PLANK CONNECTORS
Apparatuses and methods of operating the same are described. A plank connector that includes a body and a platform. The body may be on a first plane. The platform may be connected to the body. The platform may be on a second plane perpendicular to the first plane. The platform may include a first wing and a second wing. The first wing may extend outwardly along the second plane from the platform. The first wing may be shaped to be inserted into the groove of the first plank. The second wing may extend outwardly along the second plane from the platform. The second wing may be shaped to be inserted into the groove of the second plank.
An outdoor deck may include a sub-frame and planks that run along a top surface of the sub-frame to form a flooring for the outdoor deck. The planks of the outdoor deck may be interconnected to the sub-frame and each other when installed to provide a stable and secure platform for individuals to walk on or place objects on, such as furniture, grills, or decorations.
SUMMARYA plank connector that includes a body and a platform. The body may be on a first plane. The platform may be connected to the body. The platform may be on a second plane perpendicular to the first plane. The platform may include a first wing and a second wing. The first wing may extend outwardly along the second plane from the platform. The first wing may be shaped to be inserted into the groove of the first plank. The second wing may extend outwardly along the second plane from the platform. The second wing may be shaped to be inserted into the groove of the second plank.
The present description will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the present embodiment, which, however, should not be taken to limit the present embodiment to the specific embodiments, but are for explanation and understanding only.
The disclosed plank connectors will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide merely examples of the various embodiments described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the embodiments described herein. Many variations are contemplated for different applications and design considerations; however, for the sake of brevity, each and every contemplated variation is not individually described in the following detailed description.
Throughout the following detailed description, examples of various plank connectors are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, the use of related feature names will cue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader should understand that a given feature need not be the same or similar to the specific portrayal of a related feature in any given figure or example.
Planks may be long, thin, flat pieces of material used in building a flooring of a building or outdoor platform. The exterior platform may be a deck, a patio, and so forth. When the planks are used for outdoor platforms, the planks may be constantly exposed to moisture and may rot or decay with continued exposure to the moisture. For example, when it rains on a deck, water may collect on a surface of the planks and eventually penetrates into the beam.
Outdoor planks may be spaced apart to leave a gap between adjacent planks so that water can more readily drain from the surface of the deck. Conventionally, builders manually space the planks along support beams of the outdoor platform may lead to uneven spacing of the planks. The unevenly spacing planks may cause drainage issues, as water may not be able to drain properly at some locations on the outdoor platform. Additionally, the unevenly spacing planks may be ascetically unpleasing to an individual using the deck. Additionally, a builder correctly spacing the planks may be a time consuming and laborious task.
The embodiments described herein may address the above-noted deficiencies by providing a plank connector that may include a first wing that may be inserted into a first opening at the side of a first plank and a second wing that may be inserted into a second opening at the side of a second plank. The plank connector may connect the first plank and the second plank together. The first wing and the second wing of the plank connector may be shaped to universally fit into different sized and spaced openings of the sides of planks. The plank connector may also include arms to separate the side of the first plank from the side of the second plank by a defined distance to provide a space for drainage between the sides of the first plank and the second plank. As the plank connector is inserted into the sides of the first plank and the second plank, the plank connector may be relatively hidden, which may improve the overall aesthetics of the outdoor platform. The plank connector being inserted into the sides of the first plank and the second plank may also improve a strength and durability of the connection between the first plank, the second plank, and the sub-frame.
In one embodiment, the planks 102 may be spaced apart by a distance ranging from approximately one-eighth of an inch to approximately a half of an inch. In another embodiment, a spacing of the planks may be based on the environmental conditions that the outdoor platform 100 may be subjected. In one example, the planks 102 may be spaced relatively close together when the outdoor platform is located in a relatively dry environment with low annual rainfall and/or no snow. In another example, the planks 102 may be spaced relatively far apart when the outdoor platform is located in a relatively wet environment with high annual rainfall and/or snow.
In one embodiment, a plank 102 may be hardwood material, composite material, synthetic material, and so forth. In another embodiment, the plank 102 may be two inches thick, 4 inches wide and 8 feet long. Each joist 104 may be hardwood material, composite material, synthetic material, and so forth. Each joist 104 may include a top edge, a bottom edge, a front surface, and a rear surface. The top edge, the bottom edge, the front surface, and the rear surface may be substantially flat surfaces. In one example, a portion of the bottom surface of each plank 102 may rest on the top edge of one or more of the joists 104. In one embodiment, the joists 104 may be successively spaced apart from one another at defined distances. For example, the joists 104 may be spaced apart from each other by a distance of approximately 12 inches to 24 inches. The joists 104 may support one or more planks 102 that are disposed transversely across the top edges of the joists 104.
In one embodiment, the top surface 204 and/or the bottom surface 206 may be substantially flat and smooth. In another embodiment, the top surface 204 and/or the bottom surface 206 may include one or more grooves 214. The grooves 214 may be channels or conduits that control the flow or direction of the fluid. For example, the grooves 214 may extend along the top surface 204 and/or the bottom surface 206 of the plank 102 to direct the fluid to drain between the gaps or spaces between the planks 102 of the outdoor platform 100 in
The first side edge 208 and/or the second side edge 210 may include grooves 212. In one embodiment, a groove 212 may be located between the top surface 204 and the bottom surface 206 of the first side edge 208 and/or the second side edge 210. For example, the groove 212 may be located at the approximate midpoint between the top surface 204 and the bottom surface 206 of the first side edge 208 and/or the second side edge 210. In another embodiment, the groove 212 may extend longitudinally along the entire length of the first side edge 208 or the second side edge 210. In another embodiment, the groove 212 may extend longitudinally along a portion of the length of the first side edge 208 and/or the second side edge 210. For example, the groove 212 may be formed into the first side edge 208 or the second side edge 210 at one or more portions along the length of the first side edge 208 and/or the second side edge 210.
In another embodiment, the groove 212 may be substantially rectangular shaped in a lateral cross-section. In another embodiment, the groove 212 may be substantially square shaped, circular shaped, or polygonal shaped in the lateral cross-section.
In one example, the plank connector 302 may be a plastic material, a rubber material, a polyurethane material, and so forth to be durable and rust proof. In another example, the plank connector 302 may be metal to be relatively rigid and not flexible. In another example, the plank connector 302 may be nylon material to provide a relatively flexible connector that may be durable for an extended period of time. In another example, the plank connector 302 may be a unitary device formed from rigid and durable plastic material such as glass-filled nylon or polyvinyl chloride (PVC). In another example, the material of the plank connector 302 may be light in weight, such as approximately 0.0029 pounds. In one embodiment, the plank connector 302 may be formed using a molding technique. In another embodiment, the plank connector 302 may be formed using a die-cast technique.
The plank connector 302 may include a body 304 located on a first plane 306. The body 304 may be a rigid body or a semi-rigid body. The plank connector 302 may include a first connector 308. The first connector 308 may extend outwardly along the first plane 306 from a first edge 310 of the body 304. The first connector 308 may include a first arm 312 at a distal end of the first connector 308. In one example, the first connector 308 may extend approximately 3.3 millimeters (mm) from the first edge 310 to the first arm 312 and the extension may have a width of approximately 3 mm.
The first arm 312 may be shaped to be located between two planks to space the two planks apart. The first arm 312 may include a top surface, a bottom surface, and an end surface. The first arm 312 may have a rectangular shape, a square shape, a cylinder shape, and so forth. When the first arm 312 is rectangular shaped or square shaped, the width of the first arm 312 may be approximately 2.925 mm, a length of the first arm 312 is approximately 5.95 mm, and a height of the first arm 312 is approximately 8 mm.
The plank connector 302 may also include a second connector 314. The second connector 314 may extend outwardly along the first plane 306 from a second edge 316 of the body 304. The second connector 314 may include a second arm 318 at a distal end of the second connector. In one example, the second connector 314 may extend approximately 3.3 mm from the second edge 316 to the second arm 318 and the extension may have a width of approximately 3 mm. The second arm 318 may be shaped to be located between two planks to space the two planks apart. The second arm 318 may include a top surface, a bottom surface, and an end surface. The first arm 312 may have a rectangular shape, a square shape, a cylinder shape, and so forth. When the first arm 312 is rectangular shaped or square shaped, the width of the second arm 318 may be approximately 2.925 millimeters (mm), a length of the second arm 318 is approximately 5.95 mm, and a height of the second arm 318 is approximately 8 mm.
The plank connector 302 may also include a platform 320. In one example, the platform 320 may be connected to a top of the body 304. In another example, the platform 320 may be connected to a bottom of the body 304. The platform 320 may extend along a second plane 322 perpendicular to the first plane 306. In one embodiment, the platform 320 may be a defined width to provide a space between the first plank and the second plank 102.
The platform 320 may have a rectangular shape, a square shape, or another polygonal shape. In another example, the platform 320 may be a disk shape, a cylinder shape, and so forth.
In one embodiment, the first connector 308 may extend in a first direction beyond a width or diameter of the platform 320 and the second connector 314 may extend in a second direction beyond the width or diameter of the platform 320. A width of the platform 320 is approximately 16 mm and a length of the platform 320 is approximately 19 mm. In one example, the width of the platform may be a defined width to provide a space between the first plank and the second plank. A thickness of the platform is approximately 3.1 mm.
The plank connector 302 may include a first wing 326 that extends from a center of the platform 320 to a groove 212 at a first side of the plank connector 302 and a second wing 328 that extends from the center of the platform 320 to a groove 212 at a second side of the plank connector 302. The first wing 326 or the second wing 328 may have a rectangular shape, a square shape, a cylinder shape, and so forth.
The first wing 326 may include a top surface, a bottom surface, and an end surface. When the first wing 326 is inserted in the groove 212 in
The second wing 328 may include a top surface, a bottom surface, and an end surface. When the second wing 328 is inserted in the groove 212 in
The plank connector 302 may also include an opening 324 that is a channel extending through the platform 320 and the body 304. For example, the opening 324 may be a channel or hole that extends from a top side of the platform 320 to a bottom side of the body 304. The opening 324 may extend through a center of the platform 320 and the body 304. The opening 324 may be shaped to receive a fastener to connect the plank connector 302 to a joist 104 or another sub-frame structure of the outdoor platform 100.
In one embodiment, the body 304, the first connector 308, the second connector 314, and the platform 320 may integrally form a single piece of material, such as a molded or die cast piece of material. In another embodiment, the body 304, the first connector 308, the second connector 314, and the platform 320 may be separate pieces of material that may be bonded, welded, or otherwise connected together.
In one embodiment, the plank connector 302 may have an overall length of approximately 31.45 mm, an overall width of approximately 16 mm, and an overall height of approximately 11.1 mm. The dimensions of the plank connector 302 and any other dimensions discussed herein are not intended to be limiting to any particular set of dimensions.
In one embodiment, the body 304, the first connector 308, the second connector 314, and the platform 320 may form a cross-shaped spacer and connector to connect the first plank and the second plank to a joint and at a defined spacing apart. The body 304, the first connector 308, the second connector 314, and the platform 320 may be shaped to have a substantially symmetrical design about the opening 324. For example, the first connector 308 and the second connector 314 may extend radially from a common juncture point of the semi-rigid body. The substantially symmetrical construction about the opening 324 may enable the plank connector 302 to be reversible along a longitudinal axis such that the first wing 326 may be inserted in a groove 212 of the first plank and the second wing 328 may be inserted into a groove 212 of a second plank or vice versa to secure the first plank and the second plank to the joists 104. The substantially symmetrical design of the plank connector 302 and the shape and size of the first wing 326 and the second wing 328 may enable the plank connector 302 to be a universal connector to be inserted into the grooves 212 of planks regardless of the shape or size of the groove 212. The sizes and shapes of the various elements of the plank connector 302 are not intended to be limiting. For example, the sizes and shapes of the various elements of the plank connector 302 may vary based on a size of the plank it is inserted into.
The plank connector 302 may be connected to a joist 414 by inserting a fastener 406 into an opening of the plank connector 302. The plank connector 302 may connect to the joist 414 and may fasten down the first plank 402 and the second plank 404 to the joist 414. For example, when the plank connector 302 is fastened to the joist 414, the first wing 326 may be located within the first groove 410 to hold the first plank 402 against the joist 414 and the second wing 328 may be located within the second groove 412 to hold the second plank 404 against the joist 414. The order that the plank connector 302 is connected to the joist 414, the first wing 326 is inserted into the first groove 410, and the second wing 328 is inserted into the second groove 412 is not intended to be limiting. In one example, the plank connector 302 may be connected to the joist 414 prior to the first wing 326 and the second wing 328 being inserted into the first groove 410 and the second groove 412, respectively. In another example, the first wing 326 may be inserted into the first groove 410, the plank connector 302 may be connected to the joist 414 by the fastener 406, and then the second wing 328 may be inserted into the second groove 412. Additionally, as discussed above, the design of the plank connector 302 may be symmetrical such that the first wing 326 may be inserted into the second groove 412 and the second wing 328 may be inserted into the first groove 410.
The plank connector 302 may be a universal connector to fasten the first plank 402 and the second plank 404 to the joist 414. For example, the first wing 326 and the second wing 328 may be smaller than the first groove 410 of the first plank 402 and the second groove 412 of the second plank 404, respectively. While the first wing 326 and the second wing 328 may be smaller than the first groove 410 of the first plank 402 and the second groove 412 of the second plank 404, the bottom surfaces of the first wing 326 and the second wing 328 may fasten down on the bottom surfaces of the grooves 410 and 412. As discussed above, the plank connector 302 may uniformly space the first plank 402 apart from the second plank 404 by a defined space. A portion of the first plank 402 has been removed in
In one embodiment, the first wing 326 frictionally engages the first plank 402 and the second wing 328 frictionally engages the second plank 404 to secure the first plank 402 and the second plank 404 against the joist 414. In one embodiment, the first plank 402 and the second plank 404 may be fastened to the joist 414 at a first end of the first plank 402 and the second plank 404 by a first plank connector 302 and the first plank 402 and the second plank 404 may be fastened to the joist 414 at a second end of the first plank 402 and the second plank 404 by a second plank connector 302. In another embodiment, the first plank 402 and the second plank 404 may be fastened to multiple transverse joists with multiple plank connectors 302 inserted into the grooves 410 and 412 at intervals along the lengths of the first plank 402 and the second plank 404.
The disclosure above encompasses multiple distinct embodiments with independent utility. While each of these embodiments has been disclosed in a particular form, the specific embodiments disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the embodiments includes all novel and non-obvious combinations and sub-combinations of the various elements, features, functions and/or properties disclosed above and inherent to those skilled in the art pertaining to such embodiments. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims should be understood to incorporate one or more such elements, neither requiring nor excluding two or more such elements.
Applicant(s) reserves the right to submit claims directed to combinations and sub-combinations of the disclosed embodiments that are believed to be novel and non-obvious. Embodiments embodied in other combinations and sub-combinations of features, functions, elements and/or properties may be claimed through amendment of those claims or presentation of new claims in the present application or in a related application. Such amended or new claims, whether they are directed to the same embodiment or a different embodiment and whether they are different, broader, narrower or equal in scope to the original claims, are to be considered within the subject matter of the embodiments described herein.
Claims
1. A device, comprising:
- a semi-rigid body on a first plane;
- a first connector extending outwardly along the first plane from a first edge of the semi-rigid body, the first connector comprising a first arm at a first distal end, wherein the first arm is shaped to be inserted between a first plank and a second plank at a first location to space the first plank apart from the second plank by a defined distance;
- a second connector extending outwardly along the first plane from a second edge of the semi-rigid body, the second connector comprising a second arm at a second distal end, wherein: the second arm is shaped to be inserted between the first plank and the second plank at a second location to space the first plank apart from the second plank by the defined distance, and the second arm extends from a side of the semi-rigid body opposite the first arm;
- a platform connected to a top of the semi-rigid body on a second plane perpendicular to the first plane, the platform comprising: a first wing shaped to be inserted into a groove of the first plank to secure the first plank to a sub-frame of a structure; and a second wing shaped to be inserted into a groove of the second plank to secure the second plank to the sub-frame; and
- an opening extending through a center of the platform and the semi-rigid body, the opening shaped to receive a fastener to connect the device the sub-frame.
2. The device of claim 1, wherein the first connector and the second connector extend radially from a common juncture point of the semi-rigid body.
3. The device of claim 1, wherein:
- the first wing includes a top surface, a bottom surface, and an end surface; and
- when the first wing is inserted in the groove of the first plank, the top surface of the first wing is in contact with a top surface of the groove of the first plank, the bottom surface of the first wing is in contact with a bottom surface of the first plank, and the end surface of the first wing is in contact with an inner surface of the first plank.
4. The device of claim 1, wherein:
- the second wing includes a top surface, a bottom surface, and an end surface; and
- when the second wing is inserted in the groove of the second plank, the top surface of the second wing is in contact with a top surface of the groove of the second plank, the bottom surface of the second wing is in contact with a bottom surface of the second plank, and the end surface of the second wing is in contact with an inner surface of the second plank.
5. The device of claim 1, wherein the device is reversible such that the first wing is insertable into the groove of the second plank and the second wing is insertable into the first plank.
6. The device of claim 1, wherein the semi-rigid body and the platform form a cross-shaped spacer to connect the first plank and the second plank to the sub-frame.
7. The device of claim 1, where the first connector extends in a first direction beyond a width of the platform and the second connector extends in a second direction beyond the width of the platform.
8. The device of claim 1, wherein the platform is a disk.
9. The device of claim 1, wherein the platform is rectangular.
10. The device of claim 1, wherein a width of the platform is approximately 16 millimeters and a length of the platform is approximately 19 millimeters.
11. The device of claim 1, wherein a thickness of the platform is approximately 3.1 millimeters.
12. The device of claim 1, wherein:
- a width of the first arm is approximately 2.925 millimeters and a length of the first arm is approximately 5.95 millimeters, and
- a width of the second arm is approximately 2.925 millimeters and a length of the second arm is approximately 5.95 millimeters.
13. (canceled)
14. (canceled)
15. (canceled)
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. (canceled)
21. A device, comprising:
- a semi-rigid body on a first plane;
- a first connector extending outwardly along the first plane from a first edge of the semi-rigid body, the first connector comprising a first arm at a first distal end;
- a second connector extending outwardly along the first plane from a second edge of the semi-rigid body, the second connector comprising a second arm at a second distal end;
- a platform connected to a top of the semi-rigid body on a second plane perpendicular to the first plane, the platform comprising: a first wing shaped to be inserted into a groove of a first plank; and a second wing shaped to be inserted into a groove of a second plank; and
- an opening extending through a center of the platform and the semi-rigid body.
22. The device of claim 21, wherein the first arm is shaped to be inserted between the first plank and the second plank at a first location to space the first plank apart from the second plank by a defined distance.
23. The device of claim 21, wherein:
- the second arm is shaped to be inserted between the first plank and the second plank at a second location to space the first plank apart from the second plank by a defined distance; and
- the second arm extends from a side of the semi-rigid body opposite the first arm.
24. The device of claim 21, wherein:
- the first wing is configured to secure the first plank to a sub-frame of a structure; and
- the second wing is configured to secure the second plank to the sub-frame.
25. The device of claim 21, wherein the opening is configured to receive a fastener to connect the device a sub-frame of a structure.
26. A device, comprising:
- a body on a first plane;
- a first connector extending outwardly along the first plane from a first edge of the body;
- a second connector extending outwardly along the first plane from a second edge of the body;
- a platform connected to a top of the body on a second plane perpendicular to the first plane, the platform comprising a first wing and a second wing; and
- an opening extending through a center of the platform and the body.
27. The device of claim 26, wherein:
- the first connector comprises a first arm at a first distal end; and
- the second connector comprising a second arm at a second distal end.
28. The device of claim 26, wherein:
- the first wing is configured to be inserted into a groove of a first plank; and
- the second wing is configured to be inserted into a groove of a second plank.
Type: Application
Filed: Dec 18, 2017
Publication Date: Jun 20, 2019
Inventor: Eric Penewell (Tukwila, WA)
Application Number: 15/845,076