FASTENING DEVICE AND METHODS OF MAKING AND USING THE SAME

Description

FIELD OF THE INVENTION

The presently disclosed subject matter is generally directed to a fastening device for securing interior and exterior band boards together during construction of a deck. The presently disclosed subject matter also includes methods of making and using the fastening device.

BACKGROUND OF THE INVENTION

Outdoor decks have become increasingly popular in residential home construction. Homes, apartments, and a variety of other buildings often incorporate exterior decks into their design. Additionally, decks are commonly added onto existing structures. Advantageously, decks provide convenient space for a variety of outdoor activities, including cookouts, dining, sunbathing, and other leisure activities. Exterior decks typically include a series of joists supported by a frame. The joists are aligned parallel to one another. Decking boards are connected to the joists and spaced adjacent to one another. Often, a gap is left between the decking boards to allow space for expansion and contraction of the decking boards without damaging the system.

However, the house band board (e.g., interior band board) often does not provide adequate support for attaching the deck band board (e.g., exterior band board). As a result, the two band boards can peel away from one another causing deck instability or a potential collapse. Connecting interior and exterior band boards is conventionally accomplished through the use of lag bolts or carriage bolts. Specifically, lag bolts are installed by drilling through the post and into the band board and then screwing the lag into the band board. The threads of the lag bolts are intended to grip the timber fibers of the band board. Ideally, the holes in the post and in the band board are constructed using different drill bits (e.g., one sized to allow the lag to pass through the post, and one sized to allow the threads to grip the band board). Although the connection has a large capacity to resist vertical loads, the ability to resist lateral and rotational loads applied to the post is limited. Specifically, the limitation is due to the low capacity of lag bolts in tension due to pullout of the bolts through the timber band board.

Carriage bolts are installed in a similar fashion. Holes are drilled in the same location as with lag bolts, but the holes are sized to allow the carriage bolt to pass through both the post and the band board. The connection is achieved by the installation of a washer and retaining nut on the carriage bolt. When tightened, the assembly provides a through-bolted connection between the post and the band board of the deck. As with the lag bolt, the connection resists vertical loads well, but its ability to resist lateral and rotational loads applied to the post is limited. Band boards are virtually always affixed to the deck with 16-penny nails installed in the end grain of the deck joists. However, the method possesses a surprisingly low resistance in tension, allowing pullout with relatively little force.

Further, when the deck needs replacing, typical lag bolts or carriage bolt connected band boards must be replaced. However, to access the fasteners, the interior of the house or structure ceiling that conceals the bolt fasteners must be removed. As a result, significant demolition and repair must be undertaken to repair or replace the decking.

It would therefore be beneficial to provide an improved fastening system that can be used to attach interior and exterior band board together.

SUMMARY OF THE INVENTION

The presently disclosed subject matter is directed to an interior and exterior band board fastener. Particularly, the fastener is defined by a plate comprising a first side and an opposed second side, with a thickness therebetween and a central opening that spans the thickness. The plate also includes one or more screw holes that pass through the thickness of the plate. The fastener includes a securing element comprising a head and an elongated arm, wherein the head is positioned adjacent to the first side of the plate and the arm is positioned through the opening and adjacent to the second side of the plate. The plate is permanently attached to the arm at the second side of the plate. The fastener includes a nut configured to travel about a length of the elongated arm and a plurality of screws.

In some embodiments, the elongated arm includes a first end positioned adjacent to the head and an opposed second end, wherein the second end includes a plurality of external screw threads.

In some embodiments, the nut includes a plurality of internal screw thread that cooperate with the external screw threads.

In some embodiments, the fastener comprises 4 screws and 4 screw holes.

In some embodiments, the plate is welded to the arm at the second side of the plate.

In some embodiments, the thickness of the plate is about 0.1-0.5 inches.

In some embodiments, the plate comprises a length and width of about 1.5-5 inches.

In some embodiments, the plate opening has a diameter configured such that head cannot pass therethrough, but the arm can pass therethrough.

In some embodiments, the arm has a length of about 4-8 inches.

In some embodiments, the presently disclosed subject matter is directed to a method of attaching an interior band board to an exterior band board using a fastener. Particularly, the method comprises positioning the arm of the disclosed fastener of through an aperture extending through the aligned interior and exterior band boards, wherein the head and plate are exterior to the aperture and flush with an exterior face of the interior band board. The method includes positioning the nut over the second end of the arm until the nut is flush with an exterior face of the exterior band board. The method includes inserting a plurality of screws into the interior band board, partially overlapping the plate to secure the fastener in position, whereby the interior band board is attached to the exterior band board.

In some embodiments, the interior and exterior band boards are part of decking.

In some embodiments, the presently disclosed subject matter is directed to a decking system. The decking system includes a frame comprising an interior band board positioned adjacent to a house or other structure and at least one exterior band board positioned about an exterior of the frame. The system includes at least one joint secured to the frame. The system includes at least one decking board defined by a top side and a bottom side, wherein the decking board is secured to the at least one joist. The system includes one or more of the disclosed fasteners, wherein each fastener is configured to secure the interior band board to at least one exterior band board.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a is a top plan view of a portion of decking that includes interior and exterior band boards in accordance with some embodiments of the presently disclosed subject matter.

FIG. 1b is a side plan view of decking that illustrates an interior band board in accordance with some embodiments of the presently disclosed subject matter.

FIG. 2a is a side plan view of a fastener comprising a plate and securing element defined by a head and extending arm in accordance with some embodiments of the presently disclosed subject matter.

FIG. 2b is a cross sectional view of the fastener of FIG. 2a.

FIG. 2c is a perspective view of a fastener in accordance with some embodiments of the presently disclosed subject matter.

FIG. 3a is a top plan view of a fastener plate in accordance with some embodiments of the presently disclosed subject matter.

FIG. 3b is a side plan view of a fastener plate in accordance with some embodiments of the presently disclosed subject matter.

FIG. 4a is a side plan view of a fastening system securing element in accordance with some embodiments of the presently disclosed subject matter.

FIG. 4b is a perspective view of a securing element and associated nut in accordance with some embodiments of the presently disclosed subject matter.

FIG. 5a is a cross-sectional view illustrating one embodiment of using the disclosed fastening system to attach interior and exterior band boards in accordance with some embodiments of the presently disclosed subject matter.

FIG. 5b is a cross-sectional view illustrating the insertion of a fastening system into an aperture of interior and exterior aligned band boards in accordance with some embodiments of the presently disclosed subject matter.

FIG. 5c is a cross-sectional view of an inserted fastener positioned in an aperture of aligned interior and exterior band boards in accordance with some embodiments of the presently disclosed subject matter.

FIG. 5d is a cross-sectional view of an inserted fastener comprising an attached nut positioned to span aligned interior and exterior band boards in accordance with some embodiments of the presently disclosed subject matter.

FIG. 6a illustrates the attachment of the fastening system in accordance with some embodiments of the presently disclosed subject matter.

FIG. 6b is a side cross-sectional view of the attachment of the fastening system in accordance with some embodiments of the presently disclosed subject matter.

DETAILED DESCRIPTION OF THE INVENTION

For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to preferred embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alteration and further modifications of the disclosure as illustrated herein, being contemplated as would normally occur to one skilled in the art to which the disclosure relates.

Articles “a” and “an” are used herein to refer to one or to more than one (i.e., at least one) of the grammatical object of the article. By way of example, “an element” means at least one element and can include more than one element. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Unless otherwise indicated, all numbers expressing quantities of components, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the instant specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the presently disclosed subject matter.

As used herein, the term “about”, when referring to a value or to an amount of mass, weight, time, volume, concentration, and/or percentage can encompass variations of, in some embodiments +/−20%, in some embodiments +/−10%, in some embodiments +/−5%, in some embodiments +/−1%, in some embodiments +/−0.5%, and in some embodiments +/−0.1%, from the specified amount, as such variations are appropriate in the disclosed packages and methods. Thus, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “slightly above”or “slightly below”the endpoint without affecting the desired result.

As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Relative terms such as “below” or “above” or “upper” or “lower” or “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the drawing figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the drawing figures.

The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the embodiments and illustrate the best mode of practicing the embodiments. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the disclosure and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.

All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the invention.

Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

The presently disclosed subject matter is directed to a fastening device that fastens an interior band board to an exterior band board during construction of decking. The term “band board” refers to a wood beam typically found at the ends of a house or other structure. Band boards support connecting floor joists to supporting walls when constructing a deck or other building element. Band boards also function to transfer the structure load above to the foundation below. A band board is often referred to as a sill plate, rim joist, or rim. The term “deck” or “decking” refers to a flat surface capable of supporting weight (similar to a floor) but typically constructed outdoors, often elevated from the ground, and usually connected to a building, such as a house.

As illustrated in FIGS. 1a and 1b, interior band board 5a is positioned adjacent to exterior sheathing 10 of home 15 or any other support structure to which decking is attached. Thus, the installed decking system can be connected to the house or other structure on one or more sides. As shown, the interior band board rests upon sill 20 which is position on foundation 25. Joists 45 run perpendicular to the interior band board and support a plurality of beams 50 that combine to make up the decking. Exterior band boards 5b run about the perimeter of the decking, as illustrated. The interior and exterior band boards are attached together, providing structure to the decking, and helping to distribute weight evenly throughout a deck so that no area bears all of the load. As a result, sagging is avoided, and deck boards 50 remain level and structurally sound over time. The band boards also provide a practical connection point for attaching other structural elements, such as frames or support beams.

FIGS. 2a-2c illustrate one embodiment of fastening device 55 that attaches interior band board 5a to exterior band board 5b. As shown, the fastening device includes plate 60 that cooperates with securing element 75. The plate is defined by first and second opposed faces 61, 62. As described below, a portion of the securing element passes through a plate central opening. Securing element 75 is permanently attached to plate 60 at first end 61. The extending portion of the securing element is positioned adjacent to the plate second face and is configured to span the thickness of the band boards during use.

FIGS. 3a and 3b illustrate one embodiment of plate 60. The term “plate” refers broadly to a projecting rim, collar, or ring. The plate provides additional strength to the fastening device. As illustrated, the plate includes thickness 65 of about 0.19 inches (e.g., at least/no more than about 0.1, 0.2, 0.3, 0.4, or 0.5 inches). The thickness of the plate is the distance between opposed first and second faces 61, 62. The plate can include length and width 76, 77, respectively, of about 3 inches (e.g., at least/no more than about 1.5, 1.75, 2, 2.25, 2.5, 2.75, 3, 3.25, 3.5, 3.75, 4, 4.25, 4.5, 4.75, or 5 inches). The plate length is the longest straight line horizontal distance between two side edges of the plate. The plate width refers to the longest straight line distance perpendicular to the length.

The plate can have any suitable shape, such as square, rectangular, circular, oval, hexagonal, and the like. Any shape can be used.

Plate 60 includes central opening 70, as shown in FIG. 3a. Opening 70 is sized and shaped such that the securing element arm can pass through the opening, but the securing element head cannot pass through and is retained adjacent to first side 61 of the plate. The opening can have any suitable shape (e.g., circular, oval, pentagonal, square). The dimensions of the opening can be varied as desired by a user. For example, opening 70 can have length 72 and/or width 71 of about 1 inch (e.g., at least/no more than about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 inches).

The plate can also include a plurality of screw holes 6, as shown in FIG. 3a. The screw holes are sized and shaped to allow a screw to attach the plate to a board, as described below. Plate 60 can include any number of screw holes, such as about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10.

The plate can be welded or otherwise permanently affixed to the head of securing element 75 at second plate side 62. The term “welding” refers to a method of bonding two welding targets together in the solid-phase (or solid-state) without melting the two welding targets, by heating, softening, and pressing the welding targets to cause deformation. However, it should be appreciated that the presently disclosed subject matter is not limited and any mechanism that can be used to permanently affix the bolt to the plate can be used (e.g., the use of adhesives, thermoforming, and the like).

As noted above, the device also includes securing element 75, as illustrated in FIG. 4a. As shown, the securing element includes head 78 and extending arm 79. The securing element also includes first end 81 adjacent to head 75 and opposed second end 82 at the distal end of arm 79. In some embodiments, the arm can include a plurality of exterior threads 85 that extend partially or fully down the length of the arm, as shown in FIG. 4b. The threads can allow for the attachment of nut 85. As illustrated, the nut includes a plurality of internal threads 86 that cooperate with external threads 85 on the arm. In this way, the nut can be advanced along the length of the arm, towards head 75.

The length 11 of arm 79 (e.g., the distance between the first and second ends of the arm) can be about 6 inches in some embodiments. Thus, length 11 can be at least about (or no more than about) 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, or 8 inches. Length 12 of the head can be about 0.4 inches (e.g., at least/no more than about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1 inch).

To install the fastening system on a pair of interior and exterior band boards 5a and 5b, aperture 90 is positioned through the thickness of the aligned first and second band boards, as illustrated in FIG. 5a. In some embodiments, the aperture is positioned through the inside of band board during construction of a deck such that it penetrates the interior band board, any plywood flashing, and through to the exterior band board positioned adjacent to the house that supports the deck. Any element can be used to construct the aperture, such as a standard drill. The length should be of a length that spans the thickness of both band boards to allow the arm 79 to fully pass through the aperture and the thickness of both band boards.

Fastening device 50 is then inserted into aperture 90 such that arm 79 passes through and extends past the band boards, but head 78 and plate 60 remain outside the aperture, as shown in FIGS. 5b and 5c. The aperture is sized and/or shaped such that the plate and head cannot pass into the aperture. Screws 95 are then positioned through plate 60 into the interior band board to anchor the device in place. Nut 85 can then be passed over the exposed second end of the arm until it is flush with outer band board 5b, as shown in FIG. 5d.

The bolt system is self-supporting through a plurality of screws 95 that anchor the plate in place, as shown in FIGS. 6a and 6b. For example, the system can include 4 screws that extend into one of the band boards to further anchor the fastening system in place. However, any desired number of screws can be used. The screws extend into a band board, while the head of the screw overlaps the plate to keep it in position during use.

The fastening device advantageously stays in position without the use of exterior nuts and washers, which is an advantage over prior art fasteners. As a result, when the exterior deck band and joist are replaced several years after the deck is constructed, the interior of the ceiling that conceals the bolt fasteners will not need to be removed. Thus, the homeowner is saved the cost, time, and demolition and repair of the interior of the home.

Advantageously, the fastening device will remain throughout the life of any associated band boards on the exterior that holds up and support a deck. For example, 10-20 years after installation of the disclosed device, the band boards can become rotten. A carpenter can then simply place a new band board on and it attach it to the new deck and thread on bolts and washers to the exterior of the structure and then fasten the new deck.

Thus, one benefit of the disclosed fastener simply allows a connection that is required by code that will exist after the old band board fails and is removed. The difference is with bolts and washers that are required today, when the band board fails later on and the exterior nuts and washers are removed, the nuts on the inside spins or falls inside which requires demolition and a lot of costs to repair the interior. So, the disclosed fastener meets or exceeds all the code requirements. These are placed generally about 32″ to 48″ in the center of the exterior depending on what the code is in different states or localities, and it simply allows the replacement of the deck later on without having to tear up the interior of the structure.

The fastener can be constructed from a wide variety of materials. For example, the fastener can be constructed from metal or metal alloy (e.g., stainless steel, titanium, aluminum, or alloys thereof). The materials used are advantageously non-corrosive and durable. The term “non-corrosive” refers to a material that will not destroy or irreversibly damage another surface or substance with which it comes into contact. The term “durable” refers to the characteristic of resisting wear, decay, and the like (e.g., exposure to salt air in marine conditions).

The disclosed system includes many advantages over prior art fastening systems. For example, the fastening system can be easily installed by a skilled craftsman or layman.

The system also provides an affordable device for connecting the band boards used in decking or other construction projects.

While the fastener is described herein as being connected without any additional hardware, it will be appreciated that nails, screws, bolts, or any other hardware known in the art may be used to further secure the fastener to the band boards.

The foregoing description has been set forth merely to illustrate the invention and is not intended to be limiting. Each of the disclosed aspects and embodiments of the invention may be considered individually or in combination with other aspects, embodiments, and variations of the invention. In addition, unless otherwise specified, the steps of the methods of the invention are not confined to any particular order of performance. Modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, and such modifications are within the scope of the invention.