BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:
FIGS. 1A and 1B are views of a grooved decking member;
FIGS. 2A-2D are perspective, front side elevation, left side elevation, and bottom plan views, respectively, of a fastener for grooved or slotted decking members, according to a first embodiment of the present invention;
FIGS. 3A and 3B are perspective and side elevation views, respectively, of a fastener according to an additional embodiment of the present invention;
FIGS. 4A-4C and 5A-5D are side elevation views showing the fasteners in use;
FIG. 6 is a perspective view of an alternative embodiment of the fastener shown in FIGS. 3A and 3B;
FIGS. 7A-7C are end side elevation, rear side elevation, and bottom plan views, respectively, of a fastener according to an additional embodiment of the present invention; and
FIGS. 8A and 8B are end side elevation and top plan views, respectively, of a fastener according to an additional, embodiment of the present invention.
DETAILED DESCRIPTION
Referring to FIGS. 2A-5D, the present invention relates to a novel fastener device 30a, 30b for connecting (i) a first grooved or slotted board, plank, or other decking member 32 to an underlying joist or other support member 34 and (ii) a second grooved decking member 36 to the first decking member 32 in an adjacent or lateral manner. (In other words, the fastener 30a, 30b is used, in effect, to connect two decking members to one another and both decking members to an underlying support 34.) The fastener 30a, 30b includes a thin, flat body portion 38, two connection lips or “wings” 40a, 40b, and a main flange 42. The wings 40a, 40b extend out from the top edge 44 of the body portion 38 in opposite directions. In particular, the first wing 40a is attached along one side of the top edge 44 of the body 38, and extends outwardly from the body in the direction of a rear face 45a of the body portion. The second wing 40b is attached along the other side of the top edge 44 of the body 38, and extends outwardly from the body in the direction of a front face 45b of the body portion. (“Front” and “rear” are arbitrary designations.) The connection wings 40a, 40b may be oriented generally perpendicularly to the body portion 38. The flange 42 extends outwardly from the bottom edge 46 of the body portion in the direction of the rear face 45a of the body 38, and lies generally perpendicular thereto. The body 38 and/or flange 42 include an opening 48 for passage of a connector, such as a screw 50. The connection wings 40a, 40b may be generally flat, as is the case with the fastener 30a shown in FIGS. 2A-2D and 4A-4C. The leading edge of one or both wings may be provided with prongs 52. Alternatively, as is the case with the fastener 30b shown in FIGS. 3A, 3B, and 5A-5D, each connection wing may include first and second non-coplanar portions 54, 56. The first, “flat” portion 54 is connected to the body 38, and the second, “bent” portion 56 is inclined at an angle to the first portion 54. In this case, the first wing portion 54 is generally perpendicular to the body 38, while the second portion 56 extends upwardly and outwardly away from the body 38, e.g., oriented at an angle α to the body, wherein, typically, α=45° or thereabouts. Both wings 40a, 40b are generally rectangular, although the bent portion may be provided with prongs or teeth 52 for better engaging grooved decking members or other construction members. As best shown in FIGS. 2A and 2C, the wing 40a that extends out in the same direction as the flange 42 may be slightly longer than the other wing 40b, in a lateral direction from the body. The former is occasionally referred to herein as the “long” wing 40a, the latter the “short” wing 40b.
As noted above, “decking member” refers to any type of elongate board, plank, or other construction member having generally planar top and bottom surfaces, such as those suitable for use as the primary surface of a deck, and regardless of how the members are manufactured or the material(s) from which they are made. This encompasses wood, composites, laminates, polymers, and the like. Also, when it is referred to herein that the decking member grooves or slots are “formed” in the decking members, this includes any manufacturing operation resulting in the provision of the grooves/slots, such as molding, machining, the connection of varying-width laminates, or the like.
For using the fastener 30a, with reference to FIGS. 4A-4C, a first grooved decking member 32 is held in place against an underlying joist or other support member 34, e.g., the support member may be temporarily manually held against the joist, or it may be temporarily held using clamps or the like. The grooved decking member 32 has a longitudinal side groove or slot 58 formed in one or both of the member's long/lateral sides 60. (The decking member may be used as decking, whereby a number of the decking members are placed across the support members to form a deck.) The short wing 40b is positioned in the groove 58 such that the opening 48 is positioned proximate to the support member and the flange 42 faces away from the decking member 32. A screw or other connector 50 is inserted through the opening 48 and is secured in place down into the support member 34. Subsequently, as shown in FIG. 4B, a second decking member 36 is placed laterally against the first decking member by maneuvering its side groove 58 over the long wing 40a. The second decking member 36 is then moved towards the first decking member 32, as shown in FIG. 4C, until it abuts the flange 42, which establishes a gap between the two decking members. The connection wings 40a, 40b engage the decking members in the slots for securing the decking members against the support member, e.g., longitudinal lip portions “N” of the decking members, which lie below the grooves 58, are sandwiched between the connection wings 40a, 40b and the support 34, preventing the decking members from being raised upwards.
Typically, several of the fasteners 30a will be deployed at even intervals along the length of the decking member 32, for securing it to the support 34 along its length. After the second decking member 36 is positioned in place as shown in FIGS. 4B and 4C, the opposite side of the second decking member 36 is outfitted with additional fasteners. Thus, each decking member is held along both its side edges. End decking members may be held in place through abutment to structural members or the like, through the use of other fasteners, or through provision of “one sided” fasteners, such as the fastener 30a but without a connection wing 40a.
With reference to FIGS. 5A-5D (not to scale), the fastener 30b with bent wings 40a, 40b provides a positive leverage lock between the decking members and support member, resulting in an even more secure connection. In particular, a first grooved decking member 32 is held in place against an underlying joist or other support member 34. The short wing 40b of the fastener 30b is angled into the groove 58. In this position, the body 38 of the fastener abuts the lower edge 62 of the groove 58 (or thereabouts), with the body 38 and second wing 40a lying in an inclined or angled position above the support member 34. (See FIG. 5A.) Again, the opening 48 is positioned proximate to the support member, and the flange 42 faces away from the decking member 32. As shown in FIG. 5B, a connector 50 is inserted through the opening 48 and is secured in place down into the support member 34. As the connector is secured in place, this causes the short wing 40b and/or body 38 to flex slightly, causing the bent portion 56 of the short wing 40b to firmly press up against or otherwise engage the inside top of the groove 58, as indicated by the arrow “f.” (In other words, as the fastener is screwed into place, the fastener body 38 is flexed against the side 60 of the decking member, which in effect levers the short wing 40b into frictional and/or “biting” engagement with the decking member.) This prevents the decking member 32 from being easily moved laterally away from the fastener 30b. Subsequently, a second decking member 36 is maneuvered in at a slight angle to place its side groove 58 over the long wing 40a, as shown in FIG. 5C. Allowing the second decking member 36 to fall flat against the support member 34 causes the long wing 40a to flex slightly under the weight of the second decking member 36. This causes the bent portion 56 of the long wing 40a to frictionally engage the second decking member inside the groove 58, as indicated by the arrow “f2”, including possibly slightly biting into the decking member. This secures the second decking member in place. Additional decking members may be attached laterally in a similar manner. It should be noted that even if the second decking member's elevation is off, the long connection wing 40a will still tend to hold the decking member down in place against or proximate to the support 34.
As shown in FIG. 6, the fastener 30b (or 30a) may be provided with elongated or pronounced prongs 64, on either or both of the wings 40a, 40b, for a more pronounced biting engagement with a decking member groove.
The dimensions and relative orientations of the various component portions of the fasteners 30a, 30b will vary depending on the characteristics and/or dimensions of the decking members with which they are used. Thus, the fasteners 30a, 30b can be considered as being complementary to the decking members 32, 36 in terms of the relative dimensions and positioning of the fastener components and decking member slots or grooves 58. For example, with reference to FIG. 5D, an overall height “H1” of the fastener body portion and flange will approximately correspond to the height of the decking member lip “N”, at least insofar as the height H1 allows for the connection wings to extend into the slots 58 when the flange 42 abuts the underlying support 34. Also, the distances D1, D2 that the connection wings extend out laterally from the front and rear faces of the fastener body portion, respectively, are such that the connection wings extend into the slots at least a sufficient distance to engage the decking members in the slots, in consideration of the depths of the slots and the width of the gap established by the flange 42. (“Lateral” extension in this case refers to the distance between the distal end of the connection wing and the nearest of the front or rear faces of the fastener body portion, as measured normally/perpendicularly to a plane defined by the nearest face. “Distal” end or edge refers to the portion of the connection wing lying farthest away from the body portion, again, as measured normally.)
Although the dimensions of the fasteners will vary depending on the decking members, the following dimensions are for one embodiment of the fastener, provided as a typical example, and to confer a sense of scale. With reference to FIGS. 2C and 2D, a length L1 of the body portion 38 is about 1.0″ (length is measured with respect to a longitudinal axis of the body, which is the axis lying parallel to the flange and connection wings). The lengths L3, L2 of the connection wings 40a, 40b are each about 0.4-0.5″. The widths W1, W2 of the wings are also each about 0.4-0.5″, with the width W1 being longer than the width W2 to compensate for the flange 42 (width is measured normal to the body portion). The height “H2” of the flat body portion 38 is about 0.3″, where height is measured normally to the flange and connection wings. A thickness “T” of the fastener is about 0.05-0.06″.
With reference to FIG. 3B, for fasteners with non-coplanar connection wings, e.g., fastener 30b, the angle a of the “bent” portions 54 (angle α is with respect to the body 38) may be varied depending on the dimensions of the decking member grooves 58 and on the degree to which it is desired to have the connection wings flex or bend during installation. Typical values of a range between about 15° and about 75°. (With respect to a plane “P” defined by the flat wing portions 54, the plane being perpendicular to the body 38, the bent portions 54 are angled up from the plane P by an angle φ=(90°−α), e.g., φ is typically 45°, but may range from about 15° to about 75°.)
FIGS. 7A-7C show an additional embodiment of the present invention, which further illustrates possible variances in component dimensions. Here, a fastener 66 is generally similar to the fastener 30b shown in FIGS. 3A and 3B, and includes a body 68, flange 70, opening 72, and “long” and “short” connection wings 74a, 74b, respectively. However, the “bent” portion 76 of the short connection wing 74b is significantly longer than the bent portion 56 of the short connection wing 40b of the fastener 30b. With reference to FIG. 5A, and depending on the dimensions of the decking member groove 58, this may result in a greater inclination angle β of the fastener body when the short connection wing is inserted in the groove. An increased inclination angle may require a greater force to drive a fastener 50 and flex the connection wing, possibly resulting in a greater degree of flex and a tighter connection. The fastener 66 further includes an optional side flange 78. The side flange 78 is connected to the body 68 at the end of the body 68 opposite the opening 72. The side flange 78 is approximately perpendicular to the body 68, and extends in the same direction as the main flange 70. The side flange 78 helps to augment the spacing function of the main flange 70 by abutting the side 60 of the decking member 36, e.g., as at point P in FIG. 7A.
FIGS. 8A and 8B show an additional fastener embodiment 80. The fastener 80 is generally similar to the fasteners described above. Here, however, the “bent” portion 82 of each connection wing 84 is connected to the flat portion 86 by way of a radius “R.” (In other words, the boundary between the bent portion and flat portion is provided with a curved groove or indentation having a radius R.)
Although the first, “flat” wing portions 54, 86, etc. have been illustrated as lying generally perpendicular to the body, the first wing portions could be disposed at a different angular orientation other than 90° without departing from the spirit and scope of the invention.
The fasteners (30a, 30b, 66, 80) may be characterized as having: a generally flat body portion (38, 68); flange means (42, 70) connected to the body portion for establishing a gap between laterally adjacent decking members (32, 36); and connection means, namely, the wings (40a, 40b, 74a, 74b, 84), connected to the body portion (38, 68) for engaging the laterally adjacent decking members (32, 36). As noted above, the connection wings engage the decking members within the laterally adjacent grooves formed in the sides of the decking members.
As used herein in a conventional manner, the term “about” refers to ±1 of the least significant digit of the value in question, e.g., “about 45°” means 45°±1°.
The fasteners (30a, 30b, 66, 80) may be made of metal or some other suitably strong and durable material, using standard manufacturing methods. Also, the fastener may be manufactured by cutting or stamping an appropriately dimensioned flat blank from a piece of sheet metal, and then bending the blank to form the fastener as shown. In such a case, the fastener will be a unitary member, wherein each connection wing will extend out from one side of the fastener body only, i.e., each will commence at the top edge of the body and extend outwards from the front or rear face, as applicable, without extending past or otherwise breaking a plane defined by the other face. The same is true for the flanges.
Because the fasteners are complementary in shape to the decking members, an embodiment of the present invention may be characterized as a decking system that includes first and second decking members (32, 36) and a complementary-shaped fastener (30a, 30b, 66, 80) for securing the decking members together and to a support member 34 that underlies and supports the decking members. The decking members are elongate, with each having generally planar, generally parallel top and bottom surfaces interconnected by left and right longitudinal side edges (20, 22). At least one of the side edges of each decking member has a longitudinal slot (24, 26, 58) formed therein. Subsequent to installation, a first longitudinal slot formed in the first decking member will lie laterally adjacent and opposed to a second slot formed in the second decking member. The fastener (30a, 30b, 66, 80) includes a generally flat body portion (38, 68) having rear and front faces (45a, 45b). The body portion is positioned between the laterally adjacent decking members. A first connection wing (40a, 74a, 84) is attached to the body and extends outwardly from the rear face 45a of the body and into the second longitudinal slot of the second decking member 36. A second connection wing (40b, 74b, 84) is attached to the body and extends outwardly from the front face 45b of the body and into the first longitudinal slot of the first decking member 32. A flange (42, 70) is attached to a bottom edge of the body portion and extends outwardly from the rear face 45a of the body. A bottom surface of the flange abuts the support member 34, and a distal edge of the flange abuts the second decking member 36. The fastener is connected to the support member by way of an elongate connector 50 extending through an opening 48 in the fastener and into the support member. The opening 48 extends through and is defined by the flange and/or body. The connection wings (40a, 40b, 74a, 74b, 84) engage the decking members in the slots for securing the decking members against the support member 34.
As should be appreciated, the fastener (30a, 30b, 66, 80) corresponds to the shape and dimensions of the decking members, such that when the decking members lie against the support member and the fastener is attached to the support member, the connection wings extend into the decking member longitudinal grooves for engaging the decking members inside the grooves. Thus, as explained above, the height of the fastener body portion and flange (measured from the bottom surface of the flange to the top edge of the flat body portion) will approximately correspond to the height of the decking member lip N, as measured normally from the flat bottom surface of the decking member. Also, the distances that the connection wings extend out laterally from the front and rear faces of the fastener body portion, respectively, are such that the connection wings extend into the decking member longitudinal grooves by at least a distance sufficient to engage the decking members in the grooves, in consideration of the depths of the grooves, the particular shape and dimensions of the connection wings, and the width of the gap established by the flange.
As noted above, the connection wings may be “bent” in shape, with each including first and second non-coplanar portions oriented at a non-zero degree angle with respect to one another. In such a case, during installation the connection wings are flexed downwards towards the flange. This causes the connection wings to exert a leveraged force at least partly upwards against the decking members in the slots for facilitating engagement of the connection wings with the decking members. More specifically, the second connection wing (opposite the flange) is flexed upon the connector being tightened into the support member through the connector opening. The tightening action draws the fastener body portion into butting engagement with the first decking member. (See FIGS. 5A and 5B.) The first connection wing (located on the same side of the fastener body as the flange) is flexed upon placement of the second decking member against the support member subsequent to angling the slot of the second decking member over the first connection wing.
Since certain changes may be made in the above-described fastener for grooved or slotted decking members, without departing from the spirit and scope of the invention herein involved, it is intended that all of the subject matter of the above description or shown in the accompanying drawings shall be interpreted merely as examples illustrating the inventive concept herein and shall not be construed as limiting the invention.
Patent Application
20070234670
