CA2340590C - Fastener device and method for attaching a panel of semi-rigid material to a substrate - Google Patents
Fastener device and method for attaching a panel of semi-rigid material to a substrate Download PDFInfo
- Publication number
- CA2340590C CA2340590C CA 2340590 CA2340590A CA2340590C CA 2340590 C CA2340590 C CA 2340590C CA 2340590 CA2340590 CA 2340590 CA 2340590 A CA2340590 A CA 2340590A CA 2340590 C CA2340590 C CA 2340590C
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- panel
- screw
- screw part
- anchor
- substrate
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- Expired - Lifetime
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- 230000000149 penetrating effect Effects 0.000 claims abstract description 13
- 230000000295 complement effect Effects 0.000 claims description 32
- 238000009434 installation Methods 0.000 claims description 9
- 238000010276 construction Methods 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 238000009413 insulation Methods 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 238000004873 anchoring Methods 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- 239000011152 fibreglass Substances 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
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- 239000003365 glass fiber Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- AFJYYKSVHJGXSN-KAJWKRCWSA-N selamectin Chemical compound O1[C@@H](C)[C@H](O)[C@@H](OC)C[C@@H]1O[C@@H]1C(/C)=C/C[C@@H](O[C@]2(O[C@@H]([C@@H](C)CC2)C2CCCCC2)C2)C[C@@H]2OC(=O)[C@@H]([C@]23O)C=C(C)C(=N\O)/[C@H]3OC\C2=C/C=C/[C@@H]1C AFJYYKSVHJGXSN-KAJWKRCWSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B37/00—Nuts or like thread-engaging members
- F16B37/12—Nuts or like thread-engaging members with thread-engaging surfaces formed by inserted coil-springs, discs, or the like; Independent pieces of wound wire used as nuts; Threaded inserts for holes
- F16B37/122—Threaded inserts, e.g. "rampa bolts"
- F16B37/125—Threaded inserts, e.g. "rampa bolts" the external surface of the insert being threaded
- F16B37/127—Threaded inserts, e.g. "rampa bolts" the external surface of the insert being threaded and self-tapping
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B25/00—Screws that cut thread in the body into which they are screwed, e.g. wood screws
- F16B25/0005—Screws that cut thread in the body into which they are screwed, e.g. wood screws of the helical wire type
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
- F16B5/01—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening elements specially adapted for honeycomb panels
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
- F16B5/02—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening members using screw-thread
- F16B5/0208—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening members using screw-thread using panel fasteners, i.e. permanent attachments allowing for quick assembly
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Dowels (AREA)
- Connection Of Plates (AREA)
- Mounting Components In General For Electric Apparatus (AREA)
Abstract
A fastener device and method for attaching an acoustic panel to a substrate, the device having a screw part with an inner end rotatably connectable to the substrate by an anchor screw. The screw part has a helical flight capable of penetrating the rear face of the panel when rotated by an elongated drive rod projecting from its outer end and passing through the panel, so that the drive rod can be rotated at the front face of the panel to cause the screw part to secure the panel onto the substrate. The screw part is formed of two members to allow a base member thereof to be attached to the substrate by an anchor screw which is co-axial with the screw part, so that the anchor screw location can be marked accurately to coincide with a bore in the panel.
Description
Title: Fastener device and method for attaching a panel of semi-rigid material to a substrate.
Background of the Invention.
l.Field of the Invention The present invention relates to a device for fastening a panel of semi-rigid material, such as a so-called acoustic panel having a decorative face, to a substrate such as a wall or ceiling. The term "semi-rigid" is used for materials such as fiberglass (glass fiber reinforced resin , or other fibrous material, used in buildings for heat or sound insulation. Such materials are structurally weak but are capable of receiving special fasteners designed to be used with such material. The panels with which the present invention is primarily concerned usually have a decorative face and it is desired that any fastener used should be a so-called "blind" fastener which is hidden or at least does not noticeably spoil the appearance of the face .
Background of the Invention.
l.Field of the Invention The present invention relates to a device for fastening a panel of semi-rigid material, such as a so-called acoustic panel having a decorative face, to a substrate such as a wall or ceiling. The term "semi-rigid" is used for materials such as fiberglass (glass fiber reinforced resin , or other fibrous material, used in buildings for heat or sound insulation. Such materials are structurally weak but are capable of receiving special fasteners designed to be used with such material. The panels with which the present invention is primarily concerned usually have a decorative face and it is desired that any fastener used should be a so-called "blind" fastener which is hidden or at least does not noticeably spoil the appearance of the face .
2.Prior Art Many different fastening devices and methods have been used hitherto with acoustic panels or similar panels, in a manner which does not affect the appearance of the panel. A
summary of this prior art is contained in my Canadian Patent Application No.2,301,375, filed March 20, 2000 and laid open Oct. 8, 2000. The prior art has drawbacks relating to:
1. Poor holding power, for example not holding panels strongly enough to allow the panels to be used on a ceiling;
2. Where adhesives are used, the difficulty of removing panels without destruction of parts of the panels;
summary of this prior art is contained in my Canadian Patent Application No.2,301,375, filed March 20, 2000 and laid open Oct. 8, 2000. The prior art has drawbacks relating to:
1. Poor holding power, for example not holding panels strongly enough to allow the panels to be used on a ceiling;
2. Where adhesives are used, the difficulty of removing panels without destruction of parts of the panels;
3. The fact that with some devices the panel must move downwards during installation, so that a gap or "reveal" must occur between the top of a panel and a ceiling.
4. The need to install special fastener parts to a panel in a factory; use of such parts may also give difficulty in accurately locating a panel.
Although the semi-rigid material of these panels is too weak to hold ordinary wood screws, some special screws or fasteners have been designed for fiberglass insulation, for example as shown in the following U.S. patents:
No.4,762,453, issued Aug.9,1988 to DeCaro, No.4,917,554, issued Apr.17,1990 to Bronn, and No.5,426,905, issued Jun.27,1995 to Rollhauser et al.
The screws or fasteners shown in these patents have large heads and are therefore unsuitable for use where a hidden or unobtrusive fastener is needed.
This invention and that of my aforesaid '375 application resulted from a need for an improved fastener especially for acoustic or insulating panels made of semi-rigid material. The fastener of this invention has at least some of the following advantages over previous fasteners:
1. It provides a strong hold on the panel so as to be suitable for holding ceiling panels;
2. It does not require the addition of any part by the panel manufacturer; it can be used on plain panels produced by many different manufacturers;
3. It is simple and quick to apply;
4. It provides a fastener which is almost entirely hidden, with only minimal disturbance of the front of the panel; and 5. It allows the panel to be removed and replaced.
My improved fastener, like some of those of the prior art, has a large diameter screw part. However, unlike the prior art screw devices mentioned above, this is a "blind" fastener which is concealed within the panel. This result is achieved by rotatably attaching the rear or inner end of the screw part (i.e. what is normally the "head" of the screw) to the substrate before the panel is put in place, and by providing the screw part with a non-circular drive recess at its outer end (or "tail" end) whereby it can be rotated by a slim drive rod, such as a hexagonal rod, which extends through the thickness of the panel and which is rotated from the front side of the panel. After the fastener is fully in place, the rod is removed leaving only a small hole in the panel.
The method of using the device as described in my aforesaid '375 application involves firstly attaching anchoring means to the substrate, such anchoring means rotatably holding the screw part, and then inserting the drive rod into the non-circular recess in the outer end of the screw part. The panel is then pushed onto the drive rod which has a sharpened outer end so that it penetrates the panel and emerges from the front of the panel, where it is rotated by a tool to turn the screw part and draw this into the rear of the panel until the panel is secure . While this procedure works, it has the drawback that precise positioning of the panel may be difficult. The drive rod needs to be inserted into the rear of the panel while this is still separated from the substrate by at least the length of the screw member and the drive rod, so that care and judgement is required if the panel is to be correctly positioned in its final location.
The present invention also provides, in one aspect, an improved procedure whereby a panel can be more precisely positioned than using the method described in my aforesaid application. Another aspect of the present invention provides a modified fastener device particularly suited to the new method. The new method can however also be used with certain of the fastener devices described in my aforesaid application.
Summary of the Invention In accordance with the present invention, a fastener for attaching a rear face of a panel of semi-rigid material to a substrate surface comprises:
an anchor part for attachment to the substrate surface;
a screw part having an inner end connected to the anchor part so as to be rotatable relative to the substrate, the screw part having a helical member or flight with an outer end capable of penetrating the rear face of the panel upon rotation of the screw part;
drive means for rotating the screw part including an elongated drive rod arranged to project from the outer end of the screw part and which is removable from the screw part after the panel has been installed.
The drive rod is capable of penetrating, or at least passing completely through, a panel so as to extend through the panel when the helical member contacts the rear face of the panel. The drive rod is thus accessible at the front face of the panel for rotation by a suitable tool to cause the helical member or flight (hereinafter the "flight") to rotate and penetrate the rear face of the panel and to become embedded in an inner portion of the panel to secure the panel onto the substrate. The drive rod is removable after the panel has been secured, leaving only a small hole in the panel front face, and leaving the fastener concealed within the panel.
It will be understood that the screw part used in accordance with this invention is fundamentally different from screw devices hitherto used for securing insulation, or for other purposes. Not only does it have a large diameter helical member or flange, similar to that of an auger, the helical member or flight being preferably well over an inch in diameter, but, unlike all screws known to the applicant, it is driven, not from its head, but from the other or "tail" end, i.e. the end that first penetrates the semi-rigid material.
This is achieved by use of the drive rod which projects from the outer end of the screw part and passes through the material and is accessed from the front face of the panel.
The drive rod may be a non-circular rod or pin, for example a hexagonal rod, which engages in a non-circular recess in the outer end of the screw part, and which can be pulled out of the recess when the panel has been installed. Alternatively, the drive rod may be formed integrally with the screw part, for example being formed of plastic, and may be broken off when the panel has been installed. The drive rod may have a pointed outer end.
Preferably, the screw part includes a shaft rotatably held by the anchor part, and a helical flight surrounding the shaft.
The helical flight has a diameter greater than its length; in fact the diameter of the helical flight is usually more than twice the shaft length. The drive rod has a diameter such as to leave no noticeable hole when withdrawn; preferably it has a diameter less than 1/8 of an inch.
In an alternative construction, the screw part may be a shaft surrounded by a helical flight in the form of a rod having an inner end connected to the shaft and a pointed outer end, and operates somewhat in the manner of a corkscrew.
As shown in the aforesaid '375 application, the anchor part may be a plate having at least one hole for screw attachment of the plate to the substrate.
In its preferred form, the present invention makes use of a fastener in which the screw part is rotatably attached to the substrate by an anchor screw which is co-axial with the non-circular drive recess in the outer end of the screw part and therefore also co-axial with the drive rod, and, generally, co-axial with the screw part. This allows the location of the anchor screw to be aligned with a bore in the panel which is preformed before the drive rod is put in place, rather than being formed by the drive rod upon being pushed through from the panel rear face, as in my '375 application.
Constructions of the fastener device in which an anchor screw is co-axial with the screw part and its drive means are shown in my aforesaid '375 application, in Figs.9 and 10, Figs.ll and 12, and in Figs.l3 and 14 of that application. The present application shows a further, preferred design for co-axial anchor screw and drive rod having additional desirable features. In all these designs, in order to allow insertion of the anchor screw, the screw part is separable into a base member and a complementary member, the base member being attached to the substrate by the anchor screw while separated from the complementary member.
The fastener device in accordance with this invention may be defined as comprising:
a screw part having an inner end capable of being rotatably held relative to the substrate by an anchor screw having a head, the screw part having a helical flight with an outer end capable of penetrating the rear face of the panel upon rotation of the helical flight;
drive means for rotating said screw part, the drive means including a non-circular drive recess accessible from an outer end of the screw part and suitable for engagement by a drive rod which is capable of extending fully through a transverse bore in the panel so that the drive rod is accessible for rotation at the front face of the panel to cause the helical flight to penetrate and engage a rear portion of the panel, and which rod is removable from the screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
the screw part including a base member and a complementary member, the base member having an aperture~for receiving the anchor screw and being attachable to the substrate by the head of the anchor screw while the base member is separate from the complementary member, the complementary member being attachable to the base member when the anchor screw is in place in the base member aperture, said complementary member providing the non-circular drive recess, the base member being rotatable about the axis of the anchor screw when the anchor screw is in place in the substrate;
and wherein the axis of the base member aperture which receives the anchor screw is coincident with the axis of the non-circular drive recess for the drive rod in the complementary member when the two members are assembled together, whereby the bore in the panel which receives the drive rod may be co-axial with the anchor screw.
The base member may include the helical flight and the aperture for receiving the anchor screw, and may have a central socket leading to the aperture for the anchor screw. The complementary member may be an insert engageable in the central socket and which has the non-circular recess for receiving the drive rod. This is the arrangement shown in Figs.l3 and 14 of the aforesaid '375 application, and is also the preferred arrangement of this present invention. The central socket is non-circular, and the insert has an outer surface which fits non-rotatably into the central socket. In the preferred embodiment in accordance with this present invention, the insert is connected to the base member by a flexible hinge part which allows the insert to be removed from the base member while the anchor screw is being inserted into the base member aperture.
In alternative arrangements, the complementary member includes the helical flight and has screw threaded attachment to the base member.
The invention also provides a method for attaching the rear of a panel of semi-rigid material to a substrate at a desired installation position by making use of a screw part having an inner end capable of being held relative to the substrate by an anchor screw having a head, such that the screw part can rotate relative to the substrate about an axis co-axial with the anchor screw, the screw part having a helical flight with an outer end capable of penetrating the rear of the panel upon rotation of the helical flight, the screw part comprising a base member and a complementary member, the base member having an aperture for the anchor screw and the complementary member having a non-circular drive recess for a drive rod which is co-axial with the anchor screw aperture when the two members are assembled together, the method comprising the steps of forming a transverse bore in the panel and marking an anchor screw location for the anchor screw in the substrate such that the anchor screw will be aligned with the transverse bore when the panel is in its desired installation position;
fixing the base member of the screw part to the substrate by means of the anchor screw inserted at the said location, with the anchor screw having a head engaging inside the aperture of the base member, whereby an inner end of said base member is rotatably held relative to the substrate by the anchor screw head;
fitting the complementary member of the screw part to the base member;
placing a panel at the installation position and passing an elongated drive rod through the said transverse bore in the panel and fitting an inner end of the drive rod into the non-circular drive recess of the complementary~member so that a portion of the drive rod extends through the panel and has its outer end part protruding from a front face of the panel when the helical flight of the screw part contacts the panel rear face, rotating the drive rod by its protruding end part to cause the helical flight of the screw part to penetrate and engage a rear portion of the panel, and, upon further rotation of the screw part, to secure the panel onto the substrate, and removing the drive rod from the outer end of the screw part after the panel has been secured so that the fastener is essentially concealed within the panel.
Marking the locations for the anchor screw hole and making the transverse bores in the panel may be done simultaneously, by holding the panel in a position in which it is to be installed while forming the bore in the panel by use of a penetrating tool inserted from the front face, which tool at the same time also marks an anchor screw location in the substrate, so that the anchor screw location is aligned with the bore.
Alternatively, the making of the bores in the panel and the marking of locations for the anchor screws may be done separately by using a template, or other measuring means, to ensure that the anchor screws are located correctly relative to the bore positions for the panel to be properly positioned.
The drive rod may be a non-circular rod or pin, for example a hexagonal rod, which engages the non-circular drive recess in the screw part, and which can be pulled out of the recess when the panel has been installed. Unlike in the method of my aforesaid pending application, with this method it is possible to use a standard Allen key or wrench as the drive rod, since its outer end does not need to pass through the panel.
Preferably, the helical flight of the screw part has a diameter greater than its length; in fact the diameter of the helical flight is usually more than twice the shaft length. The drive rod has a diameter such as to leave no noticeable hole when withdrawn; preferably it has a diameter less than 1/8 of an inch. This is a small fraction of the diameter of the helical flight which is typically 1 1/2 to 2 inches.
Brief Description of the drawincrs.
Preferred embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which;
Fig.l is a sectioned side view of one embodiment of improved screw component of this invention fixed to a substrate;
Fig.2 shows the same parts when the fastener is fully assembled and is in position for the initial stage of engagement with a panel;
Fig.3 is a view of the same parts as Fig.2 but with the panel approaching its final position;
Fig.4 is an exploded sectional elevation of the complementary member of the screw part of Figs.l to 3;
Fig.5 is a view similar to Fig.4 of a preferred form of the complementary member in accordance with this invention;
Fig.6 is a perspective view of the main component of the preferred form of fastener in accordance with the present invention;
Fig.7 is a perspective view of a component of the complementary member the fastener of Fig.6;
Fig.8 is a perspective view of a simple template which can be used to position bores and anchor screw locations in accordance with the invention;
Fig.9 is a view of a panel indicating the use of a template of Fig.8 for positioning bores;
Fig.lO is a perspective view of two components of another screw part in accordance with the invention;
Fig.ll is a sectional elevation of the Fig.lO screw part when attached to a substrate by an anchor screw;
Fig. l2 is a perspective view of components of a further screw part;
Fig.l3 is a sectional elevation of the base member of the screw part of Fig. l2, as attached to a substrate;
Fig.l4 is a perspective view of yet another embodiment of screw part in accordance with the invention; and Fig.l5 is a view similar to Fig.l3 of the base member of the Fig. l4 embodiment.
Detailed Description.
The fasteners of Figs . 10 to 15 are the same as some of the fasteners previously described in my aforesaid Canadian Patent Application No.2,3p1,375; however this present application describes and claims a new way of installing these fasteners.
The new fastener of Figs.1 to 7, and especially Figs. 5 to 7, are now the preferred embodiments.
Figs . 1 to 4 show a f first form of device in accordance with the invention which can be used in association with other like devices to attach an acoustic panel P to a substrate S.
Typically, six of the fastening devices would be used for a 4 foot by 8 foot panel.
As shown in Figs.1 to 4 the screw part 10 is formed of two members namely a base member 12 and a complementary member 14, the latter being in the form of a hexagonal cup which fits non-rotatably into a non-circular, specifically hexagonal, socket 15 in the base member. As indicated in Fig.l, major parts of these members are integrally molded as one component; suitable plastic material for these molded parts is polypropylene. The members are attached by an integral flexible strip 16 having a thinned central hinge portion 17 which allows the complementary cup member 14 to be initially removed from the base member 12 and to be later inserted into the socket 15. At the base of the socket is a circular aperture 18 for an anchor screw 20 which is shown in Figs.1 and 2, and which can be inserted into the aperture, to engage the substrate S, while the cup member 14 is removed from the socket 15. The anchor screw 20 is an ordinary wood screw having a head suitable for engaging the interior of the socket 15 to hold the screw part in place on the substrate while allowing it to rotate about the axis of the anchor screw.
The base member of the screw part has a helical flight 23 partly surrounding a central shaft 22; the flight extends about 270° around the shaft. The helical flight is wide relative to its length, its diameter being much greater than its length, and preferably greater than twice its length. A suitable diameter is between 1/2 to 2 inches, and a suitable length for the helical flight is about 1/2 to 5/8 inches. The outer or leading edge 23a of the helical flight is sharpened and curves outwards from the adjacent thread portion so as to "bite" into the semi-rigid panel material. The shaft 22 and a main part of the flight 23 are generally co-axial with the anchor screw aperture 18.
The plastic cup 14 has a hexagonal surrounding wall 14a which non-rotatably receives a hexagonal metal nut 24; the nut is a press fit into the cup and is retained by detent lips 14b.
This nut may be a standard off-the-shelf component, and has an internal thread into which is fixed a set screw 26, shown in Fig.4, also an off-the-shelf component, having a hexagonal drive recess 27 suitable for receiving a removable hexagonal drive rod 30. This drive rod 30 may be a standard Allen key of about 3/32 inches diameter (i.e. across its opposite flat surfaces). However, in its preferred form as shown in Figs.2 and 3, the drive rod is a modified form of "Allen" key having one long leg 30a of the usual Allen key form, and the other, mutually perpendicular, leg 30b extended and sharpened so as to act as a tool for piercing the panel and for marking the anchor screw position on the substrate. The drive rod leg 30a has a length sufficient that, as shown in Fig.2, when a panel P is placed against the outside of the screw part 10, the drive rod can be inserted through a bore in the panel to engage the recess 27 of the complementary member 14 while the leg 30b of the drive rod, which is suitable for hand manipulation, remains outside the panel. The panel is typically about 1 to 1 1/8 inch in thickness, and the length of drive rod leg 30a will be about 2 inches. Clearly, by lengthening the drive rod, panels of greater than 1 inch thickness can be installed using the same system.
Figs.5, 6 and 7 show a preferred form of the screw part in which the metal nut 24', instead of being formed of two off-the-shelf parts assembled together, is an integral part die cast from zinc, and formed with the hexagonal drive recess 27' .
This nut 24' also differs from that of the first embodiment by having the recess 27' at the base of a conical depression, the inwardly sloping sides 28 of which serve to guide the end of the drive rod towards the recess 27'. This nut fits into the same cup 14 as previously described.
In one method in accordance with the invention, the first step is to hold the panel P in the desired installation position while using a penetrating tool such as leg 30b of the drive rod 30 to form a bore in the panel for each screw device which is to be used. As each bore is made the tool is pushed in sufficiently to make a lead hole or indentation in the substrate S thus to provide an anchor screw location. The panel is then removed, and, at each anchor screw location, the base member 12 of a screw part 10 is secured to the substrate as shown in Fig.l by inserting the anchor screw 20 into the aperture 18 and into the anchor screw location in the substrate. The anchor screw is left just loose enough to allow the screw part to rotate; this is of course done with the cup member 14 removed as in Fig.l. The cup member 14, complete with nut 24 or 24' , is then inserted into the socket 15, as shown in Fig.2, by bending strip 16 about hinge 17.
The panel is then placed in position, and a drive rod 30a is pushed through the appropriate bore which has been formed in the panel and into the drive member recess 27 (or 27' for the Fig.5 version), as shown in Fig.2. The panel is then pushed on to the screw part while the drive rod is rotated to turn the screw in such a direction as to cause the outer end 23a of the helical flight to engage in the rear face of the panel and to draw the panel onto the screw. Suitable rotation of the drive rod causes the screw part to become embedded in the interior of the panel as shown in Fig.3; in the final stages of movement the panel is securely in contact with the substrate and the outer end of the screw is close to the front surface of the panel. At this stage the drive rod 30 is removed, leaving only a small and unnoticeable hole at the front face of the panel.
The screw part 10 as shown in Figs.l to 3 has a "right-hand" thread or flight 23 which requires, counter-clockwise rotation to engage the panel when, as described, it is rotated by drive rod 30 from what is, in effect, the tail end of the screw. This is preferred since it has been found that rotation in the opposite sense may tend to tighten the anchor screw 20 and prevent further rotation.
This method may not work well when the panel is applied to hard surfaces which cannot easily be indented or marked by a pointed hand tool such as leg 30b of the tool described. In this case it may be necessary to use a template for setting the anchor screw locations and those of the bores in the panel; a suitable template is shown in Figs.8 and 9., As shown best in Fig.8, the template 40 is a simple plate, for example of cardboard, having a flange 42 along one edge, and having two holes 44 spaced a distance D from the flange edge of the template, and being also separated by the same distance D; the distance D is suitably 5 inches. The template may be used as shown in Fig.9 at corners of a panel to locate bores the distance "D'~ from the two adjacent sides, by holding the flange 42 against one adjacent side while aligning an adjacent edge of the template with that of the panel. Four bores for fasteners adjacent the corners may be sufficient for a 4 foot by 4 foot panel, but for a larger panel which requires 6 fasteners, such as illustrated in Fig.9, additional bores will be made near to the centers of the longer sides. For these, the template will provide only the distance "D" from the sides; the positions of the template on these longer sides must be determined by measurement.
After (or before) the bores in the panel have been made by the template, the panel is placed into the desired position on the substrate and the perimeter is marked out . The panel is then removed and the template 40 used again to mark the anchor screw positions which correspond to bores made (or to be made) in the panel. The fasteners and panel are then applied as before.
The fastener described is largely hidden when installed, leaving only a small hole at the front of the panel. The fastener holds the panel strongly enough ~to be used on a ceiling panel, and does not require glue.
The fastener also allows a panel to be removed and replaced with little damage to the panel. Although the screw part is completely hidden inside the installed panel, its position is detectable since it is close to the panel outer surface, typically within say 1/8 inch of the surface, and its hardness can be felt by a person running his hands over the slightly compressible panel. Conveniently, the template 40 can also be used to locate the position. The rod 30a can then be inserted into the screw member recess 27 and rotated in a clockwise direction to unscrew the screw member from the panel, so pushing it away from the substrate. This operation is facilitated by the use of the nut 24' shown in Figs.5 and 7 since the indented sides 28 guide the drive rod into the recess 27' .
Figs.l0 and 11 show another construction in which the screw part is formed of two members, namely base member 127 and a complementary outer member 130, the base member 127 again including the main parts of the screw part namely shaft 120 and the helical flight 123. The outer end of shaft 120 has a deep socket 120a of non-circular, specifically square, cross section, for reception of the outer member 130 which is in the form of an insert having an outer surface of square cross-section providing an interference fit into the recess, and an axial bore 130a of hexagonal cross-section for the drive rod.
The anchor screw 112 is inserted into the recess 120a while the base member is still detached from the outer member.
Preferably, the base member 127 is molded of plastic, and the insert or complementary member 130 is die cast metal.
Fig.l2 shows an exploded view of another embodiment in having an anchor screw 212, and in which the main screw part 210 is formed of two members, including a base member 227 and an outer member 222, the base member being attachable to the substrate before the outer member is attached to the base member.
As shown in Fig. l2, the screw part 222 has helical flight 223 surrounding shaft 220, the shaft having an inner end with an internal recess which is threaded to receive the threaded boss 227a of a detachable base member 227. As shown in Fig. l2, this base member has a flange 227b which provides a flat bearing surface rotatable in contact with the substrate S to maintain the proper orientation of the screw part, i.e. with its axis normal to the substrate. The base member 227 is fixed to the substrate by an anchor screw 212 which passes through a central bore in the base member and engages the top of the boss 227a; the anchor screw is put in place while the base member is detached from the main screw part 222, and is left sufficiently loose for the base member to rotate in contact with the substrate. Subsequently, the screw part 222 is threaded onto the boss 227a.
Figs.l4 and 15 show a construction similar to that of Figs . 12 and 13 in which the screw part 322 has a detachable base member 327 to which it may be attached by external screw threads 320a on the inner end of the shaft 320 and internal screw threads on a central boss 327a of the base member. While the parts are detached, the base member is rotatably attached to the substrate S by the anchor screw 312 which fits within a recess in the boss 327a, the screw 312 being left sufficiently loose for the base member to rotate with the rest of the screw part 322. The flat underside of the base member flange slides on the substrate S and maintains the desired orientation of the screw part.
Although the semi-rigid material of these panels is too weak to hold ordinary wood screws, some special screws or fasteners have been designed for fiberglass insulation, for example as shown in the following U.S. patents:
No.4,762,453, issued Aug.9,1988 to DeCaro, No.4,917,554, issued Apr.17,1990 to Bronn, and No.5,426,905, issued Jun.27,1995 to Rollhauser et al.
The screws or fasteners shown in these patents have large heads and are therefore unsuitable for use where a hidden or unobtrusive fastener is needed.
This invention and that of my aforesaid '375 application resulted from a need for an improved fastener especially for acoustic or insulating panels made of semi-rigid material. The fastener of this invention has at least some of the following advantages over previous fasteners:
1. It provides a strong hold on the panel so as to be suitable for holding ceiling panels;
2. It does not require the addition of any part by the panel manufacturer; it can be used on plain panels produced by many different manufacturers;
3. It is simple and quick to apply;
4. It provides a fastener which is almost entirely hidden, with only minimal disturbance of the front of the panel; and 5. It allows the panel to be removed and replaced.
My improved fastener, like some of those of the prior art, has a large diameter screw part. However, unlike the prior art screw devices mentioned above, this is a "blind" fastener which is concealed within the panel. This result is achieved by rotatably attaching the rear or inner end of the screw part (i.e. what is normally the "head" of the screw) to the substrate before the panel is put in place, and by providing the screw part with a non-circular drive recess at its outer end (or "tail" end) whereby it can be rotated by a slim drive rod, such as a hexagonal rod, which extends through the thickness of the panel and which is rotated from the front side of the panel. After the fastener is fully in place, the rod is removed leaving only a small hole in the panel.
The method of using the device as described in my aforesaid '375 application involves firstly attaching anchoring means to the substrate, such anchoring means rotatably holding the screw part, and then inserting the drive rod into the non-circular recess in the outer end of the screw part. The panel is then pushed onto the drive rod which has a sharpened outer end so that it penetrates the panel and emerges from the front of the panel, where it is rotated by a tool to turn the screw part and draw this into the rear of the panel until the panel is secure . While this procedure works, it has the drawback that precise positioning of the panel may be difficult. The drive rod needs to be inserted into the rear of the panel while this is still separated from the substrate by at least the length of the screw member and the drive rod, so that care and judgement is required if the panel is to be correctly positioned in its final location.
The present invention also provides, in one aspect, an improved procedure whereby a panel can be more precisely positioned than using the method described in my aforesaid application. Another aspect of the present invention provides a modified fastener device particularly suited to the new method. The new method can however also be used with certain of the fastener devices described in my aforesaid application.
Summary of the Invention In accordance with the present invention, a fastener for attaching a rear face of a panel of semi-rigid material to a substrate surface comprises:
an anchor part for attachment to the substrate surface;
a screw part having an inner end connected to the anchor part so as to be rotatable relative to the substrate, the screw part having a helical member or flight with an outer end capable of penetrating the rear face of the panel upon rotation of the screw part;
drive means for rotating the screw part including an elongated drive rod arranged to project from the outer end of the screw part and which is removable from the screw part after the panel has been installed.
The drive rod is capable of penetrating, or at least passing completely through, a panel so as to extend through the panel when the helical member contacts the rear face of the panel. The drive rod is thus accessible at the front face of the panel for rotation by a suitable tool to cause the helical member or flight (hereinafter the "flight") to rotate and penetrate the rear face of the panel and to become embedded in an inner portion of the panel to secure the panel onto the substrate. The drive rod is removable after the panel has been secured, leaving only a small hole in the panel front face, and leaving the fastener concealed within the panel.
It will be understood that the screw part used in accordance with this invention is fundamentally different from screw devices hitherto used for securing insulation, or for other purposes. Not only does it have a large diameter helical member or flange, similar to that of an auger, the helical member or flight being preferably well over an inch in diameter, but, unlike all screws known to the applicant, it is driven, not from its head, but from the other or "tail" end, i.e. the end that first penetrates the semi-rigid material.
This is achieved by use of the drive rod which projects from the outer end of the screw part and passes through the material and is accessed from the front face of the panel.
The drive rod may be a non-circular rod or pin, for example a hexagonal rod, which engages in a non-circular recess in the outer end of the screw part, and which can be pulled out of the recess when the panel has been installed. Alternatively, the drive rod may be formed integrally with the screw part, for example being formed of plastic, and may be broken off when the panel has been installed. The drive rod may have a pointed outer end.
Preferably, the screw part includes a shaft rotatably held by the anchor part, and a helical flight surrounding the shaft.
The helical flight has a diameter greater than its length; in fact the diameter of the helical flight is usually more than twice the shaft length. The drive rod has a diameter such as to leave no noticeable hole when withdrawn; preferably it has a diameter less than 1/8 of an inch.
In an alternative construction, the screw part may be a shaft surrounded by a helical flight in the form of a rod having an inner end connected to the shaft and a pointed outer end, and operates somewhat in the manner of a corkscrew.
As shown in the aforesaid '375 application, the anchor part may be a plate having at least one hole for screw attachment of the plate to the substrate.
In its preferred form, the present invention makes use of a fastener in which the screw part is rotatably attached to the substrate by an anchor screw which is co-axial with the non-circular drive recess in the outer end of the screw part and therefore also co-axial with the drive rod, and, generally, co-axial with the screw part. This allows the location of the anchor screw to be aligned with a bore in the panel which is preformed before the drive rod is put in place, rather than being formed by the drive rod upon being pushed through from the panel rear face, as in my '375 application.
Constructions of the fastener device in which an anchor screw is co-axial with the screw part and its drive means are shown in my aforesaid '375 application, in Figs.9 and 10, Figs.ll and 12, and in Figs.l3 and 14 of that application. The present application shows a further, preferred design for co-axial anchor screw and drive rod having additional desirable features. In all these designs, in order to allow insertion of the anchor screw, the screw part is separable into a base member and a complementary member, the base member being attached to the substrate by the anchor screw while separated from the complementary member.
The fastener device in accordance with this invention may be defined as comprising:
a screw part having an inner end capable of being rotatably held relative to the substrate by an anchor screw having a head, the screw part having a helical flight with an outer end capable of penetrating the rear face of the panel upon rotation of the helical flight;
drive means for rotating said screw part, the drive means including a non-circular drive recess accessible from an outer end of the screw part and suitable for engagement by a drive rod which is capable of extending fully through a transverse bore in the panel so that the drive rod is accessible for rotation at the front face of the panel to cause the helical flight to penetrate and engage a rear portion of the panel, and which rod is removable from the screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
the screw part including a base member and a complementary member, the base member having an aperture~for receiving the anchor screw and being attachable to the substrate by the head of the anchor screw while the base member is separate from the complementary member, the complementary member being attachable to the base member when the anchor screw is in place in the base member aperture, said complementary member providing the non-circular drive recess, the base member being rotatable about the axis of the anchor screw when the anchor screw is in place in the substrate;
and wherein the axis of the base member aperture which receives the anchor screw is coincident with the axis of the non-circular drive recess for the drive rod in the complementary member when the two members are assembled together, whereby the bore in the panel which receives the drive rod may be co-axial with the anchor screw.
The base member may include the helical flight and the aperture for receiving the anchor screw, and may have a central socket leading to the aperture for the anchor screw. The complementary member may be an insert engageable in the central socket and which has the non-circular recess for receiving the drive rod. This is the arrangement shown in Figs.l3 and 14 of the aforesaid '375 application, and is also the preferred arrangement of this present invention. The central socket is non-circular, and the insert has an outer surface which fits non-rotatably into the central socket. In the preferred embodiment in accordance with this present invention, the insert is connected to the base member by a flexible hinge part which allows the insert to be removed from the base member while the anchor screw is being inserted into the base member aperture.
In alternative arrangements, the complementary member includes the helical flight and has screw threaded attachment to the base member.
The invention also provides a method for attaching the rear of a panel of semi-rigid material to a substrate at a desired installation position by making use of a screw part having an inner end capable of being held relative to the substrate by an anchor screw having a head, such that the screw part can rotate relative to the substrate about an axis co-axial with the anchor screw, the screw part having a helical flight with an outer end capable of penetrating the rear of the panel upon rotation of the helical flight, the screw part comprising a base member and a complementary member, the base member having an aperture for the anchor screw and the complementary member having a non-circular drive recess for a drive rod which is co-axial with the anchor screw aperture when the two members are assembled together, the method comprising the steps of forming a transverse bore in the panel and marking an anchor screw location for the anchor screw in the substrate such that the anchor screw will be aligned with the transverse bore when the panel is in its desired installation position;
fixing the base member of the screw part to the substrate by means of the anchor screw inserted at the said location, with the anchor screw having a head engaging inside the aperture of the base member, whereby an inner end of said base member is rotatably held relative to the substrate by the anchor screw head;
fitting the complementary member of the screw part to the base member;
placing a panel at the installation position and passing an elongated drive rod through the said transverse bore in the panel and fitting an inner end of the drive rod into the non-circular drive recess of the complementary~member so that a portion of the drive rod extends through the panel and has its outer end part protruding from a front face of the panel when the helical flight of the screw part contacts the panel rear face, rotating the drive rod by its protruding end part to cause the helical flight of the screw part to penetrate and engage a rear portion of the panel, and, upon further rotation of the screw part, to secure the panel onto the substrate, and removing the drive rod from the outer end of the screw part after the panel has been secured so that the fastener is essentially concealed within the panel.
Marking the locations for the anchor screw hole and making the transverse bores in the panel may be done simultaneously, by holding the panel in a position in which it is to be installed while forming the bore in the panel by use of a penetrating tool inserted from the front face, which tool at the same time also marks an anchor screw location in the substrate, so that the anchor screw location is aligned with the bore.
Alternatively, the making of the bores in the panel and the marking of locations for the anchor screws may be done separately by using a template, or other measuring means, to ensure that the anchor screws are located correctly relative to the bore positions for the panel to be properly positioned.
The drive rod may be a non-circular rod or pin, for example a hexagonal rod, which engages the non-circular drive recess in the screw part, and which can be pulled out of the recess when the panel has been installed. Unlike in the method of my aforesaid pending application, with this method it is possible to use a standard Allen key or wrench as the drive rod, since its outer end does not need to pass through the panel.
Preferably, the helical flight of the screw part has a diameter greater than its length; in fact the diameter of the helical flight is usually more than twice the shaft length. The drive rod has a diameter such as to leave no noticeable hole when withdrawn; preferably it has a diameter less than 1/8 of an inch. This is a small fraction of the diameter of the helical flight which is typically 1 1/2 to 2 inches.
Brief Description of the drawincrs.
Preferred embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which;
Fig.l is a sectioned side view of one embodiment of improved screw component of this invention fixed to a substrate;
Fig.2 shows the same parts when the fastener is fully assembled and is in position for the initial stage of engagement with a panel;
Fig.3 is a view of the same parts as Fig.2 but with the panel approaching its final position;
Fig.4 is an exploded sectional elevation of the complementary member of the screw part of Figs.l to 3;
Fig.5 is a view similar to Fig.4 of a preferred form of the complementary member in accordance with this invention;
Fig.6 is a perspective view of the main component of the preferred form of fastener in accordance with the present invention;
Fig.7 is a perspective view of a component of the complementary member the fastener of Fig.6;
Fig.8 is a perspective view of a simple template which can be used to position bores and anchor screw locations in accordance with the invention;
Fig.9 is a view of a panel indicating the use of a template of Fig.8 for positioning bores;
Fig.lO is a perspective view of two components of another screw part in accordance with the invention;
Fig.ll is a sectional elevation of the Fig.lO screw part when attached to a substrate by an anchor screw;
Fig. l2 is a perspective view of components of a further screw part;
Fig.l3 is a sectional elevation of the base member of the screw part of Fig. l2, as attached to a substrate;
Fig.l4 is a perspective view of yet another embodiment of screw part in accordance with the invention; and Fig.l5 is a view similar to Fig.l3 of the base member of the Fig. l4 embodiment.
Detailed Description.
The fasteners of Figs . 10 to 15 are the same as some of the fasteners previously described in my aforesaid Canadian Patent Application No.2,3p1,375; however this present application describes and claims a new way of installing these fasteners.
The new fastener of Figs.1 to 7, and especially Figs. 5 to 7, are now the preferred embodiments.
Figs . 1 to 4 show a f first form of device in accordance with the invention which can be used in association with other like devices to attach an acoustic panel P to a substrate S.
Typically, six of the fastening devices would be used for a 4 foot by 8 foot panel.
As shown in Figs.1 to 4 the screw part 10 is formed of two members namely a base member 12 and a complementary member 14, the latter being in the form of a hexagonal cup which fits non-rotatably into a non-circular, specifically hexagonal, socket 15 in the base member. As indicated in Fig.l, major parts of these members are integrally molded as one component; suitable plastic material for these molded parts is polypropylene. The members are attached by an integral flexible strip 16 having a thinned central hinge portion 17 which allows the complementary cup member 14 to be initially removed from the base member 12 and to be later inserted into the socket 15. At the base of the socket is a circular aperture 18 for an anchor screw 20 which is shown in Figs.1 and 2, and which can be inserted into the aperture, to engage the substrate S, while the cup member 14 is removed from the socket 15. The anchor screw 20 is an ordinary wood screw having a head suitable for engaging the interior of the socket 15 to hold the screw part in place on the substrate while allowing it to rotate about the axis of the anchor screw.
The base member of the screw part has a helical flight 23 partly surrounding a central shaft 22; the flight extends about 270° around the shaft. The helical flight is wide relative to its length, its diameter being much greater than its length, and preferably greater than twice its length. A suitable diameter is between 1/2 to 2 inches, and a suitable length for the helical flight is about 1/2 to 5/8 inches. The outer or leading edge 23a of the helical flight is sharpened and curves outwards from the adjacent thread portion so as to "bite" into the semi-rigid panel material. The shaft 22 and a main part of the flight 23 are generally co-axial with the anchor screw aperture 18.
The plastic cup 14 has a hexagonal surrounding wall 14a which non-rotatably receives a hexagonal metal nut 24; the nut is a press fit into the cup and is retained by detent lips 14b.
This nut may be a standard off-the-shelf component, and has an internal thread into which is fixed a set screw 26, shown in Fig.4, also an off-the-shelf component, having a hexagonal drive recess 27 suitable for receiving a removable hexagonal drive rod 30. This drive rod 30 may be a standard Allen key of about 3/32 inches diameter (i.e. across its opposite flat surfaces). However, in its preferred form as shown in Figs.2 and 3, the drive rod is a modified form of "Allen" key having one long leg 30a of the usual Allen key form, and the other, mutually perpendicular, leg 30b extended and sharpened so as to act as a tool for piercing the panel and for marking the anchor screw position on the substrate. The drive rod leg 30a has a length sufficient that, as shown in Fig.2, when a panel P is placed against the outside of the screw part 10, the drive rod can be inserted through a bore in the panel to engage the recess 27 of the complementary member 14 while the leg 30b of the drive rod, which is suitable for hand manipulation, remains outside the panel. The panel is typically about 1 to 1 1/8 inch in thickness, and the length of drive rod leg 30a will be about 2 inches. Clearly, by lengthening the drive rod, panels of greater than 1 inch thickness can be installed using the same system.
Figs.5, 6 and 7 show a preferred form of the screw part in which the metal nut 24', instead of being formed of two off-the-shelf parts assembled together, is an integral part die cast from zinc, and formed with the hexagonal drive recess 27' .
This nut 24' also differs from that of the first embodiment by having the recess 27' at the base of a conical depression, the inwardly sloping sides 28 of which serve to guide the end of the drive rod towards the recess 27'. This nut fits into the same cup 14 as previously described.
In one method in accordance with the invention, the first step is to hold the panel P in the desired installation position while using a penetrating tool such as leg 30b of the drive rod 30 to form a bore in the panel for each screw device which is to be used. As each bore is made the tool is pushed in sufficiently to make a lead hole or indentation in the substrate S thus to provide an anchor screw location. The panel is then removed, and, at each anchor screw location, the base member 12 of a screw part 10 is secured to the substrate as shown in Fig.l by inserting the anchor screw 20 into the aperture 18 and into the anchor screw location in the substrate. The anchor screw is left just loose enough to allow the screw part to rotate; this is of course done with the cup member 14 removed as in Fig.l. The cup member 14, complete with nut 24 or 24' , is then inserted into the socket 15, as shown in Fig.2, by bending strip 16 about hinge 17.
The panel is then placed in position, and a drive rod 30a is pushed through the appropriate bore which has been formed in the panel and into the drive member recess 27 (or 27' for the Fig.5 version), as shown in Fig.2. The panel is then pushed on to the screw part while the drive rod is rotated to turn the screw in such a direction as to cause the outer end 23a of the helical flight to engage in the rear face of the panel and to draw the panel onto the screw. Suitable rotation of the drive rod causes the screw part to become embedded in the interior of the panel as shown in Fig.3; in the final stages of movement the panel is securely in contact with the substrate and the outer end of the screw is close to the front surface of the panel. At this stage the drive rod 30 is removed, leaving only a small and unnoticeable hole at the front face of the panel.
The screw part 10 as shown in Figs.l to 3 has a "right-hand" thread or flight 23 which requires, counter-clockwise rotation to engage the panel when, as described, it is rotated by drive rod 30 from what is, in effect, the tail end of the screw. This is preferred since it has been found that rotation in the opposite sense may tend to tighten the anchor screw 20 and prevent further rotation.
This method may not work well when the panel is applied to hard surfaces which cannot easily be indented or marked by a pointed hand tool such as leg 30b of the tool described. In this case it may be necessary to use a template for setting the anchor screw locations and those of the bores in the panel; a suitable template is shown in Figs.8 and 9., As shown best in Fig.8, the template 40 is a simple plate, for example of cardboard, having a flange 42 along one edge, and having two holes 44 spaced a distance D from the flange edge of the template, and being also separated by the same distance D; the distance D is suitably 5 inches. The template may be used as shown in Fig.9 at corners of a panel to locate bores the distance "D'~ from the two adjacent sides, by holding the flange 42 against one adjacent side while aligning an adjacent edge of the template with that of the panel. Four bores for fasteners adjacent the corners may be sufficient for a 4 foot by 4 foot panel, but for a larger panel which requires 6 fasteners, such as illustrated in Fig.9, additional bores will be made near to the centers of the longer sides. For these, the template will provide only the distance "D" from the sides; the positions of the template on these longer sides must be determined by measurement.
After (or before) the bores in the panel have been made by the template, the panel is placed into the desired position on the substrate and the perimeter is marked out . The panel is then removed and the template 40 used again to mark the anchor screw positions which correspond to bores made (or to be made) in the panel. The fasteners and panel are then applied as before.
The fastener described is largely hidden when installed, leaving only a small hole at the front of the panel. The fastener holds the panel strongly enough ~to be used on a ceiling panel, and does not require glue.
The fastener also allows a panel to be removed and replaced with little damage to the panel. Although the screw part is completely hidden inside the installed panel, its position is detectable since it is close to the panel outer surface, typically within say 1/8 inch of the surface, and its hardness can be felt by a person running his hands over the slightly compressible panel. Conveniently, the template 40 can also be used to locate the position. The rod 30a can then be inserted into the screw member recess 27 and rotated in a clockwise direction to unscrew the screw member from the panel, so pushing it away from the substrate. This operation is facilitated by the use of the nut 24' shown in Figs.5 and 7 since the indented sides 28 guide the drive rod into the recess 27' .
Figs.l0 and 11 show another construction in which the screw part is formed of two members, namely base member 127 and a complementary outer member 130, the base member 127 again including the main parts of the screw part namely shaft 120 and the helical flight 123. The outer end of shaft 120 has a deep socket 120a of non-circular, specifically square, cross section, for reception of the outer member 130 which is in the form of an insert having an outer surface of square cross-section providing an interference fit into the recess, and an axial bore 130a of hexagonal cross-section for the drive rod.
The anchor screw 112 is inserted into the recess 120a while the base member is still detached from the outer member.
Preferably, the base member 127 is molded of plastic, and the insert or complementary member 130 is die cast metal.
Fig.l2 shows an exploded view of another embodiment in having an anchor screw 212, and in which the main screw part 210 is formed of two members, including a base member 227 and an outer member 222, the base member being attachable to the substrate before the outer member is attached to the base member.
As shown in Fig. l2, the screw part 222 has helical flight 223 surrounding shaft 220, the shaft having an inner end with an internal recess which is threaded to receive the threaded boss 227a of a detachable base member 227. As shown in Fig. l2, this base member has a flange 227b which provides a flat bearing surface rotatable in contact with the substrate S to maintain the proper orientation of the screw part, i.e. with its axis normal to the substrate. The base member 227 is fixed to the substrate by an anchor screw 212 which passes through a central bore in the base member and engages the top of the boss 227a; the anchor screw is put in place while the base member is detached from the main screw part 222, and is left sufficiently loose for the base member to rotate in contact with the substrate. Subsequently, the screw part 222 is threaded onto the boss 227a.
Figs.l4 and 15 show a construction similar to that of Figs . 12 and 13 in which the screw part 322 has a detachable base member 327 to which it may be attached by external screw threads 320a on the inner end of the shaft 320 and internal screw threads on a central boss 327a of the base member. While the parts are detached, the base member is rotatably attached to the substrate S by the anchor screw 312 which fits within a recess in the boss 327a, the screw 312 being left sufficiently loose for the base member to rotate with the rest of the screw part 322. The flat underside of the base member flange slides on the substrate S and maintains the desired orientation of the screw part.
Claims (17)
1. A fastener device for attaching a rear face of a panel of semi-rigid material to a substrate, comprising:
an anchor part for attachment to the substrate a screw part having an inner end adapted to be held by said anchor part in such manner as to be rotatable relative to the substrate when said anchor part is attached to said substrate, said screw part having a helical flight with a leading edge capable of cutting into semi-rigid material, whereby an outer end of said screw part is capable of penetrating the rear face of a said panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including a non-circular recess open to an outer end of said screw part and suitable for engagement by a non-circular end of a drive rod extending through a transverse bore in the panel, such that rotation of the drive rod at the front face of the panel can cause the helical flight to penetrate and engage a rear portion of the panel, said drive means allowing removal of the drive rod from said screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
said non-circular recess being sized to allow engagement and rotation by a drive rod having a diameter which is less than 1/8 inch so as to require only a similarly small diameter bore in the panel, whereby the fastener is essentially concealed within the panel after removal of the drive rod.
an anchor part for attachment to the substrate a screw part having an inner end adapted to be held by said anchor part in such manner as to be rotatable relative to the substrate when said anchor part is attached to said substrate, said screw part having a helical flight with a leading edge capable of cutting into semi-rigid material, whereby an outer end of said screw part is capable of penetrating the rear face of a said panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including a non-circular recess open to an outer end of said screw part and suitable for engagement by a non-circular end of a drive rod extending through a transverse bore in the panel, such that rotation of the drive rod at the front face of the panel can cause the helical flight to penetrate and engage a rear portion of the panel, said drive means allowing removal of the drive rod from said screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
said non-circular recess being sized to allow engagement and rotation by a drive rod having a diameter which is less than 1/8 inch so as to require only a similarly small diameter bore in the panel, whereby the fastener is essentially concealed within the panel after removal of the drive rod.
2. A fastener according to claim 1, wherein the helical flight of the screw part has a diameter greater than one inch.
3. A fastener according to claim 1, wherein the helical flight of the screw part has a diameter greater than 1 1/2 inches.
4. A fastener according to claim 1, wherein the screw part includes a base member and a complementary member, said complementary member having said non-circular recess, said base member having a bore for receiving an anchor screw constituting said anchor part and being attachable to the substrate while the base member is separated from the complementary member, said base member having a surface rotatable while in contact with said substrate surface.
5. A fastener device for attaching a rear face of a panel of semi-rigid material to a substrate, comprising:
an anchor part for attachment to the substrate;
a screw part having an inner end adapted to be held by said anchor part in such manner as to be rotatable relative to the substrate when said anchor part is attached to said substrate, said screw part having a helical flight with an outer end capable of penetrating the rear face of a said panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including a non-circular recess open to an outer end of said screw part and suitable for engagement by a non-circular end of a drive rod extending through a transverse bore in the panel, such that rotation of the drive rod at the front face of the panel can cause the helical flight to penetrate and engage a rear portion of the panel, said drive means allowing removal of the drive rod from said screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
said non-circular recess being sized to allow engagement by a drive rod having a diameter which is a small fraction of the diameter of said helical flight so as to require only a similarly small diameter bore in the panel, whereby the fastener is essentially concealed within the panel after removal of the drive rod, and wherein the helical flight has a diameter greater than the length of the screw part.
an anchor part for attachment to the substrate;
a screw part having an inner end adapted to be held by said anchor part in such manner as to be rotatable relative to the substrate when said anchor part is attached to said substrate, said screw part having a helical flight with an outer end capable of penetrating the rear face of a said panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including a non-circular recess open to an outer end of said screw part and suitable for engagement by a non-circular end of a drive rod extending through a transverse bore in the panel, such that rotation of the drive rod at the front face of the panel can cause the helical flight to penetrate and engage a rear portion of the panel, said drive means allowing removal of the drive rod from said screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
said non-circular recess being sized to allow engagement by a drive rod having a diameter which is a small fraction of the diameter of said helical flight so as to require only a similarly small diameter bore in the panel, whereby the fastener is essentially concealed within the panel after removal of the drive rod, and wherein the helical flight has a diameter greater than the length of the screw part.
6. A fastener according to claim 5, wherein the helical flight of the screw part has a diameter greater than twice the length of the screw part.
7. The combination of a panel of semi-rigid material and a fastener device for attaching a rear face of said panel to a substrate, said fastener device comprising:
an anchor part for attachment to the substrate surface;
a screw part having an inner end adapted to be held by said anchor part in such manner as to be rotatable relative to the substrate when said anchor part is attached to said substrate, said screw part having a helical flight with an outer end capable of penetrating the rear face of a said panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including an elongated drive rod arranged to extend from an outer end portion of said screw part, said drive rod being removable from the screw part after the panel has been secured, said drive rod being capable of extending from said screw part through a bore in said panel when the helical flight is in contact with the rear face of the panel so that the drive rod is accessible for rotation at a front face of the panel to cause the helical flight to penetrate and engage a rear portion of said panel, and, upon further rotation of the screw part, to secure the panel onto the substrate, said drive rod having a diameter which is less than 1/8 inch so that said bore in the panel is of a similarly small diameter, whereby the fastener may be essentially concealed within the panel after removal of the drive rod.
an anchor part for attachment to the substrate surface;
a screw part having an inner end adapted to be held by said anchor part in such manner as to be rotatable relative to the substrate when said anchor part is attached to said substrate, said screw part having a helical flight with an outer end capable of penetrating the rear face of a said panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including an elongated drive rod arranged to extend from an outer end portion of said screw part, said drive rod being removable from the screw part after the panel has been secured, said drive rod being capable of extending from said screw part through a bore in said panel when the helical flight is in contact with the rear face of the panel so that the drive rod is accessible for rotation at a front face of the panel to cause the helical flight to penetrate and engage a rear portion of said panel, and, upon further rotation of the screw part, to secure the panel onto the substrate, said drive rod having a diameter which is less than 1/8 inch so that said bore in the panel is of a similarly small diameter, whereby the fastener may be essentially concealed within the panel after removal of the drive rod.
8. A fastener device for attaching a rear of a panel of semi-rigid material to a substrate, comprising:
a screw part having an inner end capable of being rotatably held relative to the substrate by an anchor screw having a head, said screw part having a helical flight with an outer end capable of penetrating the rear of the panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including a non-circular recess open at an outer end of said screw part and suitable for engagement by a non-circular end of a drive rod extending through a transverse bore in the panel, such that rotation of the drive rod at the front face of the panel can cause the helical flight to penetrate and engage a rear portion of the panel, said drive means allowing removal of the drive rod from said screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
said screw part including a base member and a complementary member, said base member having an aperture for receiving the anchor screw and being attachable to the substrate by the head of the anchor screw while the base member is separate from the complementary member, said complementary member being attachable to the base member when the anchor screw is in place in the base member aperture, the base member being rotatable about the axis of the anchor screw while the anchor screw engages the substrate, and wherein the axis of the base member aperture which receives the anchor screw is coincident with the axis of the non-circular recess for the drive rod when the two members are assembled together, whereby the bore in the panel which receives the drive rod may be coaxial with the anchor screw.
a screw part having an inner end capable of being rotatably held relative to the substrate by an anchor screw having a head, said screw part having a helical flight with an outer end capable of penetrating the rear of the panel upon rotation of said helical flight;
drive means for rotating said screw part, said drive means including a non-circular recess open at an outer end of said screw part and suitable for engagement by a non-circular end of a drive rod extending through a transverse bore in the panel, such that rotation of the drive rod at the front face of the panel can cause the helical flight to penetrate and engage a rear portion of the panel, said drive means allowing removal of the drive rod from said screw part after the panel has been secured so that the fastener is essentially concealed within the panel;
said screw part including a base member and a complementary member, said base member having an aperture for receiving the anchor screw and being attachable to the substrate by the head of the anchor screw while the base member is separate from the complementary member, said complementary member being attachable to the base member when the anchor screw is in place in the base member aperture, the base member being rotatable about the axis of the anchor screw while the anchor screw engages the substrate, and wherein the axis of the base member aperture which receives the anchor screw is coincident with the axis of the non-circular recess for the drive rod when the two members are assembled together, whereby the bore in the panel which receives the drive rod may be coaxial with the anchor screw.
9. A fastener according to claim 8, wherein said non-circular recess is engageable by a drive rod which has a diameter less than 1/8 inch.
10. A fastener according to claim 8, wherein the helical flight of the screw part has a diameter greater than one inch.
11. A fastener according to claim 8, wherein said base member includes the helical flight of the screw part and has a central socket leading to said aperture for receiving the anchor screw, and wherein the complementary member is an insert engageable in said central socket and which has said non-circular recess for receiving said drive rod.
12. A fastener according to claim 11, wherein said central socket is non-circular, and wherein said insert has an outer surface which fits non-rotatably into said central socket.
13. A fastener according to claim 11, wherein said insert is connected to said base member by a hinge which allows the insert to be removed from the base member while said anchor screw is being inserted into the base member aperture.
14. A fastener according to claim 13, wherein said insert has a depression with inwardly sloping sides which lead to said non-circular recess.
15. A method of attaching a rear of a panel of semi-rigid material to a substrate at a desired installation position by making use of a screw part having an inner end capable of being held relative to the substrate by an anchor screw having a head, such that the screw part can rotate relative to the substrate about an axis co-axial with the anchor screw, said screw part having a helical flight with an outer end capable of penetrating the rear of the panel upon rotation of said helical flight, said screw part having a base member and a complementary member, said base member having an aperture for said anchor screw and said complementary member having a non-circular drive recess for a drive rod which is co-axial with the anchor screw aperture when the two members are assembled together, the method comprising the steps of:
forming a transverse bore through the panel and marking an anchor screw location for said anchor screw in the substrate such that said anchor screw will be aligned with the transverse bore when the panel is in its installation position;
fixing the base member of a said screw part to the substrate by means of said anchor screw inserted at said anchor screw location, with said anchor screw head engaging inside said aperture of the base member, whereby an inner end of said base member is rotatably held relative to the substrate by said anchor screw head:
fitting said complementary member of the screw part to the base member of the screw part;
placing a panel at the installation position and passing an elongated drive rod through said transverse bore in the panel and fitting an inner end of the drive rod into the non-circular drive recess of the complementary member so that an outer end part of the rod protrudes from a front face of the panel when the helical flight of the screw part contacts the said panel rear, rotating said drive rod by its protruding end part to cause the helical flight to penetrate and engage a rear portion of the panel, and, upon further rotation of the screw part, to secure the panel onto the substrate, and removing said drive rod from the screw part after the panel has been secured so that the fastener is essentially concealed within the panel.
forming a transverse bore through the panel and marking an anchor screw location for said anchor screw in the substrate such that said anchor screw will be aligned with the transverse bore when the panel is in its installation position;
fixing the base member of a said screw part to the substrate by means of said anchor screw inserted at said anchor screw location, with said anchor screw head engaging inside said aperture of the base member, whereby an inner end of said base member is rotatably held relative to the substrate by said anchor screw head:
fitting said complementary member of the screw part to the base member of the screw part;
placing a panel at the installation position and passing an elongated drive rod through said transverse bore in the panel and fitting an inner end of the drive rod into the non-circular drive recess of the complementary member so that an outer end part of the rod protrudes from a front face of the panel when the helical flight of the screw part contacts the said panel rear, rotating said drive rod by its protruding end part to cause the helical flight to penetrate and engage a rear portion of the panel, and, upon further rotation of the screw part, to secure the panel onto the substrate, and removing said drive rod from the screw part after the panel has been secured so that the fastener is essentially concealed within the panel.
16. A method of attaching a panel to a substrate according to claim 15, wherein said steps of forming the transverse bore in the panel and marking the screw anchor location are performed simultaneously by a penetrating tool being pushed through the panel when held in its installation position.
17. A method of attaching a panel to a substrate according to claim 15, wherein said steps of forming the transverse bore through the panel and marking the screw anchor location are performed separately by use of a template to mark the positions of the bore and anchor screw, these steps including positioning the template using edges of the panel so that a hole in the template indicates the position for the bore, and positioning the template using sides of an area at which the panel is to be placed so that said hole indicates the position for the anchor screw.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2340590 CA2340590C (en) | 2000-03-20 | 2001-03-13 | Fastener device and method for attaching a panel of semi-rigid material to a substrate |
| US09/948,655 US6652208B2 (en) | 1999-04-08 | 2001-09-10 | Fastener device and method for attaching a panel of semi-rigid material to a substrate |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2,301,375 | 2000-03-20 | ||
| CA 2301375 CA2301375A1 (en) | 1999-04-08 | 2000-03-20 | Fastener device for attaching a panel of semi-rigid material to a substrate |
| CA 2340590 CA2340590C (en) | 2000-03-20 | 2001-03-13 | Fastener device and method for attaching a panel of semi-rigid material to a substrate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2340590A1 CA2340590A1 (en) | 2001-09-20 |
| CA2340590C true CA2340590C (en) | 2006-07-18 |
Family
ID=25681638
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2340590 Expired - Lifetime CA2340590C (en) | 1999-04-08 | 2001-03-13 | Fastener device and method for attaching a panel of semi-rigid material to a substrate |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2340590C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP4047223A1 (en) | 2021-02-19 | 2022-08-24 | Rotofast Inc. | Fastener device and method for attaching polyester fiber panels to a substrate |
-
2001
- 2001-03-13 CA CA 2340590 patent/CA2340590C/en not_active Expired - Lifetime
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP4047223A1 (en) | 2021-02-19 | 2022-08-24 | Rotofast Inc. | Fastener device and method for attaching polyester fiber panels to a substrate |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2340590A1 (en) | 2001-09-20 |
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Effective date: 20210315 |