening using known methods (the "Current Solution"), the <NUM> Piece Fastener Concept of the present disclosure, and the <NUM> Piece Fastener Concept of the present disclosure. The known method begins with a drill bit attached to the drill driver. A <NUM>/<NUM> inch hole is pre-drilled through the post, and a <NUM>/<NUM> inch (<NUM> cms) through bolt is hammered into the hole. A washer and nut are attached and tightened.

By combining the predrilling and installation according to the present disclosure, the <NUM> Piece Fastener Concept and the <NUM> Piece Fastener Concept provide a faster user experience. The <NUM> Piece Fastener Concept operation begins with positively retaining the bolt (i.e., at the square recess with hole in the head) to the drill driver. Next, the bolt is drilled and driven through the wood using the peck-drilling technique described above. Once the bolt is driven all the way through the post, the drill driver is removed from the head of the bolt. A washer and nut are assembled on the end of the bolt, and the entire assembly is fastened tightly together.

The <NUM> Piece Fastener Concept operation begins with connecting the bolt to the drill driver. This can be done using a socket, star, or square drive adapter. Next, a <NUM> inch (<NUM> cms) long drill bit is inserted into the recess on the tip end of the bolt. The bolt is drilled and driven into the post in one motion without the peck-drilling used by the <NUM> Piece Concept operation. The drill bit is then removed from the other side of the post, and a washer and nut are installed and tightened.

Thus, the several aforementioned objects and advantages are most effectively attained. The <NUM> Piece Fastener Concept and <NUM> Piece Fastener Concept of the present disclosure combine pre-drilling and bolt installation steps of post-to-beam fastening into one step. Use of the bolts and methods of the present disclosure result in faster and more efficient installations of deck posts and deck beams.

Claim 1:
A fastener (<NUM>) comprising:
a head (<NUM>);
a tip (<NUM>) including interior surfaces defining a recess ( <NUM>) configured to removably receive an end of a drill bit (<NUM>), and wherein the interior surfaces are configured to engage the end of the drill bit; and
a threaded shank (<NUM>) connected to the head at a first end (<NUM>) and the tip at a second end (<NUM>), the threaded shank having a longitudinal axis extending from the head to the tip and including a plurality of thread formations (<NUM>);
characterized in that the plurality of thread formations (<NUM>) extend outwardly from at least a portion of the threaded shank (<NUM>) adjacent to the tip (<NUM>);
in that the fastener (<NUM>) further comprises one or more v-grooves (<NUM>) defined in and by the thread formations (<NUM>), the one or more v-grooves extend along a portion of the thread formations; and
in that the fastener includes a locking ribs (<NUM>) under the head (<NUM>).