Note: Descriptions are shown in the official language in which they were submitted.
1
A FASTENING DEVICE AND METHODS OF MANUFACTURE
FIELD
100011 The present disclosure generally relates to the field of fastening
devices, and, in
particular, to fastening devices such as nails and staples and methods of
manufacturing same.
INTRODUCTION
[0002] Construction workers, carpenters and other people use fasteners, such
as nails and
staples, to perform various jobs or tasks with materials. Materials such as
wood can shrink over
time and can be exposed to strong winds.
SUMMARY
[0003] In accordance with an aspect, there is provided a fastening device,
having a substantially
straight body having at least one projection each extending from the body at
an upward angle.
[0004] In accordance with an aspect, there is provided a fastening device
including a
substantially straight elongated member, the elongated member extending from a
head to a
tapered tip along a longitudinal axis and having at least one projection each
extending from the
elongated member at an upward angle away from the tip.
[0005] The fastening device of claim 1, the elongated member having two
projections, each
projection being on substantially opposite sides of the surface of the
elongated member.
100061 In some embodiments, the distance measured between a first projection
tip of a first
projection and a second projection tip of a second projection is a length that
is up to the length of
the head measured along a substantially identical axis.
[0007] In some embodiments, the width of the elongated member and the distance
that one or
more of the projections extend from the elongated member measured along
substantially the
same axis, is double the width of the elongated member measured along
substantially the same
axis.
Date Recue/Date Received 2020-09-01
2
100081 In some embodiments, the body is an elongated member extending from a
head to a tip
along a longitudinal axis, the body haying two or more projections connected
to the elongated
member.
100091 In some embodiments, there is at least one projection connected to the
elongated member
and extending at an angle away from the tip.
[0010] In some embodiments, the angle is in a range from about 60 degrees to
about 88 degrees.
100111 In some embodiments, two or more projections extend from the elongated
member each
at a substantially equal distance from the head.
[0012] In some embodiments, two or more projections are connected to the
elongated member
along an axis substantially orthogonal to the longitudinal axis, the two or
more projections being
spaced apart at substantially equal distances on the surface of the elongated
member.
100131 In some embodiments, there is at least one projection connected to the
elongated member
at a distance from the head equal to about 15% of the length of the elongated
member measured
from the head to the tip.
100141 In some embodiments, there are two or more projections being spaced
apart at
substantially equal distances on the surface of the elongated member along the
longitudinal axis.
[0015] In some embodiments, there is at least one projection connected to the
elongated member
at a distance from the tip equal to about 7.5% of the length of the elongated
member measured
from the head to the tip.
[0016] In some embodiments, the tip is not sharp.
[0017] In some embodiments, the tip is sharp.
100181 In some embodiments, the head is about equal to or larger than the
elongated member.
Date Recue/Date Received 2020-09-01
3
100191 In accordance with an aspect, there is provided a fastening device,
having a first leg; a
second leg being substantially parallel to the first leg and connected to the
first leg at a joining
member arranged substantially orthogonal to the first leg and the second leg;
and at least one
projection connected to the first leg and extending from the first leg at an
angle. The fastening
device can be a staple, for example.
[0020] In some embodiments, at least one projection is connected to an
interior surface of the
first leg, the interior surface being substantially opposite to an interior
surface of the second leg.
In some embodiments, one or more projections can also be on the exterior walls
of the leg or legs
if applicable.
[0021] In some embodiments, there is at least one projection connected to the
first leg and
extending upwardly at an angle away from a tip of the first leg.
100221 In some embodiments, the angle is in a range from about 60 degrees to
about 88 degrees.
This can be an upward angle, for example.
[0023] In some embodiments, one or more projections are spaced apart at
substantially equal
distances on the interior surface of the first leg along the longitudinal
axis, and one or more
projections are spaced apart at substantially equal distances on the interior
surface of the second
leg along the longitudinal axis.
[0024] In some embodiments, the tip is not sharp.
100251 In some embodiments, the tip is sharp.
100261 In accordance with an aspect, there is provided a method for forming a
fastening device,
the method including forming a body with at least one projection connected to
the body and
extending at an angle away from a tip of the body by applying material to a
cavity in a mold and
removing the material from the mold.
Date Recue/Date Received 2020-09-01
4
100271 In some embodiments, the material is metal and the method further
includes, after
removing the material from the mold, shaping the metal to form the body with
the at least one
projection connected to the body and extending at the angle away from the top
of the body.
100281 In accordance with an aspect, there is provided a method for forming a
staple, the method
including forming a wire having at least one projection extending at an angle
from the wire by
applying material to a cavity in a mold; removing at least one piece of
material from the mold,
the at least one piece of material being the wire; and shaping the wire to
form a fastening device
having a first leg; a second leg being substantially parallel to the first leg
and connected to the
first leg at a joining member arranged substantially orthogonal to the first
leg and the second leg;
and at least one projection connected to the first leg and extending from the
first leg at an angle.
[0029] In accordance with an aspect, there is provided a fastening device,
comprising a
substantially straight body having at least one projection each extending from
the body at an
angle.
[0030] Other aspects and features and combinations thereof concerning
embodiments described
herein will be become apparent to those ordinarily skilled in the art upon
review of the instant
disclosure of embodiments in conjunction with the accompanying figures.
DESCRIPTION OF THE DRAWINGS
[0031] In the figures, embodiments are illustrated by way of example. It is to
be expressly
understood that the description and figures are only for the purpose of
illustration and as an aid
to understanding. Embodiments will now be described, by way of example only,
with reference
to the attached figures, wherein in the figures:
100321 FIG. 1 is a perspective view of a front view of a nail, according to
some embodiments;
100331 FIG. 2 is a perspective view of a front view of a nail, according to
some embodiments;
[0034] Fig. 3 is a perspective view of a staple, according to some
embodiments; and
Date Recue/Date Received 2020-09-01
5
100351 Fig. 4 is a perspective view of a staple, according to some
embodiments.
DETAILED DESCRIPTION
100361 Embodiments described herein provide a fastening device such as a nail
or staple having
projections along one or more shafts or legs. At least a portion of each
projection can extend
upwardly from the shaft or leg in a direction substantially opposite from a
tip of the shaft or leg
and help prevent backward removal of the fastening device in some embodiments.
For example,
the projections of the fastening device can improve and better secure the
fastening of material
such as wood during strong winds or when the material shrinks or dries and the
fastening device
or wood would otherwise be loosened or the fastening effect would otherwise be
diminished.
This can improve the fastening device's anchoring or holding power on wood
construction
including flooring, roofing, framing, and decking. The fastening device can
help prevent
material such as wood from splitting when the fastening device is applied to
it. This may be
accomplished when the projections are driven into the material (e.g., upon
sudden force from
wind or gradual loosening of the fastening device in the material over time)
to provide resistance
to movement according to some embodiments. In some embodiments, this can
provide an
advantage over straight or smooth nails that do not have the projections.
Fastening devices
described herein can provide an increased fastening or holding strength on the
wood structures or
other items, whether inside or outside for a longer period of time.
[0037] Various embodiments of a fastening device having a substantially
straight body and at
least one projection each extending from the body at an angle will now be
described. At least a
portion of a projection can point away from the tip of the body. The
projection can extend a
distance from the body that allows or facilitates a fastening effect of the
fastening device or that
facilitates lodging or driving the projection into a material to which the
fastening device is
applied.
100381 As an example, the size relationship between a nail's head and its body
or shank can be
between about 2.1 to 2.3 times, inclusive. In other words, the head for many
nails is at least 2
times the shank, according to some embodiments. According to some embodiments
described
Date Recue/Date Received 2020-09-01
6
herein, projections such as barbs or anchors are added to the shank such that
the total shank
diameter including the projections can be up to double the original size. In
some embodiments,
the projections can increase a nail's holding power by at least about 100% as
the projections can
allow the nail to hold, attach to, or fasten materials better than when having
a smooth shank such
as without the projections. In some embodiments, the projections can increase
a nail's shank or a
staple's leg sizes to double, and the resulting shank or leg having the
projections can increase the
holding power of the nail or staple by about 100% as the barbs can secure the
fastening device
more strongly to material than a fastening device with just a smooth shank or
legs, according to
some embodiments. In some embodiments, the projections can be of a dimension
or length such
that the total shank diameter or width measured to include the projections,
can be about: 5%,
10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%,
85%,
90%, 95%, or 98% greater than the total shank diameter or width measured to
not include the
projections.
[0039] FIG. 1 and 2 are perspective views of an example nail 100, according to
some
embodiments. As shown, nail 100 has an elongated member 110 that extends in a
longitudinal
direction (along a longitudinal axis) from a head 120 to a tip 140. The
elongated member 110
can be a shank, for example. The elongated member 110 has projections 130
along a portion of
its length from the head 120 to the tip 140 along the longitudinal axis and
extending in a
direction substantially towards the head 120. The projections 130 are
connected to the elongated
member 110 at one or more locations along the elongated member 110. The tip
140 can be sharp
or not sharp, such as blunted, rounded, or smooth, for example. In some
embodiments, the tip is
not sharp. For example, the tip can be tapered and end in a flat edge. In some
embodiments, the
tip is sharp. For example, the tip can be tapered and end in a point. A sharp
tip 140 may be not
incorporated in some embodiments as that can split the wood or other material
that the nail 100
can be applied to in some applications. For example, a smooth tip 140 can help
prevent the
wood or other material from splitting when the nail is applied by hammer or an
air gun.
[0040] The tip of a projection 130 can be smooth or sharp. A smooth tip can
enhance a holding
strength of the fastening device and/or facilitate holding of the fastening
device without hurting
one's fingers, in some embodiments. The tip of a projection 130 can be sharp
or smooth and
Date Recue/Date Received 2020-09-01
7
selected as such based on the size, application, and/or desired fastening
effect of the nail 100.
The tip of a projection 130 can refer to an end of the projection 130 that is
not directly adjoining
or abutting the elongated member 110.
100411 FIG. 1 shows an example nail 100 having projections 130 with sharp
tips, according to
some embodiments. FIG. 2 shows an example nail 100 having projections 130 with
smooth tips,
according to some embodiments.
[0042] The projections 130 can be anchors, barbs, extensions, hooks (e.g.,
similar to fish hooks),
spikes, protrusions, spurs, thorns, needles, prickles, spines, quills,
bristles, tines, or a
combination of same, for example. The projections 130 can be arranged along
the elongated
member 110 in a variety of configurations. For example, in some embodiments,
the projection
130 is designed to be in a straight shape, but can be in a curved shape for
particular usages or
where such a shape is required or warranted. The shape, quantity, angle, size,
shape, and tip
configuration can be different in different embodiments and can be configured
based on the size
or application of the nail 100.
[0043] In some embodiments, there is only one projection 130 on only one side
of the elongated
member 110. In some embodiments, there are at least two projections 130
aligned on the
elongated member 110. For example, one projection 130 can be positioned on one
portion of the
surface of the elongated member 110, while a second projection 130 can be
positioned on a
substantially opposite side of that portion of the surface of the elongated
member 110 (e.g.,
opposite being in a direction transverse to the longitudinal axis of the
elongated member 110),
with both projections 130 at a substantially equal distance from the head 120
(e.g., along the
longitudinal axis). As another example, one projection 130 can be positioned
on one portion of
the surface of the elongated member 110, while a second projection 130 can be
positioned on a
substantially opposite side of that portion of the surface of the elongated
member 110 (e.g.,
opposite being in a direction transverse to the longitudinal axis of the
elongated member 110),
where the projections 130 are along the elongated member 110 at a different
distance from the
head 120 in the longitudinal direction. In some embodiments, the elongated
member 110 has
two or more anchoring hooks 130, with the number depending on the size and
length of the
Date Recue/Date Received 2020-09-01
8
elongated member 110. Multiple projections 130 (e.g., more than two) can be so
configured and
positioned along the surface of the elongated member 110.
[0044] In some embodiments, two or more projections are positioned along an
axis substantially
transverse to the longitudinal axis and are spaced apart along that transverse
axis at substantially
equal distances on the surface of the elongated member. For example, a set of
projections 130
can include one or more projections 130 at a substantially equal distance from
the head 120 in
the longitudinal direction. Each projection 130 can extend from a different
side of the elongated
member 110 or multiple projections 130 can extend from different sides of the
elongated
member 110. For example, in a set, there may be two projections 130 arranged
on the surface of
the elongated member 110 on substantially opposite sides of the surface of the
elongated member
110 (e.g., opposite in the transverse direction). As another example, in a
set, there may be three
or more projections 130 arranged at substantially equal distances apart around
the body of the
elongated member 110 (e.g., along the same transverse axis of the elongated
member 110). In
some embodiments, projections 130 at a substantially equal distance from the
head 120 are
arranged at differing distances apart from each other around the body of the
elongated member
110 (e.g., along an axis orthogonal to the longitudinal axis of the elongated
member 110). In
some embodiments, multiple projections 130 can extend from a first side of the
elongated
member 110 and multiple projections 130 can extend from a second or multiple
other sides of the
elongated member 110. In some embodiments, the distance(s) apart that the
projections 130 are
around the elongated member 110 (e.g., around the circumference of the
elongated member) can
be fixed or designed based on the size and/or application of the nail 100.
100451 In some embodiments, two or more sets of projections 130 are arranged
along the length
of the elongated member 110 from the head 120 to the tip 140. In some
embodiments, three or
more sets of projections 130 are arranged at substantially equally spaced
distances along the
length of the elongated member 110 from the head 120 to the tip 140. For
example, the distance
can be about 7.5% of the length of the elongated member 110. This can be 0.25
inches for an
appropriately sized nail 100. In some embodiments, three or more sets of
projections 130 are
arranged along the length of the elongated member 110 from the head 120 to the
tip 140, with at
least one set at a different distance from a neighbouring set as compared to
the distance between
another set to its own neighbouring set.
Date Recue/Date Received 2020-09-01
9
100461 In some embodiments, projections 130 can be spaced apart along the
elongated member
110 in the longitudinal direction. In some embodiments, projections 130 are
spaced apart along
the elongated member 110 along the longitudinal axis at substantially equal
distances. The
projections 130 can be spaced apart at a distance that is about 7.5% of the
total length of the
elongated member 110. For example, this can be about 0.25 inches. The
projections 130, for
example, as barbs, can be spaced apart at a distance that is about 3.75% of
the total length of the
elongated member 110. For example, this can be about 1/8 inches apart. In some
embodiments,
projections 130 are spaced apart along the elongated member 110 along the
longitudinal axis at
different distances. In some embodiments, the distances apart of each set of
projections along
the length of the elongated member 110 can be subject to the size and/or usage
of the nail 100.
For example, 7.5% of the total length of the elongated member 110 can be a
reasonable distance
apart for projections 130 arranged along the length of the elongated member
110.
100471 In some embodiments, the projections 130 are arranged along a portion
of the elongated
member 110 along the longitudinal axis from a distance spaced from the head
120 to a distance
spaced from the tip 140. The distance from the head 120 and the first
projection(s) 130 along the
longitudinal axis can be about 15% of the total length of the elongated member
110 measured
along the longitudinal axis. For example, the distance can be 0.5 inches. The
distance from the
tip 140 and the closest projection(s) 130 along the longitudinal axis can be
about 7.5% of the
total length of the elongated member 110 measured in the longitudinal
direction or about half the
distance from the head 120 and the first or closest projection(s) 130 to the
head 120 along the
longitudinal axis. For example, the distance can be about 0.25 inches. As an
example, a nail 100
can be 3 inches long, gauge 9, with an elongated member 110 diameter slightly
smaller than the
head 120 and having projections 130 (e.g., anchors, barbs) along the length of
the elongated
member 110 along the longitudinal axis from about 0.5 inches (or 15% of the
total elongated
member length) below the head 120 to about 0.25 inches from the tip 140. Each
anchor of the
elongated member 110 can be spaced about 0.25 inches apart along the
longitudinal axis of the
elongated member 110. In various embodiments, the quantity and/or distance of
the projections
130 along the elongated member 110 can be based on the nail's 100 size and
application.
Date Recue/Date Received 2020-09-01
10
100481 In some embodiments, the projections 130 extend from the elongated
member 110 with at
least a portion of the projection at an angle relative to the elongated member
110. For example,
the projections 130 can extend towards the head 120 at an angle relative to
the elongated member
110 that is about equal to or less than 90 degrees or equal to about 60
degrees. As another
example, the angle can be an angle in the range of about 60 degrees to about
88 degrees. As
other examples, the angle can be about 65 degrees, about 70 degrees, about 75
degrees, or about
80 degrees. The angle can be selected based on the size or dimensions of the
nail 100, its usage
or application, and/or a desired fastening strength. As an example, if the
projection 130 is a
hook, the projection 130 can extend from the elongated member 110 initially
substantially
towards the tip 140 and subsequently substantially towards the head 120 at the
angle relative to
the elongated member 110. As another example, at least one projection 130 can
be connected to
the elongated member 110 and extend at an angle away from the tip 140, whether
near the
portion that is connected to the elongated member 110 or at another portion
such as at an end of
the projection 130 that is not connected to the elongated member 110. As
another example, the
projections 130 can extend upwards in a direction substantially towards the
head 120. As
another example, the projections 130 can extend in a direction substantially
opposite to the tip
140. In some embodiments, the projections 130 provide an improved fastening
effect by holding
the material that the nail 100 is applied to together. For example, the
projections 130 can help
prevent the nail 100 from becoming dislodged during strong winds or when the
material it is
applied to shrinks and the nail 100 would be otherwise loosened or its
fastening effect otherwise
diminished. This can be an improvement over nails without one or more
projections 130.
100491 In some embodiments, a projection 130 extends from the elongated member
110 at a
distance that can allow the projection 130 to adequately lodge into the
material to which the nail
100 is applied, for example, to impede movement of the nail 100 such as during
strong winds or
expansion of the channel in which the nail 100 is positioned in the material.
This can help secure
the nail 100 in the channel, improve the stability of the connection between
the nail 100 and the
material, and improve, maintain, or facilitate a fastening effect of the nail
100 to the material, in
some embodiments.
100501 In some embodiments, nail 100, including at one or more projections
130, can facilitate a
threshold level of fastening effect or security of the nail 100 in material to
which the nail 100 is
Date Recue/Date Received 2020-09-01
11
applied. For example, the fastening effect can secure pieces of material such
as wood together at
a location where the nail 100 is applied to the material. This level of
fastening may be greater
than, equal to, or less than the strength of a fastening effect of the nail
100 before the nail 100 is
loosened or strained, such as by strong winds, forces applied to the nail 100
or material to which
it is applied, backward or other directional forces applied to the nail 100,
shrinkage of the
material to which the nail 100 is applied, forces that tend to dislodge or
loosen the nail 100, or
other disturbance, whether over time or on sudden occasion.
[0051] In some embodiments, the head 120 is larger than the elongated member,
for example,
about 2.1 to about 2.3 times larger than the elongated member 110. For
example, in the case of a
head 120 and elongated member 110 both with circular cross sections, the
circumference of the
head 120 can be about 2.1 to about 2.3 times larger than the circumference of
the elongated
member 110. In some embodiments, the head 120 of the nail 100 is sized and
dimensioned to be
at least as large as an anticipated amount of shrinkage of the material to
which it is applied at the
location surrounding its elongated member 110. This can allow the nail 100 to
maintain or
sustain a threshold level of fastening even when the material shrinks or when
the nail 100 is
loosened. The nail 100 can be maintained in the material, for example, to
secure pieces of
material together, rather than dislodged when the head 120 is sized and
dimensioned as such. In
some embodiments, the head 120 is only slightly larger than the elongated
member. In some
embodiments, the head 120 is only slightly larger than the elongated member
110, the elongated
member 110 measured to include projection(s) 130.
100521 In some embodiments, the projections 130 are sized and dimensioned no
larger than the
head 120 of the nail 100. For example, the projections 130 may not extend a
distance away from
the elongated member 110 beyond the distance that the head 120 extends away
from the
elongated member 110 along the same axis or in the same direction. For
example, a combined
diameter or width of the total projection 130-elongated member 110 assembly
may be slightly
less than that of the head 120. In some embodiments, the projections 130
extend a distance away
from the elongated member 110 that allows, facilitates, enables, maintains,
sustains, and/or
improves a fastening effect of the nail 100 (e.g., as compared to a nail
without projections 130)
and/or facilitates driving projections 130 into the material to which the nail
100 is applied such
Date Recue/Date Received 2020-09-01
12
as to resist movement, force, or loosening. For example, the fastening effect
may be greater than
or equal to or above a threshold level of a fastening effect otherwise
achievable by the nail 100
without any projections 130.
100531 As an example, the projections 130 can extend from the elongated member
110 such that
the distance of the extensions is equal to the width or diameter of the
elongated member 110,
doubling the combined diameter or width of the total projection 130-elongated
member 110
assembly. For example, if a projection 130 extends at an angle from the
elongated member 110
and a second projection 130 extends at an angle from the elongated member 110
on the opposite
side of the elongated member 110 (opposite being on the opposite side of a
longitudinal axis
extending from the head 120 to the tip 140 of the nail 100), the total length
measured from the
portion of the first projection 130 that is farthest from the elongated member
110 to the portion
of the second projection 130 that is farthest from the elongated member 110 is
about double the
width of the elongated member 110 measured along the same axis. As an example,
if the
elongated member 110's diameter is 0.148 inches, the total diameter of the
projection 130-
elongated member 110 assembly can be 0.29 inches. For example, the projections
130 can
extend a distance from the elongated member 110 to double the diameter of the
shank measured
to include the projections 130. In some embodiments, the combined length or
diameter of the
projection 130-elongated member 110 unit is slightly less than that of the
head 120, for example,
as measured along a substantially parallel axis.
100541 In some embodiments, the projections 130 each extend a distance away
from the
elongated member 110 such that the combined diameter or width of the total
projection 130-
elongated member 110 assembly is about: 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%,
45%,
50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 98% greater than the
elongated
member 110 diameter or width measured to not include the projections and
measured along
substantially the same axis.
[0055] In some embodiments, the nail 100 includes a substantially straight
elongated member,
the elongated member extending from a head to a tapered tip along a
longitudinal axis and
having at least one projection each extending from the elongated member at an
upward angle
away from the tip. In some embodiments, the elongated member has two or more
projections.
Date Recue/Date Received 2020-09-01
13
In some embodiments, the distance measured between a first projection tip of a
first projection
130 and a second projection tip of a second projection 130 is a length that is
up to the length of
the head 120 measured along a substantially identical axis. For example, the
projections 130
along an axis substantially parallel to an axis defined by the head 120 can
extend away from the
elongated member 110 such that the farthest points away from the elongated
member 110 of
projections 130 comprise a distance that is double the width of the elongated
member 110
measured along substantially the same axis. The distance can also be up to the
width of the head
120 measured along substantially the same axis.
100561 For example, in some embodiments, the width of the elongated member 110
and the
distance that one or more of the projections 130 extend from the elongated
member 110
measured along substantially the same axis, is double the width of the
elongated member 110
measured along substantially the same axis.
100571 Example lengths of a projection 130 include about 0.07 inches for an
about 3 inch long
nail 100 with a head 120 having about a 5/16 inch diameter, about 2% of the
length of a nail 100,
or about 20% of the length or diameter of the head 120 of a nail 100. An
example configuration
of a nail 100 includes the projection 130 nearest to the head 120 positioned
at about 0.5 inches
below the head 120, with each projection 130 about 1/8 inches apart from the
nearest projection
130, and the combined diameter or length measured from the farthest extensions
of the
projections 130 (along an axis substantially orthogonal to the longitudinal
axis or substantially
parallel to an axis defined by the head 120) being about slightly less than
that of the head 120
(measured along an axis substantially parallel to the same orthogonal axis).
100581 In some embodiments, the length of a projection 130 can be equal to the
length of another
projection 130. In some embodiments, the length of a projection 130 is
different from the length
of another projection 130. For example, the projections 130 can have different
lengths.
100591 The following table describes example sizes and configurations of the
head 120 and
elongated member 110 according to some embodiments. The head 120 and elongated
member
110 can be sized and dimensioned to be about the following indications where
the nail 100 is
Date Recue/Date Received 2020-09-01
14
used for woodwork or construction applications, for example. As shown, the
head 120 can be
double the size of the elongated member 110.
Table 1. Example Dimensions for a Nail.
Nail Size Gauge Elongated Elongated Head Ratio of
INIember INIember Diameter Diameter
Diameter Length (inches) of Head to
(inches) (inches) Elongated
Member
2D 15 0.072 1 3/16 2.6
(0.183 cm) (2.54 cm) (0.476 cm)
3D 14 0.083 1.25 13/64 2.44
(0.211 cm) (3.175 cm) (0.516 cm)
4D 12 0.109 1.5 1/4 2.29
(0.277 cm) (3.81 cm) (0.635 cm)
10D 9 0.148 3 5/16 2.11
(0.376 cm) (7.62 cm) (0.794 cm)
12D 9 0.148 3.25 5/16 2.11
(0.376 cm) (8.26 cm) (0.794 cm)
16D 8 0.165 3.5 11/32 2.06
(0.419 cm) (8.89 cm) (0.864cm)
[0060] For example, nail 100 can be size 10D, gauge 9, and 3 inches long, with
an elongated
member 110 diameter of 0.148 inches, a head 120 diameter of 5/16 inches, where
the diameter is
the standard size of a nail. By including the barbs 130, its diameter can be
double. A projection
130 such as a barb can be about 1/8 inches apart, with each projection 130
being about 0.07
inches long or extending about 0.07 inches away from the elongated member 110.
[0061] The nail 100 can be made out of a variety of materials including metal,
non-metal, a
strong material, a hardening material, a combination of metal and non-metal
material, or a
Date Recue/Date Received 2020-09-01
15
combination of same. The composition of the material or metal used can be
varied and can be
selected for the particular application of the nail 100.
[0062] The head 120 and elongated member 110 can be circular, elliptical,
annular, square,
polygonal, or otherwise shaped.
[0063] The nail 100 can be applied to a material using a hammer or air gun and
can be used on
materials such as wood, asphalt, PVC, or metal, for applications such as
roofing (including
constructing a roof with shingles), flooring, wall framing, joints, siding or
tightening pieces of
material. The nail 100 can be a pneumatic nail, bulk nail, framing nail, or
nail configured for use
with various applicators such as nail guns or pneumatic nail guns, for
example. On application
of the nail 100 to the material, the nail 100 provides a fastening effect,
such as the fastening of
separate pieces of wood together, in some embodiments.
100641 FIGs. 3 and 4 are a perspective view of an example staple 200,
according to some
embodiments. As shown, staple 200 has two legs 210a and 210b having tips 240a
and 240b,
respectively, at one end of the respective leg. The tip 240 can be sharp or
not sharp, such as
blunted, rounded, or smooth, for example. FIG. 3 shows an example staple 200
having not sharp
tips 240a and 240b and projections 230 having sharp tips. FIG. 4 shows an
example staple 200
having sharp tips 240a and 240b, as well as projections 230 having smooth
tips. Each of leg
210a and 210b is joined at the other end to the other leg by joining member
220. The joining
member 220 extends substantially perpendicularly from the respective end of
each of the legs
210a and 210b. The joining member 220 can be an arch, for example. Each of leg
210a and
210b has one or more projections 230 along the length of the leg. In some
embodiments,
projections 230 are positioned at spaced intervals along the length of each
leg 210a and 210b.
The intervals can be selected based on the size and/or use or application of
the staple 200 and/or
a desired fastening strength. For example, the interval can be about 7.5% of
the total length of
the respective leg 210a or 210b. The interval distances can be equal along one
leg 210a or 210b,
equal along both legs 210a and 210b, or unequal along one or both legs 210a
and 210b. In some
embodiments, there is a distance between the end of a leg 210 that connects to
the joining
member 220 and the first or nearest projection 230 of that leg 210. This
distance may be
substantially equal to a corresponding distance at the other leg 210.
Similarly, in some
Date Recue/Date Received 2020-09-01
16
embodiments, there is a distance between the end 240 of a leg 210 and the
nearest projection 230
of that leg 210. This distance may be substantially equal to a corresponding
distance at the other
leg 210. The distance can be selected based on the size and/or use or
application of the staple
200 and/or a desired fastening strength. The distance of projections 230 along
an inside wall of
the staple 200 (e.g., an inside surface of a leg 210 such as a surface of the
leg 210 that opposes a
surface of another leg 210) can be selected based on the size and application
of the staple 200.
[0065] As an example embodiment, staple 200 can have two legs having the same
length and are
formed in a substantially upside-down U-shape. The two legs can be
substantially parallel to
each other. Staple 200 has projections 230 such as barbs that are on the
inside surface of each
leg and are directed upward. This can allow for a small outside wall of each
leg so as to be
compatible with some applicator machines. However, barbs or hooks can be
applied on a leg's or
legs' outside surfaces if required, according to some embodiments.
[0066] In some embodiments, at least a portion of one or more projections 230
extends from a
leg 210 in a substantially opposite direction from the tip 240 of that leg
210. In some
embodiments, one or more projections 230 are positioned substantially on an
interior surface of a
leg 210, that is, on a surface that opposes an opposing leg 210. In some
embodiments, no
projections 230 are positioned on any other surface of the leg 210 apart from
the interior surface
of the leg 210. In some embodiments, one or more projections 230 are
positioned at various
positions on the leg 210a and 210b, for example, on an exterior surface of the
leg 210 or other
surface, such as for smaller sized staples or special applications or where an
applicator machine
is configured to accommodate same. The projections 230 can be spaced apart at
substantially
equal distances on the surface of each leg along the longitudinal axis. The
number of
projection(s) 230 that are connected to each of the legs 210a or 210b can be
configured
depending on the size and/or length of each respective leg 210a or 210b.
[0067] The tip of a projection 230 can be smooth or sharp. A smooth tip can
enhance a holding
strength of the fastening device and/or facilitate holding of the fastening
device without hurting
one's fingers and/or reduce the splitting of wood or other material the staple
200 is applied to, in
some embodiments. The tip of a projection 230 can be sharp or smooth and
selected as such
Date Recue/Date Received 2020-09-01
17
based on the size, application, and/or desired fastening effect of the staple
200. The tip of a
projection 230 can refer to an end of the projection 230 that is not directly
adjoining or abutting a
leg 210.
100681 In some embodiments, staple 200 includes more than two legs 210 with
one or more of
the legs 210 having one or more projections 230. The one or more projections
230 facilitate a
fastening effect of the staple 200 applied to material, for example, to join
or secure multiple
pieces of material together.
100691 In different embodiments, the number, size, positioning, angle, shape,
materials,
distances, spacing, configurations relative to different components of the
staple 200, and other
configurations of any portion of the staple 200 are as described in relation
to the nail 100 in
various different embodiments. The shape, quantity, angle, size, shape, and
tip configuration of
the projections 230 can be different in different embodiments and can be
configured based on the
size or application of the staple 200. In various embodiments, the quantity
and/or distance of the
projections 230 along a leg 210 can be based on the staple 200's size and
application.
[0070] In some embodiments, the staple 200 has at least one projection
connected to a leg 210
and extending at an angle away from the tip 240 of that leg 210. For example,
the angle and
length of one or more projections 230 relative to the corresponding leg 210
can be as described
for the one or more projections 130 relative to the elongated member 110. The
angle of one or
more projections 230 relative to a leg 210 that they are connected to can be
about 60 degrees and
extending toward the joining member 220. The angle can be measured near the
portion of the
projection 230 that connects to the leg 210 or can be measured at a different
portion such as near
the other end of the projection 230. As an example, the angle can be an angle
from the range of
about 60 degrees to about 88 degrees. For example, the angle can be about 65
degrees, 70
degrees, about 75 degrees, about 80 degrees, about 85 degrees, or any angle in
between. In some
embodiments, projections 230 extend a distance away from each of one or more
legs 210 that
allows, facilitates, enables, maintains, sustains, and/or improves a fastening
effect of the staple
200 and/or facilitates driving projections 230 into the material to which the
staple 200 is applied
such as to resist movement, force, or loosening. For example, the fastening
effect may be greater
than or equal to, a fastening effect otherwise achievable by the nail 200
without any projections
Date Recue/Date Received 2020-09-01
18
230. The projections 230 can be anchors, barbs, extensions, hooks (e.g.,
similar to fish hooks),
spikes, protrusions, or a combination of same, for example.
[0071] In some embodiments, the projecting lengths of the projections 230 make
the thickness or
width of the respective leg 210 approximately double (e.g., measured along
substantially parallel
axes) when measured to include the projections 230. In some embodiments, this
arrangement
these can double a holding power, strength, and/or fastening effect of the
staple 200. In some
embodiments, the spacing or distance between the projections 230 can be
selected to be based on
the size, usage, and/or desired fastening strength of the staple 200. In some
embodiments, the tip
(e.g., an end that is not connected to the leg 210) of a projection 230 is
sharp or smooth. In some
embodiments, the configuration of the staple 200 can be changed, for example,
the staple 200
can have three or four legs 210 and projections 230 such as barbs or anchors
can be applied to all
the legs 210. These projections 230 can be configured as described in relation
to embodiments
of staple 200 having two legs 210.
[0072] In some embodiments, the length of a projection 230 can be equal to the
length of another
projection 230. In some embodiments, the length of a projection 230 is
different from the length
of another projection 230. For example, the projections 230 can have different
lengths based on
the particular design and application.
[0073] Example dimensions of the staple 200 is a 2 inch by 0.5 inch 15.5 gauge
staple. These
dimensions may be suitable for sub-floor and hardwood flooring. Other example
staple 200
dimensions include 1.2 inches, 3/4 inches, and 1 inch staples 200, measured
from a tip 240 to a
joining member 220. Staples sizes can be designed and manufactured according
to various
applications. The tips 240a and 240b can be sharp or not sharp. In some
embodiments, the tip is
not sharp. For example, the tip can be tapered and end in a flat edge. In some
embodiments, the
tip is sharp. For example, the tip can be tapered and end in a point.
[0074] In some embodiments, a nail 100 or staple 200 is created using a mold
based on the
desired design of the nail 100 or staple 200. Where the nail 100 or staple 200
is comprised of
metal, hot metal material is poured into the mold. The hot metal material is
cooled, and the
cooled material is removed from the mold and hammered and/or shaped to the
desired shape,
Date Recue/Date Received 2020-09-01
19
configuration, and design of the nail 100 or staple 200. For example,
projections 130 or 230 can
be formed in the mold and subsequently finished by hammering or shaping after
removal from
the mold or, alternatively, can be completely formed and finished in the mold
depending on the
mold design, manufacturing machinery, and desired application of the nail 100
or staple 200.
100751 As an example, when manufacturing a nail 100, a mold is made, and metal
or other
suitable material is poured into the mold to form the kind of nail required.
After the metal has
been formed into a shape, then the formed metal or wire is cut and the head of
the nail is
hammered into shape. Various nail producing machinery can be used, and the
production
method can be based on the machine one uses.
[0076] In some embodiments, staple 200 is created from a wire, where
projections 230 are
formed by cutting into the wire at an angle such as about 60%. In some
embodiments, staple 200
is manufactured by forming a wire having at least one projection extending at
an angle from the
wire by applying material to a cavity in a mold, removing at least one piece
of material from the
mold, the at least one piece of material being the wire, and shaping the wire
to form the staple
having one or more projections. For example, the staple can be a fastening
device having a first
leg; a second leg being substantially parallel to the first leg and connected
to the first leg at a
joining member arranged substantially orthogonal to the first leg and the
second leg; and at least
one projection connected to the first leg and extending from the first leg at
an angle. In some
embodiments, two or more pieces of material are removed from the mold and
glued together to
form the wire. The mold can have a cavity that is shaped to create a wire
having upward
projections such that the wire can be bent or shaped to form a staple 200.
[0077] In some embodiments, nails 100 are formed and produced in a mold, are
taken out in a
wire form, and the heads are hammered or molded depending on the machinery
being used for
making the particular type of nail 100.
[0078] A projection can be incorporated in the designing and making of nails
100 and staples
200. In some embodiments, with the projections, the nail's 100 shank or the
staple's 200 legs
will be enlarged to double the size, thus increasing the holding power of
these devices (for
Date Recue/Date Received 2020-09-01
20
example, by 100%) as a result of the projections having a better holding and
securing power than
just having a smooth shank or legs.
[0079] Nails 100 and staples 200 can be made by first making a mold. When
designing the mold,
the projections' shape and location should be taken into consideration.
Material can then be
poured into the mold. The material can be metal or another suitable material.
In manufacturing
nails 100, a machine can cut the length for the nail 100, hammer one end to
form the head, and
cut the other end to form the tip.
100801 The manufacturing of staples 200 can be similar. For example, a mold
can be created
having the projections incorporated. A staple can comprise several molded
wires that are glued
together. The wire can then be bent and cut to the desired size.
[0081] As an example, when manufacturing a staple 200, the same molding
concept is applied as
for manufacturing a nail 100, except the staples 200 are produced by putting
the designed wires
together by glue or similar material then cutting the material into the
required length and bending
same to produce an upside-down U-shape.
[0082] Different metal treatments can be used in manufacturing the nail 100 or
the staple 200
and can be selected based on the type of fastener. For example, nails 100 and
staples 200 can be
created with a rust protection coating for outdoor applications or can be heat
treated.
[0083] Various example embodiments will now be described. There are provided
fastening
devices such as a nail and a staple each having at least one projection (such
as a barb, anchor,
spike), each of the projections extending upwardly from the body at an angle
(e.g., 60 to 88
degrees) away from the bottom tip(s) of the device's body. For example, in the
case of a nail,
there can be two or more projections extending from the shank of the nail,
each spaced at
substantially equal distances apart. In the case of a staple, there can be at
least one projection
connected to the inside surface of a first leg of the staple, the first leg
being substantially
opposite to the inside surface of a second leg of the staple. The staple is in
upside-down U-shape
in some embodiments. The tip(s) of the nail or staple can be sharp or not
sharp, depending on
the device's application and size.
Date Recue/Date Received 2020-09-01
21
100841 In some embodiments, these improved fastening devices substantially
increase the
holding power due to the projections enlarging the size of the shank or the
legs to double and can
secure a wood structure or products it fastens together. This can increase the
durability, life, and
safety of wood structures and products, including houses, roofs, decks,
fences, furniture, and
related items.
[0085] Further example fastening devices will now be described. There are
provided two kinds
of fastening devices, namely: (a) a nail; and (b) a staple, each having at
least one similar type of
improvement. For example, in some embodiments, a nail is a device comprising a
substantially
straight body having at least one projection each extending from the body at
an upward angle,
the degree of the angle being based on the application and the size of the
nail. The combined
dimension of the projection (e.g., barb) and body (e.g., shank) should be
slightly less than the
head of the nail. As another example, in some embodiments, a staple is an
upside-down U-
shaped body device that has a projection extending from the inside area at an
angle, in some
embodiments, one or more projections (e.g., barbs) can also be at the outside
or exterior area or
surface of the legs). The degree of the angle is based on the application and
size of the staple.
Although these embodiments can provide an increased fastening strength and
holding power, the
application of these fastening devices can be adapted for use with applicators
such as hammers
or air guns. The fastening devices can be applied manually or mechanically.
[0086] Example specifications of a nail 100 according to some embodiments will
now be
described. In some embodiments, the nail has sharp projections. In some
embodiments, the nail
has smooth projections. In some embodiments, the nail has a sharp tip. In some
embodiments,
the nail has a smooth tip. The upward angle of a projection can be around 70
degrees. The total
combined diameter of the shank of the nail plus the projections can be
slightly less than the nail
head. The projections can start around 15% below the head, based on the total
nail length, and
be spaced apart along the length of the nail until around 7.5 % above the
bottom tip of the nail.
The distance between each projection can be variable.
[0087] Example specifications of a staple 200 according to some embodiments
will now be
described. The projections of the staple can be at around a 70 degree upward
angle. In one
embodiment, the projections can be sharp. In another embodiment, the
projections can be
Date Recue/Date Received 2020-09-01
22
smooth. The size of the projection and the staple leg are in equal
proportions. Projections can be
placed, based on the total length of the leg (measured from the arch of the
staple to the bottom of
the staple) at about 15% below the arch and be spaced along the leg until
around 7.5% above the
leg tip. The legs tips are sharp but can be smooth according to some
embodiments.
100881 Embodiments described herein can be used for wood and other applicable
construction
projects, including according to building codes and practices of Canada and
the rest of North
America for building roofs, decks, walls, floors, and other structures.
100891 Example applications of embodiments described herein will now be
elaborated.
100901 In Ontario, Canada, to build a two-story detached house with about 2500
square feet of
living area, the roof can be built with 2x6 inch studs as rafter and joist,
with 16 inch spacing over
centre (o.c.), then covered with 5/8 inch thick plywood or oriented strand
board (OSB) as
sheathing, and then cover with tar paper and shingles on top. Similar wood-
related specifications
can be used for wall framing.
[0091] To build a deck for a house, where the deck is sized 10 feet (distance
measured from the
house) by 18 feet wide, the joists can be 2x10 inch treated lumber, installed
at 16 inch o.c. as
base. On top, the decking or flooring can be 2x6 inch treated wood with or
without space in
between. Nails 100 can be the primary fastening device used.
[0092] To build an indoor floor, 2x10 inch wood (e.g., untreated wood) can be
used at 16 inch
o.c. as joists and covered with 5/8 inch or 3/4 inch thick plywood or OSB
broad as sub-floor.
Nails 100 and/or staples 200 can be the primary fastening devices used.
100931 To build a frame for two-story house with about 2500 square feet of
living space, the
frame can be built with 2x6 inch studs at 16 inch o.c. The outside can be
covered with 5/8 inch
thick plywood or OSB broad.
100941 The above woodwork specifications can be used for most residential
construction
projects. Bringing the wood together requires a fastener, such as a nail
and/or staples.
Date Recue/Date Received 2020-09-01
23
100951 For building a house, various fasteners can be used, for example, a 3
inch, No. 10d nail
(with a 0.148 inch diameter) for joists, rafters, flooring, decking; and wall
framing; a 1.25 inch
no. 8d nail for roof or wall sheathing or shingles. The fasteners can be
applied 16 inches o.c. or
per manufacturer's specifications, by using an air gun or hammer.
100961 However, materials such as wood can shrink after installation and can
diminish the
fastening effect of a nail or screw. Accordingly, a roof can be ripped off by
strong winds, floors
can develop a cracking sound or other noise such as when weight is applied to
the floor, wood
strips used in a deck may protrude or pop up, and frames can sag over time.
These effects can
develop due to the shrinkage of the material (e.g., wood) that can diminish
the fastening strength
of the nails or screws that were used with the material. Embodiments disclosed
herein can
mitigate or impede these effects. In some embodiments, a head 120 of a nail
100 is sized and
dimensioned to be at least as large as an anticipated amount of shrinkage of
the material to which
it is applied at the location surrounding its elongated member 110. This can
help the nail 100
have at least a threshold level of fastening effect. This level may be greater
than or at least equal
to the strength of a fastening effect of the nail 100 before the nail 100 is
loosened or strained, for
example, by strong winds, forces applied to the nail 100 or material to which
it is applied,
backward forces applied to the nail 100, shrinkage of the material to which
the nail 100 is
applied, or other disturbance.
[0097] In some embodiments, the design of a nail 100 or staple 200 allows
compensation for
wood shrinkage of a structure in which the nail 100 or staple 200 is used,
thus making the
structure solid and safe. After installation or construction of a wood
structure using nails 100 or
staples 200, in some cases, the wood will shrink to an extent. The nails 100,
with anchoring
hooks 130, maintain the fastening effect, in some embodiments. Similarly,
where staples 200
having projections 230 are used in a structure, staples 200 maintain the
fastening effect even
where the structure material shrinks, in some embodiments.
100981 In some embodiments, nails 100 or staples 200 provide stronger and
safer houses, such as
at roofs, frames, floors, fences, and decks when used in these structures.
Nails 100 or staples 200
can be applied and installed by air gun, hammer, or in a means used for
application of other nails
or staples, for example, like those without projections 130 or 230. Nails 100
or staples 200 can
Date Recue/Date Received 2020-09-01
24
be used more quickly and easily than screws. An applicator for a staple 200
can include a hand-
held stapler or a pneumatic stapler.
[0099] In some embodiments as described herein, projections on a fastening
device can increase
the holding power of the fastening device.
[0100] In North America, the primary material for housing construction is wood
and lumber.
Whether building a roof, wall frame, floor, deck, fence, etc., the fastening
device for holding the
wood together are nails and perhaps in combination with staples. Nails can be
as sized and
dimensioned as shown in Table 1. These nails can be from 1 inch to 3.5 inches
long, and each
comprise a head (e.g., round shaped), shank (e.g., a smooth body), and a sharp
tip at the bottom.
Workers can apply the nails by hand (hammer) or air gun. When a nail is
hammered into wood,
it creates a holding power; when a worker hammers a nail into two pieces of
wood, the effect is
to hold the wood pieces together.
[0101] This holding power can be diminished. After time and unavoidably, most
construction
grade wood will shrink a little. As the wood around the shank area of a nail
retreats, even
shrinking by only a little bit, that can cause the nail's holding power to
diminish. As a result, a
floor built using the nail can have cracking noise, or when the weather is
stormy, an entire roof
built using the nail can be lifted and blown away.
101021 The holding power of the nails can be enhanced and improved, for
example, by 100%.
As the wood for house and related construction inevitably will shrink, to make
better and safer
houses, the holding power of the fastener devices, mainly nails, and to some
degree, staples,
should be improved, especially as these two devices can be applied by hand or
machinery, and
quickly. For furniture, staples can be used for enhancing the structures'
longevity.
[0103] The effect of incorporating projections (e.g., barbs, anchors, spikes)
onto the nails' shank
or the staple's legs, according to some embodiments, is to increase these
devices' holding power,
for example, by 100%.
Date Recue/Date Received 2020-09-01
25
101041 In some embodiments, when manufacturing nails or staples, molds are
designed and
made. Barbs can be incorporated into the molds. The barbs are incorporated and
become part of
the nail's shank or the staple's legs, at an upward angle from 60 to 88
degree. The added barbs
make the shank's diameter double. The size of the barbs and the shank can be
equal. For
example, a 3-inch nail has a shank 0.148 inches in diameter and a head 5/16
inches in diameter.
The ratio of the sizes of the head to the shank is 2.11, meaning the head is
2.11 times bigger than
the shank. Table 1 shows all this ratio is bigger than 2 in those examples.
101051 The barbs can make the shank size double. By doubling the shank size
and with a
securing force provided by the barbs, the nails' holding power can be
increased by 100%, in
some embodiments.
101061 For example, according to some embodiments, if the shank's size has
enlarged to double,
the holding power will increase accordingly. The larger the shank, the greater
its holding power.
The barbs-shank assembly can improve its restraining power and can secure the
material it has
fastened into position, thus enhancing the structure's durability and safety.
101071 The sizes of nails shown in Table 1 can be used for general
construction, including roofs,
wall frames, floors, decks, fences, and drywalls. These structures rely on
nails and, to some
degree, staples, to fasten wood together. With barbs incorporated onto the
nails and staples, the
holding power can increase by 100%, in some embodiments.
101081 For greater clarity, where used herein, "substantially" includes
"equal" or "exactly" and
"substantially equal".
[0109] The discussion herein provides example embodiments of the technology.
The technology
is considered to include all possible combinations of the disclosed elements.
Accordingly, if one
embodiment comprises elements A, B, and C and a second embodiment comprises
elements B
and D, then embodiments of the technology are contemplated to also comprise
elements A, B, C,
and D, as well as other remaining combinations of A, B, C, or D, even if not
explicitly disclosed.
Date Recue/Date Received 2020-09-01
26
101101 Although embodiments have been described in detail, it should be
understood that
various changes, substitutions, and alterations can be made herein. Moreover,
the scope of the
present application is not intended to be limited to the particular
embodiments of the process,
machine, manufacture, composition of matter, means, methods and steps
described in the
specification.
[0111] As can be understood, the examples described herein and illustrated are
intended to be
exemplary only.
Date Recue/Date Received 2020-09-01
