Deck system with deck clip

Abstract

A deck system with a deck clip. The deck system may include deck boards in which narrow channels may be formed in opposing side edges. The deck boards may be placed side by side during construction of a deck. The deck boards may be formed of composite building materials such as mixtures of wood flour and polyethylene. A rotatable deck clip may be used to fasten the deck boards to the deck joists. The clip may have a first overhang member and a second overhang member and may be wider in a first horizontal dimension and shorter in a second, perpendicular horizontal dimension. When the clip is rotated into a first position, its first and second overhang members may extend into the channels of adjacent deck boards to hold the deck boards securely in place. Removal of the deck boards may be accomplished by rotating the clip ninety degrees.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation in part of co-pending U.S. patent application Ser. No. 10/087,650, filed Mar. 1, 2002, entitled “DECK SYSTEM WITH DECK CLIP,” which is a continuation of U.S. patent application Ser. No. 09/981,323, filed Oct. 16, 2001 entitled “DECK SYSTEM WITH DECK CLIP,” now abandoned, which is a continuation of U.S. patent application Ser. No. 09/232,330, filed Jan. 15, 1999, entitled “DECK SYSTEM WITH DECK CLIP,” now U.S. Pat. No. 6,314,699, all of which are hereby incorporated by reference herein in their entireties, including but not limited to those portions that specifically appear hereinafter.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable.

BACKGROUND OF THE INVENTION

[0003] 1. The Field of the Invention

[0004] The present invention relates generally to the construction of decks, and more particularly, but not exclusively, to a decking release clip for securing and releasing deck boards to and from joists as part of a decking structure.

[0005] 2. Description of Related Art

[0006] Conventional methods of constructing decks, such as patio decking and the like, are adequate and generally effective, and yet they lack certain advantages. For example, it is known to construct a deck by placing deck boards side by side upon deck joists, then attaching the deck boards to the joists with nails or screws. If the owner of such a deck desires to replace one or more deck boards, for example due to damage or discoloration to the deck boards, the owner must undertake the laborious and time consuming steps of prying the deck boards from the joints if they are nailed, or unscrew the screws holding the deck boards. This can sometimes cause further damage to the deck boards or to the joists.

[0007] The prior art is thus characterized by several disadvantages that are addressed by the present invention. The present invention minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.

[0008] The features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the invention without undue experimentation. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:

[0010] FIG. 1 is a schematic, perspective view of a deck structure made in accordance with the principles of the present invention;

[0011] FIG. 1A is a break-away cross-sectional view of adjacent deck boards intercoupled by a deck clip made in accordance with the principles of the present invention;

[0012] FIG. 2 is a side view of a deck clip turning member;

[0013] FIG. 3 is a top view of the deck clip of FIG. 1A;

[0014] FIG. 4 is a side view of the deck clip of FIGS. 1A and 3;

[0015] FIG. 5 is an end view of the deck clip of FIGS. 1A, 3, and 4;

[0016] FIG. 6 is a cross-sectional view of a deck board, made in accordance with the principles of the present invention; and

[0017] FIG. 7 is a perspective view of a deck clip and an alternative embodiment of the deck board.

DETAILED DESCRIPTION OF THE INVENTION

[0018] For the purposes of promoting an understanding of the principles in accordance with the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed.

[0019] Applicant has discovered that the construction and maintenance of decks are greatly enhanced by designing the deck boards to be removable, modular components of the deck. Applicant has thus conceived of a deck system in which a deck clip is rotatably mounting on the decking support structure, usually joists, for selectively engaging the releasing the deck boards to the joists as desired.

[0020] Referring now to FIGS. 1-6, there is shown a deck system designated generally at 10, with a deck clip 12 rotatably mounted on a deck joist 14. The deck system 10 includes deck boards 16 in which receiving chambers 18 are formed. The receiving chambers 18 are formed in both opposing side edges 20 of each deck board 16, and each chamber 18 is defined in part by a lip edge 22. The deck boards 16 are placed side by side during construction of the deck 10, closely spaced, such that the lip edges 22 of adjacent deck boards 16 define a narrow channel space 24 therebetween in which the rotatable deck clip 12 is placed. The clip 12 has a first overhang member 28 and an opposing second overhang member 30 and is thereby wider in a first horizontal dimension 32 and shorter in a second, perpendicular horizontal dimension 34, and is rotatably attached to the deck joists 14 by a screw 36 or other fastening device. The screw 36 may of course be described as a means for penetrating the decking support structure or joists 14.

[0021] When the clip 12 is rotated into a first position as shown in FIG. 1A, its first and second overhang members 28 and 30 extend into the receiving chambers 18 of adjacent deck boards 16 and engage with the lip edges 22 of each chamber 18 to hold the deck boards 16 securely in place upon the joists 14. Users may easily remove a deck board 16 by simply rotating the clip 12 ninety degrees into a section position to thereby move the overhang members 28 and 30 of the clip 12 into the channel space 24 between the lip edges 22. The deck boards 16 are thereby released because the overhang members 28 and 30 no longer reside above, nor are engaged with, the lip edges 22 and the deck boards 16 can simply be lifted up. The clip 12 is rotated with a rotating member 40 shown in FIG. 2, which resembles a common screw driver except that it terminates in a distal end portion 42 that is square in cross section.

[0022] Referring more particularly to FIG. 4, the deck clip 12 may be described as a securing member 12 having a first portion 44 and a second portion 46 fixedly secured to the first portion 44. The first portion 44 includes the first overhang member 28 extending outwardly to define an extension portion that extends outwardly with respect to the second portion 46, and the second overhang member 30. The extension or overhang portion is configured and dimensioned to extend into the receiving chamber 18 formed in the deck board 16 as shown in FIG. 1A.

[0023] The rotating member 40 may described as a turning means for (i) turning the securing member or clip 12 in a first rotational direction to thereby move the extension or overhang portions 28 and 30 into engagement with deck board 16, specifically, into engagement with the lip edges 22, and (ii) turning the securing member or clip 12 in a second rotational direction to thereby move the extension or overhang portions 28 and 30 out of engagement with the deck board 16.

[0024] The first portion 44 of the securing member 12 is an upper portion, and the second portion 46 of the securing member 12 is a lower portion fixedly secured to the upper portion. The extension or overhang portion 28 of 30 of the upper portion 44 extends outwardly to define an overhang with respect to the lower portion 46, said overhang portion being configured and dimensioned to extend into the receiving chamber 18 formed in a deck board 16.

[0025] The screw 36 may be described as a fastening means for fastening the securing member or clip 12 to the decking support structure or joists 14, in a manner to permit rotational movement of the clip 12 about the screw 36. As such, the screw 36 may be further described as a fastening means for rotatably fastening the securing member or clip 12 to the decking support structure or joists 14.

[0026] The overhang portions 28 and 30 may be further described as a first cantilever portion extending outwardly in a first direction to form a first overhang with respect to the lower portion 46, and an opposing second cantilever portion extending outwardly in a second direction to form an opposing second overhang with respect to the lower portion 46, respectively. At least one, and preferably both, of the overhang portions includes a nub 48 formed on a lower surface thereof. The nub 48 preferably extends in an orthogonal direction with respect to the upper portion 44 of the securing member or clip 12, as shown most clearly in FIG. 3.

[0027] Referring more particularly to FIGS. 3-5, the securing member or clip 12 of course includes a through-passage 50 formed therein. The through-passage 50 extends sequentially through the first portion 44 of the clip 12 and the second portion 46 of the clip 12, respectively. The through-passage 50 includes a wider, upper portion 52 and a narrower, lower portion 54. The through-passage 50 may further include an intermediate portion 56 which is an annular ledge defined by a frusto-conical boundary as shown in FIG. 1A. Alternatively, the intermediate portion may instead comprise a planer annular ledge 58 as shown most clearly in FIGS. 3 and 4, said annular ledge 58 forming a boundary between the upper portion 52 and the lower portion 54 of the through-passage 50. The wider, upper portion 52 of the through-passage 50 preferably has a non-circular cross-sectional shape, and the narrower, lower portion 54 preferably has a circular cross-sectional shape.

[0028] The wider, upper portion 52 of the through-passage 50 is preferably square-shaped in cross section, but may constitute any non-circular shape desired, such as triangular, trapezoidal, and so forth. The cross-sectional area of the wider, upper portion 52 is preferably less than one-third, and more preferably less than one-fourth, of the area defined by an upper surface 60 of the securing member or clip 12.

[0029] The distal end portion 42 of the rotating member 40 is preferably narrower than the upper portion 52 of the through-passage 50 and wider than the lower portion 54 of the through-passage 50. The distal end portion 42 is configured and dimensioned to fit within the wider, upper portion 52 of the through-passage 50. A cross section of the distal end portion 42 of the rotating member 40, which rotating member may comprise a rod, defines a cross-sectional area that is at least seventy percent of a cross-sectional area defined by a cross section of the wider, upper portion 52 of the through-passage 50, and preferably at least ninety percent.

[0030] The rotating member 40 further comprises a gripping portion 58 having a plurality of channels 60 formed therein. The screw 36 includes seating means 37, in the form of a seating surface, for seating against the frusto-conical annular ledge 56 (in FIG. 1A) or the planer annular ledge 58 (in FIG. 4) to thereby prevent removal of the securing member or clip 12 from the decking support structure or joists 14.

[0031] The upper portion 44 of the clip 12 preferably includes an upper surface 60 having a generally rectangular dimension, and the lower portion 46 preferably has a generally circular cross section.

[0032] Stated in other terms, the securing member or clip 12 may be described in that the upper portion 44 has a first cantilever portion 28 extending outwardly in a first direction to form a first overhang with respect to the lower portion 46, and an opposing second cantilever portion 30 extending outwardly in a second direction to form an opposing second overhang with respect to the lower portion 46.

[0033] It is noted that the turning member 40 operates to turn the securing member or clip 12 without unfastening the screw 36 to thereby (i) turn the securing member or clip 12 into a first position as shown in FIG. 1A such that the nub 48 is disposed in engagement with the lip edge 22 of the deck board 16, and (ii) turn the securing member or clip 12 into a second position such that the nub 48 is no longer disposed in engagement with a deck board 16. Users may prefer to first loosen the screw 36 before turning the securing member or clip 12, if desired.

[0034] Referring now to FIGS. 1A and 6, it is shown that the receiving chamber 18 is defined in part by a channel member 66 having a J-shaped cross section. The cross-sectional dimensions of the receiving chamber 18 are larger than the cross-sectional dimensions of the upper portion 44 of the securing member or clip 12, in part to permit movement to accommodate expansion and contraction of the material of the deck boards 16 and of the clip 12. The nubs 48 are optional, but are preferred so as to inhibit rotational movement of the securing member or clip 12.

[0035] The channel member 66 and the receiving chamber 18 may extend along the entire length of the deck board 16. The deck boards 16 may be hollow or solid, and may be made from various different types of materials such as polyvinyl chloride material (PVC), or composite material. The hollow cross section of the deck boards 16 is defined by an upper wall 70, a bottom wall 72, a first sidewall 74 and an opposing second sidewall 76 extending from opposing sides of the upper wall 70, respectively, and a first corner wall 78 and an opposing second corner wall 80 interconnecting the first sidewall 74 with the bottom wall 72 and the second sidewall 76 with the bottom wall 72, respectively.

[0036] The J-shaped channel members 66 extend from opposing edges 82 of the bottom wall 72. Each of the J-shaped channel members 66 preferably includes a sidewall 84 that is disposed in a substantial co-planer orientation with respect to the bottom wall 72. The J-shaped channel members 66 comprise three sequentially intercoupled sidewalls as shown, one of which is the sidewall 84. Each corner wall 78 and 80 comprises two interconnected sidewalls as shown in FIG. 6, and all of the sequentially intercoupled sidewalls of the J-shaped channel members 66 are narrower than each sidewall of the corner walls 78 and 80.

[0037] It will be appreciated that the preferred embodiment of the securing member or clip 12 comprises a means for engaging simultaneously with J-shaped channel members 78 and 80 of two adjacent deck boards 16. The J-shaped channel members 78 and 80 are preferably made from a resilient material having elastic memory, such as polyvinyl chloride (PVC).

[0038] Reference will now to made to FIG. 7 to describe an alternative embodiment of the present invention. As previously discussed, the presently preferred embodiments of the invention illustrated herein are merely exemplary of the possible embodiments of the invention, including that illustrated in FIG. 7.

[0039] It will be appreciated that the embodiment of the invention illustrated in FIG. 7 contains many of the same structures represented in FIGS. 1-6 and only the new or different structures will be explained to most succinctly explain the additional advantages which come with the embodiments of the invention illustrated in FIG. 7. The alternative embodiment of the invention includes a deck board 16a which may have a series of hollow openings 90 separated by support walls 92. The hollow openings 90 reduce the weight and quantity of material required to construct the deck board 16a, whereas the support walls 92 provide rigidity to the deck board 16a.

[0040] It will be appreciated that the configuration of the deck board 16a may be favorable for use with various composite construction materials. For example the composite materials may contain resinous materials, such as thermoplastic and thermosetting resins, for example, PVC, polyethylene, polypropylene, nylon, polyesters, polysulfones, polyphenylene oxide and sulphide, epoxies, and cellulosics. Resins such as PVC can also be alloyed with other polymers, such as ABS, acrylic, polyurethane, and nitrile rubber to improve impact resistance, tear strength, resilience, or proccessability. The composite construction materials may also contain fiber, such as glass, wood, cotton, boron, carbon, or graphite fibers, for example. Additionally, inorganic fillers, such as calcium carbonate, talc, or silica, for example, can be used. Cellulosic fibers can be derived from recycled paper products, pulp, newsprint, soft woods, such as pine, or hard woods from deciduous trees.

[0041] One embodiment of the present invention includes deck boards 16a made from a composite material including a blend of wood flour and polyethylene. Such deck boards provide the advantage of being maintenance free and can be exposed to the elements for an extended period of time without significant degradation of appearance or strength. Moreover, the composite material deck boards may be sawed, drilled, and nailed in a similar manner as natural wood. The deck boards 16a made from composite construction materials may be extruded, using conventional plastics extrusion equipment and one or more dies to provide the desired cross section shape of each board.

[0042] It will be appreciated that the structure and apparatus disclosed herein is merely one example of a turning means for turning a securing member or clip 12, and it should be appreciated that any structure, apparatus or system for turning which performs functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a turning means for turning an item, including those structures, apparatus or systems for imparting rotation which are presently known, or which may become available in the future. Anything which functions the same as, or equivalently to, a turning means for turning an item such as the securing member or clip 12 or any other item falls within the scope of this element.

[0043] It will be appreciated that the structure and apparatus disclosed herein is merely one example of a securing means for releasably securing deck boards to a decking support structure, and it should be appreciated that any structure, apparatus or system for securing which performs functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a securing means for releasably securing one object to another, including those structures, apparatus or systems for securing which are presently known, or which may become available in the future. Anything which functions the same as, or equivalently to, a securing means for securing one object to another falls within the scope of this element.

[0044] In accordance with the features and combinations described above, a preferred method of securing deck boards in place as part of a decking structure includes the steps of:

[0045] (a) selecting a deck board having a receiving chamber formed therein;

[0046] (b) placing the deck board upon a deck support;

[0047] (c) attaching a securing member to any suitable structure, and positioning said securing member such that an overhang portion of said securing member extends into the receiving chamber of the deck board.

[0048] Those having ordinary skill in the relevant art will appreciate the advantages provided by the features of the present invention. For example, it is a feature of the present invention to provide a deck structure that is simple to assemble and permits easy removal of deck boards. It is another feature of the present invention to provide a deck structure that is modular. It is a further feature of the present invention to provide a deck system that includes light weight deck boards that are durable and have a pleasing appearance.

[0049] It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements. Thus, while the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made within the scope of permissible equivalents and be covered by the eventual claims, without departing from the principles and concepts set forth herein.

Claims

1. A decking system comprising:

a plurality of deck boards for placing on a decking support structure; and

securing means rotatably attachable to the decking support structure for releasably securing the deck boards to the decking support structure;

wherein the deck boards are constructed of a blend of wood flour and polyethylene.

2. The decking system of claim 1, wherein said deck boards comprise a plurality of hollow openings extending along a length of said deck boards.

3. The decking system of claim 2, wherein said plurality of hollow openings are separated by a plurality of vertical support walls.

4. The decking system of claim 1, further comprising fastening means for fastening the securing means to the decking support structure.

5. The decking system of claim 4, wherein the fastening means comprises means for rotatably fastening the securing means to the decking support structure.

6. The decking system of claim 1, wherein the securing means comprises a through passage formed therein.

7. The decking system of claim 6, wherein the through passage includes a wider, upper portion and a narrower, lower portion.

8. The decking system of claim 7, wherein the wider upper portion of the through passage comprises a non-circular cross-sectional shape.

9. The decking system of claim 7, wherein the narrower, lower portion of the through-passage has a circular cross-sectional shape.

10. The decking system of claim 1, wherein the securing means comprises a first portion and a second portion fixedly secured to the first portion, said first portion having an overhang portion extending outwardly to define an extension portion that extends outwardly with respect to the second portion, said extension portion being configured and dimensioned to extend into a receiving chamber formed in said deck boards.

11. The decking system of claim 10, further comprising:

turning means for (i) turning the securing means in a first rotational direction to thereby move the extension portion into engagement with a deck board, and (ii) turning the securing means in a second rotational direction to thereby move the extension portion out of engagement with the deck board.

12. A decking system comprising:

a plurality of deck boards for placing on a decking support structure; and

securing means rotatably attachable to the decking support structure for releasably securing the deck boards to the decking support structure;

wherein the deck boards are constructed of PVC resin and fiber.

13. The decking system of claim 12, wherein said deck boards comprise a plurality of hollow openings extending along a length of said deck boards.

14. The decking system of claim 13, wherein said plurality of hollow openings are separated by a plurality of vertical support walls.

15. The decking system of claim 12, further comprising fastening means for fastening the securing means to the decking support structure.

16. The decking system of claim 15, wherein the fastening means comprises means for rotatably fastening the securing means to the decking support structure.

17. The decking system of claim 12, wherein the securing means comprises a through passage formed therein.

18. The decking system of claim 17, wherein the through passage includes a wider, upper portion and a narrower, lower portion.

19. The decking system of claim 18, wherein the wider upper portion of the through passage comprises a non-circular cross-sectional shape.

20. The decking system of claim 18, wherein the narrower, lower portion of the through-passage has a circular cross-sectional shape.

21. The decking system of claim 12, wherein the securing means comprises a first portion and a second portion fixedly secured to the first portion, said first portion having an overhang portion extending outwardly to define an extension portion that extends outwardly with respect to the second portion, said extension portion being configured and dimensioned to extend into a receiving chamber formed in said deck boards.

22. The decking system of claim 21, further comprising:

turning means for (i) turning the securing means in a first rotational direction to thereby move the extension portion into engagement with a deck board, and (ii) turning the securing means in a second rotational direction to thereby move the extension portion out of engagement with the deck board.

23. The decking system of claim 12, wherein said plurality of deck boards each comprise a receiving chamber for receiving said securing means.

24. A decking system comprising:

a plurality of deck boards for placing on a decking support structure, said plurality of deck boards each comprising a receiving chamber; and

a securing member having a first portion and a second portion fixedly secured to the first portion, said first portion having an overhang portion extending outwardly to define an extension portion that extends outwardly with respect to the second portion, said extension portion being configured and dimensioned to extend into said receiving chamber;

wherein said securing member is rotatable from a position in which said extension portion is engaged with said receiving chamber to a position in which said extension portion is out of engagement with said receiving chamber.

25. The decking system of claim 24, wherein said deck boards comprise a plurality of hollow openings extending along a length of said deck boards.

26. The decking system of claim 25, wherein said plurality of hollow openings are separated by a plurality of vertical support walls.

27. The decking system of claim 24, wherein said deck boards are constructed of a blend of wood flour and polyethylene.

28. The decking system of claim 24, wherein said deck boards are constructed of a blend of PVC resin and fiber.

29. The decking system of claim 24, further comprising fastening means for fastening the securing member to the decking support structure.

30. The decking system of claim 29, wherein the fastening means comprises means for rotatably fastening the securing member to the decking support structure.

31. The decking system of claim 24, wherein the securing member comprises a through passage formed therein.

32. The decking system of claim 31, wherein the through passage includes a wider, upper portion and a narrower, lower portion.

33. The decking system of claim 32, wherein the wider upper portion of the through passage comprises a non-circular cross-sectional shape.

34. The decking system of claim 32, wherein the narrower, lower portion of the through-passage has a circular cross-sectional shape.

35. The decking system of claim 24, further comprising:

turning means for (i) turning the securing member in a first rotational direction to thereby move the extension portion into engagement with a deck board, and (ii) turning the securing member in a second rotational direction to thereby move the extension portion out of engagement with the deck board.