Note: Descriptions are shown in the official language in which they were submitted.
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1
FASTENER
Field of the Invention
[I] The present invention relates to a fastener and in particular to a
fastener for wood
products, and the like.
[2] The invention has been developed primarily for the carpentry and
building industries
and will be described hereinafter with reference to this application. However,
it will be
appreciated that the invention is not limited to this particular field of use.
Background of the Invention
[3] Fasteners such as screws, nails and anchor bolts have been manufactured
with a variety
of heads and drive designs, each requiring a different kind of tool to drive
or extract them. All
fasteners employ the same general fixing principle, with the shank, which may
be threaded or
serrated, providing gripping and the head providing a bearing surface and
means to drive the
screw.
[4] One difficulty with such fasteners is the head by design is left
exposed. In building
applications, this leads to additional finishing work for the builder to
finish the workpiece
around the head.
[5] There is thus a need for a fastener which provides concealed fixing, in
that the
workpiece can be fixed in place as desired with the fastener concealed. This
will allow builders
to use pre-finished workpieces with further finishing work not being required.
[6] The inventor performed a comprehensive search of the market place and
published
patent publications and did not find a product which satisfies the inventor's
requirements.
[7] The present invention seeks to overcome or substantially ameliorate at
least some of
the deficiencies of the prior art, or to at least provide an alternative.
[8] It is to be understood that, if any prior art information is referred
to herein, such
reference does not constitute an admission that the information forms part of
the common
general knowledge in the art, in Australia or any other country.
Summary of the Invention
[9] According to a first aspect, the present invention provides a fastener
comprising:
=
a shank having a first attachment means for attachment to a first workpiece;
and
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a head having a second attachment means for attachment to a second workpiece
[10] Preferably, the fastener is a screw and the first means comprises a
thread formation on
the shank.
[11] Alternatively, the fastener is a nail.
[12] Alternatively, the fastener is an anchor bolt.
[13] Preferably, the second attachment means comprises at least one attachment
member
formed in the head, the at least one attachment member extending in a
generally opposite
direction to the shank.
[14] Preferably, each of the at least one attachment member is a prong.
[15] Preferably, the head comprises a drive formation at a central portion
thereof and the at
= least one attachment member is formed laterally of the drive formation.
[16] Preferably, the at least one attachment member extends from a peripheral
portion of the
head.
[17] Preferably, the at least one attachment member comprises a plurality of
attachment
members substantially equidistantly spaced around a peripheral portion of the
head.
= [18] Preferably, the fastener comprises three or more attachment members.
[19] Preferably, the plurality of attachment members comprises prongs which
are slightly
splayed relative to each other.
[20] Preferably, each prong has an end portion with a point, wherein the prong
is adapted to
embed into the second workpiece when the second workpiece is forced against
the second
attachment means.
[21] Preferably, each prong is adapted to substantially curl and/or skew into
the second
workpiece as the second workpiece is forced against the second attachment
means.
[22] Preferably, the plurality of attachment members comprises prongs
having serrations
formed thereon.
[23] Preferably, the prongs extend parallel to each other in a direction
opposite to the shank.
[24] Preferably, the prongs are integrally formed with the head.
[25] In one embodiment, the prongs comprise a distal pointed portion with
no serrations and
a proximal portion with serrations.
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[26] Alternatively, the prongs are slightly splayed relative to each other.
[27] In this embodiment, preferably, each prong is adapted to substantially
curl and/or skew
into the second workpiece as the second workpiece is forced against the second
attachment
means.
[28] Preferably, the fastener comprises a depth measuring means for indicating
the depth of
insertion of the first attachment means and/or the distance of the head from
the first workpiece
in use.
[29] Preferably, the depth measuring means comprises a shoulder formed at
the junction of
the head and the shank.
[30] Other aspects of the invention are also disclosed.
Brief Description of the Drawings
[31] Notwithstanding any other forms which may fall within the scope of the
present
invention, preferred embodiments of the present invention will now be
described, by way of
examples only, with reference to the accompanying drawings in which:
= [32] Fig. 1 shows a screw fastener in accordance with a preferred
embodiment of the present
invention with three integral fixing prongs, where (a) is a perspective view
showing the prongs
= slightly splayed in their initial configuration, (b) is a perspective
view showing the screw with
the three prongs being in a curled and outwardly skewed configuration when
embedded into a
workpiece; and (c) is a top view of (a);
[33] Fig. 2 shows a screw fastener in accordance with another preferred
embodiment of the
present invention with four integral fixing prongs, where (a) is a perspective
view showing the
prongs slightly splayed in their initial configuration, (b) is a perspective
view showing the
screw with the four prongs being in a curled and outwardly skewed
configuration when
embedded into a workpiece; and (c) is a top view of (a);
[34] Fig. 3(a) is a schematic cross-section view of the figure 1(a); Fig.
3(b) is a schematic
cross-section view of the figure 1(b); Fig. 3(c) is a top view of the fastener
with three prongs;
Fig. 3(d) is a top view of the fastener with four prongs; Fig. 3(e) is a top
view of a fastener with
six prongs; Fig. 3(f) is a top view of a fastener with eight prongs;
[35] Fig. 4 schematically shows the fastener of Figure 1 in use, with Figs.
4a, 4b & 4c.
schematically showing the progressive engagement of a pre-finished timber
workpiece via the
skewing and curling of the integral fixing prongs; and
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[36] Fig. 5 shows screw fasteners in accordance with other preferred
embodiments with
three integral fixing prongs, where (a) is a perspective view showing one type
of serrated
prongs, (b) shows a screw with another type of serrated prongs; and (c) is a
top view of (b).
Description of Embodiments
[37] It should be noted in the following description that like or the same
reference numerals
in different embodiments denote the same or similar features.
[38] Figures 1, 3(a) and 3(b) show a fastener 10 in accordance with a
preferred embodiment
of the present invention. The fastener comprises a shank 12 having a first
attachment means
14 for attachment to a first workpiece and a head 16 having a second
attachment means 18 for
attachment to a second workpiece. The fastener 10 is a screw and the first
attachment means
14 comprises a thread formation on the shank 12.
[39] The head 16 comprises a drive formation 22 at a central portion thereof,
in the form of
a Phillips head screwdriver recess.
[401 The second attachment means 18 in the head 16 comprises attachment
members 24
integrally formed in the head, being three prongs 24 which extend in a
generally opposite
direction to the shank 12. The prongs 24 are formed laterally of the drive
formation 22, being
equidistantly spaced around the peripheral portion 17 of the head 16.
[41] The prongs 24 include a generally flattened rectangular portion 26 and a
pointed end
27 at the end portion 29 thereof. The prongs 24 are slightly splayed relative
to each other in
their initial configuration.
[42] The screw 10 also comprises a shoulder 19 formed at the junction of the
head 16 and
the shank 12. The shoulder 19 comprises a diameter larger than the shank 12
and thus forms a
stop surface 21 with the shank 12. In use, the shank 12 can be inserted into a
first workpiece
and will stop at the stop surface 21. Thus, the shoulder 19 acts a depth
measuring means in
that the distance of the head 16 from the first workpiece for all of the
fasteners 10 will be
conSistent.
[431 Fig. 4 schematically shows the fastener 10 in use. In this example,
the fastener 10 is
used for fixing a plasterboard wall lining 42 to a frame stud 40, and also for
fixing a pre-
finished timber skirting 44 to the wall lining 42 to cover the gap 43 between
the wall lining 42
and the flooring 46.
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[44] The wall lining 42 has already been painted its final coat and is
fixed to the frame stud
40 (timber, metal or masonry) via the threaded shank 12, up until the stop
surface 21 engages
the frame stud 40. The head 16 engages the wall lining 42 with the prongs 24
extending
outwardly. The timber skirting 44 is then forced into the second attachment
means 18, being
the prongs 24.
= [45] Figures 4a, 4b & 4c schematically show the progressive
engagement of the timber
skirting 44 via the fixing prongs 24, which skew away from each other and the
end portions 29
= curl outwardly as the skirting 44 is forced into the second attachment
means 18. Figure 4a
shows the skirting 44 initially engaging the prongs 24, with the integral
fixing prongs 24 in the
set position ready for engagement. Figure 4b, shows the skirting 44 partly
engaged with the
integral fixing prongs 24 providing initial bite and commencing the skewing
into the pre-
finished timber. Figure 4c shows the skirting 44 fully engaged in the final
position, with the
integral fixing prongs 24 completely skewed and curled to lock into the pre-
finished timber.
[46] Only the back surface 48 of the skirting 44 is engaged by the prongs 24
and the front
pre-finished surface 49 is left unmarked. Thus, the fastener 10 provides
concealed fixing of
the skirting 44 and no further finishing is needed.
= [47] The fastener 10 can be embodied in other forms and can include less
or more for
different types of prongs 24 or attachment means 18.
[48] Figure 2 and 3 (d) show a fastener 10b with four prongs 24. Figure 3 (e)
shows a fastener
10c with six prongs 24, and Figure 3 (d) shows a fastener 10d with eight
prongs 24. In the
embodiment, the prongs 24 are equidistantly spaced around the periphery 17 of
the head 16.
[49] Figure 5 shows further embodiments 10e and 10f of the fastener comprising
serrated
prongs 24 which extend parallel and in a direction opposite to the shank 12.
Research of the
leading builders found the use of building materials which varies
significantly in density, and
as such product development has lead to serrated fixing prongs 24 (which are
stronger and do
not skew) being developed.
[50] Product testing shows that the integrated fixing prongs 24 of the
fastener 10 (which
gave been designed to skew and curl into the soft pine timber) cannot
penetrate the dense MDF
(Medium Density Fibreboard), and therefore did not provide any bite nor grip.
[51] The serrated fixing prongs 24 of the fasteners 10e and 10f are pin shaped
to provide
easier penetration of the dense MDF material. Product development has also
lead to variations
of the serrations on the prongs for maple/meranti timber (figure 5(a)) and MDF
(figure 5(b)).
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[52] The variation in figure 5(b) is the incorporation of 50% leading smooth
pin 25 that
penetrates easier into the dense MDF and 50% serrations, and with fewer
serrations, provides
less resistance requiring less force for penetration into the dense MDF
material.
[53] In other embodiments, the serrated prongs can also be slightly
splayed, and can be
adapted to curl outwardly similar to the prongs above.
[54] In other embodiments, the fastener can be a nail or an anchor bolt
such as a
DYNABOLTTm.
[55] The fastener of the preferred embodiment thus provides two-directional
concealed
fixing via a threaded shank in one direction, and integrated fixing prongs in
the opposite
direction. The preferred fastener has integrated fixing prongs incorporated on
the screw head
that are designed to bite, skew and curl into pre-finished timber. The
preferred fastener has the
integrated fixing prongs that provide a skewing and curling action locking the
pre-finished
timber towards the screw head. The integrated fixing prongs can generate a
gripping a force
greater than that of single trimming nails through the timber.
[56] The preferred fastener can comprise a varying number of integrated fixing
prongs in
the screw head. The preferred fastener has a shoulder that provides a depth
gauge to ensure all
integrated fixing prongs protrude past the face of the plasterboard wall
lining equidistantly.
The preferred fastener can accommodate any variation of drive system within
the head. The
preferred fastener provides fixing from the back face of the material, and
without penetrating
the surface, allows for pre-finished timber to be used.
= [57] The preferred fastener provides concealed fixing as an alternative
to the current nailing
= of internal timbers. This has been achieved with the threaded shank
providing gripping to the
= wall frame, and the integral fixing prongs providing bite and penetration
to pull the timber
towards the crown, which provides for a very strong connection. The fixing
prongs are an
integral part of the screw head giving the screw head a crown like appearance.
[58] The preferred screw is driven to the wall frame with the shoulder
providing the pre-
determined bearing depth, ensuring correct engagement of the crown. The timber
is positioned
for fastening, with pressure being applied to the face of the timber, engaging
the fixing prongs
which bite into the timber. As more pressure is applied and the timber is
forced home, the fixing
prongs skew and curl into the timber which provides a powerful locking
strength.
[59] The fixing detail is such that the fasteners are secured to each stud
frame via the
= threaded shank, with the shoulder of the fastener providing the bearing
surface to ensure all
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screw heads are set at the same depth, thus providing consistent bite force to
the timber skirting.
=
The fixing prongs in the set position, protrude forward of the face of the
Plasterboard Wall
Lining, and have been designed to bite and skew into the timber Skirting,
curling and pulling
the pre-finished timber tight with the Plasterboard Wall Lining. The result is
that the skirting
remains a tight fit along the entire length of wall, thus minimising (or
eliminating) the need for
gap filler.
[60] The fastener has the potential to change the current construction method
of nailing
through the timber surface, and allows the opportunity to provide the highest
quality of finishes,
all without compromising the construction costs nor the build time.
= [61] Whilst preferred embodiments of the present invention have been
described, it will be
apparent to skilled persons that modifications can be made to the embodiments
described.
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