Note: Descriptions are shown in the official language in which they were submitted.
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
HIDDEN FASTENER UNIT AND RELATED METHOD OF USE
BACKGROUND OF THE INVENTION
[0001] The present
invention relates to a fastener unit configured to fasten
workpieces, such as boards, to support structures, such as joists, and more
particularly to a fastener unit that engages a groove in the side of a board
to secure
the board to a support structure.
[0002] There are a
variety of structures, such as decks, platforms and flooring,
that include horizontal floors supported by an underlying support structure.
The
structures typically include boards that are placed side-by-side one another.
The
boards typically are arranged to extend cross support structures, such as
joists,
disposed under the boards at an angle, sometimes at a right angle. The boards
usually are fastened to the joists using fasteners, such as nails or screws.
The nails
or screws can frequently become discolored over time, or can work themselves
loose from the board and project upward from the board surface. Not only are
these
results aesthetically displeasing, they can present safety hazards.
[0003] Some
manufacturers have developed hidden fastener systems that fit
loosely within grooves of adjacent boards. These hidden fasteners typically
include a
biscuit-shaped upper plate having two horizontal flanges that fit into the
grooves
defined by the sides of adjacent deck boards, a single center hole through
which a
fastener extends to secure to the underlying joist, and a base that extends
downward from the upper plate to an underlying joist. While the horizontal
flanges
can engage the grooves, these elements typically do not engage those grooves
forcibly enough to tack the boards to the underlying joist and prevent them
from
moving during expansion and contraction under changing temperatures. These
systems typically also require a user to manually hold the plate in alignment
with one
or more grooves of the boards as the fastener is advanced, which can be
- 1 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
cumbersome. Depending on the height of the base and the distance of the groove
from the board lower surface, sometimes these items can be mismatched so that
the
flanges do not fit well in or align with the grooves. In addition, the flanges
are of a
fixed thickness so that if that thickness is mismatched relative to a groove,
the plate
cannot fit in the groove, let alone secure the board to the underlying joist.
Further,
where a support structure includes a double or triple joist, with two or more
joists
positioned immediately adjacent one another, the foregoing fastener systems
might
not be properly sized to conceal those joists or fit within the associated
confined
spaces.
[0004] Accordingly,
there remains room for improvement in the field of
fastener units that are configured to secure grooved boards to underlying
support
structures.
SUMMARY OF THE INVENTION
[0005] A fastener
unit and related method to secure a board to a support is
provided. The fastener unit includes a spacer block, a grip element extending
from
the spacer block and configured to fit in and engage a groove of the board,
and at
least one element extending from the spacer block, configured to secure the
spacer
block adjacent the groove to establish a gap between the board and another
board.
[0006] In one
embodiment, the element can be a resilient compression
element that is vertically compressible so that portions of it can be
compressed from
an open mode to a compressed mode. In the compressed mode, the resilient
compression element is sized and dimensioned smaller than a width of the
groove
so that the element can fit within the groove. After placement in the groove,
the
portions can expand within the groove to forcibly engage the groove, thereby
securing the resilient compression element and the joined spacer block
adjacent the
groove and a side surface of the board.
- 2 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0007] In a further
embodiment, the resilient compression element extends
laterally from the spacer body, and in the same direction as a portion of the
grip
element. Optionally, the grip element and resilient compression element can
extend
rearwardly, from a rearward face of the spacer body, an equal amount or
distance.
Further optionally, the resilient compression element can include a front edge
that
does not extend forwardly, from a forward face of the spacer body, while the
grip
element can extend forwardly another distance from the forward face of the
spacer
body.
[0008] In another
embodiment, the spacer body is of a thickness extending
from a forward face and a rearward face. The thickness can be optionally less
than
0.200 inches, further optionally less than 0.250 inches, and even further
optionally
less than 0.500 inches to provide a corresponding gap between adjacent boards.
[0009] In still
another embodiment, the resilient compression element includes
first and second portions, optionally in the form of wings, plates, rounded
sections,
ellipsoids, polygonal elements, and the like, any of which can be referred to
as wings
herein, that function similar to resilient springs. These portions can be
pinched
toward one another, to convert the resilient compression element from an open
mode to a compressed mode. In the compressed mode, the portions can be located
in the groove of the board, which optionally can be 1/8 inch to 3/8 inch wide
or other
dimensions depending on the application. When the portions are released, they
can
forcibly engage the groove to hold the fastener unit centered in the groove.
[0010] In even
another embodiment, the resilient compression element can be
joined with the spacer body at a fracturable joint. This fracturable joint can
include a
zone of weakness, such as a thinned region, a region with perforations or
holes, an
area with a brittle material, or some other weakening portion so that a user
can
- 3 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
manually break off the resilient compression element from the spacer body and
fit
the fastener unit in a particular location, for example, a confined space.
[0011] In yet
another embodiment, the grip element can be in the form of a
channel. Optionally, the channel can be a c-channel that is turned upside down
so
that its opening faces downward. Associated protrusions of the channel can be
configured to engage a lower interior surface of the board groove and
effectively bite
into that surface when the fastener is tightened down, to pull the grip
element and its
protrusions into that surface. In turn, this provides enhanced securement of
the
board to the underlying support structure, such as a joist.
[0012] In a further
embodiment, the fastener unit can be equipped with an
additional resilient compression element, projecting from the spacer body on
opposite lateral sides of the spacer body. The first and second resilient
compression
elements can cooperate to forcibly hold the spacer body and fastener unit in
place
adjacent the groove during installation of the fastener. In turn, because the
unit is
self-supported, a user can use both hands to manipulate a tool, such as a
power
drill, to install the fastener. Also, because the unit is self-supported, a
user can place
multiple fastener units, place an adjacent board, and later come back to
fasten down
one or more boards with the fastener units.
[0013] In still a
further embodiment, the spacer body defines a fastener hole
that can include an upper portion and a lower portion. These upper and lower
portions can have different diameters or dimensions to accommodate different
screw
types. In some cases the lower portion can include a diameter that is less
than a
diameter of the upper portion so that the tip of the screw can fit within the
lower
portion, while threads above that tip can fit within the upper portion.
Optionally, the
screw can be partially threaded into engagement with the spacer body, and in
particular the interior surfaces of a first fastener hole defined by the
spacer body.
- 4 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0014] In still yet
a further embodiment, the grip element can be constructed
from a first material, such as a metal and/or composite, while the spacer
body,
resilient compression element and other features can be constructed from a
polymeric material. The polymeric material can be overmolded to the grip
element to
secure the grip element thereto, with the grip element at least partially
entrapped in
the spacer body.
[0015] In even a
further embodiment, a fastener unit can include a spacer
body defining a first fastener hole having first and second different internal
dimensions, a threaded fastener supported by the spacer body within the first
fastener hole, a grip element joined with the spacer body and configured to
fit within
and engage a groove of a board, and first and second joist legs extending
downward
from the spacer body and configured to straddle and clampingly engage sides of
an
underlying joist.
[0016] In yet a
further embodiment, the fastener unit can be constructed so
that one or more joist legs are joined with the spacer body at a fracturable
joint so
that the leg can be selectively manually removed, depending on the placement
of the
fastener unit relative to one or more joists or within other confining spaces.
[0017] In still yet
a further embodiment, the fastener unit can include a spacer
block and a grip element disposed transversely relative to the spacer block,
extending from forward and rearward surfaces of the spacer block. A first
joist leg
can extend from a first lateral side of the spacer block and a second joist
leg can
extend from a second lateral side of the spacer block. The first and second
joist legs
extend outwardly and downwardly from the spacer block. One or both of the
joist
legs includes a stabilizer bar extending from the joist leg a predetermined
distance.
The stabilizer bar can be mounted below the spacer block and selectively
positioned
so that it can engage a bottom surface and/or side surface of a board, below a
- 5 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
groove of the board, placed adjacent the fastener unit. In combination, the
stabilizer
bar, joist legs and/or the spacer body can engage one or more boards, adjacent
which the spacer unit is placed, in multiple locations to thereby provide
multiple
points of contact with the spacer unit and those boards, and thereby stabilize
the
fastener unit in a particular orientation, optionally holding the fastener
associated
with the spacer unit in an upright, vertical orientation, ready for engagement
by a
tool.
[0018] In even a
further embodiment, the fastener unit can include a spacer
block and a grip element disposed transversely relative to the spacer block,
extending from forward and rearward surfaces of the spacer block. A first
joist leg
can extend from a first lateral side of the spacer block and a second joist
leg can
extend from a second lateral side of the spacer block. The first and second
joist legs
extend outwardly and downwardly from the spacer block. The grip element can
include one or more pressure distribution feet at opposing ends of the grip
element.
When a fastener of the unit is tightened down, such a pressure distribution
foot can
ensure most of the force is distributed at one or more of the opposing ends of
the
grip element, rather than near the spacer body. With certain types of grooved
boards
having a chamfer under the groove along a board bottom surface, this force
distribution, deep within the groove, can impair or prevent tipping of the
board
caused by the tightening down of the fastener unit.
[0019] In yet
another embodiment, the fastener unit can include a spacer
block and a grip element disposed transversely relative to the spacer block,
extending from forward and rearward surfaces of the spacer block. A first
joist leg
can extend from a first lateral side of the spacer block and a second joist
leg can
extend from a second lateral side of the spacer block. The first and second
joist legs
extend outwardly and downwardly from the spacer block. The spacer block can be
a
- 6 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
timing spacer block that is of a predetermined height set so that the spacer
block
engages an underlying joist or other support, optionally while a fastener of
the unit is
being tightened down to draw the fastener unit toward the joist or other
support. With
this timing spacer block, the fastener unit does not engage the grip element
against
the interior surfaces of the groove in such a way so as to pull the groove
downward
with too much force, which may cause tipping of the board in some
circumstances.
[0020] The current
embodiments of the fastener unit and related methods of
use provide benefits in hidden fasteners that previously have been
unachievable.
For example, where the fastener unit includes a multi-dimensioned fastener
hole
defined by the spacer body, the spacer body can be configured to hold a
fastener
therein, yet not split or become damaged when the fastener is advanced through
the
spacer body. Where the fastener includes one or more fracturable joints
between the
spacer body and one or more of the resilient compression elements, those
elements
can be easily removed and discarded from the unit to fit a particular joist
combination
or confined space. Where the unit includes the resilient compression element,
that
element can secure and hold the fastener unit in place adjacent the groove,
without
the need for additional hands to hold the unit. This can enable a user to
place
multiple fastener units along a board groove, install another board adjacent
those
units, and then come back and secure all the fastener units so that the boards
are
held in a fixed manner relative to the underlying support structure. Where the
grip
element is included having one or more downward protrusions or cleats, those
elements can forcibly engage the groove to prevent the board from creeping or
moving during expansion and contraction thereof during and under different
temperatures. Where the spacer body is of diminished thickness, the entire
fastener
unit can be well concealed between adjacent boards, yet provide firm
securement of
- 7 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
those boards to underlying support structure, and provide a gap large enough
to
accommodate a fastener head passing between the boards.
[0021] These and
other objects, advantages, and features of the invention will
be more fully understood and appreciated by reference to the description of
the
current embodiment and the drawings.
[0022] Before the
embodiments of the invention are explained in detail, it is to
be understood that the invention is not limited to the details of operation or
to the
details of construction and the arrangement of the components set forth in the
following description or illustrated in the drawings. The invention may be
implemented in various other embodiments and of being practiced or being
carried
out in alternative ways not expressly disclosed herein. Also, it is to be
understood
that the phraseology and terminology used herein are for the purpose of
description
and should not be regarded as limiting. The use of "including" and
"comprising' and
variations thereof is meant to encompass the items listed thereafter and
equivalents
thereof as well as additional items and equivalents thereof. Further,
enumeration
may be used in the description of various embodiments. Unless otherwise
expressly
stated, the use of enumeration should not be construed as limiting the
invention to
any specific order or number of components. Nor should the use of enumeration
be
construed as excluding from the scope of the invention any additional steps or
components that might be combined with or into the enumerated steps or
components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Fig. 1 is a
perspective view of a current embodiment of the fastener
unit with a fastener associated with the unit;
[0024] Fig. 2 is
another perspective view of the fastener unit about to be
installed in a first groove of a first board;
- 8 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0025] Fig. 3 is a front view of the fastener unit;
[0026] Fig. 4 is a side view of the fastener unit;
[0027] Fig. 5 is a front view of the fastener unit with the resilient
compression
elements being converted from an open mode to a compression mode;
[0028] Fig. 6 is a perspective view of the resilient compression elements
installed in a groove and holding the fastener unit adjacent the board;
[0029] Fig. 7 is a side sectional view of the fastener unit installed
within
grooves of adjacent boards and establishing a gap with a spacer body between
those adjacent boards;
[0030] Fig. 8 is a perspective view of a first alternative embodiment of
the
fastener unit;
[0031] Fig. 9 is a front view of the first alternative embodiment of the
fastener
unit;
[0032] Fig. 10 is a perspective view of the first alternative embodiment of
the
fastener unit being installed relative to a groove of a board and an
underlying
support;
[0033] Fig. 11 is a side sectional view of the first alternative embodiment
of
the fastener unit installed within grooves of adjacent boards and establishing
a gap
with a spacer body between those adjacent boards;
[0034] Fig. 12 is a perspective view of a second alternative embodiment of
the
fastener unit including one or more stabilizer bars;
[0035] Fig. 13 is a side sectional view of the second alternative
embodiment
of the fastener unit installed with a grip element in groups of adjacent
boards, and
with the one or more stabilizer bars engaging a lower surface of a board to
provide
further stabilization of the fastener unit
- 9 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0036] Fig. 14 is a
perspective view of a third alternative embodiment of the
fastener unit including a grip element with one or more pressure feet and a
timing
spacer block;
[0037] Fig. 15 is a
perspective view of the third alternative embodiment of the
fastener unit installed on an underlying joist and at least partially
installed in a groove
of a board; and
[0038] Fig. 16 is a
side sectional view of the third alternative embodiment of
the fastener unit installed within grooves of a boards and the fastener
installed to
apply force well within the grooves via the one or more pressure feet, and the
timing
spacer block bottomed out against the underlying joist.
DESCRIPTION OF THE CURRENT EMBODIMENTS
[0039] A current
embodiment of the fastener unit is illustrated in Figs. 1-7,
and generally designated 10. The fastener unit 10 can generally include a
spacer
body 20, a grip element 30 protruding forwardly and rearwardly from the spacer
body, and one or more resilient compression elements, such as a first
resilient
compression element 41 and a second resilient compression element 42. These
compression elements can be joined with the spacer body optionally via
respective
fracturable joints 48 and 49. A fastener 90 can be at least partially disposed
through
the spacer body 20 and/or the grip element 30 when the unit is in an
uninstalled
state as shown in Fig. 1.
[0040] The current
embodiments of the fastener unit 10 are well suited for a
variety of building and construction projects, such as commercial, residential
and
other construction projects. The fastener units, however, can be modified for
use in
other applications, such as automotive, marine, industrial and/or consumer
products.
As described herein, the fastener units can be used in the application of
grooved
boards or lap boards that are fastened to an underlying support structure. The
-10-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
boards can be constructed from wood, plastic, composites, metal, ceramic,
tile,
masonry or other materials depending on the application.
[0041] As shown in
Figs. 2 and 6, the boards 101, 102 can include respective
grooves 103 and 104. These grooves can include a groove depth GD of optionally
1/16 inch, further optionally 1/8 inch, even further optionally 1/4 inch, yet
further
optionally 1/2 inch or other depths depending on the particular application.
Further, as
shown in Fig. 2, the groove can be bounded by upper 105 and lower 107 lobes or
projections that transition to the upper and lower surfaces of the board 101.
Although
shown as a continuous groove, each of the respective grooves 103 and 104 can
be
intermittent and/or discontinuous, depending on the particular application and
board
construction. Each groove 103 also can include a lower wall 109L, a rearward
wall
109R and an upper wall 109U. These walls can be radiused and can transition
smoothly or cleanly to one another as shown. Alternatively, they can be joined
at
right angles, depending on the application.
[0042] The fastener
unit 10 of the current embodiment will be described
generally in connection with joining boards 101, 102 to an underlying joist
106,
where the deck boards lay across an upper surface 106U of the joist. The joist
106
of course can be any support structure or element and can be constructed from
any
type of material, such as wood, plastic, composites, metal, ceramic, tile,
masonry or
other materials depending on the application. Further, it will be appreciated
that the
fastener unit can be used in conjunction with any type of decking, flooring,
covering,
roofing or other components.
[0043] Turning now
to the fastener unit 10, each of the respective
components, such as the spacer block 20, resilient compression elements 41,
42,
grip element 30 and fastener 90 will now be described in more detail.
Referring to
Figs. 1-4, the spacer block 20 includes a front surface 21 and an opposing
rear
-11-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
surface 22. These surfaces are on opposite sides of the vertical axis VA of
the
spacer body 20. This vertical axis VA can correspond to a longitudinal axis of
the
fastener 90. As described further below, a first fastener hole FF1 is aligned
with this
vertical axis VA. The spacer body 20 can include a first side surface 23 and
an
opposing second side surface 24.
[0044] The spacer
block can define a thickness Ti that extends between the
front surface 21 and the second opposing rear surface 22. This thickness
corresponds to a preselected gap G (Fig. 7) that to be located between
adjacently
placed boards 101, 102. This gap and thickness can be optionally at least
0.180
inches, further optionally at least 0.200 inches, further optionally at least
0.250
inches, even further optionally at least 0.300 inches, yet further optionally
at least
0.350 inches, further optionally at least 0.400 inches, yet further optionally
at least
0.450 inches, even further optionally at least 0.500 inches, or wider or
increments
thereof, depending on the application and the desired spacing between adjacent
deck boards. Alternatively, the gap and thickness can be optionally less than
0.180
inches, further optionally less than 0.200 inches, still further optionally
less than
0.250 inches, even further optionally less than 0.300 inches, yet further
optionally
less than 0.350 inches, further optionally less than 0.400 inches, yet further
optionally less than 0.450 inches, even further optionally less than 0.500
inches, or
narrower or increments thereof, depending on the application and the desired
spacing between adjacent deck boards. Optionally, the thickness Ti and
corresponding gap G set by the spacer body can be equal to and/or greater than
the
diameter DF of the fastener head 90H. In this manner, the fastener head can
fit
between and not excessively mar board surfaces that are placed adjacent the
spacer body.
-12-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0045] The spacer
body 20 can set this gap G by way of the front surface 21
engaging in adjacent board, for example, board 102 in Fig. 7, and the rearward
opposing face 22 engaging the board 101 as shown in Fig. 7. With this spacer
body
being disposed generally between the upper and lower lobes or projections 105,
107
that straddle the respective grooves 103 and 104, the spacer body effectively
prevents those boards 101 and 102 from being placed any closer to one another
than the gap G due to the thickness Ti of the spacer body 20 there between. As
illustrated, the spacer body front surface 21 can engage the upper lobe 105 of
a
board above the groove 104. A lower portion of the spacer body 26 can engage
the
lower lobe 107 of the board, generally below the groove. Optionally, the
spacer body
can engage portions of the side surface of the board in the regions of the
lobes 105
and 107 above and below the groove 103.
[0046] As shown in
Figs. 1 and 3, the spacer body upper portion 27 can
include or define a recess 27R that extends from an upper most surface 27U, to
a
location adjacent the grip element 30. This recess 27R can be flanked by
opposing
ramped surfaces 27S. These ramped surfaces 27S can facilitate insertion of the
fastener 90 into the first fastener hole FF1 as described further below.
[0047] As shown in
Figs. 1 and 3, the lower portion 26 can include a lower
surface 26L that can be generally flat. The distance 02 between the lowermost
portion of the grip element 30 and the lower surface 26L of the lower portion
26 can
be less than the distance 03 between the lower wall 109L of the groove 103 as
shown in Fig. 5. With this distance 02 less than D3, the spacer block 20
optionally
will not interfere with the grip element 30 being brought into contact and
engagement
with the lower surface 109L of the groove. For example, if the distance D2 was
optionally greater than 03, this might interfere with the engagement of the
grip
element 30 with the components of the groove 103. Of course, this alternative
-13-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
construction can be implemented for different applications where grip element
engagement is irrelevant.
[0048] As shown in
Figs. 3 and 5, the spacer body 20 also can define a grip
element recess 28. This grip element recess can extend generally through the
spacer body, from the forward surface 21 to the opposing rearward surface 22.
This
grip element recess can be of a corresponding shape relative to the shape of
the
grip element 30. The recess 28 can be in the form of an inverted U- or C-
shaped
channel that opens downward toward a joist 106. This recess 28 can be sized to
enable the grip element 30 to be inserted through the spacer body and in some
cases, friction fit and held in place relative to the spacer body. Of course,
there can
be some gaps between the sides of the recess and the grip element 30 so that
the
spacer body does not hold that grip element well. In such constructions, the
fastener
90, extending through a grip element aperture, also called a second fastener
hole
SFH defined by the grip element 30 and into the first fastener hole FF1 of the
spacer
body 20. Due to the engagement of the threads 90T of the fastener with the
first
fastener hole FF1, the fastener can secure the grip element in place relative
to the
spacer body. Optionally, the grip element 30 can be overmolded or 3-D printed
over
with material that forms the spacer body. In such a case, the grip element can
be at
least partially encapsulated by the spacer body and held in place accordingly.
[0049] As shown in
Fig. 3, the first fastener hole FF1 can include an upper
portion FF1U and a lower portion FF1 L. The upper portion and lower portion
can be
of similar geometric shapes. For example, the upper and lower portions can
both be
cylindrical. In some cases, however, one can be frustoconical and the other
can be
cylindrical. In yet other applications, the shape can be rectangular, square,
polygonal, ellipsoid, rounded or other geometric shapes. These respective
portions
can have different diameters or dimensions. For example, the upper portion can
-14-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
include a diameter DU and the lower portion can include a diameter DL. The
lower
portion diameter DL can be less than the upper portion diameter DU. This can
enable the tip 90T of the fastener 90, which can be pointed or frustoconical
to be
inserted into and have its threads partially bite into the lower portion FF1L.
This in
turn, can enable the fastener 90 to be slightly threaded into the spacer body
so that it
is secured thereto via those threads and the interaction of the threads with
the first
fastener hole FF1. It will be noted that although referred to herein as a
diameter, that
phrase encompasses any dimension of the first fastener hole, regardless of
whether
the respective portions of the hole are circular, elliptical, rounded or
instead are
polygonal.
[0050] Turning to
Figs. 1-5, the grip element 30 can be in the form of a C-, V-
or U-shaped channel. The grip element can be joined with the spacer body and
optionally disposed within a spacer grip element recess or aperture 28. The
grip
element can include a base 33 and optional first 31 and second 32 downwardly
extending protrusions, cleats or gussets. These cleats can optionally be
integrally
formed with the base 33. The cleats can be spaced a distance from one another
and
relative to the second fastener hole SFH, and thus the fastener 90 and the
fastener
head 90H. In particular, the cleats can be spaced so that when the head 90H is
tightened and engages the grip element, first and second portions on opposite
sides
or ends of the head or its diameter respectively can exert forces downward
directly
over and on the first and second cleats 31, 32, without bending the grip
element. The
cleats can function as reinforcing members to the base in this manner,
particularly
when the fastener head 90H is pressing down on the base, to optionally prevent
buckling of that base. Optionally, as shown in Fig. 2, the cleats 31, 32 can
be spaced
so their interior facing surfaces are a distance D8 of optionally less than
0.500
inches from one another, further optionally less than 0.250 inches from one
another,
-15-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
even further optionally less than 0.200 inches from one another, yet further
optionally
less than 0.180 inches from one another, and still further optionally about
0.208 from
one another. The diameter DF of the fastener can be equal to, less than or
greater
than this distance D8. Optionally, the diameter DF can be equal to or slightly
greater
than the distance D8. In turn, this can maintain the cleats under or
immediately
adjacent the lower portions of the head 90F when those portions engage the
grip
element. Again, this can add rigidity and support closer to the fastener as it
is
tightened so the base and grip element in general do not deform, bend or
buckle due
to the downward force exerted by the fastener in the middle of the grip
element.
[0051] These cleats
can be configured to engage the grooves 103 and 104 of
the respective boards with which the fastener unit 10 is used. As shown, the
cleats
can include flat lower edges, however these edges can be sharpened so that
they
are angled and come to points. Although not shown, the cleat lower edges can
be
serrated and/or include teeth to better bite into the groove of the board when
the
fastener unit is secured in place with the fastener 90.
[0052] As mentioned
above, the grip element 30 includes a grip element
aperture or second fastener hole SFH. This fastener hole can be aligned with
the
first fastener hole FF1 of the spacer body 20 so that the fastener can fit
through both
simultaneously. This second fastener hole SFH can be disposed in the center of
the
base 33, and optionally centered halfway between the forward edge 36 and
rearward
edge 37 of the grip element 30 as shown in Fig. 2.
[0053] Optionally,
the second fastener hole SFH can be a circular hole drilled
through the base 33. In other cases, the second fastener hole SFH can be a
recess
ground through the base and one or more of the cleats 31 or 32, but only from
a
single side. This can enable the grip element to retain enough material so
that the
head 90H of the fastener 90 will engage the grip element and pull it toward
the
-16-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
underlying joist 106. The second fastener hole can be large enough to accept
the
threads of a fastener therethrough, but smaller than the diameter of the
fastener
head so that the head engages and pulls the grip element when tightened.
[0054] The grip
element can also include a forwardly extending portion 38 that
extends forwardly of the forward surface 21 of the spacer body 20. The grip
element
can also include a rearward portion 37 that extends rearwardly of the rearward
face
22 of the spacer body. The forward portion and rearward portions of the grip
element
can be of lengths L1 and L2, which can be equal extending from the respective
forward and rearward faces of the spacer body. Of course, in some applications
the
distances and lengths can vary.
[0055] The grip
element 30 can be constructed from a variety of materials,
such as metal, composites, polymers, ceramics, reinforced composites, polymers
and the like. The grip element can be strong enough so that it does not buckle
or
collapse when the fastener head 90H engages it and pulls the grip element 30
into
the lower surface 109L of the board groove 103. In this manner, the fastener
90 pulls
the grip element 30 into tight engagement with that lower surface 109L or
other
components of the groove 103. This in turn, clamps the board 101 down to the
underlying support structure 106. Due to this clamping, the board 101
effectively can
be prevented from moving upon expansion and contraction of that board when
subjected to different environmental conditions, such as heating and cooling.
This
can prevent the board from creeping in one direction or the other or generally
becoming uneven.
[0056] Optionally,
although shown as an inverted channel, the grip element
can be in the form of a small tube with corresponding teeth, a single flat
piece of
high-strength steel, optionally with serrations or knurling on its lower
surface, or
-17-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
other forms, depending on the application and the materials from which the
boards
are constructed and/or as well as the desired holding strength.
[0057] As mentioned
above, the fastener unit 10 can include first 41 and
second 42 resilient compression elements. These resilient compression elements
can be similar in structure and therefore only one will be described in detail
here. It
also will be appreciated that one of the resilient compression elements can be
eliminated from the design in certain applications. In further applications,
that area of
the fastener unit can be occupied by a simple flange or leg that extends
outwardly
from the side surface of the spacer body 20, where that component is not
compressible or movable from an open mode to a compressed mode as with a
resilient compression element.
[0058] The first
resilient compression element 41 can extend outwardly from
the first side surface 23 of the spacer body 20. The second resilient
compression
element 42 can extend outwardly from the second side surface 24 of the spacer
body, which is opposite the side 23. Thus, the resilient compression elements
optionally can be symmetric about the vertical axis VA as shown in Fig. 3.
Generally,
the resilient compression elements 41 and 42 can be joined on opposite sides
of the
vertical axis VA. In this manner, they can engage the groove distal from one
another
to provide two or four points of engagement and contact between the fastener
unit
and the groove, not counting the engagement by the grip element 30.
[0059] The first
resilient compression element can include a vertically
compressible upper wing 41UW and a vertically compressible lower wing 41LW.
These wings can be joined at a junction 41J. The wings as illustrated are
generally in
the form of flat plates angled relative to another and joined at apex at the
junction
41J. Of course, in other applications these wings can be curved, rounded, or
of other
shapes. These upper and lower wings can be designed to be vertically
compressed
-18-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
in direction VC as shown in Figs. 3 and 5. By vertically compressible, it is
meant that
the a wing or component or portion of the resilient compression element can be
moved in direction of the arrows VC, generally toward a plane P1 that is
orthogonal
to or otherwise transverse to the vertical axis VA of the spacer body 20. Due
to their
resilient nature, however, these portions resiliently deform and are urged to
expand
and re-attain their previous configuration in an open mode of those elements
as
shown in Figs. 1 and 3. After application of forces F to move the wings toward
one
another and/or generally toward the plane P1, due to the resilient nature of
the
wings, those wings are self-urged to open back up to the configuration shown
in
Figs. 1 and 3.
[0060] The
resilient compression elements 41, 42 are operable in an open
mode, as shown in Fig. 3 and a compressed mode as shown in Figs. 5-7. In the
open mode, the fastener unit 10 is not yet installed relative to a groove of a
board. In
that configuration, the ends or outermost portions of the wings, farthest from
the
spacer body 20, are disposed a distance D5 from one another. This distance D5
in
the open mode can be less than the height GH of the groove. Because of the
vertically compressible nature of the resilient wings 42UW and 42LW of the
resilient
compression element 42, these wings can be moved toward one another or
generally toward a spacer body horizontal reference plane, that is, the first
plane P1.
Optionally, this plane P1 can pass through the grip element recess 28 and/or
the
portions of the grip element 30. When these wings are vertically compressed
under a
vertical compression force F, the distance D6 between them decreases. This
distance D6 can be less than the groove height GH. Optionally, the compression
elements upper and lower portions can be separated by a variable distance.
This
distance can be varied so that the resilient compression elements can fit
within a
particular groove of a board.
-19-
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0061] Referring to
Fig. 3, the outer ends 41 EE of the wings, and generally the
resilient compression element 41, are free ends that extended the space. That
is,
they are not connected to one another. Optionally, in some applications, these
elements and the ends can be connected to one another, provided that the
connection allows vertical compression in direction VC. As an example, the
upper
and lower wings can be joined with corresponding wings, in the shape of "V",
that
extend outwardly from the ends 41 EE. In turn, this allows these components to
be
compressed. In other constructions, the vertically compressible wings can be
in the
form of elongated elliptical or circular shapes that are structured to enable
them to
be compressed and reduce their overall vertical dimension, optionally to some
dimension that is less than the groove height GH of the groove 103.
[0062] With
reference to Fig. 5, in operation, a user can manually apply a
force F to vertically compress the wings 41 and 42 in direction VC toward the
plane
P1 and/or generally toward one another. This converts the wings from the open
mode shown in broken lines to a compressed mode as shown in solid lines. The
resilient wings or portions of the compression elements bend, flex or
otherwise move
toward one another so that the distance between them is reduced from the
distance
D5 to the distance D6. This reduction in distance can be approximately 5%,
10%,
15%, 25%, 30%, 35%, 40%, 50% or more, depending on the application and amount
of vertical compression. Generally, the first wing and second wing or other
portions
of the resilient compression element are resiliently moveable toward one
another
and/or the first plane P1 such that the vertical distance between the wings
decreases
upon the application of a compressive force by a user.
[0063] With the
resilient compression elements in the compressed mode, a
user can install those elements 41 and 42 into the groove 103. Because the
distance
D6 is less than the groove height GH, these elements will now fit within the
groove.
- 20 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
When the user releases or reduces the force F applied in the compressed mode
to
the respective portions of the resilient compression element, those wings want
to go
back to the configuration of the open mode. Due to the upper 109U and lower
109L
surfaces of the groove, engagement if those wings with the resilient
compression
elements and the respective wings or other portions thereof, exert forces Fl
and F2
on the board 101 in the groove, and against the upper and lower surfaces of
the
groove. These forces can optionally be at least 0.0001 pounds, further
optionally at
least 0.001 pounds, even further optionally at least 0.05 pounds, yet further
optionally between 0.0001 pounds and 0.5 pounds. Of course, other forces can
be
exerted by the compression elements against the surfaces of the groove
depending
on the application and configuration of the resilient compression elements.
[0064] Due to the
forcible expansion of the resilient compression elements
within the groove, the resilient compression elements secure the spacer block
in a
position adjacent the first groove. In this manner, the spacer block can be
disposed
in and effectively form the gap G between the side surfaces of the boards 101
and
102 when the second board is installed, as shown in Fig. 7.
[0065] The
resilient compression elements 41, 42 can include respective front
edges 41F, 42F and rear edges 41R, 42R. The rear edges 41 are configured to
fit
within the groove 103 of the board 101. In some cases, the rear edges can be
disposed entirely within the groove and located adjacent the rear wall 109R.
The
front edges, however, can extend outward from the groove, and beyond the site
surface of the board, and in particular the lobes 105 and 107.
[0066] Optionally,
the front edge and rear edge are separated by a
compression element width CEW. This compression element width CEW can be
greater than the thickness Ti of the spacer block 20. Put another way, the
thickness
Ti of the spacer block 20 can be less than the compression element width CEW.
- 21 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
Thus, the resilient compression elements can extend forward and/or rearward
from
the front and rear surfaces of the spacer block. As illustrated, the front
edge 42F can
lay within a common plane with the front surface 21 of the spacer block 20.
The
rearward edges 41R, 42R can extend beyond and outwardly from the spacer block
rear surface 22 a distance D7 as shown in Fig. 1.
[0067] In some
cases, there can be spatial relationships between the grip
element, spacer block and resilient compression elements. For example, the
grip
element can have a grip element length L3 that extends from the front edge to
the
rear edge of the grip element 30. As mentioned, above the spacer block 20 can
include a spacer block thickness Ti and the resilient compression elements can
each include compressible element widths CEW. As illustrated, the grip element
length L3 can be greater than the compressible element width CEW. The
resilient
compression element width CEW can be greater than the spacer block thickness
Ti.
In some cases, both the grip element length L3 and the compression element
width
CEW can be greater than the thickness Ti. This can enable the respective grip
element and resilient compression elements to fit within the groove of one
board yet
not interfere with fitment of another board adjacent the first board. Indeed,
the
compression element width CEW can be less than the sum of the groove depth GD
plus the thickness Ti of the spacer block. This can enable the resilient
compression
elements to be disposed within the groove to hold the spacer block in place,
yet not
extend beyond the spacer block to interfere with the setting of a gap between
adjacent boards. With this decreased width, the resilient compression elements
also
might not interfere with or engage another groove 104 of an adjacent board
102.
Instead, only the grip element 30 optionally extends into and is engaged
against that
groove 104 to secure the boards to another.
- 22 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0068] The
resilient compression elements 41, 42 can be joined with the
spacer body 21 at respective fracture of all joints 48 and 49. As shown in
Figs. 3 and
5, these fractional joints can be effective zones of weakness where the
material
joining the spacer body and the resilient compression elements is thinned so
that
those resilient compression elements can be bent in direction B and
effectively break
off at that joint. This is illustrated in Fig. 3 where the joint 49 has been
fractured. In
some cases, the fractional joint can be a portion of plastic that has
perforations or
holes extending therethrough. With this fracture of a joint, a user can
selectively and
manually remove one of the resilient compression elements 41, 42 to fit in a
particular confined space or over a combination of abutting underlying support
joists.
[0069] A related
method of using the fastener unit 10 of the current
embodiment will now be described. In general, the fastener unit can be
provided
including its spacer body 20, grip element 30, and resilient compression
elements 41
and 42. The fastener 90 can be installed therein or can be installed by the
user
generally extending through the fastener holes as described above and engaging
different portions of those holes as also described above. A user can apply a
force F
as shown in Fig. 3 to vertically compress in direction VC the wings of the
resilient
compression element toward one another and/or generally toward a plane P1.
This
in turn, changes the distance between the ends of the wings from a distance 05
to a
lesser distance 06. When so compressed, the fastener unit transforms from an
open
mode, shown in broken lines, to a compressed mode, shown in solid lines, in
Fig. 5.
The wings of the resilient compression elements as well as the rearward
portion 37
of the grip element 30 can be inserted into the groove 103 as shown in Fig. 6.
These
elements can be pushed in direction R as shown in Fig. 2 into the groove. The
wings
can be released to remove the manually applied compressive force F on the
wings.
In turn, the wings resiliently deform back toward their configuration in the
open mode
- 23 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
from the compressed mode. This in turn, exerts forces Fl and F2 by the
resilient
compression elements against the upper and lower surfaces of the groove. This
fixes the fastener unit in place adjacent that groove. The spacer body 20 is
thus held
adjacent the first side surface 101S of the board 101 that is adjacent the
groove 103.
[0070] As mentioned
above, in some cases, two joists may be immediately
adjacent one another. To center the fasteners and associated grip elements
over
each of the joists, one resilient compression element can be broken off each
of the
adjacent fastener units. This can be achieved by the user manually bending in
direction B one of the resilient compression elements 41 to snap that
component off
from the spacer body as shown in Fig. 3.
[0071] With the
fastener unit properly installed relative to the first board 101, a
second board 102, as shown in Fig. 7, can be placed immediately adjacent the
first
board 101, but separated by a gap G established by the thickness of the spacer
body 20 of the fastener unit 10. Due to the grip element 30 extending
outwardly from
the forward face 21 of the spacer block, that grip element can be installed in
the
second groove 104 of the second board 102. With the boards so installed on the
joist
106, the fastener 90 can be rotated in direction A. As a result, the fastener
advances
through the spacer body 20, the grip element 30 and into the underlying
support or
joist 106. As it does so, the head 90H eventually engages the grip element 30.
This
in turn pulls the grip element downward toward the joist 106. As a result, the
grip
element and, for example, its cleats or protrusions bite into the lower
surfaces of the
respective grooves of the boards. This in turn provides enhanced holding force
of the
boards against the joist 106. With the fastener unit of the current
embodiments, the
overall length of the unit from end to end is generally sufficient to cover
all of the top
of the joist 106 that may otherwise be exposed through the gap G established
between the boards.
- 24 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0072] A first
alternative embodiment of the fastener unit is illustrated in Figs.
8-11 and generally designated 110. The fastener unit of this embodiment is
similar
in structure, function and operation to the embodiment described above with
several
exceptions. For example, this unit 110 includes a fastener 190 similar to the
fastener
90 above. It also includes a grip element 130 that is disposed in a recess 128
defined by a spacer body 120. The spacer body can have a spacer body width SW.
The grip element can have a grip element width GW. The grip element width can
be
less than the spacer body width. For example the grip element width can be
optionally less than 3/4 the spacer body width, further optionally less than
1/2 the
spacer body width.
[0073] The spacer
body can be configured to establish a gap between
adjacent boards, and sized with a thickness T2 similar to the thickness Ti
described
in the embodiment above. The grip element 130 can define a second fastener
hole
SFH' that is aligned with a first fastener hole FFH' of the spacer body 120
similar to
that described above. The first fastener hole FFH' also can include upper and
lower
portions FF1U' and FF1L' that have different diameters, the lower one having a
diameter less than the upper one's diameter. The grip element 130 optionally
can
extend from the forward 121 and rearward 122 surfaces of the spacer body 120
by
equal distances D10 and D11. Of course, in some applications, these distances
can
vary.
[0074] In this
embodiment, the unit 110 can include first and second
compression elements which are in the form of first and second joist legs 141
and
142 that extend downward and outward from the spacer body 120. These first and
second joist legs are configured to straddle and clampingly engage a joist.
The joist
legs are similar in construction, so only the first joist leg 141 will be
described here.
The joist leg 141 includes an outwardly extending portion 143 that extends
outward
- 25 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
from a side of the spacer body 120. That outwardly extending portion 143
transitions
to a rounded or curved portion 145 that extends downwardly, away from a bottom
126L of the spacer body 120. The curved portion 145 is generally concave,
opening
toward the vertical axis VA. That curved portion 145 extends to a lower
engagement
portion 146. This lower engagement portion is generally convex relative to the
vertical axis VA and opens away from that vertical axis VA. The engagement
portion
includes an inner engagement surface 146S which is configured to engage and
slide
over a portion of the outer walls 106W of the joist 106. This surface 146S
again is
generally curved and convex away from the vertical axis to facilitate sliding
of this
portion over the walls 106W.
[0075] Optionally,
each of the joist legs 141 and 142 can be joined with the
spacer body 120 at fracturable joints 148, 149 similar to those described
above. In
this manner, at least one of the first and second joint legs can be manually
broken
off from the spacer body to accommodate double joists or other confined
spaces.
[0076] A method of
installing the fastener unit 110 will now be described in
connection with Figs. 9-11. The fastener unit 110 can be disposed adjacent a
joist
106 and board 101 as illustrated in Fig. 10. In particular, the joist legs 141
and 142
can be resiliently deformed outward by sliding the engagement surfaces 146S
into
engagement with the walls 106W of the joist 106. Due to the rounded nature,
the
joist legs can be resiliently flexed or moved outward and can slide over those
walls.
Before the lower surface 126L of the spacer body engages the upper surface
106U
of the joist 106, the grip element 130 can be inserted into the groove 103 and
engage the groove lower surface 109L. Due to the spatial relationship of the
spacer
body, its lower surface 126L and the lower surface 109L of the groove, the
lower
surface of the spacer body can be placed at a level lower than a lower surface
of
- 26 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
the first groove, for example, the lower surface 126L of the spacer body can
be
below the lower surface 109L of the groove.
[0077] As
illustrated, the joist legs can exert a compressive or clamping force
F4 on the joist 106 to hold the grip element 130 at the elevation above the
joist
shown in Fig. 10, generally protruding into the groove 103. With the grip
element in
this location, as shown in Fig. 11, a second board 102 can be moved in place
adjacent the fastener unit 110. Due to the thickness T2 of the spacer body 120
separating the two boards, a gap G' can be established between those boards.
The
grip element 130 also extends into both of the respective gaps of the two
boards.
With the grip element so placed, and the gap G' established, a user can
advance the
fastener 90 into the underlying joist. In turn, this causes the grip element
130 and its
corresponding cleats to bite into the respective grooves, thereby securing the
board
in a fixed location over the joist 106.
[0078] Optionally,
in confined spaces, with reference to Fig. 9, one of the joist
legs 141 can be bent in direction B to resiliently break off that leg at the
fracturable
joint 149.
[0079] A second
alternative embodiment of the fastener unit is illustrated in
Figs. 12-13 and generally designated 210. The fastener unit of this embodiment
is
similar in structure, function and operation to the embodiments described
above with
several exceptions. For example, this unit 210 can include a fastener 290
similar to
the fasteners 90 and 190 above. It also can include a grip element 230 that is
disposed in a recess 228 defined by a spacer body 220. The grip element 230
optionally can extend from and beyond the forward 221 and rearward 222
surfaces
of the spacer body 220. As above, the spacer body can be configured to
establish a
gap between adjacent boards, and sized with a thickness T3 similar to the
thicknesses Ti and T2 described in the embodiments above.
- 27 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[0080] In this
embodiment, the unit 210 includes first and second joist legs
241 and 242, also referred to as resilient compression element in some cases,
that
extend downward and outward from the spacer body 220. These first and second
joist legs are configured to straddle and clampingly engage a joist. The joist
legs are
similar in construction, so only the first joist leg 241 will be described
here. The joist
leg 241 includes an outwardly extending portion 243 that extends outward from
a
side of the spacer body 220. That outwardly extending portion 243 transitions
to a
rounded or curved portion 245 that extends downwardly, away from a bottom 226L
of the spacer body 220. The curved portion 245 is generally concave, opening
toward the vertical axis VA of the spacer body 220, which can be coincident
and/or
parallel to the longitudinal axis LA of the fastener 290. That curved portion
245
extends to a lower engagement portion 246. This lower engagement portion 246
can
be convex relative to the vertical axis VA and can open away from that
vertical axis
VA. The engagement portion can include an inner engagement surface 246S
configured to engage and slide over a portion of the outer walls 106W of the
joist
106. This surface 246S can be curved and convex away from the vertical axis VA
to
facilitate sliding of this portion over the walls 106W. Of course, in other
constructions, that surface 246S can be flat, planar, rough, ridged,
triangular, or can
have other geometric configurations depending on the configuration of the
joist or
the workpiece against which the leg is to be engaged.
[0081] As shown in
Fig. 12, the first joist leg 241 can extend from a first lateral
side L1 of the spacer block 220 on a first side of the vertical axis VA, and
the second
joist leg 242 can extend from a second lateral side L2 of the spacer block
220. The
first and second joist legs can extend outwardly and downwardly from the
spacer
block. Each of the joist legs can include a forward surface and a rearward
surface,
and one or more of the joist legs can include a stabilizer bar extending from
the joist
- 28 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
leg a predetermined distance. In general, the opposing stabilizer bars 251,
252 on
the opposing joist legs 241 and 242 can be disposed at a common level L4
relative
to one another and relative to another level L3 of the bottom or lower surface
230L of
the grip element 230. Due to the similarities of the legs and the stabilizer
bars in the
embodiment illustrated, only the first joist leg 241 and its corresponding
stabilizer bar
251 will be described here.
[0082] The first
joist leg 241 can include a front surface 241F and a rear
surface 241R. The rear surface optionally can be planar and/or rounded. The
rear
surface can further include the stabilizer bar 251 projecting rearward from it
in a
direction opposite the front surface 241F of the joist leg 241. As
illustrated, the
stabilizer bar 251 can be integrally formed and joined with the leg at a
transition
location between the curved portion 245 and the lower engagement portion 246
of
the joist leg. The stabilizer bar can project from the rear surface 241R a
distance
D13. This distance D13 can be equal to a distance D14 from which an end 230E
of
the grip element 230 extends away from the rearward surface 241R of the leg
and/or
of the rear surface 222 of the spacer body. The distance D13 optionally can be
1/32
inches, further optionally 1/8 inches, further optionally 1/4 inch, yet
further optionally 1/2
inch, even further optionally 3/4 inches, or other distances depending on the
application. In some cases, D13 can be greater than, less than or equal to
D14. In
cases where a bottom of the board with which the fastener unit 210 is
utilized, the
distance D13 is greater than the distance D14 by at least 10% to 25%, such
that the
stabilizer bar 251 can adequately extend beyond a curved lower corner of the
board
and engage the under surface or bottom surface of the board as described
below.
[0083] Referring to
Fig. 1 2, the stabilizer bar 251 can include an upper surface
251U and a lower surface 251L. The upper surface 251U and lower surface 251L
optionally can be part of a continuous cylindrical wall 254 where the
stabilizer bar
- 29 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
251 is of a cylindrical shape. Of course, where the stabilizer bar 251 is of
another
geometric shape, for example, a square shape, a polygonal shape an ellipsoid
shape, or some other rounded or irregular shape, the upper and lower surfaces
can
be formed by different portions of a wall or different walls altogether.
[0084] The wall 254
can extend to the rear surface 241R of the leg 241. In
some cases, the stabilizer bar can alternatively extend also from the forward
surface
241F of the joist leg. It may extend the distance 013, or some lesser or
greater
distance, depending on the application and the type of board utilized with the
fastener unit. The stabilizer bar also can be configured such that the
stabilizer bar
251 terminates at a free end 251E that projects out into space, in which case
the
stabilizer bar is cantilevered. This end 251 E can include a ramped portion
255 and a
flattened end portion 256. The ramped portion 255 can be a frustoconical shape
or
angled or rounded. In some cases, the ramp 255 and end 256 can be merged into
a
hemispherical or otherwise rounded end. The end can be rounded or ramped as
shown so that that end easily traverses past a corner or other side surface or
bottom
of a board when the fastener unit is installed. The ramp and/or rounded
surface
easily rides over the corner of the board and/or the bottom surface of the
board for
rapid installation.
[0085] As further
shown in Fig. 12, the stabilizer bar can be disposed a
distance 012 below the lower surface 230L of the gripping element 230. For
example, the lower surface 230L can be disposed at a level L3, while the upper
surface 251U of the stabilizer bar 251 can be disposed at a second level L4.
The
distance 012 between these different levels can be equal to a distance between
a
bottom of a groove, and a bottom surface of that same board. In this manner,
the
board can be pinched or clamped between the bottom surface 230L of the
gripping
element 230 and the upper surface 251U of the stabilizer bar. Optionally, the
portion
- 30 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
of the board between the bottom of a groove of the board and the bottom
surface of
the board can be pinched or clamped between the gripping element 230 and the
stabilizer bar 251 on the joist leg 241. Via this interaction with the board,
as
described further below, the fastener unit 210 can be secured to and joined
temporarily with the board optionally to maintain the fastener 290
longitudinal axis
LA in a vertical, upright position before installation of the fastener 290
into an
underlying joist.
[0086] Although
shown as a generally cylindrical bar, the stabilizer bar 251
also can have other shapes. In some cases, the stabilizer bar 251 can be a
portion
of the joist leg 241 below the curved portion 245 at a distance D12, where
that leg
becomes a greater thickness (not shown) from its rear surface 241R to its
front
surface 241F. For example, above the stabilizer bar, the thickness T4 of the
joist leg
241 can be approximately 1/4 inch. Starting at the upper surface 251U of the
stabilizer
bar (although not shown) the leg can be of a substantially greater thickness
T5 such
that the leg is 2, 3, 4, 5 or more times as thick as the thickness T4. This
greater
thickness T5 can extend all the way to the tip of the engagement portion 246.
In
other cases (although not shown) the stabilizer bar can extend in this manner
to
taper from the thickness T5 back toward the thickness 14 or some other
thickness of
the joist leg 241 toward the tip of the joist leg.
[0087] A method of
installing the fastener unit 210 will now be described in
connection with Fig. 13. The fastener unit 210 can be disposed adjacent a
joist 106
and board 101 as illustrated in Fig. 13. In particular, the joist legs 241 and
242 can
be resiliently deformed outward by sliding the engagement portions 246, and
their
respective surfaces 246S into engagement within and along the opposing walls
106W of the joist 106. Due to the rounded nature, the joist legs can be
resiliently
flexed or moved outward and can slide over those walls. Before the lower
surface
- 31 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
226L of the spacer body engages the upper surface 106U of the joist 106, the
grip
element 230 can be inserted into the board groove 103 and engage the groove
lower
surface 109L. The joist legs 241, 242 can exert a compressive or clamping
force F4
on the joist 106 to hold the grip element 230 at the elevation above the joist
106
shown in Fig. 13, with the element protruding into the groove 103.
[0088] In addition,
as shown in FIG 13, the stabilizer bar 251 can be disposed
below the bottom surface 101B of the board 101. In particular, the upper
surface
251U of the stabilizer bar 251 can engage the bottom surface 101B adjacent the
corner 1010 of the board. The end 251E of the stabilizer bar optionally
projects a
distance that is greater than the depth GD of the groove 103 inward from the
side
surface 101S of the board 101. This distance can be the distance D13 shown in
Fig.
12. Thus, the distance D13 can be greater than groove depth GD, and optionally
greater than the distance D14 by which the grip element 230 extends from the
rear
surface of the fastener unit.
[0089] The lower
surface 230L of the grip element as mentioned above can
be a distance D12 from the upper surface 251U of the stabilizer bar 251. This
distance can be less than the distance D15 below the groove lower surface
109L,
between the groove lower surface 109 and the bottom surface 101B of the board.
Accordingly, the grip element 230, in cooperation with the stabilizer bar 251,
can
exert a force F15 on the board with the grip element 230 exerting the force
F15 on
the lower surface 109L of the groove, and the upper surface of the stabilizer
bar
exerting the force F15 on the bottom surface 101B of the board 101. This in
turn
exerts a slight clamping or pinching force on the board within that region.
Accordingly, the stabilizer bar can assist in further holding and maintaining
the
vertical axis VA of the fastener unit and the longitudinal axis LA of the
fastener 290
in a generally vertical, upright orientation. This vertical, upright
orientation can refer
- 32 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
to an orientation that optionally is perpendicular to the plane P10 of the
board 101, in
particular, its upper surface 101U, which optionally can lay in a horizontal
plane. The
upright vertical orientation can be perfectly vertical, or can be slightly
offset from
vertical by up to 5 or up to 100, depending on the application.
[0090] With the
stabilizer bar cooperating with the grip element 230, the
fastener unit exerts both a force on the board 101 and another force on the
joist 106,
the latter, by virtue of the forces exerted by the legs 241 and 242 against
opposing
sides of the joist. Thus, the joist legs exert clamping force F4 on the joist,
and the
stabilizer bars exert another force F15 on the board, between the groove and
the
bottom surface of the board. Optionally, the force F15 is a vertical force,
while the
force F4 exerted by the joist legs is a substantially horizontal force. Of
course,
depending on the orientation of the joist in the board, the directions of the
forces can
change relative to horizontal and vertical planes.
[0091] The fastener
unit 210 so installed can provide multiple points of contact
between the fastener unit and the board, and thereby stabilize the fastener
unit in a
particular orientation, optionally holding the fastener associated with the
unit in an
upright, vertical orientation, ready for engagement by a tool. Optionally, the
fastener
unit 210 can engage the board 101, and the joist 106 to prevent forward and
aft
tilting 17, generally in a direction toward or away from the side surface 101S
of the
board. The fastener unit also can prevent teetering in directions 18 which are
generally into and out of the plane of Fig. 13, such that the fastener and
fastener unit
do not slide along the side surface 101S of the board when in position. Thus,
the
fastener unit can provide multidirectional stability and support for the
fastener 290,
optionally holding it in an upright, vertical orientation as shown.
[0092] With the
fastener unit oriented as shown in Fig. 13, a second board
102 can be moved in place adjacent the fastener unit 210. Due to the
stabilization
- 33 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
and forces exerted by the joist legs, the grip element and the stabilizer bars
of the
fastener unit 210, the fastener unit can remain in position, with the other
end of the
grip element 230 sliding into the groove 102G of board 102, and the fastener
290
staying in a generally upright and vertical orientation. With the grip element
in
position in the opposing gaps of the boards, and the appropriate gap set by
the
spacer body, the user can advance the fastener 290 into the underlying joist.
In turn,
this causes the grip element 230 and its corresponding cleats to bite into the
respective grooves, thereby securing the board in a fixed location over the
joist 106.
[0093] A third
alternative embodiment of the fastener unit is illustrated in Figs.
14-15 and generally designated 310. The fastener unit of this embodiment is
similar
in structure, function and operation to the embodiments described above with
several exceptions. For example, this unit 310 can include a fastener 390
similar to
the fasteners 90, 190 and 290 above. It also can include a grip element 330
that is
disposed in a recess 328 defined by a spacer body 320. The grip element 330
optionally can extend from and beyond the forward 321 and rearward 322
surfaces
of the spacer body 320. As above, the spacer body can be configured to
establish a
gap between adjacent boards, and sized with a thickness T4 similar to the
thicknesses Ti, T2 and T3 described in the embodiments above.
[0094] In this
embodiment, the unit 310 includes first and second joist legs
341 and 342, also referred to as resilient compression element in some cases,
that
extend downward and outward from the spacer body 320. These first and second
joist legs are configured to straddle and clampingly engage a joist. The joist
legs are
similar in construction, so only the first joist leg 341 will be described
here. The joist
leg 341 includes an outwardly extending portion 343 that extends outward from
a
side of the spacer body 320. That outwardly extending portion 343 transitions
to a
rounded or curved portion 345 that extends downwardly, away from a bottom 326L
- 34 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
of the spacer body 320. The curved portion 345 is generally concave, opening
toward the vertical axis VA of the spacer body 320, which can be coincident
and/or
parallel to the longitudinal axis LA of the fastener 390. That curved portion
345
extends to a lower engagement portion 346. This lower engagement portion 346
can
be convex relative to the vertical axis VA and can open away from that
vertical axis
VA. The engagement portion can include an inner engagement surface 346S
configured to engage and slide over a portion of the outer walls 106W of the
joist
106. This surface 346S can be curved and convex away from the vertical axis VA
to
facilitate sliding of this portion over the walls 106W. Of course, in other
constructions, that surface 346S can be flat, planar, rough, ridged,
triangular, or can
have other geometric configurations depending on the configuration of the
joist or
the work piece against which the leg is to be engaged.
[0095] As shown in
Fig. 14, the first joist leg 341 can extend from a first lateral
side L1 of the spacer block 320 on a first side of the vertical axis VA, and
the second
joist leg 342 can extend from a second lateral side L2 of the spacer block
320. The
spacer block 320 itself can be formed as a timing spacer block such that the
lower
surface 326L of the spacer block of this embodiment engages the upper surface
106U of the joist as the fastener 390 is tightened to install the fastener
unit 310. This
lower surface 326L can be disposed below the lower surface 330L of the grip
element, optionally at least 1/4 inch below, further optionally at least 1/2
inch below that
surface. Optionally, the lower surface 326L can engage the upper surface 106U
of
the joist 106 when the grip element 330 engages the groove 103, for example
the
lower wall 109L of the groove 103 upon the application of a force F16 as
described
below.
[0096] With
reference to Figs. 15-16, the timing spacer block 320 can be
configured so that it has a relationship relative to a thickness T9 between
the lower
- 35 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
surface 109L of the groove and the bottom surface 101B of the board 101, or
other
boards, such as board 102 on the opposite side of the fastener unit 310. This
thickness T9 can be optionally 1/4 inch, further optionally V2 inch, or other
dimensions
depending on the particular board. The fastener unit 310 can be configured so
that
the bottom 326L of the timing spacer body is spaced a distance D16 from the
lowermost surface 330 L of the grip element 330, whether or not that grip
element
has one or more pressure feet 330P. This distance D16 can be equal to or less
than
the thickness 19 mentioned above. In some applications, the distance D16
relative
to the thickness T9 can be expressed in a ratio, for example optionally 1:1,
further
optionally 0.99:1, yet further optionally less than 1:1, even further
optionally between
0.9:1 and 1:1, inclusive.
[0097] These ratios
and the general relationship between the thickness T9
and D16 can be established so that the spacer block 320 (and in particular its
lower
surface 326L) is "timed" to engage the upper surface 106U of the joist 106
when the
predetermined force F16 is applied by a pressure foot 330 against the board
101,
and in general against the lower surface 109L of the groove 103. Optionally,
the
lower surface 326L of the timing spacer block 320 can engage the upper surface
106U of the joist 106 after or at the same time as the pressure foot 330P
engages
the lower surface 106L of the groove. This can enable the fastener unit 310 to
apply
a predetermined force F16 through the pressure foot 330P and the grip element
330
in general. When the spacer body, however, bottoms out against the upper
surface
of the joist, the amount of additional force added to the predetermined force
F16 can
be limited and/or cut off completely because the spacer body prevents the
fastener
from being tightened further, and thus prevents the fastener from advancing
farther,
which otherwise would increase or otherwise add to the predetermined force F16
applied to the board via the feet in the groove. In this manner, the timing
spacer
- 36 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
block 320 can be constructed to assist in limiting or otherwise controlling
the
predetermined force F16 that is applied to the boards 101 and 102 when and as
the
fastener unit 310 is secured in place. Also, it will be appreciated that
although only a
force F16 is illustrated in the groove 103 of board 101, another force,
substantially
equal to force F16 is being applied in the groove 103' of the other board 102
via the
feet at the other end 332 of the grip element 330.
[0098] Optionally,
the portion of the board 101 between the lower surface
109L of the groove and the bottom 101B of the board can be pinched or clamped
between the bottom surface 330L of the gripping element 330 and the upper
surface
106U of the joist with the predetermined force F16 as the fastener unit 310 is
tightened, that is when the fastener 390 is advanced into the joist 106 and
the head
390H of the fastener 390 engages the gripping element 330 to pull the gripping
element downward, upon the application of the predetermined force F16 through
the
gripping element 330. Again, this predetermined force F16 can be limited by
way of
the lower surface 326L of the timing spacer block 320 engaging the upper
surface
106U of the joist 106 to prevent and/or impair the fastener 390 from further
advancing into the joist 106, which would thus pull the gripping element 330
farther
toward the joist and produce more clamping force F16.
[0099] Further
optionally, it will be appreciated that when the timing spacer
block 320 engages the upper surface 106U of the joist 106, and the fastener
390 is
further advanced in direction FA toward and into the joist 106, the spacer
block 320
itself is placed under a compressive force CF between the upper surface of the
joist
and the gripping element 330, when the gripping element is engaged by the head
390H of the fastener 390. This compressive force CF can be greater than, equal
to
or less than the force F16. In many cases, the compressive force can be
greater
than the force F16.
- 37 -
[00100] In the embodiment illustrated in Figs. 14-16, the fastener unit
310 also
can be outfitted with a gripping element 330 that is similar to the gripping
elements
30, 130 and 230, with several exceptions. For example, this gripping element
330
can be constructed for use with a particular type of board 101, 102. As one
example, this board can be a TIMBERTECHTm or other composite deck board
commercially available from AZEK Building Products of Skokie, Illinois. Such a
board
101 can be constructed to include a groove 103 that is defined inward from
side
surface 101S. In such a board, this groove also can be duplicated and defined
on
both opposing sides of the same board 101 (although the second opposing groove
is
not shown). The groove 103 can transition inward from the side surface 101S.
The
groove can include an upper surface 109U that transitions to a rear wall 109R
which
further transitions to a lower wall 109L. The upper and lower walls of the
groove are
opposite one another and can be generally planar. The lower wall 109L can
transition out to the side surface 101S.
[00101] In some constructions, below the lower wall 109L, the side
surface
1015 can transition to a slanted wall 101A. This slanted wall 101A differs
from the
portion of the side surface 101S above the upper wall 109U of the groove 103,
in
that the slanted wall 101A angles back toward the plane P3 within which the
rear
wall 109R can at least partially lay. The slanted wall 101A can transition to
the
bottom surface 101B of the board 101 a preselected distance D17 from the plane
P3. The slanted wall 101A can be disposed at an angle Al relative to the
bottom wall
101B. This angle Al can be an obtuse angle, optionally greater than 900. This
slanted wall 101A can be rounded or slightly curvilinear, rather than linear
as
illustrated. The slanted wall 101A can transition to the bottom wall 101B at a
transition region 101T, which can form part of the angle Al. This transition
region
101T can be disposed the distance D17, closer to the side surface 1015 than
the
- 38 -
Date Recue/Date Received 2021-05-03
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
rear wall 109R of the groove 103. The region 101P between the transition
region
101T and the plane P3 within which the rear wall 109R of the groove lays can
be
configured to transfer the force F16 applied by the grip element 330 in
particular the
predetermined force F16 when this force is applied through the pressure foot
330P
as described below. Optionally, the slanted wall 101A can be disposed between
the
side surface 101S and the transition 101T. The slanted wall can extend a
distance
019 from the side surface 101S horizontally away from that surface. This
distance
019 can be less than the depth of the groove, that is the distance from the
side
surface 101S to the rear wall 109R of the groove 103.
[00102] The grip
element 330 can be similar to the grip elements 30, 130 and
230 described above, with several exceptions. For example, the grip element
330
optionally can be in the form of a C- or U-shaped channel, with the channel
opening
downward relative to the vertical axis VA or longitudinal axis LA. The grip
element
can be disposed in a recess defined by the spacer body 71 similar to force
noted
above. The grip element can be constructed to include downwardly extending
cleats,
which optionally can be portions of the channel or an elongated metal or
composite
bar. The grip element can include one or more feet or teeth, formed as part of
the
channel, the cleats or as additional protrusions extending from the grip
element. As
an example, the grip element 330 can include one or more pressure feet 330P.
These pressure feet 330P can be disposed at the first 331 and second 332 ends
of
the grip element. These pressure feet can each form at least a portion of the
lower
surface 330L of the grip element 330. The pressure feet also can come in
pairs, for
example a pair of pressure feet 331P1 and 331P2 can be disposed at the first
end
331. The second end 332 can include a similar pair of pressure feet.
[00103] The pressure
feet can include the lower surface 330L of the grip
element, with each of the pair of the pressure feet forming a portion of that
lower
- 39 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
surface 330L. The pressure feet can extend all the way to the very end 331 of
the
grip element. Although shown as flat of the lower surface 326L, the feet can
be
pointed or rounded at that lower surface. The individual ones of the pairs of
pressure
feet also can form opposing sides of the U-channel that extend downward from
the
grip element. In this manner, each end can include two opposing pressure feet.
Optionally, the pairs can distribute the predetermined force F16 evenly and
spread
out between those two pressure feet. Optionally, where the grip element is not
C or
U-shaped, and is in the form of a bar (not shown), there can be single
pressure feet
located at the opposing ends. These pressure feet can also include larger
lower
surfaces of a particular geometric shape to provide more surface contact with
the
interior of the groove.
[00104] The pressure
feet of grip element can be spaced a particular distance
from the respective front 321 and rear 322 surfaces of the fastener unit 310.
For
example, as shown in Fig. 15, the pressure feet 330P of one end 331 of the
grip
element 330 can be disposed a distance D18 from the front surface 321 of the
spacer block 320. Of course, the pressure feet at the second opposing end 332
can
be disposed a similar distance from the rear surface 322 of the spacer block.
This
distance D18 can be greater than the distance D19 mentioned above with regard
to
the slanted wall 101A. Within this distance D18 away from the spacer block 20,
the
grip element can be recessed upward from the lower surface 330L. For example,
as
shown in Figs. 15 and 16, the pressure feet 330P can transition upward to a
recessed surface 330R of the grip element. This recessed surface 330R can be
disposed at a level above the lower surface 330L of the grip element 330 such
that
the recessed surface 330R generally does not substantially contact the lower
surface 109L of the groove 103 when the fastener unit 310 is installed
relative to the
grooves and the boards. In this manner, substantially only the lower surface
330L of
- 40 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
the grip element associated with the pressure feet 330P engage that lower
surface
109L of the groove.
[00105] The pressure
feet 330P, when spaced the distance D18 on the spacer
block 320, can be configured to enable the predetermined force F16 to be
distributed
downward into the preselected pressure region 101P. Substantially all of the
force
F16 can be distributed to this region 101P. Optionally, little to no portion
of the force
F16 is distributed by the pressure feet 330P to the slanted wall 101A and/or
the
transition region 101T. Accordingly, with the force F16 distributed this far
from the
spacer block 320 and in general the side surface 101S, which can engage the
spacer block directly, the force F16 is not distributed in a manner so as to
urge the
board 101 to rotate in direction N. Thus, the board 101 is prevented from
tipping or
angling when the fastener unit 310 is advanced to pull the board downward
against
the joist 106.
[00106] Optionally,
the pressure feet 330P can be disposed the distance D18
from the spacer body 320 to ensure that the predetermined force F16
administered
through the pressure feet 330P is not administered directly vertically over
the slanted
wall 101A, but rather in pressure region 101P that is farther away from the
side
surface 101S than the slanted wall 101A. Where the region 101P forms a portion
of
the bottom surface 101B of the board 101, the pressure feet and the grip
element
thus can exert the predetermined force F16 downward, directly to the bottom
surface
101B which is in contact and generally parallel to the upper surface 106U of
the joist
106. The flat generally planar bottom surface of the board 101B can engage the
flat
generally planar upper surface 106U of the joist and the two can be pressed
together
under the predetermined force F16. And as mentioned above, this predetermined
force F16 can be limited by the spacer body 320 engaging the joist.
- 41 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[00107] A method of
installing the fastener unit 310 will now be described in
connection with Figs. 14 and 16. The fastener unit 310 can be disposed
adjacent a
joist 106 as illustrated in Fig. 14. In particular, the joist legs 341 and 342
can be
resiliently deformed outward by sliding the engagement portions 346, and their
respective surfaces 346S into engagement within the and along the opposing
walls
106W of the joist 106. Due to the rounded nature, the joist legs can be
resiliently
flexed or moved outward and can slide over those walls. The lower surface 326L
of
the spacer body 320 can be move toward and optionally can engage the upper
surface 106U of the joist 106. The joist legs 341, 342 can exert a compressive
or
clamping force on the joist 106 to hold the grip element 330 at the elevation
above
the joist 106 shown in Fig. 16, with the element protruding into the groove
103.
[00108] The grip
element 330 can be inserted into the board groove 103, for
example, into the respective grooves 103 of both of the opposing boards 101
and
102. These boards can be pushed toward one another so that the spacer body 320
and an upper portion 338, above the gripping element, can be contacted by and
engaged by the respective side surfaces 101S, 102S of the opposing boards 101
and 102. The grip element can be positioned in the respective groups of the
boards
101 and 102 such that the lower surface 330L of the respective pressure feet
330P
engage the groove lower surface 109L. When the boards are pushed together, the
pressure feet 330P are disposed at the distance D18 from the spacer body 320.
Accordingly, the pressure feet are disposed over the pressure region 101P that
corresponds to the bottom, generally planar surface 101B of the board. The
pressure
feet also can be positioned at a location within the distance D17 between the
rear
wall 109R and the transition 101T. Optionally, the pressure feet are not
disposed
directly vertically above the slanted wall 101A. Further optionally, the
pressure feet
330P can be disposed farther into the groove, closer to the rear wall 109R
than to
- 42 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
the side surface 101S of the board. As a further example, the pressure feet
can be
disposed at or greater than the distance D19 away from the side surface of the
board. The pressure feet that the opposing end 332 can be disposed in the
groove
103' and oriented relative to its surfaces in a similar manner.
[00109] The lower
surface 330L of the grip element, and in particular the
pressure feet, as mentioned above can be a distance D18 from the spacer body.
This distance can place the pressure feet 330P directly over the pressure
region
101P. When the fastener unit is installed relative to the boards 101 and 102
as
shown in Fig. 16, the fastener 390 can be advanced in direction FA, through
the
spacer body and the grip element, advancing into the underlying joist 106.
Upon
this advancement, the head 390H of fastener 390 eventually engages the upper
surface of the grip element 330. The fastener continues to be advanced into
the joist
106. If the lower surface 326L was not in direct engagement with the upper
surface
106U of the joist 106, it can begin to be so engaged as the fastener is
advanced. As
the advancement of the fastener 390 continues, the head 390H pulls the grip
element 330 downward. This engages the pressure feet 330P and the lower
surface
330L of the grip element 330 against the lower surfaces 109L of the grooves
103.
This exerts the force F16 directly downward onto to the pressure region 101P
along
the bottom surface 101B of the board. Due to the recessed surface 330R not
engaging the remainder of that lower surface, closer to the side surface, the
force
F16 is not distributed toward or through the slanted wall 101A. Accordingly,
the
board 101 does not tip in direction N due to the force F16 creating a moment
about
the transition region 101T.
[00110] As the
fastener continues to advance, the timing spacer body 320 is
placed under a compressive force CF between the head 390H of the fastener and
the portion of the fastener pulling the head into the joist 106. When this
occurs, the
- 43 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
timing spacer body generally bottoms out the fastener and in general the
fastener
unit 310 so the fastener will not advance farther. As a result, timing spacer
body
limits the amount of additional force added to the predetermined force F16 to
push
the boards 101 and 102 into further contact with the joist 106. This in turn,
can
prevent the groove from being damaged or otherwise deforming the board 101
near
the groove.
[00111] The
following additional embodiments are provided, the numbering of
which is not to be construed as designating levels of importance.
[00112] Embodiment 1
relates to a fastener unit adapted to secure at least one
board to a support, the fastener unit comprising: a spacer body defining a
first
fastener hole having an upper portion having a first diameter and a lower
portion, a
threaded fastener disposed within the spacer body in the first fastener hole,
the
threaded fastener extending within the upper portion and the lower portion; a
first
joist leg and a second joist leg extending downward from the spacer body and
configured to straddle and clamp a joist; and a grip element joined with the
spacer
body, the grip element defining a second fastener hole aligned with the first
fastener
hole, the grip element including a lower surface configured to engage a groove
of a
board.
[00113] Embodiment 2
relates to Embodiment 1, wherein the grip element
includes a pressure foot separated a distance from the spacer body by a
distance,
wherein the distance is configured to inset the pressure foot inward from a
side
surface of the board, beyond a slanted wall disposed under the groove, whereby
a
predetermined force can be distributed through the pressure foot to a bottom
surface
of the board without tipping the board.
[00114] Embodiment 3
relates to Embodiment 1 or 2, wherein a first stabilizer
bar extends from the first joist leg a predetermined distance, wherein a
second
- 44 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
stabilizer bar extends from the second joist leg the predetermined distance,
wherein
the first and second stabilizer bars are disposed at a common level, below the
spacer body.
[00115] Embodiment 3
relates to any one of the preceding Embodiments,
wherein each of the first and second joist legs each include outwardly
extending
portions that extend away from the spacer body, wherein the first and second
stabilizer bars are joined with the respective outwardly extending portions.
[00116] Embodiment 4
relates to any one of the preceding Embodiments,
wherein the first stabilizer bar extends from a rear surface of the first
joist leg,
wherein the first stabilizer bar is generally parallel to the grip element
extending from
the rear surface of the spacer body, wherein the first stabilizer bar extends
a
distance that is equal to the distance by which the grip element extends away
from
the rear surface of the spacer body.
[00117] Embodiment 5
relates to any one of the preceding Embodiments,
wherein the spacer body extends downward below the grip element a preselected
distance such that when a predetermined force is applied through the at least
one
pressure foot of the grip element, a lower surface of the spacer body is
configured to
engage an upper surface of a joist disposed below the spacer body.
[00118] Embodiment 6
relates to any one of the preceding Embodiments,
wherein the grip element includes a first end and a second end, wherein the
first end
projects forward of a front surface of the spacer body, wherein the second end
projects rearward of a rear surface of the spacer body, wherein the grip
element is a
C-shaped channel, wherein the C-shaped channel includes first and second
cleats at
the first end, wherein the first and second cleats form downwardly extending
first and
second pressure feet at the first end, wherein the first and second pressure
feet form
a lower surface of the grip element, wherein the grip element includes a
recessed
- 45 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
surface that is disposed above the lower surface between the first and second
pressure feet and the spacer body.
[00119] Embodiment 7
relates to any one of the preceding Embodiments,
wherein the first joist leg and the second joist leg each include a lower
engagement
portion disposed below and an outwardly extending portion, wherein the first
stabilizer bar is joined with the first joist leg between the respective lower
engagement portion and the outwardly extending portion, wherein the second
stabilizer bar is joined with the second leg between the respective lower
engagement
portion and the outwardly extending portion.
[00120] Embodiment 8
relates to a method of using a fastener unit comprising:
providing a fastener unit including a fastener, a spacer body defining a first
fastener
hole therethrough, a longitudinal axis, a grip element joined with the spacer
body
and projecting outward from the spacer body, with the fastener projecting
through at
least a portion of the grip element, a first resilient joist leg extending
laterally from the
spacer body, and a second resilient leg extending laterally from the spacer
body,
placing the fastener unit over a joist so that the first and second resilient
legs move
away from one another and downward relative to a first and a second sidewall
of the
joist; inserting
the grip element into a first groove of a first board; and
advancing the fastener through the first fastener hole of the spacer body and
through
the at least a portion of the grip element, wherein a head of the fastener
forces the
grip element into engagement with the first groove, thereby moving the first
board
toward the joist.
[00121] Embodiment 9
relates to Embodiment 8, wherein the spacer body
includes a lower surface, wherein the lower surface engages an upper surface
of the
joist during the advancing.
- 46 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[00122] Embodiment
10 relates to Embodiment 8 or 9, wherein the board
includes a side surface below the groove, wherein the side surface transitions
to a
slanted wall that extends toward a plane in which a rear wall of the groove is
disposed, wherein the board includes a bottom surface having a pressure
region,
wherein the grip element includes at least one pressure foot at an outward end
of the
grip element, distal from the spacer body, wherein the at least one pressure
foot
exerts a downward force that is transferred to the pressure region to push the
pressure region against an upper surface of the joist, but so as not to tilt
the board
by pushing downward directly toward the slanted wall.
[00123] Embodiment
11 relates to any of the preceding Embodiments, wherein
the spacer body is a timing spacer body that engages an upper surface of the
joist
during the advancing step, wherein the spacer body is compressed between the
grip
element and the joist, wherein the spacer body is of a predetermined thickness
to
thereby limit the amount of force exerted by the grip element against the
groove.
[00124] Embodiment
12 relates to any of the preceding Embodiments, wherein
the first joist leg includes a rear surface including a first stabilizer bar
disposed below
the spacer body, wherein the second joist leg includes a rear surface
including a
second stabilizer bar disposed below the spacer body, wherein the first and
second
stabilizer bars are each placed below a bottom surface of the board before the
advancing step to stabilize the fastener unit relative to the board.
[00125] Directional
terms, such as "vertical," "horizontal,' "top," "bottom,"
"upper," "lower," "inner," "inwardly," "outer" and "outwardly," are used to
assist in
describing the invention based on the orientation of the embodiments shown in
the
illustrations. The use of directional terms should not be interpreted to limit
the
invention to any specific orientations.
- 47 -
CA 03071807 2020-01-31
WO 2019/036146
PCT/US2018/042823
[00126] The above
description is that of current embodiments of the invention.
Various alterations and changes can be made without departing from the spirit
and
broader aspects of the invention as defined in the appended claims, which are
to be
interpreted in accordance with the principles of patent law including the
doctrine of
equivalents. This disclosure is presented for illustrative purposes and should
not be
interpreted as an exhaustive description of all embodiments of the invention
or to
limit the scope of the claims to the specific elements illustrated or
described in
connection with these embodiments. For example, and without limitation, any
individual element(s) of the described invention may be replaced by
alternative
elements that provide substantially similar functionality or otherwise provide
adequate operation. This includes, for example, presently known alternative
elements, such as those that might be currently known to one skilled in the
art, and
alternative elements that may be developed in the future, such as those that
one
skilled in the art might, upon development, recognize as an alternative.
Further, the
disclosed embodiments include a plurality of features that are described in
concert
and that might cooperatively provide a collection of benefits. The present
invention is
not limited to only those embodiments that include all of these features or
that
provide all of the stated benefits, except to the extent otherwise expressly
set forth in
the issued claims. Any reference to claim elements in the singular, for
example,
using the articles "a," "an," "the" or "said," is not to be construed as
limiting the
element to the singular. Any reference to claim elements as "at least one of
X, Y and
Z" is meant to include any one of X, Y or Z individually, and any combination
of X, Y
and Z, for example, X, Y, Z; X, Y; X, Z ; and Y, Z.
- 48 -
