Decking System
A decking system comprises a plurality of deck planks interconnected such that at least 60% of a surface of the deck plank system comprises openings to allow pass through of at least one of an environmental condition, such as, air, sunlight, rain, etc. The deck plank openings result from a plurality of evenly spaced parallel rib elements that span across from one side of the deck plank to the other side, wherein the spacing between the rib elements provides the pass through openings, and the rib elements are fixed and supported in their orientation by a plurality of rib spacers and U-shaped support tabs between the rib elements. The openings adjacent a first and second length side, comprise a plurality of regularly spaced, recessed fastening supports within them. The deck planks also comprise a plurality of inter-locking tabs at an external perimeter to facilitate assembly of the deck plank system.
The present disclosure generally relates to a decking system, more specifically, the present disclosure is directed towards a decking system that conforms to specific federal guidelines currently unavailable in the market and prior art.
BACKGROUND OF THE DISCLOSUREDecking systems are well known in the art and have been around for centuries. Typically, decking systems are used as outdoor flooring primarily for piers, docks, walkways, gangways, and the like. They are generally constructed from natural wood materials, cut to length, and assembled into the desired configuration. The downside of natural wood materials is that they have a limited life span due to extreme and cyclical outdoor environmental conditions, such as sun, heat, rain, cold, snow, sleet, mud, etc., as well as constant inundation by waves, saltwater, algae, moss, crustaceans, etc. And, because of their use as piers, walkways, docks, etc., natural wood decking material is further subjected to the harsh conditions from general use.
The life span of the natural wood may be extended by coating the wood with paints, varnishes, sealants, coatings, and other finishes to deter the eventual degradation and rotting of the wood. To further extend the life of the wood it was discovered that pressure treating the wood provided greater durability. However, coated and even pressure treated wood eventually fails subject to harsh conditions; and without constant maintenance and repair, any type of wood deck ultimately needs replacement. Moreover, due to the increasing cost of decking lumber, alternate materials were needed.
Metallic materials, such as steel, aluminum and other alloys may be used, but they suffer from other disadvantages. Although strong and durable, they too suffer from extreme environmental conditions, such as rust, pitting, corrosion, etc., and in proximity to saltwater conditions, these effects are greatly accelerated. Furthermore, metallic systems are heavy, expensive, and require extensive expertise to manufacture, assemble, weld, etc.
Recently, synthetic and composite type materials have been developed that overcome many of the above limitations. They are generally lightweight, easier to manufacture (mold), assemble, and cost effective. They are generally made from reinforced thermoplastics or thermoset type materials. However, these materials require significant reinforcement or complex engineered design to provide the strength needed to sustain regular operating and use conditions. Moreover, recent federal guidelines implemented to promote ecological concerns mandate that any decking materials used for federally funded projects or federal applications must comprise at least 60% light passage open area, i.e., at least 60% of the deck area must allow environmental elements such as, light, air, snow, rain, etc., to pass through.
Synthetic and composite decking materials that meet the federal requirements are not currently available or disclosed in the prior art, and presently are only allowed under an addendum/waiver as they do not meet the federal requirement. The prior art has other disadvantages in commercial applications as well, all of which are overcome by decking of the present disclosure. For example, U.S. Pat. No. 7,500,336 to McGivem et al. discloses a composite material used for decking, but the McGivern openings provide only about 43% light passage.
SUMMARY OF THE DISCLOSUREVarious representative embodiments of a decking system and its components are disclosed herein and comprise of a plurality of interlocking deck planks manufactured using a synthetic material engineered such that at least 60% of the deck plank area provides a pass through for light, water, air and other environmental elements. For example, in one embodiment a deck plank comprises a frame comprising a length, and a width, wherein the deck plank comprises a plurality of elongated, substantially equal, deck plank openings such that the deck plank openings comprise a deck plank openings area of at least 60% of a deck plank area, wherein the deck plank area is defined by the frame's length and width. In other words, a deck plank and deck plank system comprises a plurality of uniform openings, wherein a sum area of the surface, other than the openings, comprises no greater than 40% of an area of the deck plank as outlined by a perimeter of the deck plank.
A deck plank, as part of a complete decking system, comprises a plurality of planar rib elements, wherein each rib element spans perpendicular from a first width side of the deck plank to an opposite, second width side of the deck plank. Each planar rib element further couples perpendicularly to a rib spline at an underside and at a midpoint of the planar rib element, and the rib spline extends along the rib element span. The planar rib elements are spaced evenly apart from a first length side of the deck plank to an opposite, second length side of the deck plank, and the plurality of planar rib elements define a working deck plank surface. The deck plank further comprises a plurality of rib spacers to support and secure a position of adjacent planar rib elements, wherein each rib spacer couples to and between adjacent rib splines, and each rib spacer comprises a spacer plate coupled to a spacer spline, wherein each spacer plate is partially overlapped by adjacent planar rib elements. The deck plank also comprises a plurality of U-shaped support tabs to further support and secure the position of the rib elements, wherein each U-shaped support tab couples perpendicularly between adjacent rib splines, and adjacent planar rib elements overlap a top portion of each U-shaped support tab.
Among various deck plank embodiments the deck plank comprises a plurality of fastening ports adjacent a perimeter of the deck plank, wherein the fastening ports extend from just below the working deck plank surface to a depth, such that a top portion of a fastener secured within the fastening port is recessed or at least flush relative to the working deck plank surface. Various deck plank embodiments also comprise a plurality of interlocking tabs spaced evenly along an external portion of the perimeter of the deck plank to interlock and secure adjacent deck planks, wherein an assembly of deck planks couple to a support structure to complete the desired pier, walkway, dock, etc.
To accommodate various applications, various embodiments of a rectangular deck plank generally comprises the deck plank length to comprise a length of at least 24 inches; wherein at least one of the rib splines, spacer splines, U-shaped support tabs, and a side of the deck plank perimeter comprises a depth of at least 1.5 inches when measured from the working deck plank surface to a bottom side of the at least one of the rib splines, spacer splines, U-shaped support tabs, and side of the deck plank perimeter. Moreover, a top portion of the fastening ports are recessed at least 0.5 inches from the working deck plank surface. Among various deck plank systems, the deck planks are assembled typically using rectangular and triangular shaped planks, although planks having a geometric configuration that is square, hexagonal, octagonal, pentagonal, etc. may be employed.
A more complete understanding of the decking system may be derived by referring to the detailed description and claims when considered in connection with the following illustrative Figs. In the following Figs., like reference numbers refer to similar elements throughout the Figs.
Elements in the Figs. are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence. For example, steps that may be performed concurrently or in different order are illustrated in the Figs. to help to improve understanding of embodiments of the decking system.
DETAILED DESCRIPTION OF THE DISCLOSUREA decking system may be described herein in terms of various functional components, and such functional elements may be realized by any number of hardware components configured to perform the specified functions and achieve various results. For example, the decking system may employ deck planks comprising various geometric configurations that comprise various functional elements, e.g., rib elements, spacers, pass through openings, support tabs, interlocking tabs, fastening ports, and the like, which may carry out a variety of functions. In addition, the decking system may be practiced in conjunction with any number of piers, docks, walkways, gangways, etc., and the decking systems described are merely exemplary embodiments. Further, the decking system may employ any number of conventional techniques for manufacturing, assembling, packaging, marketing, distributing, selling and the like.
Various representative embodiments of deck planks may be applied to any system for decking Referring now to
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Among various exemplary embodiments, deck plank 100 and the various components and elements that comprise deck plank 100 are generally fabricated using a thermoset or thermoplastic type material. In some embodiments, deck plank 100 material may alternately comprise a composite material, such as fibrous impregnated composite material, such as carbon fiber or glass fiber reinforced material. Moreover, the various elements described throughout this disclosure may be individually coupled and/or assembled, but in a preferred embodiment, the various components are molded as parts of a single integrated deck plank unit.
Among various exemplary embodiments, and to accommodate general commercial applications, at least one of rib splines, spacer splines, U-shaped support tabs, and a side of the deck plank perimeter comprises a depth of at least 1.5 inches when measured from the working deck plank surface, such as working deck plank surface 224 to a bottom side of the at least one of the rib splines, spacer splines, U-shaped support tabs, and side of the deck plank perimeter.
In the foregoing specification, a decking system and its components has been described with reference to specific exemplary embodiments. Various modifications and changes may be made, however, without departing from the scope of the decking system and its components as set forth in the claims. For example, this disclosure emphasizes the importance of the deck plank openings, in total, comprise an area that is at least 60% of the total area of the deck plank, however, some embodiments may comprise a deck plank that may not meet such specification, but rather benefits from the unique architecture of the components as disclosed and shown. The specification and Figs. are illustrative, rather than restrictive, and modifications are intended to be included within the scope of the decking system. Accordingly, the scope of the decking system and its components should be determined by the claims and their legal equivalents rather than by merely the embodiments described. For example, the components and/or elements recited in the claims may be assembled or otherwise operationally configured in a variety of permutations and are accordingly not limited to the specific configuration recited in the claims.
Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments; however, any benefit, advantage, solution to problem or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced are not to be construed as critical, required, or essential features or components of any or all the claims.
As used herein, the terms “comprise”, “comprises”, “comprising”, “having”, “including”, “includes”, “is” or any variation thereof, are intended to reference a non-exclusive inclusion, such that an article, composition, device, apparatus, system and the like that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such, article, composition, device, apparatus, system, etc. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the decking system and its components, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same.
Claims
1. A deck plank comprises:
- a frame comprising a length, and a width, wherein the deck plank comprises a plurality of elongated deck plank openings such that the plurality of elongated deck plank openings comprise a deck plank openings area of at least 60% of a deck plank area, wherein the deck plank area is defined by the frame's length and width;
- a plurality of planar rib elements, wherein each rib element spans perpendicular from a first width side of the deck plank to an opposite second width side of the deck plank, wherein each rib element couples perpendicular to a rib spline at an underside and at a midpoint of the rib element, and the rib spline extends along the rib element span; the rib elements are spaced evenly apart from a first length side of the deck plank to an opposite, second length side of the deck plank; the plurality of rib elements define a working deck plank surface;
- a plurality of rib spacers to support and secure a position of adjacent rib elements, wherein each rib spacer couples between adjacent rib splines, and each rib spacer comprises a spacer plate coupled to a spacer spline, wherein each spacer plate is partially overlapped by adjacent rib elements;
- a plurality of U-shaped support tabs to further support and secure the position of the rib elements, wherein each support tab couples perpendicularly between adjacent rib splines; adjacent rib elements overlap a top portion of each U-shaped support tab;
- wherein the deck plank further comprises a plurality of fastening ports adjacent a perimeter of the deck plank; the fastening ports extend from just below the working deck plank surface to a depth, such that a top portion of a fastener secured within the fastening port is recessed relative to the working deck plank surface; and
- wherein the deck plank further comprises a plurality of interlocking tabs spaced evenly along an external portion of the perimeter of the deck plank to interlock and secure adjacent deck planks.
2. The deck plank of claim 1, wherein the spacer plates are aligned in a column from the one length side of the deck plank to the opposite length side of the deck plank.
3. The deck plank of claim 2, wherein the U-shaped support tabs are aligned in a column from the one length side of the deck plank to the opposite length side of the deck plank.
4. The deck plank of claim 3, wherein the interlocking tabs align with the U-shaped support tabs column.
5. The deck plank of claim 3, wherein opposite sides of the spacer plates that are not coupled to the rib splines, comprise an arcuate shape so as to further maximize the deck plank openings area.
6. The deck plank of claim 5, wherein the fastening ports are generally circular and threaded to receive securing screws.
7. The deck plank of claim 6, wherein the deck plank comprises the deck length sides to comprise a length of at least 24 inches.
8. The deck plank of claim 7, wherein at least one of the rib splines, spacer splines, U-shaped support tabs, and a side of the deck plank perimeter comprises a depth of at least 1.5 inches when measured from the working deck plank surface to a bottom side of the at least one of the rib splines, spacer splines, U-shaped support tabs, and side of the deck plank perimeter.
9. The deck plank of claim 6, wherein a top portion of the fastening ports are recessed at least 0.5 inches from the working deck plank surface.
10. A deck plank comprises:
- a surface, comprising a plurality of uniform openings, wherein a sum area of the surface comprises no greater than 40% of an area of the deck plank as outlined by a perimeter of the deck plank.
11. The deck plank of claim 10, wherein the surface comprises a plurality of parallel rib elements that span lengthwise from a first width side of the deck plank across to a second width side of the deck plank.
12. The deck plank of claim 10, wherein the deck plank comprises at least one of a rectangular, square, triangular, hexagonal, octagonal, and pentagonal geometric configuration.
13. The deck plank of claim 12, wherein the deck plank comprises of at least one of a thermoplastic or a thermoset molded material element.
14. The deck plank of claim 11, wherein an area of each of the uniform openings are substantially equal.
15. The deck plank of claim 14, wherein the uniform openings adjacent a first length side and a second length side further comprise a plurality of regularly spaced, recessed fastening supports within each uniform opening.
16. The deck plank of claim 15, wherein the rib elements are fixed in their orientation by a plurality of rib spacers and U-shaped support tabs.
17. A deck plank system comprises;
- a plurality of individual deck planks interconnected such that at least 60% of an area of the deck plank system allows a pass through of at least one of an environmental condition from the list of; sunlight, rain, snow, sleet, hail, and air.
18. The deck plank system of claim 17, wherein the plurality of individual deck planks comprises of at least one of a thermoplastic and a thermoset material.
19. The deck plank system of claim 18 comprising an assembly of rectangular and triangular geometric individual deck planks.
20. The deck plank system of claim 19, wherein the deck plank system affixes to a deck plank system support structure.
Type: Application
Filed: May 29, 2015
Publication Date: Dec 1, 2016
Inventor: Clark B. Stahl (Scottsdale, AZ)
Application Number: 14/725,385