Abstract:
A decking system comprised of decking panels and clips is provided. Each decking panels comprises a platform and downwardly-extending legs that rest on joists. Clips that clip onto the joists are inserted between adjacent decking panels and define a uniform gap between the panels. The clips further connect to the legs of the decking panels and hold the decking panels in place. Fasteners driven through the clips and into the joists rigidly affix the decking panels to the joists.

Description:
RELATED APPLICATIONS 
     This application is a continuation of and claims priority to U.S. provisional Application Ser. No. 61/155,594, filed Feb. 26, 2009, titled “Decking Panel System,” which is incorporated herein by reference. 
    
    
     BACKGROUND &amp; SUMMARY 
     A decking system comprised of extruded decking panels is provided. A clip attached to a joist receives and retains the outer legs of adjacent decking panels. The clip comprises downwardly-extending legs that grip the sides of the joist and hold the clip in place until a fastener is installed in the clip to permanently attach the clip and the decking panels to the joist. The clips allow an entire deck surface, or portions of the deck surface, to be set in place before the permanent fasteners are installed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. 
         FIG. 1  depicts a decking system according to an embodiment of the present disclosure. 
         FIG. 2  is a cross-sectional view of the decking system of  FIG. 1 , taken along section lines A-A of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of the decking system of  FIG. 1 , taken along section lines B-B of  FIG. 1 . 
         FIG. 4  is a side plan view of a clip according to an embodiment of the present disclosure. 
         FIG. 5  is a top plan view of the clip of  FIG. 4 . 
         FIG. 6  is a cross-sectional view of the clip of  FIG. 5 , taken along section lines C-C of  FIG. 5 . 
         FIG. 7  is a cross-sectional view of the clip of  FIG. 5 , taken along section lines D-D of  FIG. 5 . 
         FIG. 8  is a cross-sectional view of the clip of  FIG. 5 , taken along section lines E-E of  FIG. 5 . 
         FIG. 9  is an enlarged detail view taken along line “F” of  FIG. 2 . 
         FIG. 10  is an enlarged detail view taken along line “G” of  FIG. 9 . 
         FIG. 11  is a side plan view of the decking system  10  according to an embodiment of the present disclosure. 
         FIG. 12  depicts a method of installing a decking system according to an embodiment of the present disclosure. 
         FIG. 13  is a side view of a decking system illustrating a step of the method of  FIG. 12 , with one a first decking panel installed. 
         FIG. 14  is a side view of a decking system illustrating a step of the method of  FIG. 12 , after a plurality of clips is installed to the first decking panel. 
         FIG. 15  is a side view of a decking system illustrating a step of the method of  FIG. 12 , after a second decking panel is installed. 
         FIG. 16  is a side view of a decking system illustrating a step of the method of  FIG. 12 , after a third decking panel is installed 
         FIG. 17  is a side view of a decking system illustrating a step of the method of  FIG. 12 , after fasteners are installed in the third decking panel. 
         FIG. 18  is a side view of a decking system illustrating a step of the method of  FIG. 12 , after fasteners are installed into the clips. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention and its advantages are best understood by referring to the drawings. The elements of the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention. 
       FIG. 1  shows a decking system  10  according to one embodiment of the present disclosure. The decking system  10  includes a plurality of substantially identical decking panels  13  disposed upon a plurality of joists  12 . Clips  11  clipped to the joists  12  secure the decking panels  13  to the joists  12  via fasteners (not shown) installed into the clips  11 . The clips  11  further set the spacing of gaps  16  between the decking panels  13 , as is further discussed herein. 
     The joists  12  are typically fabricated from wood. In one embodiment, the decking panels  13  are extruded aluminum, though in other embodiments may be fabricated from other materials known in the art or hereafter developed, such as composite, other metals, plastic, or the like. In one embodiment, the decking panels  13  have a wall thickness of 0.065 inches. The decking panels  13  are generally rectangular and may be made in any length desired by a user (not shown), and in one embodiment are formed in lengths of 12, 16 and 20 feet. 
     The width of a decking panel according to one embodiment is 5¾ inches, though other widths may be used in other embodiments. The distance “d” from the center of one clip  11  to the center of an adjacent clip  11  is 6″ in one embodiment, though other distances may be employed in other embodiments. 
     In the illustrated embodiment, the decking panels  13  are disposed generally perpendicularly to the joists  12 . In other embodiments, the decking panels  13  may be differently angled relative to the joists  12 . 
       FIG. 2  is a cross-sectional view of the decking system  10  of  FIG. 1 , taken along section lines A-A of  FIG. 1 . In this embodiment, each decking panel  13  comprises an extruded aluminum platform  51 . The platform  51  is generally horizontal and comprises a top panel surface  14  which forms a walking surface of the decking system  10 . 
     The top panel surface  14  of the platform  51  comprises protrusions  15  that are raised areas unitarily formed with the platform  51 . The protrusions  15  provide texture to the top panel surface  14  and therefore provide traction for the user (not shown) of the decking system  10 . The protrusions  15  generally run longitudinally down the length of the platform  51 . 
     The decking panels  13  further comprise outer legs  17  and inner legs  18 . The outer legs  17  and the inner legs  18  extend downwardly from and support the platform  51  spaced apart from (i.e. raised above) the joists  12 . The outer legs  17  and the inner legs  18  extend longitudinally down the length of the decking panels  13  in this embodiment. 
     The inner legs  18  comprise generally vertical supports  50  extending generally perpendicularly down from a bottom side  52  of the platform  51 . The inner legs  18  further comprise lower side flanges  19  that extend from the generally vertical supports  50  and rest on the joists  12 . The outer legs  17  comprise an angled portion  20  that extends downwardly from an outer edge  53  of the platform  51  and a generally horizontal portion  21  connected to the angled portion  20 . The outer legs  17  thus form a “Z”-shape in conjunction with the platform  51 . In other embodiments, the outer legs  17  of the decking panels  13  are differently shaped, as is further discussed herein. 
     Each clip  11  has two (2) downwardly-extending legs  22  (one of which is shown in  FIG. 2 ) that frictionally grip opposite sides of the joist  12  to hold the clip  11  to the joist  12  until a fastener (not shown) is installed through the clip into the joist, as further discussed herein. 
     The decking panels  13  are spaced apart from one another by the gap  16  between the panels  13 . The gap  16  is maintained generally uniformly by the clip  11  which fits between the outer legs  17  of adjacent decking panels  13 , as shown. When installed, the clip  11  contacts the outer legs  17  of adjacent decking panels  13  such that when the fastener (not shown) is installed, the clip  11  secures the decking panels  13  firmly in place against the joist  12 , as further discussed herein. 
       FIG. 3  is a cross-sectional view of the clip  11  of  FIG. 1 , taken along section lines B-B of  FIG. 1 . The joist  12  has a generally rectangular cross-section in this embodiment, with two generally-straight long sides  23  and a generally straight top and bottom side,  24  and  25 , respectively, that are disposed generally perpendicularly to the long sides  23 . The clip  11  fits over the top short side  24  such that the downwardly-extending legs  22  of the clip  11  extend partially down the long sides  23 , as shown. After the clip  11  is installed on the joist  12 , a fastener  26  is installed in the clip  11  and driven into the joist  12  to secure the clip to the joist  12 . 
     The fastener  26  may be a typical threaded wood screw that is self-tapping when driven into the joist  12 . In other embodiments, other types of fasteners may be used. 
       FIG. 4  is an enlarged side view of the clip  11  of  FIG. 1 . In this embodiment, the clip  11  comprises an elongated clip body  30 , a top side  32 , two (2) angled side edges  33  (only one of which is shown in  FIG. 4 ), two (2) ends  34 , and a bottom side  31 . The downwardly-extending legs  22  extend generally perpendicularly from the bottom side  31  of the clip body  30 . The legs  22  are disposed near the ends  34  of the clip body  30 , as shown. 
     One or more raised tracks  29  are disposed on the bottom side  31  of the clip body  30 . The raised tracks  29  comprise elongated pointed protrusions integrally formed with the clip body  30 . The tracks  29  “dig into” or grasp the joist  12  ( FIG. 3 ) when the fastener  26  ( FIG. 3 ) secures the clip  11  to the joist  12 . In this regard, the joist  12  is generally formed of wood that is penetrable by sharp or pointed objects. The tracks  29  may thus penetrate the joist  12  and help to secure the clip  11  to the joist  12 . 
     In this embodiment, the clip body  30 , the legs  22 , and the tracks  29  are integrally formed from a solid material, such as by injection molding of plastic. In other embodiments, other materials and/or processes currently known or hereafter developed may be used to fabricate the clip  11 . 
     A fastener opening  27  in the clip body  30  extends through the clip body  30  and receives the fastener  26  ( FIG. 3 ). The fastener opening  27  may be a countersunk hole such that when the fastener  26  is installed, the fastener  26  does not protrude above the clip body  30 . Other configurations of openings  27  are usable with other types of fasteners  26  that may be used in other embodiments to attach the clip  11  to the joist  12 . 
     In the illustrated embodiment, the fastener opening  27  is centrally located within the body  30  (i.e., located equidistant from the ends  34  and the angled side edges  33 ). In other embodiments, the fastener opening  27  may be located elsewhere on the clip  11 . 
     The illustrated embodiment includes leg openings  28  disposed above each of the downwardly-extending legs  22 . The leg openings  28  comprise hollow rectangular channels formed in the body  30  directly adjacent to (i.e., above) the legs  22 . The purpose of the leg openings  28  is to provide “weak spots”  54  at the juncture of the body  30  and a top end  35  of the legs  22 . These weak spots  54  enable the legs  22  to be readily broken off in the event the user (not shown) desires to use the clip  11  in a configuration where there is no access for the legs  22  to clamp onto the joist  12 . Breaking off one or more legs  22  may be desired, for example, if there are two joists  12  abutted directly together. 
       FIG. 5  is a top plan view of the clip  11  of  FIG. 4 . The body  30  approximates a rectangle when viewed from the top, as shown. The fastener opening  27  is centrally located in this embodiment, as discussed above with respect to  FIG. 4 . The leg openings  28  comprise rectangularly-shaped channels that extend into the body  30 . The clip  11  is substantially symmetrical around its x and y axes in this embodiment, as illustrated. 
       FIG. 6  is a cross-sectional view of the clip  11  of  FIG. 5 , taken along section lines C-C of  FIG. 5 . In this embodiment, the raised tracks  29  comprise a pair of protrusions that extend along the bottom side  31  of the body  30 , and are integrally formed with the body  30 . The tips  66  of the tracks  29  narrow (i.e., are somewhat sharpened) such that the tips  66  may grip the surface of the joist  12  ( FIG. 2 ). 
     In this embodiment, the bottom side  31  of the clip body  30  further comprises a pair of channels  37 . The channels  37  are recessions in the bottom side  31  of the clip body  30  that extend longitudinally down the body  30 . The purpose of the channels  37  is to receive and retain the free ends  39  ( FIG. 9 ) of the outer legs  17  ( FIG. 2 ), as is further discussed with respect to  FIG. 9  below. 
     In this embodiment, the side edges  33  angle downward and outward from the top side  32 . The angle of the side edges  33  is substantially similar to the angle of the angled portions  20  of the outer legs  17  ( FIG. 2 ). The similarity in angles of the side edges  33  of the clip  11  and the angled portions  20  of the outer legs  17  enables the edges  33  of the clip  11  to snugly abut the angled portions  20  of the outer legs  17 , as shown in  FIG. 2 . In other embodiments, the side edges  33  may be differently shaped to abut differently-shaped outer legs  17 . 
     Further, in other embodiments of the clip  11  the side edges  33  may not contact the decking panels  13  ( FIG. 2 ) at all, but rather the bottom surface  31  of the clip  11  may be the only portion of the clip  11  that contacts the decking panels  13 . 
       FIG. 7  is a cross-sectional view of the clip  11  of  FIG. 5 , taken along section lines D-D (i.e., the centerline) of  FIG. 5 . The fastener opening  27  as shown extends completely through the clip body  30  from the top side  32  to the bottom side  31 , such that the fastener  26  ( FIG. 3 ) can be installed through the opening  27 , as was discussed above with respect to  FIG. 3 . 
       FIG. 8  is a cross-sectional view of the clip  11  of  FIG. 5 , taken along section lines E-E of  FIG. 5 . The leg opening  28  extends most of the way down through the body  30 , as shown, such that only thin strips  38  of material attach the leg  22  to the body  30 , so that the leg  22  may be broken off of the body  30  as may be desired by the user (not shown). 
       FIG. 9  is a detail view of the clip  11  of  FIG. 2 , taken along detail “F” of  FIG. 2 . As illustrated, the body  30  of the clip  11  fits within a somewhat trapezoidal area created by the angled portions  20  of the outer legs  17  of adjacent decking panels  13 . As was discussed above with respect to  FIG. 6 , the side edges  33  are disposed at an angle similar to the angle of the angled portions  20 , such that the body  30  may fit snugly between the angled portions  20  of adjacent decking panels  13 . The side edges  33  fitting snugly within the angled portions  20  of adjacent decking panels  13  prevents the clip  11  from moving with respect to the decking panels  13  in the ±x direction and the ±y direction. 
     In this embodiment, the body  30  fitting within the angled portions  20  sets the width “w” of the gap  16  between adjacent decking panels  13  and further maintains the uniformity of the gap  16 . In one embodiment, the width “w” of the gap  16  comprises approximately ¼ inches. In other embodiments, different widths of the gap  16  may be used. 
     The free ends  39  of the outer legs  17  comprise protrusions  40  that fit within the channels  37  of the clip body  30 . The channels  37  thus receive and retain the free ends  39 , and in this manner, the clip  11  retains the decking panels  13  in place, as further discussed herein. The protrusions  40  fitting within the channels  37  further aids in preventing the clip  11  from moving with respect to the decking panels  13  in the ±x direction. 
     The legs  22  of the clip  11  fit in between the free ends  39  of the adjacent decking panels  13 . The tracks  29  of the clip  11  also fit between the free ends  39 , such that the tracks  29  may grip the joist  12 . The tracks  29  gripping the joists  12  further aids in preventing the clip  11  from moving with respect to the decking panels  13  in the ±x direction 
       FIG. 10  is an enlarged detail view of the clip  11  of  FIG. 9 , taken along detail “G” of  FIG. 9 . The channel  37  is formed into the body  30  of the clip  11 , and in this embodiment comprises a generally flat top wall  41  and angled side walls  42  and  43 . 
     The protrusion  40  is integral with and extends upwardly from the horizontal portion  21  of the outer leg  17 , near the free end  39 . In this embodiment, the protrusion comprises a generally flat top wall  60  and angled side walls  61  and  62 . When the clip  11  is installed onto the decking panel  13 , the protrusion  40  is received by the channel  37 . In this regard, the flat top wall  60  of the protrusion  40  contacts the flat top wall  41  of the channel  37 . The angled side walls  42  and  43  help to retain the protrusion  40  within the channel  37 . 
       FIG. 11  illustrates a different embodiment of the decking panels  13 . In this embodiment, the outer legs  17  of the decking panels  13  are not Z-shaped as in the prior-discussed embodiment. Rather, the outer legs form an “L”-shape, with a generally vertical portion  50  and a generally horizontal lower end  51 . The upper ends  52  of the panel  13  comprise downwardly-curved free ends, as shown. 
       FIG. 12  depicts a method  100  for installing the decking system  10  according to an embodiment of the present disclosure. In step  100 , which is illustrated in  FIG. 13 , a first decking panel  13   a  is installed on a joist  12 . Although only one joist  12  is illustrated, it is understood that a plurality of joists  12  are required to support the decking panels  13 , as shown in  FIG. 1 . The joist  12  has a first end  71  and a second end  72 . The decking panel  13   a  is disposed upon the joist  12  near the first end  71  such that the outer legs  17   a  and  17   b  and inner legs  18  of the decking panel  13   a  rest upon a top surface  70  of the joist  12 . 
     One or more fasteners  26   a  is driven through the outer leg  17   b , which is the leg disposed at a first end  71  of the joist  12 . The fasteners  26   a  are typically installed at every joist  12  location. Joists  12  are typically located at  12 ″,  18 ″ or  24 ″ centers, though other spacing configurations of joists  12  may be used. 
     In step  102  of the method  100 , which is illustrated in  FIG. 14 , a plurality of clips  11   a  are then clipped on the joists  12  such that the clip(s)  11   a  restrain the outer leg  17   a  of the decking panel  13   a . Although  FIG. 14  shows only one clip  11   a , there may be a plurality of clips  11   a  used down the length of the panel  13   a.    
     In step  103  of the method  100 , which is illustrated in  FIG. 15 , a second decking panel  13   b  is set on the joist  12 . The outer leg  17   c  of the second decking panel  13   b  is slid underneath the clip  11   a.    
     In step  104  of the method  100 , which is illustrated in  FIG. 16 , a plurality of clips  11   b  are then installed on the joists  12  such that the clip(s)  11   b  restrain the outer leg  17   d  of the decking panel  13   b.    
     In step  105  of the method  100 , which is illustrated in  FIG. 16 , a third decking panel  13   c  is set upon the joists  12  and an outer leg  17   e  of the third decking panel  13   c  is slid underneath the clip  11   b , as shown. 
     Referring to  FIG. 17 , in the illustrated embodiment, the third decking panel  13   c  is the last decking panel, and after it is in place, one or more fasteners  26   b  are installed in an outer leg  17   f  of the panel  13   c  to secure the panel  13   c  in place. 
     In step  106  of the method  100 , which is illustrated in  FIG. 18 , fasteners  26   c  and  26   d  may be installed in the clips  11   a  and  11   b  to permanently secure the decking panels  13   a ,  13   b , and  13   c  in place. 
     Although the method  100  and the accompanying  FIGS. 13-18  illustrate a decking system  10  comprising three (3) decking panels  13   a ,  13   b , and  13   c , it is understood that a deck will generally comprise many more decking panels, which may be installed with the general method discussed herein. Further, although the method  100  and the accompanying  FIGS. 13-18  illustrate and two clips  11   a  and  11   b , it is understood that clips will preferably be installed at every intersection of a decking panel and a joist, and therefore multiple clips will generally be used. 
     This invention may be provided in other specific forms and embodiments without departing from the essential characteristics as described herein. The embodiment described is to be considered in all aspects as illustrative only and not restrictive in any manner.