ATTACHMENT DEVICE FOR A ROOF NAILER PANE.

Abstract

A system including an attachment device having a body with a hollow, axially oriented core and a radially outwardly extending flange coupled to the core. The body has an opening configured to receive a fastener therethrough, and the core has a plurality of slots formed therein. The core is configured such that at least about 20% of a perimeter of at least one location along a length of the core is defined by the slots.

Description

The present invention is directed to a panel attachment structure, and more particularly, to a panel attachment structure that can be used to secure a panel to a support structure, such as a wall that can support a roof thereon.

BACKGROUND

In precast and site cast (e.g. tilt-up) concrete building construction, concrete walls or wall portions are typically poured onto a horizontal surface and allowed to cure. After curing, the walls/wall portions are lifted or tilted to a vertical orientation, and the walls/wall portions are coupled or tied together to form a building structure. Once the wall portions are lifted or tilted to a vertical orientation, it may be desired to provide a wood ledger or roof nailer panel on the top of the concrete wall portions. The roof nailer panel provides a surface to which other components can be more easily attached and positioned, such a roof membranes, roof trusses, etc.

In many existing systems the roof nailer panel is attached to the vertically-oriented concrete walls by passing lag bolts through the upper surface of the roof nailer panel and into the underlying upper edge of the concrete wall. However this type of attachment can leave the head of the lag bolt protruding and/or create additional labor (e.g. if the heads of the lag bolts are to be countersunk). This type of attachment can also create voids when the roofing material is secured to the roof nailer panel that can prevent the roofing material from being properly secured to the roof nailer panel.

In other cases, lag bolts can be screwed into the underside of the roof nailer panel prior to the concrete pouring of the wall portions, and the lag bolts are left protruding out of the roof nailer panel. The roof nailer panel can then be used as part of the form during concrete pouring, and the protruding lag bolts act as rudimentary anchor bolts. However since lag bolts are not designed for such use they provide poor performance when used in this manner.

SUMMARY

In one embodiment the present disclosure is directed to an attachment device that is configured to couple a roof nailer product to an associated support structure, such as a concrete wall. More particularly, in one embodiment the present invention is a system including an attachment device having a body with a hollow, axially oriented core and a radially outwardly extending flange coupled to the core. The body has an opening configured to receive a fastener therethrough, and the core has a plurality of slots formed therein. The core is configured such that at least about 20% of a perimeter of at least one location along a length of the core is defined by the slots.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an upper perspective view of a roof nailer panel shown in conjunction with a wall;

FIG. 2 is a stylized cross section taken along line 2-2 of FIG. 1;

FIG. 3 is an upper perspective view of one embodiment of an attachment device;

FIG. 4 is a lower perspective view of the attachment device of FIG. 3;

FIG. 5 is a side view of the attachment device of FIG. 3;

FIG. 6 is a cross sectional view of the attachment device of FIG. 3;

FIG. 7 is a bottom view of the attachment device of FIG. 3;

FIG. 8 is an upper perspective view of a form incorporating two attachment devices of FIG. 3; and

FIG. 9 shows the form of FIG. 8 after it is filled with concrete.

DETAILED DESCRIPTION

With reference to FIGS. 1 and 2, in one embodiment a roof nailer panel or roof nailer 10 is coupled to an adjacent support structure 12 by a plurality of horizontally-spaced attachment devices 14 (shown schematically in FIG. 1). The roof nailer 10 can take the form of a board or other rectangular prism shape, and in one case is made of wood or wood products (such as engineered wood), composites, or other materials into which threaded fasteners can be secured in a construction environment. The support structure 12 can take the form of a concrete structure, such as a vertically oriented (tilted up) concrete wall, wall portion or the like. The roof nailer 10 can have about the same length and about the same width as the support structure 12, but can differ in (vertical) height with the roof nailer 10. In particular, the roof nailer 10 can have a height at least about ten times less, and typically more than ten times less, of a height of the support structure 12.

With reference to FIG. 2, each attachment device 14 can include or receive (or be coupled to) a fastener 16, such as a bolt with a head 18, a threaded shaft portion 20 and a shank 22 positioned therebetween. The fastener 16 is received in/extends through a body 24 of the attachment device 14, and the threaded shaft portion 20 is threaded into an underside of the roof nailer 10. The body 24 of the attachment device 14 is anchored in the concrete of the support structure 12 to thereby securely couple the roof nailer 10 to the support structure 12, as will be described in greater detail below.

With reference to FIGS. 3-7 the attachment device 14 can include the body 24 having a hollow, axially oriented core 26 and a radially outwardly extending flange 28 coupled to the distal/lower end of the core 26. In the illustrated embodiment the core 26 is generally cylindrical and the flange 28 is a generally flat, annular component. The body 24 (and in particular both the core 26 and the flange 28) can each include a plurality of slots 30 formed therethrough, where each slot 30 extends generally axially. The slots 30 of the core 26 can be aligned with the slots 30 of the flange 28. In this manner the slots 30 divide the body 24 into three legs 32, each leg having a foot 28a at an end thereof (defined by the flange 28). In the illustrated embodiment, the attachment device 14 has equally spaced three slots 30 and three legs 32, but can include more or less slots 30/legs 32 as desired, but in one case has at least two slots 30/legs 32.

The attachment device 14 can be made of various materials including polymers or plastic, such as high density poly ethylene, polycarbonate fiberglass, acrylonitrile butadiene styrene or the like, composite materials or combinations thereof. In one case the attachment device 14 is made of a single, unitary seamless piece of material having a thickness at all locations of less than about ¼″. The attachment device 14, or at least the core 26 and flange 28, can be infinitely symmetrical about a single center point/axis. The attachment device 14 can have a height (not counting the fastener 16) in one case of between about 1.5 inches and 4.25 inches, and have a diameter at its distal end of between about 2 inches and about 3 inches. The attachment device 14 can have a diameter at its base end (e.g. at the end defined by the end surface 36) of between about 0.75 inches and about 1.75 inches.

As will be described in greater detail below, it may be desired to provide access to the inner volume of the attachment device 14/body 24/core 26 so that during concrete pours the wet concrete can enter and fill the inner volume, and the slots 30 can help to provide such access. Thus in one case one or each slot 30 extends at least about 60% in one case, and at least about 80% in another case, of a length of the attachment device 14/body 24/core 26. In addition, the attachment device 14 can be configured such that at locations where the slots 30 are present (e.g. along at least about 60%/80% of the length in one case, as noted above), at least about 10% of the perimeter of the core 26 is defined by the slots 30 in one case, or at least about 20% in other case. In other words along circumferentially-extending line A shown in FIGS. 3 and 4, at least 10%/20% of such length of the line A is defined by the slots 30 (or gaps), and the remainder (e.g. 90%/80%) of the length of the line A is defined by the structure of the attachment device 14/body 24/core 26. By having the slots 30 extend a sufficient (axial) length, and extend sufficiently in the circumferential direction, the attachment device 14 provides good access to the inner cavity during concrete pours.

The attachment device 14 can further include a plurality of circumferentially spaced stiffening ribs 34. Each rib 34 can be generally triangular in side view, and coupled to the core 26 at along one side one and to the flange 28 at another side thereof. Each rib 34 can have an outer edge 37 that is arranged at an angle relative to an axial center of the attachment device 14, and each rib 34 thereby provides strength/stiffening to the legs 32/feet 28a.

The attachment device 14/body 24/core 26 can include an end surface 36 located at an opposite end of the attachment device 14/body 24/core 26 relative to the flange 28. The end surface 36 is generally flat and generally circular in top view in the illustrated embodiment, and is oriented in a radial plane and can include an opening 38 that extends axially therethrough. The end surface 36/opening 38/attachment device 14 is configured to receive the fastener 16 therethrough. The opening 38 can be sized to be larger than all or at least part of the threaded shaft portion 20 of the fastener 16, but be sized to be smaller than the head 18 of the fastener 16 such that the fastener 16 cannot pass entirely through the opening 38.

In one case, the opening 38 is sized to closely receive, and be slightly smaller than (e.g. between about 0.5% and about 2% smaller, in one case by diameter) the shank 22 of the fastener 16 to create a press-fit or interference fit therebetween. In this manner the fastener 16 can be press fit into the body 24 of the attachment device 14 and the body 24/fastener 16 can be assembled, stored, sold and/or installed as a single component, which can provide ease of usage since the fastener 16 will already be present. Alternatively however the body 24 and fastener 16 are not pre-assembled and can be stored, sold and/or installed separately, which can provide greater flexibility in use and installation.

In one case, the end surface 36 can be relatively thick (in the axial direction) to ensure the attachment device 14/end surface 36 retains its shape and is not bowed, buckled or deflected when the fastener 16 is tightened down. Thus in one case the end surface 36 has a thickness of at least about ⅓ of a thickness of the head 18 of the fastener 16 in one case; or has a thickness of at least about 0.09 inches in one case, or at least about 0.11 inches in another case.

It may also be desired to ensure the end surface 36 is relatively small in the radial direction/radial plane to also avoid bowing, buckling or deflection of the end surface 36 when the fastener 16 tightened down. Thus in one case the end surface 36 extends in all directions, and/or extends in the radial direction (e.g. has a diameter in the radial direction, shown as dimension B in FIG. 3) less than about 2 inches in one case, and less than about 1.5 inches in another case. In one case the end surface 36 (and the attachment device 14/body 24/core 26) includes only a single opening 38, and lacks any other corresponding opening (configured to receive a fastener 16) or other hole formed therethrough. The use of only a single opening 38 can also help to avoid bowing, buckling or deflection of the end surface 36/attachment device 14, since more than one opening 38 can allow multiple fasteners to apply external forces to the attachment device 14/end surface 36, which forces can be additive to together cause excessive bowing, buckling or deflection.

In order to form the roof nailer 10/support structure 12 assembly shown in FIGS. 1 and 2, a form 40 as shown in FIG. 8 can be provided. The form 40 can include two opposed side panels 42, a bottom panel 44, and the roof nailer 10 as a top panel. The top panel/roof nailer 10 can include a plurality of attachment devices 14 coupled to an inner surface thereof, and spaced across a length thereof. Only two attachment devices 14 are shown in FIG. 8. for ease of illustration, but it should be understood that any number of attachment devices 14 can be utilized as desired (see for example FIG. 1, showing the use of seven attachment devices 14). In addition, while FIG. 8 shows the roof nailer 10 taking the form of the top panel, if desired a separate top panel (not shown) can be positioned adjacent to, and outside of, the roof nailer 10 and secured to the side panels 42 as part of the form 40.

Each attachment device 14 can be coupled to the top panel/roof nailer 10 by passing the threaded shaft portion 20 through the opening 38 of the attachment device 14 (if not already done so) and threading the threaded shaft portion 20 into the top panel/roof nailer 10 until the head of the fastener 16 abuts against the end surface 36 of attachment device 14 and the threaded shaft portion 20 is embedded or threaded into in the roof nailer 10, pushing the end surface 36 flush against the underside of the roof nailer 10, as shown in FIG. 2. The slots 30 can provide flexibility and enable the attachment device 14 to flare radially outward if desired during installation, which can enable the attachment device 14 to accommodate the chuck of a power drill during attachment of the threaded fastener 16. In addition, if the fastener 16 is press fit into the attachment device 14, the press fit may be sufficiently tight that the attachment device 14 spins with the fastener 16 during installation of the fastener, to ensure the fastener 16 does not spin out during installation which can reduce the tight fit between the shank 22 of the fastener 16 and the attachment device 14.

If desired reinforcing metal bars such as rebar 46 can be positioned in the interior space of the form 40 and secured in place. The form 40 is then positioned on an underlying flat surface 50, and the flat surface 50 can be coated with concrete release formulation if desired.

After the system of FIG. 8 is assembled, the form 40 can be filled with concrete and allowed to cure/harden to form the support structure 12, as shown in FIG. 9. As noted above, the slots 30 of the attachment devices 14 enable the wet concrete to flow through the slots 30 and fully enter and fill the core 26, filling any voids. After the concrete is cured, the side panels 42 and bottom panel 44 (and, if utilized, separate top panel (not shown)) extending around the perimeter of poured concrete are then removed and the resultant roof nailer 10/support structure 12 assembly is released/separated from the underlying horizontal surface 50. The resultant structure is then lifted or tilted up to a vertical position, with the attachment devices 14 embedded therein and coupled to the roof nailer 10, as shown in FIG. 1.

It should be noted that, although FIGS. 8 and 9 show the support structure 12 in the form of a single concrete structure, the support structure 12 can be made of any of variety of materials and have various constructions. For example, in some cases the support structure 12 can include outer and/or inner layers/sublayers, such as insulated sandwich panels and/or insulated composite panels.

After the structure of FIG. 1 is provided, if desired a roofing membrane, trusses, or other roofing components, or other components, can be coupled to the roof nailer 10, and the roof nailer 10 provides a convenient attachment structure. The attachment devices 14 help to anchor/secure the roof nailer 10 to the support structure 12 in a secure manner such that the roof nailer 10 does not pull away from the support structure 12. In particular, the radially-outwardly extending shape of the flange 28/feet 28a provide surfaces that reduce separation of the attachment devices 14/roof nailer 10 in the axial direction of the attachment devices 14. The attachments devices 14 are also intuitive and easy to use, and relatively inexpensive.

Having described the invention in detail and by reference to the various embodiments, it should be understood that modifications and variations thereof are possible without departing from the scope of the claims of the present application.

Claims

1. A system comprising attachment device including:

a body having a hollow, axially oriented core and a radially outwardly extending flange coupled to the core, wherein the body has an opening configured to receive a fastener therethrough, wherein the core has a plurality of slots formed therein and is configured such that at least about 20% of a perimeter of at least one location along a length of the core is defined by the slots.

2. The system of claim 1 wherein the core is generally cylindrical, and wherein the flange is generally annular and coupled to a distal end of the core.

3. The system of claim 1 wherein the flange include a plurality of slots that are aligned with the slots of the core.

4. The system of claim 3 wherein the plurality of slots divide the body into a plurality of axially oriented legs, each leg having a radially-outwardly extending foot at an end thereof.

5. The system of claim 1 wherein the core includes a radially aligned end surface, and wherein the opening extends axially through the end surface.

6. The system of claim 5 wherein the end surface has a thickness of at least about ½″ and wherein the end surface extends in a radial plane, in all directions, less than about 2 inches.

7. The system of claim 5 further comprising a fastener configured to received through the opening, and wherein the end surface has a thickness of at least about ⅓ of a thickness of a head of the fastener.

8. The system of claim 1 further comprising a fastener that is retained in the opening by a press fit between a shank of the fastener and the opening.

9. The system of claim 1 wherein the attachment device further comprises a plurality of circumferentially spaced stiffening ribs, each rib being coupled to the body and to the flange, each stiffening rib having an outer edge that is arranged at an angle relative to an axial center of the body.

10. The system of claim 1 wherein the attachment device includes only a single opening.

11. The system of claim 1 wherein each slot extends at least about 60% of a length of the core.

12. The system of claim 1 wherein the core is configured such that, at locations where the slots are present, at least about 20% of a perimeter of the core is defined by the slots.

13. The system of claim 1 further comprising a roof nailer and a fastener having a head and a threaded portion, wherein the fastener extends through the opening such that the head abuts against the attachment device and the threaded portion is threaded into the roof nailer.

14. The system of claim 13 further comprising a concrete support structure, and wherein the attachment device in anchored in the support structure to thereby couple the roof nailer to the support structure.

15. The system of claim 14 wherein the roof nailer is made of wood or wood products, wherein the support structure is a vertically oriented wall or wall portion, and wherein the core of the attachment device is filled with concrete.

16. The system of claim 1 wherein the attachment device is made of a single, unitary piece of material having a thickness less than about ¼″.

17. A system comprising an attachment device including:

a body having a hollow, axially oriented generally cylindrical core and a radially outwardly extending, generally annular flange coupled to the core, wherein the body has an opening configured to receive a fastener therethrough.

18. The system of claim 17 wherein the core has a plurality of slots formed therein and is configured such that at least about 20% of a perimeter at a location along a length of the core is defined by the slots.

19. A system comprising attachment device including:

a body having a radially oriented end surface and a plurality of axially oriented legs coupled to the end surface, each leg having a radially outwardly-extending foot located at a distal end thereof, wherein the end surface has an opening configured to receive a fastener therethrough.

20. The system of claim 19 wherein body has a plurality of slots formed therein defining the legs and the feet, and wherein the body is configured such that at least about 20% of a perimeter of at least one location along a length of the body is defined by the slots.

21. A method for forming a panel comprising:

accessing an attachment device including body having a hollow, axially oriented core and a radially outwardly extending flange coupled to the core, the body having an opening, wherein the core has a plurality of slots formed therein and is configured such that at least about 20% of a perimeter of at least one location along a length of the core is defined by the slots;

accessing a roof nailer;

accessing a fastener having a head and a threaded portion; and

passing the fastener through the opening and into the roof nailer such that the threaded portion is threaded into the roof nailer and fastener thereby attaches the attachment device to the roof nailer.

22. The method of claim 21 further comprising constructing a form including or coupled to the roof nailer, pouring concrete into the form such that the body is embedded in the concrete, allowing the poured concrete to cure to form a concrete panel, removing the form, and positioning the resultant concrete panel in a vertical orientation with the roof nailer positioned above the concrete panel and coupled thereto.