Cross-Reference to Related Application

[0001] This application claims the benefit of U.S. Provisional Patent Application No.

63/010,301, filed on April 15, 2020.

Incorporation by Reference

[0002] The disclosure of U.S. Provisional Patent Application No. 63/010,301, filed on

April 15, 2020, is hereby incorporated by reference for all purposes as if set forth in its entirety.

Field of the Disclosure

[0003] The present disclosure generally relates to fasteners. More specifically, the present disclosure relates to a fastening system having a fastener or pin configured for fastening structural support framing and/or support members to each other.

Background of the Disclosure

[0004] There are a number of methods or systems for fastening or joining layers of metal materials or components together, including welding, brazing, gluing, screwing and pinning. In controlled environments, such as in industrial plants for manufacturing automobiles or other products, welding and brazing often are used to attach metal layers or components to provide advantageous strength and reduced component cost. In such controlled environments, the welding or brazing process can be automated so as to make it fast, clean, and efficient. However, for other applications, for example at outdoor construction sites, it generally becomes less efficient to weld or braze materials together, requiring significant labor and time, as well as requiring welding or brazing tanks, torches, and other materials that must be physically manipulated and carried by workers to the site(s) where they are needed.

[0005] Fastening systems including pin fastening technology have been common in the construction industry for many years and include a pin that can fasten a material to steel as securely as a common conventional screw fastener. Pins are made of special grades of steel that are hardened making them ductile and extremely strong. When driven into steel with the proper power driven tool, the ballistic-shaped point of the pin uniformly pierces the steel instead of drilling it out or tearing like a common nail. The displaced steel rebounds around the pin to create a strong compressive force on the shank of the fastener. This force, working in conjunction with a pin knurling pattern, creates a high friction force that prohibits withdrawal of the fastener from the steel.

[0006] Light Gauge Steel (LGS) structural framing is becoming more prevalent in the construction industry as an alternative to timber and structural steel framing for residential and commercial construction. LGS framing has the benefits of versatility and strength with a high strength-to-weight ratio to provide enhanced design possibilities for architects. LGS framing is also lightweight, straight and true, making it easy to handle and install, thus providing many benefits for builders.

[0007] LGS framing and support members must be securely fastened together with a secure fastening system. Also, the fastening system should include a fastener that is in contact with the LGS framing and support member that is compatible with the various corrosion resistant coatings of the LGS of the framing and support members that are jointed by the fastening system. Also, the fastening system should be suitable for application by a power-driven tool for quick and efficient application with sufficient force to securely interlock the two support members being joined by the fastening system.

[0008] Accordingly, it can be seen that a need exists for a fastening system that addresses the foregoing related and unrelated problems in the art.

Summary of the Disclosure

[0009] According to one aspect, the disclosure is generally directed to a fastening system for joining two support members fabricated from light gauge steel, the fastening system comprising a plurality of pins, each pin having a body with a first end and a second end, a head is at the first end and a pointed tip is at the second end to facilitate driving the pin through a first layer corresponding to one of the two support members and a second layer corresponding to the other of the two support members, the body comprises an unknurled section adjacent the pointed tip, and a knurled section extending between the unknurled section and the head, the knurled section includes a tapered section adjacent the unknurled section. The fastening system further comprises a holder for holding the plurality of pins, the holder comprising a plurality of pin sleeves holding a respective pin of the plurality of pins, and a power driven tool comprising a magazine for receiving the holder, the power driven tool being configured to eject a respective pin of the plurality of pins from the holder and drive the respective pin through the first layer and the second layer to join the two support members.

[0010] According to another aspect, the disclosure is generally directed to a method of fastening two support members, comprising obtaining a plurality of pins, each pin having a body with a first end and a second end, a head is at the first end and a pointed tip is at the second end, the body comprises an unknurled section adjacent the pointed tip, and a knurled section extending between the unknurled section and the head, the knurled section includes a tapered section adjacent the unknurled section. The method further comprises inserting the plurality of pins into a holder, the holder comprising a plurality of pin sleeves for receiving respective pins of the plurality of pins, loading the holder into a magazine of a power driven tool, and actuating the power driven tool to eject a respective pin of the plurality of pins from the holder and drive the respective pin through a first layer corresponding to one of the two support members and a second layer corresponding to the other of the two support members to join the two support members.

[0011] According to another aspect, the disclosure is generally directed to a holder for holding a plurality of pins for use in a fastening system for joining two support members fabricated from light gauge steel, the holder comprising a plurality of pin sleeves, each pin sleeve of the plurality of pin sleeves is hingedly connected to a respective adjacent pin sleeve.

[0012] According to another aspect, the disclosure is generally directed to a structural assembly comprising two structural support members fastened by at least one pin, the structural support members comprising light gauge steel. The at least one pin comprises a body with a first end and a second end, a head is at the first end and a pointed tip is at the second end to facilitate driving the pin through a first layer corresponding to one of the two support members and a second layer corresponding to the other of the two support members, the body comprises an unknurled section adjacent the pointed tip, and a knurled section extending between the unknurled section and the head, the knurled section includes a tapered section adjacent the unknurled section.

[0013] Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.

[0014] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

Brief Description of the Drawings

[0015] Fig. 1 illustrates a perspective view of a fastening system according to an exemplary embodiment of the present disclosure.

[0016] Fig. 2 is a side elevation view of a pin of the fastening system of Fig. 1.

[0017] Fig. 3 is an enlarged view of a portion of the pin illustrated in Fig. 2.

[0018] Fig. 4 is a perspective view of the pin of Fig. 1.

[0019] Fig. 5 illustrates exemplary structural support members that can be attached by the fastening system of the present disclosure.

[0020] Fig. 6A illustrates respective layers of respective structural support member and a pin or fastening system of the present disclosure prior to penetration of the layers.

[0021] Fig. 6B illustrates a pin or fastening system of the present disclosure after penetration of the respective layers of the respective structural support members.

[0022] Fig. 7 is a perspective view of a holder for use with the fastening system of Fig. 1 for holding a plurality of pins.

[0023] Fig. 8 is a front elevation view of the holder of Fig. 7.

[0024] Fig. 9 is a top plan view of the holder of Fig. 7.

[0025] Fig. 10 is a side elevation view of the holder of Fig. 7.

[0026] Fig. 11 is a perspective view of the holder of Fig. 7 loaded with a plurality of pins. [0027] Fig. 12 is a front elevation view of the holder and pins of Fig. 11.

[0028] Fig. 13 is a perspective view the exemplary embodiment of the fastening system, with the holder and pins loaded into a magazine of a power driven tool.

[0029] Fig. 14 is an enlarged view of a portion of Fig. 13.

[0030] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

Detailed Description

[0031] Referring now to the drawings in which like numerals indicate like parts throughout the several views, Figs. 1-4 generally illustrate portions of the fastening system 100 in accordance with one exemplary embodiment of the present disclosure. The fastening system 100 of the present disclosure is generally designed for attaching metal support members SI, S2 (Fig 5) having a respective layer LI, L2 (Figs. 6A and 6B) of steel. In one embodiment, the metal support members SI, S2 are made of light gauge steel (LGS) and are components of a LGS framing system. Fig. 5 shows exemplary designs and configurations of LGS metal support members SI, S2 that can be joined by the fastening system 100. The fastening system 100 can be used to join other designs, configurations, and cross-sections of LGS metal support members or metal support members made of alternative materials, without departing from the disclosure.

[0032] In one embodiment, the LGS metal support members can be made of Aluminum-

Zinc-Magnesium coated steel or other suitable coated or noncoated alloy. Aluminum-Zinc- Magnesium coated steel is a hot dipped Al-Zn alloy coated LGS that is corrosive resistant and suitable for building framing. The exemplary metal support members SI, S2 arranged and connected to form building framing at typical construction sites. The fastening system 100 can be used to join other suitable metal alloy layers, other structures, or other materials without departing from the scope of the disclosure.

[0033] As shown in Fig. 1, the fastening system 100 can include a plurality of pins 10 held in a collation piece or holder 61 and for loading into a power driven tool 51. In some embodiments, the fastening system 100 can include one or more of the pins 10, and can optionally include the holder 61 and/or the power driven tool 51. [0034] Figs. 2-4 show various views of a pin 10 of the fastening system 100 of the present disclosure. The pin 10 can have a body that includes include a head 14 at a first end 3 of the pin 10, a pointed tip 16 at a second end 5 of the pin 10, and a shank 15 extending between the head 14 and the tip 16. In the illustrated embodiment, the shank 15 includes a knurled section 11 and an unknurled section 13, e.g., a generally smooth section devoid of knurling and/or other surface patterns. In such an arrangement, the unknurled section 13 of the shank 15 is positioned adjacent the tip 16, and the knurled suction 11 extends from/between the unknurled section 13 and the head 14. It will be understood that a fastening system 100 according to the present disclosure can include a single pin 10 or a plurality of pins 10.

[0035] As shown, the knurled section 11 of the pin 10 includes a lead-in portion 20 that includes a tapered section adjacent the unknurled section 13 and which has an outer surface with a taper angle 21 that is generally 5 degrees, e.g., measured relative to an axis 27 defined by the pin 10, to form a tapered lead-in from the unknurled section 13 to the remaining portion of the knurled section 11. The 5-degree lead-in assists in penetrating steel and other materials while minimizing the deflection of these materials. In other embodiments, the angle 21 can be in the range of approximately 3 degrees to approximately 7 degrees. In other embodiments, the section 13 could be knurled or otherwise provided with a surface pattern without departing from the scope of the disclosure.

[0036] As shown in Figs. 1-4, the tip 16 is in the general shape of a cone and has a conical surface 26, that defines an angle 24 with the axis 27 of approximately 9 degrees. This conical shape, with the angle 24 as defined, results in a sharp point that facilitates penetration of hard surfaces such as steel, e.g., for driving the pin 10 through one or more layers of multiple LGS support members. In other embodiments, the angle 24 can be in the range of approximately 7 degrees to approximately 11 degrees.

[0037] In one embodiment, the pin 10 can be formed from 1060 steel and have two types of hardness applied. The core of the pin 10 can be subjected to a Heat treat Rc 52-55, and the surface of the pin 10 can be subjected to an Austemper R45n39-48. The pin 10 can be further plated Acid Zn/Ni .0002- 0003 (12-15% Ni) with Tritop Gold Finish.

[0038] In one embodiment, the head 14 can have a diameter 18 of approximately 0.25 inch

(6.4 mm), a thickness 12 of approximately 0.035 inch (0.89 mm) and a radius 17 at its intersection with the shank 15 of approximately 0.015 inch (0.38 mm). In one embodiment, the knurled section 11 can have the following specifications:

[0039] (1) 32 threads per inch (“TPI”) approximately 90 degrees diagonal; (2) approximately

26 degrees vertical plane right hand; (3) major diameter approximately 0.103 inch - 0.107 inch (2.61 mm - 2.72mm); and (4) Thread die #01136 (“Gripshank®”).

[0040] In one embodiment, the overall length of the unknurled 13 section can be approximately 0.36 inch (9.1 mm), with the length 30 of the tip 16 being approximately 0.26 inch (6.6 mm), the point of the tip 16 having a radius 29 of approximately 0.01 inch (0.25 mm), and the portion of the unknurled section 13 extending from the lead-in section 20 to the beginning of the tapered surface 26 of the tip 16 having a length 19 of approximately 0.1 inch (2.5 mm).

[0041] In one embodiment, the pin 10 can have an overall length 31 from the inner surface of the flange 14 to the tip 16 of approximately 0.850 inch (21.6 mm). In other embodiments, the length 31 could be less than 0.850 inch (21.6 mm). For example, the length 31 could be approximately 0.750 inch (19.05 mm) or less, the length 31 could be approximately 0.650 inch (16.5 mm) or less, the length 31 could be approximately 0.500 inch (12.7 mm) or less, or the length 31 could be approximately 0.375 inch (9.5 mm) or less, or the length could be more or less than any of the dimensions noted herein without departing from the disclosure.

[0042] Fig. 5 shows various suitable support member SI, S2 that could be fastened by the pin

10 of the present disclosure. The support members SI, S2 can be various shapes and sizes and can be made from Light Gauge Steel (LGS). In one embodiment, the support members SI, S2 can be made of Aluminum-Zinc-Magnesium coated steel that is an Al-Zn-Mg alloy coated LGS that is corrosive resistant and suitable for building framing. The two support members SI, S2 can be connected by insertion of the fastening system 10 through a first layer LI (Figs. 6A and 6B) of the first support member SI and a second layer L2 (Figs. 6A and 6B) of the second support member S2. The layers LI, L2 can have a thickness in the range of approximately 0.012 inch (0.30 mm) to approximately 0.059 inch (1.50 mm), can have a thickness in the range of approximately 0.02 inch (0.51 mm) to approximately 0.039 inch (1.0 mm), or may have a thickness equal to or greater than approximately 0.060 inch (1.50 mm), or can have a thickness less than approximately 0.012 inch (0.30 mm) without departing from the disclosure. [0043] As shown in Figs. 6A and 6B, the fastening system 10 can be used to attach two support members SI, S2. In one method of use, the pin 10 can be driven through the respective layers LI, L2 of the support members SI, S2 by a power-driven tool 51 (Figs. 1, 13, 14). In one embodiment, the power-driven tool 51 is a pneumatic driven power tool such as a Model ST3025, or a Model GT38Li tool available from Aerosmith Fastening Systems of Indianapolis, Indiana. Other suitable power-driven tools could be used to drive the pin 10 through the layers LI, L2, such as other low pressure pneumatic tools or cordless, gas driven, or battery powered power driven tools without departing from the disclosure. Such suitable power-driven tool can have a depth of drive adjustment feature for use with the pins 10. In one embodiment, the power driven tool 51 can be selected to drive the pin 10 at a force to deliver no more than approximately 90 Joules of Impact Energy.

[0044] When the pin 10 is driven through the layers LI, L2, the point 16 of the pin 10 pierces the layers LI, L2 of material and the pin 10 is rapidly inserted through the layers LI, L2 by the force generated by the power driven tool 51. Upon penetration of the layers LI, L2, the shank 15 of the pin 10 having the knurled surface 11 fuses to the layers of material LI, L2, thus forming a strong connection between the layers LI, L2 and the pin 10 and thus joining the two layers LI, L2 of the structural members SI, S2 to each other with a strong connection.

[0045] As shown in Fig. 6B, after the pin 10 has been driven through the layers LI, L2, the head 14 of the pin 10 is flush with a first exterior surface 53 of the joined layers LI, L2 and the end 5 of the pin extends beyond a second exterior surface 55 of the joined layers LI, L2 by a distance 57 of approximately 0.375 inch (9.5 mm). The distance 57 could be in the range of approximately 0.375 inch (9.5 mm) to approximately 0.625 inch (15.9 mm) without departing from the disclosure. In one embodiment, a structural assembly of the present disclosure includes the two structural support members SI, S2 that are fastened together by the pin 10 that joins the two layers LI, L2.

[0046] Figs. 7-12 show a collation piece or holder 61 for holding a plurality of pins 10 for loading into the power driven tool 51. The holder 61 includes a plurality of pin sleeves 63 that are separably connected by respective upper hinges 65 and lower hinges 67. Each pin sleeve 63 has an upper collar 81, a lower collar 83, and a central portion 85 extending between the upper collar and the lower collar. Each pin sleeve 63 includes an upper opening 68 in the upper collar and a lower opening generally aligned with the upper opening 68 so as to define a passage 69 through the pin sleeve. In one embodiment, the lower collar 83 of each pin sleeve 63 includes two notches 87 on respective opposite surfaces of the lower collar 83. The upper hinges 65 and the lower hinges 67 allow the holder 61 to flex, e.g., articulate such that one or more of the pin sleeves 63 moves relative to the remainder of the pin sleeves 63. Accordingly, one or more of the upper hinges 65 and the lower hinges 67 can be configured for movement relative to a respective pin sleeve 63, e.g., via a pivotable/rotatable connection to the pin sleeve and/or configured for flexion/deformation upon the application of an external force.

[0047] In this regard, the holder 61 can be fed through a magazine 71 or storage area of the power driven tool 51. Each pin sleeve 63 holds a respective pin 10 of the plurality of pins held in the holder 61.

[0048] Figs. 13 and 14 show the holder 61 being loaded into the power driven tool 51. The individual pin sleeves 63 are manipulated as the holder 61 flexes when being fed through the power driven tool 51. Each individual pin sleeve 63 flexes at the upper and lower hinges 65, 67 to allow the holder 61 to be fed through the power driven tool 51. Upon actuation of the power driven tool 51, a respective pin sleeve 63 separates from a respective adjacent pin sleeve at the upper and lower hinges 65, 67 and the pin 10 is ejected from the discharge/ barrel of the power driven tool with the individual pin sleeve 63 attached to the pin (Fig. 6A). In this way, the pin sleeve 63 acts as a guide that is initially attached to an individual pin 10 to help align the pin 10 for perpendicular contact with the layers LI, L2 of structural support members SI, S2 at an angle of engagement of precisely 90 degrees relative to the layers. The angle of engagement of the pin 10 with the layers LI, L2 being at precisely 90 degrees is critical in providing high connection strength when the pin is driven through the layers. The pin 10 and the pin sleeve 63 initially contact the layers LI, L2, with the pin continuing to move in the direction of arrow A1 (Fig. 6A) through the layers LI, L2 and the pin sleeve being compressed by the head 14 of the pin against the outermost layer LI as the pin advances into the layers LI, L2. The pin sleeve has 63 weakening features in the form of the shape of the opening 68, the passage 69, and the notches 87 in the lower collar 83 that causes the wall thickness of the pin sleeve to have failure points that causes the pin sleeve to fracture and separate from the pin 10 as the pin continues to move in the direction of arrow A1 into the layers LI, L2. The pin sleeve 63 fractures and separates from the pin 10 prior to the pin being fully driven through the layers LI, L2 (Fig. 6B) so that no flagging exists where residual material of the pin sleeve 63 remains between the head 14 of the pin and the layers. As such, the pin sleeve 63 is configured with the weakening points to allow the pin sleeve to fracture and separate from the pin 10 to eliminate flagging. Fig. 6B shows the pin sleeve 63 fracture into two pieces, but the pin sleeve could fracture into more than two pieces without departing from the disclosure.

[0049] In one embodiment, the holder 61 is made from a material such as plastic (e.g., High

Density Polyethylene (HDPE), or other suitable thermoplastic material), rubber, composite, or any other suitable material. In one embodiment, the upper collar 81 of the pin sleeve 63 can have a material thickness T1 (Fig. 9) of approximately 0.022 inch (0.5 mm) at the apex of two points of the opening 68, relative to the outermost surface of the pin sleeve. Similarly, the lower collar 83 of the pin sleeve 63 can have a material thickness of approximately 0.022 inch (0.5 mm). The reduced material thickness of the pin sleeve 63 at the openings 68 in the upper collar 81 and at the notches 87 in the lower collar 83 create the weakening features that allow the pin sleeve 63 to fracture when compressed by the head 14 of the pin 10 against the layer LI when the pin is driven into the layers LI, L2. The fracture of the pin sleeve 63 facilitates complete removal and separation of the pin sleeve from the pin 10 prior to the pin being driven into layers LI and L2 (Fig. 6B). The holder 61 and the pin sleeves 63 could have other features and could be otherwise shaped, arranged, and/or configured without departing from the scope of the disclosure.

[0050] In other embodiment, the pins could be driven into layers LI, L2 by use of tools other than the tools 51 shown and described herein.

[0051] The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non- illustrated embodiments of the disclosure.