This application is the U.S. National Stage of International Patent Application No. PCT/AU2010/001657 filed on Dec. 8, 2010, which claims priority to Australian Patent Application No. 2009905992 filed on Dec. 8, 2009 the disclosures of which are hereby incorporated by reference in their entireties.
1. Field of the Invention
THIS INVENTION relates to decking or flooring systems, and to components for such systems.
The invention particularly relates, but is not limited to, decking or flooring systems enabling (substantially) concealed joining of the adjacent ends of decking boards or flooring boards; and to the “connectors” and decking boards or floorboards suitable for the flooring system.
Throughout the specification, the terms “decking system” or “decking systems” shall be used to include decking systems, flooring systems, wall systems (e.g. wall cladding), ceiling systems and other building construction systems.
Throughout the specification, the term “decking boards” shall be used to include decking boards, floorboards, wall cladding, ceiling cladding and the like.
2. Prior Art
Modern building construction methods are primarily based on “modular” spacing of the frame components, including the wall studs, the decking- or flooring joists, the roof or ceiling battens, and the like: Typically, the modular spacing is 450 mm (=18 inches); although modular spacing's of 300 mm (=12 inches) or 600 mm (=24 inches) are sometimes used
Until recently, the decking boards for decking systems were secured to the supporting joists by nails, screws or other like fasteners. These systems had a number of limitations, especially when the upper surfaces of the decking boards were to be left exposed.
Various decking systems have been produced where the decking boards have complementary interlocking profiles along respective side walls of the decking boards. Typically, one side wall of each decking board has a projection, or tongue, engageable in a complementary recess or groove in the other side wall of a similar decking board, when the two decking boards are placed together. In some examples of these systems, the projections may be releasably lockable within the recesses or grooves, with the projections typically having hook-like profiles in end view.
A further type of decking system which has been adopted uses fixing members, commonly called “biscuits”, which are placed at (usually regular) spacings along the decking joists and are engageable in the recesses or grooves, having parallel sides, provided along the side walls of the decking boards. Typically, with these decking systems, the first decking board is laid on the decking joists, a set of biscuits is engaged in the recess or groove of the first decking board, the biscuits are fixed to their respective decking joists; and a second decking board is placed in position, with one side wall engaged with a first set of biscuits, and then secured along its other side wall by a second set of biscuits fixed to their respective decking joists.
All of the existing decking systems hereinbefore described have one or more practical limitations, e.g. in the requirements for their installation.
However, one limitation with all the existing flooring systems is the inability to maintain the decking boards in secure (i.e., non-rattling) fixing to the supporting joists, as the decking boards typically undergo expansion and contraction due to differences in temperature and/or (more particularly) humidity in the building locations, where they are installed.
Any decking system which is subject to “rattling” or “drumming” of the decking boards, as the decking is traversed, is unacceptable to the market place.
A further, more important, limitation has been the need to fix the adjacent ends of the decking boards to the joists to prevent flexing of the decking boards when the decking is in use.
The decking boards are typically supplied not cut to accurate lengths. For example, “2.7 meter” decking boards will be at least 2.7 meters long, but may be nearly 3 meters long. So their ends can be fixed at the joists, they must be cut to precisely 2.7 meters (2700 mm) long, so that their length is (N×450)mm long (where N is a whole number).
The time for installing decking is increased, when each decking board has to be accurately cut to length; and the wastage of the timber of the decking boards may be of the order of 7 to 10%, or higher.
It is an object of the present invention to provide a decking system, as hereinbefore defined, which overcomes; or ameliorates, the limitation(s) of the prior art decking systems.
It is a preferred object of the present invention to provide a decking system which will enable easy, but secure, interconnection of adjacent ends of the decking boards, whilst accommodating expansion or contraction of the decking boards.
It is a further preferred object of the present invention to provide such a decking, system where the adjacent ends of the decking boards may be interconnected intermediate the supporting construction (e.g. intermediate the decking joists).
It is a still further preferred object of the present invention to provide complementary profiles on the decking connectors and the grooves or recesses in the decking boards to form a “wedging” engagement therebetween.
It is a still further preferred object of the present invention to provide connectors for the decking system which can be used with decking boards within a range of thicknesses.
It is a still further preferred object of the present invention to provide connectors for the decking system which can accommodate decking boards having a range of different widths.
Other preferred objects of the present invention will become apparent from the following description.
In one aspect, the present invention resides in a connector for interconnecting adjacent ends of a pair of decking boards of a decking system (as hereinbefore defined), the connector including:
a connecting member, the connecting member having a body defined by a pair of substantially parallel side edges in plan view, a first, or inner, of the pair of side edges being operable to engage grooves or recesses in aligned side walls of the pair of decking boards, across a joint between the respective ends of the pair of decking boards.
Preferably, a second, or outer, of the side edges of each body engages a groove or recess in the side wall of a decking board laid adjacent the joint between the adjacent ends of the pair of decking boards.
More preferably, the second side edge engages such a groove or recess intermediate the length of a decking board laid adjacent the joint, i.e. the respective joints between adjacent ends of the pairs of decking boards are staggered or offset.
Preferably, the side edges of the bodies may be of convergent profile in end view, and are operable to engage the grooves or recesses of the pair of decking boards having complementary profiles.
Preferably, the side edges of the bodies engage the grooves or recesses in the side walls of the respective decking boards in a “wedge-type” engagement.
In one arrangement, the connector has a pair of the connector members interconnected by a bridging member, which preferably engages respective rebates in the adjacent ends of the pair of decking boards.
Preferably, the bridging member is adjustable in length in a horizontal plane, but is relatively rigid (or non-deflectable) in a vertical plane, when in use.
Preferably, in one embodiment, the bridging member is capable of flexing, e.g. in a substantially “S-shape”, “V-shape” or “U-shape” (in plan view) in the horizontal plane, when in use. In an alternative embodiment, the bridging member is telescopic or otherwise adjustable in length to be used with decking boards having a variable width range of, e.g. 10-50 mm, more preferably 20-30 mm.
In an alternative arrangement, the connector has a single connector member with a bridging member extending substantially-laterally there-from, the bridging member engaging in respective rebates in the adjacent ends of the pair of decking boards.
Preferably, the bridging member is relatively rigid (or non-deflectable) in a vertical plane, when in use.
Preferably, the length of the bridging member is selected so that at least a small clearance is provided between distal ends of the respective bridging members of a pair of the connectors at the joint between the ends of the pair of decking boards.
Preferably, the bridging member has at least one reinforcing rib or flange lying in the vertical plane, when in use; and may be, e.g. of “T-shape”, “inverted U-shape”, triangular-, cruciform-, circular- or box-section, or other like shape.
Preferably, the bridging member has at least one horizontal top surface engageable by the respective substantially horizontal top walls of the rebates in the ends of the adjacent pair of decking boards.
Preferably, the top surface of the bridging member has a drainage groove to enable moisture collected thereon to drain to a distal end of the bridging member or to a drain-hole in the bridging member.
Preferably, the connector is integrally manufactured, e.g. by injection moulding, from a suitable polymer/plastics-material, such as nylon (Registered Trade Mark), polyvinyl chloride (PVC), polyethylene, polypropylene, where the material is preferably UV-stabilised; cast or moulded from metals, such as aluminium; and may incorporate glass-, carbon- or other reinforcing, fibres for increased mechanical strength.
The body of each connector member may have a lower body portion, including at least one block portion, surmounted by an upper body portion having the substantially parallel side edges. Reinforcing ribs and/or flanges may be provided on the side and/or end walls of the lower body portions to increase the mechanical strength thereof; while being able to absorb, e.g. 1-2 mm expansion of the adjacent decking boards, when in use.
Preferably, the upper body portions are of solid construction, and may have a substantially planar or convex top face interconnecting the elongate upper faces of the side edges, where the elongate upper faces of the side edges may be connected to complementary elongate lower faces on the side edges by a curved nose.
Preferably, the body had a bore extending therethrough to enable the body to be secured to a supporting structure underlying the joint between the ends of the pair of decking boards.
In a second aspect, the present invention resides in a decking system (as hereinbefore defined) including:
a supporting structure;
a plurality of decking boards, as hereinbefore described, laid on the supporting structure, with each of the decking boards having respective recesses or grooves in their side walls and, optionally, rebates in their end walls; and
a plurality of the connectors, as hereinbefore described;
wherein:
the, or each, connector has at least one connector member operably engaged with the grooves or recesses in aligned side walls of a pair of the decking boards arranged end-to-end across a joint, the, or each, connector securing adjacent ends of the decking boards together.
Preferably, the bridging member of each connector is engaged in the rebates of the adjacent ends of the pair of decking boards.
Preferably, the respective connecting members of each connector are also operably engaged in the grooves or recesses in the adjacent side walls of respective decking boards laid adjacent to, and optionally overlapping, the joint between the adjacent ends of the pair of decking boards.
To enable the invention to be fully understood, preferred embodiments will now be described with respect to the accompanying drawings, in which:
NB: Any notations on the drawings are by way of illustration only, and are not limiting to the present invention.
Referring to
The decking system 10 has a plurality of decking boards 20, formed from suitable timber, such as “Merbau” (Class 1 or 2 hardwood), typically of 85 mm-115 mm width and 18-25 mm thickness. These dimensions are non-limiting.
The boards 20 (see
The side faces 23, 24 are provided with elongate grooves 29, 30, which have inwardly-convergent top and bottom faces 31, 32 interconnected by a concave inner face 33 (see
The rebates 34 in the end faces 25, 26 of the decking boards 20 have parallel top and bottom faces 35, 36 connected by a vertical inner face 37. It should be noted that this shape of the rebate is exemplary only and any suitable shape known to a skilled addressee may be used
As illustrated in
Alternatively, as illustrated in
It will be noted by the skilled addressee, from the following description that, any vertical deflecting loads applied to the adjacent ends 25, 26 of the decking boards 20 are not only distributed between that pair of decking boards 20, but are also distributed to the respective decking boards 20 lying along either side of the joint.
Referring to
For ease of description, connector member 41 will be described in detail, and the skilled addressee will appreciate that the reference numerals for the features of connector member 41 will also apply to the corresponding features of the connecting member 42.
Connector member 41 has a lower body portion 43 which is substantially rectangular in bottom plan view and is provided with laterally-extending ribs 44 arranged to absorb lateral expansion (or contraction) of the adjacent decking boards 20 with which it is engaged. The lower body portion 43 may have a cavity 45 to reduce the volume of plastics-material required for manufacture of the connector 40.
The connecting member 41 has an upper body portion 46 terminated by concave end faces 47, 48, and is defined by parallel outer side edges 49 with convergent top and bottom faces 50, 51 interconnected by a convex nose 52.
As illustrated in
The connector members 41, 42 are interconnected, intermediate their respective lengths, by a bridging member 53 of a thickness enabled to be “snugly” received in the opposed rebates 34 in the adjacent ends 25, 26 of the decking boards 20.
The top face 54 of the bridging member 53 has a substantially V-shape groove 55 to enable any moisture entering the joint to be drained away. (A drainhole, not shown, may be provided through the bridging member 53, from the groove 55, to assist in the drainage of the moisture.)
As seen in more detail in
The connector 40 is preferably injection-moulded from high strength plastics-material, e.g. HDPE, which may incorporate fibre reinforcing.
In experimental tests, where decking boards 20 of “Merbau” timber, each 115 mm wide×19 mm thick, were laid over the joists J at 450 mm spacing's, a vertical load of 250 kg caused no more than 2 mm vertical deflection of the decking boards 20, where the joint therebetween was equally spaced between the joists J.
In an alternative (second) embodiment illustrated in
In the embodiments illustrated in
It will be readily apparent to the skilled addressee that the bridging members 53, 153 may incorporate respective telescopic portions, preferably formed integrally with respective connecting members 41, 42, 141, 142, and telescopically slidable to enable the spacing between the connecting members 41, 42, 141, 142 to be adjusted to suit decking boards 20 with widths, e.g. in the range 85 mm-115 mm.
For example, one of the connecting members 41 may have a bar or rod, forming one portion of the bridging member 53, telescopically received in a bore or a channel in a complementary second portion of the bridging member 53 connected to, or integral with, the other connecting member 42.
In addition to the substantially rectangular cross-section for the bridging members 53, 153 illustrated in the embodiments in
Bridging members having “T-shape” (
The deflection or flexing of the intermediate bridge portion 256 enables the connector 240 to be used with decking boards 20 having a range of widths, e.g. 85 mm-115 mm.
Flanges 257 may be provided on the outer bridge portions 254, 255 to provide a spacer between the adjacent ends 25, 26 of the decking boards 20. The flanges 257 can absorb limited expansion/contraction of the decking boards 20.
Drain holes 258 may be provided in the outer bridging portions 254, 255 to assist in draining away any moisture which collects in the joint between the ends 25, 26 of the decking boards 20.
Connector member 341 has an upper body portion 346 terminated by convex end faces 347, 348. Wedge-like flanges 349A, 349B on the upper body portion 346 can absorb any tolerances between the elongate grooves 29, 30 in the decking boards 20 and the connector member 341.
A “stepped-bore” 380 is provided through the body of the connector member 341, the bore 380 being substantially-elliptical in plan view, and having a peripheral “shoulder” 381 which is downwardly convergent to sealably engage the underside of the head of a fastener (not shown) used to secure the connector member 341 to a supporting joist J, even when the shank of the fastener is inclined relative to the axis of the bore 380. (By driving the fastener into the joist J at an angle, the force required to pull the fastener free is increased, and the fastener may be more easily fixed in the joist J.)
The connector member 341 has a bridging member 353, where the “V-shaped” drainage groove 355 in the top face 354 is inclined downwardly towards the distal end of the bridging member 353, to allow any moisture to flow to the distal end and drain away.
As illustrated in
As illustrated in
As illustrated in
The skilled addressee will appreciate the present invention provides connectors for a decking system where the ends of the decking boards 20 need not be connected or joined over the supporting joists J. This means the rebates 34 can be cut or provided in the decking boards 20, without having to cut the decking boards 20 to accurate lengths. The connectors prevent the adjacent ends of the decking boards 20 flexing as a load is applied to, or passes over, the joint between the adjacent ends.
Where, however, the joints overlie the supporting joists J, screws or other fasteners can be driven through the bores 380 in the bodies of the connector members 341 to secure the connector members 341 to the joists j, thereby securely anchoring the ends of the decking boards 20 to the joists J.
In addition, the connectors can be produced relatively inexpensively (e.g. by injection moulding from polymers/plastics-materials), and are easy to install.
Other materials (e.g. cast or moulded metals, such as aluminium) and/or other profiles (e.g. for the connector members and/or the bridging member) may be used in the manufacture of the connectors.
Various changes and modifications may be made to the embodiments described and illustrated without departing from the present invention defined in the appended claims.
Number | Date | Country | Kind |
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2009905992 | Dec 2009 | AU | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/AU2010/001657 | 12/8/2010 | WO | 00 | 8/17/2012 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2011/069198 | 6/16/2011 | WO | A |
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6920732 | Mårtensson | Jul 2005 | B2 |
20010010139 | De Kerpel et al. | Aug 2001 | A1 |
20020031646 | Chen et al. | Mar 2002 | A1 |
20020194807 | Nelson et al. | Dec 2002 | A1 |
20040060255 | Knauseder | Apr 2004 | A1 |
20080250744 | Hrovath et al. | Oct 2008 | A1 |
20090241460 | Beaulieu | Oct 2009 | A1 |
20090249730 | Vibiano | Oct 2009 | A1 |
Number | Date | Country |
---|---|---|
1207246 | May 2002 | EP |
Entry |
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IPRP for related PCT/AU2010/001657 completed on Mar. 22, 2012. |
WO for related PCT/AU2010/001657 completed on Jan. 19, 2011. |
ISR for related PCT/AU2010/001657 mailed on Jan. 27, 2011. |
Number | Date | Country | |
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20120311952 A1 | Dec 2012 | US |