Abstract:
A portable decking system formed from a plurality of flat panels adapted to be placed directly on the ground is provided with special clips that facilitate interconnection of adjacent edges of adjacent panels. The clips are generally W-shaped in cross-section to define a pair of channels each of which is receptive to a frame member of a flat panel. The clips are constructed to securely connect the panels together but in a manner that enables their ready detachment, all of which may be accomplished without tools or additional fasteners.

Description:
This is a continuation of the parent application Ser. No. 08/159,716 filed Nov. 30, 1993, which went abandoned Dec. 21, 1994. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to decking systems formed from a plurality of interlocking panels adapted to be placed directly on the ground and to connector-spacer devices for connecting adjacent edges of such panels. 
     BACKGROUND OF THE INVENTION 
     Among the various types of decking systems is that of a plurality of flat panels that may be placed directly on the ground in a desired pattern to form a continuous deck surface. Such panels may be used in a wide variety of configurations including, for example, garden walkways, decks, pool side aprons, screen house floor systems, kennel floors and the like. The panels typically include a rectangular wooden frame with a plurality of flat boards attached to the frame to define the decking surface. The panel is placed frame surface down with the frame resting directly on the ground. Because the panels may be made in sizes small enough to be handled manually, such systems may be considered as portable, that is, they can be taken up and rearranged, stored or transported to another site. The portability of such decking systems enhances their use as seasonal decking so that they can be removed during the off season so as to reduce exposure to the elements. 
     Among the difficulties presented with such decking systems is that the panels tend to shift about thus resulting in discontinuities along the decking surface. Such shifting may result from one or more of weather, soil erosion or simply the forces applied to the system when it is walked upon. The surface discontinuities detract from the appearance of the decking system and additionally may present potential danger to those walking on it. It would be desirable, therefore, to provide an improved flat panel decking system in which shifting of the adjacent panels is avoided yet which does not detract from the portability of the system. 
     SUMMARY OF THE INVENTION 
     The invention includes the use of a special connector-spacer by which adjacent edges of adjacent decking panels may be connected together firmly and in a predictable spacing, but in a manner that enables the panels to be detached readily. The connector is W-shaped in cross-section to define a pair of parallel channels that receive the adjacent frames of adjacent deck panels. Preferably two such connectors are placed along the adjacent edges of a pair of adjacent panels. Each of the two channels of each connector-spacer has inner and outer side walls and a connective bottom wall. The upper end of each channel is open to receive the frame of a deck panel. The inner side walls of the connector-spacer are secured rigidly to each other and are spaced a predetermined amount to control the intended spacing between adjacent edges of the top boards of adjacent decking panels. The outer walls of each channel are inclined upwardly and inwardly at a slight angle to define a slightly constricted entry into the channel. The constricted entry is slightly narrower than the thickness of the frame that is to be inserted into the channel. The bottom of the channel width is adequate to receive the frame. The outer walls of each channel are sufficiently flexible so that as the frame is urged into the channel, the outer wall will flex sufficiently to permit entry of the frame. When the frame has been pressed into the channel, the outer wall effects a firm frictional grip on the frame. An adjacent frame is placed in the other channel with the central member serving to space the panels by a predetermined amount. Although the connector-spacers are sufficient to maintain a secure grip to stabilize the deck panels, the deck panels are easily detached to enable movement, rearrangement or seasonal storage of the deck panels. 
     It is among the general objects of the invention to provide an improved deck panel system in which the deck panels are securely yet detachably connected to each other. 
     Another object of the invention is to provide an improved deck system in which the edge of a panel is uniformly spaced from the edge of an adjacent panel. 
     An additional object of the invention is to provide an improved deck system which is easily disassembled and lends itself to portable use. 
     A further object of the invention is to provide an improved deck panel system and connector-spacer for use therewith by which the frames of adjacent deck panels are attached to the connector by frictional engagement. 
     Another object of the invention is to provide a deck system of the type described which may be assembled without requiring the use of any tools or other conventional fasteners. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     The foregoing and other objects and advantages of the invention will be appreciated more fully from the following further description thereof, with reference to the accompanying drawings wherein: 
     FIG. 1 is an illustration of a number of panels of a decking system attached to each other with the connector-spacer of the present invention; 
     FIG. 2 is an illustration of the connector-spacer of the present invention; 
     FIG. 3 is an end view of the connector-spacer of the present invention; 
     FIG. 4 is an illustration, in section, of the connector-spacer as seen along the line 4--4 of FIG. 3; and 
     FIG. 5 is an illustration of the connector-spacer engaged with the frames of a pair of adjacent deck panels as seen from an end of the connector-fitting and with the frame member in section. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 illustrates a plurality of deck panels, indicated generally at 10. The panels are illustrated as arranged in a parquet pattern and may form a portion of a deck, walkway or the like. In the illustrative embodiment, each deck panel is rectangular and includes a rectangular frame formed from wood frame members 12. A plurality of surface boards 14 are attached, as by nails, to the frame members 12. The surface boards 14 typically are spaced from each other a predetermined amount, for example, 1/8&#34; to 1/4&#34;. Preferably, the periphery defined by the surface boards 14 is slightly greater than the periphery defined by the underlying frame so that the surface boards 14 overhang slightly beyond the frame, as indicated at 16 in FIG. 5. 
     The deck panels 10 are intended to be placed directly on the ground. It is preferred that the panels be placed so that the adjacent edges of the surface boards 14 of adjacent panels are spaced a distance equal to the spacing between surface boards in the deck panel. By maintaining the spacing uniform, the esthetic appearance of the system is preserved. Additionally, when the panels are placed with their boards all extending in the same direction, the decking will appear seamless, that is, the separation between adjacent panels will not be apparent. 
     FIGS. 2-4 illustrate the preferred embodiment of the connector used to join the panels together. The connector, indicated generally at 18, preferably is formed from a suitable polymeric material having adequate toughness. Polycarbonate has been found to be suitable. Polycarbonate material displays good memory, is non-corrosive and displays good low temperature operability. In the preferred embodiment of the connector-spacer, the clip is formed to include a pair of channels 20, 22 which are receptive to adjacent frame members 12 of adjacent panels as indicated in FIG. 5. Each of the channels includes an inner wall 24 having upper and lower ends. The upper ends are connected by an integral web 26. The lower ends of the inner walls 24 merge into outwardly extending bottom walls 28 which, in turn, merge into upwardly extending outer walls 30. A stiffener and spacer 32 is secured, as by a suitable adhesive, to the inwardly facing surfaces of the inner walls 24. The stiffening spacer 32 may be T-shaped in cross-section as shown in FIG. 4. 
     The channels 20, 22 are dimensioned so that their width, along the bottom wall 28 corresponds to the width of the frame members 12. The upper ends of the outer walls 30, however, are inclined inwardly at a slight angle A, of the order of a few degrees. Thus, the spacing between the inner and outer walls 24, 30 is somewhat restricted at the upper entry end. The outer walls 30 and bottom walls 28 are sufficiently flexible so that the walls 30 can flex to expand the width at the upper end of the channel thereby to receive the frame members 12 as indicated in FIG. 5. When the frame members 12 are so received in the channels, the outer walls 30 will be biased inwardly firmly toward and against the frame member 12 to securely grip the frame member 12. The upper ends of the outer walls 30 preferably are formed with smoothly curved inwardly facing surfaces 34 which will engage the frame member and smoothly guide the frame member into the channel while the outer wall 30 flexes outwardly to receive the full width of the frame member 12. 
     The connector-spacer 18 preferably is formed with its inner walls 24 spaced so that the adjacent edges of the surface boards 14 of adjacent deck panels 10 will have the same spacing that exists between adjacent surface boards 14 within a given deck panel. Thus, as illustrated in FIG. 5, it will be appreciated that the device is formed so that the inner walls 24 will maintain the spacing of the adjacent edges 36 of adjacent panels. Such uniform spacing is illustrated in FIG. 1 from which it can be seen that the spacing between the surface boards of adjacent panels 10 corresponds to that between the adjacent surface boards 14 in a single panel and presents a satisfactory overall appearance. The web 26 and inner spacer 32 are dimensioned accordingly. 
     By way of dimensional example, for a system including deck panels in which the frames are formed from conventional two by fours (having actual cross-sectional dimensions 1.5&#34;×3.5&#34;). The width of each channel at its bottom preferably is 1.5&#34;. The height of the device measured from the underside of the bottom wall 28 to the top of the web 26 preferably is 3&#34;. The height of the outer walls 30 is 2&#34;. The width of the central portion is measured between outwardly facing surfaces of the inner walls 24 preferably is 0.75&#34;. The walls and webs preferably are of the order of 0.150&#34; thickness throughout the device. 
     Also among the features of the invention is that the connector-spacer is not readily visible because it is substantially concealed by the deck panels. This is apparent from FIG. 5 from which it may be seen that the approximate 1/4&#34; space between edges 36 of adjacent panels does not provide sufficient space to see easily the web 26 of the connectors. The connectors may be injected molded or extruded and cut from lengths of the extrusions. Preferably the W-shaped portion is formed first and the T-shaped brace is inserted and adhesively attached in a separate step. 
     From the foregoing it will be appreciated that the invention provides for a decking system in which panels can be attached, edge-to-edge, easily and securely thereby assuring that they will not shift out of position. The connectors are effective to secure the panels together and to maintain them at a desired spacing. A decking system using the connector spacers can be assembled easily without requiring special tools or connectors and also is easily disassembled, thus enhancing its portability. 
     It should be understood, however, that the foregoing description of the invention is intended merely to be illustrative thereof and that other embodiments, modifications and equivalents may be apparent to those skilled in the art without departing from its spirit.