Deck plank extrusion and retaining clip

This is a continuation-in-part of application Ser. No. 09/575,420, filed May 20, 2000 now abandoned.

None

This invention relates to deck planks, specifically to an easily installed and user-friendly plank and retaining clip which attaches to wood or metal joists and the like used to form the supporting structure of a deck or dock.

Usually a deck or boat dock is constructed of horizontal wood members (ledgers or putlogs) which support a finish surface layer, typically wood planks. Such decks or docks (hereinafter decks) are exposed to the environment and thus tend to rot and decay. Even redwood and pressure-treated lumber used for deck planks often needs regular annual maintenance that is costly as well as a nuisance. Often when the deck deteriorates, the supporting structure or joists are also likely to deteriorate; thus expensive repairs are needed.

Plastic extruded deck planks have been used in the past, but these have disadvantages, such as an irritable squeaking sound when the planks are walked upon due to rubbing together and the method of connection. Plastic planks are also very difficult to install properly without expert help, which adds tremendously to the cost of the residential homeowner's project.

U.S. Pat. No. 5,009,045 to Yoder (1991) shows a clip strip used to attach the deck plank to the floor assembly. The labor and skill required to engage the plank to the clip correctly is so great that professional help is often needed for proper installation. Once engaged, the deck plank is difficult to disengage (e.g., for remodeling) without damage to plank or clip. Also the plank is not able to span existing joist spacing easily when replacing a deck surface. U.S. Pat. No. 5,950,377 to Yoder (1996) shows a clip strip used to attach the deck plank to the floor assembly. Again, the labor and skill required to engage the plank to the clip correctly is so great that professional help is often needed for proper installation. Once engaged, the deck plank is difficult to disengage (e.g., for remodeling) without damage. Also the plank is not able to span existing joist spacing easily when replacing a deck surface.

U.S. Pat. No. 5,642,592 to Andres (1997) shows an engagement strip that runs perpendicular to the supporting members in the same direction as the deck planks. These strips must be fully engaged along the full length of the plank. If this is not done, the plank will rub and make noise due to the lack of full engagement. The installation of these strips is also tedious and time consuming and will have an unsightly appearance if due care is not taken upon installation.

U.S. Pat. No. 6,112,479 to Andres (2000) shows a snap connector strip that runs generally perpendicular to the horizontal surface of wood joists in the same direction as the deck plank. These strips have an elongated base portion and must be fully engaged along the full length of the plank, as is required in the strip of the Andres U.S. Pat. No. 5,642,592. If this is not done, the plank will rub and make noise due to lack of full engagement, an inherent disadvantage of this design. The installation of these strips is also tedious and time consuming and will have an unsightly appearance if due care is not taken during installation. This strip system is not conducive to placement over flat surfaces due to the inability of the strips to fully engage themselves; thus noise is created from the plank and strip rubbing together.

U.S. Pat. No. 4,965,980 to Leavens (1990) shows a deck, sold under the trademark Deckmaster, by Contemporary Sundecks and Patio Covers, Inc., Sebastopol, Calif. A bracket is attached to the joist with screws and boards are attached to the brackets. Screws are then driven from the underside of the deck planks through the bracket and into the bottom of the planks. Although the screws are hidden from the top surface of the planks, the installation is tedious and must be performed by either working from the underside of the deck structure or by bending over and reaching under the deck boards in order to fasten the screws to the deck boards. This form of attachment is cumbersome and expensive. Also, it is not an easy way to remove the plank from the bracket.

Existing plastic extruded deck plank assemblies are labor intensive and require a great deal of skill to install. It is also difficult to disengage the deck plank for repairs or alterations.

Insofar as I am aware all existing deck layer are either difficult to assemble and/or are laid out non-uniformly. Most residential homeowners can neither install the plank assembly if desired, nor repair and alter the deck if needed.

Accordingly, several objects and advantages of my invention are:

(a) to provide an improved deck structure,

(b) to provide a deck plank that can be engaged to its attachment device in a manner that does not require a great deal of skill or effort,

(c) to provide a deck plank which will engage easily, yet remain in place for its primary use,

(d) to provide a deck plank which will assemble in a uniform manner, giving ease of layout to those skilled or unskilled in the art,

(e) to provide a deck plank which can be disengaged readily with little effort,

(f) to provide a deck plank and engagement clip which will engage mechanically in such a manner as to allow the planks to expand and contract naturally and freely in the bounds of their assembly without damage,

(g) to provide a track assembly which will aid in ease and speed of installation for the home owner.

Further objects and advantages are to provide a deck plank which will have skid resistance and aesthetically pleasing qualities, which does not require costly or labor intensive annual maintenance, that is rot and insect resistant, and which can be installed by residential homeowners. Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.

In accordance with the invention I provide a new plastic plank and retaining clip or track. The plank has an oblique-supporting panel which provides space for an end of an engaging clip to be fastened to a joist, while keeping fastening screws concealed from the plank surface. The oblique-supporting panels also add strength to the plank structure; this keeps the plank straight, while providing the benefits mentioned above. An engaging ledge of the plank is located higher in the recess structure of the plank from that of prior-art planks. This raised position of the engaging ledge creates a better hold between the plank and the engaging clip, which is both advantageous and novel. The improved shape of the ledge allows for an improved engagement and fastening capability.

FIG. 1 is a partial perspective view of an extruded plastic deck plank with slip-resistant channels and an embossed top surface, in accordance with the invention.

FIG. 2 is an end view of the deck plank shown in FIG. 1, illustrating a concave feature of the slip resistant channel extruded in the top surface of the deck plank.

FIG. 3 is a side view of the engagement clip and attachment screw that hold the clip into place.

FIG. 4 is a top view of the engagement clip with lines indicating retaining flange projections of the clip body and an alignment lap joint on the engagement clip.

FIG. 5 is an end view of the deck plank and engagement clip showing the deck plank engaged to the engagement clip that in turn is secured to a horizontal-supporting member.

FIG. 6 is an end view of deck plank and engagement clip showing a plurality of deck boards engaged to engagement clips that in turn is secured to the horizontal-supporting member.

FIG. 7 is an end view of the deck plank and a removal tool inserted into elongated recess of deck plank.

FIG. 8 is a top view of the removal tool, showing a square opening for a socket wrench.

FIG. 9 is an alternative embodiment of clip showing an alignment notch and a deformation from underside of clip used to attach clip to joist or structure.

FIG. 10 is an exploded view of an alternative embodiment of an elongated track member showing a plurality of boss assemblies engaged to an elongated track that is secured to the horizontal supporting member.

FIG. 11 is a side view of a track assembly attached to a supporting member.

FIG. 12 is an isometric view of an alternative embodiment showing a lap over and engagement connection between a plurality of track assemblies.

FIG. 13 is an enlarged partial view of FIG. 12 showing a lap over and engagement connection between a plurality of track assembly ends.

FIG. 14 is an isometric view of an alternative embodiment showing an dovetail engagement between a plurality of track assembly ends.

FIG. 15 is an enlarged partial view of FIG. 14 showing a dovetail engagement between a plurality of track assembly ends.

FIG. 16 is an isometric view of an alternative embodiment showing an interlocking engagement between a plurality of track assembly ends.

12—Plank

14—Embossed plank imprint

16—Slip-resistant channel

18—Upper horizontal supporting member

20—Cap stock

22—Substrate

24—Bottom horizontal supporting member

26—Bottom horizontal supporting member

28—Intermediate integral vertical supporting panel

29—Elongated recess

30—Intermediate integral vertical supporting panel

32—Outside vertical supporting panel

34—Outside vertical supporting panel

36—Oblique supporting panel

38—Oblique supporting panel

40—Horizonal stabilizing web

41—Removal tool

42—Engaging ledger

43—Socket slot

44—Engaging ledger

45—Alignment hole

46—Engaging clip

47—Alignment lap joint end of engaging clip

48—Attachment screw

49—Structural supporting member

50—Inner mediate supporting web

51—Inner mediate supporting web

52—Retaining flange projection

53—Attachable deformation

54—Retaining flange projection

55—Alignment notch

56—Elongated track

57—Boss alignment hole

58—Flange boss assembly

59—Attachment hole

60—Alignment lap joint end of engaging track

61—Track angle

62—Flat end of engagement tract

63—Track attachment hole

64—Raised nob

66—First end FIG. 13

67—Second end FIG. 13

68—First end FIG. 15

69—Second end FIG. 15

70—First end FIG. 16

71—Second end FIG. 16

A preferred embodiment of the deck plank attachment system of the invention is illustrated in FIG. 1 (partial perspective view) and FIGS. 5 and 6 (end views). A floor assembly consists of several horizontal-supporting stringers or joists, one of which is shown as joist 49 (FIGS. 5 and 6). The joists are spaced parallel to one another. Each joist supports a series of overlapping clips 46, which extend along the top of each joist. A series of deck planks 12 are spaced apart and run perpendicular to the joists. Each plank is held to each joist by one of the overlapping clips along the top of the joist. Each plank perpendicularly overlies a group of parallel joists; e.g., if a plank is 4.88 meters long and the joists are spaced on 40.6 cm centers, then each plank is supported by 13 joists.

In the preferred embodiment, clip 46 is an aluminum extrusion. However, clip 46 can consist of any other suitable material, such as fiberglass, plastic, composite, or an other metal. Deck plank 12 is preferably a plastic, such as polyvinyl chloride. However, plank 12 can consist of composites, fiberglass, another metal, or even wood or wood inlaid with metal ledges.

At one end of each engagement clip 46 is a lap joint end 47 which overlaps a flat end of a previously installed engagement clip 46, as illustrated in FIGS. 3, 5, and 6. An alignment hole 45 is provided in both ends of the clip. These holes aid in aligning adjacent clips: the installer adjusts the clips with the holes of adjacent clips for alignment and this will ensure that the clips form a straight line.

The clip has two upright flange support legs with respective flange projections 52 and 54 (FIG. 3), which extend out horizontally from the upper sides of the legs. The flanges are at a height that allows a connection to be made between engagement clip 46 and deck plank 12.

Deck plank 12 typically has one elongated recess 29 (FIG. 3), which extends along the length of the underside of the deck plank. In other embodiments, there may be a plurality of elongated recesses. In this preferred embodiment the recess is located at the middle of the underside of the deck plank. Engaging ledges 42 and 44 (FIGS. 1 and 2) are located within the elongated recess and extend along the length of the deck plank.

The plank has intermediate integral vertical supporting panels or partitions 28 and 30, which are joined by a horizontal stabilizing web 40 which decreases the spreading capability of the plank, helping it to remain firmly affixed to engagement clip 46 (FIGS. 5 and 6). Web 40 and intermediate vertical supporting panels 28 and 30 extend along the length of the deck plank. Intermediate vertical supporting panels 28 and 30 join upper horizontal supporting member 18 to bottom horizontal supporting members 24 and 26. The plank also has intermediate supporting webs 50 and 51 (FIGS. 1, 2, 5, 6, and 7), which also extend along the length of the deck plank for added structural support.

Bottom horizontal-supporting members 24 and 26 form the base of the deck plank and are directly connected to oblique supporting panels or sections 36 and 38. The oblique panels give structural stability to the deck plank while creating an area or void for a raised portion of the alignment lap joint end 47 of the retaining clip. Outside vertical supporting panels or sections 32 and 34 connect the oblique panels to an upper horizontal-supporting member 18 (FIG. 1).

The horizontal-supporting member has an embossed plank imprint 14, which is integrally formed on the top surface of the deck plank. The top surface has five slip resistant channels 16 extruded along the length of the top surface of the deck plank. Although five channels are shown, the number of channels may vary in alternative embodiments. The four inner surface areas between channels have a “T” pattern and the outer two surfaces have a “V” pattern. However a variety of other patterns or textures or other distortions may be used for the top surface of the deck plank.

FIG. 2, an end view of plank 12, shows a cap or outer layer 20 over the top of the plank, which contains ultra-violet inhibitors that protect the vinyl from sunlight. The embossed imprint and slip resistant channels are located within this cap. A substrate 22 or inside layer of the deck plank is preferably polyvinyl chloride and contains reduced ultraviolet protection, making fabrication by a co-extrusion process more affordable without compromising quality or performance.

FIG. 7 shows an end or elevational view of deck plank 12 and with a cammable removal tool 41 inserted in elongated recess 29 in the underside of the deck plank.

FIG. 8 is a top view of removal tool 41 showing a rectangular opening 43 for a socket wrench to be inserted in the center of the tool.

The manner of installing the deck plank and retaining clip to floor joists is superior to that of planks in present use. One first installs engaging clips 46 (FIGS. 4 and 9) to a joist 49 with an attachment screw 48 in the center of each clip. A first clip is installed over and parallel to the joist. As shown in FIGS. 3 and 5, succeeding clips are installed in the same manner so that each succeeding clip is parallel to and above the joist and end 47 of one clip overlaps end 46 of the succeeding clip. The clips are installed over and in parallel with all joists over the area to be covered by deck planks.

Next, the installer holds a deck plank directly centered over the pair of flanges 52 and 54 portion of clip 46 so that the elongated recess of the plank aligns with the flanges. Then the installer applies a downward force to deck plank 12. This is most easily done by stepping on deck plank so that the weight of the installer causes inwardly sloping surfaces in the slot under the plank to ride over flanges 52 and 54, whereby the deck plank engages and attaches to clip 46. Specifically retaining flange projections 52 and 54 of the clip will ride over the sloping surfaces and then engage the upper surfaces of ledges 42 and 44 (FIGS. 5 and 6). The installer installs enough clips and planks to cover the entire deck.

To remove deck plank 12 (FIGS. 7 and 8) from engagement clip 46; e.g., for remodeling or alteration or repairs, one inserts tool 41 (FIG. 7), which has a greater length than the space between retaining flanges 52 and 54, under deck plank 12 into elongated recess 29 at one end of the deck plank. The worker then turns tool 41 ninety degrees using a standard socket wrench. This forces the flanges outward and thereby separates the end of the deck plank from ledges 42 and 44, releasing the end from the retaining flange projections 52 and 54 of the clip. The end of the deck plank can now be lifted and removed and in the same manner the rest of the deck plank can be separated and removed off the clips.

If the ends of the planks are not accessible, e.g., due to their abutting a wall, access may be obtained by either crawling under the deck, if accessible, or by ripping a plank or part of a plank so as to gain access to underside of deck structure.

FIG. 9 is an end view of an alternative embodiment of the clip showing an alignment notch 55 for receiving an opposing end of another clip. A deformation or attachment boss 53 is shown at underside of clip. This deformation may also be extruded, injection molded, or machined in different forms. An attachment screw 48 (FIG. 5) can attach the clip and be so located as to conceal screw 48 from the top surface. This location can be in the center of the flanges 52 and 54 or at the void area between adjacent planks. The top of the clip over deformation 53 can be struck with a hammer to embed deformation 53 in the joist to set clip 46 in place for ease of installation.

FIG. 10 is an exploded view of an alternative embodiment of an elongated track assembly. The track assembly shows three flange boss assemblies 58 which can attach to an elongated track portion 56. An attachment screw 48 can secure flange boss assembly 58 to elongated track 56 to structural supporting member 49. An alignment lap joint end of engagement track 60 laps over flat end of engagement track 62. The flange boss assembly 58 has two flanges opposing one another with a middle section which connects the two flanges to form a boss assembly. An attachment hole 59 in the middle of the boss allows for easy installation. A boss alignment hole 57 on either side of attachment hole 59 will intricately engage the raised nob 64 portion of the elongated track 56 to connect the boss assembly and elongated track to form an elongated track assembly. Raised nob 64 and attachment hole 59 can be evenly spaced along the length of the track so a uniform alignment can be maintained with improved accuracy over prior art assemblies. Angle 61 is shown on track assembly 56 which when placed on support member 49 will align itself for ease of installation. Track attachment hole 63 can secure track assembly ends 60 and 62 to support member 49.

FIG. 11 is a side view of an elongated track assembly 56 attached to supporting member 49. Three boss assemblies are shown attached to the elongated track. The length of the track assembly can be extended since it is an extruded track. The ends of the track can be flat or so formed to interconnect, fasten or engage one another.

In FIG. 10, the elongated track is a two-piece track consisting of elongated track 56 and flange boss assembly 58. The two components of the track can be extruded. However it is possible to have a one-piece track system that is made by a chemical reaction (polymerization) which forms the elongated track and flange bosses in a monolithic pour of a suitable plastic. An elongated injection mold can also produce an elongated track with some limitations compared to an extruded track. Flange boss assembly 58 can also be injected molded and used in conjunction with elongated track 56. The track can also be machine punched to form the flanges and angle portion in a single monolithic operation with extruded or sheared material. The resulting track of an extruded material can be fastened or engaged to form an elongated track for attaching a plurality of deck boards.

The track of FIG. 10 has advantages over present clip strip systems because of the accuracy of the extruded track in length, due to the reduced number of pieces needed to form a completed strip. A side panel 61 can also be placed on at least one side of the elongated portion of the track 56 to help placement and attachment of the track members. Side panel 61 also helps prevent water damage to structural supporting members 49. Deck planks 12 can be installed in a similar manner with the elongated track assembly as with the deck plank and retaining clip to floor joists mentioned earlier in operations section.

FIG. 12 is an isometric view of an alternative embodiment showing a lap over and engagement connection between track assembly ends. A first end 66 has a male projecting portion which engages with a second female receiving portion 67 which connects the ends to form a plurality of elongated track assemblies.

FIG. 13 is an enlarged partial view of the lap over and engagement connection between track assemblies. First end 66 engages with second end 67 when a plurality of track assemblies is required to complete a deck installation.

FIG. 14 is an isometric view of an alternative embodiment showing a dovetail engagement connection between track assembly ends. The first end 68 has a male projecting portion to engage with a second female receiving portion 69 which connects the ends to form a plurality of elongated track assemblies.

FIG. 15 is an enlarged partial view of the dovetail engagement connection between track assemblies first end 68 engages with second end 69 when a plurality of track assemblies is required to complete a deck installation.

FIG. 16 is an isometric view of a further alternative embodiment showing an interlocking engagement between track assembly ends. The first end 71 has a semicircular recessed portion which engages with a second end 70, which has a semicircular flange portion to form a plurality of elongated track assemblies. FIGS. 12 and 14 can have an attachment screw 48 which will secure the two ends to supporting member 49.

From the description above a number of advantages of my deck plank extrusion and retaining clip or track become evident:

(a) The combination of the clip and deck plank allows quick and easy installation by a homeowner.

(b) The embossed imprint and slip resistant channels of my deck plank provides a slip resistant surface to walk upon.

(c) The elongated recess at underside of plank allows access removal of the plank with little effort to disengage nor unsightly damage to the plank from the disengagement process.

(d) The structure and height of the engaging flanges add durability to the flanges and a superior positive connection of the plank to the engagement clip.

(e) The oblique supporting panels add strength to the deck plank by the novel structure of that particular bend in the deck plank, which is not found in other decking extrusions, and which enables the deck plank to maintain form.

(f) The planks can be removed easily for repair, alterations, or remodeling.

(g) The track assembly allows for rapid accurate installation, thus giving the homeowner a friendly system to work with.

Accordingly the reader will see that my deck plank extrusion and retaining clip or track can be used readily in deck and dock applications as well as other uses, such as installing planks over concrete slab floors or other none wood joist floor structures. It can be removed easily when necessary without damaging the retaining clip or engagement flanges. Furthermore, the deck plank and retaining clip have additional advantages in that;

they permit the top surface of the deck plank to be free of unsightly, fasteners that detract from the aesthetic look of the top deck surface;

they provide a superior, embossed slip-resistant surface to walk upon; and

they provide a deck that is easily assembled, even by those unskilled in the art.

they provide an elongated track assembly which allows for an easily assembled structure for attaching a plurality of deck boards while holding to greater accuracy which is superior to that of previous inventions.

Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustration of some of the presently preferred embodiments of this invention, other embodiment are possible. For example, the engagement clip or elongated track assembly can be entirely flat at the bottom with no raised lap joint connections. The engagement clip or track assembly can have a right angle side which rest along the side of a joist for attachment and ease of installation. The engagement clip or track assembly can have deformations located on the bottom or side portion of the clip, which will attach the clip or track to the joist. The engagement clip or track assembly can be shaped to shed water from the clip or track. Fasteners may also be used to attach the clip in a multitude of places. A number of elongated recesses on the deck plank, can be added which will change the shape of the underside of the plank structure as well as the number of flanges needed for the clip to connect and join the two components together. The height of the intermediate horizontal stabilizing web 40 can be raised or lowered within the elongated recess to alter the spreading capability of the deck plank by so positioning the web. Materials such as composites can be used in place of vinyl, as well as a multitude of other plastics, minerals, inorganic, organic, fiberglass, and metal materials, which can be attached over a flat surface rather then joists. Materials such as composites can be extruded in a solid form that matches the outer contours of the mentioned deck profile and use the clip or track attaching method as previously mentioned to attach the deck plank to the clip which is attached to a structural supporting member or joist. The engagement track assembly can have opposing ends which engage each other in a multitude of ways formed by a mechanical or injection molded process.

Therefore, the scope of the present invention should be determined by the appended claims and their legal equivalents, and not by the examples given.