Abstract:
A deck including a panel, a retainer and a fastener. The panel includes a flange having an aperture therein. The retainer includes an upper leg and a lower leg embracing the flange therebetween, with the lower leg having a fastener receiving opening. The fastener is for attaching the panel to structural framework, with the fastener including a shoulder. The fastener extends through the aperture of the flange and the opening of the lower leg of the retainer. The shoulder extends through the aperture in the flange and abuts against the lower leg of the retainer to secure the retainer. Furthermore, the shoulder is sufficiently tall as to prevent the fastener from tightly clamping the flange. Additionally, the flange embraced between the upper leg and the lower leg of the retainer is adapted to expand between the upper leg and the lower leg. Therefore, thermal expansion of the panel is accommodated.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to decking, and in particular to deck panels. 
     Deck panels have been used to cover decks of houses, boat docks, floating docks and other structures having a surface exposed to the environment. Deck panels for decking provide a support surface for people walking on the decking. 
     Heretofore, deck panels have been placed on a structural framework. The structural framework preferably includes dimensional lumber or aluminum pieces fastened together by typical means, such as nails and screws. The deck panels have thereafter been fastened or otherwise fixedly attached to the structural framework. Deck panels have been made of materials including wood or metal planking. However, wood planking tends to warp, splinter and rot, thereby shortening the life span of the deck panels. Likewise, metal planking tends to corrode in a humid environment and often becomes uncomfortably hot in direct sunlight. 
     Deck panels have recently been constructed of thermoplastic materials to prolong the life of the deck panels and to maintain the safety of the decking. However, thermoplastics have a tendency to expand in heat and contract in cold. Consequently, thermoplastic deck panels cannot be tightly secured to the structural framework without causing damage to the deck panels as they expand and contract. Since the deck panels are typically secured tightly to the structural framework, the deck panels can have a relatively short life span because of the damage done to the deck panels by the fasteners as the deck panels expand and contract. 
     Accordingly, an apparatus solving the aforementioned disadvantages and having the aforementioned advantages is desired. 
     SUMMARY OF THE INVENTION 
     In the deck panels of the present invention, thermal expansion and contraction are accommodated without sacrificing secure fastening by providing an oversized fastener receiving aperture in a panel attachment mounting flange, a retainer which embraces the mounting flange at the fastener receiving aperture, and a fastener having a shoulder which passes through the mounting flange and a bottom leg of the retainer, with the shoulder of the fastener seating securely on the bottom leg of the retainer. 
     Accordingly, the deck can be placed onto a structural framework and can expand and contract in various weather conditions without causing cracks or other failures in the deck panels. The deck panels are easy and economical to manufacture, easy to install, efficient in use, capable of a long operable life, and particularly adapted for the proposed use. 
     These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a deck embodying the present invention on a structural framework. 
     FIG. 2 is a partial perspective view of a deck panel of the present invention. 
     FIG. 3 is a partial top view of the deck panel of the present invention. 
     FIG. 4 is a side view of the deck panel of the present invention. 
     FIG. 5 is a perspective view of a retainer of the present invention. 
     FIG. 6 is a top view of the retainer of the present invention. 
     FIG. 7 is a side view of a fastener of the present invention. 
     FIG. 8 is a partial cross-sectional view of a pair of deck panels connected together and to a structural framework. 
     FIG. 9 is a top view of the deck panel connected to the structural framework. 
     FIG. 10 is a partial perspective view of a starter panel of the present invention. 
     FIG. 11 is a partial cross-sectional view of the deck panel connected to a starter panel of the present invention. 
     FIG. 12 is a partial perspective exploded view of a trim panel of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as orientated in FIG.  1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     The reference number  10  (FIG. 1) generally designates a deck embodying the present invention. The deck  10  preferably includes a plurality of deck panels  12  and a starter panel  14  placed onto a structural framework  16 . The starter panel  14  assists in connecting the deck panels  12  to the structural framework  16 . The deck  10  also preferably includes a trim strip  18  covering ends of the deck panels  12  and the ends of the starter panel  14 . 
     In the illustrated example, the structural framework  16  is a dock having a pair of support surfaces  20  and legs  22  for supporting the support surfaces  20  above the ground. The structural framework  16  preferably includes dimensional lumber or aluminum pieces fastened together by typical means, such as nuts and bolts. Although the structural framework  16  is shown as being a dock, the structural framework  16  could be any framework, including commercial and residential decks and docks. Furthermore, the supporting surfaces  20  of the structural framework  16  could be supported above the ground with legs  22  as shown in FIG. 1 or could be placed directly on the ground. The term structural framework as defined herein includes any structure that could support the deck  10  and have the deck panels  12  connected thereto. 
     The illustrated deck panels  12  (FIGS. 2-4) are placed onto the structural framework  16  to provide a walking surface for the structural framework  16 . Each deck panel  12  has a substantially rectangular cross-section and includes a top wall  24 , a bottom wall  26 , a first side wall  28  and a second side wall  30 . The bottom wall  26  of the deck panel  12  has a bottom surface  31  that largely rests upon the support surface  20  of the structural framework  16 . The deck panels  12  are preferably made out of a thermoplastic material, such as rigid PVC or composites. The top wall  24  of the deck panel  12  includes a top surface  34  having a plurality of substantially X-shaped channels  36  and ridges  38  surrounding the X-shaped channels  36 . The X-shaped channels  36  and associated ridges  38  are aligned in off-set rows along the top surface  34  of the top wall  24 . Since the deck panels  12  are typically used on decks and docks, the deck panels  12  can get wet from rain, lake water, etc. The X-shaped channels  36  and ridges  38  assist in providing traction to the top surface  34  of the deck panels  12 . Therefore, the deck panels  12  are supported on the structural framework  16  and allow people to easily and safely walk upon the deck panels  12 . 
     In the illustrated example, the first side wall  28  and the second side wall  30  of the deck panels  12  connect the top wall  24  to the bottom wall  26 . The first side wall  28  is connected to a first side edge  40  of the top wall  24  and the second side wall  32  is connected to a second side edge  42  of the top wall  24 . The top wall  24  is preferably horizontal and the first side wall  28  extends vertically downward from the first side edge  40  of the top wall  24 . The second side wall  30  includes a first vertical portion  44  extending downward from the second side edge  42  of the top wall  24 , an angled portion  46  extending towards the first side wall  28 , a horizontal portion  48  also extending towards the first side wall  28 , and a second vertical portion  50 . The bottom wall  26  has a horizontal portion  52  extending from a second side union  54  with the second side wall  24  towards the first side wall  30  and an arched portion  54  extending upwards to a first side union  56  with the first side wall  30 . The horizontal portion  52  of the bottom wall  26  has the bottom surface  31  that rests on the support surface  20  of the structural framework  16 . The deck panel  12  also preferably includes a plurality of parallel, planar struts  59  extending between the top wall  24  and the bottom wall  26  of the deck panel  12  to support the top wall  24 . 
     The illustrated deck panel  12  includes a mounting flange  60  extending from the second side union  54  of the bottom wall  26  and the second side wall  30 . The mounting flange  60  includes a first portion  62  having a bottom surface  63  coplanar with the bottom surface  31  of the bottom wall  26 , a second angled portion  64  extending away from the second side wall  30 , and a third portion  66  having a bottom surface  68  parallel to the bottom surface  63  of the first portion  62  of the mounting flange  60  and the bottom surface  31  of the bottom wall  26 . The mounting flange  60  includes a plurality of aligned oval fastener receiving apertures  70  aligned along the length of the third portion  66  of the mounting flange  60 . As explained in more detail below, the fastener receiving apertures  70  in the mounting flange  60  assists in connecting the deck panel  12  to the structural framework  16 . Furthermore, the fastener receiving apertures  70  allow the mounting flange  60  to thermally expand and contract without damaging the deck panel  12 . 
     In the illustrated example, the deck panel  12  includes a tongue  72  and a groove  74  for connecting adjacent deck panels  12  together. The groove  74  is located between the mounting flange  60  and the second side wall  30 . The groove  74  is defined by the first portion  62  of the mounting flange  60 , the second vertical portion  50  of the second side wall  30  and the horizontal portion  48  of the second side wall  30 . The tongue  72  extends from the first side union  56  of the first side wall  28  and the bottom wall  26 . The tongue  72  includes a curved portion  76  extending away and downward from the first side union  56  and a short tab  78  extending horizontally from the curved portion  76 . The short tab  78  of the tongue  72  extends into the groove  74  of an adjacent deck panel  12  when the deck  10  is constructed. 
     In the illustrated example, retainer  80  (FIGS. 5 and 6) and a fastener  81  (FIG. 7) attach the deck panels  12  to the structural framework  16 . The retainer  80  is a U-shaped clip and includes an upper leg  82 , a lower leg  84  and a connecting portion  86  connecting the upper leg  82  and the lower leg  84 . The upper leg  82  and the lower leg  84  define a slot  85  therebetween. The upper leg  82  of the retainer  80  includes a hole  88  and the lower leg  84  includes a fastener receiving opening  90  aligned with and concentric to the hole  88  in the upper leg  82 . As seen in FIG. 6, the hole  88  in the upper leg  82  has a larger diameter than the fastener receiving opening  90  in the lower leg  84 . As explained in more detail below, the fastener  81  is inserted through the hole  88  in the upper leg  82  and the fastener receiving opening  90  in the lower leg  82  to secure the retainer  80  and the deck panel  12  to the structural framework  16 . The fastener  81  includes a threaded portion  92 , a circular shoulder  94  and a head  96 . The shoulder  94  has a diameter smaller than the hole  88  in the upper leg  82  of the retainer  80 , but a larger diameter than the fastener receiving opening in the lower leg  84  of the retainer  80 . 
     To connect the deck panels  12  to the structural framework  16 , retainers  80  are connected to the deck panels  12  by inserting the mounting flange  60  of a first deck panel  12  into the slot  85  of the retainer  80 . The number of retainers  80  used to connect each deck panel  12  to the structural framework  16  can vary, depending on the length of the deck panels  12  and the configuration of the structural framework  16 . Two retainers  80  should be used to connect each deck panel  12  to the structural framework  16  having a pair of parallel beams as the support surfaces  20 , with one retainer  80  for connecting the deck panel  12  to each beam. The hole  88  in the upper leg  82  of the retainer  80  and the fastener receiving opening  90  in the lower leg  84  of the retainer  80  are aligned with the fastener receiving aperture  70  in the mounting flange  60  of the first deck panel  12 . The first deck panel  12  is then placed onto the structural framework  16  and the fasteners  81  are inserted through each retainer  80 , through the fastener receiving aperture  70  in the mounting flange  60 , and into the structural framework  16 . 
     As the fasteners  81  are inserted through each retainer  80  and the mounting flange  60 , the shoulder  94  of the fastener  81  is allowed to pass through the hole  88  in the upper leg  82  of the retainer  80  and the fastener receiving aperture  70  in the mounting flange  60 . However, since the shoulder  94  has a larger diameter than the fastener receiving opening  90  in the lower leg  84  of the retainer  80 , a bottom surface  98  of the shoulder  94  will not be able to pass through the fastener receiving opening  90  in the lower leg  84  and will press against a top surface  100  of the lower leg  84  of the retainer  80  to secure the lower leg  84  of the retainer  80  against the structural framework  16  (see FIG.  8 ). Furthermore, the height of the shoulder  94  is larger than the distance between the top surface  100  of the lower leg  84  and a top surface  102  of the upper leg  82  of the retainer  80 . Therefore, the head  96  of the fastener  81  does not press against the top surface  102  of the upper leg  82  and the mounting flange  60  of the deck panel  12 . The thermoplastic material of the deck panel  12 , and in particular the mounting flange  60 , is therefore allowed to expand and force the top leg  82  and the bottom leg  84  of the retainer  80  apart without applying a force against the fastener  82 . 
     Since the fastener receiving apertures  70  are oval shaped, fasteners  81  are allowed to slide within the apertures  70  as the deck panels  12  expand in the longitudinal direction (see FIG.  9 ). The longest diameter of the oval apertures  70  are preferably parallel to the longitudinal direction of the deck panels  12 . Since the deck panels  12  will experience most of the thermal expansion in the longitudinal direction because that is the direction of most of the material of the deck panels  12 , the apertures  70  will move more in the longitudinal direction with the expansion than in any other direction. Therefore, the apertures  70  are preferably oval to allow the apertures  70  to slide about the fasteners  81  as the apertures  70  move in the longitudinal direction during thermal expansion of the deck panels  12 . Since the deck panels  12  have a much shorter lateral dimension compared to the longitudinal direction, the apertures  70  will not move very far in the lateral direction. Consequently, the apertures  70  can be oval because the deck panels  12  and their associated apertures  70  will not move very far in the lateral direction. 
     After the first deck panel  12  has been connected to the structural framework  16 , more deck panels  12  are positioned next to the first deck panel  12  to build the deck  10 . Therefore, the tongue  72  of a second deck panel  12  is then inserted into the groove  74  of the first deck panel  12  to connect the first deck panel  12  to the second deck panel  12 . The second deck panel  12  is thereafter connected to the structural framework  16  with one of the retainers  80  and fasteners  81  as described above for the first deck panel  12 . More deck panels  12  are thereafter connected to the deck panels  12  connected to the structural framework  16  in the manner described above. 
     In the illustrated example, the deck  10  preferably includes the starter panel  14  (FIGS.  10  and  11 ). The starter panel  14  is similar to the deck panel  12  and has a substantially rectangular cross-section. The starter panel  14  includes a top wall  108 , a bottom wall  110 , a first side wall  112  and a second side wall  114 . The bottom wall  110  of the starter panel  14  has a bottom surface  118  that rests upon the support surface  20  of the structural framework  16 . The first side wall  112  and the second side wall  114  of the starter panel  14  connect the top wall  108  to the bottom wall  110 . The top wall  108  is preferably horizontal and the first side wall  112  extends vertically downward from the top wall  108  to the bottom wall  110 . The second side wall  114  of the starter panel  14  has the same configuration as the second side wall  30  of the deck panel  12 . The second side wall  114  of the starter panel  14  therefore includes a first vertical portion  120  extending downward from a second side edge  122  of the top wall  108 , an angled portion  124  extending towards the first side wall  112 , a horizontal portion  126  also extending towards the first side wall  112 , and a second vertical portion  128 . The starter panel  14  is preferably made out of a thermoplastic material, such as rigid PVC or composites. 
     The illustrated starter panel  14  includes a starter panel mounting flange  130  for connecting the starter panel  14  to the structural framework  16 . The starter panel mounting flange  130  is similar to the mounting flange  60  of the deck panel  12  and extends from a second side union  132  of the bottom wall  110  and the second side wall  114  of the starter panel  14 . The starter panel mounting flange  130  includes a first portion  134  having a bottom surface  136  coplanar with the bottom surface  118  of the bottom wall  110 , a second angled portion  138  extending away from the second side wall  114 , and a third portion  140  having a bottom surface  142  parallel to the bottom surface  136  of the first portion  134  of the starter panel mounting flange  130  and the bottom surface  118  of the bottom wall  110 . The starter panel mounting flange  130  includes a plurality of aligned oval fastener receiving apertures  144  aligned along the length of the third portion  140  of the starter panel mounting flange  130 . 
     In the illustrated example, the starter panel  14  includes a groove  146  for accepting the tongue  72  of an adjacent deck panel  12  for connecting the starter panel  14  to the adjacent deck panel  12 . The groove  146  is located between the starter panel mounting flange  130  and the second side wall  114 . The groove  146  is defined by the first portion  134  of the starter panel mounting flange  130 , the second vertical portion  128  of the second side wall  114  and the horizontal portion  126  of the second side wall  114 . 
     The illustrated starter panel  14  is connected to the structural framework  16  using the retainer  80  and the fastener  81  in the same manner as the connection of the deck panel  12  to the structural framework  16 . Therefore, the starter panel mounting flange  130  is inserted into the slot  85  of the retainer  80  and placed on the structural framework  16 . The starter panel  14  is preferably placed adjacent an edge of the structural framework  16  such that the starter panel  14  and the deck panels  12  will cover the entire structural framework  16 . The fasteners  81  are then placed through each retainer  80 , through the fastener receiving aperture  144  in the mounting flange  130 , and into the structural framework  16 . The fasteners  81  abut against the lower leg  84  of the retainer  80  and therefore allow the starter panel  14  to expand and contract in the same manner as the deck panel  12  described above. The tongue  72  of the deck panel  12  is inserted into the groove  146  of the starter panel  12  and the deck panel  12  is thereafter connected to the structural framework  16  as described above. Additional deck panels  12  are also used to construct the deck  10  through the use of tongues  72  and grooves  74  of adjacent deck panels  12 , retainers  80  and fasteners  81 , also as described above. 
     When the deck panels  12  are used on a deck that abuts against a structure, the deck panel  12  adjacent the structure may have to be shortened or cut along its width in order to be able to abut the structure. Therefore, the final deck panel  12 , or the deck panel  12  that abuts the structure, is cut along its longitudinal direction such that the tongue  72  of the final deck panel  12  may be inserted into the groove  74  of the full deck panel  12  closest to the structure and then have the bottom surface  31  of the bottom wall  26  of the final deck panel  12  rest on the support surfaces  20  of the structural framework  16 . Holes (not shown) are then drilled into the top wall  24  and bottom wall  26  of the final deck panel  12  along the end edges of the top wall  24 . Fasteners (not shown) are then inserted into the holes along the end edges of the top wall  24  and bottom wall  26  and into the structural framework  16 . Heads of the fasteners are not placed flush against a top surface of the bottom wall  26 , thereby allowing the final deck panel  12  to expand and contract. In an alternative configuration, the starter panel  14  could be placed adjacent the structure and the last deck panel  12  of the deck  10  away from the structure could be screwed to the structural framework  16  as described above with fasteners inserted into holes along the top edge of the top wall  24  and the bottom wall  26  and into the structural framework  16 . 
     In the illustrated example, the deck panels  12  and starter panel  14  preferably include trim strips  18  (FIG. 12) placed along the end edges of the panels  12  and  14  to cover the open side edges of the panels  12  and  14  and to cover the holes drilled into the final deck panel  12 . The trim strip  18  preferably includes a C-shaped cover member  200  and a trim panel  202 . The C-shaped cover member  200  includes a bottom arm  204 , a side arm  206  and a top arm  208 . The top arm  208  and the side arm  206  are preferably perpendicular and the bottom arm  204  preferably extends from the side arm  206  at an acute angle such that the top arm  208  and the bottom arm  204  are biased against each other. The top arm  208  includes a pair of inverted, inwardly facing L-shaped fingers  210  and  210 A extending from side edges of the top arm  208  along the length of the top arm  208 . The top arm  208  also includes an elongate mounting flange  212  extending along the length of the top arm  208  between the L-shaped fingers  210  and  210 A. The L-shaped fingers  210  and  210 A connect the trim panel  202  to the C-shaped cover member  200  and the elongate mounting flange  212  helps to support the trim panel  202  above the top arm  208 . The trim panel  202  includes a plate  214  having a plurality of parallel ribs  216  along a top surface of the trim panel  202  and a pair of outwardly facing L-shaped rails  218  and  218 A extending from a bottom surface of the trim panel  202 . The pair of outwardly facing L-shaped rails  218  and  218 A of the trim panel  202  are configured to be snapped over the top arm  208  of the C-shaped cover member  200  between the pair of inverted, inwardly facing L-shaped fingers  210  and  210 A of the C-shaped cover member  200  to connect the trim panel  202  of the C-shaped cover member  200 . Preferably, one of the L-shaped rails  210  is inserted into a channel  400  defined between one of the L-shaped fingers  210  and the top arm  208  and then the other L-shaped rails  210 A is snapped over the other of the L-shaped fingers  210  to connect the C-shaped cover member  200  to the trim panel  202 . The trim panel  202  also includes a downwardly slanted mounting flange  220  extending from a side edge of the plate  214  of the trim panel  202  that covers one of the pair of inverted, inwardly facing L-shaped fingers  210  and  210 A when the trim panel  202  is connected to the C-shaped cover member  200 . 
     The illustrated trim strips  18  are connected to the deck panels  12  and the starter panel  14  by placing the C-shaped cover member  200  over end edges of the deck panels  12  and the starter panel  14  (see FIG.  1 ). Christmas-tree shaped push pins (not shown) are then placed through holes in the top arm  208  of the C-shaped cover member  200  and the top wall  24  of the deck panel  12  or the top wall  108  of the starter panel  14  to connect the C-shaped cover member  200  of the panels  12  and  14 , respectively. Furthermore, since the top arm  208  and the bottom arm  204  of the C-shaped cover member  200  are biased towards each other, the C-shaped cover member  200  will be frictionally held in place on the panels  12  and  14 . The trim panel  202  of the trim strip  18  is then snapped over the top arm  208  of the C-shaped cover member  200  as described above to cover the screws in the C-shaped cover member  200 . 
     In the illustrated example, the deck panels  12  preferably include notches  300  (FIG. 3) in the tongue  72  spaced along the length of the tongue  72  to assist in draining water from the top surface  34  of the top wall  24  of the deck panel  12 . As best seen in FIG. 8, water on the top surface  34  of the top wall  24  of the deck panel  12  can run between the first side wall  28  and the second side wall  30  of adjacent deck panels  12 , through the notches  300  and through the unused fastener receiving apertures  70  in the mounting flanges  66  of the deck panels  12 . Furthermore, as best seen in FIG. 11, water can also run between the first side wall  28  of the deck panel  12  and the second side wall  114  of the starter panel  14 , though the notches  300  and through unused fastener receiving apertures  144  in the mounting flanges  130  of the starter panel  14  adjacent the deck panel  12 . 
     It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. For example, the trim strip  18  could have the bottom arm  204  co-planar with the side arm  206 , thereby forming an L-shaped cover member for covering the side of the deck panels  12  and the starter panels  14 . Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.