THREADED EXTENSION NUT

Description

TECHNICAL FIELD

The present invention relates generally to a thread nut extension system, and more specifically to a threaded extension nut that enables the attachment of a locking nut and washer onto a threaded anchor bolt, thereby securing construction lumber to a concrete foundation. The present invention is particularly applicable in situations where the anchor bolt is of insufficient length to accommodate a standard nut.

BACKGROUND INFORMATION

Connecting concrete foundations and mudsills using anchor bolts involves a precise and sturdy process crucial for ensuring the structural integrity of a building. The process begins during the pouring of the concrete foundation. Anchor bolts, which are L-shaped with threads on one end, are strategically placed onto wooden forms, then wet concrete is poured in. These bolts are positioned vertically, with their threaded ends extending above the surface of the foundation to allow for attachment to the mudsills later. The placement and spacing of the anchor bolts are critical and must adhere to building codes and engineering specifications to ensure adequate support and stability. Once the concrete has cured and hardened, the mudsill, typically a pressure-treated piece of lumber, is positioned over the bolts. Holes are pre-drilled in the mudsill at locations corresponding to the anchor bolts to ensure a precise fit. The mudsill is then lowered onto the bolts, and washers and nuts are tightened onto the threaded ends of the bolts, securing the mudsill firmly to the concrete foundation. This connection method ensures that the building's superstructure is anchored securely to its foundation, providing resistance to lateral forces such as wind and seismic activity. Proper installation of anchor bolts and mudsills is essential for the overall safety and durability of the building.

SUMMARY

In a first novel aspect, an apparatus for engaging a threading of an anchor bolt for a cement-to-lumber connection, includes: a shaft member with a first end and a second end; and a head, wherein the first end of the shaft member is connected to the head, wherein the second end of the shaft member is configured to connect to a threaded bolt. The second end of the shaft member includes: an internal threading on an internal surface of the shaft member; an external chamfer; and an internal chamfer.

In a second novel aspect, the shaft member also includes an external threading on the outer surface of the shaft member.

In a third novel aspect, the internal threading extends fully through the shaft member.

In a fourth novel aspect, the internal threading extends at least halfway through the shaft member.

In a fifth novel aspect, the internal threading extends partially through the shaft member.

Further details and embodiments and techniques are described in the detailed description below. This summary does not purport to define the invention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, where like numerals indicate like components, illustrate embodiments of the invention.

FIG. 1 is a diagram illustrating the prior art usage of a standard nut to connect a mudsill to a concrete foundation.

FIG. 2 is a perspective view diagram illustrating a new double threaded extension nut.

FIG. 3 is a side view diagram illustrating a new double threaded extension nut.

FIG. 4 is a perspective view diagram illustrating a new double threaded extension nut.

FIG. 5 is a top-down view diagram illustrating a new double threaded extension nut.

FIG. 6 is a perspective view diagram illustrating a new double threaded extension nut.

FIG. 7 is a cutaway view diagram illustrating a new double threaded extension nut.

FIG. 8 is a cutaway view diagram illustrating a new double threaded extension nut attached to bolt passing through a mudsill.

FIG. 9 is a cutaway view diagram illustrating two uses of a new double threaded extension nut.

FIG. 10 is a flowchart diagram illustrating the operation of a new double threaded extension nut.

FIG. 11 is a cutaway view diagram illustrating a new single threaded extension nut.

FIG. 12 is a cutaway view diagram illustrating the improved functionality of a new double threaded extension nut over the prior art.

DETAILED DESCRIPTION

Reference will now be made in detail to background examples and some embodiments of the invention, examples of which are illustrated in the accompanying drawings. In the description and claims below, relational terms such as “top”, “down”, “upper”, “lower”, “top”, “bottom”, “left” and “right” may be used to describe relative orientations between different parts of a structure being described, and it is to be understood that the overall structure being described can actually be oriented in any way in three-dimensional space.

Achor bolts have several specially designed shapes such as “J”, “L” and “S”, and come is several commons sizes ranging from ⅜″ to 1″ in diameter with an overall length of 10 inches long, which when encased in cured cement retaining walls, offer a mechanical locking method to attach building material to cement for resistance to tension and shear loads in residential and commercial buildings. Hex nuts are used to secure down construction lumber onto the anchor bolts providing lumber to be securely fastened to a cement foundation establishing a strong transition in the construction of residential and commercial buildings. The function of installing washers in between the nuts and material surface is to increase the bearing area to distribute the clamping pressure so as to prevent collapse of the hole perimeter around the smaller nut.

During the construction process, there are several trades completing multiple steps each following the work of the previous trade. The cement trade step of pouring liquid into the forms for the cement retaining wall is completed before the framing up of lumber to walls. When the liquid cement is poured into the forms, the worker needs to use a large vibrator placed within the wet cement to ensure that all of the crevices are filled in and there are no air pockets weakening the cement wall. This often creates problems of the anchor bolts sinking into a lower position than optimal placement height of the building code required 7 inches minimum below the cement surface and 3 inch above before it cures to a hardened cement with insufficient bolt threads exposed above the cement line. This sinking of the anchor bolt into the wet cement can happen upwards of 20-30% of the total 100-300+ anchor bolts being installed at a construction project. The anchor bolt threads are required to pass up through a clearance hole in the base lumber, through the 3″×3″ washer, and lastly though the nut with a minimum of 3 threads showing to comply with applicable building code and pass the building inspector's visual inspection. In these instances, a worker must use a hand tool to gouge out the lumber material in the shape of the 3″×3″ washer deep enough to allow the washer and nut to recess into the lumber exposing enough threads for the washer and nut to pass though. The gouging of the lumber material by weakening that specific section and compromises the structural integrity of the foundation lumber and walls at the most critical point of transition from base cement to lumber in the event of a seismic movement or strong upward wind draft causing building uplift. If this material gouging were to be necessary on several consecutive anchor bolts, that entire building section, second and third floor being supported, or corner section could be severely compromised. In addition, this process of material gouging is completed by a worker using any available tools to complete this task putting his safety at risk from self-injury. It can take a worker on average 10-20 minutes to gouge out a single hole causing the framing contractor a loss of critical production labor time and excess expenses of paying workers to complete these tasks.

Furthermore, lumber shrinkage occurs when the moisture content is reduced over time due to natural drying process, influenced by three variable, installed moisture content, equilibrium moisture content, and cumulative thickness of cross-grain wood elements. Shrinkage in light-frame wood construction can occur in the range of 0.05″ to 0.50″ per floor level. This lumber shrinkage effects the anchor bolts by lowering the foundation lumber height causing the nut and washer to now settle at a height above the lumber surface creating a gap up to 0.50″ further reducing the structural integrity of the cement foundation to lumber framing. During the installation of the tightening nut, a worker typically uses an impact gun to ensure enough tension is placed on the nut to secure the lumber to the cement foundation.

While the installation of the washer and nut is effective when the anchor bolt is in the correct placement above the cured cement, there is currently no casy method of installing the washer and nut on the shorter bolts other than gouging out the lumber material. The cement already has the anchor bolts placed within the cured cement wall which cannot be adjusted by the time the framing trade is ready to start their work of installing the lumber foundation. Because the gouging of the lumber cannot be avoided in order to install the required washer and nut, compromising of the structural integrity may cause a substantial problem. This practice is frowned upon by building inspectors, and the inspection can be “failed” if decided to be excessive.

Over time, the contraction of a mudsill can lead to a variety of structural problems that may compromise the stability and safety of a building. Mudsills, typically made from pressure-treated wood, are prone to shrinkage as they dry out and lose moisture. This contraction can cause the mudsill to pull away from the anchor bolts, creating gaps between the mudsill and the concrete foundation. These gaps reduce the effectiveness of the anchor bolts, diminishing the structural integrity and the building's ability to withstand lateral forces such as wind and earthquakes. Additionally, the separation can allow moisture and pests to infiltrate the gap, leading to potential wood rot, mold growth, and pest infestations, which further weaken the structure. As the mudsill contracts and moves, it can also cause misalignment and stresses on the framing above, potentially leading to warping or cracking in walls and floors. This movement can create creaking floors, sticking doors and windows, and visible gaps or cracks in the walls, all of which are signs of compromised structural integrity. Furthermore, the contraction of the mudsill can disrupt the building's load path, which is essential for safely transferring loads from the roof and upper floors down to the foundation. If not addressed, these issues can escalate, requiring costly repairs and even jeopardizing the overall safety of the building. Regular inspection and maintenance, including tightening of anchor bolts and ensuring proper moisture control, are essential to mitigate these problems and maintain the building's structural health.

Addressing the problem of mudsill contraction involves a combination of preventative measures, regular maintenance, and corrective actions to ensure the structural integrity of the building. Prevention starts with selecting high-quality, pressure-treated lumber for the mudsill, as this type of wood is more resistant to moisture and less likely to shrink significantly over time. Proper storage and handling of the lumber before installation are also crucial, keeping it dry and well-ventilated to minimize moisture absorption. During construction, the mudsill should be pre-drilled with precision to ensure a snug fit over the anchor bolts, and high-quality washers and nuts should be used to secure it firmly. Applying a construction adhesive between the mudsill and the concrete foundation can also enhance the bond and reduce the potential for gaps forming due to contraction.

Regular maintenance is essential to monitor the condition of the mudsill and the tightness of the anchor bolts. Periodic inspections should check for signs of gaps, wood rot, pest infestations, and moisture accumulation. If gaps are found, the nuts on the anchor bolts should be tightened to re-establish a secure connection. In cases where the contraction has caused significant separation or damage, shims can be inserted between the mudsill and the foundation to fill gaps and restore stability. For more severe cases, sections of the mudsill may need to be replaced entirely.

Moisture control is another critical aspect of addressing mudsill contraction. Ensuring proper drainage around the foundation, installing vapor barriers, and maintaining adequate ventilation in crawl spaces or basements can significantly reduce the amount of moisture the mudsill is exposed to, thereby minimizing shrinkage. Additionally, using moisture-resistant coatings or sealants on the mudsill can provide an extra layer of protection against environmental elements. By combining these preventative and corrective measures, the risks associated with mudsill contraction can be effectively managed, helping to maintain the long-term stability and safety of the building.

Embodiments of the disclosed apparatus are configured, on one end, a hex nut head, to allow the positive rotation to lock down onto anchor bolt. The flange under the hex nut provides more surface area for the nut to engage with the washer. The long nut body being round in shape below the flange, allows the nut to engage onto the bolt threads in a much lower position below the lumber and washer surface plain and spin freely within the lumber clearance hole. The core of the apparatus having an internal female thread from one end thought to the other end to engage the threaded anchor bolt to any depth required. The shaft end having a beveled inner radius helps to center the nut onto the anchor bolt for easier start to the tightening process. The outer bevel edge helps the apparatus to self-position into the lumber clearance hole and will compress and push through the lumber material in the event of any mis-drilled clearance holes. The washer may be welded directly onto the apparatus to allow easier and faster installation and a more secure locking mechanism and may have secondary holes for additional support screws to pull downward on the washer during lumber shrinkage ensuring a constant downward force is applied.

FIG. 1 is a diagram illustrating the prior art usage of a standard nut to connect a mudsill to a concrete foundation.

FIGS. 2-7 illustrate various views of a new double threaded extension nut. One embodiment of the present invention, as illustrated in FIGS. 2-7, relates to a threaded extension nut designed for engaging the threading of an anchor bolt, facilitating a secure cement-to-lumber connection. This apparatus comprises a shaft member and a head 10, each with distinct functional features. The shaft member has a first end and a second end. The first end is integrally connected to the head, providing a robust interface for handling and installation. The first end may also include a flange 11 to provide additional tightening friction between the threaded extension nut and the top surface of the washer over the mudsill (wood). The second end of the shaft member is specifically configured to connect to a threaded bolt, ensuring a firm and reliable attachment. The shaft member features internal threading 12 along its internal surface, allowing it to securely engage with the threads of an anchor bolt, and exterior threading 13 along its exterior surface, allowing secure engagement with the surrounding mudsill (wood). Additionally, the shaft member is equipped with an exterior chamfer 14 and an interior chamfer 15. The interior chamfer aids in guiding the shaft member onto the anchor bolt, facilitating easier alignment and installation, while the exterior chamfer helps in smoothly transitioning the connection and reducing stress concentrations at the mudsill. This combination of features ensures that the apparatus can effectively and securely engage with an anchor bolt, providing a stable and durable connection between cement and lumber in various construction applications.

Construction nuts can be made from a variety of materials, cach offering distinct benefits depending on the application and environmental conditions. Steel, particularly carbon steel, is one of the most common materials used for construction nuts due to its high tensile strength and durability, making it suitable for heavy-duty applications. Carbon steel nuts can also be heat-treated to enhance their strength and hardness, and completed in a variety of finishes such as zinc plating for corrosion resistance. Stainless steel is another popular choice, known for its corrosion resistance, making it ideal for use in environments exposed to moisture or chemicals. This material also offers good mechanical properties and an aesthetically pleasing finish. Brass nuts, though not as strong as steel, provide excellent corrosion resistance and are often used in plumbing applications and electrical components due to their non-sparking properties and conductivity. Aluminum nuts are lightweight and resistant to corrosion, making them suitable for applications where weight reduction is crucial, such as in aerospace and automotive industries. Titanium nuts, although more expensive, offer an exceptional combination of strength, light weight, and corrosion resistance, making them ideal for high-performance and critical applications. Lastly, plastic nuts, made from materials such as nylon, are used in applications where electrical insulation, resistance to chemicals, and reduced weight are important. They are commonly found in electronic assemblies and light-duty applications. Each of these materials offers unique advantages, allowing for the selection of the most appropriate type of construction nut based on the specific requirements of the project.

FIG. 8 is a cutaway view diagram illustrating a new double threaded extension nut attached to bolt 25 passing through a mudsill. In the figure, the bolt extruding through the mudsill only protrudes to the height of the top surface of the washing. Therefore, a conventional nut would not be able to connect at all to the protruding bolt. However, the new double threaded extension nut includes a shaft member that actually extends downward into the mudsill thereby providing additional surface area that is able to engage with the bolt. To aid the bolt engagement, the shaft member includes an interior threading on the interior surface of the shaft member. This interior threading mates with the bolt threading to create a strong connection. Moreover, the shaft member includes an exterior threading 23 that is configured to engage with the mudsill (wood) and create a strong and lasting connection between the extension nut and the mudsill. This new ability to create a strong and secure bond between the extension nut and the bolt without altering the mudsill is a great improvement to the current state of the art. As will be described in more detail below, altering the mudsill so to expose more of the bolt so that a traditional bolt can engage the bolt, requires additional labor and reduces the structural integrity of the mudsill and the lumber supported thereon.

FIG. 9 is a cutaway view diagram illustrating two uses of a new double threaded extension nut. The example on the left side of the figure is a similar situation as described in FIG. 8 above. The example on the right side of the figure illustrates that the new extension nut can still be used when the bolt 41 protrudes as intended. This feature is very important and practical, in that construction workers do not want to carry a variety of nuts to complete a job. With this design, a single new extension nut can be used for the entire project.

FIG. 10 is a flowchart diagram illustrating the operation of a new double threaded extension nut. In step 50, an extension nut is inserted into the mudsill (wood) opening. In step 51, the interior threading of the extension nut engages a bolt connected to a concrete foundation. In step 52, the head of the extension nut is rotated thereby causing the extension nut to mate with the bolt and causing the exterior threading to mate with the mudsill (wood). In step 53, the head of the extension nut is rotated until the nut is securely fastened to the mudsill (wood). In step 54, the amount of interior threading mating with the bolt threading is measured. When it is determined that the amount of the extension nut interior threading that is mating with the bolt threading is above a threshold value, the connection passes inspection.

FIG. 11 is a cutaway view diagram illustrating a new single threaded extension nut. The previous figures illustrate an embodiment where the extension nut includes both interior and exterior threading. However, the Applicant expressly discloses a second embodiment wherein the extension nut only includes a single interior threading. The single threaded extension nut includes an extension nut head 60, a flange 61, an interior threading 62, an exterior chamfer 63, and an interior chamfer 64.

The interior threading function similarly to mate with the bolt threading. However, the exterior surface of the shaft member is smooth and is configured to slide into the space between the extension nut and the mudsill (wood).

FIG. 12 is a cutaway view diagram illustrating the improved functionality of a new double threaded extension nut over the prior art. As discussed above, use of a prior art nut requires that a section of the mudsill (wood) be removed so to expose additional bolt threading (see left side of FIG. 12). This result has multiple negative aspects. First, additional labor is required to remove the section of mudsill before installing the nut. Second, the mudsill integrity is diminished due to the removal. This workaround also is undesirable due to the high probability that it will not pass building code and fail inspection, thereby causing further costs and delays.

The example of the new extension nut solution on the right hand side of FIG. 12 illustrates the benefit of the present invention. In this example, the mudsill remains totally intact, and the extension nut member shaft extends down into the mudsill to properly engage with the bolt 78. This solution provides a needed solution to pass building code and building inspections, thereby causing reduced costs and delays.

Although certain specific embodiments are described above for instructional purposes, the teachings of this patent document have general applicability and are not limited to the specific embodiments described above. Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the claims.