WO2013007878A1

WO2013007878A1 - A fastening member for elements, a method and a system for manufacturing a fastening member, and an arrangement wherein elements are fastened using a fastening member

Info

Publication number: WO2013007878A1
Application number: PCT/FI2012/050707
Authority: WO
Inventors: Ari P Kinnunen; Harri Latikka
Original assignee: Upm-Kymmene Corporation
Priority date: 2011-07-08
Filing date: 2012-07-05
Publication date: 2013-01-17
Also published as: FI20115740L; EP2729641A4; EP2729641A1; FI20115740A0; CN103649438A; US20140174025A1

Abstract

The invention relates to a fastening member for fastening of elements, which fastening member has at least a first side (3) and a second side (2), wherein the first side (3) of the fastening member (1) has at least two transversal extensions (12a, 12b). The fastening member has at least one longitudinal extension (11 a, 11b), and at least two holes (10a, 10b, 10c), in the longitudinal axis of the fastening member. The invention further relates to a system and a method for manufacturing a fastening member used for fastening of elements, and an arrangement and a use for fastening elements.

Description

A fastening member for elements, a method and a system for manufacturing a fastening member, and an arrangement wherein elements are fastened using a fastening member Field of the Invention

This invention relates to a fastening member for elements. The invention further relates to a method and a system for fastening elements using a fastening member. The invention also relates to a method and a system for manufacturing a fastening member for elements. In addition, the invention relates to an arrangement wherein elements are fastened using a fastening member.

Background of the Invention

Decking boards and railstep boards are typically used as terrace elements. Fastening of the decking boards and the railstep boards is usually implemented by screwing screws through the elements to the substructure. Summary of the Invention

The present invention discloses a new fastening member. In addition, the present invention discloses a method and a system for manufacturing a fastening member. The present invention further discloses an arrangement wherein elements, such as boards, are fastened using a fastening member. Additionally, the present invention discloses a use of the fastening member.

The inventors of the present invention have surprisingly found a novel solution for fastening of the elements, such as decking boards and railsteps. One fastening member according to the invention can be contacted with two or three elements when fastened. There is at least one longitudinal extension in the fastening member. In addition, there are preferably two transversal extensions in the fastening member. The fastening member advantageously comprises at least two holes, more preferably at least three holes in the longitudinal axis of the fastening member in order to fasten the elements perpendicular to each other. According to an example embodiment of the invention, some of the holes of the fastening member may be covered by plastic film in order to facilitate the use of the fastening member during the installation process.

Thanks to the new solution, it is possible to fasten an element, such as a decking board, perpendicular to another element, such as a decking board or a railstep board. Aspects of the invention are characterized by what is stated in the independent claims. Various embodiments of the invention are disclosed in the dependent claims.

With the novel fastening member, the fastening of the elements, such as decking boards and the railstep boards, may be indirect. In other words, the fastening member may fasten the elements to the support rail in such a way that thermal expansion is provided for.

The new fastening member may make it possible

- to fasten elements, such as a railstep board and a decking board, perpendicularly with each other,

to cover a support rail; hence, the support rail may be of any colour if it is covered by the fastening member,

to fasten even long decking boards and/or railstep boards in such a way that normal thermal elongation is allowed,

that thermal expansion may not cause problems due to the longitudinal extension of the fastening member.

The fastening member preferably comprises recycled cellulose fibers and recycled plastic polymers. It is preferably manufactured by an injection moulding technique.

When used in practice, the fastening member may be connected, for example, to two or three decking boards, or to two decking boards and one railstep board, or to two railstep boards and one decking board, or to two decking boards. If the fastening member is connected to three elements, one of the elements is placed perpendicular to the others.

Description of the Drawings

In the following, the invention will be illustrated by drawings in which

Figs 1 to 8 show example embodiments of the fastening member, Fig. 9 shows an example embodiment of the system according to the invention,

Figs 10 to 13 show example embodiments of the use of the fastening member.

Detailed Description of the Invention

The following reference numbers are used in this application:

1 fastening member,

2 second side of the fastening member,

3 first side of the fastening member,

4 width of the first side of the fastening member,

5 height of the first side of the fastening member,

6 height of the second side of the fastening member,

7 width of the second side of the fastening member,

8 length of the first side of the fastening member,

9 length of the second side of the fastening member,

10 hole, for example a screw hole,

10a first hole,

10b second hole,

10c third hole,

1 1 longitudinal extension of the first side,

1 1 a first longitudinal extension of the first side,

1 1 b second longitudinal extension of the first side, 12 transversal extension of the first side,

12a first transversal extension of the first side,

12b second transversal extension of the first side,

13 end side of the fastening member,

13a first end of the fastening member,

13b second end of the fastening member,

14 bevel of the hole 10a, 10b, 10c,

20 raw materials,

21 decking board,

22 angle element, i.e. railstep board,

23 support rail,

24 injection moulding apparatus, compression moulding apparatus, or extruder,

FS first transversal side, and

SS second transversal side.

The term "first side" refers to the side that is partly visible when the fastening member has been installed. If the fastening member (when installed) is part of a floor, the first side is the top side of the fastening member.

The term "second side" refers to the side that is not usually visible (at all) when the fastening member has been installed. If the fastening member (when installed) is part of a floor, the second side is the bottom side of the fastening member.

The term "elements" refers to decking boards 21 and to railstep boards 22.

The term railstep board 22 refers to an angle element. In figures 1 , 5, 7a, and 7b, the fastening member is shown from the first side. In figures 2 and 6, the fastening member is shown from the second side. In figure 3, the fastening member is shown from a longitudinal side. In figures 4a and 4b, the fastening member is shown from an end side 13a, 13b. Figure 8 shows a longitudinal cross-sectional view of the fastening member 1 . Figures 10, 1 1 , 12 and 13 illustrate some examples of the fastening member in use, wherein figure 13 shows a cross-sectional view of the fastened elements, and figure 12 shows fastened elements partially in a cross- sectional view.

The fastening member 1 is preferably symmetrical in the width direction 4, i.e. the first transversal side FS of the fastening member is preferably substantially a mirror image of the second transversal side SS of the fastening member. Therefore, the dimensions of the fastening member 1 presented in this application relate to both transversal sides, i.e. to the first transversal side FS and to the second transversal side SS even if only one of the transversal sides FS, SS may be described.

The new fastening member 1 is a product which is capable of fastening elements simultaneously. The railstep 22 is very often installed perpendicular to the decking board 21 , which may prevent the use of a normal fastening member since there should always be space for thermal expansion between the boards. By using the fastening member 1 , elements, such as the railstep board 22 and the decking board 21 , may be fastened and there may still remain space for thermal expansion. The fastening member has preferably a structure that is compatible with a decking board 21 and/or a railstep board 22 in order to achieve good fastening of the fastened elements.

The fastening member 1 has a first side 3 and a second side 2. The width 4 of the first side 3 of the fastening member 1 is preferably between 18 and 26 mm, for example 22 mm. The height 5 of the first side 3 of the fastening member is preferably between 5 and 7 mm, for example 6 mm. The length 8 of the first side 3 of the fastening member 1 may be at least 30 mm, preferably at least 40 mm, and more preferably at least 55 mm, in order to achieve good fastening effect of the fastened decking boards and/or railstep boards and to cover the support rail beneath. By covering the support rail 23 with a fastening member 1 it may be possible to manufacture the support rail 23 in any given colour. The length 8 of the first side 3 of the fastening member 1 is preferably not greater than 100 mm, more preferably not greater than 80 mm. The width 7 of the second side 2 of the fastening member 1 is preferably between 5 and 15 mm, more preferably between 5 and 10 mm or between 5 and 7 mm. The height 6 of the second side 2 of the fastening member 1 is preferably between 5 and 10 mm or between 5 and 8 mm, for example 6 mm. The length 9 of the second side 2 of the fastening member 1 is preferably at least 31 mm, more preferably at least 33 mm, in order to achieve good fastening effect of the fastened elements.

The weight of the fastening member 1 may be between 0.8 and 1 .4 g/cm³, more advantageously between 0.9 and 1 .3 g/cm³, i.e. the weight of one fastening member is preferably between 5 and 20 g, more preferably between 7 and 15 g.

The fastening member 1 has preferably two transversal extensions 12a, 12b, wherein the first transversal extension 12a is placed on the first transversal side FS of the fastening member 1 and the second transversal extension 12b is placed on the second transversal side SS of the fastening member 1 . Thanks to the transversal extensions 12a, 12b of the fastening member, it is possible to fasten two parallel elements indirectly, i.e. screws (etc.) do not need to go through the element to be fastened. In other words, the transversal extensions 12a, 12b fasten the element to be fastened, for example, from the tongue of the element in such a way that the element cannot substantially move in vertical direction but horizontal extension of the element is still possible. This is presented in Figure 10.

The fastening member 1 has at least one longitudinal extension 1 1 a, 1 1 b in order to fasten at least one element 21 , 22 perpendicular to another element. There may also be two longitudinal extensions 1 1 a, 1 1 b, one on each end side 13a, 13b of the fastening member. Thanks to at least one longitudinal extension 1 1 a, 1 1 b, it is possible to fasten indirectly two elements that are perpendicular to each other. In other words, the longitudinal extensions 1 1 a, 1 1 b fasten the element that is perpendicular to another element (end to the fastening member), for example, from the tongue of the element in such a way that said element cannot substantially move in vertical direction but horizontal extension of said element is still possible. This is presented in Figures 10, 1 1 , 12 and 13. The widths of the transversal extensions 12a, 12b and the first longitudinal extension 1 1 a of the first side 3 of the fastening member 1 are preferably substantially equal. In other words, the width of the first longitudinal extension 1 1 a of the first side 3 is preferably 0.8 - 1 .2 times the width of the transversal extensions 12a, 12b of the first side 3 of the fastening member. According to an advantageous embodiment of the invention, the width of the first longitudinal extension 1 1 a of the first side 3 is 0.90 - 1 .00 times the width of the transversal extensions 12a, 12b of the first side 3 of the fastening member, more preferably 0.95 - 1 .05 times the width of the transversal extensions 12a, 12b of the first side 3 of the fastening member.

The fastening member 1 has at least two holes 10 or at least three holes, for example exactly two or three holes 10a, 10b, 10c, and most preferably exactly three holes 10a, 10b, 10c. The holes 10 of the fastening member 1 are advantageously in the longitudinal axis of the fastening member, as can be seen, for example, in Figures 1 , 2 and 5.

The diameter of the hole 10a, 10b, 10c is preferably from 3 to 5 mm. According to an advantageous embodiment, the diameter of the hole is 4 mm. The screw, nail etc. possibly used with the fastening member 1 has preferably a diameter between 6 and 8 mm, more preferably a diameter between 5 and 7 mm. According to an example embodiment, a screw, a nail etc. with a diameter of 4 mm is used with the fastening member 1 . The holes 10 are placed to the fastening member 1 in such a way that at least one of the holes 10a, 10b, 10b is closer to one end side 13 of the fastening member than another hole 10a, 10b, 10c. In other words, at least one of the holes 10a, 10b, 10c is closer to the centre point of the length 8 of the first side of the fastening member than at least one other hole 10a, 10b, 10c.

The midpoint of the hole(s) 10a, 10bc placed closest to the end side 13a, 13b of the fastening member 1 is preferably 12 to 20 mm from the end side 13a, 13b of the fastening member, more preferably between 14 and 18 mm from the end side 13a, 13b of the fastening member. According to an example, the midpoint of the hole(s) 10a, 10c placed closest to the end side 13a, 13b of the fastening member is 16 mm from the end side 13a, 13b of the fastening member.

The first distance between the first hole 10a and the second hole 10b is preferably between 7 and 20 mm. The second distance between the second hole 10b and the third hole 10c is preferably between 7 and 20 mm.

The hole 10a, 10b, 10c preferably has a bevel 14 of approximately 60°, for example, between 40 and 80°, or between 50 and 70° in order to sink the countersunk screw during installation process.

The hole 10b in the middle of the fastening member 1 is preferably used for fastening two parallel elements. In other words, the hole 10b that is placed closest to the centre point of the length 8 of the first side of the fastening member is preferably used to fasten two parallel decking boards. If only one hole, i.e. the hole placed closest to said centre, is used for fastening parallel elements 21 , 22, it is possible to decrease the installation work needed and, for example, the number of the screws needed. Said hole 10b may not be needed to fasten elements perpendicularly.

At least one, preferably exactly one hole or exactly two holes, which are closest to the end side 13 of the fastening member, are used to fasten elements perpendicular to each other. In other words, if three elements (usually two decking boards and one railstep board, or two railstep boards and one decking board, or three decking boards) are going to be fastened by the fastening member 1 in order to fasten one of the elements perpendicularly, the two holes 10a, 10c placed closest to the first and the second end 13a, 13b of the fastening member 1 are preferably used. As said holes 10a, 10c are quite close to the end of the fastening member 1 , the fastening member 1 may provide a greater fastening force into the elements 21 , 22 without creating too high a torque in the fastening member 1 itself; thus, it is possible to fasten the elements without unnecessary forces that might break the fastening member 1 . The raw material 20 of the fastening member 1 should be selected in such a way that the strength properties of the manufactured fastening member 1 are feasible and the product may be weatherproof. The fastening member 1 may be, for example, a wood plastic composite, such as a paper plastic composite and/or a label stock composite, or the fastening member may consist of, for example, plastic.

The fastening member 1 comprises preferably recycled material. The fastening member advantageously comprises 0 - 85 w-% of cellulose fibers, preferably 20- 80 w-% of cellulose fibers. The cellulose fibers used for the fastening member may comprise at least 60 % of chemically treated cellulose fibers (i.e. lignin free cellulose fibers); preferably, the fibers used for the fastening member comprise at least 70 % or at least 80 %, preferably at least 90 % or at least 95 % of chemically treated lignin free cellulose fibers. It is also possible, for example, to use mechanically treated cellulose fibers instead of the chemically treated cellulose fibers. In addition, the fastening member advantageously comprises plastic polymers. The content of the plastic polymers may be between 0 and 100 w-%, preferably between 20 and 80 w-%. The plastic polymer may comprise, for example, one of the following: polyamide (PA), polyvinyl alcohol (PVA), and polypropylene (PP). The plastic polymer may be virgin or recycled. Inorganic fillers may be added in order to increase the stiffness properties of the product. The fillers may comprise talc. The fastening member may be coloured, for example, by using inks or masterbatches. Therefore, the fastening member 1 may comprise colours. The fastening member may also comprise silicone. If recycled material is used, the amount of raw materials 20 depends on the amount of the different raw materials coming along the recycled material. The fastening member 1 may be manufactured mainly from recycled materials, i.e. the fastening member may comprise at least 90 w-%, more preferably at least 95 w-%, for example 100 w-%, of recycled materials.

The recycled raw material preferably comprises paper and plastic. The proportion of the recycled paper and recycled plastic may vary depending on the product application. The recycled label material may comprise surplus paper and plastic left over from the production of self-adhesive label materials. In an embodiment, the adhesive label laminate waste originates from adhesive label laminate production, from which primarily production reject waste, edge cuttings from rolls and roll ends are produced; from adhesive label laminate printing stations, from which primarily roll ends and label material left over from the die cutting of stickers and labels as well as reject are produced; and/or from the end user clients of the adhesive label laminate, who paste the printed stickers and labels or the like onto their products. The waste coming from the end users is primarily release material, roll ends, and waste from the finished product. The adhesive label laminate waste is typically formed of label material, an adhesive layer, and release material. The liner of the label is usually a paper having a silicone coating or a plastic coating. The plastic polymer is preferably polypropylene. The plastic polymer may also be PVC, polyethylene, polypropylene, polystyrene or polyester. The content of the adhesive label laminate waste in the fastening member 1 is preferably between 50-100 w-%. The adhesive label laminate waste typically comprises adhesives 0 - 5 w-%, silicone 0-10 w-%, cellulose fibers 20-100 w-%, and polymers 0 - 100 w-%.

The fastening member 1 may be manufactured, for example, by extrusion, compression moulding or injection moulding processes. Advantageously, the fastening member 1 is manufactured by an injection moulding technique. An example system of the present invention is presented in Figure 9.

According to another embodiment of the invention, the fastening member 1 comprises metal or consists of metal. In this case, the amount of the metal from the fastening member is at least 80 w-%, preferably at least 90 w-% or at least 95 w-%.

Many kinds of screws and nails etc. may be used with the fastening member 1 according to the invention, due to the holes 10a, 10b, 10c of the fastening member 1 .

The novel solution makes it possible to have a safe installation where thermal elongation or slight movement of the elements will not jeopardize the installation. Thanks to the novel fastening member 1 , it is also possible to cover the support rail 23 and to fasten elements simultaneously, i.e. it may be possible to place the support rail totally under the perpendicular boards using the fastening member 1 . Thus, it is possible to manufacture the support rails from heterogeneous material in order to increase the efficiency of the production.

A person skilled in the art readily understands different embodiments of the invention. Therefore, it is obvious that the present invention is not limited solely to the above-presented embodiments, but it can be modified within the scope of the appended claims.

Claims

:

A fastening member for fastening of elements, which fastening member has at least a first side (3) and a second side (2), wherein the fastening member (1 ) has at least two holes (10a, 10b, 10c) along the longitudinal axis of the fastening member,

the first side (3) of the fastening member (1 ) has at least two transversal extensions (12a, 12b),

the first side (3) of the fastening member has at least one longitudinal extension (1 1 a, 1 1 b), and

the width of a first longitudinal extension (1 1 a) of the first side (3) of the fastening member (1 ) is 0.8 - 1 .2 times a width of the transversal extensions (12a, 12b) of the first side (3) of the fastening member.

A fastening member according to the claim 1 for fastening decking boards and/or railstep boards.

A fastening member according to the claim 1 or 2, characterized in that the fastening member has at least three holes (10a, 10b, 10c).

A fastening member according to any of the preceding claims, characterized in that the length (8) of the first side (3) of the fastening member (1 ) is at least 45 mm, preferably at least 55 mm.

A fastening member according to any of the preceding claims, characterized in that the fastening member (1 ) is a wood plastic composite.

A fastening member according to any of the preceding claims, characterized in that the fastening member (1 ) comprises recycled cellulose fibers and recycled plastic polymers.

A fastening member according to any of the preceding claims, characterized in that the fastening member comprises at least 90 w- % of recycled materials. A method for manufacturing a fastening member used for fastening of elements, comprising providing the fastening member with at least a first side (3) and a second side (2), providing the first side (3) of the fastening member (1 ) with at least two transversal extensions (12a, 12b), wherein the method further comprises:

providing the first side (3) of fastening member with at least one longitudinal extension (1 1 a, 1 1 b);

providing the fastening member (1 ) with at least two holes (10a, 10b, 10c) along the longitudinal axis of the fastening member; and

manufacturing the fastening member (1 ) by one of:

- an injection moulding process,

- a compression moulding process, or

- an extrusion process.

A system for manufacturing a fastening member used for fastening of elements, the fastening member comprising at least a first side (3) and a second side (2), the first side (3) of the fastening member (1 ) comprising at least two transversal extensions (12a, 12b), wherein the first side (3) of the fastening member comprises at least one longitudinal extension (1 1 a, 1 1 b) and at least two holes (10a, 10b, 10c) along the longitudinal axis of the fastening member; and the system comprises at least one of:

an extruder,

means for an injection moulding process, and

means for a compression moulding process.

An arrangement for fastening elements, the arrangement comprising three elements (21 , 22), and

a fastening member (1 ), which has a first side (3) and a second side (2),

wherein

the first side (3) of the fastening member (1 ) has two transversal extensions (12a, 12b), the first side (3) of the fastening member has at least one longitudinal extension (1 1 a, 1 1 b), and

the fastening member (1 ) has at least two holes (10a, 10b, 10c) in the longitudinal axis of the fastening member,

and in the arrangement:

- the three elements (21 , 22) are fastened in such a way that two elements are placed parallel to each other and one element is placed perpendicularly to the two elements, in which arrangement the fastening member is in contact with each of the three elements.

1 1 . An arrangement according to claim 10, characterized in that the elements are decking boards, and in the arrangement the decking boards are fastened in such a way that two of the decking boards are placed parallel to each other and one of the decking boards is placed perpendicularly to the others, wherein the fastening member (1 ) is in contact with each decking board.

12. An arrangement according to claim 10, characterized in that the elements comprise two decking boards and one railstep, and in the arrangement the decking boards are placed parallel to each other and the railstep board is placed perpendicularly to the decking boards, wherein the fastening member (1 ) is in contact with each element. 13. An arrangement according to claim 10, characterized in that the elements comprise one decking board and two railsteps, and in the arrangement the railsteps are placed parallel to each other and the decking board is placed perpendicularly to the railstep boards, wherein the fastening member (1 ) is in contact with each element.

14. A terrace having the arrangement according to any of the preceding claims 10 to 13.

15. Use of a fastening member according to any of the claims 1 to 7 in order to cover a support rail (23) beneath.