Note: Descriptions are shown in the official language in which they were submitted.
CA 02307587 2003-02-05
- 1 -
A FASTENER HAVING TORQUE REDUCING THREAD
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to roof gutters.
More parti::ularly, it relates to a roof gutter fastener
and method for the applicaticn thereof, that utilizes a
threaded shank portion for securing the gutter to the
facia panel.
2A. Background Information
In the past, using z:olled or 1at.hed threads on such
threaded prior art fasteners required piloi holes before
penetrating into thin pieces of fac,.e wood.
The developmental procedure leading to the
invention of the gutter bolt is as follows. First seven
inch metal threaded self tapped coated steel Phillips
head 3/16"thick insulation sc:rews were tested. Each was
fastened witn a #3 Phillips bit/i"lag bolt hex head.
CA 02307587 2000-05-01
WO 99l23326 PCT/US98/22776
- 2 -
The results are as follows. Extensive stripping of the
bolt head due to the torque applied to the long steel bolt to
screw it into the wood that was meant for metal installation.
Even cutting a wider and deeper slotted head into steel screws
did not solve the problem. Changing it into a universal
Phillips or slotted head also failed to solve the problem.
The force required for holding a drill that need to be applied
caused a splitting of facia boards. The drill tip would pop
out and then accidentally mark or puncture the gutter. Pilot
holes thusly had to be drilled. The excessive damage and the
amount of time required for this procedure did not make those
screws commercially applicable in business. A head with more
points of controlled contact is provided.
Another attempt was made to use lag bolts. Lag bolts
require a pilot hole when fastening into new wood, so that
there is no splitting of the facia board. Once again this is
a very time consuming procedure. Also the bolt head protruded
out from the front of the gutter. Quite often, the lag bolt
head projected very far out in front of the gutter. The lag
bolts therefore have an unsightly appearance and bring
unwanted attention to the fastener for the gutter. Cutting
back the heads of the lag bolt is not acceptable, even when
the heads are painted to match the color of the gutter. When
fastening due to torque of the tool, the fastener paint is
CA 02307587 2000-05-01
WO 99l23326 PCT/U598/22776
- 3 -
removed and chipped away. Touch up painting is required to
prevent rusting which starts occurring immediately.
In the past, the spinning motion of the fastener when
making contact with the front of the gutter strips the paint
off the gutter where the fastener head presses against gutter
leaving raw metal exposed to the weather. Rusting occurs
along with staining and marking of the gutter. These results
are not acceptable due to complaints from homeowners.
Scratching of the gutter occurs when the socket wrench
makes the final turns to cause the gutter to be attached to
the facia. This problem can be solved by the invention if a
washer is built into the head of the gutter bolt. This built-
in washer has a large enough diameter to be able to shield the
face of gutter from contact with the socket wrench.
After all the testing of the head and the threads was
completed to achieve the proper specific requirements for
performance and appearance, it was decided to use the same
material as that used to manufacture most gutters, namely
aluminum. The advantages are that after an installation there
will be no electrolysis, rusting or corrosion by bringing into
contact different types of metals. This is especially when
metals are exposed to many types of weather conditions, or
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 4 -
chemical exposure, and humidity variations, that encourage
oxidation of the metals to occur.
Beginning with aluminum nails, it was decided to make
them into gutter bolts. First there was the head portion and
then cutting threading for making a gutter bolt. If the
material was too soft, it would snap just going through 3/4"
pine board. But with the use of a pilot hole, it would
penetrate wood and hold formally. But the metal hardness had
to be increased to go through Douglas Fir wood without using a
pilot hole. Then a heat treating process was developed to
harden the aluminum alloy. Further testing of the materials
showed that some would drill right through 3/4" pine board but
snapping would occur or heads would strip off on most of the
other materials which were used and with the same results.
Rods or coil aluminum was used plus heat treating application
followed by specific machining techniques. Eventually, five
different types of aluminum were tested with eight heat
treatment processes involved with the different aluminum
material before using current material. Hundreds of tests
were made by drilling seven inch bolts into three-quarter inch
pine boards. Then there was test drilling into Douglas Fir
for the occasional situation wherein the gutter bolt hits the
rafter tails that holds up the facia board.
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 5 -
Finally an aluminum bolt material was found that had the
strength necessary to achieve the desired results.
It was impossible to locate any type of bolt system
comparable to gutter bolts from any hardware stores, Fastening
Co., Home Depot and even the Thomas Register, exhausting all
possibilities for finding a source of supply for the gutter
bolts and materials that was to be tested and then eventually
finally perfected. Many types of material such as steel,
aluminum, or copper, etc., from which gutters are made, or any
other product in existence or similar metal used for any other
fastener was unsuccessful. Attempts were made to find a
manufacturer to make gutter bolts through the Yellow Pages,
The Business to Business Telephone Book, and the Thomas
Register, and by contacting hundreds of manufacturers. The
most often heard response was "What is a gutter bolt?" After
providing the manufacturer with a copy of the specifications,
the response after reviewing the specification was that
machining and tooling to produce this type of bolt due to
length, and for the thread pitch would take a great deal of
labor. New techniques and new technologies would be needed to
produce this combination of length and the unique threading
for the bolt. The threading was very unique and was not
similar to the threads of thousands of observed wood screws.
A search of this prior art found nothing comparable to the
CA 02307587 2000-05-01
WO 99l23326 PCT/US98/22776
- 6 -
pitch, depth, and length of the threading of the inventive
gutter bolt.
2B. The Prior Art
U.S. Patent No. 3,909,905 to Giordano, discloses gutter
installation tools. The invention consists of a spacer tool
having a U-shaped channel and being positioned between the
front and rear panels of the gutter. When the tool is in
place, a conventional spike can be driven through the front
gutter panel into the U-shaped channel and the rear gutter
panel to fasten the gutter to the structure. Once the spike
has been driven in, the tool can be removed and used again.
In addition, the prior art discloses a novel spike design that
adds a notch on the shaft near the head for engaging the front
portion of the gutter. The notch enables a more secure
coupling between the spike and the gutter.
These prior art gutter fasteners are nails that
ultimately end up having to be re-secured over time. As such,
the gutter partially detaches from the facia panel and thereby
prevents the efficient operation of the gutters.
In addition, by providing a more secure connection
between the gutter and the facia panel, the safety of the
working conditions for workers in the roofing, siding and
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 7 -
gutter fields is significantly increased. On many occasions,
these workers find themselves leaning on the gutters, which
causes stress on the gutter fasteners and usually requires the
gutter to be re-secured. A more secure connection will
alleviate this stress. Furthermore, it often happens that one
of these workers loses their balance while working and grabs
onto the gutter for support. With the old gutter fasteners,
the weight of an adult would literally rip the gutter from the
facia panel causing the worker to fall to the ground.
Depending on the height of the gutter, this can be a
potentially fatal circumstance. A more secure connection
between the gutter and facia panel would be desirable to
eliminate this danger by preventing the gutter from detaching
when subject to the weight of an adult. Also, denting of
gutter from hammering or re-hammering of gutter nails is
prevented.
Other prior art attempts to fasten gutters are described
in the Marulic U.S. Patent No. 4,888,920, the Hardin U.S.
Patent No. 5, 549, 261, and the British Patent No. 2707.
However, these prior art fasteners have all of the
disadvantages described above.
CA 02307587 2007-08-31
- $ -
SI7NIlMARY OF THE INVENTION
It is an object of the present invention to provide
a gutter fastener that overcomes the shortfalls of the
prior art by enabling a more secure connection between
the gutter and the facia panel. This more secure
connection eliminates the need for subsequent re-
securing of the gutter with the facia panel. This more
secure connection also eliminates the need for using a
pilot hole in the facia board.
In accordance with one aspect of the present
invention there is provided a fastener having opposing
ends, a longitudinal axis, a radius, and a threaded
portion and an unthreaded portion coaxially arranged
along said longitudinal axis, wherein the threaded
portion consists of a helical groove recessed into an
outer surface of the fastener defined by the radius, the
fastener comprising: a plurality of facets disposed
serially within and extending transverse to the helical
groove, said facets being operable to reduce the torque
required to drive said fastener into a work object,
wherein each of said plurality of facets comprise
different lengths, and points having varying radial
distances with respect to each other and the
longitudinal axis, and wherein said points further
comprise a high point, an intermediate point and a low
point, each of said high point, intermediate point and
low point having a different radial distance from the
longitudinal axis with respect to each other, each of
said different radial distances being smaller than the
radius of the fastener outer surface, and wherein said
CA 02307587 2007-08-31
- 8a -
different lengths comprise a short length, an
intermediate length and a long length, said short length
being defined as the distance between said low point and
said intermediate point, said intermediate length being
defined as the distance between said intermediate point
and said high point, said long length being defined as
the distance between said high point and said low point.
In accordance with another aspect of the present
invention there is provided a fastener having opposing
ends, a longitudinal axis, an outer surface defined by a
first radial distance from the longitudinal axis, and a
threaded portion and an unthreaded portion coaxially
arranged along said longitudinal axis, wherein the
threaded portion consists of a helical groove recessed
into the outer surface of the fastener, said helical
groove having a second radial distance defined as the
radial surface distance from the longitudinal axis to a
lowest point of the helical groove, the fastener
comprising: a plurality of facets disposed within and
extending transverse to the helical groove and having
different lengths and points, said different points
having different radial distances with respect to each
other, wherein said different radial distances are
greater than the second radial distance formed by the
helical groove and less than the first radial distance
of the outer surface, and wherein said points further
comprise a high point, an intermediate point and a low
point, each of said high point, intermediate point and
low point having a different radial distance from the
longitudinal axis with respect to each other, each of
CA 02307587 2007-08-31
- 8b -
said different radial distances being smaller than the
first radial distance of the fastener, and wherein said
different lengths comprise a short length, an
intermediate length and a long length, said short length
being defined as the distance between said low point and
said intermediate point, said intermediate length being
defined as the distance between said intermediate point
and said high point, said long length being defined as
the distance between said high point and said low point.
According to the invention, a wood screw or gutter
fastener is provided having a head portion for receiving
a tool, a first shank portion integrally formed with
head portion, and second shank portion integrally formed
with the first shank portion.
The first and second shank portions each have a
specific length, and share a common longitudinal axis.
The length of the first shank portion is such that the
gutter fastener can pass through the front of a gutter
and extend across the water collecting opening in the
gutter. The second shank portion has a length
substantially equal to one-half the length of the first
shank portion. The second shank portion is threaded in
a screw-like manner, and has a pointed end for
facilitating the engagement of the gutter fastener with
the gutter and facia panel.
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 9 -
It is therefore a further object of the present invention
to provide a wood screw or gutter fastener that utilizes a
threaded end to secure the gutter to the facia panel.
It is another object of the invention to provide a gutter
fastener that does not require additional time to install and
does not require the use of a pilot hole.
A further object of the invention is to provide a wood
screw or gutter fastener that eliminates the need for re-
securing the gutter to the facia panel after a period of time.
It is another object of the invention to provide a wood
screw or gutter fastener that operates more efficiently and
reliably that the prior art gutter fasteners.
The present invention solves this prior art problem. The
solution for using these bolts without pilot holes resides in
cutting the threads to such a degree of pitch, curvature,
height, depth, sharpness, so that the threading cuts like a
drill bit and the threading holds like a wood screw. After 30
different tests, it was determined to cut eleven threads to
the inch at a thread depth of one-third the gutter bolt
diameter from top to bottom of thread. A steep pitch in the
front of the thread is for cutting and lesser curved or
shallow pitch behind the thread enables the thread to cut like
CA 02307587 2000-05-01
WO 99n3326 PCT/US98/22776
- 10 -
a drill due to the steepest pitch and hold like a wood screw
due to the shallow portion of the thread.
Threads extended from the smooth portion length and
threading includes 2.5 inch cut into the seven inch length
bolt. This was researched for use with fasteners of 3
different size gutters (4", 5", 6") and gives the most support
to the four inch smooth portion meeting the cut portion. This
is due to taking away 1/16" from actual thickness of smooth
portion from cutting in threads and for fastening a gutter,
example 4" gutter 2 1/4" passes through the 3/4" standard
thickness facia board with 1/4" of thread still embedded in
back facia. The one-half inch smooth portion is embedded into
the facia with the four inch smooth portion supporting the
gutter with washer hex head contacting the gutter.
For a 5" standard residential gutter, 1 1/4" threaded
portion passes through the 3/4" facia board; and 3/4" threads
embedded into the facia W" threaded portion extended out from
the front of the facia combined with the 4&1" smooth portion
as support for the gutter washer hex head.
For a 6" commercial gutter, 1/4" portion passes through
the facia 3/4" embedded into the facia. 1 1/2" extends out of
the front of the facia with the 44" smooth portion. The
weakest point of the gutter bolt is where the threads meet the
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 11 -
smooth portion of the gutter bolt length. As discovered with
the degree of hardness of aluminum used to get the proper
strength needed, it was found that bolts will not snap when in
use.
The gutter bolt of the invention is 7 inch in total
length and includes a 2.5 inch wood screw threaded end portion
on the one-quarter inch diameter thick gutter bolt. The
threading is primarily to go through the facia board and the
rafter tails if necessary. The gutter bolt is of so great a
strength that this fastener can hold the entire weight of
gutter system without the use of a bracket system as in the
prior art. A sleeve may be added but only to keep the cavity
of gutter from being crushed if pressed towards the facia
board. This is in case of force applied to front of gutter
and is other than what gutter is designed to support.
The smooth unthreaded shank portion of the gutter bolt
connects into the threaded part of the gutter bolt so as to
provide the maximiun strength to support the gutters. This is
because all the threading is embedded into the wood so that
only the smooth shank can be covered by the sleeve to the
depth of the 5" cavity of the gutter.
There is no need to drive pilot holes into the facia.
Due to height, depth and pitch of threaded portion, the angle
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 12 -
of threads and sharpness of threading, the gutter bolt can
penetrate the pieces of wood close to the edge of the wood
without splitting. Prior art rolled or lathed wood threading
fasteners are known to split the wood without first having a
prior pilot hole being drilled into the wood.
As a preferred embodiment, the hexagonal shaped head, or
hex head, provides six points of fastening contact on the
sides of the gutter bolt head. Thus, there is substantial
support even if a great torque is needed for twisting the
gutter bolt fastener into the facia. Also there is no marking
on the gutter outside surface by the gutter bolt fastener that
occurs in conventional gutter fastener installations.
The preferred embodiment of a hex head washer combination
attached to the smooth portion of the shank provides a greater
holding force at the front of the gutter. Since the washer
has a larger diameter than hex head diameter, the washer also
prevents the socket wrench used for turning the hex head from
touching the front of the gutter and from leaving a ring mark
or scratch on the gutter face when securing the bolt to the
gutter.
In a further embodiment, facets are added to the screw
portion of the fastener part for wood screw installation to
reduce the required torque. Facets are notches cut or rolled
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 13 -
in between each thread of the fastener. Facets reduce the
torque on the head, rod, threading, tools and reduce the
stress on the material being fastened, such as the facia.
Facets are shaped multiangle and do not exceed the highest or
lowest point of the threading. They are a separate function
of the screw portion. Facets are located on the remaining
solid portion of the rod and between each of the threads.
Facets are recessed at different angle pitches allowing the
wood to pass over the highest point of the facet and to reside
in the deepest most recessed portion of the notch. This
relieves the stress on the wood as the fastener screws into
the wood. This gives the wood a chance to expand and contract
for maximum stress relief while the fastener of the invention
is advancing into the wood. With the turning penetration of
the threaded fastener, each individual thread allows this
stress relief process to happen.
Specifically, the present invention is thusly directed to
a screw-threaded portion of a wood screw or gutter bolt
fastener comprising a shaft having threads thereon, and each
thread having a front; said thread having a steep pitch in the
front of the thread and having a shallow curved portion behind
the thread; and facets comprising notches located in the
shallow curved portion behind the thread.
CA 02307587 2000-05-01
WO 99/23326 PCT/US98l22776
- 14 -
The angle of the facet reduces stress in the wood. As
the wood slides up to the next facet, it gradually builds up
torque until it reaches the highest point of the facet. This
equals the amount of pressure of a solid rod fastener without
facets until it rolls over into the cavity of the next facet.
With many facets placed on each thread having multiple threads
per inch, stress relief will occur on each individual thread.
With the facets in place, the screw threaded portion of
the fastener holds better within the wood. When unscrewing
the threaded portion from the wood, the wood now slides up to
the highest point of the facet. The wood has to overcome the
maximum height of the facet.
In order to manufacture the facets in the threads
according to the invention, the facets are added to the
shallow portion of the thread. This requires slowing down the
turning RPM of the cutting blade as it contacts the rod. This
permits the cutting blade to reside in one area of the
circumference of the bolt for a longer time and to make deeper
cuts of random or controlled depths and sizes within the
facet. Thus there can be a variable number of facets for each
individual thread.
The angles of the facets vary in degrees. This allows
screwing the threaded portion into the wood so as to turn the
CA 02307587 2000-05-01
WO 99/23326 PCT/1JS98/22776
- 15 -
fibers with the threads. Hence the fibers of wood will
conform to the low-high angles of the facets.
Facets provide a gradually sloped portion of the thread
when turning the fastener clockwise into the wood. This
allows fibers of the wood to travel up the least slope part of
the facet to the normal pressure depth of the thread. Fibers
of wood then drop off the steep end of the facet allowing
expansion of the fibers of wood down into the lowest portion
of the facet. This reduces the pressure and the force that
are applied to the wood fibers by the solid portion in between
the threads.
By having multiple facets per thread, the facets permit
the wood fibers to have a constant pressure relief at all
times per thread, since in one embodiment there are many
facets randomly placed at different depths per thread. Wood
fibers are not evenly placed on any two facets at one time
allowing a multiple action for pressure release all the time.
Hence, there are expansion, and contraction, of wood fibers
around the threaded portion of the fastener as it penetrates
into the wood. There are from 5 to 15 facets, or notches, per
thread, preferably from 8 to 10 facets per thread.
With facets being notched into the shallow curved portion
behind the thread, this also gives the threaded portion of the
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 16 -
fastener a superior holding power in the wood in two ways.
First, with the facets cut in between the threads, it allows
wood fibers to expand into the facet cavities. Wood fibers
are embedded into the facets within the threaded portion of
the rod allowing the wood fibers to expand and fill in the
space between the threads. Secondly, because facets are angled
and sloped with a sharp drop off, when removing the fastener,
the sharp drop of the facet now becomes a barrier of
resistance against removal. Due to the wood fibers expanding
into the facet and taking the shape of the facet, the steep
angle resists the removal of the fastener due to a gripping
action of the wood fibers. On the other hand, the gentle
sloped area of the facet causes a much lower level of
resistance by the wood fibers during insertion and advancement
of the fastener.
By adding facets to the threading of wood fasteners,
according to the invention, there are unique and beneficial
advantages as follows. It takes less torque to install, with
there being better holding of the fastener once installed into
wood and with less chance of the fastener loosening. There is
less chance of stripping the head off from the fastener.
There is less chance of snapping the fastener. There is
less wear on the tools used: slotted tip (saves on snapping),
Phillips tip (saves on snapping), electric drill (less wear on
the motor) and nut setter or socket (less stripping). Energy
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 17 -
saving is due to less electricity used when installing. There
is increased safety due to less force and torque used to
install the fastener. There is a choice of different metals
being useful, other than steel, for example aluminum, copper
or whatever metal can be used depending on the weather
environment or the metal specifications required. There is a
better holding power on the fastener within the wood.
Utilizing a small machine shop, a cold header was built
and mill cutter production was begun. First production was at
a very slow pace. Improvements were made to increase
production.
Three types of aluminum gutters were tested, namely
narrow (0.19 to 0.20 inch), medium (0.25 to 0.27 inch), and
heavy (0.30 to 0.32 inch) in diameters. Damage to a gutter
has been known to occur due to the weight of the snow, the ice
or the tree debris weight load. The back portion of the
gutter would not remain fastened to the facia board. Trying
to repair the gutter lip and the prior art hanger clip due to
metal fatigue damage has made the most worn point on the
hidden hanger even more worn out. This is especially true
where a tremendous amount of weight and loading does occur.
If the required repairs to the damaged area are neglected, the
situation worsens over time. The problem of gutter loosening
is well known and has existed since the beginning of the use
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 18 -
of gutters. The present invention is a solution to this
problem due to the uniqueness of gutter bolts. For example,
they fasten three types of gutters with one size of fastener
having adequate holding power, and not having to predrill
pilot holes for the fastener gutter bolt of the invention.
Refastening an existing gutter is possible without making new
holes in the front and the back of the gutter or facia board.
Time and money are saved by not having to refasten gutters
once this gutter has been fastened by the gutter bolt of the
invention. Also the very important matter of safety is
emphasized by usiiig the gutter bolt of the invention which
achieves a very high degree of safety.
The gutter bolts of the invention have several important
advantages. The gutter bolts have achieved significantly
improved sales in spite of the cost of producing the bolt.
Commercial success has been achieved with very little
advertising and is the result of demonstrations of the product
by the inventor, installers, homeowners, etc.
Gutter bolts can be up to five times more expensive than
a prior art gutter spike, and are 1.5 times more expensive
than prior art bracket systems. The savings in using gutter
bolts of the invention is due to over the years not having to
pay another person to renail the gutter back into position.
Also there is avoiding the risk of the repair person falling
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 19 -
to the ground in an attempt to nail back the loosened'gutters.
Also when nails do not grip in the same hole that was made
with the original installation, the repair person would move
that nail enter to the left or to the right of the existing
.5 hole for refastening of the loosened gutter. This causes
additional holes in the back of gutter and in the facia board
which in turn will permit water seepage to cause damage to the
facia board. Also when replacing gutters in the past, it was
necessary to replace facia board due to this excessive number
of holes, and due to possible splitting of the wood, and water
damage.
The gutter bolts of the invention can solve these
problems, due to the unique operational quality of the
invention not only for new installations but also for gutter
spike replacement as well. It is just necessary to remove the
old original gutter spike and to install a new gutter bolt
through the front opening and the back opening that had been
previously made by the original gutter spike and then to screw
the gutter bolt snugly into the facia. If the hole in the
facia board is reamed out due to the gutter spike and if the
threading does not grab into the wood, one could add a one
inch plastic anchor into the reamed out hole. Then install
the gutter bolt. For a secure fastening installation to hold
that gutter, it is no longer necessary to use the leading
prior art bracket system known as the hidden hanger. This
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 20 -
prior art bracket system screws through the back of the gutter
and only clips onto the front return lip of the gutter.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will
become apparent from the following detailed description
considered in connection with the accompanying drawing which
discloses several embodiments of the present invention. It
should be understood, however, that the drawing is designed
for the purpose of illustration only and not as a definition
of the limits of the invention.
In the drawing, wherein similar reference characters
denote similar elements throughout the several views:
FIG. 1 is a perspective view of the gutter fastener
according to the invention;
FIG. 2 is a partial cross-sectional view of a gutter
secured to a facia panel with the gutter fastener according to
the invention;
FIG. 3 is a top view of a first embodiment of the tool
receiving end of the gutter fastener according to the
invention;
CA 02307587 2000-05-01
WO 99123326 PCT/US98R2776
- 21 -
FIG. 4 is a top view of a second embodiment of the tool
receiving end of the gutter fastener according to the
invention;
FIG. 5 is a top view of a third embodiment of the tool
receiving end of the gutter fastener according to the
invention.
FIG. 6 is a perspective view of another embodiment of the
gutter fastener according to the invention having the
integrally attached washer at the tool receiving end of the
fastener;
FIG. 7 is a partial cross-sectional view of a gutter
secured to a facia panel with the gutter fastener according to
the invention, and having the integrally attached washer
contacting the gutter;
FIG. 8 is a top view of a fourth embodiment of the tool
receiving end of the gutter fastener according to the
invention, also having the integrally attached washer;
FIG. 9 is a top view of a fifth embodiment of the tool
receiving end of the gutter fastener according to the
invention, also having the integrally attached washer;
CA 02307587 2000-05-01
WO 99/23326 PCT/US98122776
- 22 -
FIG. 10 is a top view of a sixth embodiment of the tool
receiving end of the gutter fastener according to the
invention, also having the integrally attached washer;
FIG. 11 is an enlarged view of the partial cross-section
shown in FIG. 7 showing in detail the second shank portion;
FIG. 12 is a plan view of the manufacturing technique for
producing the unique threading of gutter bolt of the
invention; and
FIG. 13 is a section view along line 13-13 of FIG. 12
showing facets added to the screw threaded portion of the
fastener.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning now in detail to the drawings, FIGS. 1'and 2 show
the gutter fastener 10 according to the invention. Fastener
10 has a first shank portion 14 and a second shank portion 16
integrally formed with one end of the first shank portion. A
head portion 12 is integrally formed with the opposite end of
first shank portion 14. First shank portion 14 and second
shank portion 16 share a common central or longitudinal axis
30.
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 23 -
First shank portion 14 has a length L, and second shank
portion 16 has a length L2. Length L1 is substantially equal
to twice the length LZ. In other words, length L2 is
substantially equal to one-half the length L1. Although other
lengths could be employed for L1 and L2, these are the
preferable lengths that enable gutter fastener 10 to operate
more efficiently than other gutter fasteners.
The length L, of first shank portion 14 is such that this
shank portion can completely pass through ferrule 22 and
across water collecting opening 28 in gutter 20 (FIG. 2).
Once installed as shown in FIG. 2, the threaded second shank
portion 16 is completely secured within facia panel 24 and
thereby secures gutter 20 to the facia panel. The overall
length of fastener 10 is proportional to the diameter D such
that an approximate ratio of 24:1 length to diameter is
formed. For example, with diameter D equal to 1/4", the
overall length of Ll and L2 combined would be approximately
6". The overall length of fastener 10 can be in the range of
6"- 8" without the head. The preferred length of second shank
portion 16 is 2 inches to 2.67 inches based upon an overall
length of 6 to 8 inches.
The length of fastener 10 plays an integral part in the
design of the fastener. As the length is increased, the
torque applied to the head when being forced into facia panel
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 24 -
24 causes an additional torsional stress to occur at the
weakest points along fastener 10. The weakest points of
fastener 10 are the point at which head 12a connects with
first shank portion 14, and the transition point between first
shank portion 14 and second shank portion 16 (i.e. where the
threaded portion meets the non-threaded portion). Thus, head
12a can have a thickness in the range of 1/8" -'i".
The total length of the gutter bolt fastener of the
invention is such that the same size fastener can support a 4
inch gutter, a 5 inch gutter, or a 6 inch gutter, by itself
without the use of any other fastener means.
Second shank portion 16 has an end 18 that is pointed to
facilitate the initial engagement of fastener 10 with gutter
and facia pane'_ 24. In addition, pointed end 18 enables
the user to hammer fastener 10 through gutter 20 and into
facia panel 24 to further facilitate the initial engagement.
20 Fastener 10 has a diameter D that can be, for example,
1/4". Diameter D is chosen such that it is slightly larger
that the diameter of a standard gutter nail. Thus, the
current gutter nails can be replaced with gutter fastener 10
using the same hole left by the removed gutter nail.
CA 02307587 2000-05-01
WO 99/23326 PCT/US98R2776
- 25 -
In another embodiment of the invention, diameter D of
fastener 10 can be different for first shank portion 14 and
second shank portion 16. For example, the diameter of second
shank portion 16 could be slightly larger that of first shank
portion 14.
FIGS. 6 to 10 correspond respectively to FIGS. 1 to 5,
except that in FIGS. 6 to 10 the integrally attached washer 40
is shown. Washer 40 is integrally attached to the head 12a on
the inner surface 42 of head 12a such that washer 40 is
located between the head and the first shank portion 14.
Thus, the first shank portion 14, the washer 40 and the head
12a are of a unitary continuous construction having a tandem
relationship to each other.
The screw-like threads 50 (FIG. 11) of second shank
portion 16 have sharp edges 15, and a pitch P suitable for
engaging wood. The sharp edges provide a deeper thread than
that of machine threads. The thread depth for wood is
enlarged to compensate for the low strength of wood in
comparison to the strength of steel. Pitch P can be in a
range of 1/16" - 3/16" (i.e. approximately 5 to 16 threads per
inch). Thus, pitch P and diameter D have a ratio such that
when one increases the other increases, and vice versa. The
pitch P is chosen such that it is small enough to reduce the
torque needed to drive the fastener 10, without effecting the
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 26 -
ability to apply the fastener to the wood, or causing the
fastener to torsionally break at its weakest point.
The head 12a washer 40 combination attached to the smooth
portion 14 of the shank provides a greater holding force at
the front of the gutter. Since the washer 40 is circular in
shape and has a larger diameter than head diameter 12a, the
washer 40 also prevents the socket wrench used for turning the
head 12a from leaving a ring mark or scratch on the gutter
face when securing the bolt 10 to the gutter 20.
In the past, using rolled or lathed threads on such a
threaded prior art fasteners required pilot holes before
penetrating into thin pieces of wood. The present invention
solves this prior art problem as shown in FIG. 11. The
solution for using these bolts without pilot holes resides in
cutting the threads 50 to such a degree of pitch P, curvature
C, height H, depth d, sharpness S, so that the threading 50
cuts like a drill bit and the threading 50 holds like a wood
screw. After 30 different tests, it was determined to
preferably cut eleven threads 50 to the inch at a thread depth
of one-third the gutter bolt diameter D from top to bottom of
thread. A steep pitch in the front of the thread is for the
cutting and a lesser curved or shallow pitch portion C behind
the thread enables the thread to cut like a drill due to the
steepest pitch and hold like a wood screw due to the shallow
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 27 -
portion of the thread. The height H or the depth d refers to
the distance from the edge at the sharpest point of the
sharpness S to the surface of the shallow pitch position C of
the curvature. The shallow portion of the curvature C is
concave to such a degree that preferably the radius of
curvature is almost infinite and thus the shallow portion C is
almost flat. The sharpness S of the thread 50 is such that
the angle of S relative to C is about 900, or preferably is a
right angle of 90 degrees.
In an alternative embodiment of the invention, an oil or
a TEFLON coating (e.g. a non-stick polymer lubricant coating)
or a paraffin coating can be applied to the screw-like threads
of second shank portion 16 to aid in reducing friction between
fastener 10 and facia panel 24, thereby reducing the torque
required to drive the fastener. The screw-like threading on
second shank portion 16 provides an extra secure coupling of
gutter 20 with facia panel 24.
FIGS. 3, 4, and 5 show the first, second and third
embodiments of head portion respectively. When securing
fastener 10 as shown in FIG. 2, head portions 12a, 12b, and
12c are engaged by a manual or automatic tool operated by the
user which applies the requisite rotational motion and
pressure to secure gutter 20 to facia panel 24. Fastener 10
can be made from aluminum, galvanized steel, stainless steel,
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 28 -
or any other suitable known material. Preferably the gutter
bolt 10 is made from aluminum.
In an actual installation, pointed end 18 is placed
against the gutter and lightly hammered through the front of
the gutter and through the back of the gutter, until end 18
engages facia panel 24 under roof 26. A ferrule 22 is fit
around fastener 10 before the hammer blow that penetrates the
back wall of the gutter. Upon initial contact with facia
panel 24, repeated light hammer blows to head portions 12a,
12b, and 12c will cause pointed end 18 to further penetrate
facia panel 24, and the threads on second shank portion 16
will cause fastener 10 to begin to rotate in the thread
direction. At this time, the user may apply a manual or
electric power tool to head 12a and further secure fastener 10
into the facia panel.
Preferably the aluminum alloy used for the manufacture of
the gutter bolt 10 is alloy number 5356-0 from AlcoTec Wire
Company of Traverse City, Michigan, and has the following
chemical composition limit's in % by weight based upon the
total weight:
Element Minimum % Maximum %
Si 0.0 0.25
Fe 0.0 0.40
Cu 0.0 0.10
Mn 0.05 0.20
Mg 4.5 5.5
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 29 -
Cr 0.05 0.20
Zn 0.0 0.10
Ti 0.06 0.20
Be 0.0 0.0008
Aluminum 95.34 93.0492
TOTAL: 100% 100%
The method of manufacture is shown in FIG. 12. In order
to achieve the degree of pitch and angle needed for the
threads of the invention, it was not possible to use prior art
lathing or rolling to manufacture the threading. These prior
art techniques were not able to produce the correct pitch
angle and depth in the threads needed for using the gutter
bolts without pilot holes.
It was therefore decided to carry out the cutting of the
threads 50 into an aluminum metal rod 52 by using a 30,000 rpm
cutting blade 54 to cut one angle on the front 56 of the
thread as the rod was going into and through the cutter
machine 58. Then, instead of ejecting the bolt after one
cutting pass, the bolt was pulled back through the cutter and
to contact the cutting blade to cut it again to give the
correct angle and cutting edge to the threads front edge by
the return pulling of the gutter bolt past the blade in the
reverse direction. The movement of the rod relative the blade
54 is by means of the mobile attachment device 60 that has
holding means 62 for gripping the rod 52 and for moving it in
the forward direction 64 and in the reverse direction 66. In
CA 02307587 2006-11-01
- 30 -
doing so, this technique of double cutting of the front edge
of the thread enables the bolt threads to be able to be
drilled into the pieces of wood without splitting the wood.
The gutter bolt actually drills its own pilot hole for the
threads as it penetrates the wood. Thus, the gutter bolt
drills like a drill bit and holds like a screw. Therefore, it
takes a double cutting of the front portion of the thread of
the gutter bolt to produce the steep slope thread front
portion and to provide the shallow almost flat portion behind
that front portion. By double cutting it at the front part of
the thread, this gives the threads the sharpness needed to cut
into wood like a drill bit. Only the front of the thread is
cut during the reverse cutting pass 66 through the cutter
machine 58.
FIG. 13 shows the embodiment in which facets 80 are added
to the screw portion of fastener threads 50 for wood screw
installation to reduce the torque required. Facets 80 are
notches cut or rolled in between each thread of the
fastener. Facets 80 reduce torque on the head, rod,
threading, tools and reduce stress on material. Facets 80 are
shaped multiangle and do not exceed the highest or lowest
point of the threading. They are a separate embodiment of the
screw portion. Facets are located on the remaining shallow
curved portion behind the thread and in between each of the
threads.
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 31 -
Facets are recessed at different angle pitches allowing
wood to pass over the highest point 84 of the facet into a
notched pitched angle. This relieves the stress on the wood
as the fastener screws into the wood. The facet gives the
wood a chance to expand and contract. With the turning
penetration into the wood of the threaded fastener, each
individual thread allows this process to happen.
The angle of the facet reduces stress in the wood. As
the wood slides up to the next facet, it gradually builds up
torque until it reaches the highest point 84 of the facet.
This equals the amount of pressure of a solid rod fastener
without facets until it rolls over into the cavity or lowest
portion 86 of the facet. With many facets placed randomly or
in an exact location on each thread having multiple threads
per inch, relief of stress will occur on each individual
thread. Between the highest point 84 and the lowest point 86
is the intermediate point 88 of the facet.
With the facets in place, the screw portion of the
fastener holds better in wood. When unscrewing
(counterclockwise rotation) the threaded portion from the
wood, the wood now slides up to the highest point 84 of the
facet. The wood has to overcome the resistence to removal at
the maximum height: 84 of the facet. On the other hand, it is
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 32 -
easier for the wood to slide down to low point 86 when the
fastener advances into the wood (clockwise rotation).
By adding facets to the shallow portion between the
threads, it is necessary to slow down the turning RPM of the
cutting blade of the rod. This is shown in FIG. 12. This
leaves the cutting blade in one area longer and permits a
deeper cut notch at random or controlled depths and sizes.
Thus there can be a variable number of facets for each
individual thread. The method for manufacturing the facets is
based upon utilizing the procedure described above for FIG.
12. FIG. 13 shows 8 facets.
The angles of the facets vary in degrees. The angle
is subtended between points 86-88-84 and ranges between 90 to
120 . The angle R is subtended between points 88-84-86 and
ranges between 130 to 160 . This allows screwing the fastener
portion into the wood to turn with the threads causing fibers
of wood to conform to the low-high angles of the facet.
The facet has three sections of unequal length, namely
the shortest length 90, the longest length 92 and the
intermediate length 94. The intermediate length 94 connects
the shortest length 90 to the longest length 92. The angle
is located at the intersection of the shortest length section
90 and the intermediate length section 94. The angle 0 is
CA 02307587 2000-05-01
WO ~M26 PCT/US98/22776
- 33 -
located at the intersection of the intermediate length section
94 and the longest length section 92.
EXAMPLE 1
Comparative testing was conducted with a torque wrench.
Five fasteners were used in each of three groups to screw in
the threaded portion of a rod 1/4" x 2" into Douglas fir
construction-grade lumber. All fasteners had 11 threads per
inch. The average results for the groups were as follows:
TORQUE REQUIRED
GROUP FOR INSTALLATION
(1) Prior Art wood threading 13 to 15 foot
pounds.
(2) Wood threading of the invention 10 to 12 foot
without facets pounds.
(3) Wood threading of the invention 7 to 9 foot
with facets pounds.
Thus substantially less torque is required to install a
fastener according to the invention as compared to the.prior
art.
EXAMPLE 2
A comparison for using gutter bolts of the invention as
opposed to prior art gutter fasteners when using a standard
3/4" pine facia board is demonstrated. Standard 7" or 8"
gutter nails are used for fastening gutters, as shown in the
Marulic Patent No. 4,888,920. The normal spacing for all
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 34 -
gutter fasteners is 24 to 3 feet apart. Due to weather
conditions, gutter nails tend to loosen after a year or two.
The nails can even fall out if the weather conditions are
severe, causing damage to the gutters and facia board which
could allow water to seep into the house or basement. When
installing gutters, gutter nails tend to split the facia board
when they are inserted too close to the edge of the wood.
Also, the nails will bend when they hit something solid, for
example a knot in the wood or the rafter tail. Gutter nails
tend to bend when using pressure treated wood.
Comparison testing for removing a gutter nail from wood
was conducted. A gutter nail was removed from a 3/4" thick
piece of pine woo(l. It took 60 pounds of pressure to pull it
out. If installing a 25' gutter using 10 gutter nails, there
is 600 pounds of tiolding force for the 25' gutter.
As shown by the hidden hanger of the Faulkner U.S. Patent
No. 5,388,377, when using the front edge of gutter for
support, its strength depends on the diameter of the gutter
materials. This can range from .019 inch to .032 inch. When
using a .032 inch clip edge, it takes approximately 50 pounds
of pressure for the clip to rip from the gutter, leaving the
front of the gutter unsupported. Also, it is not possible to
reclip the hidden hanger due to damage to the gutter lip from
the hanger when screwing back the portion of the hanger to the
CA 02307587 2000-05-01
WO 99/23326 PCT/US98/22776
- 35 -
facia board. From highest back point of gutter to lowest back
point of gutter, there is damage to the edge of the roof
overhang into the gutter when screwing the hidden hanger into
the facia board. An example of the strength of a usual hidden
hanger is as follows. When using 10 hidden hangers per 25' of
gutter, you have 500 pounds of support holding the front and
the bottom of the gutter. Since the screws for the hangers
are metal, over time they tend to rust and you have metal
fatigue. Since the front clip would not fit tightly to the
gutter lip, there is movement.
Gutter bolts of the invention are a unique improvement.
For example, there is full control when installing the gutter
bolts. There is no more swinging of a hammer or leaning over
the gutter from a ladder to screw in a hidden hanger. Gutter
bolts are screwed in with an electric drill or 12 volt
cordless drill. There is a reduced chance of an accident
happening because of more control when fastening the gutter
bolts. It is possible to use aluminum gutter bolts to install
aluminum gutters, or to use copper gutter bolts for installing
copper gutters. There is no mixing of metals. When fastening
gutter bolts, they go right through knots in the wood, rafter
tails or extremely hard woods. Gutter bolts do not need pilot
holes. Gutter bolts do not split the wood even when being
installed close to the edge of the wood.
CA 02307587 2000-05-01
WO 99/Z3326 PCT/US98/22776
- 36 -
It takes about 875 pounds to remove a gutter bolt of the
invention from a 3/4" pine board. If there is a 25' gutter
and the gutter bolts are spaced 24' apart, or installing 10
gutter bolts, there would be 8,750 pounds holding up a 25'
gutter that weighs 20 pounds. If only 5 gutter bolts were
used on a 25' gutter, there would be 4,375 pounds of holding
force for a 20 pound gutter. The holding force for the gutter
bolt of the invention greatly surpasses all existing prior art
gutter fasteners, as can be seen from the prior art test
results of 500 to 600 pounds for the prior art fasteners.
While several embodiments of the present invention have
been shown and described, it is to be understood that many
changes and modifications may be made thereunto without
departing from the spirit and scope of the invention as
defined in the appended claims.
