Patent Application
20100180532
The invention relates to deck plank fastener for securing a deck plank to a joist and for supporting deck planks relative to one another. More particularly, the invention relates to a hidden deck plank fastener that is not visible, does not protrude from the deck surface, and is secured against the under-side of the planks.
The simplest deck plank fastening system consists of a plurality of securing or anchoring elements, such as nails or screws, driven downward through the top of a plank, such as a wood or composite board, and into the top surface of a supporting beam, such as a joist or ledger board. Although the concept is simple, professional quality installation using this approach requires a high degree of precision, significant time expenditure, and sometimes leads to a flawed result.
Deck planks installed using the simplest system of the preceding paragraph must be carefully aligned to achieve a desirable aesthetic as well as functional result, for example, secure attachment and uniform spacing or parallelism without large gaps. Also, the insertion of the nails or screws must be performed carefully to ensure proper penetration of the joist, which will be concealed from view by the overlying wood board at the time of insertion, in order to achieve optimal attachment. This process is time consuming and requires some skill.
Even if the installation is performed properly, the anchoring element's penetration of the upper surface of the plank leaves the plank with a pock-marked appearance and prone to rot and weather damage, which severely decreases the longevity of the deck. In addition, the nail or screws may work loose and protrude from the upper surface of the planks, which poses a risk of injury to users of the deck. Penetration of the top of the plank decreases the integrity of the plank and thus the deck as a whole, and increases the risk of injury.
These and other problems have spurred on numerous advancements in the field. For instance, an improved deck plank fastening system includes fasteners that attach to a side surface of the plank and a top surface of the joist using nails or screws. Such designs facilitate uniform spacing or parallelism of planks by providing tabs or vertically oriented flanges that engage adjacent planks. The tabs facilitate installation by locating the points of penetration at more readily visible and accessible positions. The fasteners improve the longevity of the resulting deck by repositioning the point of penetration to the side of the plank, which is less prone to weathering. In addition, the tabs reduce the risk of injury to the user of the deck by hiding the nails or screws below the surface. Also, the fasteners improve the aesthetic appeal of the deck.
Many other improvements and permutations have been conceived in this field, including: replacing the use of nails or screws with sharp prongs or teeth that penetrate or bite into the deck planks to provide attachment; and increasing the angle of insertion (relative to the vertical) of the nail or screw into the joist to facilitate insertion. Such improvements have specific advantages in specific circumstances, but have not foreclosed innovation in the field.
The object of the present invention is, therefore, to provide an improved deck plank fastener, which, among other desirable attributes, significantly reduces or overcomes the above-mentioned deficiencies of prior deck plank fasteners.
Accordingly, the present invention provides a hidden deck plank fastener, a decking system, and methods for assembling a decking structure.
A first aspect of the present invention is a hidden deck plank fastener for securing a deck plank to a joist. The fastener comprises a substantially flat body having a top surface, a first end, a second end and two opposing lateral edges. The fastener further comprises a first hole in the first end, and a second hole the second end. The fastener further comprises two tabs extending upward away from the body at an angle to the top surface from two opposing positions located along the opposing lateral edges.
A second aspect of the present invention is a decking system using the hidden deck plank fastener of the first aspect of the present invention. The decking system comprises a plurality of joists arranged in a planar array at spaced intervals. The decking system further comprises a plurality of planks in spaced and side-by-side relationship on the joists, each plank having a near and a far edge, the near and far edges of adjacent planks being parallel to one another and confronting one another. The decking system further comprises a plurality of hidden fasteners securing the planks to the joists, each of a first set of the hidden fasteners connecting the bottom of a plank at the near edge to the top of a joist, and each of a second set of the hidden fasteners connecting to the bottom of a plank at a far edge projecting under the near edge of the adjacent plank.
A third aspect of the present invention is a method for assembling a decking structure using the hidden deck plank fastener of the first aspect of the present invention. The first step of the method comprises providing a base formed by an array of spaced-apart joists, each joist having an upper surface lying in a common plane with the other joists. The second step comprises affixing a first plank to the plurality of joists in a desired position to serve as a reference plank. The third step comprises positioning a second plank with a bottom surface of the second plank facing upward. The fourth step comprises attaching each of a first plurality of fasteners to the bottom of the second plank at a far edge of the second plank and at positions corresponding to the underlying joists. The fifth step comprises attaching each of a second plurality of fasteners to the bottom of the second plank at a near edge of the second plank and at positions offset from the underlying joists. The sixth step comprises turning the second plank over so that the bottom surface of the second plank and the fasteners face downward. The seventh step comprises then positioning the second plank in the desired position side-by-side with the reference plank with each of the first plurality of fasteners overlying a joist, and each of the second plurality of fasteners projecting under an adjacent edge of the reference plank. The eighth step comprises securing each of the first plurality of fasteners to a corresponding joist. Lastly, the method includes installing a plurality of additional planks to the decking structure by repeating the third and subsequent steps with the second plank as the reference plank and the additional plank as the second plank.
A fourth aspect of the present invention is a method for assembling a decking structure having planks angled at a predetermined angle, such as 45 degrees, to the joists using the hidden deck plank fastener of the first aspect of the present invention. The first step of the method comprises providing a base formed by an array of spaced-apart joists, each joist having an upper surface lying in a common plane with the other joists. The second step comprises affixing a first plank to a corner of the plurality of joists in a desired position and at the predetermined angle to the joists to serve as a reference plank. The third step comprises positioning a second plank on the joists side-by-side with the reference plank and in a position corresponding substantially to the desired position of the second plank in the decking structure with a top surface of the second plank facing upward. The fourth step comprises marking the bottom surface of the second plank along each joist with a marking line extending across the plank from the near edge to the far edge, each marking line being positioned to correspond substantially with the edge of the joist nearest the reference plank. The fifth step comprises attaching each of a first plurality of fasteners to the bottom surface of the second plank along the far edge at a position such that one of the plurality of marking lines is visible through a first hole of the first plurality of fasteners. The sixth step comprises attaching each of a second plurality of fasteners to the bottom surface of the second plank along the near edge at positions such that each marking line is visible through a first hole of the second plurality of fasteners. The seventh step comprises positioning the second plank in the desired position side-by-side with the reference plank with each of the second fasteners projecting under the adjacent edge of the reference plank. The eighth step comprises securing each of the plurality of the first plurality of fasteners to a joist. Lastly, the method includes installing a plurality of additional planks to the decking structure by repeating the third and subsequent steps with the second plank as the reference plank and the additional plank as the second plank.
Referring to
It should be appreciated that a symmetrical or asymmetrical deck plank fastener 1 is possible, and thus the designations of first end 5, second end 6, long edges 11 and short edges 12 do not necessarily indicate structural distinctions in all embodiments.
The deck plank fastener 1 also has a first hole 8 formed at a substantially central position of the first end 5 of the body 2, and a second hole 9 formed at a substantially central position of the second end 6 of the body 2. The first hole 8 and the second hole 9 are sized to receive an anchoring element, such as a wood screw 24 as shown in
The deck plank fastener 1 also has two tabs 10 which are integral with the long edges 11 of the body 2 and extend upward at an angle to the top surface 3. The width of tabs 10 is set to establish plank-to-plank spacing in the resulting deck structure. The tabs 10 may be positioned either closer toward the first end 5 or the second end 6 of the body 2. Generally, the width and lateral placement of the tabs 10 is only limited by the distance between and relative positions of the first hole 8 and second hole 9. The tabs 10 may be formed using a number of techniques but, preferably, are formed in the metal forming press contemporaneously with the forming of the body 2.
The body 2 is formed to include a plurality of ribbed contours, such as impressed reinforcement contours 13. The contours 13 serve many functions including, for example, reinforcing the structure of the body 2, promoting traction between the fastener 1 and the planks or joists, and providing body thickness for a deeper first hole 8 and second hole 9.
The first hole 8 and second hole 9 are circumscribed by a pair of conical recesses 18,19, respectively, for engaging with screws 24. The conical recess 18, which surrounds the first hole 8, is tapered inwardly from the bottom surface 4 to the top surface 3 and, hence, is larger at the bottom and smaller at the top as the first hole 8 approaches the top surface 3. The taper of the conical recess 18 engages a screw 24 that is inserted from the bottom side of the body 2 through the first hole 8 and into a plank that abuts the top surface 3 of the body 2. Whereas the conical recess 19, which surrounds second hole 9, is tapered inwardly from the top surface 3 to the bottom surface 4 and, hence, is larger at the top and smaller at the bottom as the second hole 9 approaches the bottom surface 4. The taper of conical recess 19 engages a screw 24 that is inserted from the top side of the body 2 through the second hole 9 and into a joist that abuts the bottom surface 4 of the body 2. Referring to
Preferably, the anchoring elements are screws 24, such as wood screws having conical-shaped head portions, as shown in
Referring to
Referring to
A first plank 23a is attached to one side of the decking structure 20. Preferably, the first plank 23a is affixed to the joists 21 and ledger board 22 along one edge of the base structure such that second plank 23b can be attached in parallel across the entirety of the working surface created by the joists 21. For discussion purposes, a plank has a near and a far edge, wherein the near edge faces the viewer in
For illustrative purposes, in
The second and subsequent planks 23 are also attached to the joists 21 using hidden fasteners 1. The planks 23 may be cut to length before placement or after being secured to the joists 21. For the purposes of illustration and description, it will be assumed that several planks 23a, 23b have already been installed, as shown in
As shown in
With the plank 23c inverted in the desired position, the hidden fastener 1c is attached to the near edge of the plank 23c above each underlying joist 21 with the tabs 10 butted up against the edge of the plank 23c, the bottom surface 4 facing upward and the free end 6 of the hidden fastener 1c projecting outward from the edge. The first end 5 of the hidden fasteners 1c is secured to the plank 23c by inserting a screw 24 or other anchoring element through the first hole 8 of the first hidden fastener 1c and driving the screw 24 into the plank 23c with a drill D or screw driver.
As shown in
With the hidden fasteners 1c, 1d attached to the bottom surface of the plank 23, the plank 23c is turned over into an upright position so that the top surface of the plank 23c faces upward and the hidden fasteners 1c, 1d are facing downward.
As shown in
The final positioning of the plank 23c relative to the plank 23b is accomplished as shown in
Referring to
It should be appreciated that the turning over step and the positioning step may be merged into a single motion, for instance, by simultaneously rotating the plank 23c proximate to the reference plank 23b, thereby causing the protruding end 6 of the fasteners 1d to pivot under the reference plank 23b rather than slide, and pressing the plank 23c toward the reference plank 23b so that the plank 1c is firmly held in the desired position. In either arrangement, the far edge of the second plank 23c faces (or “confronts”) the near edge of the reference plank 23b, creating the desired aesthetic of the decking structure.
Additional planks 23 are installed in the decking structure 20 by repeating the fastener attachments and plank installing steps until the entire working surface of the decking structure 20 is complete.
Referring to
A base structure is provided using known techniques and methods as mentioned above. In general, the base structure comprises horizontal support beams, including the parallel joists 21 connected at their ends with transverse ledger boards 22 to establish a support surface for the planks.
Referring to
It should be appreciated that a decking structure having planks angled relative to the joists at an angle other than 45 degrees would use a first plank of another shape (i.e. not an isosceles right triangle). For instance, a decking structure having planks angled at 30 degrees relative to the joists would use a first plank of a 30-60 degree right triangle.
Referring to
The hidden fastener 1f of the first plank 23d is secured by a screw 24 along the hypotenuse edge of the plank 23d at a position such that the first hidden fastener 1f is a predetermined distance from the apex of the adjacent 45 degree angle. The predetermined distance is set so that the projecting second end 6 of the hidden fastener 1f overlies the joist 21 or ledger board 22 when the plank 23d is installed in the upright position, as shown, for example, in
It should be appreciated that the amount that first plank 23d overhangs the outermost joist 21 and ledger board 22 may be adjusted by altering the placement of the hidden fasteners 1f and 1g along the hypotenuse edge of the first plank 23d. In addition, to create a deck wherein the planks 23 are flush with the edge of the joists 21 and ledger board 22, a doubler (not shown) may be required at the corner for the first plank 23d. In general, a doubler is attached to the inside of the outermost joist 21 or the ledger board 22 facing toward the array of joists 21 and extending from the intersection of the outermost joist 21 and the ledger board 22 a sufficient distance to provide fastening points for the fasteners connected to the first plank 23d. If a doubler is used, the initial hidden fastener 1e may be affixed to the doubler rather than the outermost joist 21 or the ledger board 22.
Referring to
After placement, the first plank 23d is secured to the outermost joist 21 and ledger board 22 by inserting screws 24 downward through the second holes 9 of the hidden fasteners 1f, 1g of the first plank 23d into the outermost joist 21 and ledger board 22, respectively. Finally, the outermost joist 21 is secured to the first plank 23d by inserting a screw 24 upward through the second hole 9 of the initial hidden fastener 1e into the first plank 23d.
Once installed, the first plank serves the function of a reference plank for the adjacent planks.
An exposed near edge of the second plank 23f is marked with a marking utensil 25 at marking positions 26 corresponding to the intersections of the edge of the plank 23f and the far side of each joist 21. Each intersection of the plank 23f edge with the joists 21 is marked.
The plank 23f is then turned over so that the bottom surface of the plank 23f faces upward, as shown in
It should be appreciated that the plank 23f may be marked with marking positions 26 and/or marking lines 27 without being placed on the surface of the joists 21 and/or having marking positions 26 marked. One skilled in the art could measure and mark marking positions 26 and/or marking lines 27 along the bottom surface of the plank 23f based on the known positions of, distance between, and orientation of the joists 21.
Referring to
The plank 23f is ready to be positioned and affixed to the joists 21 adjacent a previously installed plank 23e.
The plank 23f is aligned relative to the previously installed plank 23e, which serves as a reference together with its secured fasteners 1j. First, the protruding ends 6 of the hidden fasteners 1h are slid under the adjacent edge (i.e. near edge) of the reference plank 23e. Next, plank 23f is pressed against the adjacent edge of the reference plank 23e until the tabs 10 of the fasteners 1h, 1j abut the adjacent edges of the planks 23e, 23f when the planks are in their desired final position. The hidden fasteners 1i at the near edge of the plank 23f can then be secured to the joists 21 by inserting screws 24 downward through the second hole 9 of the hidden fastener 1g into the joist 21.
Additional planks are installed in the decking structure in the same manner as plank 23f until the entire surface of the decking structure 20 is complete.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the broader aspects of the present invention. For example, the hidden fasteners can be stamped in a number of shapes with or without ribbed contours. The projecting ends of the hidden fasteners which are slid under a previous attached plank can be secured with screws from below after installation, or be left unsecured. This one secured edge of a plank holds down the adjacent edge of the adjacent plank. Accordingly, the invention has been described in several preferred embodiments by way of illustration rather than limitation.
