Patent Abstract:
A framing system has a plank member with ribs protruding therefrom and a frame member with a receptor pocket therein such that the rib of the plank member is resiliently engaged within the receptor pocket of the frame member to secure the plank member to the frame member. The plank member may also be laterally moved relative to the frame member such that the ribs slide within and engage the receptor pockets. The invention is also directed to a method for engaging the plank member with the frame member along with a method for fabricating the frame member.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application No. 60/539,361, filed Jan. 27, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The invention relates to frame construction, such as decks and docks, and, more particularly, to a fastener-free framing system by which plank members are secured to frame members through ribs which are engaged within receptor pockets.  
         [0004]     2. Description of Related Art  
         [0005]     Exterior decks are considered to be the most popular addition to homes throughout the United States today. Decks are places where people can extend their living space beyond the walls of their home. Decks are built out of a variety of materials and are fabricated in a variety of designs.  
         [0006]     Typically, decks and similar structures are constructed with horizontal planking materials and are fastened to an underlying structural frame. The most popular planking and structural framing material is pressure treated wood. Pressure treated wood contains harmful toxins; one of them is called Copper-Chromium Arsenic (CCA). It is designed to extend the life of the product in exterior elements and protect it from weather and insect infestation, such as termites. However, pressure treated wood planking tends to warp, rot, splinter and require periodic maintenance. These problems are inherent only in wood and are accelerated in exterior climates.  
         [0007]     The structural frame for the majority of the decks built in the United States is constructed out of pressure treated wood due to the familiarity and availability of the product. However, other alternative planking materials are plastic/wood composite, synthetic, extruded plastics, extruded metals, cold-rolled metals, and extruded aluminum, etc.  
         [0008]     Attaching the planking to the structural frame with fasteners, through the surface into the underlying structure, is the most commonly accepted method in the industry. There are other methods that conceal the fastening system from the underside using special clips, brackets and the like. However, this typically requires the same amount or additional fasteners to adequately connect planking to the supporting substructure.  
         [0009]     Attaching the planking to the structural frame through the top planking surface yields unsightly blemishes to the decking surface. Typically, planking members require two fasteners to be installed through its surface into the underlying substructure (joists) to be adequately installed. More specifically, where a planking member crosses over the underlying substructure, two fasteners must be installed.  
         [0010]     Attaching the planking to the structural frame through the bottom planking surface using specialty clips is a slow and tedious process requiring more skilled labor and fasteners to adequately install. There are often space requirements below the structure and above the ground to adequately install subsurface fastening systems.  
         [0011]     If nailed, these fasteners can work themselves out of the substructure, just above the surface, and cause injury. Special screws can reduce the chances of nail popping but are typically more expensive since they must be non-corrosive to avoid weathering and often require specialty tools to fasten them. Fastening the planks to the substructure using screws is the most advantageous method, however, it requires some skill to properly place so that the fastening holes align somewhat consistently with the others.  
         [0012]     As mentioned, wood structures have many disadvantages. They rot, warp, split, splinter, burn, require annual maintenance, burn, get eaten by termites, are only produced in limited pre-cut lengths, and are not recyclable just to name a few. In order to extend the life of wood structures, special preservatives, like Copper-Chromium Arsenic (CCA) are applied to them. However these chemicals have been found to be toxic and the growing environmental impact concerns have led the Environmental Protection Agency (EPA) to begin nationwide bans on these chemicals starting Jan. 1, 2004. There will be serious impacts on the industry like lack of product supply, increased costs and product capabilities.  
         [0013]     It is obvious that an alternative framing system that eliminates fastening of the planking must be developed. If it is possible to produce an alternative underlying framing structure that does not require chemicals treatment to make them effective, then that must be developed as well. Currently, there are no solutions that integrate popular planking systems like composite and extruded decking materials with the underlying substructure without the use of special fasteners like screws, nails or clips, etc.  
         [0014]     Therefore, an object of the present invention is to provide a plank member that has a special shape integrated on the underside of the plank, which is used to attach itself to the underlying structure without fasteners.  
       SUMMARY OF THE INVENTION  
       [0015]     One embodiment of the subject invention is directed to a framing system comprising a plank member having a front, generally fiat, surface and an opposing back surface with at least one rib protruding therefrom or at least one receptor pocket extending therein. The framing system has a frame member of an underlying structure having at least one receptor pocket extending therein or at least one rib protruding therefrom, wherein the frame member rib or pocket is matable with the plank member pocket or rib. The at least one rib has a profile with a first side and a second side which diverge from one another as they extend away from the member to which they are attached and then converge. The maximum height of a rib occurs at the place of maximum divergence and the receptor pocket has a minimum width less than that of the maximum height of the rib such that the rib may be captured within the receptor pocket.  
         [0016]     Another embodiment of the subject invention is directed to a plank member comprising a front, generally flat, surface and an opposing back surface with at least one rib protruding therefrom. The at least one rib has a profile with a first side and a second side which diverge from one another as they extend away from the member to which they are attached and then converge. The maximum height of a rib occurs at the place of maximum divergence such that the rib is adapted to be received within a receptor pocket having a minimum width less than that of the maximum height of the rib.  
         [0017]     Yet another embodiment of the subject invention is directed to a frame member of an underlying structure, wherein the frame member comprises at least one receptor pocket extending therein, wherein the pocket is adapted to receive a rib. The receptor pocket has a minimum width less than that of the maximum height of the rib such that the rib may be captured within the receptor pocket.  
         [0018]     Yet another embodiment of the subject invention is directed to a method of assembling a framing system having a plank member with a front, generally flat, surface and an opposing back surface with at least one rib protruding therefrom or at least one receptor pocket extending therein and having a frame member of an underlying structure with the other of at least one receptor pocket extending therein or at least one rib protruding therefrom, wherein the frame member rib or pocket is matable with the plank member pocket or rib. The method comprises the steps of: 
        a) aligning the at least one rib with the at least one receptor pocket;     b) urging the at least one rib within the at least one receptor pocket until the rib snaps into the pocket; and     c) wherein the at least one rib or the at least one receptor pocket is resilient.        
 
         [0022]     Still another embodiment of the subject invention is directed to a method of making a frame member adapted to receive protruding ribs from a plank member comprising the steps of: 
        a) punching slots within a flat sheet; and     b) bending the sheet into a structural member having a top surface and a bottom surface, wherein the slots extend within the top surface to provide a receptor pocket adapted to receive the protruding ribs from the plank member.       
 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0025]      FIG. 1  is a perspective view of a framing system in accordance with the subject invention;  
         [0026]      FIG. 2  is an enlargement of the encircled portion found in  FIG. 1 ;  
         [0027]      FIG. 3  is a section view indicating the manner in which the plank member and frame member are engaged;  
         [0028]      FIGS. 4A and 5A  are section views similar to that of  FIG. 3 , but illustrating different embodiments of the plank member;  
         [0029]      FIGS. 4B and 5B  are section views identical to  FIGS. 4A and 4B , except the rib in each is in a compressed state;  
         [0030]      FIGS. 6A and 6B  are side views similar to that of  FIG. 3 , but illustrating how the frame member may deflect to accommodate the rib;  
         [0031]      FIG. 7  is a section view of a framing system with the receptor pockets on the plank member and the ribs on the frame member;  
         [0032]      FIG. 8  is a section view of the plank member with a separate piece rib attached thereto;  
         [0033]      FIG. 9  is a section view of the framing system with overlapping plank members;  
         [0034]      FIG. 10  is a side section view of a plank member and end view of a frame member;  
         [0035]      FIGS. 11-16  are alternate embodiments of the plank member;  
         [0036]      FIGS. 17A-17G  illustrate sketches of different rib profiles;  
         [0037]      FIG. 18  is a section view illustrating a dovetail arrangement for the rib and receptor pocket;  
         [0038]      FIG. 19  is a top view of a flat plate prior to being formed into a plank member;  
         [0039]      FIG. 20  is an end view of a finished plank member;  
         [0040]      FIG. 21  is a side view of the framing system being utilized for a wall; and  
         [0041]      FIG. 22  is an end view of a framing member with a rib embedded therein. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0042]      FIG. 1  illustrates the framing system  10  in accordance with the subject invention, while  FIG. 2  illustrates an enlargement of the encircled portion of the framing system  10  in  FIG. 1 . The framing system  10  is comprised of a plank member  15  having a front generally flat surface  17  and an opposing back surface  19  with at least one rib  20  protruding therefrom. A frame member  25  of an underlying structure  27  has at least one receptor pocket  30  extending therein. The rib  20  extending from the plank member  15  is matable with the receptor pocket  30  of the frame member  25 .  
         [0043]      FIG. 3  is a side view of a portion of the framing system illustrating the manner by which the rib  20  of the plank member  15  engages the receptor pocket  30  of the frame member  25 . In particular, the rib  20  has a profile with a first side  35  and a second side  37  which diverge from one another as they extend away from the plank member  15  to which they are attached. Thereafter, they converge and connect with one another. The maximum height H of the rib  20  occurs at the place of maximum divergence. The receptor pocket  30  has a minimum width W less than that of the maximum height H of the rib  20  such that the rib  20  may be captured within the receptor  30 . It should be noted that while the rib  20  has a general shape of a teardrop, it will hereinafter be made clear that this shape is not to be intended as a limitation to the subject invention.  
         [0044]     As illustrated in  FIG. 1 , the plank member  15  and the frame member  25  are secured to one another through the engagement of the ribs  20  with the pocket receptors  30 .  
         [0045]     In one embodiment of the subject invention, the rib  20  is resilient such that the rib  20  deforms in order to enter the receptor pocket  30 . Directing attention to  FIG. 3 , the height H of the rib  20  would diminish so that the rib  20  would be able to enter the receptor pocket  30 . This may be achieved in one of at least two ways.  
         [0046]     In particular, with attention directed to  FIG. 4A , the rib  20  may have a hollow interior  40  such that a compressive force indicated by arrows  42  will deform the walls  44  of the rib  20 , as illustrated in  FIG. 4B , such that the resultant height J is less than the width W of the opening within the receptor pocket  30 . Because the rib  20  is resilient upon entry within the receptor pocket  30 , the rib  20  will expand, thereby locking the plank member  15  within the frame member  25 . The walls  44  of the rib  20  actually bend to provide the resiliency of the rib  20 .  
         [0047]     As illustrated in  FIG. 5A , the rib  20  may also be made of a resilient material which itself compresses. In particular,  FIG. 5A  illustrates the rib  20  having a height H and subsequent to compressive forces  42 , the rib  20 , which may be solid, resiliently compresses to a height J as shown in  FIG. 5B , sufficient to fit within the receptor pocket  30 .  
         [0048]     It should be noted that the compressive forces  42  required to reduce the width of the rib  20  are those compressive forces generated by urging the plank member  15  against the receptor pocket  30  of the frame member  25 .  
         [0049]     In yet another embodiment of the subject invention illustrated in  FIGS. 6A and 6B , the receptor pocket  30  has receptor pocket walls  46 ,  48  which initially have a width K and are expanded by the rib  20  having a height H such that the width K of the walls  46 ,  48  expands to accommodate the height H of the rib  20 , as illustrated in  FIG. 6B . Under these circumstances, the rib  20  is relatively rigid and the materials of the frame member  25  must be resilient.  
         [0050]     Typical materials that may be used for the rib  20  may be structural metal of any kind, wood, wood composites, cementitious composites, plastic composites, structural steel composites, fiberglass, and carbon composites. It should be appreciated that this list is not exhaustive and that any material suitable for the application described herein may be suitable.  
         [0051]     In each of these scenarios described in  FIGS. 4A through 6B , at least one rib  20  or the receptor pocket walls  46 ,  48  are rigid.  
         [0052]     What has been discussed so far is a receptor pocket  30  within the frame member  25  and the rib  20  within the plank member  15 . Directing attention to  FIG. 7 , it is entirely possible for the plank member  15  to have receptor pockets  50  while the frame member  25  has ribs  55  which engage the receptor pockets  50  in the manner previously described.  
         [0053]     Directing attention to  FIG. 8 , it is also possible for the rib  20  to be a separate piece  60  secured within the plank member  15  or, in the alternative, secured within the frame member  25 , which is not shown but is an obvious variation of the arrangement illustrated in  FIG. 8 . The rib  20  may be secured to the plank member using any number of different fastener techniques. As an example, the rib  20  may have a threaded shank  62  which engages the plank member  15 .  
         [0054]      FIG. 9  illustrates a cross-section view of one embodiment of the framing system  10 , whereby each plank member  15  has a recess  65  which is covered by an overhang  70  in an adjacent plank member  15 ′. Such an arrangement promotes retention of the plank member  15  within the frame member  25 .  
         [0055]      FIG. 10  illustrates a side view of the framing system  10 , whereby the rib  20  of the plank member  15  is aligned to be engaged with a plurality of frame members  25 . A complete framing system  10  may be comprised of a plurality of plank members  15  arranged side-by-side over a plurality of spaced apart frame members  25 .  
         [0056]     In one embodiment illustrated in  FIG. 11 , the plank member  115  may have a tongue  117  on one side and a groove  119  on the other side which engage a mating groove  119 ′ in plank member  115 ′, and a mating tongue  117 ′ associated with plank member  115 ″.  
         [0057]     It should be appreciated that one focal point of the subject invention is the interlocking ribs and receptor pockets. The plank member may embrace a variety of different designs to satisfy the different needs to which the framing system may be subjected.  
         [0058]      FIG. 12  illustrates a plank member  215  having a generally oval cross-section with ribs  220  similar to those previously discussed extending therefrom.  
         [0059]     The material of the plank member discussed herein may be wood, composite wood, metal, plastic or a carbon fiber composite. As an example, if the rib  220  of plank  220  is solid therethrough, then it is necessary for the material of the rib  220  to itself be resilient such that the rib  220  resiliently fits within the receptor pocket  230  of the frame member  225 . In the alternative, if the rib  220  has a hollow portion therein, then it is only necessary for the walls of the rib  220  to flex to fit within the receptor pocket  230 . Furthermore, as previously discussed, it is also possible for the receptor pocket walls to have resiliency themselves to accept a rib  220 .  
         [0060]      FIG. 13  illustrates another variation of a plank member  315  having a front surface  317  and a back surface  319  with ribs  320  protruding therefrom. The variety of designs available for the plank member  315  are unlimited inasmuch as the back surface  319  has extending therefrom ribs  320  that may interlock with receptor pockets (not shown) of a frame member.  
         [0061]      FIGS. 14, 15  and  16  illustrate further variations of plank members  415 ,  515 ,  615 , respectively, having back surfaces for  419 ,  519 ,  619  with ribs  420 ,  520 ,  620  extending therefrom. The designs illustrated in  FIGS. 14-16  are of particular interest because these designs may be fabricated through extrusion processes using a variety of different materials including structural steel, structural metal, and structural plastic or other structural materials capable of being extruded.  
         [0062]     The ribs  20  so far discussed have been in the general shape of a teardrop. A number of other rib shapes may be used inasmuch as these ribs may be snapped into the receptor pocket  30  of the frame member  25 .  FIGS. 17A-17G  illustrate a few such ribs  720  shapes. In each of these shapes, the first side  722  divergence from the second side  724  and then converges. As a result, these ribs  720  may snap into an approximately sized receptor pocket (not shown) located in the frame member. As illustrated in  FIGS. 17F and 17G , each rib  720  may also resemble a barb  726 .  
         [0063]     Briefly returning to  FIGS. 1 and 2 , one method of attaching the plank member  15  to the frame member  25  is to press the plank member  15  against the frame member  25  such that the ribs  20  resiliently deform to engage the receptor pocket  30  or, in the alternative, a rib  20  engages the resilient walls  46 ,  48  of the receptor pocket  30  until the rib  20  snaps into place within the receptor pocket  30 . It should be appreciated that, to the extent the rib  20  conforms with the shape of the receptor pocket  30 , it is possible to slide the plank member  15  into the frame member  25  such that the rib  20  engages the receptor pocket  30  without the need for resilient deformation. Under such circumstances, the plank member  15  slides into the frame member  25  from the side. Since the rib  20  is no longer required to resiliently fit with the receptor pocket  30 , the shape of these two elements may change.  
         [0064]     Directing attention to  FIG. 18 , a plank member  815  may have a rib  820  in the shape of a dove-tail which engages the frame member  825  through a receptor pocket  830  in the shape of a matching dove-tail. It should be appreciated that, while the shape of the dove-tail has been presented, any number of different positive locking shapes may be utilized for this arrangement.  
         [0065]     The subject invention is also directed to a method of assembling a framing system  10  having a plank member  15  with the front generally flat surface  17  and an opposing back surface  19  with at least one rib  20  protruding therefrom or at least one receptor pocket  30  extending therein and having a frame member  25  of an underlying structure with the other of at least one receptor pocket  30  extending therein or at least one protruding rib  20  extending therefrom. The frame member rib  20  or pocket  30  is matable with the plank member pocket  30  or rib  20 . The method comprises the steps of aligning the ribs  20  with the receptor pockets  30 . The ribs  20  are then urged within the receptor pockets  30  until the ribs  20  snap into the pockets  30 . For this to occur, the rib  20  or the receptor pocket  30  must be resilient.  
         [0066]     In an alternative embodiment, the method of assembling a framing system  10  would comprise the steps of aligning the rib  20  with the receptor pocket  30  and sliding the rib  20  within the receptor pocket  30  until properly positioned. Under these circumstances, it is not necessary for either the rib  20  or the receptor pocket  30  to be resilient.  
         [0067]     So far illustrated is a frame member  25  having a generally C shape. Although other shapes may be utilized, this is a convenient shape that will typically be implemented for these structures.  FIGS. 19 and 20  illustrate the method by which the frame member  25  is manufactured from a flat sheet  900 . In particular, openings  905  are punched within the flat sheet  900 , wherein at each end of the opening  905  is a slightly enlarged portion  910  which, in this instance, is designed to have the general shape of a rib  15  illustrated in  FIG. 1 . Once the openings  905  are punched, the flat sheet  900  is then bent into a structural member having a top surface  915  and a bottom surface  920 , wherein the openings  905  extend within the top surface  915  to provide a receptor pocket  930  adapted to receive the protruding ribs  20  from the plank member  15  illustrated in  FIG. 1 .  
         [0068]     While  FIGS. 1 and 2  illustrate the use of the framing system  10  for decking, the framing system  10  should not be limited to such applications and may be used in any application for which this design is appropriate.  FIG. 21  illustrates the use of the framing system  10  as a fence or a wall. The framing system in accordance with the subject invention may have a multitude of other applications including use as a dock or an interior or exterior wall of a structure such as a building.  
         [0069]      FIG. 22  illustrates a sketch whereby the rib  1020  is embedded within the frame member  1025 . This may be achieved by embedding the rib  1020  during an extrusion process used to form the frame member  1025 .  
         [0070]     While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. The presently preferred embodiments described herein are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.

Technology Classification (CPC): 4