Abstract:
A floor panel and method of manufacturing wherein each panel comprises a sheet having at least two stiffening members extending from the lower surface and substantially the length of the sheet. A bead is defined along one of the stiffening members while a tab is defined along the other stiffening member. Clips are provided to fasten the bead and tab in a locking relationship to hold the sheet in position. A flange formed at one end of the panel is received within a recess formed at an opposite end of another panel to automatically space one panel from another.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   This application claims priority of U.S. Provisional Patent Application No. 60/469,477 filed 9 May 2003, the contents of which are incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to building materials. In particular, the invention concerns an improved panel system, and more particularly the invention relates to a panel system for use as flooring or decking. 
   2. Discussion of the Related Art 
   Traditionally, building materials consist of various forms of natural resources, such as stone, wood, and clay. More recently, man-made materials have been introduced. There has been an increase on the demand for man-made materials substituting polymeric materials for wood products. Certain companies have combined a mixture of polymers and wood chips and/or dust and extruded this mixture to form long planks. Once cured, these planks have been used as decking materials and at times used for outdoor furniture. However, a major disadvantage associated with these types of wood substitutes is the coefficients of expansion and contraction for the polymeric material. Often, the expansion and contraction is so substantial that the planks buckle and/or leave substantial gaps from shrinkage. The purpose of this invention is to provide a polymeric decking system that accommodates the shrinkage and expansion of the polymeric material produced by changes in temperature. 
   SUMMARY OF THE INVENTION 
   According to one form of the invention, a floor panel assembly is provided having a tabular sheet defined by an upper surface, a lower surface, and a common peripheral edge. At least two spaced apart stiffening members extend from the lower surface and run substantially the length of the tabular sheet. A bead is defined along a free edge of one stiffening member while a tab extends from the free edge of the opposite stiffening member. 
   In a further embodiment of the invention, a plurality of clips are included, each of which is adapted to be fastened to a substrate and receive a one of the free edges in locking relationship for holding said tabular sheet in position. The two stiffening members extending from said lower surface of the tabular sheet and having the bead and tab preferably have a height less than other stiffening members to account for the height of the mounting clips. To help facilitate the location of each panel, a plurality of spacing bosses are defined at predetermined intervals along the length of one of the bead and tab. The bosses restrict the longitudinal movement of each panel during periods of expansion and contraction. 
   In another embodiment of the panel, and to help automatically facilitate spacing, a tapered flange is located at one end of each panel. Likewise, a corresponding recess is defined in the opposite end of another panel to receive the tapered flange. To provide a finished appearance along an edge of the floor, a finishing panel is provided having a vertical member depending from the lower surface proximate one end and at an angle to the stiffening members. 
   In yet another embodiment, each of the clips include a dedicated recess for receiving a respective one of the bead and the tab at the ends of the stiffening members. Moreover, on each of the plurality of clips, the recess for the tab is outboard of the recess for said bead. In the alternative, and depending upon the desired configuration the dedicated recess for the bead is outboard of the recess for the tab. 
   In another embodiment of the invention, a decking system is provided comprising a plurality of decking panels adapted to be arranged in a predetermined array over a predetermined substrate. Each of the plurality of decking panels includes an upper surface of predetermined extant and an opposing lower surface of substantially equal extant joined to the upper surface by a shared peripheral edge. At least two, spaced apart, and generally parallel stiffening members are defined extending from the lower surface and run substantially along the length of each panel to provide structural rigidity. One of the stiffening members includes a bead of predetermined geometric cross-section defined along a free edge. The opposite one of the stiffening members includes a projection defined along a free edge thereof to assist in fixing the relative position of each panel. Mounting is actually accomplished by a plurality of clips, each constructed to be rigidly fixed to the substrate and receive one of the bead and the projection extending from one of the stiffening members. To help in positioning the panel, a plurality of spacing bosses are spaced at predetermined intervals along one of the bead and the projection. To help provide a rigid surface, a third stiffening member extends from the lower surface and is positioned intermediate the two stiffening members mentioned earlier. One end of each panel terminates in a tapered flange. The opposite end of each panel includes a recess for receiving the tapered flange of another panel. 
   In yet another form of the invention, a method for manufacturing the decking or floor panel is provided and comprises the steps of producing a panel of predetermined dimension with an upper surface and a lower surface sharing a common peripheral edge. At least two spaced apart stiffening members are defined extending substantially perpendicular from the lower surface of said panel. The method further includes the steps of forming one of a bead and a projection along a free edge of one of the stiffening members, and an opposite one of the bead and projection on a free edge of the other stiffening member. 
   A further embodiment of the method includes forming a tapered flange at one end of the panel which adapted to be received within a recess formed at an opposite end of another panel. The tapered flange is formed in a manner to automatically space the end of one panel from the end of an adjoining panel. In a preferred embodiment, each of the panels is formed using one of the methods of injection molding, extrusion molding, machining, forging and casting. Likewise, the plurality of clips are formed separate and apart from the panels so that each is configured to be anchored to a substrate. Each of the clips is formed with a plurality of attachment members adapted to receive a respective one of the bead and the projection to retain the panel to the substrate. The method further comprises forming a plurality of spacing bosses at predetermined intervals along one of the bead and the projection. To help provide longitudinal stability, each clip is adapted to be received between a pair of spacing bosses. 
   These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a fragmentary plan view illustrating one possible pattern for the planking material of this invention; 
       FIG. 2  is a side elevational view of one embodiment of a panel of the invention; 
       FIG. 3  is an end elevational view of the panel shown in  FIG. 2 ; 
       FIG. 4  is a fragmentary oblique view of one end of a panel of the invention; 
       FIG. 5  is a fragmentary oblique view illustrating adjoining ends of panels; 
       FIG. 6  is a fragmentary oblique view illustrating the underside of two adjacent end panels; 
       FIG. 7  is a fragmentary oblique view illustrating an end or cap wall of a panel of the invention; and 
       FIGS. 8   a ,  8   b ,  8   c , and  8   d  schematically illustrate assembly relationships between laterally adjacent panels of the invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   For purposes of the following description, the terms “upper,” “lower,” “left,” “rear,” “front,” “vertical,” “horizontal” and derivatives of such terms shall relate to the invention as oriented in  FIGS. 2 and 3 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the inventive concepts of this invention. Specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting unless expressly stated otherwise. 
   The instant invention comprises an improved decking and flooring material in the form of three dimensional tabular sheets or planks  10  having a length substantially greater than its width which in turn is substantially greater than the thickness. In a preferred embodiment, each of the tabular sheets may be formed using one of injection molding and extrusion of a polymeric material. For example, the reader is referred to  FIGS. 1 through 3  illustrating an injection molded polymeric structure having a length (L) on the order of 48 inches, a width (W) of approximately 6 inches, and a height (H) ranging between 1 and 1½ inches. As shown in  FIG. 1 , a number of panels  10  are assembled together to form a panel assembly  12 . In the panel assembly  12  each of the tabular sheets or planks  10  are arranged longitudinally adjacent each other and supported by perpendicularly arranged joists  14  spaced at predetermined intervals or other suitable substrate. In this case, the spacing between the joists  14  has been established at 16 inches-on-center. Although the joists  14  are spaced 16 inches-on-center, the spacing may be changed depending in large part upon the length of each of the tabular sheets or planks  10 . As briefly mentioned above, other suitable substrates may include steel or aluminum beams, plywood sheeting, concrete or other stable surface. 
     FIGS. 2 and 3  generally illustrate one embodiment of structural features in each tabular sheet or plank  10 . As briefly mentioned above, each tabular sheet or plank  10  is preferably injection molded or extruded from a polymeric material. One example of a suitable material includes polyvinyl chloride, although other materials may also be used so long as they provide stability to ultra violet radiation and maintains their integrity at hot and cold temperatures. In the embodiment illustrated in this application, each plank  10  contains an upper surface  16 , a lower surface  18  and a plurality of longitudinal stiffening members  20 , each extending substantially perpendicular from the lower surface  18 . Outboard of longitudinal stiffening members  20  are plank sidewalls  22  and  24  which also extend the length of each plank. As best illustrated in  FIG. 3 , sidewall  22  depends from the lower surface  18  substantially at the peripheral edge  26  of surfaces  16  and  18 . Moreover, the vertical height (H) of sidewall  22  is slightly less than that of the inboard longitudinal stiffening members  20  for reasons which will become immediately apparent below. The lower terminal edge of sidewall  22  includes a lateral extension running the length of the sidewall  22  defined by a shoulder  28  and tapered vertical wall  30  to define a tab structure. The sidewall  24  extending downwardly from lower surface  18  on the opposite side of the plank  10  is offset laterally inward from the peripheral edge  26   a  of surfaces  16  and  18 . The lower end of sidewall  22  terminates in a longitudinal bead  32  which extends substantially along the length of the plank  10 . The particular transverse form of longitudinal bead  32  may vary so long as the requisite function is performed. For example, the bead may be in the form of a substantially linear post, a polygon, or even an oval or circle. 
   Spaced periodically along the outer surface  34  of sidewall  24  and extending from the upper portion of the bead  32  onto the sidewall  24  is a spacing boss  36 . In a preferred embodiment, the distance between each spacing boss  36  is narrowest toward a transverse middle portion of each panel, and increases as one moves toward one of the opposing ends of the plank  10 . For example, the distance between the spacing bosses  36  at the center of the plank may be on the order of one inch and on the order of one and one-half inch at the ends of the plank  10 . 
   Each plank  10  is anchored to the underlying joist  14  by a plurality of clips  40  generally identified by reference numeral  40 . Each clip  40  is substantially tabular in shape with a substantially cylindrical recess  42  extending along edge  44 . Immediately adjacent the cylindrical recess  42  and inboard from edge  44  is a second recess  46  defined by inclined wall  48  and shoulder  50 . Spaced from the recesses  42  and  46 , and proximate the opposing edge  52  are one or more perforations  54  for receiving a screw, nail, or other anchor for attaching the clip  40  to the joists  14 . Additional attachment methods for rigidly attaching each of the plurality of clips may include one of a screw, a rivet, a bolt, an adhesive, a clamp, and a pinch flange. In a preferred embodiment, the width of each clip  40  is substantially the same, and slightly less than the minimal distance between the spacing bosses  36 . In particular, for the example described above, it is preferred that the width of the clip  40  be less than one inch. As best illustrated in  FIG. 3 , a plurality of clips  40  are used to anchor each plank  10  to the joist  14  by sidewall  22  and shoulder  28  received within the recess  46  to engage shoulder  50 , thus keeping that portion of plank  10  securely anchored against the joist  14 . On the opposite sidewall  24 , the longitudinal bead  32  is received within the recesses  42  of each of the plurality of clips  40  spaced along the length of each plank and anchored to the underlying joist  14 . The recess  42  in turn is received in snap fit arrangement around the bead  32  to retain the sidewall  24  against the joists  14 . The difference in height between the longitudinal stiffening members  20  and the outboard sidewalls  22  and  24  are compensated by the thickness of the tabular portions of the clips  40 . It should be noticed that the spacing between the recess  46  and the cylindrical recess  42  are such that outside wall  22  may be positioned in a fixed spaced relationship with respect to sidewall  24  of the adjacent plank  10  to ensure even spacing between the adjoining planks. The distance between each of the spacing bosses  36  and the clips  40  provides adequate room for each plank to expand and contract in a direction parallel to the longitudinal axis. 
   Returning to  FIGS. 1 and 4  through  6 , the instant invention also accommodates for expansion between the ends of adjacent planks  10 . Referring to the referenced drawing figures, a first end  60  of each plank  10  includes a tapered flange  62  positioned slightly lower than the upper surface  16  and slightly inboard of each sidewall  22 ,  24 . Each tapered flange  62  is dimensioned to be received within a dimensionally close fitting recess  64  defined in the second end  66  of the adjacent plank  10 . The dimension of the tapered flange  62  is sufficient to continue to span the gap between adjacent planks  10  when each plank  10  has retracted to its maximum extent in cold weather, and more than adequate to span the distance when each plank has reached its maximum point of expansion. Appropriate spacing between the ends of the respective planks  10  is automatically provided by a tab  68  molded onto the tapered flange  62  to space the first end  60  relative to the second end  66 . 
     FIG. 7  illustrates one embodiment of a finished end of a plank  72  to be used at the exposed edges of the deck or flooring planks  10 . The finished edge of each finishing plank  72  is provided by an end or cap wall  70  interconnecting the sidewalls  22  and  24  at one end of the finishing plank. Additional planks  72  provided with the finished end will cover the second end of the plank  10  so that both ends of a series of interconnected planks have a finished professional look. It is also contemplated that end caps or finishing planks  72  may be formed to provide angled faces  70 . The range of available angled ends can be provided to cover a predetermined combination of angle orientations. 
     FIG. 8   a  through  FIG. 8   d  generally illustrate the method for assembling a floor or deck assembly using the instant invention. A first plank  10  is initially fit with a plurality of clips  40  by positioning the longitudinal bead  32  at the end of sidewall  24  adjacent the cylindrical recess  42  in the clip  40 . The bead  32  is forced into the recess  42  under pressure. The clip  40  is then automatically centered within the space between adjacent spacing bosses  36  by shoulder  50  engaging the bosses  36  and being urged into the space between the bosses. With the tab clip  40  attached to the sidewall  24 , the clip  40  is placed at the appropriate location on the joist  14  so the plank  10  is properly aligned and anchored with a fastener such as one of those described above and identified by reference numeral  76 . The immediately adjacent plank  10  is then positioned by inserting the sidewall  22  into the recess  46  of the clip  40  so that the shoulder  28  engages the shoulder  50 . The pressure exerted against the interior of sidewall  22  by the inclined wall  48  ensures engagement of the respective shoulders to lock the sidewall  22  into clip  40  (see  FIG. 8   d ). The lateral and longitudinal spacing of the planks  10  with respect to each other and the manner using the clips  40  provides sufficient room for expansion and contraction of the material as a result in change of temperature. Moreover, the variation in spacing between the bosses  36  along each plank  10  ensures that the distances and gaps between adjacent planks will be accommodated substantially uniformly to prevent any major gaps between the plank, or excessive buckling between the ends which would be detrimental to the appearance of the surface formed by the planks  10 . 
   As mentioned briefly above, it is contemplated that each of the planks  10  and the clips  40  be formed from a polymeric material using conventional techniques. In a preferred embodiment, the polymeric material may be a polyurethane, polyethylene, or polyvinyl material. In some cases and applications other polymeric materials may be used to work suitably within different environments. In addition, it is contemplated that a certain crown may be formed on the upper surface  16  to improve the runoff of moisture or debris from the plank surface  16 . Certainly these and other modifications would be apparent to one of ordinary skill in the art. Other modifications may also be gleaned by one of ordinary skill in the art based on this disclosure. 
   The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and the examples set forth herein are described merely for illustrative purposes and not intended to limit the scope of the invention as interpreted according to the principles of patent law, including the doctrine of equivalents.