Abstract:
A method and apparatus for plank top installation for a deck comprising two tools and their method of use. The method is capable of attaching a top plank material and a bottom plank material, typically the “Teck Deck” system from Heritage Vinyl Products, together in a quick and non-destructive manner without the use of hammers or mallets. The method comprises the use of a first plank top installation tool for placing most of said planks together and then uses a plank top end installation tool to place the remaining unattached planks. Each tool comprises a series of rollers and force application components for applying the necessary force between a top and bottom plank for attachment of said planks.

Description:
This application claims priority of Provisional Patent Applications 60/103,895 filed Oct. 31, 1998 and 60/120,265 filed Feb. 16, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates in general to a method and apparatus for installing planks for decking material and more particularly, to a set of specialty tools and method of use for installation, placement and setting of flexible planking material for decks. The apparatus of the present invention represents a unique, lightweight, and portable tool set and method of use for installation of said flexible top decking material. 
     A vinyl deck construction system which includes a sandwich of a bottom and top plank portion is currently available from Heritage Vinyl Products of Macon, Miss. The vinyl deck plank construction comprises a bottom structural plank member which is placed and secured onto a deck frame and a top flexible plank decking material which is placed, pressed, and snapped into place on said bottom decking. This unique deck material form and style which is provided by Heritage Vinyl Products is known as the “Teck Deck” system. It provides a vinyl deck surface which is comprised of a series of planks which are formed from said bottom and top plank decking materials. The top plank snaps onto a set of ears of the bottom plank via the action of a groove within said top plank when the ears on said bottom plank are compressed. No claim is made to the decking materials which are proprietary to Heritage Vinyl Products. 
     The current method of snapping said top plank onto said bottom plank requires the installer to use a large mallet or hammer. The installer currently places the top planking and decking material onto the bottom plank and proceeds to hammer the top plank into place in order to compress the ears of said bottom plank into the groove of the top plank. This method is extremely time consuming, difficult to perform, and further risks damage to the top and bottom planking material. 
     The art of the present invention allows for the installation of said top plank onto said bottom plank via the action of a set of specialty installation tools and without the use of mallets or hammers. That is, the apparatus of the present art represents a set of specialty tools which are capable of snapping the top and bottom planks together via the action of a set of specially designed rollers and guides. By the using the special apparatus of the current art, a method has been developed which allows for installation of the top and bottom planking materials while the installer simply walks or crawls behind and pushes the specialty tool apparatus. This method of installation eliminates the risk of damage to the top and bottom decking planks and also provides for a quick and easy installation of said top plank onto said bottom plank. 
     Accordingly, it is an object of the present invention to provide a method and apparatus for installing a flexible top plank decking material onto a bottom plank decking material, especially for the Teck Deck series of decking materials and any decking materials which are substantially similar, without the use of mallets or hammers. 
     Another object of the present invention is to provide a method and apparatus for installing a flexible top plank decking material onto a bottom plank decking material which is quick and easy to use without damaging said decking materials and which is substantially capable of use by an installer working from a standing or crawling position. 
     A further object of the present invention is to provide an apparatus for installing a flexible top plank decking material onto a bottom plank decking material which is portable. 
     SUMMARY OF THE INVENTION 
     To accomplish the foregoing and other objects of this invention there is provided a method and apparatus for installing flexible decking planks. The apparatus comprises two roller systems which are described separately but used in conjunction with one another in order to perform the installation method described herein. The first roller system is defined as the plank top installation tool and the second roller system is defined as the plank top end installation tool. The plank top installation tool is used to place and secure substantially all of the flexible plank top onto the bottom plank, whereas the plank top end installation tool is used to place and secure the ends of the plank top. The method of placing said plank top onto said plank bottom first requires use of the plank top installation tool to secure and place most of the plank top and then use of the plank top end installation tool to secure and place the ends of said plank top. 
     The preferred embodiment of the plank top installation tool comprises a roller and face plate yoke, a face plate, a front roller guide, a pressure roller, a front roller guide axle, a pressure roller axle, and a handle. The face plate is of substantially flat form with ears extending upward to provide a pivoting attachment to the yoke via the front roller guide axle. The yoke acts as the central housing upon which all parts attach directly or indirectly. The bottommost portion of the face plate comprises one or more alignment grooves for proper alignment with and onto the ears of the bottom plank. The face plate along with the front roller guide is attached via the front roller guide axle. The front roller guide acts to guide and align the flexible top plank material under the pressure roller via the one or more roller grooves contained on the front roller guide. The pressure roller is mounted rearward of the front roller guide and serves to press the top plank onto the bottom plank after being fed over the front roller guide. The pressure roller is held in place with the pressure roller axle. The handle attaches to the yoke in order to provide a means by which pressure may be applied to the top plank material through the pressure roller and while the user is in a standing position. The alignment grooves in the face plate further serves to hold the frontmost portion of the plank top installation tool onto the ears of the bottom plank in order to provide a moment arm force onto the pressure roller without raising the face plate from its contact and connection with the bottom plank. 
     The preferred embodiment of the top plank end installation tool comprises a front pressure roller and a rear roller, a right side plate with one or more guide ears, a left side plate with one or more guide ears, a force application front handle, a force application rear handle, a front spacer bushing, and a rear spacer bushing. In a preferred embodiment, said bushings are held in place by fasteners such as bolts which penetrate both the right side plate and the left side plate and serve as axles. Alternative embodiments may incorporate pins or dowels in place of said bolts. Said front roller is mounted onto said front spacer bushing and said rear roller is mounted onto said rear spacer bushing in such a relation that each are allowed to roll on said bushings. Each of said rollers are slightly shorter in length than the bushing onto which they are mounted in order to ensure free rolling of said rollers. The placement of each of said rollers is such that said guide ears extend below the surface of said rollers and serve to guide the top plank end installation tool on the flexible top plank. Said rollers place a user supplied force on said top plank in order to push said top plank onto said bottom plank and press or snap it into place. It is important to note that although the rollers are mounted on bushings in a preferred embodiment, alternative embodiments may incorporate rollers which simply bear upon the fasteners or bolts which hold them and the side plates together. 
     In operation of the plank top installation tool, the user first places, aligns and secures the bottommost portion of the face plate containing the alignment grooves onto the interfacing portion of the bottom plank containing the bottom plank ears. Thereafter, the user threads a flexible top plank over the front roller guide and under the pressure roller. With the top plank threaded, the user the presses downward with the handle and begins walking in a forward direction. As the user walks, the top plank hooked portions or grooves are forcibly secured onto the extending ears of the bottom plank or bottom plank ears via the force provided by the pressure roller. Pressure is provided by and onto the pressure roller due to the fact that the unique configuration of the alignment grooves in the face plate serve to hold it onto the ears of the bottom plank and form a moment arm due the force supplied by the handle, thereby providing a downward force onto said pressure roller. 
     The installation method of the present art is completed by use of the plank top end installation tool. In operation of the plank top end installation tool, the installer first places most of the flexible top plank material with the aforesaid plank top installation tool. After most of the flexible top plank is placed, the installer then places the top plank end installation tool on the end of the top plank which is still unplaced and unsecured with said bottom plank. The installer then contacts the front pressure roller and rear roller with the unsecured top plank end and aligns the guide ears with the edges of said top plank and presses downward while rolling forward to finish the top plank installation. The user supplied force on the force application front handle and force application rear handle serve to provide enough force onto said rollers to secure the flexible top plank onto the bottom plank. After the top plank is fully placed, the user simply lifts the top plank end installation tool off of the top plank and the method of installation is complete. 
     The installation method of the present invention requires use of both tools described. That is, the plank top installation tool is generally used first, then the installation is completed by using the plank top end installation tool. The apparatus of both tools and the associated components may be manufactured of many types of materials including but not limited to plastic, composites, wood and various metals and their alloys as required by the application. In a preferred embodiment, the plank top installation tool and plates and handles of the plank top end installation tool are manufactured from an aluminum alloy whereas the rollers of the plank top end installation tool are manufactured from a plastic material. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Numerous other objects, features and advantages of the invention should now become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawings, in which: 
     FIG. 1 is a perspective view of the plank top installation tool showing an installer holding the handle and using the apparatus. 
     FIG. 2 is a front side plan view of the plank top installation tool. 
     FIG. 3 is a rear side plan view of the plank top installation tool. 
     FIG. 4 is a left side plan view of the plank top installation tool which is symmetrical with a right side plan view thereof with a flexible top plank material threaded therethrough. 
     FIG. 5 is a left side plan view of the plank top installation tool which is symmetrical with a right side plan view thereof. 
     FIG. 6 is a top side plan view of the plank top installation tool. 
     FIG. 7 is a bottom side plan view of the plank top installation tool. 
     FIG. 8 is a perspective view of the plank top end installation tool showing an installer holding the handles and using the apparatus. 
     FIG. 9 is a front side plan view of the plank top end installation tool also showing a cross section of top plank material in place. 
     FIG. 10 is a rear side plan view of the plank top end installation tool. 
     FIG. 11 is a right side plan view of the plank top end installation tool which is symmetrical with a right side plan view thereof with a flexible top plank material threaded thereunder. 
     FIG. 12 is a right side plan view of the plank top end installation tool which is symmetrical with a right side plan view thereof. 
     FIG. 13 is a top side plan view of the plank top end installation tool. 
     FIG. 14 is a bottom side plan view of the plank top end installation tool. 
     FIG. 15 is a cross section view of a flexible top plank known as “Teck Deck” which is manufactured by Heritage Vinyl Products. 
     FIG. 16 is a cross section view of a bottom plank known as “Teck Deck™” which is manufactured by Heritage Vinyl Products. 
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, there is shown in FIGS. 1-7 a preferred embodiment of the plank top installation tool and in FIGS. 8-14 a preferred embodiment of the plank top end installation tool both of which form the apparatus of the present invention. FIGS. 15-16 show a cross-sectional view of the typical decking material with which the method and apparatus of the present art is used. The method and apparatus of the present art is particularly adapted for use in placing and securing a top plank  14  of decking material to the bottom plank  18  of said decking material without using hammers, mallets or other techniques which may damage the decking material. A unique feature of the present invention is its utilization of the shape and form of the top  14  and bottom  18  plank in such a way as to allow a moment arm of force created with a handle  27  to snap grooves  16  within the top plank  14  onto one or more ears  20  of the bottom plank  18 . Generally, the aforesaid is accomplished with the installer using the apparatus while in a standing position. The plank top end installation tool  11  may require the installer to operate in a crouched or kneeling position in some situations. All component attachments, when necessary, are achieved with conventional fasteners such as screws, bolts, threads, pins, welds, adhesives or rivets as desired by the manufacturer of the art described. 
     Drawings  1 - 7  show a preferred embodiment of the plank top installation tool  10  comprising a roller and face plate yoke  21 , a face plate  22 , a front roller guide  23 , a pressure roller  24 , a front roller guide axle  25 , a pressure roller axle  26 , and a handle  27 . The yoke  21  acts as the central housing upon which all parts attach directly or indirectly. It is of generally “U” shape in the horizontal plane with mounting holes for placement of said axles  25 ,  26  and said handle  27 . The yolk  21  has a front, rear, top and bottom portion. Alternative embodiments of said yolk  21  may vary from a “U” shape and not affect the operation of said plank top installation tool  10 , provided that the relative position of the pressure roller  24  and the face plate  24  are kept the same as herein described. Moreover, methods of mounting said axles  25 ,  26  and handle  27  other than with holes in said yolk  21  may be used without departing from the spirit of the present art. 
     In a preferred embodiment, the face plate  22  is of substantially flat form with one or more plate ears  28  extending upward to provide a pivoting attachment to the front portion of the yoke  21  via the front roller guide axle  26 . Each of said plate ears  28  has a hole through which said roller guide axle  25  may be placed. The face plate  22  along with the front roller guide  23  is attached via the front roller guide axle  25  near the front portion of the yolk  21 . The front roller guide axle  25  is removably mounted to the yolk  21  towards the front portion of the yolk  21 . The front roller guide  23  is of substantially cylindrical shape and is located near the front portion of the yolk  21  and onto said front roller guide axle  25  between said plate ears  28 . The front roller guide  23  is located in such a fashion that it is rotatable and capable of guiding said top plank  14  into and through said yolk  21 . In a preferred embodiment, said front roller guide  23  contains one or more alignment grooves  30  which correspond and fit with the underside grooves  16  of the top plank  14 . Alternative embodiments may forego use of a roller guide axle  25 , plate ears  28 , and pivoting attachment of the yoke  21  without departing from the spirit of the present art. Moreover, alternative embodiments may incorporate a front roller guide  23  which is not substantially cylindrical in shape and which does not rotate. 
     The bottommost portion of the face plate  22  comprises one or more alignment grooves  32  for proper alignment with and onto the ears  20  of the bottom plank  18 . In a preferred embodiment, there are two of said grooves  32  that are of substantially inverted “L” cross sectional shape whereby the bottom plank ears  20  are capable of insertion and holding within said grooves  32 . Alternative embodiments may have more or less grooves  32  which have a cross section of inverted “T” shape, “U” shape or an inverted tapered “U” shape, or any other shape which is capable of accepting and holding said bottom plank ears  20 . 
     The front roller guide  23  acts to guide and align the flexible top plank material  14  under the pressure roller  24  via the one or more roller alignment grooves  30  contained on the front roller guide  23 . In a preferred embodiment, the pressure roller  24  is of cylindrical shape and rotatably mounted toward the rear of the yolk  21 , rearward of the front roller guide  23 , and onto the pressure roller axle  26 . The pressure roller  24  serves to press the top plank  14  onto the bottom plank  18  after the top plank  14  is fed over the front roller guide  23  when a downward force is placed on the handle  27 . In a preferred embodiment, the pressure roller axle  26  is held in and through the yolk  21  via holes in the yolk  21  which are placed rearward of said front roller guide  23 . The handle  27  attaches to the rear portion of the yoke  21  in order to provide a means by which pressure may be applied to the top plank material  14  through the pressure roller  24  while the installer is in a standing position. This is accomplished due to the fact that the alignment grooves  30  in the face plate  22  serve to hold the frontmost portion of the plank top installation tool  10  onto the ears  20  of the bottom plank  18  in order to provide a moment arm force onto the pressure roller  24 . The face plate  22  does not raise from its contact and connection with the bottom plank  18  during use. Alternative embodiments may forego use of a pressure roller axle  26  without departing from the spirit of the present art. Moreover, alternative embodiments may incorporate a pressure roller  24  which is not substantially cylindrical in shape and which does not rotate. 
     The preferred embodiment of the top plank end installation tool  11  comprises a cylindrical front pressure roller  43  and a cylindrical rear roller  44 , a right side plate  41  with one or more guide ears  50 , a left side plate  42  with one or more guide ears  50 , a force application front handle  45 , a force application rear handle  46 , a cylindrical front spacer bushing  47 , and a cylindrical rear spacer bushing  48 , all of which are secured together and to said plates  41 , 42  with fasteners  49  such as bolts or pins. Each of said plates  41 , 42  has a front, back, top and bottom portion with said guide ears  50  near the bottom portion of said plates  41 , 42 . In a preferred embodiment, said bushings  47 , 48  are held in place by fasteners  49  such as bolts or pins which penetrate both the right side plate  41  and the left side plate  42  and serve as axles. Alternative embodiments may incorporate pins or dowels in place of said bolts or mount said components between and directly to said plates  41 , 42 . Further alternative embodiments may forego the use of guide ears  50 . 
     Said front roller  43  is mounted onto said front spacer bushing  47  and toward the front portion of said plates  41 , 42 . Said rear roller  44  is mounted toward the rear of said plates  41 , 42  and the rear of said guide ears  50  and onto said rear spacer bushing  48 . Each roller  43 , 44  is mounted over and allowed to roll on its respective bushing  47 , 48 . Each of said rollers  43 , 44  are slightly shorter in length than the respective bushing  47 , 48  onto which it is mounted in order to ensure free rolling of said rollers  43 , 44 . The placement of each of said rollers  43 , 44  is such that said guide ears  50  extend below the surface of said rollers  43 , 44  and serve to guide the top plank end installation tool  11  on the flexible top plank  14 . Said rollers  43 , 44  place a user supplied force on said top plank  14  in order to push said top plank  14  onto said bottom plank  18  and snap or attach said top plank  14  into place with said bottom plank  18 . It is important to note that although the rollers  43 , 44  are mounted on bushings  47 , 48  in a preferred embodiment, alternative embodiments may incorporate rollers  43 , 44  which simply bear upon the fasteners  49  or bolts which hold them and the side plates  41 , 42  together. Further alternative embodiments may incorporate rollers which are not cylindrical in shape and which do not rotate. 
     The force application front handle  45  is located near the front and top portion of said plates  41 , 42 . Furthermore, The force application rear handle  46  is located near the rear and top portion of said plates  41 , 42 . Alternative embodiments may place said handles  45 , 46  wherever they are most conveniently used by the installer. 
     The plank top end installation tool  11  with its placement of rollers  43 , 44 , especially the front pressure roller  43 , allows the last portions, generally a few inches, of plank top  14  to be secured to the bottom plank  18 , especially when said planks  14 ,  18  are abutted to a wall or structure. It is important to note that the plank top end installation tool  11  is used in conjunction with the plank top installation tool  10  and usually after said plank top installation tool  10  in order to perform the method of the present art as further described. 
     The preferred method of plank top installation of the present art requires the user or installer to first use the plank top installation tool  10  to install most of the top plank  14  to the bottom plank  18  and then finish installing the ends of the top plank  14  with the plank top end installation tool  11 . Alternative methods may use the plank top end installation tool  11  first then complete the installation with the plank top installation tool  10 . When operating the plank top installation tool  10 , the user or installer first places, aligns and secures the bottommost portion of the face plate  22  containing the alignment grooves  30  onto the interfacing portion of the bottom plank  18  containing the bottom plank ears  20 . The alignment grooves  30  snap into place over said bottom plank ears  20  due to the fact that said ears  20  are flexible and pliable. As aforementioned, the shape of said alignment grooves  30  is such that said face plate  22  is held to said bottom plank  18  yet allowed to move linearly forward on said bottom plank  18  during the installation process. 
     After said face plate  22  is placed, the user or installer threads a flexible top plank  14  over the front roller guide  23  and under the pressure roller  24 . With the top plank  14  threaded, the user then presses downward with the handle  27  and begins walking in a forward direction until the user approaches the end of the top plank  14 . As the user walks, the top plank  14  hooked portions or grooves  16  are forcibly secured onto the extending ears  20  of the bottom plank  18  or bottom plank ears  20  via the force provided by the pressure roller  24 . Pressure is provided by and onto the pressure roller  24  due to the fact that the unique configuration of the alignment grooves  30  in the face plate  22  serve to hold said face plate  22  onto the ears  20  of the bottom plank  18  and form a moment arm of force due to the force supplied by the handle  27 . When the user reaches the end of said top plank  14 , the user removes the face plate  22  from the bottom plank ears  20  and further removes the plank top installation tool  10  and then completes the installation with the plank top end installation tool  11 . 
     The installation method of the present art is fully completed by use of the plank top end installation tool  11 . In operation of the plank top end installation tool  11 , the installer places the top plank end installation tool  10  onto the end of the top plank  14  which is still unplaced and unsecured with said bottom plank  18  by contacting said top plank  14  with the rollers  43 , 44 . The installer then contacts the front pressure roller  43  and rear roller  44  with the unsecured top plank  14  end and aligns the guide ears  50  with and around the edges of said top plank  14  and presses downward on the front handle  45  and rear handle  46  while rolling forward to finish the top plank installation. The user supplied force on the force application front handle  45  and force application rear handle  46  serves to provide enough force onto said rollers  43 , 44  to secure the flexible top plank  14  onto the bottom plank  18 . After the top plank  14  is fully placed, the user simply lifts the top plank end installation tool  11  off of the top plank  14  and the method of installation is complete. 
     As described, the art of the present method is shown and described along with the apparatus used to accomplish said method. The art of the present invention is drawn only to the method and apparatus shown and described and makes no claim to the configuration, shape or construction of the decking materials described. 
     From the foregoing description, those skilled in the art will appreciate that all objects of the present invention are realized. A method and apparatus for plank top installation for a deck is shown which is particularly adapted for operation with the “Teck Deck” system from Heritage Vinyl Products of Macon, Miss. The method and apparatus of this invention is able to provide the required force for pressing and securing a top plank onto a bottom plank of said decking materials without using hammers, mallets or other tools which may harm said decking materials. 
     Having described the invention in detail, those skilled in the art will appreciate that modifications may be made to the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described. Rather it is intended that the scope of this invention be determined by the appended claims and their equivalents.