Abstract:
The system for mounting elongated panels to a substructure is a steel track having a series of formed connectors for receiving and engaging decking planks. The system for mounting elongated panels to a substructure will allow a deck system to be installed without the use of any mechanical fasteners such as screws, nails or individual fasteners, and will allow installation of deck systems mounted onto wood, concrete, or steel substructures, in a horizontal, vertical, overhead (or anything in between) fashion. The upper fasteners and receivers, referred to as tangs, maintain the desired gap between composite deck boards for the life of the deck.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority benefit, with regard to all common subject matter, of earlier filed U.S. provisional patent application titled “SYSTEM FOR MOUNTING ELONGATED PANELS TO A SUBSTRUCTURE” application No. 61/846,957, filed Jul. 16, 2013. The earlier filed provisional patent application is hereby incorporated into the present application by specific reference. 
    
    
     BACKGROUND 
     The use of manufactured composite wood and plastic planking for decks, ceilings and wall coverings is becoming more and more common. Such planks frequently are manufactured with slots formed into the lateral sides to receive clamps, to obviate the need to drill through the plank for installation, which would expose the plank interior to water and rotting. 
     The planking requires a supporting substructure to install to, such as floor or ceiling joists, or wall studs or stringers. Conventional installation methods require a large number of clips to be fastened to the substructure individually. This conventional method is time consuming, difficult to ensure quality control, and not very strong or reliable—especially in high-wind weather—because the clips are not interconnected to be mutually supporting. 
     Composite planks are also less combustible, thus they are being used more frequently for construction of deck surrounds on structures in wildfire-prone areas. This often includes the use of steel or aluminum girder substructures, which creates a fireproof or fire resistant barrier around the structure. 
     The inventor previously developed an improved system using a strip of mounting clips mountable to a floor joist, which is described in U.S. Pat. No. 8,146,303 (issued Apr. 3, 2012) but that system was not a complete solution. The clips are subject to distortion during installation, and the receiver-side tangs do not securely engage the plank slot sidewalls or back walls. Thus, although the planking is able to accept deadweight in an exterior flooring use, the planks are vulnerable to lifting in hurricane situations, and the system is not reliable for installations on vertical walls or ceilings. Also, the prior system does not provide for easy integration with steel or aluminum girder substructures. Furthermore, the prior system requires a specialized tool to engage the fastening tangs. 
     Thus, there is a need for a system to engage planks to a substructure which provides improved installation efficiency, improved performance in extreme weather, reliable installation on vertical and ceiling surfaces, greater compatibility with metal girder substructures, and does not require a proprietary tool. 
     SUMMARY AND ADVANTAGES 
     The system of the present invention presents numerous advantages, including: (1) more reliable engagement of panels to the substructure; (2) less likely for connectors to bend or warp when installing; (3) less likely for connectors to bend or break due to temperature fluctuations that cause the expansion or contraction of the deck panels and/or substructure; (4) provides for installation using standard flooring hammer and tools; (5) provides for installation using standard hammer; (6) provides ability to use with steel girder substructures; (7) provides ability to use on vertical surfaces; (8) provides ability to hang from overhead substructure, as a suspended ceiling surface; (9) provides for less expensive manufacturing process; (10) provides for much faster, less labor intensive, and more accurate on-site installation; (11) provides ability to use laser alignment tools to align base portions on substructure; and (12) provides ability to mount to a concrete substructure. 
     Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. Further benefits and advantages of the embodiments of the invention will become apparent from consideration of the following detailed description given with reference to the accompanying drawings, which specify and show preferred embodiments of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the present invention and, together with the detailed description, serve to explain the principles and implementations of the invention. 
         FIG. 1  shows several views of a first embodiment. 
         FIG. 1A  shows a partial top plan view of a first embodiment. 
         FIG. 1B  shows an end view of a first embodiment, from the leading edge. 
         FIG. 1C  shows a partial side view of a first embodiment. 
         FIG. 2  shows several additional views of a first embodiment. 
         FIG. 2A  shows a top plan view of a first embodiment, 
         FIG. 2B  shows a side view of a first embodiment, with intermediate panel connectors inclined at an angle. 
         FIG. 2C  shows a side view of a first embodiment, with intermediate panel connectors at a vertical angle. 
         FIG. 2D  shows a side view of a first embodiment showing two elongated members oriented end-to-end. 
         FIG. 3  shows a close up view of a breakaway cutout of a first embodiment. 
         FIG. 4  shows a perspective top view of a portion of an elongated member of a second embodiment, cut off at location X. 
         FIG. 5  shows a partial side view of a portion of a second embodiment with a leading edge connector. 
         FIG. 6  shows a close up view of an intermediate panel connector of a second embodiment. 
         FIG. 7  shows two close up partial views of a second embodiment. 
         FIG. 7A  shows a close up view of a trailing edge panel connector of a second embodiment. 
         FIG. 7B  shows another close up view of a trailing edge panel connector of a second embodiment. 
         FIG. 8  shows a cutaway cross-section view of a common type of composite plank or panel. The term “capped” refers to the fact that the exterior sealing membrane completely encloses the panel, including being formed into the interiors of the side channels. 
     
    
    
     DETAILED DESCRIPTION 
     Before beginning a detailed description of the subject invention, mention of the following is in order. When appropriate, like reference materials and characters are used to designate identical, corresponding, or similar components in differing figure drawings. The figure drawings associated with this disclosure typically are not drawn with dimensional accuracy to scale, i.e., such drawings have been drafted with a focus on clarity of viewing and understanding rather than dimensional accuracy. 
     In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer&#39;s specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure. 
     In the description, terms of orientation are used, for example “top” and “bottom”, “upper” and “lower” are for reference only. In this context, “bottom” or “lower” &amp; etc., refers to portions proximate the substructure to which the apparatus is to be mounted, while “top” and “upper,” etc., refers to portions distal from the substructure. In cases where the apparatus is mounted to a vertical substructure, or under-hung from a ceiling substructure, the “top” portion may actually be facing horizontally outward, or downward towards the ground or floor. Similarly, “forward”, “front” and similar terms refer to the direction toward the “leading edge”, while “aft”, “rearward” and similar terms refer to the direction toward the “trailing edge”. 
     Additionally, reference is made to “plank”, “panel” and similar terms. In this regard, a “plank” is simply a type of elongated “panel”, and, referring to  FIG. 8  showing a cutaway end view of a plank or panel A, the terms are used interchangeably to refer to longitudinally elongated members having lateral side channels or grooves B 1 , B 2 , to allow installation without drilling or nailing through the panel, 
     As shown in  FIGS. 1-3 , a first embodiment of the system  10  is shown. The first embodiment is optimized for mounting to a substructure comprising wood or composite joists, studs or stringers. In the first embodiment, the system  10  includes an elongated base member  12  extending from a leading edge  14  to a trailing edge  16 . Elongated base member  12  is formed into a generally u-shaped channel having a top plate  18  and opposed first and second sidewalls  20  &amp;  22 , respectively, extending downward from the top plate  18  at top plate opposed right and left edges  44 ,  45 , respectively. Top plate  18  width extends from first sidewall  20  to second sidewall  22 , and has a bottom surface  24  and a top surface  26 . Top plate  18  includes a plurality of top spacers  28  extending upwards from the top plate top surface  26 . The top spacers  28  accommodate variations in plank thicknesses, impart upward pressure on planks so that the first engagement tangs  54  and second receiving tangs  56  will engage the planks more securely and provide an air space for water drainage, helping to prevent rot. 
     In the embodiment, a penetration  30  is adapted to receive a fastener, for example a nail, wood screw, beveled screw or rivet, or self-tapping screw, or to be used to receive a spot weld. 
     A leading edge panel connector  34  is disposed proximate the base leading edge  14  and projecting upward from the top plate  18 , the leading edge panel connector  34  comprising a connector base plate  36  extending from a bottom portion  38  coupled to the top plate  18  to an upper portion  40 , and a receiving tang  42  projecting from the connector base plate upper portion  40  toward the elongated base trailing edge  16 . Leading edge panel connector bottom portion contains stiffening beads  71  formed by indentations in the folded area, which provide stability and support to the connector. Leading edge panel connector engagement tang  42  extends transversely from proximate the top plate right edge  44  to a point equal or less than the longitudinal center of the top plate (to accommodate the trailing edge panel connector  32 ). 
     The trailing edge panel connector  32  is disposed proximate the base trailing edge  16  and projecting upward from the top plate  18  at an approximate 60-degree angle, the trailing edge connector  32  comprising a connector base plate  90  extending from a bottom portion  92  coupled to the top plate  18  to an upper portion  94 , and an engagement tang  96  projecting from the connector base plate upper portion  94  toward the elongated base toward the elongated base leading edge  14 . 
     The system  10  includes a plurality of intermediate panel connectors  46  disposed along the length of the top plate  18  and projecting upward from top plate  18 . Each intermediate panel connector  46  comprises a connector base plate  48  extending from a bottom portion  50  coupled to the top plate to an upper portion  52 , a first engagement tang  54  projecting from the connector base plate upper portion  52  toward the elongated base leading edge  14 , and a second receiver tang  56  projecting from the connector base plate upper portion  52  toward the elongated base trailing edge  16 . 
     In the first embodiment, each intermediate panel connector base plate  48  extends from top plate  18  at an angle inclined toward the base portion trailing edge  16 . This permits easy installation of a plank into the adjacent connector  46 , then forcing the next inclined panel connector  46  upward to force engagement tang  54  into the side channel B 1 , B 2  of a prefabricated plank A, In the first embodiment, each intermediate panel connector base plate  48  angle is approximately 60 degrees. 
     In the first embodiment, each intermediate panel connector first engagement tang  54  includes a downward folded lip  58  proximate the free end, which may fold when the intermediate panel connector  46  is hammered into a plank side channel B 1 , B 2 , providing a flat compression surface against the channel interior back wall E 1 , E 2  and downward facing teeth to more tightly engage the side channel lower interior sidewall C 1 , C 2  or D 1 , D 2 . In the embodiment, the second receiving tang  56  is not bent and does not contain any teeth, to facilitate insertion of the next plank. Each intermediate panel connector second receiver tang includes an approximate 45-degree angled cut  102  to allow clearance for hammering and engagement of the intermediate connectors. 
     In the first embodiment, intermediate panel connectors  46  are formed into the top plate  18  by cutting or punching the intermediate panel connector outline  60  into the top plate  18 , folding the intermediate panel connector  46  upward and folding the first and second engagement tangs  54 ,  56 , respectively, forward and aft. In the first embodiment, a connector base plate oval penetration  62  is provided in the panel connector base plate  48  disposed along the forward edge of the fold line where the connector base plate  48  bends upward from the top plate  18 . The oval penetration  62  allows for proper engagement of the intermediate connector by providing stress relief and facilitates engagement without cracking at the fold line. 
     In the first embodiment, each intermediate connector base plate  48  includes leading and trailing spacers  68 ,  70 , respectfully, projecting outward to ensure proper spacing between adjacent panel members. In the embodiment, the combined thickness of the leading and trailing edge spacers  68 ,  70  is 3/16 inch to ensure adequate drainage, air flow, and to accommodate manufacturing tolerances and shrinkage and swelling. 
     The elongated base member leading and trailing edges  14 ,  16 , each include an aligning edge  64  &amp;  66 , respectively, to facilitate laying the apparatus in series (as shown in  FIG. 2D ), wherein the trailing edge aligning edge  66  of one base member abuts the leading edge alignment edge  64  of the next following elongated base member  12 . The leading edge  14  contains a recessed portion disposed to accommodate the trailing edge  16  and corresponding trailing edge panel connector  32 , to further facilitate laying the apparatus in a series. 
     Referring to  FIG. 3 , in the first embodiment, each elongated base member first and second sidewalls  20 ,  22 , includes a breakaway cutout  72  proximate the leading edge aligning edge  64 , Each breakaway cutout  72 , when removed, provides a right-angled notch to allow the elongated base member  12  to fit firmly up against and over a header board or blocking. In the embodiment, the breakaway cutout  72  is formed by partially cutting a 90-degree notch  74 , and can be easily removed at the installation site as needed, using conventional metal snippets or folding back and forth to break the remaining material. The breakaway cutout  72  may be left intact if not needed to fit against a header or blocking, providing additional strength, thereby preventing the top plate  18  from buckling or lifting over time. 
     In the first embodiment, each of elongated base member first and second sidewalls  20 ,  22  are angled inward toward each other from proximate the top plate  18  (where they connect to form the “shoulder” of the U-shaped cross section) to a respective longitudinal fold line  76 ,  78  proximate to but set back from their open edges  80 ,  82 , respectively, to create first and second sidewall outwardly flared extensions  84 ,  86 , respectively. A plurality of inwardly oriented teeth  88 , with apex oriented upwards, are formed into each sidewall  20 ,  22 , disposed along the length of the respective fold lines  76 ,  78 . The inward angle of the sidewalls  20 ,  22 , inwardly oriented teeth  88  provide tight engagement over a substructure member, such as a joist, and prevent lifting or shifting during installation, without using special tools and without having to immediately insert fasteners, thereby ensuring proper alignment is maintained until securely fastened. In many cases, no further fasteners will be required to securely anchor the elongated base member to the substructure. 
     Referring to  FIGS. 4-7 , a second embodiment of a system  10  is shown, adapted for installation on a wood or metal girder substructure. The second embodiment comprises an elongated base member  12  which includes a flat top plate  18  to go against the members of a substructure, such as one or more wood or metal girders, the top plate  18  including a top surface  26 . Top plate including intermediate top plate edge recesses  98 , identical on each side of the top plate, providing for lighter weight design. 
     Leading edge panel connector  34  proximate leading edge alignment edge  64  includes a receiving tang oriented aft, and intermediate panel connectors  46  with receiving and engagement tangs  54 ,  56 , projecting from base plate  48  are provided. A plurality of top spacers  28  are provided, distributed on the upper surface  26  of the top plate  18 . 
     The system  10  described in the second embodiment may be integrated into prefabricated metal girders as well, In another embodiment, not shown, the elongated base member  12  of the second embodiment may be pre-mounted to a metal girder using precision alignment techniques in a manufacturing plant by spot welding, riveting, or otherwise permanently coupling the top plate  18  to a girder upper surface, thereby obviating the need to align and mount the system  10  in the field. 
     The panel connectors  46  and  1046  of the described embodiments may be oriented at an angle relative to the longitudinal axis of the elongated base member  12 ,  1012 , in order to provide installation of planks in a pattern having a different alignment than the substructure. In this way, the panels may be aligned in the most aesthetically pleasing orientation, or multiple orientations, for the design of the overall structure without compromising the structural integrity of the supporting substructure and plank connections, or requiring complicated or expensive alterations to the substructure. As an example, the panel connectors  46 ,  1046 , may be rotated to a 45-degree angle relative to the elongated base member  12 ,  1012 , to provide diagonal alignment of planks, or a chevron pattern, if desired. 
     Alternatively, as shown with the second embodiment, the elongated base members may be mounted across the substructure members at a perpendicular or an oblique angle, to install the planking at any desired orientation. 
     As can be seen, the system may also be used with conventional wood planking having side channels routed into the lateral sides. 
     Those skilled in the art will recognize that numerous modifications and changes may be made to the preferred embodiment without departing from the scope of the claimed invention. It will, of course, be understood that modifications of the invention, in its various aspects, will be apparent to those skilled in the art, some being apparent only after study, others being matters of routine mechanical, chemical and electronic design. No single feature, function or property of the preferred embodiment is essential. Other embodiments are possible, their specific designs depending upon the particular application. As such, the scope of the invention should not be limited by the particular embodiments herein described but should be defined only by the appended claims and equivalents thereof.