Abstract:
An above-grade decking system having a plurality of deck members overlying a plurality of joists with clip member connectors connecting the deck members to the joists. The present decking system is particularly adapted for use with concrete composite materials that are shaped into construction materials and testured to resemble wood or stone products. The clip members are shaped to hold the deck memebers onto the joists. The clip members fit into slots in the deck memebers and are attached to the joists using commonly available connectors. The deck memebers can be shaped and configured to fit together with the clip memebers therebetween.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    A. Field of the Invention  
           [0002]    The field of the present invention relates generally to structural building materials and systems for utilizing the same, specifically such building materials that are made out of concrete but are manufactured to resemble wood boards or stone and systems for installation of the same. More specifically, this invention relates to building materials that are made out of concrete boards that have an appearance similar to standard wood or stone products which are joined together with connectors.  
           [0003]    B. Background  
           [0004]    Although the apparatus of the present invention is suitable for use with a number of different structures, the discussion in this disclosure will focus on the use of the present invention as a structural material for decking. It is well known that wood and stone are commonly used as building materials to construct a large variety of structures, including backyard decking. Many people prefer wood or stone due to its natural appearance and feel. As a decking material, however, wood does have a number of disadvantages. These disadvantages include the need for preservatives and coatings to protect the wood from exposure to sun, rain and other weather elements. Failure to place these materials on the wood decking when constructed will substantially shorten the structure&#39;s life and result in a decking of unsatisfactory appearance after a relatively short time period. In addition to the initial coating of the preservatives, the owner of the decking must ensure that it is properly treated over varying intervals of the life of the decking. Failure to properly maintain the decking will also result in a much shorter life for the decking and decking that is of undesirable appearance. The care of the wood decking requires both an investment in money and time. Stone materials also have a number of disadvantages when used as a decking material. The primary disadvantage has to do with limitations on the size and placement of the stone materials  
           [0005]    In addition to the care requirements for wood materials set forth above, many people are turning away from wood where acceptable substitutes are available for environmental reasons. The most common wood material used for decking and the like is redwood and cedar. Both these materials are becoming generally less available and, as a result, more expensive to be used as structural materials in relatively large structures (such as decking). In addition, the primary system available for placing these materials in their proper positions are the use of nails, screws and/or bolts of various types. These connectors generally result in the heads or tops of the connectors being visible and, often, protrusions above the surface of the deck or other structure.  
           [0006]    A number of different materials have been developed to be used as a structural material in place of wood or stone. These materials include various plastics, metals and concrete. In general, these materials are not utilized as much as standard wood or stone products. The lack of use is primarily due to the less attractive appearance and feel of these materials. In addition, the systems available for installation of these materials are typically less than satisfactory. Recent developments in the use of plastic composites have added a new material that can be used for decking and other structures. The plastic composites are generally manufactured out of a concrete resin, such as recycled polyethylene, and waste wood fibers. The plastic and wood fibers are mixed together and then formed into board-shaped or stone-shaped structural materials that are used for decking and other structural needs as a replacement for wood boards or stone. The use of plastics for building materials has a number of disadvantages, such as the petroleum products from which it is made, the expense and difficulty in making the product and the susceptibility of plastic to damage from the weather elements.  
           [0007]    What is needed is a structural material that can serve as a replacement for wood and stone and be used in place of wood and stone for constructing various structures, such as decking. To successfully replace the wood and stone products, the structural material must have the ability to be shaped as a wood member (i.e., a board) or a stone slab, be able to have a color added to it and be durable and weather resistant. A more preferable connector for installing these materials is also needed so as to provide a more secure and attractive system.  
         SUMMARY OF THE INVENTION  
         [0008]    The above-grade concrete decking system of the present invention provides the benefits and solves the problems identified above. That is to say, the present invention discloses a building system that can be used in place of wood and stone building materials, is easy to manufacture, durable and relatively maintenance free. The system used to install the subject building material provides a stable structure, such as a decking, that is easy to install and provides a long life structure.  
           [0009]    In its broadest form, the primary embodiment of the present invention comprises a plurality of adjoining deck members overlying a plurality of spaced apart joists that are connected together with a clip member shaped and configured to hold the deck members to the joists. The plurality of deck members comprises at least a first deck member and a second deck member on top of the plurality of spaced apart joists. Each of the deck members has a first side and an opposing second side, a top surface and a bottom surface. At least one of the opposing sides of each deck member has a slot therein. The slot can either be a single slot that runs the length of the deck member or it can be a series of slots that are spaced apart an amount equal to the spacing of the joists. The clip member has at least a base portion, a vertical portion and an insert portion. The various components of the clip member are sized and configured such that the insert portion is disposed in the slot when the base portion is disposed between the bottom surface of the deck member and the joist and the vertical member is disposed between the adjoining deck members. The deck members can be a concrete composite material shaped and configured into a board member that simulates a natural wood finish or shaped and configured into a stone member that simulates a natural stone material.  
           [0010]    In one specific configuration, the deck system utilizes a adjoining deck members that have slotted sides that face each other and are intended to abut each other in the finished form. The insert portion of the clip member has extensions that extend away from the vertical portion of the clip member in opposite directions such that the insert portions are disposed in the slots in the opposing sides of the adjoining deck members. To further improve the stability of the decking system, an adhesive can be used between the deck members and the joist. In addition, the base portion of the clip member should have at least one opening therein that is configured to receive a connector, such as a nail, screw, bolt or other connector, to secure the clip member base portion to the joist.  
           [0011]    Instead of utilizing slots in the deck members, one embodiment of the present invention utilizes deck members that are shaped and configured to fit together with the clip member (and if desired adhesive material) between the deck members or between the deck members and the joist. In another embodiment, the deck members fit together and include a slot in at least one of the deck members so as to receive the insert portion of the clip member.  
           [0012]    Accordingly, the primary objective of the present invention is to provide an above-grade decking system that securely connects the surface deck members to the underlying joists without the need for connectors going through the top of the deck members.  
           [0013]    It is also an important objective of the present invention to provide an above-grade decking system that utilizes shaped clip members that are used to secure deck members to underlying joists.  
           [0014]    It is also an important objective of the present invention to provide an above-grade decking system that is suitable for securing deck members made out of concrete composite materials, which are shaped into looking like wood or stone products, to joists.  
           [0015]    It is also an important objective of the present invention to provide an above-grade decking system that utilizes decking members shaped and configured to fit together with a clip member therebetween.  
           [0016]    The above and other objectives of the present invention will be explained in greater detail by reference to the figures and the description of the preferred embodiment which follows. As set forth herein, the present invention resides in the novel features of form, construction, mode of operation and combination of parts presently described and understood by the claims. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    In the drawings which illustrate the best modes presently contemplated for carrying out the present invention:  
         [0018]    [0018]FIG. 1 is a perspective view of a deck utilizing board members made out of the concrete material and utilizing the system described herein;  
         [0019]    [0019]FIG. 2 is a side view of the connector shown in FIG. 1;  
         [0020]    [0020]FIG. 3 is a top view of the connector in FIG. 2;  
         [0021]    [0021]FIG. 4 is a side view of an alternate embodiment of the connector shown in FIGS. 2 and 3;  
         [0022]    [0022]FIG. 5 is a perspective view of the use of a deck portion utilizing stone slabs and a connector of the present invention;  
         [0023]    [0023]FIG. 6 is a perspective view of the connector illustrated in FIG. 5;  
         [0024]    [0024]FIG. 7 is a side view of an alternative embodiment of the present invention; and  
         [0025]    [0025]FIG. 8 is a side view of an alternative embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0026]    With reference to the figures where like elements have been given like numerical designations to facilitate the reader&#39;s understanding of the present invention, the preferred embodiments of the present invention are set forth below. The enclosed figures and drawings are merely illustrative of the preferred embodiments and represent several different ways of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein.  
         [0027]    An above-grade concrete decking system manufactured out of the materials and pursuant to the system of the present invention is shown generally as  10  in FIGS. 1, 5,  7  and  8 . As shown in FIG. 1, a typical decking system  10  has a plurality of adjoining deck members  12 , comprising at least a first deck member  12   a  and a second deck member  12   b  in the shape of board members (i.e., wood boards) or stone material (i.e., stone slabs), positioned above and attached to a plurality of spaced apart joists  14  (one of which is shown) that support deck members  12  to form deck  10 . Deck members  12 , having first side  13   a,  opposing second side  13   b,  top  13   c  and bottom  13   d,  are typically made out of wood. As discussed above, deck members  12  can be made out of a concrete composite material, such as concrete mixed with plastic, sawdust or other materials that is then formed into a board shape (i.e., a two-by-four) member  12 . Generally, the outer surfaces of the composite deck members  12  are contoured and configured to resemble natural wood or stone products. The builder of deck  10  obtains sufficient quantity of deck members  12  to cover the area where the deck  10  is to be placed. Typically, a deck  10  made out of wooden deck members  12  utilizes nails, screws or bolts to connect deck members  12  to joist  14  by driving or placing the connectors through the individual deck members  12  into joist  14 . With composite board-shaped members  12 , however, this is typically not possible or practical. Instead, a layer of adhesive (shown as  16  in FIG. 1) is placed on top of joist  14  or the bottom  13   d  of deck member  12  so as to be between the deck members  12  and the joist  14 . The adhesives for use with the present invention are well known in the industry and commonly known. The deck members  12  are then placed on the adhesive  16  and are left to dry or cure. The integrity of the decking system for concrete composite members utilizing the system of installation of the prior art relies on the ability of the adhesive  16  to sufficiently bond deck members  12  to joist  14 . Unfortunately, this bond often weakens as the wood framing expands and contacts over time, resulting in deck members  12  becoming loose. The loosening of deck members  12  requires repair or replacement of deck  10 .  
         [0028]    To improve the integrity of a deck  10  utilizing deck members  12  made out of composite materials, the present invention utilizes a plurality of clip members  18  to mechanically attach deck members  12  to joist  14 . As shown in FIG. 1, clip members  18  are utilized between adjoining deck members  12  and between deck members  12  and joist  14 . As shown in FIGS. 2 and 3, one configuration for clip member  18  is the use of an elongated base portion  20 , vertical portion  22  and one or more insert portions  24  (FIG. 2 shows the use of two opposite facing insert portions  24   a  and  24   b ). Base portion  20  can include a hole  26 , sized for a nail, screw, bolt or other connector  30 , for use in attaching clip member  18  to joist  14 . Alternatively, base portion  20  of clip member  18  can include an integral attachment or connector portion (shown in FIG. 4 as  27 ) protruding downward from base portion  20  that is suitable for attachment to joist  14 . If a flush surface is desired for base portion  20 , hole  26  can be contoured such that the top of the connector  30  (i.e., the head of a nail) will be flush with base portion  20  after it is driven or placed through joist  14 .  
         [0029]    In use, insert portion  24   ab  of clip member  18  is inserted into a slot  28  located on side  13   b  of first deck member  12   a  already in place on joist  14  such that vertical portion  22  abuts against side  13   b  of deck member  12   a.  Slot  28  can extend the entire length of the deck members  12  or be spaced a distance apart approximately equal to the spacing of the joists  14 . A nail or other connector  30  is inserted through hole  26  and into joist  14 . An adjoining second deck member  12   b  is placed along side the first deck member  12   a  such that insert portion  24   b  extends into slot  28  and the bottom  13   d  of the second deck member  12  is over base portion  20 . First side  13   a  of second deck member  12   b  can either abut vertical portion  22  of clip member  18  and second side  13   b  of the first deck member  12   a  or a gap can be provided between the two deck members  12   a  and  12   b  so that grout material can be placed therebetween. The deck member  12  on the outer edge of deck  10  placed on joist  14  can either use a modified clip member  18  having only a single facing insert member  24   b  (i.e., a C-shaped clip member) or a clip member  18  with one portion of the insert member  24   a  broken off. The deck system  10  of the present invention using clip member  18  can also be utilized with adhesive layer  16  to provide a deck system which has deck members  12  even more securely attached to joist  14 . The use of adhesive  16  also provides a cushioning effect for clip members  18 , even after the adhesive  16  loosens over time from the natural expansion and contraction of the wood joist  14 . Clip members  18  are placed between each deck member  12  at every joist  14  that make up the complete deck  10 .  
         [0030]    Clip member  18  can be made from a variety of materials having a variety of sizes and configurations. One material found suitable for this purpose by the inventor is 0.060 ({fraction (1/16)}″) gauge galvanized metal. For ease in manufacturing, clip member  18  can be made from a generally rectangular piece of metal that is cut to form the separate insert portions  24   a  and  24   b  and then bent at the appropriate places to form base portion  20 , vertical portion  22  and insert portions  24 . In one configuration, the inventor has found that an insert portion  24   a  and  24   b  of one-fourth to one-half inch width is sufficient to provide the needed support to anchor deck members  12  to joist  14 . Alternatively, clip member  18  can be configured to different sizes and/or shapes. One such alternative, shown in FIG. 4., uses an oval-shaped insert portion  32 . Alternatively, insert portion  32  can be rectangular or otherwise shaped to fit into slot  28  of deck members. If a different configuration for clip member  18  is to be used, the configuration of slot  28  could be modified to best match clip member  18  to ensure clip member  18  provides the mechanical support desired.  
         [0031]    Another embodiment of the above-grade decking system of the present invention is shown in FIG. 5. In this embodiment, deck  10  has a plurality of adjoining deck members  12 , comprising at least a first deck member  12   a  and a second deck member  12   b  in the shape of wood or stone materials, that are attached to joist  14  with an adhesive layer  16  and a clip member  36 . The use of adhesive  16  alone with the deck members  12  has the same problems described above (i.e., they loosen over time). Clip member  36  is made out of the same materials as clip member  18  and comprises a base portion  38 , vertical portion  40  and insert portion  42 . Located on base portion  38  can be a hole  44 , which can be contoured as discussed above, for allowing connector  30  (i.e., a nail) to be attached to joist  14 . The use of an adhesive layer  16  with clip member  36  provides integrity support and a the cushioning effect described above. One configuration for clip member  36  is a 1″ base portion  38 , ⅝″ vertical portion  40  and ½″ insert portion  42 .  
         [0032]    In use, clip member  36  is placed between adjacent deck members  12   a  and  12   b,  which are placed on a layer of adhesive material  16 , such that insert portion  42   b  is on top of lower extension  46  of second deck member  12   b.  A nail  30  or other connector is driven through hole  44  in base portion  38  and into joist  14  to mechanically connect deck member  12   b  to joist  14 . The first deck member  12   a  is placed adjacent to the second deck member  12   b  such that the bottom of first deck member  12   a  is placed on top of base portion  38  and its side abuts vertical portion  40 . Insert portion  42   a  extends into slot  28  on deck member  12   a  and the upper extension  48  of deck member  12   a  is placed on top of insert portion  42   b.  In some installations, it is preferable that upper extension  48  does not abut the adjacent deck member  12   b  so that gap  50  is created for placement of grout between the deck members. Alternatively, deck members  12   a  and  12   b  can abut each other. The above procedure is repeated throughout the joists  14  and deck members  12  used to form deck  10 .  
         [0033]    Another alternative configuration for the present invention, shown in FIG. 7, a plywood member  52 , or other types of wood material, disposed between deck members  12  and joist  14  to reduce the overall weight of the deck  10  (by utilizing thinner deck members  12 ). A connector  36 , held in place with nail  30  that goes through plywood member  52  into joist  14 , provides mechanical support to deck members  12 . As with the embodiments described above, an adhesive (not shown) can be used between deck members  12  and plywood  52  and/or between plywood  52  and joist  14 .  
         [0034]    Another embodiment of the present invention is illustrated in FIG. 8. In this embodiment, the adjoining deck members  12   a  and  12   b  are shaped and configured to fit together with a clip member  54  that is shaped to take advantage of the deck members  12  fitting together. Each deck member  12  has a protruding segment  56  on one side (i.e., first side  13   a ) and a recessed segment  58  on the opposite side (i.e., second side  13   b ), as shown in FIG. 8. The protruding segment  56  is shaped and configured to be received into the recessed segment  58  when the two adjoining deck members  12   a  and  12   b  are placed side by side. The clip member  54  has an insert portion  60  that comprises a single portion that extends the opposite side of vertical member  62  as the base portion  64  (forming a s-like shape) that is configured to be inserted between the protruding segment  56  of one deck member  12   a  and the recessed segment  58  of the adjoining deck member  12   b.    
         [0035]    Although the deck system  10  of the present invention works best for composite concrete materials shaped and configured to resemble wood or stone products, due to the weight of the material bearing down on the joists, it can also be utilized with wood members. For instance, deck members  12  made out of wood can be cut on the sides to form the slots  28  shown in FIG. 1 so the clip member  18  can be utilized with the deck  10 . The advantage of utilizing the present system  10  over traditional mechanisms for connecting deck members  12  to joists  14  is the elimination of the nail head, or equivalent top of connector  30 , from being visible from and extending above top surface  13   c  of deck  10 .  
         [0036]    While there are shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use. For instance, there are numerous components described herein that can be replaced with equivalent functioning components to accomplish the objectives of the present invention. One such modification is the use of different materials than those set forth herein. Another modification would be a change in the dimensional characteristics of the various components.