Patent Application
20050257473
The present invention relates generally to decking or fencing systems, and more particularly to an improved anchor fastener and anchoring system for decks or fences.
In both new building constructions and renovation projects, there is an increasing demand in the residential, commercial and public building construction industries to provide private homes, businesses such as shops and restaurants, and public park facilities with deck structures. These structures typically comprise joists overlain with planks or floor boards and bound by a plurality of posts. Because of its natural beauty, comparatively low cost and abundant supply, wood has historically been the predominant material of choice in the construction of decks and similar structures, e.g., walkways, steps, and boat decks and piers. However, the lumber used in the construction of such structures requires considerable and costly maintenance to slow its inevitable deterioration caused by continual exposure to the sun, rain, snow and other natural elements. Moreover, wooden decks and related structures are subject to splintering which can be a hazard to individuals in bare feet. And, wooden structures are highly flammable.
The traditional manner of attaching wooden decking planks to underlying joists is by nailing or screwing through the plank into the joist below. This attachment method presents a number of disadvantages. For example, nail or screw heads exposed on the top surface of the decking planks are aesthetically unappealing and may also present tripping, scratching or splintering hazards. Further, the nails may be pried upwards away from the joists by flexing of the deck planks caused by repeated foot traffic. Additionally, the use of nails or screws necessarily creates holes the decking planks which may cause the wood to split, and which may accelerate deterioration of the plank caused by weather or insects. Further disadvantages include increased difficulty of cleaning and/or painting the decking planks.
Recently, decking systems using rigid plastics such as polyvinyl chloride (PVC), and plastic/fiber composites have become an increasingly popular alternative to wood in the construction of decks and similar structures. These decking systems have been designed with various securing mechanisms. According to some of these designs, the flooring planks are secured to fastener strips which in turn are secured to the joists. In others, the decking planks are secured directly to the joists via screws or similar fastening means.
U.S. patent application Ser. No. 10/365,870 to Bruchu et al. discloses a decking system formed of extruded thermoplastic wood fiber composite having hollow profile deck planks which interact with decking anchors to form a platform structure. The deck planks have anchor flanges which cooperate with the anchor structure. The anchor structure has a shape that conforms to the anchor flanges to hold the planks in place. The anchor structure includes a vertical aperture into which a fastener is inserted to fix the anchor in place. This decking system requires a fairly complex design for the cooperating planks and anchor.
U.S. Pat. No. 5,953,878 to Johnson discloses a decking system formed of extruded hollow polyvinyl or plastic planks having a plurality of slots on the side surfaces which overly the joists. The slots are engaged by mounting cleats which act to secure the planks to the joints and to each other. The cleats include a vertical slot through which a fastener is inserted to secure the cleat to the underlying frame. The cleat in slot arrangement allows for the different rates of thermal expansion and retraction of the plastic planks compared to the supporting wood frame.
U.S. Pat. No. 5,660,016 to Erwin et al. discloses an extruded plastic decking plank and attachment system having planks formed of a rigid foam core and a resilient outer plastic shell. The attachment system includes hold down blocks which have a shape that cooperates with clamping portions on the planks to secure the planks to a support structure. The hold down blocks are secured to the support structure by a fastener which is inserted vertically through a top of the block.
An improved low cost, easily installed decking structure and decking anchor is desired.
According to one exemplary embodiment, an anchor for installing a plank in a deck system includes a base portion, a plank-engaging portion and a fastener aperture. The plank-engaging portion has at least one protrusion. The fastener aperture has a longitudinal axis which is inclined from vertical and extends through the base portion and plank-engaging portion.
The anchors described herein may advantageously be used to secure planks to joists in decking systems. Unlike current decking systems having anchors with vertical fastener apertures, which require an installer to keep the anchor tight against the joist when installing the fastener, the angled aperture of the anchors described herein reduces or eliminates the need for a tight controlled positioning of the anchor.
According to another aspect, a decking system includes a plurality of anchors and a plurality of planks. The anchors include a base portion, a plank-engaging portion, and at least one fastener aperture. The plank-engaging portion includes at least one protrusion. The fastener apertures have a longitudinal axis disposed obliquely from a vertical plane and which extend through the base portion and plank-engaging portion. The planks include a side wall having an anchor-engaging groove for cooperating with a corresponding protrusion of a corresponding anchor.
According to a further aspect, a method of installing a deck system comprises providing a plank having an anchor-engaging groove, providing an anchor having a plank-engaging portion and a fastener aperture having a longitudinal axis which is disposed obliquely from a vertical plane, laying the plank on a decking joist, inserting the plank-engaging portion of the anchor into the anchor-engaging groove of the plank, and inserting a fastener through the fastener aperture and into the decking joist.
According to another aspect, a decking system includes a plurality of decking planks, a plurality of anchors and a plurality of fasteners. The decking planks are disposed over supporting joists. Each of the decking planks have a first and second curvilinear side edge portion. The anchors have first and second side surfaces capable of frictionally mating between the first and second curvilinear side edge portion of adjacent ones of the decking planks. The fasteners are disposed through the anchors at an oblique angle from vertical for joining the decking planks to the supporting joists.
According to another aspect, a decking anchor has a generally key-hole shaped cross-section and a planar bottom surface.
According to another aspect, a system for anchoring adjacent planar members to a base member includes a plurality of anchors, a plurality of planar members and at least one base member. The plurality of anchors have a base portion, a planar member-engaging portion having at least one protrusion, and at least one fastener aperture with a longitudinal axis disposed obliquely from a vertical plane and extending through the base portion and planar member-engaging portion. The plurality of planar members include a side wall having an anchor-engaging groove for cooperating with a corresponding protrusion of a corresponding anchor. The anchors are fastened into the base member.
This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
Referring to
The anchors 10, planks 30 and joists 40 of decking system 100 may be comprised of a variety of materials, including wood, metal, polymer, and composite materials. These articles may be cut, molded, drawn, injection-molded or extruded, for example. Preferably, the planks and anchors are comprised of a thermoplastic/fiber composite. The thermoplastics that can be used may include polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyacrylic materials, polyester materials and other common thermoplastics. More preferably, the anchors, planks and/or joists are comprised of an extruded vinyl/wood composite such as that employed in BOARDWALK® Composite decking and railing systems sold by CertainTeed Corporation of Valley Forge, Pa. The consolidation of vinyl and wood fibers into composite reinforcement may be made in-situ during in-line extrusion of the final end product extrudate, or, alternatively, prepared as a tape or rod and incorporated into an off-line extrusion of final product. The commingled fibers may also be pultruded, followed by overlay extrusion of a capstock polymer using a separate extruder, all in-line. In this case, the capstock polymer would preferably cover only the outside surface of the plank, anchor and/or joist. The capstock may be applied by coating or painting as well as coextruding. The polymer or composite articles, or the capstock overlaying the articles, may further include pigments, thermal stabilizers, impact modifiers, ultra-violet (UV) radiation screening agents and other performance and/or aesthetic enhancing additives.
Referring to
The anchor 10 can have a fastener aperture predrilled or premolded, or the fastener can form its own aperture when it is drilled or nailed, for example. The anchor 10 could also have one or more starter holes or notches for helping to start the fastener. The fastener aperture 16, 16′ is preferably pre-pierced in the anchor 10, 10′. It extends through the plank-engaging portion 14 and the base portion 12 at an oblique angle ø away from vertical. Preferably the angle ø is between about 5 and 60 degrees away from vertical. By placing the fastener aperture 16, 16′ at an angle away from vertical, the bottom surface 18 of the anchor 10, 10′ does not have to be held tight against the joist when installing the fastener as is typically the case with anchors having vertical fastener apertures.
The anchor may include one fastener aperture 16, as shown in
Referring again to
Referring now to
Advantageously, anchors 10, 10′, 15 are hidden or substantially hidden from view when installed in the decking system 100. The anchors 10, 10′, and 15 also allow installation of the fasteners 50 from the top of the deck as opposed to the bottom, and therefore makes it easier to build decks which are near ground level. Also, unlike some decking systems having hidden fasteners which require special fasteners, standard fasteners, such as nails or deck screws may be used in decking system 100.
Referring to
The planks 30 can be of any length or width, but preferably have a length and width equal to those of standard wood lumber. Where the planks are comprised of polymer or composite materials, the planks can be fabricated to include a simulated wood grain outer surface. Also, where the planks are comprised of polymer or composite materials, the planks may be substantially solid, partially solid, or hollow. Where the planks are hollow, they may include internal reinforcement braces. As stated above, the planks comprised of a polymer or composite material may include a capstock layer as an outer layer of the plank.
Referring now to
The anchors 110 of decking system 200 comprise a base portion 112, a plank-engaging portion 114, and a plurality of fastener apertures 116. Unlike anchors 10, 10′, 15, anchors 110 preferably extend substantially the length of the planks 30. This configuration of the anchor advantageously provides extra support for the planks which is beneficial in demanding applications. (Alternatively, the anchors may have a length extending at least the distance between two joists.) A bottom surface 118 of the base portion 112 lies on the joist 40. As best shown in
The fastener apertures 116 are preferably pre-pierced in the anchor 110. They are preferably spaced intermittently along the length of the anchor 110 at locations where the anchor will intersect a joist 40. The fastener apertures 116 extend through the plank-engaging portion 114 and the base portion 112 at an angle ø away from vertical. Preferably the angle ø is between about five and sixty degrees away from vertical. As stated above, by placing the fastener aperture 116 at an angle away from vertical, the bottom surface 118 of the anchor 110 does not have to be held tight against the joist when installing the fastener, as is typically the case with anchors having vertical fastener apertures.
The anchor 110 may include a plurality of fastener apertures 116 having an entry point along only one protrusion as shown in
As with anchors 10, 10′, 15, anchor 110 is capable of being hidden or substantially hidden from view when installed in the decking system 200.
Referring to
This anchor embodiment allows the single anchor 310 to be used to secure two planks that are perpendicular to one another, and therefore would be beneficial for employment in picture-framing deck planks (see
Referring to
Referring to
Although advantageously employed in decking systems, the anchors and planks described herein may also be beneficially employed in fencing systems to form a fence with a hidden fastening system. Such a system may eliminate unappealing visible nail or screw holes. Referring to
Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.
