Multi-featured panel fastener and panel system including the multi-featured panel fastener

Abstract

A panel fastener is provided that has a head having a first surface and a second surface opposite the first surface; an engagement feature on the first surface of the head, the engagement feature being configured to be engaged by a driving tool; a shank extending from the second surface of the head; a threaded portion extending from the shank, the threaded portion having first and second helical threads arranged in an intertwined manner; the first thread extending farther radially from the central axis than does the second thread; and the shank being located between the head and the threaded portion.

What is claimed is: 
     
         1 . A building panel system, comprising:
 a building panel having a thickness;   a panel fastener for mounting the building panel to a structure, the panel fastener extending along a central axis, the fastener comprising:
 a head having a first surface and a second surface opposite the first surface; 
 an engagement feature on the first surface of the head, the engagement feature configured to be engaged by a driving tool; 
 a shank extending from the second surface of the head to an end surface; 
 a threaded portion extending from the end surface of the shank, the threaded portion comprising a central shaft and one or more helical threads extending radially from the central shaft; and 
 the shank having a shank length measured from the second surface of the head to the end surface; and 
 wherein a ratio of the shank length to the thickness of the building panel is in a range of 0.9:1 to 1:1. 
   
     
     
         2 . The building panel system of  claim 1  wherein a ratio of the shank length to the thickness of the building panel is in a range of 0.95:1 to 1:1. 
     
     
         3 . The building panel system of  claim 1  wherein the shank is a cylinder having a shank diameter, the shank diameter being constant over the entire length of the shank. 
     
     
         4 . The building panel system of  claim 1  wherein the threaded portion has first and second helical threads arranged in an intertwined manner; and the first thread extends farther radially from the central axis than does the second thread. 
     
     
         5 . The building panel system of  claim 1  wherein the end surface of the shank forms an annular shoulder at a proximal end of the threaded portion, and the one or more helical threads of the threaded portion extend from the end surface of the shank. 
     
     
         6 . The building panel system of  claim 1  wherein the one or more helical threads of the threaded portion have a maximum outer diameter and the shank has a shank diameter, the shank diameter being greater than the maximum outer diameter of the one or more threads of the threaded portion. 
     
     
         7 . The building panel system of  claim 1  wherein the first and second surfaces of the head are planar and parallel to one another. 
     
     
         8 . The building panel system of  claim 1  wherein the building panel is made of a fibrous material. 
     
     
         9 . A building panel system comprising:
 a building panel having a thickness;   a panel fastener for mounting the building panel to a structure, the panel fastener extending along a central axis, the fastener comprising:   a head having a first surface and a second surface opposite the first surface;   an engagement feature on the first surface of the head, the engagement feature configured to be engaged by a driving tool;   a shank extending from the second surface of the head to an end surface that forms an annular shoulder, the shank having a shank diameter;   a threaded portion extending from the end surface of the shank, the threaded portion comprising a central shaft and one or more helical threads extending radially from the central shaft, the one or more helical threads having a maximum outer diameter; and   the shank having a shank length measured from the second surface of the head to the end surface;   the shank length being less than or equal to the thickness of the building panel; and   the shank diameter being greater than the maximum outer diameter of the one or more threads of the threaded portion.   
     
     
         10 . The building panel system of  claim 9  wherein a ratio of the shank length to the thickness of the building panel is in a range of 0.9:1 to 1:1. 
     
     
         11 . The building panel system of  claim 9  wherein a ratio of the shank length to the thickness of the building panel is in a range of 0.95:1 to 1:1. 
     
     
         12 . The building panel system of  claim 9  wherein the shank is free of helical threads and the shank diameter is constant over the entire length of the shank. 
     
     
         13 . The building panel system of  claim 9  wherein the building panel is made of a fibrous material. 
     
     
         14 . The building panel system of  claim 9  wherein a ratio of the shank diameter to the maximum outer diameter of the one or more threads is in a range of 1:1 to 2:1. 
     
     
         15 . The building panel system of  claim 9  wherein a ratio of the shank diameter to the maximum outer diameter of the one or more threads is in a range of 1.11:1 to 1.83:1. 
     
     
         16 . A method of installing a surface covering system, the method comprising:
 a) positioning a building panel having a thickness adjacent to a structure; and   b) mounting the building panel to the structure by driving at least one panel fastener through the building panel and into the structure until an annular shoulder of the at least one panel fastener abuts the structure and stops the at least one panel fastener from further insertion, the at least one panel fastener comprising: a head having a first surface and a second surface opposite the first surface; an engagement feature on the first surface of the head, the engagement feature configured to be engaged by a driving tool; a shank extending from the second surface of the head to an end surface; a threaded portion extending from the end surface of the shank, the threaded portion comprising a central shaft and one or more helical threads extending radially from the central shaft; and the shank having a shank length measured from the second surface of the head to the end surface; wherein a ratio of the shank length to the thickness of the building panel is in a range of 0.9:1 to 1:1; and wherein the end surface of the shank forms the annular shoulder.   
     
     
         17 . The method according to  claim 16  wherein a ratio of the shank length to the thickness of the building panel is in a range of 0.95:1 to 1:1. 
     
     
         18 . The method according to  claim 16  wherein the shank is a cylinder having a shank diameter, the shank diameter being constant over the entire length of the shank. 
     
     
         19 . The method according to  claim 16  wherein the building panel is made of a compressible fibrous material. 
     
     
         20 . The method according to  claim 16  wherein the threaded portion has first and second helical threads arranged in an intertwined manner; and the first thread extends farther radially from the central axis than does the second thread.