Extrusion for use in a floor assembly
An extrusion for use in a floor assembly including a load bearing horizontal portion and at least one horizontal support member in a substantially parallel horizontal plane, and a plurality of leg members extending downwardly from the load bearing horizontal portion. The extrusion also includes a tongue extending outwardly from a first outside surface thereof and a receiving portion provided at the second outside surface thereof that is sized and positioned to receive therein a tongue of a second extrusion forming a part of the floor assembly. The second outside surface also includes at least one aperture that is sized and positioned to receive therethrough at least one fastener for securing the extrusion to a rigid underlying support such as a plurality of wood joists.
The present invention relates to floor assemblies, and more particularly, to extrusions, such as plastic extrusions, which are connected to a rigid underlying support, such as a plurality of wood joists, to form a floor assembly.
BACKGROUND OF THE INVENTIONIt is very well known to construct floor assemblies, such as decks for homes and boat docks, using wood planks secured to an underlying support, such as spaced wood joists. There are, however, several disadvantages with using exposed wood planks for these applications. Wood, if left untreated, can quickly rot, thus requiring replacement of some if not all of the wood planks. This occurs especially for wood decks and boat docks that are subject to outdoor weather conditions such as rain, snow and sunlight. In addition, wood planks can shrink, creating unsightly and dangerous gaps in the planking. Finally, wood is becoming more and more expensive.
Pressure treated lumber is widely used to protect the wood from rotting. However, even pressure treated lumber begins to rot over time with exposure to the elements. In addition, it is recommended by most vendors of pressure treated lumber that a protectant be applied to the wood. This protectant usually must be applied annually. This is a major disadvantage of wood decks, due to the expense and time-consuming nature of applying and reapplying this protectant year after year. Failure to be diligent in these applications can lead to early rotting of the exposed wood planks and the major expense and inconvenience of replacing some if not all of the wood planks.
It is known to provide a floor assembly constructed of a number of elongated extrusions. For example, U.S. Pat. No. 5,553,427 to Andres and U.S. Pat. No. 6,112,479 to Andres, owned by the assignee hereof, the disclosures of which are incorporated herein by reference, each describe a floor assembly constructed of a number of elongated extrusions each secured to an elongated snap connector, which in turn is secured to a rigid underlying support such as a plurality of spaced wood joists. While these floor assemblies are effective and well-suited for their intended purposes, improvements and advancements, which would result in even better floor assemblies, are desirable.
SUMMARY OF THE INVENTIONThe present invention relates to an extrusion for use in a floor assembly such as an outdoor residential deck, boat dock, patio enclosure, dance floor or any other flooring assembly where materials such as wood are currently used. The extrusion includes a load bearing horizontal portion in a first horizontal plane and at least one horizontal support member in a second horizontal plane substantially parallel to the first horizontal plane. The extrusion also includes a first outside surface located adjacent to a first end of the at least one horizontal support member and a second outside surface located adjacent to a second end of the at least one horizontal support member and opposite the first outside surface. A plurality of leg members extend downwardly from the load bearing horizontal portion. In addition, a tongue extends outwardly from the first outside surface and the second outside surface includes a receiving portion that is sized and positioned to receive therein a tongue of a second extrusion forming a part of the floor assembly. The at least one horizontal support surface also includes at least one first aperture that is sized and positioned to receive therethrough at least one fastener for securing the extrusion to a rigid underlying support such as a plurality of wood joists. The at least one first aperture is located between the receiving portion and the first outside surface at a position that is adjacent to the receiving portion. The plurality of leg members may comprise a first outer leg member and a second outer leg member, and the tongue may be connected to the first end of the at least one horizontal support member, with the receiving portion being part of the second outer leg member. The extrusion may also include at least one second aperture provided in the second outer leg member. In one embodiment, the at least one horizontal support member includes a first horizontal support member and a second horizontal support member, with the tongue being connected to the first horizontal support member and the at least one first aperture being provided in the second horizontal support member.
In another embodiment of the extrusion, the at least one horizontal support member includes a first horizontal support member and a second horizontal support member, and the extrusion further includes a first inner leg member connected to the first horizontal support member and a second inner leg member connected to the second horizontal support member. The first and second inner leg members define a channel disposed along a longitudinal axis of the extrusion for receiving a snap connector secured to the rigid underlying support. The first inner leg member and the second inner leg member may also include a retaining tab which cooperates with the snap connector for mechanically securing the extrusion to the snap connector and thus to the rigid underlying support.
In another embodiment of the extrusion, the at least one first aperture may include a plurality of first apertures, and the at least one second aperture may include a plurality of second apertures, wherein each of the first apertures is aligned with a corresponding one of the second apertures such that each first aperture and the corresponding second aperture are adapted to receive therethrough a fastener for securing the extrusion to the rigid underlying support. The apertures may each be an elongated slot, and are preferably sized to allow water and debris to pass therethrough, from the load bearing horizontal portion, when a fastener is inserted therethrough.
The receiving portion of the extrusion may be an overhang portion, wherein the second outer leg member includes a vertical member extending upwardly from the at least one horizontal support member and a horizontal member connected to the vertical member, the vertical member and the horizontal member forming the overhang portion. In addition, the second outer leg member may further include an outwardly and downwardly extending angled member, with the at least one second aperture being provided in the angled member.
The extrusion is preferably made of an extruded plastic material, such as PVC material. The extrusion may also be made of a first extruded material and a second extruded material, wherein the second extruded material forms the outer surface of the extrusion. The first extrusion material may be recycled PVC material and the second extruded material may be virgin PVC material. Furthermore, the load-bearing horizontal portion may include a plurality of depressions on the exposed surface thereof. Also, the extrusion may further include at least one soft layer attached to the bottom surface of the at least one horizontal support member, wherein the load-bearing horizontal portion, the at least one horizontal support member and the plurality of leg members are made of a first material, and the soft material is a material having a durometer that is softer than a durometer of the first material. Such a soft material may be soft PVC.
The present invention also relates to a floor assembly including a plurality of extrusions according to one or more of the embodiments just described, wherein each of the extrusions is secured to a rigid underlying support by at least one fastener inserted through the at least one first aperture of each extrusion and into the rigid underlying support, and wherein each of the receiving portions of each of the extrusions except for a last extrusion forming the floor assembly receives therein the tongue of the extrusion located directly adjacent thereto. In one embodiment, the floor assembly comprises a plurality of snap connectors secured to the rigid underlying support, and each of the extrusions forming the floor assembly is mechanically secured to a corresponding one of the snap connectors. In another embodiment, the floor assembly includes one or more snap connectors secured to the rigid underlying support, and each of one or more of the extrusions is mechanically secured to a corresponding one of the snap connectors. In this embodiment, the one or more snap connectors may include first and second snap connectors secured to the rigid underlying support, and a first one of the extrusions may be mechanically secured to the first snap connector and a second one of the extrusions may be mechanically secured to the second snap connector. In addition, the first one of the extrusions may be a first extrusion forming the floor assembly, such as an extrusion located adjacent to a wall, and the second one of the extrusions may be the last extrusion forming the floor assembly, that is the extrusion located farthest away from the first extrusion. In yet another embodiment, no snap connectors are used at all, and instead each extrusion is secured to the rigid underlying support using fasteners inserted through the apertures of the extrusion.
BRIEF DESCRIPTION OF THE DRAWINGSFurther features and advantages of the present invention will be apparent upon consideration of the following detailed description of the present invention, taken in conjunction with the following drawings, in which like reference characters refer to like parts, and in which:
The extrusions shown herein are used to form floor assemblies, such as an outdoor residential deck. It will be appreciated, however, that there are numerous other uses for the extrusions disclosed herein including, but not limited to, boat docks, enclosure patios, dance floors or any flooring assembly where other materials, such as wood, are currently used. Therefore, although the description set forth herein focuses on a residential deck, it will be appreciated that the invention is not so limited and can encompass other flooring assemblies such as those mentioned above as well as more.
Referring to
Horizontal support member 35 includes tongue 55 extending outwardly therefrom at an end of horizontal support member 35 located opposite retaining tab 45. Tongue 55 thus extends outwardly from the first outside surface of extrusion 5. Tongue 55 preferably extends along the longitudinal axis of extrusion 5 along the entire length thereof, although it is possible that it extend along only a part of such length. Outer leg member 20 includes a lower portion 60 that includes outwardly and downwardly extending angled member 65, first vertical member 70, horizontal member 75 and second vertical member 80. As seen in
As shown in
Extrusion 5 preferably consists of a substrate made of an extruded plastic material, such as polyvinyl chloride (PVC). Most preferably, extrusion 5 is made of recycled PVC covered by a co-extruded virgin capstock material, such as weatherable, hard, virgin PVC material. It will be appreciated that recycled PVC can, in this most preferred embodiment, be used in the substrate because the substrate has all of its exposed surfaces covered by the virgin capstock material. Thus, the bulk of the extrusion can be made of less expensive, less attractive and readily available recycled PVC. In addition, the virgin capstock material is preferably applied to the substrate so as to provide a crown on the top surface and at the center of extrusion 5. Advantageously, this allows water, such as rain, to run off of extrusion 5.
In order to eliminate annoying squeaking sounds which may be made when load bearing objects, such as persons, move across the floor, a soft, PVC layer or layers may be applied to the bottom surface of each of the horizontal support members 35 and 40. This layer (or layers) has a softer durometer than the PVC used for the remainder of extrusion 5. In this way, the soft layers act as a cushion between the rigid underlying support, such as a wood joist, and the remainder of extrusion 5 so that there is not rigid structure-to-rigid structure contact therebetween. This, in turn, eliminates the annoying squeaking sound common to such floor assemblies.
Referring to
According to a first embodiment of the present invention shown in
Once extrusion 5A, and in particular retaining tabs 45 and 50, are pressed down far enough to clear bottom sections 145 and 150 of flanges 125 and 130, extrusion 5A and snap connector 100 snap into position as shown in
Next, referring to
According to an alternate embodiment of the present invention, snap connectors 100 are only used in connection with certain extrusions 5 used to create the floor assembly. In other words, not every extrusion 5 used to create the floor assembly is secured to a corresponding snap connector 100. In this embodiment, shown in
In yet another embodiment of the present invention shown in
In any of the embodiments described herein, an elongated end cap (not shown) as is known in the art may be provided over the outside surface (including outer leg member 20) of the last extrusion 5 forming the floor assembly (i.e., the extrusion 5 positioned opposite wall 65). Such an end cap covers outer leg member 20, giving the floor assembly a more pleading finished look.
The terms and expressions which have been employed herein are used as terms of description and not as limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the invention claimed. Although particular embodiments of the present invention have been illustrated in the foregoing detailed description, it is to be further understood that the present invention is not to be limited to just the embodiments disclosed, but that they are capable of numerous rearrangements, modifications and substitutions. For example, an alternate extrusion 5 may be constructed having only a single horizontal support member instead of two horizontal support members such as horizontal support members 35 and 40. In such an extrusion 5, there would be no channel created by inner leg members for receiving a snap connector 100, such as the channel created by inner leg members 25 and 30. Thus, such an extrusion 5 would only be able to be utilized in embodiments, or portions thereof, where a snap connector 100 is not used to secure the extrusion 5 to a rigid underlying support.
Claims
1. An extrusion for use in a floor assembly, comprising:
- a load bearing horizontal portion in a first horizontal plane;
- at least one horizontal support member in a second horizontal plane substantially parallel to said first horizontal plane, said extrusion having a first outside surface located adjacent to a first end of said at least one horizontal support member and a second outside surface located adjacent to a second end of said at least one horizontal support member and opposite said first outside surface;
- a plurality of leg members extending downwardly from said load bearing horizontal portion;
- a tongue extending outwardly from said first outside surface, said second outside surface having a receiving portion sized and positioned to receive a tongue of a second extrusion therein;
- said at least one horizontal support surface having at least one first aperture, said at least one first aperture being sized and positioned to receive therethrough at least one fastener for securing said extrusion to a rigid underlying support, said at least one first aperture being located between said receiving portion and said first outside surface at a position that is adjacent to said receiving portion.
2. An extrusion according to claim 1, said plurality of leg members comprising a first outer leg member and a second outer leg member, said tongue being connected to said first end of said at least one horizontal support member, said receiving portion being part of said second outer leg member.
3. An apparatus according to claim 2, further comprising at least one aperture provided in said second outer leg member.
4. An extrusion according to claim 3, said at least one horizontal support member comprising a first horizontal support member and a second horizontal support member, said tongue being connected to said first horizontal support member, said at least one first aperture being provided in said second horizontal support member.
5. An extrusion according to claim 1, said at least one horizontal support member comprising a first horizontal support member and a second horizontal support member, said extrusion further comprising a first inner leg member connected to said first horizontal support member and a second inner leg member connected to said second horizontal support member, said first and second inner leg members defining a channel disposed along a longitudinal axis of said extrusion for receiving a snap connector secured to said rigid underlying support.
6. An extrusion according to claim 5, said first inner leg member and said second inner leg member each including a retaining tab which cooperates with said snap connector for mechanically securing said extrusion to said snap connector.
7. An extrusion according to claim 3, said at least one first aperture comprising a plurality of first apertures, said at least one second aperture comprising a plurality of second apertures, each of said first apertures being aligned with a corresponding one of said second apertures such that each said first aperture and the corresponding second aperture are adapted to receive therethrough a fastener for securing said extrusion to said rigid underlying support.
8. An extrusion according to claim 3, said at least one first aperture and said at least one second aperture each being an elongated slot.
9. An extrusion according to claim 3, said at least one first aperture being aligned with said at least one second aperture such that said at least one first aperture and said at least one second aperture are adapted to receive therethrough said at least one fastener, said at least one first aperture and said at least one second aperture being sized to allow water and debris to pass therethrough when said at least one fastener is received therethrough.
10. An extrusion according to claim 7, each of said first and second apertures being an elongated slot.
11. An extrusion according to claim 7, each of said first and second apertures being sized to allow water and debris to pass therethrough when a fastener is received through each said first aperture and the corresponding second aperture.
12. An extrusion according to claim 2, said receiving portion being an overhang portion, said second outer leg member including a vertical member extending upwardly from said at least one horizontal support member and a horizontal member connected to said vertical member, said vertical member and said horizontal member forming said overhang portion.
13. An extrusion according to claim 3, said second outer leg member including an outwardly and downwardly extending angled member, said at least one second aperture being provided in said angled member.
14. An extrusion according to claim 7, said second outer leg member including an outwardly and downwardly extending angled member, said plurality of second apertures being provided in said angled member.
15. An extrusion according to claim 1, said extrusion having a longitudinal axis, said tongue and said receiving portion extending along an entire length of said extrusion along said longitudinal axis.
16. An extrusion according to claim 1, said extrusion being made of an extruded plastic material.
17. An extrusion according to claim 16, said plastic material being PVC material.
18. An extrusion according to claim 1, said extrusion being made of a first extruded material and a second extruded material, said second extruded material forming an outer surface of said extrusion.
19. An extrusion according to claim 18, said first extruded material being recycled PVC material and said second extruded material being virgin PVC material.
20. An extrusion according to claim 1, said load bearing horizontal portion having an exposed surface, said exposed surface having a plurality of depressions.
21. An extrusion according to claim 1, further comprising at least one soft material layer attached to a bottom surface of said at least one horizontal support member, said load bearing horizontal portion, said at least one horizontal support member, and said plurality of leg members being made of a first material, said soft material having a durometer that is softer than a durometer of said first material.
22. An extrusion according to claim 21, said soft material layer being soft PVC.
23. A floor assembly, comprising:
- a plurality of extrusions, each extrusion including: a load bearing horizontal portion in a first horizontal plane; at least one horizontal support member in a second horizontal plane substantially parallel to said first horizontal plane, said extrusion having a first outside surface located adjacent to a first end of said at least one horizontal support member and a second outside surface located adjacent to a second end of said at least one horizontal support member and opposite said first outside surface; a plurality of leg members extending downwardly from said load bearing horizontal portion; a tongue extending outwardly from said first outside surface, said second outside surface having a receiving portion sized and positioned to receive therein a tongue of an adjacent one of said plurality of extrusions; said at least one horizontal support surface having at least one first aperture, said at least one first aperture being located between said receiving portion and said first outside surface at a position that is adjacent to said receiving portion;
- each of said extrusions being secured to a rigid underlying support by at least one fastener inserted through said at least one first aperture and into said rigid underlying supporting, each of said receiving portions of each of said extrusions except for a last one of said extrusions forming said floor assembly receiving therein the tongue of the extrusion located directly adjacent thereto.
24. A floor assembly according to claim 23, said plurality of leg members comprising a first outer leg member and a second outer leg member, said tongue being connected to said first end of said at least one horizontal support member, said receiving portion being part of said second outer leg member.
25. A floor assembly according to claim 24, each said extrusion further comprising at least one second aperture provided in said second outer leg member.
26. A floor assembly according to claim 23, further comprising a plurality of snap connectors secured to said rigid underlying support, each of said extrusions being mechanically secured to a corresponding one of said snap connectors.
27. A floor assembly according to claim 26, said at least one horizontal support member comprising a first horizontal support member and a second horizontal support member, each said extrusion further comprising a first inner leg member connected to said first horizontal support member and a second inner leg member connected to said second horizontal support member, said first and second inner leg members defining a channel disposed along a longitudinal axis of said extrusion for receiving said corresponding one of said snap connectors.
28. A floor assembly according to claim 27, each of said first inner leg members and said second inner leg members including a retaining tab which cooperates with said corresponding one of said snap connectors for mechanically securing said extrusion to said corresponding one of said snap connectors.
29. A floor assembly according to claim 28, each of said snap connectors including an elongated base portion and a pair of flanges attached to opposite sides of said base portion, each said flange including a pilot surface to facilitate mechanical securing of the corresponding extrusion thereto.
30. A floor assembly according to claim 23, further comprising one or more snap connectors secured to said rigid underlying support, each of one or more of said extrusions being mechanically secured to a corresponding one of said one or more snap connectors.
31. A floor assembly according to claim 30, said at least one horizontal support member of each of said extrusions mechanically secured to a corresponding one of said one or more snap connectors comprising a first horizontal support member and a second horizontal support member, each of said extrusions mechanically secured to a corresponding one of said one or more snap connectors further comprising a first inner leg member connected to said first horizontal support member and a second inner leg member connected to said second horizontal support member, said first and second inner leg members defining a channel disposed along a longitudinal axis of said extrusion for receiving said corresponding one of said one or more snap connectors.
32. A floor assembly according to claim 31, each of said first inner leg members and said second inner leg members including a retaining tab which cooperates with said corresponding one of said one or more snap connectors for mechanically securing said extrusion to said corresponding one of said one or more snap connectors.
33. A floor assembly according to claim 32, each of said snap connectors including an elongated base portion and a pair of flanges attached to opposite sides of said base portion, each said flange including a pilot surface to facilitate mechanical securing of the corresponding extrusion thereto.
34. A floor assembly according to claim 21, further comprising first and second snap connectors secured to said rigid underlying support, a first one of said extrusions being mechanically secured to said first snap connector and a second one of said extrusions being mechanically secured to said second snap connector.
35. A floor assembly according to claim 30, said at least one horizontal support member of said first one of said extrusions and said second one of said extrusions comprising a first horizontal support member and a second horizontal support member, said first one of said extrusions and said second one of said extrusions each further comprising a first inner leg member connected to said first horizontal support member and a second inner leg member connected to said second horizontal support member, said first and second inner leg members defining a channel disposed along a longitudinal axis of said extrusion, said channel of said first one of said extrusions for receiving said first snap connector and said channel of said second one of said extrusions for receiving said second snap connector.
36. A floor assembly according to claim 35, each of said first inner leg members and said second inner leg members including a retaining tab, said retaining tabs of said first one of said extrusions cooperating with said first snap connector for mechanically securing said first one of said extrusions to said first snap connector and said retaining tabs of said second one of said extrusions cooperating with said second snap connector for mechanically securing said second one of said extrusions to said second snap connector.
37. A floor assembly according to claim 36, each of said first and second snap connectors including an elongated base portion and a pair of flanges attached to opposite sides of said base portion, each said flange including a pilot surface to facilitate mechanical securing of the corresponding extrusion thereto.
38. A floor assembly according to claim 34, said first one of said extrusions being a first extrusion forming said floor assembly and said second one of said extrusions being a last extrusion forming said floor assembly.
39. A floor assembly according to claim 25, said at least one horizontal support member comprising a first horizontal support member and a second horizontal support member, said tongue being connected to said first horizontal support member, said at least one first aperture being provided in said second horizontal support member.
40. A floor assembly according to claim 25, said at least one first aperture comprising a plurality of first apertures, said at least one second aperture comprising a plurality of second apertures, and said at least one fastener comprising a plurality of fasteners, each of said first apertures being aligned with a corresponding one of said second apertures, each said first aperture and the corresponding second aperture having inserted therethrough and into said rigid underlying support one of said fasteners.
41. A floor assembly according to claim 25, said at least one first aperture and said at least one second aperture each being an elongated slot.
42. A floor assembly according to claim 25, said at least one first aperture being aligned with said at least one second aperture such that said at least one first aperture and said at least one second aperture are adapted to receive therethrough said at least one fastener, said at least one first aperture and said at least one second aperture being sized to allow water and debris to pass therethrough when said at least one fastener is received therethrough.
43. A floor assembly according to claim 40, each of said first and second apertures being an elongated slot.
44. A floor assembly according to claim 40, each of said first and second apertures being sized to allow water and debris to pass therethrough when said one of said fasteners is received through each said first aperture and the corresponding second aperture.
45. A floor assembly according to claim 24, said receiving portion being an overhang portion, said second outer leg member including a vertical member extending upwardly from said at least one horizontal support member and a horizontal member connected to said vertical member, said vertical member and said horizontal member forming said overhang portion.
46. A floor assembly according to claim 25, said second outer leg member including an outwardly and downwardly extending angled member, said at least one second aperture being provided in said angled member.
47. A floor assembly according to claim 40, said second outer leg member including an outwardly and downwardly extending angled member, said plurality of second apertures being provided in said angled member.
48. A floor assembly according to claim 23, each of said extrusions having a longitudinal axis, each of said tongues and said receiving portions extending along an entire length of each of said extrusions along said longitudinal axis.
49. A floor assembly according to claim 23, each of said extrusions being made of an extruded plastic material.
50. A floor assembly according to claim 49, said plastic material being PVC material.
51. A floor assembly according to claim 23, each of said extrusions being made of a first extruded material and a second extruded material, said second extruded material forming an outer surface of each of said extrusions.
52. A floor assembly according to claim 51, said first extruded material being recycled PVC material and said second extruded material being virgin PVC material.
53. A floor assembly according to claim 23, said load bearing horizontal portion having an exposed surface, said exposed surface having a plurality of depressions.
54. A floor assembly according to claim 23, each of said extrusions further comprising at least one soft material layer attached to a bottom surface of said at least one horizontal support member, said load bearing horizontal portion, said at least one horizontal support member, and said plurality of leg members being made of a first material, said soft material having a durometer that is softer than a durometer of said first material.
55. A floor assembly according to claim 54, said soft material layer being soft PVC.
56. A floor assembly according to claim 23, wherein each of said at least one first apertures of each of said extrusions is not obscured by the tongue of the extrusion located directly adjacent thereto.
57. A floor assembly according to claim 40, wherein each said first aperture and the corresponding second aperture of each of the extrusions define a continuous channel for allowing water and debris to pass from the load bearing horizontal portion of the extrusion through said channel.
Type: Application
Filed: Jun 7, 2004
Publication Date: Dec 29, 2005
Inventor: Thomas Andres (N. Versailles, PA)
Application Number: 10/862,841