HK1214641B - Fastener - Google Patents

Description

Fastening piece

Technical Field

The present invention relates to a fastener and particularly to a fastener for wooden products and the like.

The invention has been developed primarily for use in the wood industry and the construction industry and will be described hereinafter with reference to this application. It should be understood, however, that the invention is not limited to this particular field of use.

Background

Fasteners such as screws, nails, and anchor bolts have been manufactured using various head and drive designs, each requiring a different kind of tool to drive or extract them. All fasteners use the same general fastening principle, in which a shank, which may be threaded or serrated, provides the grip, and a head provides the bearing surface and means for driving the screw.

One difficulty with such fasteners is that the head is exposed by design. In construction applications, this results in additional machining (finishing) work for the builder to machine the workpiece around the head.

Accordingly, there is a need to provide a fastener that is secured in a concealed manner so that the workpiece can be secured in place as desired with the fastener concealed. This would allow the builder to use the pre-machined workpiece without additional machining work.

The present inventors have conducted a thorough search of the market and published patent publications, but have not found a product that meets the requirements of the inventors.

The present invention seeks to overcome or substantially ameliorate at least some of the disadvantages of the prior art, or at least to provide an alternative.

It will be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in australia or any other country.

Disclosure of Invention

According to a first aspect, the present invention provides a fastener comprising: a handle having a first attachment means for attachment to a first workpiece; and a head having a second attachment device for attachment to a second workpiece.

Preferably, the fastener is a screw and the first means comprises a threaded formation on the shank.

Optionally, the fastener is a nail.

Optionally, the fastener is an anchor bolt.

Preferably, the second attachment means comprises at least one attachment member formed in the head, the at least one attachment member extending in a direction generally opposite to the handle.

Preferably, each of the at least one attachment members is a prong (prong).

Preferably, the head comprises a drive structure at a central portion thereof, and the at least one attachment member is formed laterally of the drive structure.

Preferably, at least one attachment member extends from a peripheral portion of the head.

Preferably, the at least one attachment member comprises a plurality of attachment members substantially equally spaced around a peripheral portion of the head.

Preferably, the fastener comprises three or more attachment members.

Preferably, the plurality of attachment members comprise prongs that flare slightly outwardly (splay) relative to one another.

Preferably, each prong has an end with a prong, wherein the prongs are adapted to nest into the second work piece when the second work piece is pressed to the second attachment means.

Preferably, each prong is adapted to substantially curl and/or deflect into the second workpiece as the second workpiece is pressed against the second attachment means.

Preferably, the plurality of attachment members comprise prongs having serrations (serrations) formed thereon.

Preferably, the prongs extend parallel to each other in a direction opposite the handle.

Preferably, the prongs are integrally formed with the head.

In one embodiment, the prong includes a distal prong portion without serrations and a proximal portion with serrations.

Optionally, the prongs are slightly flared relative to each other.

Preferably, in this embodiment, each prong is adapted to substantially curl and/or deflect into the second workpiece as the second workpiece is pressed against the second attachment means.

Preferably, the fastener comprises depth measuring means for indicating, in use, the depth of insertion and/or the distance of the head of the first attachment means from the first workpiece.

Preferably, the depth measuring means comprises a shoulder formed at the junction of the head and the shank.

Other aspects of the invention are also disclosed.

Brief Description of Drawings

Although any other form may fall within the scope of the invention, a preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a screw fastener with three integral fixation prongs in accordance with a preferred embodiment of the present invention, wherein (a) is a perspective view showing the slightly outwardly splayed prongs in their initial configuration, (b) is a perspective view showing the screw with the three prongs in a crimped and outwardly biased configuration when embedded in a workpiece; and (c) is a top view of (a);

FIG. 2 shows a screw fastener with four integral fixation prongs in accordance with a preferred embodiment of the present invention, wherein (a) is a perspective view showing the prongs in their initial configuration slightly flared outwardly, (b) is a perspective view showing the screw with the four prongs in a crimped and outwardly deflected configuration when inserted into a workpiece; and (c) is a top view of (a);

FIG. 3(a) is a schematic cross-sectional view of FIG. 1 (a); FIG. 3(b) is a schematic cross-sectional view of FIG. 1 (b); FIG. 3(c) is a top view of a fastener having three prongs; FIG. 3(d) is a top view of a fastener having four prongs; FIG. 3(e) is a top view of a fastener having six prongs; FIG. 3(f) is a top view of a fastener with eight prongs;

FIG. 4 schematically illustrates the fastener of FIG. 1 in use, with FIGS. 4a, 4b &4c schematically illustrating the progressive engagement of a pre-machined wood workpiece via deflection and crimping of an integral fixed point; and

FIG. 5 shows a screw fastener with three integral fixation prongs in accordance with other preferred embodiments, wherein (a) is a perspective view showing one type of serrated prong and (b) shows another type of serrated prong; and (c) is a top view of (b).

Description of the embodiments

It should be noted that in the following description, similar or identical reference numbers in different embodiments refer to the same or similar features.

Fig. 1, 3(a) and 3(b) show a fastener 10 according to a preferred embodiment of the present invention. The fastener includes a shank 12 having a first attachment means 14 for attachment to a first workpiece and a head 16 having a second attachment means 18 for attachment to a second workpiece. The fastener 10 is a screw and the first attachment means 14 comprises a threaded formation on the shank 12.

The head 16 includes a drive formation 22 in the form of a phillips head screwdriver recess in a central portion thereof.

The second attachment means 18 in the head 16 comprises an attachment member 24 integrally formed in the head, the attachment member 24 being three prongs 24 extending in a direction generally opposite to the handle 12. Prongs 24 are formed laterally of the drive structure 22, equally spaced around the peripheral portion 17 of the head 16.

Prong 24 includes a generally flat rectangular portion 26 and a tip 27 at an end 29 thereof. The prongs 24 are slightly flared relative to each other in their initial configuration.

Screw 10 further includes a shoulder 19 formed at the junction of head 16 and shank 12. The shoulder 19 comprises a diameter that is larger than the shank 12 and thus forms a stop surface 21 with the shank 12. In use, the handle 12 may be inserted into a first workpiece and stopped at the stop surface 21. Thus, the shoulder 19 acts as a depth measuring device since the head 16 is a uniform distance from the first workpiece for all fasteners 10.

Figure 4 schematically shows the fastener 10 in use. In this example, the fastener 10 is used to secure a plasterboard wall liner 42 to the frame upright 40 and also to secure a prefabricated wooden skirting 44 to the wall liner 42 to cover the gap 43 between the wall liner 42 and the floor 46.

The wall lining 42 has been coated with its final coating and secured to the frame stud 40 (wood, metal or masonry) via the threaded shank 12 until the stop surface 21 engages the frame stud 40. The head 16 engages the wall lining 42 with the prongs 24 extending outwardly. The wooden kick 44 is then forced into the second attachment means 18 as a prong 24.

Fig. 4a, 4b &4c schematically show the progressive engagement of the wooden kickers 44 via the fixing prongs 24, the prongs 24 splaying outwards away from each other and the ends 29 curling outwards when the kickplates 44 are pressed into the second attachment means 18. Fig. 4a shows the kick plate 44 beginning to engage the prong 24, with the integral fixed prong 24 in the ready position ready for engagement. Fig. 4b shows the skirting board 44 partially engaged with the integral fixed prong 24, which provides an initial bite and begins to deflect into the pre-finished wood. Fig. 4c shows the skirting board 44 fully engaged in the final position with the integral fixing prong 24 fully deflected and curled to lock into the pre-finished wood.

Only the rear surface 48 of the skirting 44 is engaged by the nibs 24 and the front prepared surface 49 is left unmarked. Thus, the fastener 10 provides a concealed securement of the skirting line 44 and requires no additional finishing.

The fastener 10 may behave in other ways and may include more or less different types of prongs 24 or attachment means 18.

Fig. 2 and 3(d) show a fastener 10b having four prongs 24. Fig. 3(e) shows fastener 10c with six prongs 24, while fig. 3(d) shows fastener 10d with eight prongs 24. In this embodiment, the prongs 24 are equally spaced around the periphery 17 of the head 16.

Fig. 5 shows additional embodiments of fasteners 10e and 10f that include serrated prongs 24 that extend parallel to the shank 12 and in a direction opposite the shank 12. Leading builder research has found that the use of building materials varies significantly in density, and therefore product development has been directed to serrated fixed prongs 24 (which are stronger and do not deflect) being developed.

Product testing has shown that the integral fixation prongs 24 of the fastener 10, which are designed to deflect and crimp into soft pine, are not able to pierce through dense MDF (medium density fiberboard) and therefore do not provide any bite or grip.

The serrated fixation prongs 24 of fasteners 10e and 10f are spike shaped to provide easier penetration through the dense MDF material. Product development has also been directed to variations of serrations on the prongs for maple/meranti (fig. 5(a)) and MDF (fig. 5 (b)).

The variation in fig. 5(b) more easily pierces the combination of 50% of the leading smooth spikes 25 and 50% of the serrations of the dense MDF and provides less resistance with less serrations, requiring less force to pierce the dense MDF material.

In other embodiments, the serrated prongs may also flare slightly outward, and may be adapted to curl outward similar to the above prongs.

In other embodiments, the fastener may be a nail or an anchor bolt, such as dyabaolt^TM。

Thus, the fastener of the preferred embodiment provides bi-directional blind securement via a threaded shank in one direction, and an integral securement prong in the opposite direction. The preferred fastener has an integral securing prong incorporated into the head of the screw designed to bite, deflect and crimp into the prepared wood. The preferred fastener has an integral fixing point which provides a deflecting and crimping action to lock the prepared wood toward the head of the screw. The integral fixing point can generate a clamping force larger than that generated by a single decorative nail (trimming nail) passing through the wood.

Preferred fasteners may include a variable number of integral fixation prongs at the head of the screw. The preferred fastener has a shoulder that provides a depth gauge to ensure that all of the integral fixing prongs project equidistantly beyond the surface of the plasterboard wall lining. The preferred fastener can accommodate any variation of the drive system within the head. The preferred fastener provides securement from the rear surface of the material and does not pierce the surface, allowing the use of pre-finished wood.

As an alternative to the current internal wood nails, the preferred fastener provides a concealed fixation. Concealed fixing has been achieved using a threaded shank to provide grip to the wall frame, and an integral fixing prong which provides a bite and puncture to pull the wood towards the crown, which provides a very secure connection. The fixed pointed object is an integral part of the head of the screw, so that the head of the screw has the appearance like a crown.

The preferred screws are driven into the wall frame using shoulders that provide a predetermined depth of support to ensure proper engagement of the crown. The wood is positioned for fastening using pressure applied to the surface of the wood, thereby engaging the fixed prongs that bite into the wood. When more pressure is applied and the wood is pressed deep, the fixing prongs deflect and curl into the wood providing strong locking strength.

The securing details are such that a fastener is secured to each stud frame via a threaded shank, wherein the shoulder of the fastener provides a bearing surface to ensure that all screw heads are secured at the same depth, thereby providing a consistent biting force for the wood kick. The fixed prongs in fixed position project forward of the surface of the plasterboard wall liner and have been designed to bite and deflect into the wood skirts, curling and tightening together the prefabricated wood cylinder plasterboard wall liner. The result is that the skirting board remains a tight fit along the entire length of the wall, thus minimizing (or eliminating) the need for gap fillers.

The fastener has the potential to change the current construction method of nailing through the surface of the timber and allows the highest quality finish to be provided without compromising construction costs or construction time.

While preferred embodiments of the invention have been described, it will be apparent to the skilled person that modifications may be made to the described embodiments.

Claims (7)

1. A fastener, comprising:

a handle having a first attachment device for attachment to a first workpiece; and

a head having a second attachment device for attachment to a second workpiece;

a shoulder formed at the junction of the head and the shank, wherein the shoulder is cylindrical and comprises a diameter greater than the shank to form a stop surface with the shank;

wherein the stop surface is spaced apart from the head;

wherein the stop surface engages the first workpiece in use, thereby causing the shoulder to act as a depth measuring device for indicating the distance of the head from the first workpiece in use;

and wherein the head is wider than the shoulder.

2. The fastener of claim 1, wherein the fastener is a screw and the first attachment means comprises a threaded structure on the shank.

3. The fastener of claim 2, wherein the second attachment means comprises at least one attachment member formed in the head, the at least one attachment member extending in a direction generally opposite the shank.

4. The fastener of claim 3, wherein the head includes a driving feature at a central portion thereof, and the at least one attachment member is formed laterally of the driving feature.

5. The fastener of claim 4, wherein the at least one attachment member comprises a plurality of attachment members substantially equally spaced around a peripheral portion of the head.

6. The fastener of claim 5, wherein the plurality of attachment members comprise prongs that flare slightly outward relative to one another.

7. The fastener of claim 6, wherein each prong is adapted to substantially crimp and/or deflect into the second workpiece as the second workpiece is compressed to the second attachment means.