BRACKET FOR SECURING DECKING MEMBER

Abstract

A bracket for attaching a decking member to a supporting member comprises a main flange, a side flange extending approximately perpendicular to the main flange, at least one through hole defined in the side flange for receiving a fastener to attach the bracket to a side of a decking member and at least one protrusion extending from a lower side of the main flange and serving to contact the supporting member and to space the bracket and decking member above the supporting member. A method of securing a decking member to a supporting member is also described.

Description

BACKGROUND

Outdoor structures such as decks and other similar structures must withstand the elements without deteriorating before the end of their design life. Materials commonly used today include many different types of wood, composites and other non-wooden materials. Construction methods have changed because of new materials in some cases and also because of new safety requirements, to name just two reasons. As a result, the choices of hardware to secure decking members to supporting members fall short for many applications.

SUMMARY

Described below are implementations of a new bracket for securing a decking member to a supporting member that provides for a robust connection, avoids the need to drive fasteners through a top surface of the decking material, can be quickly installed in various orientations and can be produced at a competitive price.

In one implementation, a bracket for attaching a decking member to a supporting member comprises a main flange, a side flange extending approximately perpendicular to the main flange, at least one through hole defined in the side flange for receiving a fastener to attach the bracket to a side of a decking member and at least one protrusion extending from a lower side of the main flange and serving to contact the supporting member and to space the bracket and decking member above the supporting member.

The main flange can comprise a widened portion having a lateral dimension wider than a side of the mounting member to which the bracket is configured for mounting. The main flange can be dimensioned to extend away from the side of the decking member when the bracket is installed.

The at least one mounting opening in the main flange can be countersunk relative to an upper side of the bracket. The at least one protrusion can be aligned with the at least one mounting opening. The main flange can comprise four mounting openings. The at least one protrusion can comprise an annular shape.

The at least one protrusion can comprise at least two protrusions spaced apart to support the decking member above the supporting member such that an space is defined between protrusions and between an upper surface of the supporting member and a lower surface of the decking member.

The main flange can have a thickness of approximately 0.150 inch in an area comprising the at least one protrusion.

The main flange can comprise at least one chamfered corner. Similarly, the side flange can comprise at least one chamfered corner.

The bracket can be formed by a process in which a portion of material in a plane of the main flange is bent into the side flange.

The main flange can comprise an attachment region having at least one mounting opening and a contiguous support region extending laterally away from the attachment region, and wherein the side flange extends from the support region. Alternatively, the main flange can be L-shaped.

The side flange can extend at a position approximately midway along a longitudinal axis of the main flange.

According to a method implementation, a method of securing a decking member to a supporting member with a bracket comprises providing a bracket having a main flange and a side flange extending approximately perpendicular to the main flange, at least one through hole in the side flange, at least one mounting opening in the main flange and at least one protrusion extending from the main flange. The method comprises positioning the side flange over a side surface of the decking member at a desired position, securing the side flange to the side surface with a fastener extending through the at least one through hole to thereby attach the bracket to the decking member, positioning the decking member with the attached bracket at a desired position relative to an underlying supporting member with the at least one protrusion contacting the supporting member to space the bracket and decking member above the supporting member and securing the main flange to an upper surface of the supporting member with a fastener extending through the at least one mounting opening.

The method may further comprise spacing the decking member from a previously secured decking member. The side flange can have a thickness, and the thickness of the side flange can serve to provide a uniform spacer for a next decking member to be secured.

In another method implementation, the at least one mounting opening in the main flange comprises at least two mounting openings that remain exposed after the side flange is secured.

In another method implementation, the side flange is secured to the side surface of the decking member before the main flange is secured to the upper surface of the supporting member.

The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an implementation of the bracket, showing a bracket body having a main flange and a side flange.

FIG. 2 is a top plan view of the bracket of FIG. 1.

FIGS. 3, 4, 5, 6 and 7 are rear elevation, front elevation, left side elevation, right side elevation and bottom plan views of the bracket of FIG. 2.

FIG. 8 is a perspective view showing an implementation of the bracket as aligned relative to a typical supporting member or joist prior to installation.

FIG. 9 is a perspective view showing two brackets installed on opposite edges of a decking member to secure it to alternating supporting members or joists in a typical mid-span application.

FIG. 10 is a perspective view showing portions of first and second decking members each secured to a common joist with one bracket at a selected spacing between the first and second decking members.

FIG. 11 is a side elevation view showing an end view of an installed decking member and portions of the adjacent decking members as they are held spaced above the supporting members by the brackets securing them.

FIG. 12 is a top plan view of a section of a completed deck showing a series of decking members installed with brackets to multiple supporting members, with the decking members shown in transparent lines to show the brackets in more detail.

DETAILED DESCRIPTION

FIGS. 1-7 show an implementation of a bracket for securing a decking member. Although the bracket is described herein in terms of its function in securing a decking member, it can of course be used in other similar applications where two members need to be held in place relative to each other at desired positions.

As best shown in the perspective view of FIG. 1, a bracket 10 has a body 12 in which a main flange 14 and a side flange 16 are defined. The side flange 16 is angled with respect to the main flange 14. The main flange 14 and the side flange 16 are each generally planar. In the illustrated implementation, the side flange 16 is angled with respect to the main flange 14 by approximately 90°, but the flanges may be separated by other angles according to the specific application in which the bracket is being used.

As shown, the main flange 14 has one or more mounting holes 18, which may be arranged in any suitable pattern. For example, in the illustrated implementation (see, e.g., FIGS. 1, 2 and 7), there are four mounting holes 18 that are spaced longitudinally and laterally. Similarly, the side flange 16 can have one or more mounting holes 20. In the illustrated implementation, there is a single mounting hole 20 in the side flange 16, as best seen in FIGS. 1, 3 and 5.

Optionally, the one or more mounting holes 18 may be counter sunk relative to the upper surface of the main flange 14 as seen in FIGS. 1 and 2. In this way, if screws, for example, are used to secure the main flange to a supporting member, the heads of the screws will be recessed or protrude only slightly above the upper surface of the main flange 14.

Further, the one or more of mounting holes 18 may be formed with mounting protrusions 24 protruding from a bottom side of the bracket 10, as best seen in FIGS. 3, 4, 5, 6 and 7. The mounting protrusions 24 may be formed as a result of the counter sinking operation, or they may be provided for separately. The mounting protrusions 24 can have a generally annular shape. Advantageously, the mounting protrusions 24 can be used to space the remainder of the bracket 10 and the decking board to which it is secured above the surface of the supporting member by a gap H, as best shown in FIG. 11. It has been found that providing the gap H assists with preventing moisture from being entrained over the entire covered surface of the supporting member. In addition, providing the gap H helps reduce undesirable noises (including, e.g., squeaking) that can occur if broader areas of the decking members of some materials are in contact with the supporting members.

The bracket 10 may be formed with one or more chamfered corners. In the illustrated implementation, there may be chamfered corners 22 on the main flange 14 and on the side flange 16 as shown. Of course, it would be possible to configure the bracket with fewer or more chamfered corners, or with corners that are rounded, square or of another shape, as would be appreciated by those of skill in the art.

The main flange 14 can be described as having an attachment portion where the mounting holes 18 are located and an adjacent support region extending laterally away from the attachment region, and from where the side flange 16 extends. Stated differently, the main flange can be described as being L-shaped.

Referring to FIG. 2, it can be seen that when viewed in a longitudinal direction A, the side flange 16 is positioned approximately midway between opposite ends of the main flange 14. Referring to FIG. 3, a dimension S of the side flange 16 can be selected based on the thickness of the decking material or decking members. For example, if the decking material is 2″ by 6″ dimensional lumber (boards) or other 2″ boards, which have a finished thickness of 1½″, then the dimension S can be sized accordingly so as not to exceed the thickness of the decking members. For example, in one implementation, the dimension S may be about 1.25 inch with the mounting hole located at about 0.75 inch. In the same way, for decking material made of 5/4 lumber (having a finished thickness of 1 1/16″), a bracket having a side flange with a dimension S of about 0.725 inch and the mounting hole located at about 0.525 inch.

As best shown in FIG. 7, the side flange 16 can have a lateral dimension of any selected length, such as a length B as shown in the illustrated implementation. Optionally, the side flange 16 can be separated from the attachment portion of the main flange by a gap G.

The bracket 10 may be formed of any suitable material, e.g., galvanized sheet stock. According to one implementation, the bracket is made by stamping, and the side flange is formed as one piece with the main flange. In the illustrated implementation, the side flange and the main flange are made of 22 gauge material. In the illustrated implementation, the entire thickness of the main flange in the area of the mounting protrusions 24 is approximately 0.150 inches.

FIG. 8 is a perspective view of a typical supporting member M1, such as a wooden joist, with the bracket 10 positioned on an upper side surface of the joist prior to being secured to the joist, such as with a fastener F, e.g., a screw. FIG. 8 shows the screw F inserted through a second of the mounting holes 18. In general, only one screw is necessary in most applications. If the second hole is not convenient, e.g., if the supporting member has an irregularity such as a knot directly below the second hole, then the screw can be driven into the supporting member through the first of the mounting holes 18 (not shown).

FIG. 9 is a perspective view showing first, second and third joists M2, M3 and M4 that are spaced apart from each other (such as by, e.g., 16″ or 24″) and one decking member N1 that is secured in place at one edge by a first bracket 110 connecting the decking member N1 to the first joist M2 and by a second bracket 112 connecting the decking member to the third joist M4. In addition, the opposite second edge of the decking member N1 is secured by a third bracket 114 oriented opposite the first bracket 110 and also secured to the first joist M2, and by a fourth bracket 116 oriented opposite the second bracket 112 and also secured to the third joist M4. In some applications, it is possible to skip intermediate joists, such as the second joist M3 as shown, particularly at mid-span locations.

As can be seen in FIG. 9, each side flange 16 is secured to a side surface P of the decking member N using a fastener, e.g., a screw, driven through the mounting opening 20 in the side flange 16 to secure it to the decking member N1. Similarly, at least one fastener is driven through one of the mounting holes 18 in each main flange 14 to secure the brackets 110, 112 to the first joist M2 and the third joist M4, respectively.

FIG. 10 is another perspective view of the third joist M4 and the installed decking board N1 of FIG. 9 shown at greater scale, and a second decking board N2 shown in position relative to the first decking board N1 and prior to its installation. As can be seen in FIG. 10, in the illustrated implementation approximately half of the main flange 14 extends below the decking member N1 to which it is attached, and about half of the main flange extends away from the side of the decking member N1 to expose two of the mounting holes 18. Other proportions are also possible.

FIG. 10 also shows that the fourth bracket 116 serves to help space adjacent decking boards by a uniform distance. In particular, the side flange 16 helps to space adjacent decking boards, such as the decking boards N1 and N2 as shown in FIG. 10.

FIG. 11 shows an end view of an installed decking board N4 relative to adjacent decking boards N3 and N5, and a supporting member M5. As shown, the brackets 210 and 212, and in particular their protrusions, serve to space the decking boards N3, N4 and N5 above the supporting member M5. In the area of the decking member N4, it can be seen that a gap H is defined between the lower surface of the decking member N4 and the upper surface of the supporting member M5. By providing space between the decking boards and the supporting members, the brackets help to promote airflow between the decking boards and the supporting members, which helps to control moisture, condensation and mold.

FIG. 12 is a top plan view of a section of a completed deck showing a series of decking members N6, N7, N8, N9, N10 installed with brackets 210 to multiple supporting members M6, M7 and M8, with the decking members shown in transparent lines to reveal the brackets and their connections. As also shown in Fig, 12, at junctions where two brackets are used, the brackets are preferably oriented opposite to each other.

In this example, each junction between one of the decking boards and one of the supporting members includes one or two of the brackets 210. In contrast, as shown in FIG. 9, some applications allow for brackets to be used on alternating supporting members. Similarly, in some applications two brackets are used at every junction only at the ends of decking members, which would be their end connections to a supporting member.

In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.

Claims

1. A bracket for attaching a decking member to a supporting member, comprising:

a main flange shaped for positioning on an upwardly facing narrow face of a supporting member;

a side flange extending approximately perpendicular to the main flange;

at least one through hole defined in the side flange for receiving a fastener to attach the bracket to a side of a decking member;

at least one mounting opening defined in the main flange to receive a fastener to attach the bracket to the supporting member; and

at least one protrusion coinciding with the at least one mounting opening and protruding relative to a lower side of the main flange and serving to contact the supporting member and to space the bracket and decking member above the supporting member.

2. The bracket of claim 1, wherein the main flange includes a widened portion having a lateral dimension wider than a side of the mounting member to which the bracket is configured for mounting.

3. The bracket of claim 1, wherein the at least one mounting opening in the main flange is countersunk relative to an upper side of the bracket.

4. (canceled)

5. The bracket of claim 1, wherein the main flange comprises four mounting openings.

6. The bracket of claim 1, wherein the at least one protrusion comprises an annular shape.

7. The bracket of claim 1, wherein the at least one protrusion comprises at least two protrusions spaced apart to support the decking member above the supporting member such that a space is defined between protrusions and between an upper surface of the supporting member and a lower surface of the decking member.

8. The bracket of claim 1, wherein the main flange has a thickness of approximately 0.150 inch in an area comprising the at least one protrusion.

9. The bracket of claim 1, wherein the main flange comprises at least one chamfered corner.

10. The bracket of claim 1, wherein the side flange comprises at least one chamfered corner.

11. The bracket of claim 1, wherein a portion of material in a plane of the main flange is bent into the side flange.

12. The bracket of claim 1, wherein the main flange comprises an attachment region having the at least one mounting opening and a contiguous support region extending laterally away from the attachment region, and wherein the side flange extends from the support region.

13. The bracket of claim 1, wherein the main flange is L-shaped.

14. The bracket of claim 1, wherein the side flange extends at a position approximately midway along a longitudinal axis of the main flange.

15. A method of securing a decking member to a supporting member with a bracket comprising:

providing a bracket having a main flange and a side flange extending approximately perpendicular to the main flange, at least one through hole in the side flange, at least one mounting opening in the main flange and at least one protrusion extending from the main flange;

positioning the side flange over a side surface of the decking member at a desired position;

securing the side flange to the side surface with a fastener extending through the at least one through hole to thereby attach the bracket to the decking member;

positioning the decking member with attached bracket at a desired position relative to an underlying supporting member with the at least one protrusion contacting the supporting member to space the bracket and decking member above the supporting member; and

securing the main flange to an upper surface of the supporting member with a fastener extending through the at least one mounting opening.

16. The method of claim 15, further comprising spacing the decking member from a previously secured decking member.

17. The method of claim 15, wherein the side flange has a thickness, and wherein the thickness of the side flange and any protruding fastener serves to provide a uniform spacer for spacing the decking member from an adjacent decking member.

18. The method of claim 15, wherein the at least one mounting opening in the main flange comprises at least two mounting openings that remain exposed after the side flange is secured.

19. The method of claim 11, wherein the side flange is secured to the side surface of the decking member before the main flange is secured to the upper surface of the supporting member.