Note: Descriptions are shown in the official language in which they were submitted.
DUAL POSITIONABLE FASTENER
INSTALLATION TOOL ADAPTOR
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Patent
Application
No. 15/239,047 filed on August 17, 2016, which is a continuation-in-part of
U.S.
Patent Application No. 14/211,685 filed on March 14, 2014, which application
claims the priority of U.S. Provisional Patent Application No. 61/787,170
filed on
March 15, 2013 and U.S. Provisional Patent Application No. 61/890,905 filed on
October 15, 2013, the disclosures of which applications are incorporated
herein
in their entirety.
BACKGROUND
[0002] The present disclosure relates to generally fastening systems
employed to connect wood structural members to comply with construction
codes. The present disclosure relates generally to tools and methods for
installing a fastener to secure wood framing components. More particularly,
this
disclosure relates to tools and techniques to precisely install fasteners to
secure
the top plate to roof trusses or rafters.
[0003] Local and state building codes, which are typically based on
universal codes such as the International Residential Code and the
International
Building Code, set forth various requirements for securing wooden framing
components. Provisions are made in such codes to require that the top plate
and
the rafters, or roof trusses, must be connected to comply with pre-established
connection force standards calculated to resist substantial uplift forces that
may
be experienced throughout the lifetime of the structure. For locations which
are
susceptible to high wind uplift and/or seismic activity, typically, a stronger
force-
resistant connection between the top plate and rafters or trusses is required.
1
CA 3054843 2019-09-10
[0004] To satisfy building code requirements, the use of metal brackets
and a large number of nails are commonly installed using pneumatic nail guns.
Many of the structural locations requiring these robust connections are at the
top
corners of walls and where walls meet roof trusses and the like. These
locations
typically require workers to stand on ladders and employ a hammer or pneumatic
nail guns to nail brackets to roof rafters, roof trusses and the like. A
common
complaint is that the ladders are not a stable platform and maneuvering bulky
nail
guns into cramped locations while standing on a ladder is both difficult and
dangerous.
[0005] The concept of a continuous load path (CLP) from the peak of the
roof to the foundation is one that is gaining some popularity in the
construction
industry. Various devices of straps, brackets, cables, threaded rods and bolts
are
currently employed to tie various building components together and create an
integrated unit where stress on any one structural component is transferred to
other components for additional durability.
[0006] There are a number of techniques, fasteners and hardware items
that are conventionally employed to provide the required connection between
the
top plate and the rafters or roof trusses. Hurricane clips or other forms of
metal
straps or clips are traditionally used and secured by multiple nails or
threaded
fasteners. There is commonly a trade-off between connection integrity and
construction efficiency. For example, hurricane clips, which are effective and
widely used in many locations, may require eight or more nails or threaded
fasteners to meet the requisite code connection standard.
[0007] It is possible to employ threaded fasteners such as elongated
screws to replace some of the metal brackets and nails currently employed to
meet building codes. However, such screws need to be installed at a particular
angle and position to ensure penetration through several wood members to
engage, for example, a roof truss or rafter. There is a need for a
construction
system that would facilitate the use of threaded fasteners to connect building
2
CA 3054843 2019-09-10
'
, ,
components in a manner that meets building codes and allows building
inspectors to visually confirm correct installation of such threaded
fasteners.
[0008] A highly secure and efficient connection between the top
plate and
rafters or roof trusses can be implemented by employing multiple specialty six-
inch threaded fasteners, such as TimberLOK wood screws manufactured and
marketed by OMG, Inc., of Agawam, Massachusetts. To secure the framing
components with the sufficient retentive force, each threaded fastener is
driven
through the top plate and into the rafters or roof trusses at a 22.5 50
optimum
angle with respect to the vertical. Although securing multiple threaded
fasteners
is typically more efficient than attaching a hurricane clip or other strap-
type
connector, it is difficult to consistently implement a 22.5 angle within a
reasonable range of precision. The usage of protractors, levels and other
similar-type tools to obtain the optimum angle for the threaded fastener has
proven to be clumsy, difficult, time consuming and, at best, only marginally
advantageous over more conventional securement methods.
[0009] The present disclosure addresses the need for a tool and
method
to connect the top plate and rafters or roof trusses by efficiently installing
multiple
threaded fasteners having a consistently precise optimum connection angle.
SUMMARY
[0010] Briefly stated, a dual positionable adaptor mounts to a
fastener
driver assembly to precisely provide a location and an entry angle for driving
a
fastener to achieve an optimum connection for various wood structural
components.
[0011] In one preferred embodiment, a dual positionable adaptor
for a
fastener driver assembly comprises a guide head which mounts a fastener
receiver assembly and has a reference surface which defines a fastener
opening.
A connector is configured to mount the guide head to the driver assembly so
that
a fastener received in the receiver assembly is drivable through the opening.
A
guide assembly pivotally mounted to the guide head comprises a pair of spaced
3
CA 3054843 2019-09-10
wings having opposed faces. Each wing has an engagement end wherein the
engagement ends are coplanar. When the guide assembly is at a first angular
position and each edge engages an upper horizontal member and the reference
surface engages a vertical member. A fastener is drivable by the fastener
drive
assembly through the fastener opening at a first oblique entry angle into the
vertical member and the horizontal member. When the guide assembly is at a
second angular position and each engagement end engages a lower horizontal
member and the reference surface engages a vertical member, a fastener is
drivable through the fastener opening at a second oblique entry angle into the
vertical member and the horizontal member.
(0012) The first entry angle relative to the vertical member is
approximately 110. The faces engage spaced surfaces of the vertical member.
In one application, the vertical member is a stud, the horizontal member is a
top
plate, header or multi-ply beam and the lower horizontal member is a bottom
plate. Claws extend from the engagement edges. The guide head assembly has
an indicator indicating a flush position of the reference surface. The guide
head
also may have a second indicator indicating a flush position of the reference
surface.
(0013) The wings are each securably positionable at two angularly spaced
positions. The connector comprises a tubular member having two diametrically
opposed detents and mounting two projecting lugs. The fastener driver
assembly further comprises a distal tube having notches which engage the lugs
and a clamp which engages onto a detent to detachably secure the adaptor to
the tube at a fixed angular position of the driver assembly. The fastener
receiver
assembly further forms a fastener channel and further comprises a magnet
assembly for retaining the fastener in the channel. The connector further has
an
arcuate slot for receiving a distal end portion of the tube.
(00141 A fastener installation tool comprises a fastener driver assembly
comprising a distal tube with opposed notches and a clamp actuatable by a
lever.
A guide head has an entry reference surface and defines a fastener opening in
4
CA 3054843 2019-09-10
'
,
. ,
the entry reference surface. A connector is configured to mount the guide head
to the driver assembly at two angular positions so that a fastener is drivable
through the opening. A guide assembly is mounted to the guide head and
comprises a pair of spaced wings having opposed faces. Each wing has an
engagement edge. The engagement edges are substantially coplanar.
[0015] When the guide assembly is secured at a first angular
position
relative to the driver assembly, the wings capture a vertical member between
the
faces, the entry reference surface engages the vertical member and each
engagement edge engages an upper horizontal member, a fastener is drivable
by the fastener driver assembly through the fastener opening at an oblique
entry
angle into the vertical member. When the guide assembly is secured at a
second angular position relative to the driver assembly, the wings capture a
vertical member between the faces, the entry reference surface engages the
vertical member and each engagement edge engages a lower horizontal
member, a fastener is drivable through the fastener opening at an oblique
entry
angle into the vertical member and the lower horizontal. In some applications,
a
wing is pivoted so that an engagement edge does not engage a horizontal
member and the vertical member is not captured by one face.
[0016] Preferably, the entry angle is approximately 11 and the
vertical
member is a stud with the upper horizontal member being a top plate header or
multi-ply beam and the lower horizontal member being a bottom plate.
[0017] The first angular position is 1800 from the second angular
position.
A plurality of claws project from each of the first engagement edges. The
wings
are independently pivotally positionable. The wings are securable at two
pivotal
positions by a threaded fastener having a knob which is disposed outwardly
relative to each wing.
[0018] A fastener receiver assembly is mounted to the guide head
and
defines a fastener channel leading to the opening wherein a fastener is
retainable in the channel by means of a magnet assembly. The connector
CA 3054843 2019-09-10
receives an end portion of the distal tube and has a detent which is engaged
by
clamp and lugs which are received in the notches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Fig. 1 is a side view, partly broken away, of a fastener
installation
tool for securing a top plate to a roof support member;
[0020] Fig. 2 is a fragmentary top plan view of the installation tool of
Fig. 1;
[0021] Fig. 3 is a fragmentary partially disassembled side view of the
installation tool of Fig. 1;
[0022] Fig. 4 is a representative perspective view, partly in schematic,
of a
structure during its construction phase and illustrating the usage of a
fastener to
connect a top plate to a roof support member;
[0023] Fig. 4A is a fragmentary side sectional view of the structure of
Fig.
4, illustrating a fastener connecting a top plate to a roof support member at
a
location adjacent a vertical stud;
[0024] Fig. 4B is a fragmentary side sectional view of the structure of
Fig.
4, illustrating a fastener connecting a top plate to a roof support member at
a
location between vertical studs;
[0025] Fig. 5 is a side elevational view, portions broken away to show
detail and partly in diagram form, of the installation tool of Fig. 1;
[0026] Fig. 6 is a side elevational view, portions broken away to show
detail and partly in diagram form, of a modified embodiment of the fastener
installation tool of Fig. 1;
[0027] Fig. 7 is a perspective view, partly in diagram form, of a guide
portion of the installation tool of Fig. 1;
[0028] Fig. 8 is a perspective view of the guide portion of Fig. 7,
portions
being shown in phantom and portions being shown to reveal internal detail;
[0029] Fig. 9 is an annotated composite schematic view illustrating the
sequential operation of the installation tool of Fig. 1;
6
CA 3054843 2019-09-10
, [0030] Fig. 10 is a side elevational view, partly broken away, of a
second
embodiment of a fastener installation tool for connecting a top plate with a
roof
support member;
[0031] Fig. 11 is a fragmentary top plan view of the installation tool
of Fig.
10;
[0032] Figs. 12A-12C are side elevational views, partly in schematic,
illustrating the sequential operation of the installation tool of Fig. 10;
[0033] Fig. 13 is a side elevational view, partly broken away, of a
third
embodiment of a fastener installation tool for connecting a top plate with a
roof
support member;
[0034] Fig. 14 is a fragmentary top plan view of the installation tool
of Fig.
13;
[0035] Figs. 15A-15D are annotated representative side elevational
views,
partly in schematic, illustrating the sequential operation of the installation
tool of
Fig. 13;
[0036] Figs. 16A-16B are schematic diagrams illustrating the usage and
versatility of a representative fastener installation tool for different
structural
heights and wherein the installers have different heights;
[0037] Fig. 17 is a perspective view of a fourth embodiment of an
installation tool without the power driver assembly wherein certain external
portions are shown as transparent to reveal internal components;
[0038] Fig 18 is an enlarged perspective view of a portion of the
installation tool of Fig. 17 wherein certain external components are shown as
transparent to reveal internal components;
[0039] Figs. 19A and 19B are top sectional views of portions of the
installation tool of Fig. 17;
[0040] Fig. 20 is an enlarged end sectional view of the installation
tool of
Fig. 17 and further illustrating a fastener received in the installation tool;
[0041] Fig. 21 is an enlarged generally top plan view of the guide
head
portion of the installation tool of Fig. 17;
7
CA 3054843 2019-09-10
[0042] Fig. 22 is an enlarged generally bottom perspective view of a
guide
head portion of Fig. 21;
[0043] Fig. 23 is an enlarged generally opposite side elevational view,
portions removed, of a handle assembly for the installation tool of Fig. 17;
[0044] Fig. 24 is an enlarged side elevational view, portions in
section and
portions removed, of the handle assembly of Fig. 23;
[0045] Fig. 25 is an enlarged generally right side view of a portion of
the
handle portion of Fig. 24, taken from the right thereof and partially broken
away
to show detail
[0046] Fig. 26 is an annotated side elevational view, partly in
schematic, of
an installation tool;
[0047] Fig. 27 is a side elevational view, partly in schematic and
partly
annotated, of an installation tool;
[0048] Figs. 28A and 28B are annotated side views of an installation
tool
together with an enlarged top plan view of a portion of the tool,
respectively;
[0049] Fig. 29 is an annotated side elevational view of an installation
tool;
[0050] Fig. 30 is a schematic view of an installer illustrating a belt
holster
and a representative installation tool for reception by said holster;
[0051] Figs. 31A and 31B are respectively a schematic view illustrating
a
bandolier holder for fasteners and a representative installation tool and an
enlarged fragmentary front view of the bandolier holder and fasteners;
[0052] Figs. 32A and 32B are respectively a schematic side view of a
thigh-mounted fastener holder and a representative installation tool and an
enlarged fragmentary front view of the thigh-mounted fastener holder and
fasteners;
[0053] Fig. 33 is a perspective view of a representative fastener that
may
be employed in the installation tools;
[0054] Figs. 34A-34D are respectively a side view of a fastener
employed
in an installation tool, an enlarged top plan view of the fastener and a side
8
CA 3054843 2019-09-10
elevational view of a fastener with a different tint together with an enlarged
top
plan view of the fastener with the different tint;
[0055] Figs. 35A-35E schematically illustrate an installer using an
installation tool for fastening respectively a truss to a top plate, a stud to
a top
plate, a stud to a bottom plate, a bottom plate to a rim, and a top plate to a
rim;
[0056] Figs. 36A-36C are respectively a perspective view, a diagrammatic
side view and an end view of a fastener which may be employed for an
installation tool;
[0057] Figs. 37A-37C are respectively a diagrammatic view of a fastener
which may be employed for an installation tool, a perspective view of the
fastener
and a top plan view of the head of the fastener;
[0058] Figs. 38A-38C are respectively fragmentary portions of a
perspective view of a representative construction illustrating the use of a
bracket
assembly, an exploded view of the brackets, and a side sectional view
illustrating
the mounting of the brackets;
[0059] Figs. 39A-39E respectively illustrate another bracket for
construction in connection with a portion of a truss, a schematic view of a
fastener in connection with a second truss assembly portion together with the
brackets, a third side end view of the bracket together with a fastener in a
truss
assembly, a perspective view of the bracket and a side elevational view of the
bracket;
[0060] Figs. 40A-40B respectively illustrate a perspective view of
another
bracket as mounted in place and a top view in a preassembled stage for the
bracket;
[0061] Figs. 41A-41D respectively illustrate a first step and tool which
may
be employed in installing the bracket of Figs. 40A and 40B, a second step in
the
installation process, a third step in the installation process, and an
installed view
of the bracket
9
CA 3054843 2019-09-10
. .
[0062] Fig. 42 is a representative perspective view of a structure
during its
constructive phase and illustrating another embodiment of an installation tool
guide head;
[0063] Fig. 43 is a representative perspective view, partly in
schematic, of
a structure during its construction phase and illustrating a further
embodiment of
an installation tool guide head;
[0064] Fig. 44 is an annotated schematic view illustrating a
fastener
installation tool adaptor as used in connection with fastening a wall stud to
a top
plate and as used in fastening a wall stud to a bottom plate;
[0065] Fig. 44A is an enlarged schematic view of the adaptor and
wall
stud/top plate portion of Fig. 44;
[0066] Fig. 44B is an enlarged schematic view of the adaptor and
wall
stud/bottom plate portion of Fig. 44;
[0067] Fig. 45 is a perspective view of the adaptor of Fig. 44;
[0068] Fig. 46 is a perspective view of the adaptor of Fig. 45
from a
different perspective;
[0069] Fig. 47 is a side view, portions in phantom, of the adaptor
of Fig.
45;
[0070] Fig. 48 is a diagrammatic bottom plan view, portions in
phantom, of
the adaptor of Fig. 47;
[0071] Fig. 49 is a right side view, portions in phantom, of the
adaptor of
Fig. 47;
[0072] Fig. 50 is a side view, portions in phantom, of a modified
adaptor;
[0073] Fig. 51 is a bottom plan view, portions in phantom, of the
modified
adaptor of Fig. 50;
[0074] Fig. 52 is an annotated schematic view illustrating the
usage of
another embodiment of a fastener installation tool adaptor to fasten a top
plate to
lateral blocking, to fasten a plate to a rim board/lateral blocking from an
upper
installation position and to fasten a top plate to a rim board/lateral
blocking from a
lower position;
CA 3054843 2019-09-10
.. ..
[0075] Fig. 52A is an enlarged schematic view of the adaptor and
plate/lateral blocking of Fig. 52;
[0076] Fig. 52B is an enlarged schematic view of the adaptor and
bottom
plate/rim board/lateral blocking from a mid-position of Fig. 52;
[0077] Fig. 52C is an enlarged schematic view illustrating the
adaptor and
top plate/rim board/lateral blocking from a lower position;
[0078] Fig. 53 is a frontal view of the fastener installation
tool adaptor of
Fig. 52;
[0079] Fig. 54 is an enlarged view of the adaptor of Fig. 53 in a
top pivot
position;
[0080] Fig. 55 is a side view of the adaptor of Fig. 53 in a
bottom pivot
position;
[0081] Fig. 56 is a side elevational view of the adaptor of Fig.
53 in a top
pivot position;
[0082] Figs. 57A and 57B are respectively side views of a dual
positionable adaptor and a fastener driver assembly in a dismounted and
mounted disposition for a first installation position;
[0083] Figs. 58A and 58B are respectively enlarged side views of
the
adaptor and a portion of the driver assembly of Fig. 57A in a dismounted and
mounted disposition for the first position;
[0084] Figs. 59A and 59B are respectively side views of the
adaptor and
driver assembly of Fig. 57A in a mounted and a dismounted disposition for a
second installation position;
[0085] Figs. 60A and 60B are respectively enlarged side views of
the
adaptor and driver assembly of Fig. 59A in a mounted and a dismounted position
illustrating the second installation position;
[0086] Figs. 61A and 61B are perspective views of the dual
positionable
adaptor respectively illustrating a flush indicator in a non-flush mode and a
flush
mode;
11
CA 3054843 2019-09-10
[0087] Figs. 62A and 62B are generally bottom and left end perspective
views, respectively, of the dual positionable adaptor;
[0088] Figs. 63A and 63B are respectively a side view and a bottom plan
view of the dual positionable adaptor;
[0089] Figs. 64A and 64B are central sectional views of the dual
positionable adaptor illustrating a non-flush mode and a flush mode for the
adaptor for a first and a second flush indicator, respectively;
[0090] Fig. 65 is a central sectional view of the dual positionable
adaptor
with a received fastener with indicators in a flush mode;
[0091] Fig. 66 is a fragmentary enlarged sectional view of the adaptor
and
fastener of Fig. 65;
[0092] Fig. 67 is an exploded perspective view of portions of the dual
positionable adaptor;
[0093] Figs. 68A and 68B are perspective views of the adaptor and a
portion of the drive assembly illustrating an unsecured and secured position,
respectively, for the adaptor and driver assembly at a first installation
position;
[0094] Figs. 69A and 69B are side views of the adaptor and driver
assembly portion of Figs. 68A and 68B, respectively;
[0095] Figs. 70A and 70B are perspective views of the adaptor showing
the pivoting transformation of a wing from a tandem wing relationship to a
pivoted
position, respectively;
[0096] Figs. 71A and 71B are side views of the adaptor illustrating the
wing positions of Figs. 70A and 70B, respectively;
[0097] Figs. 72A and 72B are perspective views illustrating the adaptor
transformation of a wing from a tandem relationship to a pivoted position,
respectively;
[0098] Figs. 73A and 73B are side views of the adaptor positions
illustrating the wing portions of Figs. 72A and 72B, respectively;
[0099] Fig. 74 is a fragmentary side perspective view illustrating how
the
wing pivoting is achieved and secured; and
12
CA 3054843 2019-09-10
. ..
[00100] Figs. 75A and 75B are fragmentary side views of the adaptor
illustrating an adaptor installation position for a stud to bottom plate
configuration
from a side and a rear view, respectively.
DETAILED DESCRIPTION
[00101] With reference to the drawings wherein like numerals
represent like
parts throughout the several figures, a fastener installation tool is
generally
designated by the numeral 10. The fastener installation tool 10 is a heavy-
duty
hand tool adapted for installing threaded fasteners 12 at a consistent angle
of
approximately 22 1/2 (to the vertical) into a top plate for connection with a
roof
support member.
[00102] As best illustrated in Figs. 4, 4A and 4B, for a
representative
structure 20 for which the installation tool 10 is particularly adapted, a top
plate
22, which may include a single 2x4 or a double 2x4, is mounted at the top of
spaced vertical studs 24. Roof support members 26 of roof trusses 28 are
mounted and supported on the top plate 22. Threaded fasteners 12 are driven
into the top plate at a 22 1/2 angle for engagement with the roof support
member 26. Multiple spaced threaded fasteners 12 are sequentially driven at
pre-established spacings to provide the proper uplift resistance.
[00103] Fig. 4A illustrates the fastener driven at the upper
location of the
stud 24. Fig. 4B illustrates the fastener as driven at the location along the
top
plate between the vertical studs 24. The fasteners 12 are each preferably a
six-
inch fastener having a continuous threaded portion with a pointed tip and a
head
defining a socket or a six-inch TimberLOK fastener manufactured and marketed
by OMG, Inc., of Agawam, Massachusetts. The TimberLOK fastener 12 has a
hex head 14 and a drill tip 16. Alternative configurations for head 14 are
also
possible.
[00104] As will be further described below, the installation tool
10 is
preferably dimensioned, principally by means of the length of a telescopic
tube
assembly 30, to provide an installation tool which may be effectively used by
13
CA 3054843 2019-09-10
installers having a wide range of height and reach for a wide range of
commonly
vertically dimensioned structures. The principal function of the telescopic
tube
assembly 30 is to exert positive forward or upward pressure against the top
plate/roof support interface.
[00105] With reference to Figs. 5 and 6, representative tube assembly
lengths are designated by L and t and representative fastener lengths are
designated by D and d which also represents the travel distance to drive the
screws. For one example in Fig. 5, L= 36.14" and D = 8". In Fig. 6, t = 27.4"
and
d = 6". The telescopic tube assembly 30 preferably has a maximum length of
between 27.4 inches and 36.14 inches to accommodate the height and reach of
the installer. For a six-inch fastener 12, the telescopic assembly 30 must
retract
6 inches to drive the fastener, as will be described below.
[00106] The installation tool 10 dimensions allow for the tool to be
effectively and efficiently used for connecting the top plates 22 to the roof
support
members 26 without requiring the use of a ladder, platforms or other means for
providing the proper effective height relationship for driving the fasteners
12.
Moreover, the proper fastener angle may be sequentially implemented from
location to location along the top plate 22 to ensure a proper consistent
angle for
each of the multiple fasteners and to provide an integrated composite
connection
having an uplift resistance of high integrity.
[00107] The installation tool 10 preferably comprises a driver assembly
40
which includes a power driver 42. The driver 42 may be a conventional drill
gun
such as DeWaltTM model or an impact driver. The elongated telescopic tube
assembly 30, which may have a rounded, rectangular or other profile, is
mounted
over and attaches to the forward torque end 44 of the driver 42. The
telescopic
tube assembly 30 comprises a proximal tube 32 which receives and mounts the
driver 42 and a longer tube 34 secured to the tube 32. During fastener
driving,
tube 32 slides relative to tube 34 which essentially remains stationary in
relation
to the components to be connected by the fastener. Tube 34 terminates in a
distal end 36.
14
CA 3054843 2019-09-10
[00108] A fastener guide assembly 50 is mounted at the distal tip 36 of
the
tube assembly. The guide assembly 50 provides the proper alignment structure
for implementing the preferred 22 1/2 entry angle for the fastener. The
assembly 50 also engages the support member for stabilizing the installation
tool
during the driving process. The guide assembly 50 is dimensioned in
accordance with the dimensions of a given fastener. The guide assembly has a
fastener channel 52 which functions to receive and load the fastener in a
muzzle-
loading fashion. The fastener drill tip 16 is positioned proximate the channel
opening 53. The fastener is inserted head 14 first into the fastener channel
52 of
the guide assembly. The fastener head 14 is engaged by a complementary
torque coupler 43, such as a socket, for a hex thread fastener or a projecting
coupler for a fastening head socket at the applicator end of the torque drive
assembly train 45. The drive train 45, which may include multiple components,
extends through and is housed within the tube assembly 30 and is driven by the
torque driver 42.
[00109] With reference to Figs. 7 and 8, guide assembly 50 is preferably
a
cast or molded member of a lightweight rigid form which is mounted at the
distal
end 36 of the tube assembly. The guide assembly 50 has a frame 60 with a
planar locating or engagement surface 62 disposed at an acute angle with
respect to lower planar mounting surface 64. Mounting surface 64 preferably
engages against the end of the tube assembly and transversely extends across
the end of the tube 34. A planar end plate 66 is preferably perpendicular to
surface 62 and is positioned and configured to closely approach or even
contact
the underside of the roof support member 26 (as will be explained below). The
acute angle is preferably 22 1/2 , although other angles may be provided
depending on the intended application of the installation tool 10.
[00110] The fastener channel 52, which may be formed by a cylinder, has a
central axis which is perpendicular to the surface 64. The fastener channel
axis
is disposed at an acute angle of preferably 22 1/2 to the surface 62. Surface
62
CA 3054843 2019-09-10
defines the channel opening 53. The channel 52 receives the fastener 12 so
that
the head 14 is proximate and readily engageable with the torque coupler 43.
[00111] A
transverse slot 65 receives an alignment bracket 68 having a T-
shaped section which protrudes transversely at opposed sides of the
engagement surface 62 and also projects outwardly from the surface 62. The
alignment bracket 68 is positioned and configured to fit or ride below the 2x4
of
the top plate 22 to ensure proper perpendicular alignment with the top plate
22.
The alignment bracket 68 may be secured in the frame by a friction or
interference fit or may be secured by a fastener (not illustrated) to the
frame and
can be transversely moved. In one embodiment, the bracket C is located
approximately 1 5/8 inches below the end plate 68.
[00112] The
upper portion of the frame is traversed by a slot 69 which
receives a metal stabilizer plate 70. The stabilizer plate is secured in place
by a
threaded adjustment knob 72. The knob 72 connects with a threaded rod 74.
The rod extends through an opening in the plate 70 and threads into a central
threaded opening 75. The
stabilizer plate 70 preferably has a square
configuration with four vertices which form edges 76. The edges 76 are
sharpened. When the plate 70 is mounted in position, one edge 76 or vertex
projects upwardly from the end surface 66 of the frame. Openings 78 are
provided in the plate to provide a height adjustment for vaulted ceilings and
other
configurations. Alternatively, the projecting structure is in the form of a
barb.
[00113] The
function of the stabilizer plate 70 is to provide a stabbing point
to engage into the wood proximate the interface of the top plate 22 and the
roof
support member 26 to thereby stabilize the tool and prevent movement while the
fastener is being torqued by the installation tool. The stabilization is
especially
important at the initial stages of driving the fastener.
[00114] In
addition, the stabilizer plate functions to present a stabbing point
so that upon inspection, an inspector will readily perceive that the fastener
is at
the proper angle.
16
CA 3054843 2019-09-10
. ..
[00115] The guide assembly 50 is positioned by the installer at the
intersection of the top plate 22 and the roof support member 26 with the
projecting stabilizer plate edge 76 engaging into the wood and the engagement
surface 62 engaging in surface-to-surface relationship against the vertical
side of
the top plate 22. The end surface 66 is typically positioned proximate the
underside of the roof support member 26, but is slightly offset due to the
less
than complete penetration of the stabilizer edge, and the alignment bracket 68
engages the lower edge portion of the top plate 22.
[00116] Prior to engagement of the guide assembly with the top
plate/roof
support structure (as previously described), a fastener 12 is dropped into the
fastener channel 52 with the fastener head 14 proximate to or engaging with
the
complementary coupler 43. A portion of the fastener 12 is typically initially
received in a chamber of tube 34 adjacent the distal end 36. The fastener
drill tip
16 is proximate the channel opening 53 in the engagement plate 62. It will be
appreciated that the guide assembly 50 as properly positioned provides the
proper entry point and entry angle for the fastener 12 as the fastener is
driven
through the top plate 22 into the roof support member 26.
[00117] With reference to Figs. 42 and 43, alternative embodiments
of the
guide assembly that mount to the end of the telescopic tube assembly of an
installation tool are generally designated as guide head 150A and guide head
150B, respectively. These guide heads include additional features both for
providing the proper alignment and positioning for the screw and for enhancing
the ability of the operator and/or an inspector to verify that a proper
connection
has been made. Each of the guide heads has a frame 160 with a planar locating
surface 162 disposed at an acute angle with respect to a tube assembly.
Locating surface 162 defines a channel opening for the fastener channel access
of the tube assembly. A planar end plate 166 is configured to engage or
closely
approach the underside of the roof support member 26.
[00118] An L-shaped bracket preferably extends transversely at
opposed
sides of the engagement surface and projects outwardly from the surface to
17
CA 3054843 2019-09-10
provide an alignment bracket 168 to engage the vertical support 24. Bracket
168
may be adjustable. A pair of arms 180 and 182 is pivotally mounted at the top
of
the frame. One or more of the arms 180 and 182 may be pivoted upwardly to
engage a vertical side of member 26 and provide a proper positioning relative
to
the roof support member 26.
[00119] A stabber point 170 projects through the end plate 166. In
addition,
the upper portion of the frame mounts a linear ink pad 190. In the embodiment
position illustrated in Figs. 42 and 43, the guide heads 160A and 160B have
not
been positioned against the roof support member 26. Upon proper positioning,
the pivotal arms 180 and 182 would engage against the sides of the support
member 26, and the ink pad would make a linear mark indicated at 191 on the
bottom of the roof support member 26. In addition, the stabber 170 would stab
into the wood and leave a mark 171 as indicated. It should be appreciated that
either the ink mark 191 or the stab mark 171 could be used to identify both
the
proper fastener as well as the proper entry angle of the fastener and
accordingly
indicate that a proper connection has been completed.
[00120] The guide head 150B illustrated in Fig. 43 has a pair of barbs
176
projecting from the end plate 166. When properly engaged under the roof
support member 26, the pair of barbs would provide two marks 177 which would
again provide a unique marking for indicating the proper connection. Of
course,
the barbs 176 also enhance the stability of the installation tool and the
fastener
during the installation process.
[00121] The installation tool preferably includes an auxiliary handle (in
addition to the handle on the driver 40) to facilitate two-handed positioning
and
stability during the driving process. Various auxiliary handle configurations
can
be employed.
[00122] With reference to Figs. 2 and 9, an auxiliary handle 80 is
slidably
mounted to the tube and is longitudinally adjustable to provide an auxiliary
handle for the installer. The handle 80 includes a rear grip 82 which radially
projects radially or quasi-radially relative to the longitudinal axis of the
tube
18
CA 3054843 2019-09-10
assembly. A forward rod 84 extends from the grip generally parallel to the
tube
assembly. The rod 84 connects to a forward yoke 86 which envelopes the outer
surface of the tube assembly and is slidable along the tube assembly. The
intermediate portion of the rod is received in a cam lock 88 carried by the
fixed
proximal tube 32 that mounts to the forward portion of the driver 42. The rod
locks in place with the cam lock 88.
[00123] The tube 34 telescopes with the proximal tube 32 and is slidably
receivable throughout the driving of the fastener 12 in the installation
process as
the fastener is driven to complete the connection. The changing dynamic
relationships of the fastener 12, the guide assembly 50, the telescopic tube
assembly 30 and the handle 80 at the various stages of installation are
illustrated
in Fig. 9.
[00124] The auxiliary handle 80 is selectively adjustable by the
installer to
provide maximum stability and comfort to the installer. The handle locks in
place
with a pin 85. The handle 80 is initially adjustable. A button 87 is pressed
to
release the telescoping tube 34 from its fixed relationship with the proximal
tube
32 and drive the threaded fastener. The handle 80 essentially remains
stationary
as the driver moves during the installation progress, as best illustrated in
Fig. 9.
The tube 32 retracts relative to tube 34 to accommodate the progressive
expelling of the fastener 12 from the fastener chamber 52. The telescoping
tubes 32 and 34 only lock when in the fully driven position, at which point,
the
fastener 12 is fully driven.
[00125] It should be appreciated that approximately six-inch driving link
is
required for driving a six-inch fastener.
[00126] With reference to Figs. 10, 11 and 12A-C, an automatic locking
handle is generally designated by the numeral 90. The handle 90 is generally
configured to radially extend from the proximal tube 32 and slide along the
tube
32 during the driving process until it automatically locks at the full drive
position.
The handle has an orthogonally projecting grip 92 which connects with a yoke
94. The yoke 94 wraps around the tube 32 and is exteriorly slidable
therealong.
19
CA 3054843 2019-09-10
(00127) The
automatic locking handle 90 is automatically locked by the use
of balls 96 which are entrapped in a bearing 98. The driving rod 49 has a
varying
diameter along a longitudinal portion. As best illustrated in the sequence of
Figs.
12A-C, as the fastener 12 is driven, the geometry of the driving rod has
reduced
diametric surfaces allowing the balls to slip by and the outer distal tube 34
to fully
telescope. The external handle can be placed anywhere along the proximal tube
32. It will be appreciated that as the fastener 12 is driven, the handle is
rearwardly displaced toward the driver 42 until a fully locked position is
obtained
and the telescoping tube 34 is retracted.
(001281 With
reference to Figs. 13, 14 and 15A-D, another handle which
may be employed for a third embodiment of a fastener installation tool is
generally designated by the numeral 110. The
handle 110 includes a
circumferential grip 112 which extends around the proximal tube 132. The grip
112 may be easily moved along the base tube 32 and tightened in position or
loosened by means of a twisting motion on the grip about the longitudinal axis
of
the tube assembly 30.
[00129] A
protrusion 114 rides within an internal slot 116 which is attached
in fixed relationship to the driver 42. The proximal tube 132 forms the
internal
slot 116, and the sliding tube 134 includes an external rib 147. The internal
slot
116 is not aligned with the rib 147 in the dormant/non-drive state (Fig. 15A).
As
the driver starts to drive, the protrusion 114 starts to ride in the internal
slot 116
until it changes geometry and twists, thereby causing the handle to twist
(Figs.
15B-C). The foregoing continues until the second slot is aligned with the
external
rib, thereby allowing the tube 134 to fully telescope inwardly (Fig. 15D).
When
the installer feels the handle 110 rotate slightly, the installer knows that
the
fastener 12 has been sufficiently initially driven, and the installer can
release the
grip 112 on the handle and place both hands on the driver 42.
[00130]
Naturally, other handles are possible. In some embodiments, an
auxiliary handle as such is not required. In such embodiments, the installer
CA 3054843 2019-09-10
merely grips along the tube assembly at a location that appears to be most
advantageous.
[00131] The installation tool 10 is preferably battery powered and
includes a
chargeable battery power pack. However, in some embodiments, the power
driver (not illustrated) may be directly electrically powered and include a
cord
which connects with the power line.
[00132] With reference to Figs. 16A and 16B, two different structural
heights of the top plane 22 and two appropriately dimensioned installation
tools
for relatively tall and short installers (shown in silhouette) are
illustrated, it should
be appreciated that the dimensioning of the telescopic tube assembly 30, in
terms of longitudinal length, is established to accommodate the preferred
application in connection with connecting a top plate 22 to a roof support
member
26 without the installer needing a ladder or a platform to obtain the correct
reach
for driving the fastener. In addition, because the height and reach of an
installer
may significantly vary, the length of the telescopic tube assembly 30 is
preferably
selected to accommodate a wide range of installers' physical dimensions.
[00133] For applications wherein a fastener greater than 6 inches or even
less than 6 inches may be applicable, an alternative guide assembly may be
employed. For such a guide assembly, the effective depth of the fastener
channel is altered. In addition, the telescopic extremes of the telescopic
tubes 32
and 34 are adjusted to accommodate for the driving length for the fastener.
Naturally, the coupler of the installation tool is adapted to complement the
head
of the fastener.
[00134] It should also be appreciated that for applications in which an
angle
other than 22 1/2 is desired, the guide assembly may also be configured so
that
the fastener channel is at an acute angle relative to the engagement surface
at
the prescribed optimum angle. Naturally, the position of the alignment bracket
68
may also be varied in accordance with a specific project. Multiple guide
assemblies for various installation angles may be provided and attached to the
telescopic tube assembly as desired.
21
CA 3054843 2019-09-10
'
,
. .
[00135] For some embodiments, the power driver 40 is easily
dismounted
from the telescopic tube assembly 30. The telescopic tube assembly may
employ a receiver configured to receive and functionally attach to a wide
range of
dismountable drill guns without the torque driver being fully integrated with
the
telescopic tube assembly.
[00136] With reference to Figs. 17-25, another embodiment of an
installation tool (which does not show the power driver assembly) is generally
designated by the numeral 200 (Fig. 17). Installation tool 200 includes a
receiver
202 for the power driver assembly (not illustrated), a telescopic tube
assembly
230 comprising telescopic tubes 232 and 234, and a fastener guide head
assembly 250 which is mounted at the end 236 of tube 234.
[00137] A handle assembly 210 is disposed in longitudinally fixed
relationship to tube 234 and includes a trigger 212 which is depressible into
one
of essentially two positions. One partially depressed position of the trigger
212
allows for the handle assembly to be angularly adjusted about the longitudinal
axis of the distal tube 234 at a preset defined angular position. The full
depressed position of the trigger 212 allows for the proximal tube 232 to be
retracted relative to the distal tube 234 when the fastener 12 is driven. The
handle assembly 210 also provides for two-handed support of the tool so that
the
stabilizing edge 276 can be effectively stabbed into the support member. It
should be appreciated that the tubes 232 and 234 do not rotate relative to
each
other with the non-rotatable position being ensured by a longitudinal flat 236
which engages through the handle assembly.
[00138] With reference to Figs. 19A-B and 23-25, the handle 210
has a grip
portion 214 which carries the trigger 212. The handle assembly 210 is attached
to the distal tube 234 by a yoke 240 which is longitudinally fixed between a
pair
of collars 241 and 243. The trigger 212 moves a ramp 216 which engages
complementary ramp 218 of a plunger 220. The plunger 220 has a radially
acting detent 222 which is biased inwardly into the tube 234.
22
CA 3054843 2019-09-10
[00139] A
plurality of (preferably five) recesses 225 are angularly spaced in
fixed relationship to the outer tube 234. The
projectable detent 222 is
longitudinally aligned with the recesses 225 and receivable in a selected
recess
for retention under the plunger bias. Upon depressing the trigger 212, the
detent
222 is retracted from a recess 225. Angularly rotating the grip 214 relative
to the
distal tube 234 allows detent 222 to be angularly engageable into a selected
recess 225 to fix the angular position of the handle assembly 210 as desired
by
the installer. That angular position is further secured by a thumb screw 246
at
the top which is tightened to secure the desired angular position.
[00140] A
pair of internal collar mounts 245 and 247 are respectively fixedly
mounted interiorly of the tubes 232 and 234. The mounts allow rotational and
axial movement of the drive train. A spring 248 bears against the mounts and
essentially biases the tubes 232 and 234 to a maximum extended position which
is limited by a stop 249. The spring 248 may be optional. Stop 249 allows for
replacement of the driver bit 282 to complement the fastener head. The plunger
detent 222 also extends through an opening 223 to prevent movement between
the distal tube 234 and the proximal tube 232 and thus fix the effective tool
length. When the trigger 212 is fully depressed, the plunger is retracted from
the
opening 223 to allow the proximal tube to move relative to the distal tube
against
the bias of the spring 248 until the fastener is fully driven.
[00141] With
additional reference to Figs. 5, 17 and 20-22, a dual floating
alignment bushing or receiver guide 280 is mounted at the interior of the
distal
tube 234 and has a central opening which receives the output coupler 284 of
the
drive train 282. The guide 280 ensures a concentric alignment between the
fastener and the driver. The dual receiver guide 280 has a double conical or
funnel-like constriction 286 which receives the head 14 of the fastener 12 and
centers it for engagement by the coupler 284 as illustrated.
[00142] A
fastener guide head assembly 250 is mounted at the distal tip
236 of the tube assembly. The guide head assembly 250 has a generally
cylindrical base 251 which is retained to the distal tube 234 by means of one
or
23
CA 3054843 2019-09-10
more set screws 239 (Fig. 17). A sleeve 252 extends through the base 251 to
form a channel which receives and guides the fastener 12. Surface 262 defines
the sleeve input opening 253 to sleeve 252 for the fastener as correspondingly
described with respect to guide assembly 50. The sleeve 252 receives the
fastener so that the head 14 is properly positioned to be readily engageable
by
the torque coupler 282. The major thread diameters of the fastener 12 and the
interior diameter of the sleeve 252 are configured so that the interior
diameter of
the sleeve is only slightly larger than the major thread diameters of the
fastener.
Preferably, the maximum diameter of the head 14 is approximately equal to the
major diameter of the threads. It will be appreciated that as the fastener 12
is
loaded into the guide head assembly 250, the head 14 moves through the sleeve
or channel 252 and is convergently directed via the funnel-like constriction
286
(Fig. 20) toward engagement with the torque coupler 284 of the drive train.
The
coupler 284 is also axially centered by the dual receiver guide 280. The dual
receiver guide 280 can axially move or float within the tube. The movement is
inwardly limited by a dimple 281.
[00143] The guide head assembly 250 is preferably a cast or molded
member of lightweight rigid form which includes a frame extending from the
base
with a planar engagement surface 262 disposed at an acute angle with respect
to
the lower planar mounting surface 264. Mounting surface 264 preferably
engages against the end of the tube assembly and transversely extends across
the distal end 236 of the tube 234. A planar end plate 266 is parallel to
surface
264 and positioned to engage the underside of the roof support member 26. The
acute angle is preferably 22 1/2 , although other angles may be provided
depending on the intended application of the installation tool. The specific
angle
can be provided with a guide head assembly having the required angle of the
sleeve or guide channel relative to the engagement surface 262.
(001441 A transverse slot 265 receives an L-shaped alignment bracket 268
which protrudes transversely at opposed sides of the engagement surface 262
and also projects outwardly from the surface 262. A set screw 271 secures the
24
CA 3054843 2019-09-10
'
. .
bracket 268 and allows the bracket 268 to be adjusted laterally, for example,
when required at corners. The alignment bracket 268 is positioned and
configured to fit below the 2x4 at the top plate 22 to ensure proper
perpendicular
alignment with the top plate. For corner configurations, the alignment bracket
268 may be moved to an extreme lateral position, either left or right of the
position as shown in Fig. 21.
[00145] The upper portion of the frame is traversed by a slot 269
which
receives a metal stabilizer plate 270. The stabilizer plate is secured by an
adjustment knob 272 which connects with a threaded rod 274. The rod extends
through an opening in the plate and threads into separate threaded opening
275.
The stabilizer plate 270 preferably has a square configuration with four
vertices
which form edges 276. The edges 276 are sharpened. When the guide head
assembly 250 is properly positioned a sharp edge 276 projects upwardly from
the
edge surface 266 of the frame. The function of the stabilizer plate 270 with
edge
276 is to provide a stabbing structure to engage into the wood proximate the
interface of the top plate 22 and the roof support member 26 to thereby
stabilize
the tool 200 and prevent movement or walking while the fastener 12 is being
torqued by the installation tool. The stabilization is important at the
initial stages
of driving the fastener.
[00146] Figs. 26-29 illustrate installation tools 300, 400, 500
and 600 which
incorporate various adaptors for coupling with the conventional rotary driver
tools.
[00147] Fig. 26 illustrates an installation tool 300 which an
adaptor 302 for
attachment to the type of rotary driver tool which includes a collar mounted
auxiliary handle. Such handles are frequently found on hammer type drills to
provide additional leverage for the user. In this case, the disclosed adaptor
302
replaces the auxiliary handle of the driver tool 340 with a collar attachment
to
secure the adaptor to the rotary driver behind the chuck. The chuck is used to
secure the extended length drive shaft to the rotary driver and a grip 310
permits
the user to securely grasp and maneuver the tool 300 and adaptor 302. The grip
CA 3054843 2019-09-10
310 of the tube assembly 330 receives a manually fed plunger front portion.
The
plunger front portion is configured to telescope inside the grip of the
adaptor
during screw installation. The manual feed plunger incorporates a screw guide
353 which surrounds and guides the screw during installation. The guide head
350 is configured to permit the user to accurately place the screw in the
center of
a wood structural member so that the screw will be installed centered on the
truss and parallel to truss orientation, and preferably at a 22.5 angle with
respect
to a vertical direction. This 22.5 angle is selected to ensure that the
installed
screw passes through the lower building components and accurately penetrates
an upper building component, for example a roof truss. It will be apparent to
those skilled in the art that other angles may be suitable for other
applications
and that alternative plunger tip configurations will be desirable for other
screw
installations.
[00148] The rotary tool adaptor illustrated in Fig. 26 includes a
cylindrical
screw magazine 390 disposed about the grip 310 of the tube assembly 330. In
this embodiment, screws 392 are removed from the magazine 390 and manually
inserted into the screw guide 353 located in the plunger front end of the tube
assembly 330. The screw guide is configured to closely receive a screw without
excess radial space around the screw. The screw guide is configured to
accurately start and deliver the screw 392 through the wood structural
members.
The length of the screw and the intended structural purpose of the
installation
require precise guidance and delivery of the screw through the associated wood
members.
[00149] Fig. 27 illustrates an installation tool 400 with a second
embodiment
of a tool adaptor for use with the disclosed construction system. The
embodiment of Fig. 27 illustrates a pistol grip adaptor 402 configured to
engage a
rotary driver tool 440. The pistol grip permits the user to maintain control
over
the adaptor and rotary tool during screw installation. This embodiment also
includes a grip 412 forward of the pistol grip 410 and a plunger/screw guide
453
at the forward end of the tube assembly 430. The tip of the plunger/screw
guide
26
CA 3054843 2019-09-10
. ..
is configured to assist the operator to drive screws at the 22.5 angle (Fig.
27,
lower right), though other tip configurations and angles are compatible with
the
disclosed construction system.
The embodiment of Fig. 27 shows an
arrangement where the position of the pistol grip 410 is adjustable on the
rear
portion of the tube assembly 430. This arrangement permits the user to
customize the ergonomics of the adaptor to the task and an operator. A lever
actuated cam lock system 414 allows the user to disengage the pistol grip 410
from a tubular rear portion and to fix the pistol grip in a selected
alternative
position. Fig. 27 illustrates a view of a guide head 450 for the screw guide
plunger which includes a sight line enhancing an operator's ability to center
the
screw on a structural member during installation.
[00150]
Figs. 28A and 28B illustrate an installation tool 500 with an
alternative embodiment of a tool adaptor 502. The embodiment of Figs. 28A and
28B includes a pair of flexible arms 504 configured to elastically deform and
grip
the sides of a rotary driver tool 540. Thermoplastic resin pads 506 enhance
frictional engagement between the arms and the sides of the rotary tool. The
adaptor 502 of Figs. 28A and 28B also includes an extended grip area 510 for
use by the operator. The screw guide/plunger front end of the adaptor is shown
with one of several contemplated plastic guide heads 550. The illustrated head
550 is configured to aid the operator in installing a screw at a 22.5 angle
relative
to the vertical as previously described. A plurality of plastic tips for
mounting on
the end of the screw guide can be swapped out for different screw installation
purposes.
(00151]
In installation tool 600 with a further alternative tool adaptor 602 is
disclosed in Fig. 29. In this embodiment, the adaptor is secured to the rotary
tool
by a ratchet type strap 604 extending from the sides of the adaptor around a
rear
portion of the rotary tool 640. This configuration permits the adaptor to be
securely integrated with the rotary tool. Various means may be provided to
tighten the ratchet strap in a manner similar to arrangements used on snow
sport
bindings for example. In the embodiment of Fig. 29, the rear grip portion 610
has
27
CA 3054843 2019-09-10
. ..
an ergonomic shape and a textured grip area to enhance operator ease of use
and safety. The embodiment of Fig. 29 shows a molded plastic plunger guide
head 650 with an integrated molded 6" screw clip 690. The grip portion 610 is
configured to permit the forward plunger portion to recede into the grip
portion
during screw delivery. A pump action screw feeder is illustrated where screws
are moved from a clip to a screw guide by manual cycling of the manual pump
grip 695. Once the first screw is manually fed into the screw guide, further
screws may be delivered with the longitudinal cycling of the screw guide
during
subsequent screw installation. A sight line 691 on top of a clip 690 enhances
the
user's ability to center the screw guide on a structural member for accurate
delivery of screws.
[00152] Accessories can also aid in efficient use of the disclosed
installation
tools and the construction system. Various ways of maintaining a supply of
fasteners on the person of an operator are disclosed. Such accessories
minimize the necessity to interrupt installation to renew a supply of
fasteners.
For example, Fig. 30 illustrates a belt holster 700 holding several screws
from
which the operator efficiently retrieves a screw and manually installs each
screw
in a screw guide.
[00153] Figs. 31A-31B and 32A-32B respectively illustrate a
bandolier 700A
and leg mounted screw holster 700B as alternatives for maintaining a number of
screws 702 on the person of the operator. The screw holding systems
illustrated
in Figs. 31A-31B and 32A-32B may include magnets arranged to maintain
screws in the disclosed holders while the worker is moving about the
construction
site. This reduces the chance that screws may fall out of the disclosed
holders
and enhance ease of use. The fastener holders of Figs. 30-32B may include
tapered plastic tubes 704 for each fastener. The tubes can be configured to
cover the sharp points of the fasteners to avoid inadvertent injury to the
operator.
For example, the bottom end of the tapered tubes 704 may be closed.
[00154] The disclosed installation tools may be adapted for use in
driving a
wide range of fasteners to implement various connections of wood components
28
CA 3054843 2019-09-10
in a wood structure. A preferred fastener 900 which has particular
applicability
for providing a connection between a top plate and a truss frame is
illustrated in
Fig. 33. Fastener 900 is a six-inch fastener which has an uninterrupted thread
910 extending from a gimlet point 912 toward a head 914. The thread 910 is
approximately five inches. In one embodiment, the gimlet point has a 300
angle.
The head 914 has a socket which may be a T25 Autosert drive or other socket
configuration with a fixed diameter that preferably ranges from 0.260 to 0.290
inches, which is approximately the major diameter of the thread 910.
(001551 Depending upon the application, a number of other fasteners are
possible depending upon the connection to be implemented as well as the
specific structural components.
[00156] Figs. 34A-34D illustrate representative fasteners compatible with
the disclosed construction system. The disclosed fasteners 920A and 920B are
double-threaded, having a self-drilling tip 922 and approximately 2" bottom
thread 924 paired with a threadless center shank portion 926 and 1W-2" top
thread. The top thread 928 (under the head 930A and 930B) is for increasing
head pull-through performance. The top thread 928 in one configuration has a
higher pitch, e.g., a greater number of threads per inch, to reduce the rate
of
penetration of the fastener as the top thread enters the wood during
installation.
This configuration will reduce the likelihood of board jacking and enhance
clamping during installation. The top thread 928 may be of the same major and
minor diameter as the bottom thread or may have a larger major and/or minor
diameter to enhance pull-through resistance. The axial length of the top
thread
928 may be as short as 1/2" depending upon the configuration of the upper
thread
and the desired pull-through resistance. The threadless center portion of the
screw is arranged to permit maximum penetration of the bottom thread 924 into
the various structural members prior to engagement of the top thread. The
screws are illustrated with a Torx type drive socket 932 configured to
facilitate
automated or mechanized screw installation in the disclosed screw guides.
29
CA 3054843 2019-09-10
[00157] Different bright colors or tints are applied to the screws 920A
and
920B to readily identify the fastener for both proper connection and
inspection
purposes. Currently, building inspectors can easily identify metal brackets
applied to structural members. The alternative use of threaded fasteners
potentially makes inspections more problematic. Threaded fasteners are not as
easily seen by building inspectors. Even if the inspector can see the ends of
the
fasteners, the inspector would not necessarily know what type of fastener is
installed. The disclosed construction system addresses this issue by applying
bright colors to the fastener or at least the head of each fastener. Brightly
colored fastener heads 930A and 9306 provide a clear visual indication of the
type of fastener installed in a given location. Bright colors can also help
builders
and workers to identify the correct fastener for a particular purpose.
[001581 Figs. 35A-35E illustrate an embodiment of the representative
installation tool and construction system being used to install the disclosed
threaded fasteners to connect various structural components. Note that the
construction worker standing on the floor has clear sight lines to the
installed
fasteners whether the installation is overhead or at floor level. The worker
is
neither climbing a ladder nor squatting down at floor level. The disclosed
construction system should enhance workers' safety and productivity while
reducing the possibility of injury or worker discomfort.
[001591 Figs. 36A-36C illustrate a proposed embodiment of a fastener 940
compatible with the disclosed construction system. A Torx drive socket 942 in
the screw head 944 is shown but other socket-type drive heads, such as square
drive, Torx T-Tap, TOD( Plus, Phillips, etc. are possible. The head 944 of the
fastener employs an internal (socket) type drive, is compact and relatively
small
in diameter to reduce the likelihood of interference with other building
components such as sheathing on the outside and sheetrock on the inside of a
structure. The relatively small head can reduce the fastener resistance to
pulling
through wood structural members when subjected to forces along the axis of the
fastener.
CA 3054843 2019-09-10
(00160] In the disclosed fastener 940 shown in Figs. 36A-360, it can be
seen that the top thread 946 has a higher pitch than the bottom thread 948.
This
thread pitch differential between top and bottom threads for some applications
to
reduces board jacking and enhances building component clamping during
installation of the disclosed screws. The top threads of the disclosed
fasteners
are configured to enhance pull-through resistance of the disclosed fasteners.
It
will be noted that the major diameter of the top thread 946 is larger than the
major diameter of the bottom thread 948. The disclosed fastener employs a
single diameter shank which is formed to result in the disclosed thread
patterns.
Multi-diameter blanks are also contemplated where the diameter of the shank at
the top of the fastener may be larger to provide more material for the top
thread
resulting in enhanced pull-through resistance. The disclosed threaded
fasteners
are contemplated between 5.25%6" in length but length will vary depending on
the intended purpose of the fastener. The illustrated fastener 940 has a 2"
bottom thread 948 and a 1.75" top thread 946. The length of the top thread and
the length of the unthreaded center portion of the screw shank can be varied
to
tune screw performance.
[00161] While the fastener 940 employs a thread configuration where the
top thread 946 has a higher thread count (TPI) than the bottom thread 948,
fasteners with the same thread count or a bottom thread having a higher thread
count than the top thread may be useful for some purposes.
[00162] Figs. 37A-37C illustrate an alternative screw configuration 960
contemplated as useful for certain locations in a structure. This fastener is
a
single thread fastener with a fin 962 or wing type boring feature adjacent to
the
tip. Fastener 960 may be suitable for a bottom plate to rim joist applications
for
example. The flared head 964 of this fastener provides enhanced pull-through
resistance in locations where interference with sheathing or sheetrock is not
a
concern. The boring feature reduces the possibility of cracking the wood
structural member during screw installation. This fastener has a large
diameter
main thread 966 to reduce strip out of the fastener when tightening multiple
plies
31
CA 3054843 2019-09-10
of laminated veneer lumber beams together. Alternatively, the boring feature
may be configured as more of a fin type wing that can appear as a spiral and
may be applied by a threading machine, eliminating the need for a secondary
pointing operation. There may be two, three or four fins 962 that are equi-
angularly distributed about the circumference of the screw tip. Each of the
fasteners illustrated in Figs. 36A-360 and 37A-37C are configured so that the
head penetrates slightly into a structural member or sits flat against the
member
to prevent interference with other building components such as sheathing or
brackets, straps and joist hangers that may need to be installed.
(00163] Figs. 38A-38C illustrate various metal brackets and straps that
may
be employed in conjunction with the disclosed construction system. Figs. 38A-
38C illustrates the junction of a roof truss with the top plate of a
structure. This is
a location where many building codes require that the truss be strapped or
tied to
the top plate using a hurricane tie or the like. Metal plates 802 are
typically used
to hold truss components together. Such truss plates 802 are installed in a
factory setting and include perforations that provide metal penetrating barbs
to
hold the plate to the truss components, thereby securing the truss components
to
each other. The resulting perforated configuration may provide an opportunity
to
attach L-shaped brackets 804 to tie the roof truss to the top plate of the
wall as
shown in Figs. 38A-38C. Screws or bolts 806 may pass through the roof truss
plates 802 and L-shaped brackets 804. Threaded fasteners 808 may be used to
attach the lower portion of the L-shaped bracket to the top plate. Fig. 38C
illustrates an L-shaped bracket 804 with perforations and wood penetrating
barbs
arranged to match the perforations in the truss plates. The L-shaped bracket
804
could be installed by pressing or hammering into the truss plates and threaded
fasteners 808 can be employed to tie the L-shaped bracket 804 to the top
plate.
(00164] Figs. 391A-39E illustrates a possible alternative configuration
for a
truss plate. The disclosed truss plate 810 is U-shaped with the vertical
portions
of the U including perforations and wood penetrating points configured to
secure
the truss plate to the truss components. The bottom portion of the U-shape
32
CA 3054843 2019-09-10
includes wood penetrating barbs 812 directed away from the truss and intended
to penetrate the top plate of the wall. Threaded fasteners 814 contemplated in
the disclosed construction system are then installed to tie the truss to the
top
plate and wall. The downward extending barbs 812 from the proposed U-shaped
truss plate grip the top plate and enhance a secure connection of the truss to
the
wall. Further, the metal bottom panel 818 of the proposed truss plate 810
enhance pull-through resistance of the fastener relative to the truss.
(001651 Figs. 40A-40B illustrates an alternative metal construction
bracket
system. Flexible metal brackets 820 are arranged in elongated strips with
score
marks 822 or indentations between the segments. The elongated strips may be
cut or broken between segments to provide metal brackets of different length.
Fig. 40A illustrates a five-segment bracket placed to tie a vertical stud to a
top
plate and a roof truss. The disclosed metal brackets 820 include metal
perforations which can be pressed into the wood to provide a secure bracket to
wood connection.
(001661 Figs. 41A-41D illustrates a tool 830 complementary to the
disclosed
flexible metal brackets 820. The tool 830 is configured to bend and clamp the
proposed bracket in place, pushing the perforated metal barbs into the wood. A
tool adaptor 832 provides clamping force on the disclosed brackets. A rotary
drive tool adaptor is disclosed, though a hydraulic tool is also suitable for
this
purpose. The jaws of the tool include protrusions configured to mate with
perforations on the brackets and push portions of the brackets into the wood,
thereby attaching the brackets to the wood.
(001671 With reference to Figs. 44-49, an adaptor 1000 is adapted for use
in mounting to the end of an installation tool, such as tools 10, 200, 300,
400, 500
and 600 (without guide assemblies or adaptors) to provide a reference guide to
reliably implement a proper entry angle and location of a fastener 1012
connecting through a support stud into a top plate and also into a bottom
plate.
The same adaptor 1000 may be used for both the illustrated top plate fastener
installation and the bottom plate fastener installation as illustrated in Fig.
44. The
33
CA 3054843 2019-09-10
, stud is designated by the letter S, the top plate by TP and the bottom
plate by BP
in Figs. 44, 44A and 44B.
[00168] The adaptor 1000 comprises an adaptor head 1010 which mounts
via coupling tube 1020 to the distal tube of a telescopic tube assembly. The
head defines a reference entry surface 1030 which is at an angle to the
fastener
opening 1032 and fastener channel 1034 aligned with the drive axis of the
tube.
A pair of irregularly shaped polygon arms 1040, which are identical in shape,
connect at opposite sides of the head and define spacing distance D which is
substantially equal to the width of the stud S (Fig. 48). The arms 1040 each
have
a first reference edge 1042 and a second reference edge 1044 that intersect
and
are at angles to each other. The reference edges 1042 are co-planar, and the
reference edges 1044 are co-planar.
[00169] The arms have substantially parallel inner faces 1046. The inner
faces 1046 of the arms receive and essentially capture the upper portion of
the
stud S. The entry surface 1030 engages against the edge of the stud and the
first reference edges 1042 of the arms engage the underside of the top plate
TP,
as best illustrated in Figs. 44 and 44A. The concurrent engagement of the
entry
surface 1030 and the first reference edge 1042 properly fixes the position and
the entry angle of the fastener 1012 into the stud S (from the edge) and
ultimately the top plate TP to provide an optimum connection. In the preferred
embodiment, the entry angle a (relative to the vertical) is approximately 350
.
[00170] When it is desired to use the installation tool to provide a
connection between the lower portion of the wall stud S and the bottom plate
BP,
the installation tool with the fixed adaptor is merely repositioned so that
the entry
surface 1030 of the head engages the lower portion of the edge of the stud and
the second reference edge 1044 engages the top portion of the bottom plate BP
to provide an optimal position and entry angle for driving a fastener 1012
into the
stud S and the bottom plate BP as illustrated in Fig. 44B. In the preferred
embodiment, the entry angle a relative to vertical is approximately 35 .
34
CA 3054843 2019-09-10
[00171] With reference to Figs. 50 and 51, a modified version of adaptor
1000 is designated as adaptor 1050. This adaptor 1050 is substantially
identical
to adaptor 1000 except that the arms 1040 are pivotally mounted to the adaptor
head by a pivot pin 1060. The arms may be independently pivotal, but for most
fastener installations, generally align as illustrated for adaptor 1000. This
adaptor 1050 thus allows for one arm to be pivoted in the event that there is
a
headroom constraint or obstacle which prevents both of the arms from engaging
opposing sides of a vertical stud S.
[00172] With reference to Figs. 52-56, a fastener installation tool
adaptor
1100 is configured to mount to the end of a fastener installation tool and
provide
a proper entry for a fastener 1012 for a plate to a rim board or blocking B as
illustrated in Figs. 52-52C. The fasteners are installed to resist uplift
and/or
lateral forces in the structure. For adaptor 1100, there are two pivotal
positions.
Each pivot position defines a different entry angle into a horizontally
disposed
member.
[00173] The head 1110 mounts to a connector or coupling tube 1120 and
provides an opening for the fastener so that the fastener is driven at an
optimum
location and angle. Two substantially identical irregular four sided arms 1140
are
pivotally mounted to the head by a pivot pin 1112. A transverse bridge 1150
connects the arms 1040. The arms 1140 pivot in tandem. The arms define first
reference edges 1142 and second reference edges 1144 that are at substantially
right angles or orthogonal to each other. The first reference edges 1142 are
coplanar and the second reference edges 1144 are coplanar.
[00174] In the upper or TOP position, as best illustrated in Fig. 52A,
reference edges 1142 engage the underside of the top plate TP and reference
edges 1144 engage against a sheathing SH. This fixes the proper location and
entry angle 13 (relative to the vertical) for the fastener which connects the
top
plate to the lateral blocking LB. This position is also illustrated in Fig.
52C.
[00175] The arms 1140 may also be pivoted in tandem to a second
BOTTOM position wherein the first reference edges 1144 engage the upper
CA 3054843 2019-09-10
surface of a lower plate and the second reference edges 1142 engage the
sheathing SH to provide the proper location and entry angle y (relative to the
vertical) into the rim board/lateral blocking LB, as best illustrated in Fig.
52B.
[00176] With reference to Fig. 54, the bridge 1150 preferably includes an
arrow 1152 and the head has indicia 1114 and 1116, respectively, indicating
TOP and BOTTOM pivot position. Selectively pivoting positioning the arrow
1152 relative to the head 1110 indicates the proper pivotal position of the
adaptor
1100 for a desired fastener connection. The entry angles are preferably
approximately 20 for the entry angle p of the top plate TP to the lateral
blocking
LB (Fig. 52C) and approximately 12 for the entry angle y of the bottom plate
BP
to the lateral blocking LB (Fig. 52B).
[00177] With reference to Figs. 57A to 75, a dual positionable fastener
installation tool adaptor is generally designated by the numeral 2000. The
adaptor 2000 functions to provide the proper entry angle and location for
driving
a fastener to connect a vertical member, such as a stud, with a horizontal
member. Adaptor 2000 mounts to the end of a fastener driver assembly 2010
having a telescopic tube assembly with a distal tube 2020. The adaptor 2000
and distal tube 2020 of the driver assembly are configured so that the adaptor
may be mounted to the tube at one of two angular positions about the central
axis of the distal tube 2020 at essentially 180 spaced angular positions.
[00178] A first mounted position is illustrated in Figs. 57A and 57B. The
adaptor engages a vertical member and a horizontal member in a stable, fixed
position to provide a proper angle for driving a fastener, for example,
through a
vertical stud into a bottom plate. In a second mounted position illustrated in
Fig.
59B, the adaptor 2000 is configured to engage the stud in a stable, fixed and
properly aligned relationship and drive a fastener into a top plate. The
adaptor
2000 thus provides an optimal location and entry angle for connecting an upper
top plate and an optimal location and entry angle for driving a fastener for
connecting a lower bottom plate.
36
CA 3054843 2019-09-10
[00179] The key to obtaining the dual positions is unclamping the adaptor
2000 at a first defined angular position relative to the tool, slightly
axially
displacing the adaptor, rotating the adaptor 1800 to a second angular
position,
slightly axially displacing the adaptor, and reclamping the adaptor 2000 in
position.
[00180] The adaptor 2000 includes a base 2100 which has a generally
planar first reference surface 2110 and a generally opposite second generally
planar reference surface 2120. Surfaces 2110 and 2120 are not parallel. The
reference surface 2120 of the base defines a fastener opening 2122 (Fig. 63B).
A fastener receiver assembly 2300 (Fig. 65) is received by the base 2100 and
is
disposed at an acute angle relative to the reference surface 2120. The forward
distal portion of the base 2100 forms a planar nose 2130 (Fig. 62A). The base
also mounts a flush indicator 2140 which is pivotal relative to the reference
surface 2120 to provide an indicator that the reference surface 2120 is flush
with
the appropriate member as desired for driving the fastener.
[00181] The surface 2110 of the base defines a recess 2112 which receives
a second pivotal flush indicator 2150 which, when the reference surface 2120
is
flush against upper vertical reference surface, the indicator 2150 pivots to
indicate a flush position (Fig. 61B). The indicator is spring biased to extend
outwardly from the reference surface when a component is not engaged in
surface-to-surface relationship with the reference surface 2120.
[00182] Transversely spaced wings 2200, which are preferably
substantially
identical in shape, function in tandem as guides to properly position and
stabilize
the adaptor. The wings pivotally mount to the base about a pivot 2210 at a
location generally adjacent the nose 2130 of the base. The wings preferably
have a quasi-triangular shape with a restricted access opening 2212 (Fig. 72B)
and a second restricted access opening 2214 at quasi-opposed vertex positions.
Openings 2212 and 2214 are equidistantly spaced from pivot 2210. A threaded
pin 2230 with a knob 2232 threads into the base and extends through one of the
37
CA 3054843 2019-09-10
openings to secure the wing 2200 at a given pivotal position (see Fig. 74). In
that
position, the other access opening is temporarily non-functional.
[00183] With additional reference to Fig. 62B, a wing has a reference
engagement edge 2240. A metal plate 2250 is preferably mounted in a recess of
an inner surface 2245. The plate 2250 is integrally affixed with a pair of
spaced
claws 2252 and 2254. The claws preferably have a claw configuration wherein
the claws essentially traverse in three directions. The claws 2252, 2254
project
from the reference engagement edges 2240. The claws are adapted to bite into
the structural members to provide a stable fixed position for the fastener
installation tool. As described herein, engagement by edges 2240 encompasses
direct edges 2240 and/or claws 2252, 2254.
[00184] It will be appreciated that the wings 2200 are transversely
spaced
so that they receive between surfaces 2245 opposite sides of a stud so that
the
opening 2122¨and hence the fastener¨can be driven through the medial center
line of the stud. The reference surface 2120, of course, also functions to
engage
against the stud surface-to-surface relationship to provide an optimum angle
entry for the fastener.
[00185] With reference to Figs. 64A-67, the base mounts a fastener
receiver assembly 2300 that employs a multifunction tube 2410 which defines a
fastener channel 2310 for a received fastener F (Figs. 65, 66). The channel is
disposed at a pre-established angle relative to the reference surface 2120,
e.g.,
the entry angle. A conical or quasi-conical funnel-like guide 2320 is mounted
at
an upper portion of the receiver assembly to center the received fastener F so
that the driver bit or coupler (not illustrated) from the driver tool will
properly
engage the fastener head H. The lower portion of the tube assembly also
includes a guide sleeve 2340 so that the driver will be unidirectionally
driven into
the member without wobble. A pair of wraparound magnets 2350 is secured by
cooperative engaged pronged plugs 2360 at the driver coupling end of the tube.
The magnets 2350 function so that the fastener is retained within the adaptor
and
38
CA 3054843 2019-09-10
, does not slide out through the opening 2122 prior to drive engagement with
the
driver coupler.
[00186] A connector assembly 2400 extends from the base 2100. The
assembly functions to receive the distal end of the telescopic tube assembly
of
the installation tool. The connector assembly employs the tube 2410 which
defines and extends coaxially with the channel 2310. A pair of cooperative
arcuate brackets 2450 surrounds a lower portion of the tube to form an arcuate
receiving slot 2454. A lug 2460 (Fig. 68A) projects from the tube 2410. A
second lug 2460 also projects at a diametrically opposed location.
[00187] The fastener driver assembly 2010 has a distal tube portion 2020
with two notches 2030 at diametrically opposed positions at its terminus. A
lever
clamp 2040 is spaced from the distal end. The clamp 2040 is pivotally actuated
to govern the radial position of a lock member. The distal tube portion 2030
slides over tube 2410 into slot 2454. The adaptor tube 2410 and distal tube
2020
align so that each circumferential lug 2460 is received in a distal notch 2030
(Fig.
68A). The handle of clamp 2040 is forced inwardly to secure the adaptor to the
tool by the lock member engaging a detent 2470 on the tube 2410.
[00188] It will be appreciated that the adaptor is positioned at the
selected
angular position on the telescopic end of the installation tool, the lugs are
captured in the notches and the clamp is locked to axially secure the adaptor
to
the driver assembly at the desired angular position. A fastener is then loaded
in
the channel 2310. The adaptor 2000 may be, for example, positioned, as
indicated in Fig. 75A (the fastener driver assembly 2010 is omitted for
purposes
of clarity) where the claws engage the bottom rim or plate H and the wings
capture the opposite sides of the vertical stud V. The reference surface 2120
of
the base is moved against the edge of the stud V and the engagement edges
2240 and/or claws 2252, 2254 engage the surface of plate H. The flush
indicator
2140 indicates the flush position, as best illustrated in Figs. 75A and 75B.
The
installation tool with the mounted adaptor 2000 may then drive the fastener at
the
39
CA 3054843 2019-09-10
properly located entry position and angle to fasten the stud V to the bottom
plate
H.
[00189] For some applications, there is an obstruction which prevents the
tandem usage of the wings 2200 in positioning the adaptor for properly driving
the fastener. The wings 2020 may be independently pivoted out of the way by
loosening the knob 2032, pivoting the wing 2020 and then securing the
previously unused access opening 2214 against the threaded pin 2230 of the
knob 2232 and tightening the knob 2232, such as illustrated in and in Figs.
70B
and 71B. For this application, only a single wing is employed to install the
fastener. Likewise, the opposed wing may also be pivoted out of position and
secured by the opposing knob, as best illustrated in Figs. 72B and 73B. It
should
be appreciated that Fig. 70A and 70B together illustrate pivoting the wing out
of
the way from the normal tandem wing position of Fig. 70A. Figs. 72A and 72B
illustrate pivoting the opposed wing from the normal tandem wing position to
the
pivoted position for a second adaptor/driver assembly position. Accordingly,
it
will be appreciated that either wing 2200 may be independently pivoted, if
required, to accommodate a structural obstacle.
[00190] It will thus be appreciated that the adaptor 2000 has a novel
claw
feature to lock the adaptor in place. The adaptor 2000 also provides two flush
indicators to readily indicate that the proper flush position for the adaptor
has
been achieved. The adaptor 2000 functions to angularly pivot and be secured in
position on the distal tube portion of the driver assembly to provide the
optimal
driving position and angle for both the top plate and the bottom plate
fastener
connection. The adaptor 2000 also functions to provide a feature for retaining
a
loaded fastener within the adaptor by means of a pair of magnets. In addition,
the adaptor 2000 is highly versatile in that, if required, either wing 2200
may be
independently pivotally retracted and secured to accommodate obstacles
wherein the tandem wing arrangement cannot be employed.
[00191] While the preferred embodiments of the foregoing have been set
for purposes of illustration, the foregoing description should not be deemed a
CA 3054843 2019-09-10
,
limitation of the invention herein. Accordingly, various modifications,
adaptations
and alternatives may occur to one skilled in the art without departing from
the
spirit and the scope of the present invention.
41
CA 3054843 2019-09-10
