Hidden Decking Fastener

Abstract

A hidden fastener for use in assembling a decking structure by attaching a series of grooved deck planks to underlying joists is disclosed. The fastener is configured with a horizontal body between a leading arm and trailing leg. The leading arm transitions to a leading wing while the trailing leg transitions to a trailing foot. At least one prong extends from the body at a downward angle. The leading wing and trailing foot are configured optimally for engagement within the grooves of adjacent deck planks. The body defines a hole for receipt of an elongated securing member that can be driven therethrough, optionally by a power driving tool, to attach the fastener to an underlying joist. The fastener spaces adjacent decking planks an optimal distance for drainage while providing improved resistance to lateral plank movement caused by thermal expansion or physical forces.

Description

FIELD OF THE INVENTION

The invention relates to deck plank fasteners for securing a deck plank to a joist and for supporting deck planks relative to one another. More particularly, the invention relates to a hidden deck plank fastener that is not visible and does not protrude from the deck surface when installed to secure a deck plank with undercut side grooves.

BACKGROUND

One simple deck plank fastening system consists of a plurality of securing or anchoring members, such as nails or screws, driven downward through the top of a plank, such as a wood or composite board, and into the top surface of a supporting beam, such as a joist or ledger board. Although the concept is simple, professional quality installation using this approach requires a high degree of precision, significant time expenditure, and sometimes leads to a flawed result.

Deck planks installed using the simple system of the preceding paragraph must be carefully aligned to achieve a desirable aesthetic as well as functional result, for example, secure attachment and uniform spacing or parallelism without large gaps. Also, the insertion of the nails or screws must be performed carefully to ensure proper penetration of the joist, which will be concealed from view by the overlying wood board at the time of insertion, in order to achieve optimal attachment. Thus, although the system itself is simple, methods for making and using the system are not.

Even if the above-described simple system is properly installed, penetration of each deck plank by several securing members leaves each plank with a pock-marked appearance and prone to rot and weather damage, which severely decreases the longevity of the deck. In addition, each nail or screw may work loose and protrude from the upper surface of the planks, presenting a risk of injury to users of the deck. In summary, the simple conventional system of deck plank installation, using fasteners driven through each plank, detracts from the integrity of each plank and of the deck as a whole, and presents a risk of injury to users.

These and other problems have spurred on numerous advancements in the field. For instance, an improved deck plank fastening system includes fasteners that attach to a side surface of the plank and a top surface of the joist using nails or screws. Such designs facilitate uniform spacing or parallelism of planks by providing tabs or vertically oriented flanges that engage adjacent planks. The tabs facilitate installation by locating the points of penetration at more readily visible and accessible positions. The fasteners improve the longevity of the resulting deck by repositioning the point of penetration to the side of the plank, which is less prone to weathering. In addition, the tabs reduce the risk of injury to the user of the deck by hiding the nails or screws below the surface. Also, the hidden fasteners improve the aesthetic appeal of the deck.

Many other improvements and permutations have been conceived in this field, including the provision of deck planks with side grooves for receiving the teeth or tabs of hidden fasteners. Such improvements have specific advantages in specific circumstances, but have not foreclosed innovation in the field. For example, it has been proposed to provide deck planks with undercut side grooves so as to mitigate a possible problem of moisture collection in the side grooves. However, it is considered that known hidden fasteners are not compatible to planks with undercut side grooves.

SUMMARY

In one embodiment, a fastener has a generally flat body which extends from a left end to a right end between a leading edge to a trailing edge. The body defines a hole extending therethrough. A leading arm extends upward from the leading edge and has a leading wing extending therefrom in a direction away from the body. A trailing leg extends upward from the trailing edge of the body and has at least one trailing foot extending therefrom in a direction away from the body. The trailing leg defines a notch which is indented toward the body and substantially in registry with the hole. The notch splits the trailing leg into a right portion and left portion. At least one prong extends downward from the trailing edge.

In another embodiment, a fastener has a generally flat body extending from a left end to a right end between leading and trailing edges. The body defines a hole extending therethrough. A leading arm extends upward from the leading edge. A leading wing is formed as a bend at the top end of the leading arm and extends in a direction away from the body. A trailing leg extends upward from the trailing edge and has a notch formed therein which splits the trailing leg into left and right portions. Each of the left and right portions has a trailing foot formed as a bend at the respective top end which extends in a direction away from the body. A prong is formed as a bend and extends downward from the body, substantially in registry with the notch.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a hidden fastener for use with a deck planks with undercut side grooves;

FIG. 2 shows a different perspective view of the fastener of FIG. 1;

FIG. 3 is an end view of the fastener depicted in FIGS. 1 and 2;

FIG. 4 is a view of the fastener from the opposite end of FIG. 3;

FIG. 5 is a bottom view of the fastener of FIGS. 1-4;

FIG. 6 is a top view of the fastener of FIGS. 1-4;

FIG. 7 is a side view of the fastener of FIGS. 1-6;

FIGS. 8 and 9 show different perspective views of an alternative embodiment of fastener for use with deck planks having undercut side grooves;

FIG. 10 is a side view of the fastener of FIGS. 8 and 9;

FIG. 11 is a vertical cross section view of a typical deck plank with which the disclosed fastener is configured for use; and

FIG. 12 is a depiction of an assembly of a decking system having a series of deck planks like that shown in FIG. 11 attached to joists with a plurality of the disclosed fasteners.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the drawings wherein like numerals represent like parts throughout the Figures, an improved deck plank fastener is provided. Embodiments allow installers to attach individual adjacent decking planks quickly in a single driving step, while also maintaining a strong, durable connection between adjacent planks. After driving installation, the fasteners remain hidden from view between the attached planks. The disclosed fasteners offer a significant improvement in durability and aesthetic enhancement compared to known decking plank attachment products.

Referring first to FIGS. 1-7, a deck plank fastener 10 is provided with a generally horizontal body 12 having leading and trailing edges, 14 and 16, each extending from a left to a right end. At the leading edge 14, the fastener is bent upwardly to form an upwardly extending leading arm 18. Similarly, the fastener is bent upwardly at the trailing edge 16 to form a trailing leg 20 with left and right portions, 20a and 20b, spaced apart by a notch 20c. As shown, the body 12 extends between and spaces apart the arm 18 and leg 20 which are generally parallel in this embodiment.

The leading arm 18 has an upper bend 22 which transitions the leading arm 18 to a leading wing 24. The leading wing 24 can be generally parallel to the horizontal body 12 or at an angle. Preferred embodiments include a leading wing 24 that is angled downward from a plane parallel to the horizontal body 12 from approximately 0° to 20°. A preferred embodiment is angled downward from the horizontal approximately 10° to 14°. As shown in the subject Figures, the leading wing 24 extends from a left end to a right end and includes first and second claws, 26a and 26b, formed as bends at opposite ends or corners thereof. The claws are configured to at least partially penetrate a decking plank when the fastener is driven downward. In a particularly preferred embodiment, the claws 26a and 26b are bent downward at an angle of approximately 30° to 45° relative to the leading wing 24. This particular claw configuration has been found to be optimal for resisting plank movement in an assembled decking structure due to thermal expansion.

In the depicted embodiment, the leg portions, 20a and 20b, each have upper bends, 28a and 28b, which transition respectively to left foot 30a and right foot 30b. The feet 30a and 30b extend outwardly from the legs 20a and 20b in the direction away from the body 12. The left foot 30a includes an upwardly projecting extension or toe 32a and the right foot includes a similar extension or toe 32b. The depicted embodiment has feet that are generally symmetrical, however this is non-limiting characteristic of the fastener 10. Numerous embodiments include asymmetrical feet and/or extensions. As shown in the depicted embodiment, the edges of the extensions 32a and 32b can be configured with a generally rounded contour, which can assist in allowing smooth engagement and optional disengagement of a deck plank during installation.

As best shown in FIGS. 7A and 7B, the feet 30a and 30b can be angled slightly downward from a plane parallel to the horizontal body 12. Preferably, the feet extend downward at an angle between approximately 0° and 20° from the horizontal, and more preferably at approximately 9°-11°. With reference to FIG. 7B, the angle A between the foot 30 and extension 32 is approximately 110°. FIG. 7B is a depiction of the fastener 10 of the previous Figures showing approximate relative angles and bend radial dimensions of a preferred embodiment of the fastener 10. As can be seen, angle B measures the angle at which the leading wing 24 projects relative to the generally vertical arm 18. Angle C measures the angle at which the foot 30 projects relative to the generally vertical leg 20. Angle D will be discussed in detail below.

The fastener 10 also includes an attachment hole 34 defined by the horizontal body 12 and extending therethrough. The hole 34 is configured to receive an elongated securing member 80, such as a screw or nail, for securing the fastener 10 to a joist underlying decking planks. An additional improvement over known fasteners is the dome 36 formed partially surrounding the attachment hole 34. In operation, the dome 36 provides an additional leverage on the head portion of an elongated securing member 80, thereby assisting in creating a stronger, more rigid and more durable mating between the fastener 10, adjacent decking planks and joist. The leverage created by the elevated dome 36 with head portion of the securing member 80 further enhances the driving ability of the power tool, thereby significantly assisting the forcing of the claws, 26a and 26b, into the lower plank nub 54b and the prong 46 into the joist during deck assembly (discussed in further detail below). The dome 36 also assists fluidly sealing the fastener 10 and elongated securing member driven through the hole to attach the fastener to a joist, as will be described in greater detail below. The leading upper bend 22 is fit with alignment holes 38 extending therethrough, which generally brackets the position of the domed attachment hole 34. The alignment holes 38 are configured to cooperate with extensions or like elements on a pneumatic nail driver or similar power tool to thereby engage the fastener 10 without the need of manual holding.

As depicted most clearly in FIGS. 7A and 7B, the leading wing 24 is indented across its width by a first bend score 40. From proximate the first bend score 40, left and right corners of the leading wing are bent downward to form the claws, 26a and 26b, configured for engagement with the lower nub 54a and 54b of a typical grooved deck plank 50 (see FIG. 11). In a preferred embodiment, the claws 26a and 26b are bent downward at approximately 135° from the lower surface 42 of the leading wing 24. This preferred angle of projection has been found to be particularly useful in assisting the claws 26 at penetrating the lower nub 54a and 54b of a decking plank during installation and is non-limiting.

Also depicted in FIG. 7A is the second bend score 44 indenting across the width of each portion of the trailing foot 30. The second bend score 44 transitions the left and right portions 30a and 30b into the respective extension or toe 32a and 32b (shown generally in the side profile of FIG. 7A as reference numeral 32).

In the depicted embodiment, the leading arm 18 extends slightly further than the trailing leg 20 from the body 12. In a preferred embodiment, the leading arm 18 extends approximately 0.360 cm and the leg extends approximately 0.323 cm, as measured vertically from the lower surface of the body 12. The size, configuration and approximate bend angles disclosed herein have been shown to be optimal for securely engaging grooved deck planks, such as that shown as reference numeral 50 in FIG. 11, without causing any damage to the plank lower nubs. As noted above, the exact angles can vary as desired according to specifications for deck planks of different size, shape, material or other properties.

As shown, the leg portions 20a and 20b define a notch 20c therebetween formed substantially in registry with the position of the attachment hole 34. In some embodiments, the notch 20c permits access to the attachment hole 34 by a power driver tool. The alignment holes 38 and the notch 20c are preferably positioned to engage the hidden fastener 10 onto a power driving tool such that a securing member 80 driven by the power driver tool can pass through the attachment hole 34 at approximately between 30° and 50° from a plane defined by the leading arm 18.

The improved fastener 10 also includes a downwardly projecting prong 46 extending and formed from the horizontal body 12. Preferably, the prong 46 is positioned laterally between the separated edges of the left and right leg portions which define the notch 20c. In some embodiments, the prong is positioned laterally at the approximate midpoint between the portions 20a and 20b such that the tip 47 approximately bisects the lateral extent of the notch 20c. In the depicted embodiment, the prong 46 extends at approximately 60° relative the plane defined by the horizontal body 12 (see angle D in FIG. 7B). The particular angle at which the prong 46 extends relative to the body 12 can be altered to fit a particular type, size or style of decking member, or as otherwise preferred. For example, embodiments exist having a prong that extends at an approximate relative angle of 30°, 45° and numerous additional relative angles therebetween. The left/right location along the body and number of prongs can also vary for different applications.

FIG. 11 shows a vertical cross section view of a decking plank 50 with which the disclosed fastener 10 is configured to be optimally used. The elongated plank 50 has a top surface 58 and opposite bottom surface 60. The top and bottom surfaces can be generally flat or have slight curvatures. One preferred embodiment includes a slightly convex top surface 58 which assists in shedding fluid such as precipitation. As shown, the plank 50 also has opposite side grooves, 56a and 56b, extending at least a portion of the length thereof and dividing each edge into an upper nub, 52a and 52b, and lower nub, 54a and 54b. The upper nubs, 52a and 52b, preferably protrudes further from the vertical bisection point of the plank 50 than the lower nubs, 54a and 54b, such that the lower surface 60 is narrower than the upper surface 58. These characteristics assist in concealing the disclosed fasteners 10 after installation as well as reducing moisture buildup within the respective side grooves, 56a and 56b.

Referring to FIG. 12, a plurality of hidden fasteners 10 can be used with a corresponding plurality of elongated securing members 80 (nails, screws or like members) for fastening a series of planks 50, like those of FIG. 11, onto the upper surfaces 70 of a planar array of joists, which may be fixed in any number of conventional ways, such as by brackets, toe-nails, or the like to a backstop 72 (i.e., a wall or array of posts).

During assembly, a lead plank 50a is positioned onto the upper surfaces 70 of the joists with one of its grooved edges positioned against the backstop 72, leaving the other grooved side exposed on the opposite side. A first plurality of hidden fasteners 10 are then positioned with their leading wings 24 at least partially within the open side groove 56b, and each hidden fastener is attached to one of the joists 70 by an elongated securing member 80, such as a nail or screw, typically one fastener per joist. The fasteners are preferably configured such that upon driving of the elongated securing member the claws, 26a and 26b, penetrate the lower nub 54b and the prong 46 penetrates the joist 70. Embodiments exist wherein the attachment hole 50 is configured such that each elongated securing member 80 forms a substantially water tight joint with each fastener body 12, thereby assisting in shedding water from the upper surface of each joist even at the locations of penetration by the securing members. The materials of the hidden fastener and associated securing member may be varied and selected for compatibility with each other and the deck planks as well as to improve weather-resistant properties.

As disclosed above, embodiments exist that allow each of the hidden fasteners 10 to be held by a pneumatic nail driver or other power driver tool (not shown). The fastener 10 is engaged with the lead plank 50a, and concurrently attached to one of the joist surfaces 70 by an elongated securing member 80 driven from the power driver tool, substantially as disclosed in co-pending and co-owned U.S. patent application Ser. No. 12/573,540. Engagement of the disclosed fastener 10 into the side groove 56b and over the lower nub 54b may be improved by driving each elongated securing member into the joist from the power driver tool at an angle of between approximately 25°-50° relative to a vertical plane aligned with corresponding joist. More preferably, each elongated securing member is driven at an angle of between approximately 30°-45° relative to the vertical.

With further reference to FIG. 12, subsequent to attachment of the lead plank 10a onto the joist edges 70 with the first series of fasteners, a first trailing plank 50b is assembled onto the trailing foot portions, 30a and 30b, of the first series of fasteners. The trailing foot toes, 32a and 32b, and associated bends, 33a and 33b, are configured so that trail planks may be engaged to and removed from the hidden fasteners without significant dislodgement of the hidden fasteners or damage to the trail plank lower nubs during assembly. A second series of fasteners are then assembled to the first trail plank open end and attached to the joist surfaces, substantially as described above with respect to the first series of fasteners. The leading arm 24 and the trailing leg 30 are configured to positively position the lower nubs of such planks so that the upper nubs and top surface of each adjacent plank is separated by appropriate gaps to allow drainage. An end rail, such as that depicted as reference numeral 74, can be positioned at the end of the deck surface to conceal the trailing feet of a final series of hidden fasteners.

As noted above with reference to FIGS. 1-7B, driving of a securing member 80 through the hole 34 drives the downwardly extending prong 46 at least partially into the joist 70. The prong 46 thereby provides additional resistance to lateral movement of adjacent decking planks 50. The prong 46 additionally assists in level installation of the fastener 10 by preventing trailing edge 16 and leg 20 from sinking into the joist 70 when driven downwardly by the securing member 80. Protecting against sinking of the trailing edge 16 into the joist 70 ensures that sufficient clearance remains between the joist surface and feet, 30a and 30b, to accommodate the lower nub 54a of a trailing plank 50b.

The embodiment depicted in FIGS. 1-7B shows a prong 46 that extends from the horizontal body 12 at an approximate relative angle of 60°, although the particular angle is nonlimiting. Embodiments exist wherein the prong 46 extends at different angles, for example 30°-75°, as may be particularly suitable for use with joists and/or planks of different materials, sizes, shapes or other properties. In use within the disclosed decking system, the prong 46 has been found to assist significantly in resisting or even eliminating lateral movement of the planks 50 from physical forces, thermal expansion, or like phenomena. The prong 46 is preferably formed in the single unit fastener 10 by cutting dog ears in the metal unit (for example, steel) to define the point 47, and simply bending the piece downwardly to a desired angular position to form the prong 46. Each of the other elements of the fastener is formed as cuts or bends in the piece as well. Consequently, the inventive fastener 10 can be manufactured as a single unit without requiring advanced machinery or attachment of separate pieces by soldering, welding, or the like.

FIGS. 8-10 depict an alternate embodiment of the fastener shown in FIGS. 1-7B. As can be seen, this embodiment of fastener 100 includes at least one lower lance (or flange), depicted in the Figures as reference numerals 102a and 102b, formed in the leading arm 114 and extending outwardly from proximate the leading edge of the horizontal body 112. Installation of the fastener 100 and assembly of the decking system is performed substantially as described above with respect to the embodiment of the fastener 10. The lances, 102a and 102b, are bent from the leading arm 114 and configured to abut the edge of the lower nub 54b of the groove 56b within which the corresponding leading arm 124 is inserted during installation. The depicted preferred embodiment includes lances 102a and 102b depicted extend outwardly at an angle E of approximately 45° relative to an approximately vertical plane defined by the leading arm 124. This particular configuration has been shown to be optimal for use in the decking system as described above with reference to FIGS. 11 and 12 and the fastener embodiment shown as reference numeral 10. The lances, 102a and 102b, have been shown to provide substantial stabilization to individual deck planks and decking system (especially when installing on a joist that is uneven) as well as resistance to forces acting downward on the top surface of the deck planks. The lances, 102a and 102b, can be configured specially for application with specifically dimensioned planks. While the depicted embodiment includes two lances, 102a and 102b, positioned at opposite sides of the leading arm 124, the lances are not limited in terms of size, number, positioning or relative angle of extension.

While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage.

Claims

1. A fastener for use in adjoining adjacent decking members, comprising:

a generally flat body extending from a left end to a right end between leading and trailing edges, the body defining a hole extending therethrough;

a leading arm extending upward from the body leading edge, having a leading wing extending therefrom in a direction away from the body;

a trailing leg extending upward from the body trailing edge, having at least one trailing foot extending therefrom in a direction away from the body, the trailing leg defining a notch indented toward the body substantially in registry with the body hole, the notch splitting the trailing leg into right and left portions; and

at least one prong extending downward from the body trailing edge.

2. The fastener of claim 1, wherein the leading arm defines at least one alignment hole extending therethrough.

3. The fastener of claim 1, wherein the prong is positioned substantially in registry with the trailing leg notch and body hole.

4. The fastener of claim 3, wherein the prong extends downward from the flat body at an angle of between approximately 30-60 degrees.

5. The fastener of claim 1, wherein the leading wing is bent to extend outward at an angle of between approximately 70 and approximately 95 degrees relative to the leading arm.

6. The fastener of claim 1, wherein the leading wing defines two opposing corner edges and said corner edges are bent downwardly to form a pair of claws.

7. The fastener of claim 6, wherein the claws are bent downward at an angle of between approximately 115 to approximately 140 degrees relative to the leading wing.

8. The fastener of claim 1, comprising at least one toe extending angularly from an end of the trailing foot.

9. The fastener of claim 8, wherein the at least one toe is bend upward from the trailing foot.

10. The fastener of claim 9, wherein the at least one toe extends at an angle of between 100 and 120 degrees relative to the trailing foot.

11. The fastener of claim 10, wherein the at least one toe extends upward at an angle of approximately 110 degrees relative to the trailing foot, the leading wing extends outward at an angle of approximately 78 degrees relative to the leading arm and defines two opposing corner edges which are each bent downward to form a pair of claws, and the prong extends downward an angle of approximately 45 degrees relative to the flat body.

12. The fastener of claim 1, wherein the hole has a generally circular cross section and the body defines a partial radial dimple extending upward around a portion of circumference of the hole.

13. The fastener of claim 1, wherein the dimple defines an upper surface that extends between approximately 0.03 and 0.06 inches above an upper surface of the body.

14. The fastener of claim 1, comprising at least one lower extension formed in the leading arm and extending therefrom co-directionally with and at the opposite arm end from the leading wing.

15. The fastener of claim 14, wherein each of the adjacent decking members has opposite front and rear edges and a groove on each opposite edge thereof splitting the respective edge into an upper and lower nub, the at least one lower extension is bent from the leading arm and configured to abut the lower nub when the leading wing is positioned within the groove of a decking member.

16. A fastener for use in adjoining adjacent decking members, comprising:

a generally flat body extending from a left end to a right end between leading and trailing edges, the body defining a hole extending therethrough;

a leading arm extending upward from the leading edge, having a leading wing formed as a bend at a top end thereof and extending in a direction away from the body;

a trailing leg extending upward from the body trailing edge, having a notch formed therein splitting the trailing leg into left and right portions, each of the left and right portions having a trailing foot formed as a bend at the top end thereof and extending in a direction away from the body; and

a prong formed as a bend and extending downward from the body, positioned substantially in registry with the notch.

17. The fastener of claim 16, wherein the respective trailing leg bends are generally symmetrical to each other and asymmetrical to the leading arm bend.

18. The fastener of claim 17, comprising at least one claw formed as a bend in and extending angularly downward from the leading wing.

19. The fastener of claim 17, comprising a toe formed as a bend in and extending angularly upward from at least one of the trailing feet.

20. The fastener of claim 16, wherein the leading arm defines at least one alignment hole extending therethrough positioned at least partially within the bend.