Flooring assembly and fastener therefor

Abstract

A flooring assembly and fastener therefor comprises flooring planks, preferably made of recycled lumber, and a clip fastener arranged between opposing longitudinal edges of the planks. The planks, in one embodiment, use tongue and groove construction. The clip is Z-shaped in cross section, one end portion of the clip catching the groove of a plank with the other end portion acting as a base for fastening to the joist. The clip fasteners are spaced along each joint and adjacent joints to retain the planks on the joists while permitting the planks to expand and contract at rates different than the joists themselves.

Description

FIELD OF THE INVENTION

[0001] The present invention is directed to a flooring assembly and fastener therefor and, in particular, to recycled plastic lumber decking and clips to retain the decking on joists.

BACKGROUND ART

[0002] In the prior art, various fasteners have been proposed to retain flooring or decking in place. U.S. Pat. No. 5,660,016 to Erwin et al. discloses a foam-filled extruded decking plank and decking attachment system. This system includes clamps or hold down blocks which are secured onto a structure that supports the planks. The blocks permit relative motion between the planks. U.S. Pat. No. 4,599,842 to Counihan discloses a fastening system for fastening planar sections such as flooring boards to a base surface. The system includes fastening strips that interlockingly engage in a set of grooves cut in the ends of the boards. While the system of Erwin et al. recognizes that joist and deckings fabricated from different materials of construction may expand or contract at differing rates, this system is rather complex and adapted for especially extruded decking. In light of these complexities, a need has developed to provide an improved and simple system for assembling flooring or decking planks. In response to this need, the present invention provides an assembly and a fastener therefor which is simple but effective in retaining flooring planks to a support structure such as joists.

SUMMARY OF THE INVENTION

[0003] Accordingly, it is a first object of the present invention to provide an improved flooring assembly, particularly for recycled plastic lumber.

[0004] Another object of the present invention is to provide an improved fastener to retain flooring or decking in place.

[0005] A still further object of the present invention is a fastener for use with tongue and groove deck planks.

[0006] One other object of the present invention is a method of installing flooring using interconnecting flooring and the inventive flooring fastener.

[0007] Other objects and advantages of the present invention will become apparent as a description thereof proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Reference is now made to the drawings of the invention wherein:

[0009] FIG. 1 is a sectional view of one embodiment of the inventive assembly in exploded form to show greater detail;

[0010] FIG. 2 shows the assembly of FIG. 1 in a partially assembled state;

[0011] FIG. 3 shows a perspective view of one embodiment of the inventive fastener;

[0012] FIG. 4 shows a perspective view of a second embodiment of the inventive fastener;

[0013] FIG. 5 shows a perspective view of a third embodiment of the inventive fastener; and

[0014] FIG. 6 shows a connection between adjacent planks; and

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] A first embodiment of the inventive assembly and fastener is disclosed in FIG. 1 and is represented by the reference numeral 10. The assembly includes floor or decking planks (hereinafter planks) 1 and a plurality of fastening clips 3 (one shown in FIG. 1). The planks 1 are longitudinal or elongated in shape and rest on a series of transversely-positioned joists 3.

[0016] A longitudinal side end of each plank has a tongue 7 with the opposing side edge having a groove 9. The tongue is sized to engage the groove 9 of an adjacent plank when the planks 1 are placed in a side-by-side relationship.

[0017] Referring to FIGS. 3 and 6, each clip 3 comprises a base 11 and a groove-engaging end portion 13. The base 11 is connected to the groove-engaging end portion 13 by a leg portion 15.

[0018] In the FIG. 3 embodiment, the base 11 has a throughhole 17 sized to receive a screw 19. The screw 19 extends through the throughhole 17 and is threadably attached to joist 5.

[0019] The FIG. 3 embodiment also shows a pair of protrusions 21 which extend from an underside of the base 11. The protrusions 21 extend into the joist 5 to further secure the clip thereto. The protrusions 21 also function as an anti-rotation feature so that the edge 23 of the groove-engaging portion 13 remains generally parallel to the longitudinal axis of the groove 9. In this way, the clip 3 does not rotate, and possibly disengage from the groove 9.

[0020] As shown in FIGS. 1, 3 and 6, the leg member 15 can be slightly curved in cross section to match a rounded edge 25 of a plank 1. The leg member 15 can be configured in other shapes to match the edges of a given plank.

[0021] Referring to FIG. 6 again, the end portion 13, when installed, is positioned between a face 29 of the groove 9 and a lower face 31 of the tongue 7. With the groove-engaging end portion 13 positioned as shown in FIG. 6, the planks 1 are in a tongue and groove engagement and retained against the joist 5. With this arrangement, no fasteners have to be driven through the planks 1. This is a significant advantage when the planks 1 are made from materials such as recycled and extruded plastic materials. Since these materials expand and contract at differing rates than the wood joist 5, the clips 3 allow for longitudinal expansion of the planks 1 while still maintaining the planks adjacent the joists.

[0022] FIG. 2 shows an exemplary method of forming the inventive flooring assembly. The fastening clips 3 can be installed using the proper measurements based on the width of the planks 1 at one time or in sequence after successive planks are laid on the joists. Once planks 1a and clips 3a are installed, another plank 1b is laid on the joists 5 with the leading edge 41 being positioned beneath the end portion 13 of the clip 3a. The plank 1b is then moved in the direction shown by the arrow in FIG. 2 so that the tongue 7 fully engages the groove 9 and the end portion 13a is securely engaged between the faces 31 and 29, see FIG. 6. This sequence of installation can then be repeated until all planks are laid on the transversely-arranged joists.

[0023] The plank 1b has its tongue removed so that it can flushly engage a side wall 43, where the joists 5 extend therefrom.

[0024] The clips 3 can be made of any material but are preferably made of high-strength material so that the end portion 13 is not easily bent in a direction to as to release the planks from the joists.

[0025] FIGS. 4 and 5 show alternative embodiments to the clip shown in FIG. 3. In FIG. 4, the base 11′ is shown with two throughholes 17 for clip attachment to a joist. In this embodiment, by virtue of the two attachment points via the screws 19, the protrusions 21 become optional.

[0026] FIG. 5 shows a clip 3b having four protrusions 21 in substitution for the combination of a screw and protrusions or multiple screws. In the FIG. 5, the base 11″ lacks any throughholes. In this embodiment, the protrusions or prongs 21 can be driven into a joist using a hammer or the like.

[0027] As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfills each and every one of the objects of the present invention as set forth above and provides new and improved flooring assembly and fastener therefor.

[0028] Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims.

Claims

1. A flooring assembly comprising:

a) a plurality of elongated flooring planks, each plank having at least one of a tongue-containing first longitudinal edge and a groove-containing second longitudinal edge;

b) a plurality of joist members, the plurality of flooring planks arranged on the joist members so that a tongue of one plank engages a groove of an adjacent plank;

c) a plurality of clips, each clip fastened to a respective joist and arranged between adjacent flooring planks, a distal end portion of each clip positioned between a lower face of the tongue of the one plank and an upper face of the groove of an adjacent plank;

d) whereby the clips retain adjacent planks to the joist members while permitting the planks to expand and contract longitudinally.

2. A flooring assembly comprising:

a) a plurality of elongated flooring planks, each plank having a tongue-containing first longitudinal edge and a tongue-containing second longitudinal edge;

b) a plurality of joist members, the plurality of flooring planks arranged on the joist members so that a tongue of one plank opposes a tongue of an adjacent plank;

c) a plurality of clips, each clip fastened to a respective joist and arranged between adjacent flooring planks, an end portion of each clip positioned in a groove of the one plank and the groove of an adjacent plank;

d) whereby the clips retain adjacent planks together while permitting the planks to expand and contract longitudinally.

3. The assembly of

claim 1, wherein each clip has a z-shape in vertical cross section.

4. The assembly of

claim 1 or

2, wherein each flooring plank is made of an extruded recycled plastic throughout.

5. The assembly of

claim 1 or

2, wherein the clips fastened to each joist are in a spaced apart relationship.

6. The assembly of

claim 1 or

2, wherein the joists are made of wood.

7. The assembly of

claim 1 or

2, wherein each clip further comprises a pair of prongs extending from a base portion of the clip, the prongs engaging the joist when the clips are fastened thereto.

8. A clip for fastening planks to a support surface comprising a base, at least one fastening means to secure the base to the support surface, a leg extending from the base, and a free end portion extending from the leg, the free end portion vertically spaced from the base and sized to engage a groove of one of adjacently positioned planks to retain the planks against the support surface.

9. A method of installing the assembly of

claim 1 or

2 comprising:

a) providing a plurality of floor planks;

b) fastening the clips in spaced apart relationship along joists arranged to support the plurality of floor planks;

c) arranging the floor planks on the joists in side-by-side relationship to create a flooring, the clips positioned between opposing longitudinal edges of adjacent planks to retain the planks on the joists.

10. The method of

claim 11, wherein the clips are fastened to prevent rotation thereof.

11. The clip of

claim 8, wherein the base includes means for preventing the base to rotate when attached to the support surface.