Deck Clip

Abstract

A deck clip that may be used in the construction of a deck and a method of using the same is provided. The deck clip may include a grip and a spacer. Portions of both the grip and the spacer may be received within the grooves of deck boards used in decks. Thus, the deck clip may be selectively affixed to deck boards. Further, the deck clip may be configured to receive a fastener for anchoring the deck clip to joists. Thus, the deck clip may be used to couple deck boards to joists. Advantageously, the deck clip may be used to construct a deck without exposed fasteners, the geometry of the spacer may assist with creating a consistent gap between adjacent deck boards, and the grip may comprise saw-tooth shaped surfaces for improved retention of the deck boards.

Description

BRIEF SUMMARY OF THE INVENTION

This disclosure generally relates to a deck clip. More particularly, the disclosure relates to an improved deck clip for quickly and securely attaching deck boards to joists without the use of exposed fasteners.

BACKGROUND OF THE INVENTION

A deck is a flat surface capable of supporting weight, similar to a floor, but typically constructed outdoors, often elevated from the ground, and usually connected to a house. The top of a deck is typically made up of deck boards that lay horizontal and span between joists. The deck boards may be made of wood, or a composite material such as a blend of wood and plastic.

Traditionally, deck boards are attached directly to the joists using fasteners, such as wood or metal screws. The screws in a traditional deck are orientated vertically and inserted through the top of the deck boards such that the heads of the screws are either flush with the top surface of the deck boards or sit slightly below the surface. However, because the screws remain visible, the screws may detract from an appearance of the deck.

Additionally, the screws can cause the deck boards to split during assembly or over time leading to accelerated degradation of the deck and an increased risk of splinters for the user.

Prior solutions to address these problems include using deck clips of various designs. Deck clips are brackets that couple deck boards to joists. Deck clips are typically affixed to joists using screws and are typically coupled to deck boards using a groove-and-groove system, where the deck clip may be inserted into to grooves on the sides of each board.

Alternatively, a tongue-and-groove system may be used, where the tongue portion contacts solely the bottom surface of the groove. Additionally, the traditional tongue-and-groove system is made up of smooth surfaces. Because the smooth surfaces offer limited friction and because of the relatively small contact area between the tongue and the groove, the typical deck clip system is a flawed method of coupling the deck boards to the joists.

The typical system does not offer a secure attachment method, and over time, the deck boards that are not securely attached can shift or become detached. This can lead to an unstable and unsafe deck which can be hazardous to the user.

Moreover, typical deck clip systems fit into the groove but are not held in place by anything other than the screw, meaning the clip must be inserted into the groove, and the screw must first be started into the joist before the next board can be put in place, with the screw being tightened down thereafter. If the screw is not started before the next board is put in place, the deck clip may get knocked off of the joist while aligning the next board. Thus, there is a need for a deck clip design without needing to contact the screws at least twice during installation, and to address some or all of the additional deficiencies.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a deck clip with a fastener according to an example embodiment;

FIG. 2 illustrates an exploded view of the deck clip of FIG. 1 with a fastener;

FIG. 3 illustrates a front perspective view of a spacer of the deck clip of FIG. 1;

FIG. 4 illustrates a rear perspective view of the spacer of FIG. 3;

FIG. 5 illustrates a top perspective view of a grip of the deck clip of FIG. 1;

FIG. 6 illustrates a side perspective view of the grip of FIG. 5;

FIG. 7 illustrates a side view of the deck clip of FIG. 1 together with a fastener;

FIG. 8 illustrates a top view of deck clip of FIG. 1 together with a fastener;

FIG. 9 illustrates a perspective view of a deck assembly partially assembled according to an example embodiment;

FIG. 10 illustrates a side view of a first step of assembling the deck assembly of FIG. 9;

FIG. 11 illustrates a side view of a second step of assembling the deck assembly of FIG. 9.

FIG. 12 illustrates a side view of a third step of assembling the deck assembly of FIG. 9.

FIG. 13 illustrates a side view of a fourth step of assembling the deck assembly of FIG. 9.

Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Example embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. Also, the terminology used herein is for the purpose of description and not of limitation.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will be described in detail herein specific embodiments with the understanding that the present disclosure is an exemplification of the principles of the invention. It is not intended to limit the invention to the specific illustrated embodiments. The features of the invention disclosed herein in the description, drawings, and claims may be significant, both individually and in any desired combinations, for the operation of the invention in its various embodiments. Features from one embodiment may be used in other embodiments of the invention.

As shown in FIGS. 1-13, embodiments of this disclosure include a deck clip that can be used with a fastener.

Referring to FIGS. 1 and 2, a deck clip 100 according to an embodiment may include a spacer 200 and a grip 300. A fastener 400 may also be provided to fasten the grip 300 with the spacer 200.

As illustrated in FIGS. 3 and 4, the spacer 200 may include a central member 210 that extends from a first end 202 to a second end 204. In some embodiments, the central member 210 may be substantially flat and rectangular in shape.

The central member 210 may include a top surface 212 and, opposite from and parallel to the top surface 212, a bottom surface 214 (see FIGS. 10-13). Additionally, the central member 210 may also include a front surface 216 (see FIG. 3) and a rear surface 218 (see FIG. 4) opposite from the front surface 216. The front surface 216 and the rear surface 218 may be perpendicular to the top surface 212 and the bottom surface 214.

In between the first end 202 and the second end 204, a protrusion 220 may be provided that protrudes upwardly and away from the top surface 212 of the central member 210. The protrusion 220 may include a upper surface 222 that is substantially parallel to the top surface 212 of the central member 210.

A first fastening hole 224 may be provided on the top surface 212. The first fastening hole 224 may be substantially circular in shape. The first fastening hole 224 may matches an outer profile of the fastener 400, thus permitting the fastener 400 to extend through the first fastening hole 224.

The first fastening hole 224 may extend from the upper surface 222 of the protrusion 220 down to the bottom surface 214 of the central member 210, thereby creates a bore through the entirety of the protrusion 220 and through the entirety of the central member 210.

A plurality of fastening nubs 226 may be provided in the first fastening hole 224. The fastening nubs 226 may be spaced radially along the circumference of the first fastening hole 224. In an embodiment, there may be four fastening nubs 226. In other embodiments, however, there may be more or less fastening nubs 226, or no fastening nubs 226 at all.

Further, at the first end 202, a first arm member 230 may be provided that protrudes upwardly and away from the top surface 212. Similarly, at the second end 204, a second arm member 240 may be provided that protrudes upwardly and away from the top surface 212. A first gap 252 may be provided between the protrusion 220 and the first arm member 230, and a second gap 254 may be provided between the protrusion 220 and the second arm member 240.

The first arm member 230 and the second arm member 240 may be substantially rectangular; however, other shapes are also foreseeable. Similarly, in the example embodiment, the first arm member 230 and the second arm member 240 are bound by the front surface 216 and the rear surface 218 of the central member 210; however, other configurations are also contemplated.

In addition, the first arm member 230 and the second arm member 240 may include a first cantilever member 232 and a second cantilever member 242 respectively. The first cantilever member 232 may protrude outwardly from the first arm member 230 towards the second end 204, and the second cantilever member 242 may protruding outwardly from the second arm member 240 towards the first end 202. The first cantilever member 232 and the second cantilever member 242 may be substantially rectangular; however, other shapes are also foreseeable.

In some embodiments, the first cantilever member 232 may substantially overlap the first gap 252 and the second cantilever member 242 may substantially overlap the second gap 254. More particularly, the first cantilever member 232 may have a first width that is substantially similar to a width of the first gap 252. Likewise, the second cantilever member 242 may have a second width that is substantially similar to a width of the second gap 254.

Referring now to FIG. 3, where the first cantilever member 232 joins the first arm member 230, a first corner 234 may be provided. The first corner 234 may be rounded, squared, or other suitable geometry. Similarly, where the second cantilever member 242 joins the second arm member 240, a second corner 244 may be provided. Likewise, the second corner 244 may be rounded, squared, or other suitable geometry.

A channel 250 may be formed in the spacer 200. More particularly, the channel 250 may be formed between the first arm member 230, the second arm member 240, the first cantilever member 232, the second cantilever member 242, and the protrusion 220. The channel 250 may match an outer profile of the grip 300 such that the grip 300 may slidingly engage the spacer 200.

Referring to FIG. 4, a first extension 260 may be provided that protrudes outwardly and away from the rear surface 218 of the first arm member 230. The first extension 260 may be flexible and may form a first angle 262 with the rear surface 218 of the central member 210.

Similarly, a second extension 270 may be provided that protrudes outwardly and away from the rear surface 218 of the second arm member 240 is illustrated. The second extension 270 may also be flexible form a similar, second angle 272 with the rear surface 218 of the central member 210.

Where the first extension 260 joins the first arm member 230 and where the second extension 270 joins the second arm member 240, there may be a first tapered portion 264 and a second tapered portion 274 respectively. The first tapered portion 264 and the second tapered portion 274 may be designed to bend in response to a downward shear force being applied to the first extension 260 and the second extension 270. For example, when no external forces are applied, the first angle 262 and the second angle 272 may each be between 90 degrees and 120 degrees. In some embodiments, when no external forces are applied, the first angle 262 and the second angle 272 may each be between 100 degrees and 110 degrees. More specifically, the first angle 262 and the second angle 272 may each be approximately 104 degrees.

However, when external forces are applied, the first tapered portion 264 and the second tapered portion 274 may bend such that the first angle 262 and the second angle 272 may decrease to 90 degrees or less. In order to prevent fractures resulting from bending, in the first tapered portion 264 and the second tapered portion 274, the cross-sectional area may be largest proximal to the rear surface 218, and the cross-sectional area may be smallest distal to the rear surface 218.

Referring now to FIG. 5, the grip 300 of the deck clip 100 is illustrated. The grip 300 may include a cross section 305 that extends from a first end 310 to a second end 315. The cross section 305 may be substantially C-shaped or U-shape. However, other shapes are contemplated. The cross section 305 of the grip 300 may be substantially similar to the channel 250 of the spacer 200. The cross section 305 may define an outer surface 320 of the grip 300. Additionally, parallel to and offset from the outer surface 320, an inner surface 325 may be provided (see FIG. 6).

The cross section 305 may include several distinct portions. First, a center portion 330 may be provided. A first leg portion 340 may be provided that is orthogonal and joined to the center portion 330. A second leg portion 345 may also be provided that is parallel to and offset from the first leg portion 340 and joined to the center portion 330. The center portion 330, the first leg portion 340, and the second leg portion 345 may each be substantially rectangular. The first leg portion 340 and the second leg portion 345 may both extend a length 349 down from the center portion 330 to their terminations.

In addition, the grip 300 may further include a first rounded edge 342 and a second rounded edge 347 where the center portion 330 joins the first leg portion 340 the second leg portion 345 respectively. The first rounded edge 342 and the second rounded edge 347 may have a curved profile that is substantially similar to the profile of the first corner 234 and the second corner 244 of the spacer 200.

A second fastening hole 335 may be provided through the center portion 330. The second fastening hole 335 may be substantially circular and it be located approximately equidistant from the first end 310 and the second end 315 of the grip 300. The second fastening hole 335 may also be positioned approximately equidistant from the first leg portion 340 and the second leg portion 345. In some embodiments, the second fastening hole 335 may also be countersunk or counterbored.

As best illustrated in FIG. 6, the grip 300 may include a first end region 350, a second end region 355, and a middle region 352. The first end region 350 may be proximal to the first end 310 of the grip 300; the second end region 355 may be proximal to the second end 315 of the grip 300; and the middle region 352 may be positioned between the first end region 350 and the second end region 355.

In the middle region 352 of the grip 300, the length 349 of the first leg portion 340 and the second leg portion 345 may be relatively constant. Thus, the first leg portion 340 and the second leg portion 345 may each have a mating surface 360 in the middle region 352. In some embodiments, the mating surface 360 may be substantially flat.

Conversely, in the first end region 350 and the second end region 355, the length 349 of the first leg portion 340 and the second leg portion 345 may vary substantially. Thus, in the first end region 350 and the second end region 355, the first leg portion 340 and the second leg portion 345 may each have grip surfaces 365 that may be irregularly shaped. More specifically, the grip surfaces 365 may be saw-tooth shaped surfaces having a plurality of peaks and a plurality of valleys or sinusoidal shaped surfaces; however, other shapes are contemplated.

In some embodiments, the channel 250 may be of a dimension such that when the grip 300 is inserted into the channel 250, a friction relative to the grip 300 can be applied on the grip 300. Such friction may prevent the grip 300 from moving in a vertical position toward or away from the first extension 260 or the second extension 270. In further embodiments, once the grip 300 is inserted into the channel 250, the first cantilever member 232 and the second cantilever member 242 may each abut a portion of the outer surface 320 of the grip 300, such that the grip 300 is prevented from moving in a vertical position toward or away from the first extension 260 or the second extension 270.

FIGS. 7 and 8 illustrate the deck clip 100 selectively assembled with a fastener 400 partially inserted. As shown in FIG. 7, when the deck clip 100 is selectively assembled, the cross section 305 of the grip 300 may be selectively inserted within the channel 250 of the spacer 200.

In some embodiments, when the deck clip 100 is selectively assembled, the mating surfaces 360 of the grip 300 may abut the top surface 212 of the spacer 200; the inner surface 325 of the center portion 330 of the grip 300 may abut the upper surface 222 of the protrusion 220 of the spacer 200; and the outer surfaces 320 of the first leg portion 340 and the second leg portion 345 of the grip 300 may be abut the first arm member 230 and the second arm member 240 of the spacer 200. Moreover, the outer surface 320 of the center portion 330 of the grip 300 may partially abut the first cantilever member 232 and the second cantilever member 242 of the spacer 200. In other embodiments, a dimension of the channel 250 may be slightly larger such that at least some surfaces of the grip 300 do not abut the spacer 200.

As best shown in FIG. 8, when the deck clip 100 is selectively assembled, the second fastening hole 335 of the grip 300 may align axially with the first fastening hole 224 of the spacer 200 such that the fastener 400 can be inserted therethrough. When a fastener 400 is inserted therethrough, the fastening nubs 226 may act to retain the fastener 400 within the first fastening hole 224.

FIG. 9 illustrates an enlarged view of a partially assembled deck assembly 500. The deck assembly 500 may include joists 510 (only one shown). Spanning across and resting on top of the joists 510, deck boards 550 (only one shown) may be provided. The joists 510 and the deck boards 550 may be made of wooden materials. In some embodiments, the deck boards 550 may be composite boards including a blend of multiple materials, such as a blend of wood and plastic.

In an example embodiment, each deck board 550 may include one or more grooves 555 (only one shown) that run longitudinally along the length of the deck boards 550. The grooves 555 may be pockets with a bottom groove face 556, and a top groove face (not shown) that is parallel to and opposite from the bottom groove face 556. In some embodiments, the grooves 555 may be substantially rectangular pockets, although a curved pockets or other geometries are also contemplated. The grooves 555 may also include a side groove face (not shown) that is orthogonal to both the bottom groove face 556 and the top groove face.

As shown in FIG. 9, the deck assembly 500 may include deck clips 100 (only one shown) with fasteners 400. The deck clips 100 may be positioned directly above the joists 510. The first extensions 260 and the second extensions 270 of the spacers 200 of the deck clips 100 may be positioned within the grooves 555 of the deck boards 550. The grips 300 of the deck clips 100 may also be positioned within the grooves 555 of the deck boards 550.

FIGS. 10-13 illustrate a method of assembling the deck assembly 500. First, a joist 510 may be provided. A first deck board 560 may be provided perpendicular to and on top of the joist 510. The first deck board 560 may be substantially the same as the deck boards 550 previously described. Similar to the deck boards 550, the first deck board 560 may include two grooves 565, each with a bottom groove face 566, a top groove face 567, and a side groove face 568.

Therefrom the deck clip 100 may be inserted into the first deck board 560. More particularly, the first extension 260 and the second extension 270 of the deck clip 100 may be inserted into the groove 565 of the first deck board 560. The first extension 260 and the second extension 270 may be introduced into the groove 565 while the deck clip 100 is angled (i.e., the top surface 212 of the spacer 200 is not parallel to the joists 510).

Next, as illustrated in FIG. 11, the first end region 350 of the grip 300 may also be inserted into the groove 565 of the first deck board 560. This may be accomplished by rotating the deck clip 100 such that the deck clip 100 is no longer angled (i.e., rotating the deck clip 100 until the top surface 212 of the spacer 200 is parallel with the joists 510).

As the grip 300 of the deck clip 100 is inserted into the groove 565, the first extension 260 and the second extension 270 abut the top groove face 567, and the grip 300 abuts the bottom groove face 566. Resulting in the groove 565 imparts a sheer force onto the first extension 260 and the second extension 270. Said sheer force may cause the first tapered portion 264 and the second tapered portion 274 to undergo elastic deformation such that the first angle 262 and the second angle 272 decrease from approximately 104 degrees to approximately 90 degrees.

Accordingly, as the grip 300 is inserted into the groove 565, the first extension 260 and the second extension 270 are forced into the top groove face 567, and the grip 300 is forced into the bottom groove face 566. Thus, a friction created by an expansive force may be applied between the bottom grove face 566 and the grip surface 365 to prevent the grip 300 from easily disengaging the first deck board 560. Thereafter, the grip 300 may be further inserted into the groove 565 until the rear surface 218 of the spacer 200 abuts the first deck board 560.

Next, as illustrated in FIG. 12, a second deck board 570 may be introduced. The second deck board 570 can be quickly and accurately positioned by ensuring the front surface 216 of the spacer 200 abuts the second deck board 570.

Similar to the first deck board 560, the second deck board 570 may include two grooves 575 each with a bottom groove face 576, a top groove face 577, and a side groove face 578. Also similar to the first deck board 560, the grip 300 of the deck clip 100 may be inserted within the groove 575 of the second deck board 570. Here, however, it is the second end region 355 of the grip 300 that may be inserted into the groove 575. Similar to before, the grip surface 365 of the grip 300 may also abut the bottom groove face 576 of the second deck board 570. Accordingly, a firm connection between the deck clip 100 and the second deck board 570 may be formed.

Finally, as illustrated in FIG. 13, a fastener 400 may be utilized to affix the deck clip 100 to the joists 510. In the example embodiment, the fastener 400 may be a screw; however, other fastening means are foreseeable. Here, the fastener 400 may be inserted into and through the first fastening hole 224 of the spacer 200 and the second fastening hole 335 of the grip 300. Further, the fastener 400 may be inserted or screwed into the joists 510 to affix the deck clip 100 to the joist 510, thus creating a secured connection between the joists 510 and the deck clip 100. As can be appreciated, a distance between the front surface 216 and the rear surface 218 of the spacer 200 may defines the spacing between the first deck board 560 and the second deck board 570.

Once the fastener 400 is inserted into the joists 510, the downward force asserted due to the fastener 400 may cause the grip surface 365 to sink into or embedded itself in the bottom groove face 566 the first deck board 560, thus forming a secured connection. Further, by having the fastener 400 inserted into and through both the first fastening hole 224 of the spacer 200 and the second fastening hole 335 of the grip 300, the grip 300 can be held firmly in place (both vertically and horizontally) relative to the spacer 200, thus forming the deck clip 100.

A quick and secure connection may be provided between the joists 510, the first deck board 560, and the second deck board 570 without any fasteners 400 being exposed. The steps described herein can then be repeated until the desired number of deck boards 550 are connected to form the deck assembly 500 of the desired size. In each subsequent iteration of the steps, the so-called second deck board of the previous iteration may become the so-called first deck board in the subsequent iteration. Finally, when the process is completed, the deck assembly 500 may be securely formed without having exposed fasteners. Because the fasteners may be hidden in the grooves well below the top surface of the deck boards, the fasteners may be difficult to see by an end user, thus the top surface of the deck board can remain clear of any fasteners detracting from the appearance.

Further, because the deck clip 100 may be held in the deck boards alone through a friction fit due to an expansive force applied by the grip 300 and the first extension 260 and/or the second extension 270 of the spacer 200, multiple deck boards may be placed before having to fasten the deck clip 100 into the joists 510 via the fastener 400. Resulting in an increased ease of installation and efficiency.

Specific embodiments of a deck clip according to the present invention have been described for the purpose of illustrating the manner in which the invention may be made and used. It should be understood that the implementation of other variations and modifications of this invention and its different aspects will be apparent to one skilled in the art, and that this invention is not limited by the specific embodiments described. Features described in one embodiment may be implemented in other embodiments. The subject disclosure is understood to encompass the present invention and any and all modifications, variations, or equivalents that fall within the spirit and scope of the basic underlying principles disclosed and claimed herein.

Claims

1. A deck clip comprising: a grip configured to be received within a groove positioned on a side surface of a deck board; anda spacer comprising: a rear surface configured to abut the side surface of the deck board;a channel configured to receive the grip; anda first extension that protrudes outwardly and away from the rear surface, wherein the first extension is configured to also be received within the groove.

2. The deck clip of claim 1 further comprising a second extension that protrudes outwardly and away from the rear surface, wherein the second extension is configured to also be received within the groove.

3. The deck clip of claim 1, wherein the first extension is positioned above the grip.

4. The deck clip of claim 1, wherein once the grip is received in the channel, the grip is prevented from moving vertically toward or away from the first extension.

5. The deck clip of claim 1, wherein the deck clip comprises an at least one fastening hole configured to receive a fastener for anchoring the deck clip to a joist.

6. The deck clip of claim 1, wherein the first extension is configured to bend when the first extension is received within the groove.

7. The deck clip of claim 5, wherein the at first extension forms an angle with the rear surface, and wherein said angle is approximately between 100 degrees and 110 degrees when the first extension is not acted on by external forces.

8. The deck clip of claim 1, wherein the grip is configured to abut a bottom surface of the groove, and wherein the first extension is configured to abut a top surface of the groove.

9. A method for anchoring deck boards to joists comprising: providing a first joist;providing a first deck board on top of the first joist;providing a deck clip having a spacer and a grip;angling the deck clip such that it is not parallel to the first joist;inserting a first extension of the spacer into a first groove of the first deck board;rotating the deck clip such that it is parallel to the first joist; andinserting a first end of the grip into the first groove.

10. The method of claim 8 further comprising the steps of: inserting the first extension and the grip into the first groove such that a rear surface of the spacer abuts the first deck board;providing a second deck board parallel to the first deck board and on top of the first joist;inserting a second end of the grip into a second groove of the second deck board such that a front surface of the spacer abuts the second deck board; andproviding a fastener to secure the deck clip to the first joist,wherein the front surface is opposite from and parallel to the rear surface.

11. The method of claim 9, wherein the first extension imparts a first upward force on the first groove and the grip imparts a first downward force on the first groove.

12. The method of claim 10, wherein the second groove imparts a second upward force on the grip, and wherein the fastener imparts a second downward force on the deck clip.

13. The method of claim 10, wherein the fastener is a screw.

14. A clip assembly comprising: a grip having a first region that is proximal to a first end, a second region that is proximal to a second end opposite the first end, and a third region that is located between the first end and the second end;a spacer configured to receive the third region of the grip;at least one fastening hole configured to receive a fastener;wherein the spacer includes a first extension and a second extension configured to be received within a first groove of a first deck board;wherein the first region of the grip is configured to be received within the first groove;wherein the second region of the grip is configured to be received within a second groove of a second deck board.

15. The clip assembly of claim 13, wherein the first region and the second region of the grip each include a plurality of saw-tooth shaped surfaces each having a plurality of peaks and a plurality of valleys.

16. The clip assembly of claim 13, wherein the third region of the grip includes smooth surfaces.

17. The clip assembly of claim 13, wherein the at least one fastening hole includes a plurality of fastening nubs spaced radially along a circumference of the at least one fastening hole, and wherein the plurality of fastening nubs are configured to couple the fastener to the clip assembly.

18. The clip assembly of claim 13; wherein the at least one fastening hole includes a countersink or a counterbore.

19. The clip assembly of claim 13, wherein the spacer further comprises a front surface and a rear surface, wherein the rear surface is parallel to the front surface, wherein the front surface is configured to abut the second deck board, and wherein the rear surface is configured to abut the first deck board.

20. The clip assembly of claim 13, wherein once the clip assembly is assembled, a topmost surface of the spacer is positioned below an uppermost surface of the spacer.