TOP DECK PANEL SYSTEM

Abstract

A Top Deck Panel System cover made from a plastic material, such as Polyvinyl chloride (PVC), Polypropylene (PP), Polyethylene (PE), Polyethylene Terephthalate (PET), Nylon and/or wood composite, wherein the top deck exterior walking cover is assembled without the use of mechanical fasteners such as screws or nails. The Top Deck Panel System cover is designed to be either a temporary or permanent exterior walking surface and can be placed on ground such as gravel, sand, limestone, soil and/or used to cover existing decks, concrete walkways or porches, brick walkways or porches, or other walking surfaces. The Top Deck Panel System cover can be quickly and effectively installed. The Top Deck Panel System provides a mobile walking surface that allows the Top Deck Panel System to be moved easily, efficiently and economically.

Description

CLAIM OF PRIORITY

This application claims priority to U.S. Provisional Application No. 60/886,970, filed on Jan. 29, 2007.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The presently disclosed invention relates to decks and, more particularly, decks that do not require a support framework and that can be assembled without special tools.

2. Description of the Prior Art

Many types and styles of decks are known in the prior art. Most of these decks are permanent designs that are intended for use only in connection with a structure or framework that supports and stabilizes the deck. Examples are shown in U.S. Publication No. 2003/0192275 and U.S. Pat. Nos. 6,619,002; 6,467,118; 6,260,322; 5,050,361; and 5,758,467.

Various mechanisms have been used to secure such decks to the support structure and keep the deck panels or planks in the same relative position. In many cases, the panels or planks that comprise the deck surface are secured directly to the underlying support structure. Examples are shown in U.S. Pat. Nos. 5,613,339; 6,453,630; 6,594,961; 5,009,045; D485,373; D492,797 and Des 418,926. Other decks include structure that is intended to engage adjacent deck panels and maintain the panels or planks in position and to strengthen the overall structure. Examples of those structures are shown in U.S. Pat. Nos. 6,233,886 and 5,660,016 wherein a third member or connector is located between adjacent panels and cooperates with both panels to secure them together. In other cases such as shown in U.S. Pat. Nos. D485,621, 5,647,184; 6,272,808; 6,199,340; and 6,324,796, opposite side surfaces of the deck plank have cooperative features such that when the planks are aligned in a parallel array, the side of one plank will engage the opposing side of the adjacent plank so that the planks are connected together laterally.

However, there was a need for a deck surface that could be used with or without a dedicated support structure. Such a deck surface would have the advantage of being more widely applicable because it could be supported either by dedicated support structure such as a wood or metal frame, or, alternatively, could be deployed directly on the ground or on a general floor surface such as a concrete floor.

Prior art deck panels and planks generally were not well-suited for such multiple applications. In many instances, prior deck planks and panels could not be secured together without the intended support structure. In other instances, the deck panels and planks had sides with mating configurations so that two adjacent panels could engage together. However, such panels and planks were prone to separating while in service. Some of such planks and panels, such as shown in U.S. Pat. Nos. D485,621; 5,647,184; 6,272,808; and 6,199,340 had mating surfaces that were joined by moving the planks laterally together. Other planks and panels such as shown in U.S. Pat. No. 6,324,796 could be joined by relative vertical movement of adjacent planks. Those planks sometimes performed better when there was a solid, relatively flat supporting surface such as a concrete floor. However, when used on open ground, these configurations also were prone to separation.

Accordingly, there was a need for a deck with planks or panels that remained secured together notwithstanding their particular application with or without support structure. Also, there has been a need for a deck that can be assembled for a temporary application. Therefore, it also would be preferable for the deck planks to be assembled simply and without need of tools.

SUMMARY OF THE INVENTION

In accordance with the presently disclosed invention, an interlocking top deck panel system that provides an exterior walking surface has a generally rectangular profile with horizontal top and bottom surfaces and two sides. The panel system can be made from a plastic material and can be installed without mechanical fasteners. A plurality of walls are longitudinally aligned with the panels and protrude from the bottom surface of the panel. First and second connector rails are secured to opposite sides of the panel and oriented longitudinally with respect to the panel. The first and second connector rails are shaped in complementary relationship so that a first connector rail on one panel can engage a second connector rail on an adjacent panel by sliding the first connector rail longitudinally with respect to the second connector rail to fasten the adjacent panels together.

Preferably, the panel is comprised of a plastic selected from the group of polyvinyl chloride, polyethylene, polypropylene, polyethylene teraphalate, polyamide, and combinations thereof. Also preferably, the panel can be comprised of a wood composite material. The polyvinyl chloride and other plastic materials can be cellular or foamed.

More preferably, the panel is comprised of recycled materials selected from the group of polyvinyl chloride, polyethylene, polypropylene, acrylonitrile butadiene styrene, polystyrene, polyethylene terephthalate, nylon, poly carbonate, and combinations thereof.

The top deck panel system can be extruded or co-extruded from more than one plastic material and also can have a plurality of surface grooves that are longitudinally aligned in the top surface of the panel to convey water off of the deck. The surface grooves can be V-shaped grooves that are adopted to convey moisture to the ends of the panel. A least a portion of the top surface of the panel can also have a grooved textured surface to increase the coefficient of friction of said top surface. The grooves of the grooved textured surface also can be generally parallel to the V-shaped grooves or can be orthogonal to the V-shaped grooves, or both orientations of textured grooves can be used. The portion of the top surface having a grooved textured surface can be located between at least two V-shaped grooves in the top surface of the panel.

The top deck panel system can include at least one channel that is defined by the bottom surface of the panel and at least two walls that are longitudinally oriented with the panel and extend from the bottom surface of the panel, said channel adapted to convey moisture to the longitudinal ends of the panel.

Also preferably, at least two end pieces can be used as accessory pieces to trim out the top deck panel system. One end piece has an outer surface and a connector structure that has a profile that corresponds to the profile of the second connector rail. The other end piece has an outer surface with a connector structure that has a profile that corresponds to the profile of the first connector rail. The outer surface of one end piece corresponds to the outer surface of the second end piece so that the outer surfaces of the two end pieces have the same appearance and provide the lateral sides of the deck with a finished appearance. The end pieces can also have a screw boss for securing the end pieces to another structure.

Most preferably, the top deck panel system can include an end clip to hold the top deck panel system together. The end clip can have a top side that has a textured surface and that also can have grooves. The end clip can be made of plastic.

Other features, advantages and objects of the presently disclosed invention will become apparent to those skilled in the art as a description of a presently preferred embodiment thereof proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS

Included with the disclosure and hereby specifically incorporated herewith are Figures that show and describe a particular example of the panel, panel assembly, deck and components thereof as further described herein in which:

FIG. 1 is a perspective view of a presently preferred embodiment of a deck panel as disclosed herein;

FIG. 2 is a top plan view of the deck panel shown in FIG. 1;

FIG. 3 is a bottom view of the deck panel shown in FIG. 1;

FIG. 4 is a right side elevation view of the deck panel shown in FIG. 1;

FIG. 5 is a left side elevation view of the deck panel shown in FIG. 1;

FIG. 6 is a rear end view of the deck panel shown in FIG. 1;

FIG. 7 is a front end view of the deck panel shown in FIG. 1;

FIG. 8 is an end view of a deck that includes two deck panels such as shown in FIG. 1 together with side rails on the outer sides of each deck panel and wherein the deck is secured to a joist;

FIG. 9 is an end view of a deck that includes two deck panels such as shown in FIG. 1 together with side rails on the outer sides of each deck panel and wherein the deck is supported by the ground;

FIG. 10 is an end view of the deck shown in FIG. 9 with a bracket that covers the end of the deck;

FIG. 11 is a perspective view of a presently preferred embodiment two deck panels that are connected together by respective connector rails;

FIG. 12 is a top plan view of the deck panels shown in FIG. 11;

FIG. 13 is a right side elevation view of the deck panels shown in FIG. 11;

FIG. 14 is a bottom plan view of the deck panels shown in FIG. 11;

FIG. 15 is a left side elevation view of the deck panels shown in FIG. 11;

FIG. 16 is a rear end view of the deck panels shown in FIG. 1 with interior structure shown in hidden lines;

FIG. 17 is a front end view of the deck panels shown in FIG. 11 with interior structure shown in hidden lines; and

FIG. 18 is an end view of a deck panel in combination with an alternative side rail.

DESCRIPTION OF THE INVENTION

As further disclosed in the accompanying drawings, a deck surface 10 is composed of a plurality of panels 12 that are interlocked together along their lateral sides as more particularly shown and described herein.

Each of the panels 12 includes a panel body 14 that defines a planar top surface 16 and a bottom surface 18 that is oppositely disposed on the panel body 14 from the planar top surface 16. The panel body 14 also defines a first lateral side 20 that is located between the planar top surface 16 and the bottom surface 18 and a second lateral side 22 that is also located between the planar top surface 16 and the bottom surface 18. The second lateral side 22 is oppositely disposed on the panel body 14 from the first lateral side 20.

Each panel 12 further includes at least one wall 24 that extends from the bottom surface 18. The wall 24 cooperates with the panel body 14 to support and mechanically strengthen the panel body 14. In addition, where panel 12 includes two or more walls 24, the walls that are located adjacent to each other cooperate with bottom surface 18 to define a channel 26. Channel 26 conveys moisture toward the ends of the panel.

Each panel 12 also includes a first connector rail 28 that is secured to the first lateral side 20 of the panel body 14. The first connector rail is aligned longitudinally parallel to the longitudinal axis 30 of the panel body 14. Panel 12 also includes a second connector rail 32 that is secured to the second lateral side 22 of the panel body 14. The second connector rail 32 is also aligned longitudinally parallel to the longitudinal axis 30 of the panel body 14.

In the presently disclosed example of the preferred embodiment, the first connector rail 28 has a profile that defines an enlarged distal portion. In the example of the preferred embodiment, the enlarged distal portion is the “T” portion of a T-shaped profile or cross-section 34. The second connector rail 32 has opposed arms that define a gap therebetween. In the example of the preferred embodiment, the second connector rail 32 cooperates with side 22 to form a C-shaped profile or cross-section 36. T-shaped cross section 34 and C-shaped cross-section 36 are sized and shaped in complementary fashion such that the T-shaped cross-section 34 of one panel 12 can be longitudinally received in the C-shaped cross-section of another panel 12 and will slidably engage inside of the C-shaped cross-section 36 of the other panel 12. In this way, the two panels can be secured together along their respective longitudinal lengths by slidably inserting one end of T-shaped cross-section 34 of one panel 12 into an end of C-shaped cross-section 36 of another panel 12.

Specifically, the panels 12 are placed in end-to-end relationship with one longitudinal end (for example, end 42) of T-shaped cross-section 34 of one panel 12 opposite from the longitudinal end (for example, end 44) of C-shaped cross-section 36 of the other panel 12. One panel 12 is then moved in a longitudinal direction with respect to the other panel 12 so that the T-shaped cross-section 34 of the one panel travels longitudinally into the C-shaped cross-section 36 of the other panel. The two panels are moved together in the longitudinal direction until the ends 42 and 44 of one panel 12 have a longitudinal position that is even with the ends 42 and 44 of the other panel. The T-shaped cross-section 34 of the first connector rail 28 of one panel is then captured in interlocking relationship inside the C-shaped cross-section 36 of the second connector rail 32 of the other panel.

First connector rail 28 is sized such that the cross-sectional dimension of the “T” portion 62 of connector rail 28 is too large to pass laterally through the gap 64 of C-shaped profile of second connector rail 32. In this way, the panels 12 are laterally interlocked, meaning that the panels are not joined or separated by forces acting laterally between the panels.

This manner of securing panels 12 provides for the assembly of a plurality of panels to form a walking surface such as a deck 37. Any number of panels can be assembled in the this way to produce a walking surface or deck 37 of any predetermined size. Also in this way, the panels can be laterally connected without need of any fasteners or special tools.

Preferably, the top surface 16 of panel 12 defines a textured surface 38. In this way, the panel affords improved traction when incorporated into an assembled walking surface. The textured surface can be an embossed pattern in which an array of parallel grooves are oriented parallel to V-grooves 40. Also, the grooves of the textured surface 38 can be oriented orthogonally to V-grooves 40 and spaced about 0.30 inch as measured along longitudinal axis 30. Preferably, the embossed grooves have a V-shaped cross-section that is about 0.050 inch wide and about 0.030 inch deep.

Panel 12 can be made of a number of suitable materials. Preferably, such materials have the mechanical strength necessary for a deck, do not rust, and resist color fading due to sun exposure. Also, preferably, the panel material will maintain such properties over many years and over a wide range of temperatures. Among other materials, panel 12 can be made of polyvinyl chloride, polypropylene, polyethylene teraphalate, polyamide, wood composite, or combinations of those materials. Also preferably, panel 12 can be made of Polyvinyl Chloride (PVC), Polypropylene (PP), Polyethylene Terephthalate (PET), polyamide, Polyethylene (PE), Acrylonitrile Butadiene Styrene (ABS), Polystyrene (PS), nylon, Poly carbonate (PC) or combinations of those materials. The polyvinyl chloride or other materials can be foamed or cellular.

Panel 12 can also include an array of grooves 40 in top surface 16. Grooves 40 are longitudinally aligned with the longitudinal axis 30 of the panel 12. Preferably, grooves 40 define a V-shaped cross-section and convey moisture toward the ends 42 or 44 of panel 12.

When a plurality of panels 12 are assembled into a deck 37, the deck can further include a first side rail 46. The first side rail 46 has a side surface 48 and a female connector structure 50 that has a profile that corresponds to the profile of second connector rail 32. First side rail 46 is engageable with the first connector rail 28 of one of panels 12. Deck 37 can further include a second side rail 52 that has a side surface 54 and a male connector structure 56 that has a profile that corresponds to the profile of the T-shaped cross-section 34 of the first connector rail 28. Second side rail 52 is engageable with the second connector rail 32 of panel 12. The side surface 48 of first side rail 46 has a profile that inversely corresponds to the profile of side surface 54 of second side rail 52. First side rail 46 and second side rail 52 can be applied to the perimeter of an assembly of panels 12 that comprise deck 37. Because surface 48 corresponds to surface 54, the peripheral surfaces of first side rail 46 and second side rail 52 have the same appearance and the lateral sides of deck 37 have a finished appearance.

It is not necessary to secure deck 37 to any support surface. However, in some applications it will be desired to secure deck 37. For those applications first and second side rails 46 and 52 can further include screw bosses or ports 53a and 53b for receiving fasteners 53c to secure the deck 37 to another object such as a wooden deck that is in disrepair.

Deck 37 can further include elements that afford a finished appearance to the sides of deck 37 that are defined by the ends 42 and 44 of panels 12. Disclosed herein is an L-bracket 58 that is securable to the panel assembly along ends 42 and 44 to cover ends 42 and 44 of panels 12. L-bracket 58 can be secured to the panel assembly by a fastener 60. Preferably, fastener 60 is a detent fastener that requires no special tools for insertion thereof and that can be removed and reused from time-to-time in the event that the user wants to relocate deck 37 or modify its size.

Deck 37 can further include an alternative side rail 70 as shown in FIG. 18. Side rail 70 includes an arm 72 that extends over the top surface 16 of an adjacent deck panel 12. Arm 72 and the vertically extending leg 73 of the side rail 70 cooperate to maintain the vertical and lateral position of the deck panel 12 at times when side rail 70 is secured to a support structure or other fixed structure.

Side rail 70 also includes a side surface 74 that forms the peripheral surface of the deck when the side rail 70 is assembled with an array of deck panels 12. Side rail 70 can be used on the sides and/or the longitudinal ends 42, 44 of deck panel 12 so that the edges of the deck have the same appearance. Side rail 70 has a screw boss 76 that can receive screws or similar fasteners for securing the deck to a support or foundation. In this way, the deck can be secured to the foundation by the side rails 70 on each side of the deck and no fasteners are required directly for the deck panels 12 of the deck. Preferably, side rail 70 further includes a cap 78 that covers screw boss 76 to protect the fastener and to afford a more finished appearance for the deck.

While a presently preferred embodiment of the invention has been shown and described herein, the presently disclosed invention is not limited thereto but can be otherwise variously embodied within the scope of the following claims.

Claims

1. A panel for use in combination with other panels to form a panel assembly that provides a walking surface, said panel comprising:

a panel body that defines a top surface, a bottom surface that is oppositely disposed on said panel body from said top surface, a first side that is located between said top surface and said bottom surface, and a second side that is located between said top surface and said bottom surface and oppositely disposed on said panel body from said first side;

at least one wall that extends from the bottom surface of said panel, said wall cooperating with said panel body to support and strengthen said panel body;

a first connector rail that is secured to the first side of said panel body, said first connector rail being longitudinally aligned with said panel body, said first connector rail also having a profile that defines an enlarged portion; and

a second connector rail that is secured to the second side of said panel body, said second connector rail being longitudinally aligned with said panel body and sized to longitudinally receive the first connector rail of another panel, said second connector rail having opposed arms that define a gap therebetween, said gap having a width that is less than the cross-section dimension of the enlarged portion of said first connector rail such that the arms of said second connector rail block the passage of the enlarged portion of said first connector rail laterally through the gap of said second connector rail and said first and second connecter rails are not joined or separated by moving the first connector rail laterally with respect to the second connector rail.

2. The panel of claim 1 wherein said first connector rail has a T-shaped cross-section and wherein said second connector rail has a C-shaped cross-section.

3. The panel of claim 1 wherein said top surface defines a textured surface.

4. The panel of claim 1 wherein said panel is comprised of a material that is selected from at least one of the group comprising polyvinyl chloride, polypropylene, polyethylene teraphalate, polyamide, and wood composite.

5. The panel of claim 1 wherein said panel is comprised of a material that is selected from one or more of the group comprising Polyvinyl Chloride (PVC), Polypropylene (PP), Polyethylene Terephthalate (PET), polyamide, Polyethylene (PE), Acrylonitrile Butadiene Styrene (ABS), Polystyrene (PS), nylon, and Poly carbonate (PC).

6. The panel of claim 1 wherein said top surface defines an array of grooves that are longitudinally aligned on said panel.

7. The panel of claim 1 wherein said panel includes two or more of said walls with adjacently located walls cooperating with the bottom surface of said panel body to define a channel, said channel being aligned longitudinally with the ends of said panel.

8. The panel of claim 6 wherein said grooves define a V-shaped cross-section, said grooves being aligned longitudinally with the ends of said panel.

9. A deck surface comprising a plurality of panels that can be secured together, each of said panels defining:

a panel body that defines a top surface, a bottom surface that is oppositely disposed on said panel body from said top surface, a first side that is located between said top surface and said bottom surface, and a second side that is located between said top surface and said bottom surface and oppositely disposed on said panel body from said first side;

at least one wall that extends from the bottom surface of said panel, said wall cooperating with said panel body to support and strengthen said panel body;

a first connector rail that is secured to the first side of said panel body, said first connector rail being longitudinally aligned with said panel body; and

a second connector rail that is secured to the second side of said panel body, said second connector rail being longitudinally aligned with said panel body, said second connector rail being longitudinally engageable with said first connector rail of an adjacent second panel, and said first connector rail being longitudinally engageable with the second connector rail of an adjacent third panel.

10. The deck surface of claim 9 wherein the first connector rail of one panel is slideable in a longitudinal direction inside the second connector rail of an adjacent panel so that the panels are engaged.

11. The deck surface of claim 10 and further comprising:

a first side rail having a side surface and a female connector structure that is engageable with the first connector rail of one of said panels.

12. The deck surface of claim 11 and further comprising:

a second side rail having a side surface and a male connector structure that is engageable with the second connector rail of one of said panels.

13. The deck surface of claim 9 and further comprising:

an L-bracket that is securable to said panel assembly and that covers the ends of said panels that define one edge of said panel assembly.

14. The deck surface of claim 12 wherein the first and second side rails include ports for receiving fasteners to secure said panel assembly to another object.

15. The deck surface of claim 13 wherein said L-bracket is secured to said panel assembly by a fastener.

16. The deck surface of claim 15 wherein said fastener is a detent fastener.

17. The deck surface of claim 9 and further comprising:

a side rail that includes an arm that extends over the top surface of said panel body, said side rail maintaining the lateral and vertical position of said panel body.