Extruded Aluminum Deck Plank with Lighting and Heating Features
An extruded aluminum deck plank includes a pair of longitudinally extending parallel tubular plank halves interconnected by a web extending between the lower walls of the plank halves. The inner side walls of the plank halves and the web define a U-shaped channel adapted to receive fasteners that are inserted vertically into the channel, through the web and into underlying deck plank supports. A closure strip for the channel snaps into the top of the channel to provide a smooth top surface for the deck plank and to close off the channel. The channel may be lighted and/or heated with an appropriate energy source enclosed in the channel.
This application relates to and claims priority from U.S. Provisional Application Ser. No. 61/239,474, filed Sep. 3, 2009; Ser. No. 61/243,342, filed Sep. 17, 2009; and Ser. No. 61/247,353, filed Sep. 30, 2009.
BACKGROUND OF THE INVENTIONThe subject invention pertains to planks for use in the construction of decks, piers and the like and, more particularly, to an extruded aluminum deck plank that provides simple and effective arrangements for attaching side-by-side to an underlying wooden support and for attaching the planks end-to-end.
It is well known in the art to use extruded aluminum planks in structures such as bleachers. In these structures, the extruded aluminum planks may serve both as the seat member and the foot rest. However, typical attachment of these extruded members to underlying supports require complex fastening systems.
It is also well known in the art to make deck planks from plastic extrusions. Such plastic extrusions are commonly used for decks and piers, but have typically not found successful use in bleachers where the loads are greater and typically more concentrated. Furthermore, plastic is not considered to be as durable as aluminum, particularly in outdoor applications.
SUMMARY OF THE INVENTIONIn accordance with the present invention, an extruded aluminum deck plank utilizes two rectangular plank halves extruded together and connected at their lower surfaces with a narrow web. The lower plank half walls and connecting web are coplanar and the connecting web is provided with holes for the receipt of screws or other connectors driven through the connecting web and into an underlying wooden support member. Inner side walls of the plank halves form, with the connecting web, a U-shaped channel that is closed (after fastening) with a long aluminum closure strip that is snapped into the channel and has an upper surface generally coplanar with the upper surfaces of the plank halves.
The closure strip has a generally inverted U-shape cross section and the upper surface of the closure strip joins two integrally formed downwardly depending side walls that engage the side surfaces of the U-shaped channel with engaging ribs to hold the closure strip in place.
Provision is also made for connecting the deck planks end-to-end with splice pieces inserted into and joining the ends of longitudinally adjacent plank halves.
In an alternate embodiment of the invention, the U-shaped channel is provided with a string of LED lights and the closure strip is made from a transparent or other light-transmitting plastic material.
In a modified deck plank, an extruded cross section is provided that imparts a longitudinal rib surface along the surfaces of the U-shaped channel as well as the corresponding inside surfaces of the plank halves. The ribs provide a heat sink for heat generated by the string of LED lights and the heat is conducted away from the ribs to the plank surfaces to inhibit the formation of ice and to dry accumulated moisture. A strip of heat tape may be used instead for heating.
Referring initially to
The narrow connecting web 14 forms with the interior side walls 17 of the plank halves a U-shaped channel 18. Suitable fasteners, such as screws 20, may be inserted through holes in the connecting web 14 and driven into an underlying wooden support 21 as shown in
Once a deck plank 10 has been fastened to one or more suitable wooden joists or supports 21, the U-shaped channel 18 is closed by pressing the closure strip 11 into the channel 18 where it is snapped and locked into position. When locked in place, the horizontal upper surface 22 of the closure strip lies generally coplanar with the upper surfaces 15 of the plank halves 12.
As best seen in
As shown in
Although the splice pieces 26 used to join the ends of adjacent longitudinally extending planks 10 are preferably made of aluminum extrusions, they could be made of plastic or wood. However, aluminum extrusions are still preferred because of their enhanced strength and durability as compared to plastic or wood materials.
As also best seen in
Referring to
By using the embodiment of
A modified deck plank 33 is shown in
In the embodiment best shown in
Heat may also be provided by substituting a heat tape for the light string 30. This would, of course, eliminate the lighting feature, but still utilize the heating feature.
Claims
1. An extruded aluminum deck plank comprising:
- a pair of longitudinally extending parallel tubular plank halves, said plank halves being laterally spaced apart and each plank halve having upper and lower walls connected by outer and inner side walls,
- an integral connecting web coplanar with the lower wall of the plank halves and extending between and connecting the plank halves, the web and the opposed inner side surfaces of the inner side walls defining a U-shaped channel, the channel adapted to receive fasteners inserted vertically into the channel, through the web and into underlying deck plank supports, and
- a closure strip for the channel having an inverted U-shaped cross section, the closure strip having a generally planar upper surface and downwardly depending side walls, the closure strip closing the channel with the upper surface of the strip generally coplanar with the upper surfaces of the plank halves, and the side walls of the strips in locked engagement with the opposed inner side surfaces of the channel.
2. The deck plank as set forth in claim 1 wherein the closure strip is aluminum.
3. The deck plank as set forth in claim 2 wherein the closure strip comprises an aluminum extrusion.
4. The deck plank as set forth in claim 1 wherein the closure strip is plastic.
5. The deck plank as set forth in claim 4 wherein the closure strip comprises a plastic extrusion.
6. The deck plank as set forth in claim 1 comprising an energy source enclosed in the channel.
7. The deck plank as set forth in claim 6 wherein the closure strip comprises transparent plastic, and the energy source comprises a light string extending along the channel.
8. The deck plank as set forth in claim 6 wherein the energy source comprises a heat tape extending along the channel.
9. The deck plank as set forth in claim 6 wherein the inner and outer side surfaces of the inner side walls are provided with longitudinally extending ribs to enhance heat transfer from the channel to the interior of the plank halves.
10. The deck plank as set forth in claim 9 wherein the longitudinal ribs on the inner side surfaces are smaller than the longitudinal ribs on the outer side surfaces.
11. The deck plank as set forth in claim 1 including holes for the fasteners in the web extending along the channel.
12. The deck plank as set forth in claim 1 wherein the opposed inner surfaces of the inner side walls have a longitudinally extending locking rib positioned to be overridden by longitudinally extending oppositely facing detent ribs on the closure strip to provide the locked engagement.
13. The deck plank as set forth in claim 1 including splice pieces inserted into the interior of longitudinally adjacent deck planks to join the planks together.
14. The deck plank as set forth in claim 13 wherein the splice pieces comprise aluminum extrusions.
15. The deck plank as set forth in claim 14 wherein the extrusions have a C-shaped cross section.
Type: Application
Filed: Sep 2, 2010
Publication Date: Mar 3, 2011
Inventor: Robert F. Dierbeck (Hartford, WI)
Application Number: 12/874,889