AU2013200949B2 - Fastener - Google Patents

Abstract

Abstract A fastener (10) comprising a shank (12) having a first attachment means (14) for attachment to a first workpiece (40) and a head (16) having a second attachment means (18) for attachment to a second workpiece (44). In one embodiment, the fastener (10) is a screw and the first attachment means (14) comprises a thread formation on the shank (12). Preferably, the second attachment means (18) comprises a plurality of prongs (24) formed in the head (16) extending in a generally opposite direction to the shank. 1(a) 1(b Figure 1(c)

Description

FASTENER

Field of the Invention [1] The present invention relates to a fastener and in particular to a fastener for wood products, and the like.

[2] The invention has been developed primarily for the carpentry and building industries and will be described hereinafter with reference to this application.

However, it will be appreciated thit the invention is not limited to this particular field of use.

Background of the Invention [3] Fasteners such as screws, nails and anchor bolts have been manufactured with a variety of heads and drive designs, each requiring a different kind of tool to drive or extract them. All fasteners employ the same general fixing principle, with the shank, which may be threaded or serrated, providing gripping and the head providing a bearing surface and means to drive the screw.

[4] One difficulty with such fasteners is the head by design is left exposed. In building applications, this leads to additional finishing work for the builder to finish the workpiece around the head.

[5] There is thus a need for a fastener which provides concealed fixing, in that the workpiece can be fixed in place as desired with the fastener concealed. This will allow builders to use pre-finished workpieces with further finishing work not being required.

[6] The inventor performed a comprehensive search of the market place and published patent publications and did not find a product which satisfies the inventor’s requirements.

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

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

Summary of the Invention [9] According to a first aspect, the present invention provides a fastener comprising: a shank having a first attachment means for attachment to a first workpiece; and a head having a second attachment means for attachment to a second workpiece [10] Preferably, the fastener is a screw and the first means comprises a thread formation on the shank.

[11] Alternatively, the fastener is a nail.

[12] Alternatively, the fastener is an anchor bolt.

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

[14] Preferably, each of the at least one attachment member is a prong.

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

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

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

[18] Preferably, the fastener comprises 3 or more attachment members.

[19] Preferably, the plurality of attachment members comprises prongs which are slightly splayed relative to each other.

[20] Preferably, each prong has an end portion with a point, wherein the prong is adapted to embed into the second workpiece when the second workpiece is forced against the second attachment means.

[21] Preferably, each end portion adapted to substantially curl and/or skew into the second workpiece as the second workpiece is forced against the second attachment means.

[22] Preferably, the plurality of attachment members comprises prongs having serrations formed thereon.

[23] Preferably, the prongs extend parallel to in a direction opposite to the shank.

[24] Preferably, the prongs are integrally formed with the head.

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

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

[27] Other aspects of the invention are also disclosed.

Brief Description of the Drawings [28] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings in which: [29] Fig. 1 shows a screw fastener in accordance with a preferred embodiment of the present invention with three integral fixing prongs, where (a) is a perspective view showing the prongs slightly splayed in their initial configuration, (b) is a perspective view showing the screw with the three prongs being in a curled and outwardly skewed configuration when embedded into a workpiece; and (c) is a top view of (a); [30] Fig. 2 shows a screw fastener in accordance with another preferred embodiment of the present invention with four integral fixing prongs, where (a) is a perspective view showing the prongs slightly splayed in their initial configuration, (b) is a perspective view showing the screw with the four prongs being in a curled and outwardly skewed configuration when embedded into a workpiece; and (c) is a top view of (a); [31] Fig. 3(a) is a schematic cross-section view of the figure 1(a); Fig. 3(b) is a schematic cross-section view of the figure 1(b); Fig. 3(c) is a top view of the fastener with three prongs; Fig. 3(d) is a top view of the fastener with four prongs; Fig. 3(e) is a top view of a fastener with six prongs; Fig. 3(f) is a top view of a fastener with eight prongs; [32] Fig. 4 schematically shows the fastener of Figure 1 in use, with Figs. 4a, 4b & 4c. schematically showing the progressive engagement of a pre-finished timber workpiece via the skewing and curling of the integral fixing prongs; and [33] Fig. 5 shows screw fasteners in accordance with other preferred embodiments with three integral fixing prongs, where (a) is a perspective view showing one type of serrated prongs, (b) shows a screw with another type of serrated prongs; and (c) is a top view of (b).

Description of Embodiments [34] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[35] Figures 1, 3(a) and 3(b) show a fastener 10 in accordance with a preferred embodiment of the present invention. The fastener comprises a shank 12 having a first attachment means 14 for attachment to a first workpiece and a head 16 having a second attachment means 18 for attachment to a second workpiece. The fastener 10 is a screw and the first attachment means 14 comprises a thread formation on the shank 12.

[36] The head 16 comprises a drive formation 22 at a central portion thereof, in the form of a Phillips head screwdriver recess.

[37] The second attachment means 18 in the head 16 comprises attachment members 24 integrally formed in the head, being three prongs 24 which extend in a generally opposite direction to the shank 12. The prongs 24 are formed laterally of the drive formation 22, being equidistantly spaced around the peripheral portion 17 of the head 16.

[38] The prongs 24 include a generally flattened rectangular portion 26 and a pointed end 27 at the end portion 29 thereof. The prongs 24 are slightly splayed relative to each other in their initial configuration.

[39] The screw 10 also comprises a shoulder 19 formed at the junction of the head 16 and the shank 12. The shoulder 19 comprises a diameter larger than the shank 12 and thus forms a stop surface 21 with the shank 12. In use, the shank 12 can be inserted into a first workpiece and will stop at the stop surface 21. Thus, the shoulder 19 acts a depth measuring means in that the distance of the head 16 from the first workpiece for all of the fasteners 10 will be consistent.

[40] Fig. 4 schematically shows the fastener 10 in use. In this example, the fastener 10 is used for fixing a plasterboard wall lining 42 to a frame stud 40, and also for fixing a pre-finished timber skirting 44 to the wall lining 42 to cover the gap 43 between the wall lining 42 and the flooring 46.

[41] The wall lining 42 has already been painted its final coat and is fixed to the frame stud 40 (timber, metal or masonry) via the threaded shank 12, up until the stop surface 21 engages the frame stud 40. The head 16 engages the wall lining 42 with the prongs 24 extending outwardly. The timber skirting 44 is then forced into the second attachment means 18, being the prongs 24.

[42] Figures 4a, 4b & 4c schematically show the progressive engagement of the timber skirting 44 via the fixing prongs 24, which skew away from each other and the end portions 29 curl outwardly as the skirting 44 is forced into the second attachment means 18. Figure 4a shows the skirting 44 initially engaging addressing the prongs 24, with the integral fixing prongs 24 in the set position ready for engagement. Figure 4b, shows the skirting 44 partly engaged with the integral fixing prongs 24 providing initial bite and commencing the skewing into the pre-finished timber. Figure 4c shows the skirting 44 fully engaged in the final position, with the integral fixing prongs 24 completely skewed and curled to lock into the pre-finished timber.

[43] Only the back surface 48 of the skirting 44 is engaged by the prongs 24 and the front pre-finished surface 49 is left unmarked. Thus, the fastener 10 provides concealed fixing of the skirting 44 and no further finishing is needed.

[44] The fastener 10 can be embodied in other forms and can include less or more for different types of prongs 24 or attachment means 18.

[45] Figure 2 and 3 (d) show a fastener 10b with four prongs 24. Figure 3 (e) shows a fastener 10c with six prongs 24, and Figure 3 (d) shows a fastener 10d with eight prongs 24. In the embodiment, the prongs 24 are equidistantly spaced around the periphery 17 of the head 16.

[46] Figure 5 shows further embodiments 10e and 10f off the fastener comprising serrated prongs 24 which extend parallel and in a direction opposite to the shank 12. Research of the leading builders found the use of building materials which varies significantly in density, and as such product development has lead to serrated fixing prongs 24 (which are stronger and do not skew) being developed.

[47] Product testing shows that the integrated fixing prongs 24 of the fastner 10 (which gave been designed to skew and curl into the soft pine timber) cannot penetrate the dense MDF (Medium Density Fibreboard), and therefore did not provide any bite nor grip.

[48] The serrated fixing prongs 24 of the fasteners 10e and 10f are pin shaped to provide easier penetration of the dense MDF material. Product development has also lead to variations of the serrations on the prongs for maple/meranti timber (figure 5(a)) and MDF (figure 5(b)).

[49] The variation in figure 5(b) is the incorporation of 50% leading smooth pin 25 that penetrates easier into the dense MDF and 50% serrations, and with fewer serrations, provides less resistance requiring less force for penetration into the dense MDF material.

[50] In other embodiments, the fastener can be a nail or an anchor bolt such as a dynabolt.

[51] The fastener thus provides for provides for two-directional concealed fixing via a threaded shank in one direction, and integrated fixing prongs in the opposite direction. The fastener has integrated fixing prongs incorporated on the screw head that are designed to bite, skew and curl into pre-finished timber. The fastener has the integrated fixing prongs that provide a skewing and curling action locking the pre-fimshed timber towards the screw head. The integrated fixing prongs can generate a gripping a force greater than that of single trimming nails through the timber.

The fastener can comprise a varying number of integrated fixing prongs in the screw head. The fastener has a shoulder that provides a depth gauge to ensure all integrated fixing prongs protrude past the face of the plasterboard wall lining equidistantly. The fastener can accommodate any variation of drive system within the head. The fastener provides fixing from the back face of the material, and without penetrating the surface, allows for pre-finished timber to be used.

[52] The fastener provides concealed fixing as an alternative to the current nailing of internal timbers. This has been achieved with the threaded shank (5) providing gripping to the wall frame, and the integral fixing prongs (2) providing bite and penetration to pull the timber towards the crown, which provides for a very strong connection. The fixing prongs are an integral part of the screw head giving the screw head a crown like appearance.

[53] The screw is driven to the wall frame with the shoulder providing the predetermined bearing depth, ensuring correct engagement of the crown. The timber is positioned for fastening, with pressure being applied to the face of the timber, engaging the fixing prongs which bite into the timber. As more pressure is applied and the timber is forced home, the fixing prongs skew and curl into the timber which provides a powerful locking strength.

[54] The fixing detail is such that the fasteners are secured to each stud frame via the threaded shank, with the shoulder of the fastener providing the bearing surface to ensure all screw heads are set at the same depth, thus providing consistent bite force to the timber skirting. The fixing prongs in the set position, protrude forward of the face of the Plasterboard Wall Lining, and have been designed to bite and skew into the timber Skirting, curling and pulling the pre-finished timber tight with the Plasterboard Wall Lining. The result is that the skirting remains a tight fit along the entire length of wall, thus minimising (or eliminating) the need for gap filler.

[55] The fastener has the potential to change the current construction method of nailing through the timber surface, and allows the opportunity to provide the highest quality of finishes, all without compromising the construction costs nor the build time.

[56] Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that modifications can be made to the embodiments described.

Interpretation

Embodiments: [57] Reference throughout this specification to “one embodiment” or "an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[58] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[59] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

Different Instances of Objects [60] As used herein, unless otherwise specified the use of the ordinal adjectives first, second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details [61] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology [62] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "forward", "rearward", "radially", "peripherally", "upwardly", "downwardly", and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

Comprising and Including [63] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise" or variations such as “comprises" or "comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[64] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention [65] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[66] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Industrial Applicability [67] It is apparent from the above, that the arrangements described are applicable to the building industries.

Claims (7)

1. A fastener comprising: a shank having a first attachment means for attachment to a first workpiece; and a head having a second attachment means 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 larger than the shank to form a stop surface with the shank; wherein the stop surface is spaced from the head; wherein the stop surface engages the first workpiece in use and acts as a depth measuring means 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 means comprises a thread formation 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 generally opposite direction to the shank.

4. The fastener of claim 3 wherein the head comprises a drive formation at a central portion thereof and the at least one attachment member is formed laterally of the drive formation.

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

6. The fastener of claim 5 wherein the plurality of attachment members comprises prongs which are slightly splayed relative to each other.

7. The fastener of claim 6 wherein each prong is adapted to substantially curl and/or skew into the second workpiece as the second workpiece is forced against the second attachment means.