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Fastener for sheet materialRelated Patent Categories: Expanded, Threaded, Driven, Headed, Tool-deformed, Or Locked-threaded Fastener, Impact Driven Fastener, E.g., Nail, Spike, Tack, Etc., Shank Or Penetrating End StructureFastener for sheet material description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070122252, Fastener for sheet material. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] This invention generally relates to apparatus and methods for attaching deformable sheet material to a substrate. More particularly, the invention provides for a fastener that is useful in applying cladding material onto a nailable substrate such as wood. [0002] In the building construction industry there is a need to apply a cladding material such as aluminum of vinyl sheet material to wood members of buildings. This is done to improve an overall appearance of a building and to provide some protection for the underlying wood member. In that context, the sheet material primarily perform a cosmetic role. [0003] Typically, nails are used to attach the sheet material to the wood members. In order to preserve the cosmetic properties of the sheet material, the nails are provided with heads which are colored to match the color of the sheet material. In the prior art, nails were driven through the sheet material and into the underlying wood. This technique produced a secure attachment of the sheet material, but it also produced a visible distortion or dent in the sheet material in the region of the nail. These dents result from frictional forces that develop when the nail shaft is driven through the sheet material. Dents are undesirable because they reduce the overall cosmetic value of the sheet material. [0004] In order to reduce or eliminate formation of the dents, some tradesmen employ a practice of pre-drilling holes in the sheet material. The pre-drilled holes are made with a diameter slightly larger than a diameter of a shaft of the nail. Attachment is performed by placing the shaft of the nail into the pre-drilled hole and then driving it into the wood. When this technique is used, the shaft of the driven nail does not exert a frictional force on the sheet material and consequently dents are not formed. [0005] However, pre-drilling holes in sheet material at the application stage is a difficult and time consuming task. Sheet material are often used for cladding of building fascia. In these cases a worker usually performs the application task from a ladder or scaffolding. It is commonly the case that the worker will need to hold a piece of the sheet material with one hand while driving a nail with the other hand. Pre-drilling holes in this setting is a difficult and onerous task. [0006] As can be seen, there is a need for a sheet material application system that reduces deleterious effects of nail denting encountered in the prior art. More particularly, there is a need for such a system that does not require pre-drilling of the sheet material at the time of application. SUMMARY OF THE INVENTION [0007] In one aspect of the present invention a fastener comprises a cylindrical shaft with an insertion tip formed at a first end of the shaft and a head formed at a second end of the shaft. The shaft comprises at least two cylindrical members of different diameters. A first cylindrical member with a first diameter D1 is contiguous with the first end of the shaft. A second cylindrical member with a second diameter D2 is contiguous with the second end. The second diameter D2 is smaller than the first diameter D1. [0008] In another aspect of the present invention a method for attaching sheet material to a substrate comprises the steps of supporting the sheet material adjacent the substrate; driving a cylindrical fastener having a first diameter D1 along a first portion of its length and a second smaller diameter D2 along a second portion of its length through the sheet material and into the substrate to produce a hole in the sheet material that is as large as the first diameter; and driving the fastener further into the substrate to position the second portion of the fastener into alignment with the sheet material. [0009] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims. BRIEF DESCRIPTION OF THE DRAWINGS [0010] FIG. 1 is a cross-sectional view of a fastener employed in accordance with the prior art; [0011] FIG. 2 is an illustration of a fastener constructed according to the present invention; [0012] FIG. 3 is a cross sectional view of the fastener of FIG. 2 employed in accordance with the present invention; and [0013] FIG. 4 is schematic diagram illustrating one aspect of the present invention. DETAILED DESCRIPTION OF THE INVENTION [0014] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims. [0015] The present invention may be useful for field application of sheet material as a cosmetic and protective cladding onto building members. For illustrative purposes, the following description is of a nailable fastener used to attach sheet material such as aluminum to a wood substrate such as a building fascia. However, it is understood that other applications can be substituted for the subject attachment system. [0016] The present invention may prevent undesirable denting in the sheet material during a nailing process. The present invention may prevent this condition without a need to pre-drill holes for nail shafts. This is accomplished by utilizing a nail with different shaft diameters along its length. [0017] Referring now to FIG. 1 there is shown a prior-art fastener 10 comprising a head 12 and a cylindrical shaft 14. The prior-art fastener 10 is shown embedded into a substrate 16 and attaching a portion of sheet material 18 to the substrate. [0018] FIG. 1 illustrates a prior-art condition in which the prior-art fastener 10 has been driven through the sheet material 18 and into the substrate 16. The act of driving the prior-art fastener 10 though the sheet material produces a perforation 20 in the sheet material 18. The perforation 20 has a diameter that is the same as the diameter of the cylindrical body 14 of the prior-art fastener 10. Frictional engagement develops between the cylindrical body 14 and a portion 22 of the sheet material 18 surrounding the perforation 20. As the prior-art fastener 10 is driven further into the substrate 16, this frictional engagement produces an inwardly dragging force on the portion 22 of the sheet material 18. This dragging force produces a distortion or dimple 24 in the sheet material 18. This dimple 24 may have a diameter that is substantially lager than a diameter of the head 12 of the prior-art fastener 10. Thus the head 12 does not cover the dimple 24 and the dimple 24 remains a visible and unsightly blemish after attachment of the sheet material 18 is complete. [0019] Referring now to FIG. 2, there is shown a fastener, designated generally by the numeral 30, which is constructed in accordance with the present invention. The fastener 30 comprises an insertion tip end 32 and a head end 34. A first cylindrical member 36 with a first diameter D1 is positioned at the tip end 32. The first cylindrical member 36 is provided with a tapered tip 38 adapted to penetrate sheet materials and substrates. A second cylindrical member 40 having a second diameter D2 is positioned at the head end 34 of the fastener 30. The second cylindrical member 40 is provided with a flattened head 42 adapted to be struck with a hammer to drive the fastener 30 through sheet material and into a substrate. The first diameter D1 is greater than the second diameter D2. [0020] Referring now to FIG. 3, the fastener 30 is shown in a driven position. In other words, the fastener 30 is shown as it would appear after having been driven through the sheet material 18 and into the substrate 16. it can be seen that tip end 32 of the fastener 30 produces a hole 50 in the sheet material 18. The hole 50 has a diameter that is at least as large as the diameter D1 of the cylindrical member 36. The cylindrical member 40 at the head end 34 of the fastener 30 is not in contact with a portion 52 of the sheet material 18 that surrounds the hole 50. This, of course, is because the hole 50 has a diameter D1 which is greater than the diameter D2 of the cylindrical member 40. Continue reading about Fastener for sheet material... Full patent description for Fastener for sheet material Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Fastener for sheet material patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Fastener for sheet material or other areas of interest. ### Previous Patent Application: Cold-rolled fixing screw comprising a self-tapping thread Next Patent Application: Preset depth adapter and finger guard for screws and nails when installing sheetrock Industry Class: Expanded, threaded, driven, headed, tool-deformed, or locked-threaded fastener ### FreshPatents.com Support Thank you for viewing the Fastener for sheet material patent info. 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