Abstract:
A Top Deck Panel System cover made from a plastic material, such as Polyvinyl chloride (PVC), Polypropylene (PP), Polyethylene (PE), Polyethylene Terephthalate (PET), Nylon and/or wood composite, wherein the top deck exterior walking cover is assembled without the use of mechanical fasteners such as screws or nails. The Top Deck Panel System cover is designed to be either a temporary or permanent exterior walking surface and can be placed on ground such as gravel, sand, limestone, soil and/or used to cover existing decks, concrete walkways or porches, brick walkways or porches, or other walking surfaces. The Top Deck Panel System cover can be quickly and effectively installed. The Top Deck Panel System provides a mobile walking surface that allows the Top Deck Panel System to be moved easily, efficiently and economically.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims priority to U.S. Provisional Application No. 60/886,970, filed on Jan. 29, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The presently disclosed invention relates to decks and, more particularly, decks that do not require a support framework and that can be assembled without special tools. 
         [0004]    2. Description of the Prior Art 
         [0005]    Many types and styles of decks are known in the prior art. Most of these decks are permanent designs that are intended for use only in connection with a structure or framework that supports and stabilizes the deck. Examples are shown in U.S. Publication No. 2003/0192275 and U.S. Pat. Nos. 6,619,002; 6,467,118; 6,260,322; 5,050,361; and 5,758,467. 
         [0006]    Various mechanisms have been used to secure such decks to the support structure and keep the deck panels or planks in the same relative position. In many cases, the panels or planks that comprise the deck surface are secured directly to the underlying support structure. Examples are shown in U.S. Pat. Nos. 5,613,339; 6,453,630; 6,594,961; 5,009,045; D485,373; D492,797 and Des 418,926. Other decks include structure that is intended to engage adjacent deck panels and maintain the panels or planks in position and to strengthen the overall structure. Examples of those structures are shown in U.S. Pat. Nos. 6,233,886 and 5,660,016 wherein a third member or connector is located between adjacent panels and cooperates with both panels to secure them together. In other cases such as shown in U.S. Pat. Nos. D485,621, 5,647,184; 6,272,808; 6,199,340; and 6,324,796, opposite side surfaces of the deck plank have cooperative features such that when the planks are aligned in a parallel array, the side of one plank will engage the opposing side of the adjacent plank so that the planks are connected together laterally. 
         [0007]    However, there was a need for a deck surface that could be used with or without a dedicated support structure. Such a deck surface would have the advantage of being more widely applicable because it could be supported either by dedicated support structure such as a wood or metal frame, or, alternatively, could be deployed directly on the ground or on a general floor surface such as a concrete floor. 
         [0008]    Prior art deck panels and planks generally were not well-suited for such multiple applications. In many instances, prior deck planks and panels could not be secured together without the intended support structure. In other instances, the deck panels and planks had sides with mating configurations so that two adjacent panels could engage together. However, such panels and planks were prone to separating while in service. Some of such planks and panels, such as shown in U.S. Pat. Nos. D485,621; 5,647,184; 6,272,808; and 6,199,340 had mating surfaces that were joined by moving the planks laterally together. Other planks and panels such as shown in U.S. Pat. No. 6,324,796 could be joined by relative vertical movement of adjacent planks. Those planks sometimes performed better when there was a solid, relatively flat supporting surface such as a concrete floor. However, when used on open ground, these configurations also were prone to separation. 
         [0009]    Accordingly, there was a need for a deck with planks or panels that remained secured together notwithstanding their particular application with or without support structure. Also, there has been a need for a deck that can be assembled for a temporary application. Therefore, it also would be preferable for the deck planks to be assembled simply and without need of tools. 
       SUMMARY OF THE INVENTION 
       [0010]    In accordance with the presently disclosed invention, an interlocking top deck panel system that provides an exterior walking surface has a generally rectangular profile with horizontal top and bottom surfaces and two sides. The panel system can be made from a plastic material and can be installed without mechanical fasteners. A plurality of walls are longitudinally aligned with the panels and protrude from the bottom surface of the panel. First and second connector rails are secured to opposite sides of the panel and oriented longitudinally with respect to the panel. The first and second connector rails are shaped in complementary relationship so that a first connector rail on one panel can engage a second connector rail on an adjacent panel by sliding the first connector rail longitudinally with respect to the second connector rail to fasten the adjacent panels together. 
         [0011]    Preferably, the panel is comprised of a plastic selected from the group of polyvinyl chloride, polyethylene, polypropylene, polyethylene teraphalate, polyamide, and combinations thereof. Also preferably, the panel can be comprised of a wood composite material. The polyvinyl chloride and other plastic materials can be cellular or foamed. 
         [0012]    More preferably, the panel is comprised of recycled materials selected from the group of polyvinyl chloride, polyethylene, polypropylene, acrylonitrile butadiene styrene, polystyrene, polyethylene terephthalate, nylon, poly carbonate, and combinations thereof. 
         [0013]    The top deck panel system can be extruded or co-extruded from more than one plastic material and also can have a plurality of surface grooves that are longitudinally aligned in the top surface of the panel to convey water off of the deck. The surface grooves can be V-shaped grooves that are adopted to convey moisture to the ends of the panel. A least a portion of the top surface of the panel can also have a grooved textured surface to increase the coefficient of friction of said top surface. The grooves of the grooved textured surface also can be generally parallel to the V-shaped grooves or can be orthogonal to the V-shaped grooves, or both orientations of textured grooves can be used. The portion of the top surface having a grooved textured surface can be located between at least two V-shaped grooves in the top surface of the panel. 
         [0014]    The top deck panel system can include at least one channel that is defined by the bottom surface of the panel and at least two walls that are longitudinally oriented with the panel and extend from the bottom surface of the panel, said channel adapted to convey moisture to the longitudinal ends of the panel. 
         [0015]    Also preferably, at least two end pieces can be used as accessory pieces to trim out the top deck panel system. One end piece has an outer surface and a connector structure that has a profile that corresponds to the profile of the second connector rail. The other end piece has an outer surface with a connector structure that has a profile that corresponds to the profile of the first connector rail. The outer surface of one end piece corresponds to the outer surface of the second end piece so that the outer surfaces of the two end pieces have the same appearance and provide the lateral sides of the deck with a finished appearance. The end pieces can also have a screw boss for securing the end pieces to another structure. 
         [0016]    Most preferably, the top deck panel system can include an end clip to hold the top deck panel system together. The end clip can have a top side that has a textured surface and that also can have grooves. The end clip can be made of plastic. 
         [0017]    Other features, advantages and objects of the presently disclosed invention will become apparent to those skilled in the art as a description of a presently preferred embodiment thereof proceeds. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    Included with the disclosure and hereby specifically incorporated herewith are Figures that show and describe a particular example of the panel, panel assembly, deck and components thereof as further described herein in which: 
           [0019]      FIG. 1  is a perspective view of a presently preferred embodiment of a deck panel as disclosed herein; 
           [0020]      FIG. 2  is a top plan view of the deck panel shown in  FIG. 1 ; 
           [0021]      FIG. 3  is a bottom view of the deck panel shown in  FIG. 1 ; 
           [0022]      FIG. 4  is a right side elevation view of the deck panel shown in  FIG. 1 ; 
           [0023]      FIG. 5  is a left side elevation view of the deck panel shown in  FIG. 1 ; 
           [0024]      FIG. 6  is a rear end view of the deck panel shown in  FIG. 1 ; 
           [0025]      FIG. 7  is a front end view of the deck panel shown in  FIG. 1 ; 
           [0026]      FIG. 8  is an end view of a deck that includes two deck panels such as shown in  FIG. 1  together with side rails on the outer sides of each deck panel and wherein the deck is secured to a joist; 
           [0027]      FIG. 9  is an end view of a deck that includes two deck panels such as shown in  FIG. 1  together with side rails on the outer sides of each deck panel and wherein the deck is supported by the ground; 
           [0028]      FIG. 10  is an end view of the deck shown in  FIG. 9  with a bracket that covers the end of the deck; 
           [0029]      FIG. 11  is a perspective view of a presently preferred embodiment two deck panels that are connected together by respective connector rails; 
           [0030]      FIG. 12  is a top plan view of the deck panels shown in  FIG. 11 ; 
           [0031]      FIG. 13  is a right side elevation view of the deck panels shown in  FIG. 11 ; 
           [0032]      FIG. 14  is a bottom plan view of the deck panels shown in  FIG. 11 ; 
           [0033]      FIG. 15  is a left side elevation view of the deck panels shown in  FIG. 11 ; 
           [0034]      FIG. 16  is a rear end view of the deck panels shown in  FIG. 1  with interior structure shown in hidden lines; 
           [0035]      FIG. 17  is a front end view of the deck panels shown in  FIG. 11  with interior structure shown in hidden lines; and 
           [0036]      FIG. 18  is an end view of a deck panel in combination with an alternative side rail. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0037]    As further disclosed in the accompanying drawings, a deck surface  10  is composed of a plurality of panels  12  that are interlocked together along their lateral sides as more particularly shown and described herein. 
         [0038]    Each of the panels  12  includes a panel body  14  that defines a planar top surface  16  and a bottom surface  18  that is oppositely disposed on the panel body  14  from the planar top surface  16 . The panel body  14  also defines a first lateral side  20  that is located between the planar top surface  16  and the bottom surface  18  and a second lateral side  22  that is also located between the planar top surface  16  and the bottom surface  18 . The second lateral side  22  is oppositely disposed on the panel body  14  from the first lateral side  20 . 
         [0039]    Each panel  12  further includes at least one wall  24  that extends from the bottom surface  18 . The wall  24  cooperates with the panel body  14  to support and mechanically strengthen the panel body  14 . In addition, where panel  12  includes two or more walls  24 , the walls that are located adjacent to each other cooperate with bottom surface  18  to define a channel  26 . Channel  26  conveys moisture toward the ends of the panel. 
         [0040]    Each panel  12  also includes a first connector rail  28  that is secured to the first lateral side  20  of the panel body  14 . The first connector rail is aligned longitudinally parallel to the longitudinal axis  30  of the panel body  14 . Panel  12  also includes a second connector rail  32  that is secured to the second lateral side  22  of the panel body  14 . The second connector rail  32  is also aligned longitudinally parallel to the longitudinal axis  30  of the panel body  14 . 
         [0041]    In the presently disclosed example of the preferred embodiment, the first connector rail  28  has a profile that defines an enlarged distal portion. In the example of the preferred embodiment, the enlarged distal portion is the “T” portion of a T-shaped profile or cross-section  34 . The second connector rail  32  has opposed arms that define a gap therebetween. In the example of the preferred embodiment, the second connector rail  32  cooperates with side  22  to form a C-shaped profile or cross-section  36 . T-shaped cross section  34  and C-shaped cross-section  36  are sized and shaped in complementary fashion such that the T-shaped cross-section  34  of one panel  12  can be longitudinally received in the C-shaped cross-section of another panel  12  and will slidably engage inside of the C-shaped cross-section  36  of the other panel  12 . In this way, the two panels can be secured together along their respective longitudinal lengths by slidably inserting one end of T-shaped cross-section  34  of one panel  12  into an end of C-shaped cross-section  36  of another panel  12 . 
         [0042]    Specifically, the panels  12  are placed in end-to-end relationship with one longitudinal end (for example, end  42 ) of T-shaped cross-section  34  of one panel  12  opposite from the longitudinal end (for example, end  44 ) of C-shaped cross-section  36  of the other panel  12 . One panel  12  is then moved in a longitudinal direction with respect to the other panel  12  so that the T-shaped cross-section  34  of the one panel travels longitudinally into the C-shaped cross-section  36  of the other panel. The two panels are moved together in the longitudinal direction until the ends  42  and  44  of one panel  12  have a longitudinal position that is even with the ends  42  and  44  of the other panel. The T-shaped cross-section  34  of the first connector rail  28  of one panel is then captured in interlocking relationship inside the C-shaped cross-section  36  of the second connector rail  32  of the other panel. 
         [0043]    First connector rail  28  is sized such that the cross-sectional dimension of the “T” portion  62  of connector rail  28  is too large to pass laterally through the gap  64  of C-shaped profile of second connector rail  32 . In this way, the panels  12  are laterally interlocked, meaning that the panels are not joined or separated by forces acting laterally between the panels. 
         [0044]    This manner of securing panels  12  provides for the assembly of a plurality of panels to form a walking surface such as a deck  37 . Any number of panels can be assembled in the this way to produce a walking surface or deck  37  of any predetermined size. Also in this way, the panels can be laterally connected without need of any fasteners or special tools. 
         [0045]    Preferably, the top surface  16  of panel  12  defines a textured surface  38 . In this way, the panel affords improved traction when incorporated into an assembled walking surface. The textured surface can be an embossed pattern in which an array of parallel grooves are oriented parallel to V-grooves  40 . Also, the grooves of the textured surface  38  can be oriented orthogonally to V-grooves  40  and spaced about 0.30 inch as measured along longitudinal axis  30 . Preferably, the embossed grooves have a V-shaped cross-section that is about 0.050 inch wide and about 0.030 inch deep. 
         [0046]    Panel  12  can be made of a number of suitable materials. Preferably, such materials have the mechanical strength necessary for a deck, do not rust, and resist color fading due to sun exposure. Also, preferably, the panel material will maintain such properties over many years and over a wide range of temperatures. Among other materials, panel  12  can be made of polyvinyl chloride, polypropylene, polyethylene teraphalate, polyamide, wood composite, or combinations of those materials. Also preferably, panel  12  can be made of Polyvinyl Chloride (PVC), Polypropylene (PP), Polyethylene Terephthalate (PET), polyamide, Polyethylene (PE), Acrylonitrile Butadiene Styrene (ABS), Polystyrene (PS), nylon, Poly carbonate (PC) or combinations of those materials. The polyvinyl chloride or other materials can be foamed or cellular. 
         [0047]    Panel  12  can also include an array of grooves  40  in top surface  16 . Grooves  40  are longitudinally aligned with the longitudinal axis  30  of the panel  12 . Preferably, grooves  40  define a V-shaped cross-section and convey moisture toward the ends  42  or  44  of panel  12 . 
         [0048]    When a plurality of panels  12  are assembled into a deck  37 , the deck can further include a first side rail  46 . The first side rail  46  has a side surface  48  and a female connector structure  50  that has a profile that corresponds to the profile of second connector rail  32 . First side rail  46  is engageable with the first connector rail  28  of one of panels  12 . Deck  37  can further include a second side rail  52  that has a side surface  54  and a male connector structure  56  that has a profile that corresponds to the profile of the T-shaped cross-section  34  of the first connector rail  28 . Second side rail  52  is engageable with the second connector rail  32  of panel  12 . The side surface  48  of first side rail  46  has a profile that inversely corresponds to the profile of side surface  54  of second side rail  52 . First side rail  46  and second side rail  52  can be applied to the perimeter of an assembly of panels  12  that comprise deck  37 . Because surface  48  corresponds to surface  54 , the peripheral surfaces of first side rail  46  and second side rail  52  have the same appearance and the lateral sides of deck  37  have a finished appearance. 
         [0049]    It is not necessary to secure deck  37  to any support surface. However, in some applications it will be desired to secure deck  37 . For those applications first and second side rails  46  and  52  can further include screw bosses or ports  53   a  and  53   b  for receiving fasteners  53   c  to secure the deck  37  to another object such as a wooden deck that is in disrepair. 
         [0050]    Deck  37  can further include elements that afford a finished appearance to the sides of deck  37  that are defined by the ends  42  and  44  of panels  12 . Disclosed herein is an L-bracket  58  that is securable to the panel assembly along ends  42  and  44  to cover ends  42  and  44  of panels  12 . L-bracket  58  can be secured to the panel assembly by a fastener  60 . Preferably, fastener  60  is a detent fastener that requires no special tools for insertion thereof and that can be removed and reused from time-to-time in the event that the user wants to relocate deck  37  or modify its size. 
         [0051]    Deck  37  can further include an alternative side rail  70  as shown in  FIG. 18 . Side rail  70  includes an arm  72  that extends over the top surface  16  of an adjacent deck panel  12 . Arm  72  and the vertically extending leg  73  of the side rail  70  cooperate to maintain the vertical and lateral position of the deck panel  12  at times when side rail  70  is secured to a support structure or other fixed structure. 
         [0052]    Side rail  70  also includes a side surface  74  that forms the peripheral surface of the deck when the side rail  70  is assembled with an array of deck panels  12 . Side rail  70  can be used on the sides and/or the longitudinal ends  42 ,  44  of deck panel  12  so that the edges of the deck have the same appearance. Side rail  70  has a screw boss  76  that can receive screws or similar fasteners for securing the deck to a support or foundation. In this way, the deck can be secured to the foundation by the side rails  70  on each side of the deck and no fasteners are required directly for the deck panels  12  of the deck. Preferably, side rail  70  further includes a cap  78  that covers screw boss  76  to protect the fastener and to afford a more finished appearance for the deck. 
         [0053]    While a presently preferred embodiment of the invention has been shown and described herein, the presently disclosed invention is not limited thereto but can be otherwise variously embodied within the scope of the following claims.