Patent Application
20130025228
This invention relates generally to deck fasteners for securing deck boards together and to a supporting member, and more particularly with a deck fastener which does not protrude from the deck surface.
In decking and frame construction, it is often desirable to provide a blind or invisible interconnection between the decking boards and the underlying supporting joists. This desire is accentuated with decking that is exposed to the open environment as the exposed connectors may be susceptible to oxidation, leaching and similar environmental affects. Various connectors and decking designs have been proposed to resolve this issue. Though some designs have successfully decreased the aforementioned problems, issues still remain with hidden fastening of decking.
Decking systems commonly include a series of joists supported by a frame. The joists are aligned parallel to one another. Decking boards are connected to the joists and spaced adjacent to one another. Often, a gap is left between the decking boards to allow space for expansion and contraction of the system, specifically expansion and contraction of the decking boards, without damaging the system.
Decking fasteners are used to connect the decking boards to the joists and to one another. Decking boards are commonly mounted perpendicular to the joists such that each decking board is supported by multiple joists. A decking fastener may connect to both the joist and the decking board to prevent the decking board from moving with respect to the joists. Often, fasteners are mounted at the edge of a decking board and further connect to the adjacent decking board. Thus, a single fastener may fix a decking board to both a joist and an adjacent decking board.
Hidden decking fasteners are used to hide the fastener beneath the surface of the decking board and away from harsh environmental elements. However, as many decking designs include a space between the decking boards, many hidden fasteners are still visible from above and are still susceptible to environmental elements. Additionally, many decking fasteners require the use of nails, screws, bolts, and other extraneous hardware to connect the fasteners to the joists. This hardware complicates assembly of the deck. Therefore, an improved decking system is needed to cure these and other design defects.
This invention relates generally to deck fasteners for securing deck boards together and to a supporting member, and more particularly with a deck fastener which does not protrude from the deck surface.
In one embodiment, the present invention relates to a decking fastener comprising: a first joist connector, the first joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; a second joist connector, the second joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; and a board connector, the board connector having a first side, a second side and a bottom, wherein the first side and the second side of the board connector are operatively coupled to opposite sides of the bottom and are arranged in a substantially parallel manner to one another, wherein the remaining sides of the bottom of the board connector are operatively coupled to at least a portion of the top edges of the first and second joist connectors so that the first and second joist connectors are arranged in a substantially perpendicular manner to the first and second board connector sides.
In another embodiment, the present invention relates to a decking system comprising: a frame; at least one joist, the at least one joist being secured to the frame; at least one decking board, the at least one decking board having a top side and a bottom side, the bottom side having formed therein at least one slotted opening, wherein the at least one decking board is secured to the at least one joist via at least one decking fastener, the decking fastener comprising: a first joist connector, the first joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; a second joist connector, the second joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; and a board connector, the board connector having a first side, a second side and a bottom, wherein the first side and the second side of the board connector are operatively coupled to opposite sides of the bottom and are arranged in a substantially parallel manner to one another and wherein the board connector is designed to operatively engage the slotted opening in the bottom of the at least one decking board, wherein the remaining sides of the bottom of the board connector are operatively coupled to at least a portion of the top edges of the first and second joist connectors so that the first and second joist connectors are arranged in a substantially perpendicular manner to the first and second board connector sides.
In still another embodiment, the present invention relates to a method of assembling a decking system comprising the steps of: forming a frame; securing at least one joist to at least a portion of the frame; securing at least one decking board to at least a portion of the at least one joist via at least one decking fastener, the at least one decking board having a top side and a bottom side, the bottom side having formed therein at least one slotted opening, the decking fastener comprising: a first joist connector, the first joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; a second joist connector, the second joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; and a board connector, the board connector having a first side, a second side and a bottom, wherein the first side and the second side of the board connector are operatively coupled to opposite sides of the bottom and are arranged in a substantially parallel manner to one another and wherein the board connector is designed to operatively engage the slotted opening in the bottom of the at least one decking board, wherein the remaining sides of the bottom of the board connector are operatively coupled to at least a portion of the top edges of the first and second joist connectors so that the first and second joist connectors are arranged in a substantially perpendicular manner to the first and second board connector sides.
The operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:
Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention.
With reference to
The decking system 10 includes a series of joists—one of which is shown as 11—supported by the frame. The joists 11 may be arranged parallel to each other to provide a support grid for a plurality of decking boards 12. Alternatively, the joists 11 may be arranged in any configuration to support the decking boards 12. The decking boards 12 may be located perpendicular to the joists 11 such that each decking board 12 is supported by multiple joists 11. Alternatively, the decking boards 12 may be arranged parallel to the joists 11 or at an angle with respect to the joists 11.
The decking system 10 may include a fastener 14 to interconnect the decking boards 12 to the joists 11. The fastener 14 may be of any material such as a metal, a metal alloy, etc. In one embodiment, fastener 14 is formed from titanium, aluminum, stainless steel, or hardened steel (e.g., 1050 or 1056 steel). The fastener 14 may comprise a joist connector 16 and a board connector 18. The joist connector 16 may be configured to engage a portion of the joist 11. For example, as illustrated in
The joist connector 16 may further include a secondary feature to prevent the fastener 14 from sliding relative to the joist 11. For example, as shown in
In an alternative embodiment, shown in
The decking system 10 may be configured to hide the fasteners 14 from above and shelter them from exposure to environmental elements. Traditional decking systems include decking boards that are arranged with spaces therebetween to allow for expansion and contraction of the decking boards. The fasteners are often positioned between the decking boards to interconnect the decking boards and the joists. However, the space between the decking boards allows for the fasteners to be seen from above and exposed to environmental elements.
To hide the fasteners 14, the decking boards 12 may be configured to completely cover the fasteners 14. As shown in
Each decking board 12 may include a plurality of openings 22 to receive multiple fasteners 14. The openings 22 may be perpendicular to the length of the decking board 12 such that the fasteners 14 are space apart along the length of the decking board 12 to align with the joists 11. Alternatively, the decking board 12 may include a single extruded opening 22 along its length. Multiple fasteners 14 may be inserted into the opening 22 and spaced apart so as to align with the joists 11. As illustrated in
In use, a plurality of fasteners 14 is connected to a decking board 12. The fasteners 14 are inserted into an extruded opening 22 on the underside 24 of the decking board 12 and arranged so as to be hidden under the decking board. The fasteners 14 are arranged to align with and engage the joists 11. The opening of each u-shaped joist connector 16 is placed over a portion of the corresponding joist 11, and a force is applied to the decking board 12 above each fastener 14. The tabs 20 may be hammered or driven into the joist 11 to prevent the fastener 14 from sliding or moving with respect to the joist 11. Alternatively, the fasteners 14 may be attached to the underside 24 of the decking board 12 as shown in
The decking system 10 may provide a secure fit between the decking boards 12 and the joists 11. More specifically, many of the prior art decking systems, especially those that purport to be hidden fastener systems, do not provide sufficient updraft strength. The attachment of the decking boards to the joists is not strong enough to prevent the deck boards from lifting during heavy wind conditions. The fastener 14 of the present embodiment provides a strong connection between the decking boards 12 and the joists 11. The present embodiment may resist a predetermined amount of updraft to help prevent the deck boards 12 from lifting from the joists 11 during windy conditions.
While the present embodiment shows the decking boards 12 being perpendicular to the joists 11, the decking boards 12 may use the decking system 10 and have the decking boards 12 installed at 45 degree angles with respect to the joists 11. Additionally, the joists 11 may be installed such that the decking boards 12 may be installed perpendicular thereto while being installed 45 degrees relative to a structure against which the decking system 10 is installed.
Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.
This application claims the benefit of U.S. Provisional Patent Application No. 61/507,177, entitled “Decking System with Hidden Dovetail Fastener,” filed on Jul. 13, 2011, which is hereby incorporated in its entirety by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61507177 | Jul 2011 | US |
