Patent Publication Number: US-2011047901-A1

Title: Extruded Aluminum Deck Plank with Lighting and Heating Features

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application relates to and claims priority from U.S. Provisional Application Ser. No. 61/239,474, filed Sep. 3, 2009; Ser. No. 61/243,342, filed Sep. 17, 2009; and Ser. No. 61/247,353, filed Sep. 30, 2009. 
    
    
     BACKGROUND OF THE INVENTION 
     The subject invention pertains to planks for use in the construction of decks, piers and the like and, more particularly, to an extruded aluminum deck plank that provides simple and effective arrangements for attaching side-by-side to an underlying wooden support and for attaching the planks end-to-end. 
     It is well known in the art to use extruded aluminum planks in structures such as bleachers. In these structures, the extruded aluminum planks may serve both as the seat member and the foot rest. However, typical attachment of these extruded members to underlying supports require complex fastening systems. 
     It is also well known in the art to make deck planks from plastic extrusions. Such plastic extrusions are commonly used for decks and piers, but have typically not found successful use in bleachers where the loads are greater and typically more concentrated. Furthermore, plastic is not considered to be as durable as aluminum, particularly in outdoor applications. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, an extruded aluminum deck plank utilizes two rectangular plank halves extruded together and connected at their lower surfaces with a narrow web. The lower plank half walls and connecting web are coplanar and the connecting web is provided with holes for the receipt of screws or other connectors driven through the connecting web and into an underlying wooden support member. Inner side walls of the plank halves form, with the connecting web, a U-shaped channel that is closed (after fastening) with a long aluminum closure strip that is snapped into the channel and has an upper surface generally coplanar with the upper surfaces of the plank halves. 
     The closure strip has a generally inverted U-shape cross section and the upper surface of the closure strip joins two integrally formed downwardly depending side walls that engage the side surfaces of the U-shaped channel with engaging ribs to hold the closure strip in place. 
     Provision is also made for connecting the deck planks end-to-end with splice pieces inserted into and joining the ends of longitudinally adjacent plank halves. 
     In an alternate embodiment of the invention, the U-shaped channel is provided with a string of LED lights and the closure strip is made from a transparent or other light-transmitting plastic material. 
     In a modified deck plank, an extruded cross section is provided that imparts a longitudinal rib surface along the surfaces of the U-shaped channel as well as the corresponding inside surfaces of the plank halves. The ribs provide a heat sink for heat generated by the string of LED lights and the heat is conducted away from the ribs to the plank surfaces to inhibit the formation of ice and to dry accumulated moisture. A strip of heat tape may be used instead for heating. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of the deck plank and closure strip of the present invention. 
         FIG. 2  is an enlarged cross section taken on line  2 - 2  of  FIG. 1 . 
         FIG. 3  is a vertical section taken through the closure strip shown in  FIG. 1 ; 
         FIG. 4  is a sectional view, similar to  FIG. 2 , showing the closure strip in place; 
         FIG. 5  is a perspective view similar to  FIG. 1 , showing a spliced connection for joining the ends of two deck planks; 
         FIG. 6  is a perspective view similar to  FIG. 1  showing another embodiment of the invention; 
         FIG. 7  is a vertical section similar to  FIG. 4  showing details of the  FIG. 6  embodiment; 
         FIG. 8  is a perspective view of the modified plank, similar to  FIGS. 1 and 5 ; and, 
         FIG. 9  is an enlarged vertical cross sections taken on line  9 - 9  of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to  FIG. 1 , an extruded aluminum deck plank  10  is shown with a closure strip  11  before the strip is attached to the plank. The closure strip in this embodiment is also an aluminum extrusion. The extruded plank includes two rectangular plank halves  12  whose horizontal lower walls  13  are joined by a connecting web  14  to form a coplanar lower surface. The upper walls  15  of the plank halves  12  are provided on their outside surfaces with longitudinal ribs  16  to enhance the footing of persons walking on the upper surfaces  15  of the planks  10 . 
     The narrow connecting web  14  forms with the interior side walls  17  of the plank halves a U-shaped channel  18 . Suitable fasteners, such as screws  20 , may be inserted through holes in the connecting web  14  and driven into an underlying wooden support  21  as shown in  FIG. 7  This arrangement is shown in  FIG. 4 . 
     Once a deck plank  10  has been fastened to one or more suitable wooden joists or supports  21 , the U-shaped channel  18  is closed by pressing the closure strip  11  into the channel  18  where it is snapped and locked into position. When locked in place, the horizontal upper surface  22  of the closure strip lies generally coplanar with the upper surfaces  15  of the plank halves  12 . 
     As best seen in  FIG. 2 , the transition between the upper walls  15  of the plank halves  12  and the surfaces of the interior side walls  17  are rounded. The closure strip  11  has an inverted U-shaped cross section including downwardly depending side walls  23  that are slightly rounded and outwardly concave to match and receive the rounded interface. Lower ends of the closure strip side walls  23  are provided with oppositely facing longitudinal detent ribs  24  that are adapted to override horizontally extending locking ribs  25  on the side walls  17  of the plank halves. The closure strip  11  snaps into position to provide a continuous upper surface, concealing the fasteners  20  and keeping debris out of the channel  18 . The tight fitting closure strips  11  also add to and enhance the stiffness of the deck plank  10 . 
     As shown in  FIG. 5 , if it is necessary join plank halves  12  end-to-end, short splice members  26  are inserted into the adjoining open ends of the plank halves  12  where they may be secured in place with horizontal end fasteners, such as sheet metal screws  27 . The splice or joint members  26  also comprise aluminum extrusions and have a C-shaped cross section. 
     Although the splice pieces  26  used to join the ends of adjacent longitudinally extending planks  10  are preferably made of aluminum extrusions, they could be made of plastic or wood. However, aluminum extrusions are still preferred because of their enhanced strength and durability as compared to plastic or wood materials. 
     As also best seen in  FIG. 5 , the tops of the wooden supports  21  (which may comprise conventional 2×8 wood joists) may be covered with an aluminum joist cap  28 . In such case, the fasteners  20  would be driven into the wooden joists through holes in the joist cap  28 , as well as the connecting web  14 . 
     Referring to  FIGS. 6 and 7 , the utility and safety of the extruded planks may be substantially enhanced by placing a string of LED lights  30  in the U-shaped channel  18  after it has been fastened with fasteners  20  to the underlying wooden support  21 . The extruded aluminum closure strip  11  of the previously described embodiment is replaced by a transparent or other light-transmitting plastic closure strip  31 . 
     By using the embodiment of  FIGS. 6 and 7  in the construction of a pier, for example, the LED lights  30  provide a safety feature as well as an esthetic addition. Piers made with planks containing LED light strings provide guidance for both users on the pier or users of a boat to help locate the edge of the pier in poor light or dark conditions. 
     A modified deck plank  33  is shown in  FIGS. 8 and 9 . It has been found that the string of LED lights  30  placed in the channel  18  and enclosed by the transparent and UV-stable closure strip  11  generates considerable heat in use. To capture and distribute the heat, the side surfaces  34  of the U-shaped center channel  33  are provided with longitudinal ribs  35  to create a heat sink. Similarly, the opposite inside surfaces  36  of the plank halves  38  are provided with longitudinal ribs  37  that enhance the heat sink and heat distribution properties of the modified plank  32 . 
     In the embodiment best shown in  FIG. 9 , internal longitudinal ribs  35  are somewhat smaller and more closely spaced than the longitudinal ribs  37  on the adjacent inside surfaces of the plank halves  38 . The heat flowing to the heat sink provided by the ribs is conducted away from the central U-shaped channel  33  and conducted to the main body of the plank  32 . In particular, the upper surfaces  40  of the plank halves  38  are warmed sufficiently to prevent freezing and the accumulation of ice and to dry any water that may accumulate thereon. 
     Heat may also be provided by substituting a heat tape for the light string  30 . This would, of course, eliminate the lighting feature, but still utilize the heating feature.