Note: Descriptions are shown in the official language in which they were submitted.
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FASTENER FOR GROOVED OR SLOTTED DECKING MEMBERS
FIELD OF THE INVENTION
[0001] The present invention relates to a deck fastener for securing
decking members (e.g., boards or planks) together and to a supporting member
and, more particularly, to a fastener for securing grooved or slotted decking
members to an underlying support member.
BACKGROUND OF THE INVENTION
[0002] Composite deck boards or planks have become increasingly
common as a replacement or alternative to traditional wood planks for outside
decking or the like. Composite boards are made of a combination of materials
usually including a polymer matrix material and one or more reinforcement
materials such as wood fibers, with the polymer matrix surrounding and
supporting the wood fiber reinforcement material. The reinforcement material
provides strength, workability, and dimensional stability, while the polymer
matrix
material provides low-maintenance characteristics, durability (especially in
terms
of color longevity), and splinter-free wear.
[0003] Composite deck boards may be fastened to underlying support
members in the same manner as traditional wood planking, e.g., by driving a
fastener down through the body of the deck board. Despite improved
mechanical qualities, however, composite boards are still subject to possible
splitting. Moreover, users prefer not to have fasteners protruding above the
decking surface, as may be unsightly and/or create a hazard. For example,
conventional nails, even if countersunk in the first instance, have a tendency
to
work themselves above the decking surface over time as the planking contracts
and expands due to changing weather conditions. Accordingly, various systems
have been proposed for securing deck boards together and to underlying
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supports in a "hidden" manner, e.g., the fasteners do not protrude above the
decking surface.
[00041 The decking itself may be provided with features for facilitating
"hidden" attachment. For example, FIGS. 1A and 1 B show a generally
rectangular, generally planar, composite plank 10 having an elongate body 12,
first and second lateral ends 14, 16 (e.g., the ends are perpendicular to a
longitudinal axis 18 of the plank, which is the axis defined by the longest
dimension of the plank), and left and right longitudinal sides 20, 22 (e.g.,
the
sides are parallel to the longitudinal axis 18 of the plank)..-_Each side 20,
22 has
a longitudinal groove or slot 24, 26 formed therein. In operation, a biscuit
device
such as shown in U.S. Pat. No. 6,402,415 to Eberle, III is used to hold
adjacent
planks together and to an underlying support. However, since the top of the
biscuit-like device is only press fit into the grooves 24, 26, the connection
between planks may not be as secure as desired. For example, the planks may
be subject to shifting or other movement.
SUMMARY OF THE INVENTION
[00051 An embodiment of the present invention relates to a fastener for
securing laterally adjacent, grooved decking members to an underlying support.
("Grooved decking member" refers to an elongate board, plank, or other
construction member having generally planar top and bottom surfaces, such as
those suitable for use as the surface of a deck, where one or both of the side
edges of the member are provided with longitudinal grooves or slots.) The
fastener includes a generally flat body portion with front and rear faces and
top
and bottom edges. A first connection wing is attached to the top edge of the
body and extends outwardly from the rear face of the body in a first
direction. A
second connection wing is also attached to the top edge of the body, but
extends generally outwardly from the front face of the body in a second,
opposite
direction. A flange is attached to the bottom edge of the body portion and
extends outwardly from the rear face of the body in the general direction of
the
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first connection wing. The flange and/or body portion include an opening for
passage of a connector (e.g., screw) through the fastener. The connection
wings are adapted in size and shape to engage laterally adjacent decking
members when the wings are inserted into the longitudinal grooves formed in
the
sides of the decking members and the fastener is connected to a supporting
member that supports and underlies the laterally adjacent decking members.
[0006] Thus, in use, a first decking member is held in place against the
underlying support member. The fastener's second connection wing (e.g., the
connection wing opposite the flange) is positioned in the decking member's
longitudinal groove such that the connector opening is positioned proximate to
the support member and the flange is facing away from the decking member. A
screw or other connector is inserted through the opening and is secured in
place
down into the support member. (Typically, several fasteners are deployed in
this
manner at even intervals along the length of the decking member.) Then, a
second decking member is placed laterally against the first decking member by
maneuvering its longitudinal side groove over the fastener's first connection
wing. The second decking member lies against the support member, and is then
moved towards the first decking member until it abuts the flange, which
establishes a gap between the two decking members. The connection wings
engage the decking members in the slots for securing the decking members
against the support member, e.g., lip-like portions of the decking members,
which lie below the grooves, are sandwiched between the connection wings and
the underlying support, preventing the decking members from being
substantially
raised upwards.
[0007] In another embodiment, the flange is generally perpendicular to the
rear face of the body portion. In compensation for the gap created by the
flange,
the first connection wing (e.g., the wing positioned on the same side as the
flange) is longer than the second connection wing in a latter manner. This
means that the first connection wing extends out from the body portion by a
lateral distance greater than that of the second connection wing. ("Lateral
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distance" refers to the distance between the body portion and the farthest,
distal
edge of the wing, as measured normally/perpendicularly to the front or rear
face
of the body portion, as applicable.)
[0008] In another embodiment, the connection wings are "bent" in shape,
with each including first and second portions that are non-coplanar to one
another. Thus, for example, for each connection wing, the first non-coplanar
portion is attached to the top edge of the body and lies generally
perpendicular
to the fastener body portion. The second non-coplanar portion, which defines
the distal end of the connection wing, is attached to an edge of the first
portion
opposite (and typically parallel to) the top edge of the body. The second
portion
is inclined at an angle with respect to the first portion for leveraged
engagement
of the connection wing with a decking member when inserted into a longitudinal
groove thereof.
[0009] In use, a first grooved decking member is held in place against an
underlying joist or other support member. The second, laterally shorter
connection wing (e.g., the connection wing on the opposite side of the body
from
the flange) is angled into the decking member's longitudinal groove. In this
position, the body of the fastener abuts the lower lip of the groove (or
thereabouts), with the body and second wing lying in an inclined or angled
position above the support member. Again, the fastener's connector opening is
positioned proximate to the support member, and the flange faces away from the
decking member. A connector is inserted through the connector opening and is
secured in place down into the support member. As the fastener is secured in
place, this causes the short connection wing and/or body to flex slightly,
causing
the angled, distal portion of the wing to firmly press up against or otherwise
engage the decking member in the inside top of the groove. This prevents the
decking member from being easily moved laterally away from the fastener.
Subsequently, a second decking member is maneuvered in at a slight angle to
position its longitudinal side groove over the first, laterally longer
connection
wing of the fastener. Allowing the second decking member to fall into place
flat
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against the support member causes the long wing to flex slightly under the
weight of the second decking member. This in turn causes the angled, distal
portion of the long wing to frictionally engage the second decking member
inside
the groove, including possibly slightly biting into the decking member. This
secures the second decking member in place in a positive leveraged manner.
[0010] In another embodiment, with respect to a geometrical plane
defined by the perpendicular portions of the connection wings, the fastener
body
and flange are located on one side of the plane, and the angled or bent
portions
of the wings extend out past the opposite side of the plane. Typically, the
angled
or bent portions are angled from about 15 to about 75 with respect to the
plane
defined by the first connection wing portions.
[0011] In another embodiment, the connection wings are generally
rectangular and have generally rectangular distal ends. The distal ends may be
provided with wedge-shaped prongs, e.g., positioned at the left and right
corners
of the distal end, for the connection wings to bite into the decking members
inside the longitudinal grooves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will be better understood from reading the
following description of non-limiting embodiments, with reference to the
attached
drawings, wherein below:
[0013] FIGS. 1A and 1 B are views of a grooved decking member;
[0014] 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;
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[00151 FIGS. 3A and 3B are perspective and. side elevation views,
respectively, of a fastener according to an additional embodiment of the
present
invention;
[00161 FIGS. 4A-4C and 5A-5D are side elevation views showing the
fasteners in use;
[0017] FIG. 6 is a perspective view of an alternative embodiment of the
fastener shown in FIGS. 3A and 3B;
[00181 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
[0019] 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
[00201 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
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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 a to the body, wherein, typically, a = 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.
[0021] 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
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manufacturing operation resulting in the provision of the grooves/slots, such
as
molding, machining, the connection of varying-width laminates, or the like.
[00221 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.
[00231 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
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fasteners, or through provision of "one sided" fasteners, such as the fastener
30a but without a connection wing 40a.
[0024] 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
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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.
[0025] 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.
[0026] 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.)
[0027] 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"
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(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".
[00281 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
a 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 f = (90 - a), e.g., 4
is
typically 45 , but may range from about 15 to about 75 .)
[00291 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 (3 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
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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.
[0030] 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.)
[0031] 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.
[0032] 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.
[0033] 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
450 1'.
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[00341 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.
[00351 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
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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.
[00361 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.
[00371 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
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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.
[00381 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.
