Abstract:
This present invention relates generally to deck fasteners for securing deck boards together and to a supporting member, and more particularly with a deck fastener which does not protrude from the deck surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/507,177, entitled “Decking System with Hidden Dovetail Fastener,” filed on Jul. 13, 2011, which is hereby incorporated in its entirety by reference. 
     
    
     FIELD OF ART 
       [0002]    This invention relates generally to deck fasteners for securing deck boards together and to a supporting member, and more particularly with a deck fastener which does not protrude from the deck surface. 
       BACKGROUND OF THE INVENTION 
       [0003]    In decking and frame construction, it is often desirable to provide a blind or invisible interconnection between the decking boards and the underlying supporting joists. This desire is accentuated with decking that is exposed to the open environment as the exposed connectors may be susceptible to oxidation, leaching and similar environmental affects. Various connectors and decking designs have been proposed to resolve this issue. Though some designs have successfully decreased the aforementioned problems, issues still remain with hidden fastening of decking. 
         [0004]    Decking systems commonly include a series of joists supported by a frame. The joists are aligned parallel to one another. Decking boards are connected to the joists and spaced adjacent to one another. Often, a gap is left between the decking boards to allow space for expansion and contraction of the system, specifically expansion and contraction of the decking boards, without damaging the system. 
         [0005]    Decking fasteners are used to connect the decking boards to the joists and to one another. Decking boards are commonly mounted perpendicular to the joists such that each decking board is supported by multiple joists. A decking fastener may connect to both the joist and the decking board to prevent the decking board from moving with respect to the joists. Often, fasteners are mounted at the edge of a decking board and further connect to the adjacent decking board. Thus, a single fastener may fix a decking board to both a joist and an adjacent decking board. 
         [0006]    Hidden decking fasteners are used to hide the fastener beneath the surface of the decking board and away from harsh environmental elements. However, as many decking designs include a space between the decking boards, many hidden fasteners are still visible from above and are still susceptible to environmental elements. Additionally, many decking fasteners require the use of nails, screws, bolts, and other extraneous hardware to connect the fasteners to the joists. This hardware complicates assembly of the deck. Therefore, an improved decking system is needed to cure these and other design defects. 
       SUMMARY OF THE INVENTION 
       [0007]    This invention relates generally to deck fasteners for securing deck boards together and to a supporting member, and more particularly with a deck fastener which does not protrude from the deck surface. 
         [0008]    In one embodiment, the present invention relates to a decking fastener comprising: a first joist connector, the first joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; a second joist connector, the second joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; and a board connector, the board connector having a first side, a second side and a bottom, wherein the first side and the second side of the board connector are operatively coupled to opposite sides of the bottom and are arranged in a substantially parallel manner to one another, wherein the remaining sides of the bottom of the board connector are operatively coupled to at least a portion of the top edges of the first and second joist connectors so that the first and second joist connectors are arranged in a substantially perpendicular manner to the first and second board connector sides. 
         [0009]    In another embodiment, the present invention relates to a decking system comprising: a frame; at least one joist, the at least one joist being secured to the frame; at least one decking board, the at least one decking board having a top side and a bottom side, the bottom side having formed therein at least one slotted opening, wherein the at least one decking board is secured to the at least one joist via at least one decking fastener, the decking fastener comprising: a first joist connector, the first joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; a second joist connector, the second joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; and a board connector, the board connector having a first side, a second side and a bottom, wherein the first side and the second side of the board connector are operatively coupled to opposite sides of the bottom and are arranged in a substantially parallel manner to one another and wherein the board connector is designed to operatively engage the slotted opening in the bottom of the at least one decking board, wherein the remaining sides of the bottom of the board connector are operatively coupled to at least a portion of the top edges of the first and second joist connectors so that the first and second joist connectors are arranged in a substantially perpendicular manner to the first and second board connector sides. 
         [0010]    In still another embodiment, the present invention relates to a method of assembling a decking system comprising the steps of: forming a frame; securing at least one joist to at least a portion of the frame; securing at least one decking board to at least a portion of the at least one joist via at least one decking fastener, the at least one decking board having a top side and a bottom side, the bottom side having formed therein at least one slotted opening, the decking fastener comprising: a first joist connector, the first joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; a second joist connector, the second joist connector having a first side edge, a second side edge, a bottom edge and a top edge, the first and second side edges being opposite one another, wherein each of the first and second side edges has at least one anchoring tabs formed therein; and a board connector, the board connector having a first side, a second side and a bottom, wherein the first side and the second side of the board connector are operatively coupled to opposite sides of the bottom and are arranged in a substantially parallel manner to one another and wherein the board connector is designed to operatively engage the slotted opening in the bottom of the at least one decking board, wherein the remaining sides of the bottom of the board connector are operatively coupled to at least a portion of the top edges of the first and second joist connectors so that the first and second joist connectors are arranged in a substantially perpendicular manner to the first and second board connector sides. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0011]    The operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein: 
           [0012]      FIG. 1  is a perspective view of a decking system having a hidden decking fastener in an embodiment of the invention. 
           [0013]      FIG. 2  is a perspective view of an embodiment of a hidden fastener of the hidden decking system. 
           [0014]      FIG. 3  is a perspective view of an embodiment of the hidden decking system with the hidden fastener not attached. 
           [0015]      FIG. 4  is a perspective view of an embodiment of the hidden decking system with the hidden fastener attached. 
           [0016]      FIG. 5  is a view taken along lines  5 - 5  of  FIG. 4  of the hidden decking system of the present invention with the hidden fastener installed. 
           [0017]      FIG. 6  is a view taken along lines  6 - 6  of  FIG. 5  of the hidden decking system of the present invention with the hidden fastener installed. 
           [0018]      FIG. 7  is a front view of an embodiment of the hidden fastener. 
           [0019]      FIG. 8  is a side view of an embodiment of the hidden fastener. 
           [0020]      FIG. 9  is a top view of an embodiment of the hidden fastener. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention. 
         [0022]    With reference to  FIGS. 1 through 9 , an improved decking system  10  having a hidden fastener  14  is provided. The decking system  10  may be free-standing or connected to a structure on one or more sides. The decking system  10  may be generally supported by a frame (not shown). The frame may include a plurality of posts and cross-beams configured to provide a base structure for the decking system  10 . 
         [0023]    The decking system  10  includes a series of joists—one of which is shown as  11 —supported by the frame. The joists  11  may be arranged parallel to each other to provide a support grid for a plurality of decking boards  12 . Alternatively, the joists  11  may be arranged in any configuration to support the decking boards  12 . The decking boards  12  may be located perpendicular to the joists  11  such that each decking board  12  is supported by multiple joists  11 . Alternatively, the decking boards  12  may be arranged parallel to the joists  11  or at an angle with respect to the joists  11 . 
         [0024]    The decking system  10  may include a fastener  14  to interconnect the decking boards  12  to the joists  11 . The fastener  14  may be of any material such as a metal, a metal alloy, etc. In one embodiment, fastener  14  is formed from titanium, aluminum, stainless steel, or hardened steel (e.g., 1050 or 1056 steel). The fastener  14  may comprise a joist connector  16  and a board connector  18 . The joist connector  16  may be configured to engage a portion of the joist  11 . For example, as illustrated in  FIG. 1 , the joist connector  16  may be a substantially u-shaped clamp that is sized and shaped to engage an edge of a joist  11 . Although a u-shaped clamp is shown, it should be understood that the present invention is not limited to such and may comprise additional shapes. The clamp portion of the joist connector  16  may be tapered to hold the joist  11  in a frictional fit. The joist connector  16  may be fixed to the joist  11  by aligning the opening of the u-shaped clamp with an edge of the joist  11  and applying a force thereto. 
         [0025]    The joist connector  16  may further include a secondary feature to prevent the fastener  14  from sliding relative to the joist  11 . For example, as shown in  FIGS. 2 ,  7 - 9 , the joist connector  16  may include tabs  20  that may be hammered or driven into the joist  11  to further secure the fastener  14  thereto. While the fastener  14  is described herein as being connected to the joist  11  without any additional hardware, it will be appreciated that the nails, screws, bolts or any other hardware known in the art may be used to further secure the fastener  14  to the joist  11 . In this embodiment, the tabs  20  may further help prevent the decking boards  12  from coming loose from the joists  11 , especially during windy conditions. The tabs  20  can add additional security of the fasteners  14  into the joists  11 . 
         [0026]    In an alternative embodiment, shown in  FIG. 9 , the fasteners  14  may include an aperture  40  on the top surface  42  of the fastener  14 . The aperture  40  can be sized and shaped to receive a fastening device (not shown), such as a screw, nail or the like. In this embodiment, the fastener  14  can be positioned in the opening  22 . Then the fastening device can be inserted into the aperture  40  with the stop surface  42  resting in the opening  22  of the decking boards  12  and fastened to the decking boards  12 . This permits an installer to attach the fasteners  12  to the opening  22  in the decking boards to aid in installation of the decking system  10 . 
         [0027]    The decking system  10  may be configured to hide the fasteners  14  from above and shelter them from exposure to environmental elements. Traditional decking systems include decking boards that are arranged with spaces therebetween to allow for expansion and contraction of the decking boards. The fasteners are often positioned between the decking boards to interconnect the decking boards and the joists. However, the space between the decking boards allows for the fasteners to be seen from above and exposed to environmental elements. 
         [0028]    To hide the fasteners  14 , the decking boards  12  may be configured to completely cover the fasteners  14 . As shown in  FIGS. 1 ,  3 - 6 , the underside  24  of the decking boards  12  may include an opening  22  to receive the board connector  18 . The opening  22  may be a channel configured to hold the board connector  18  therein. In an embodiment, the opening  22  is an extruded portion having a negative angle, such as a dovetail shaped extrusion. The board connector  18  is similarly shaped and capable of being slid or snapped into the opening  22 . The negative angle or features of the opening  22  will retain the board connector within the opening. While the opening  22  is shown and described as being dovetail shaped, it will be appreciated that the opening  22  and board connector  18  may be of any shape and size that allows the fastener  14  to be retained by within the opening  22 . 
         [0029]    Each decking board  12  may include a plurality of openings  22  to receive multiple fasteners  14 . The openings  22  may be perpendicular to the length of the decking board  12  such that the fasteners  14  are space apart along the length of the decking board  12  to align with the joists  11 . Alternatively, the decking board  12  may include a single extruded opening  22  along its length. Multiple fasteners  14  may be inserted into the opening  22  and spaced apart so as to align with the joists  11 . As illustrated in  FIGS. 1 ,  3 - 6 , the opening may be centrally located on an underside  24  of the decking board  12  such that the decking board  12  completely covers the fastener  14 , thereby hiding the fastener from view above and sheltering it from the environment. 
         [0030]    In use, a plurality of fasteners  14  is connected to a decking board  12 . The fasteners  14  are inserted into an extruded opening  22  on the underside  24  of the decking board  12  and arranged so as to be hidden under the decking board. The fasteners  14  are arranged to align with and engage the joists  11 . The opening of each u-shaped joist connector  16  is placed over a portion of the corresponding joist  11 , and a force is applied to the decking board  12  above each fastener  14 . The tabs  20  may be hammered or driven into the joist  11  to prevent the fastener  14  from sliding or moving with respect to the joist  11 . Alternatively, the fasteners  14  may be attached to the underside  24  of the decking board  12  as shown in  FIGS. 4-6 . Once the fasteners  14  are attached, the decking board  12  may be placed on top of the joists  11  and then stepped on to drive the decking board  12  onto the joists  11 . This provides a system that is not difficult to install. 
         [0031]    The decking system  10  may provide a secure fit between the decking boards  12  and the joists  11 . More specifically, many of the prior art decking systems, especially those that purport to be hidden fastener systems, do not provide sufficient updraft strength. The attachment of the decking boards to the joists is not strong enough to prevent the deck boards from lifting during heavy wind conditions. The fastener  14  of the present embodiment provides a strong connection between the decking boards  12  and the joists  11 . The present embodiment may resist a predetermined amount of updraft to help prevent the deck boards  12  from lifting from the joists  11  during windy conditions. 
         [0032]    While the present embodiment shows the decking boards  12  being perpendicular to the joists  11 , the decking boards  12  may use the decking system  10  and have the decking boards  12  installed at 45 degree angles with respect to the joists  11 . Additionally, the joists  11  may be installed such that the decking boards  12  may be installed perpendicular thereto while being installed 45 degrees relative to a structure against which the decking system  10  is installed. 
         [0033]    Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.