Patent Abstract:
The present disclosure provides a decking system including a receiver and deck plank, wherein the plank removeably connects to receiver for installation. For example, the receiver may provide a snap lock function that secures and automatically spaces the deck planks on the receiver, which is fastened to a deck joist. In addition, the system is designed to conceal fasteners used to attach the system to the deck joist.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application incorporates by reference and claims priority to U.S. Provisional Application 61/786,325 filed on Mar. 15, 2013. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present subject matter relates generally to decking systems. More specifically, the present invention relates to a plastic or composite exterior decking system that includes a simple snap locking fastener system for installation. 
         [0003]    Previous decking solutions suffer from several drawbacks. For example, conventional decking solutions require complicated and cumbersome installation of current deck products. For example, the decking solutions often included a user to manually space and align each deck board for the proper installation of the deck boards. Such solutions result in many failed attempts at evenly spaced deck boards and hours of frustration on the user&#39;s behalf. 
         [0004]    Further, previous decking solutions lack weather protection for underlying deck joists. As a result, existing systems often have exposed fasteners that detract from the appearance of the deck and allow the elements to directly effect the fasteners causing them to rust or discolor. 
         [0005]    In addition, previous decking solutions are typically made in designs and of materials that degrade in response to expansion and contraction caused by seasonal fluctuations in temperature. 
         [0006]    Accordingly, there is a need for a decking system that is simple to install, spaces itself automatically, provides weather protection to the deck joists and fasteners, and resists degradation due to expansion and contraction, as described herein. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The present disclosure provides a solution to the above mentioned problems. Specifically, the system may include a receiver and deck plank, wherein the plank removeably connects to receiver for installation. For example, the receiver may provide a snap lock function that secures and automatically spaces the deck planks on the receiver, which is fastened to a deck joist. The receiver may further act as a flashing for the deck joists to protect the deck joists from the elements. In addition, the planks are adapted to snap onto the snap lock receiver and act as a cover to protect the underlying fasteners. The receiver may be injection molded from any of a number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, to name a few. The planks may be extruded from any number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, to name a few. 
         [0008]    The receiver is installed directly on a deck joists and acts as a receiver for the plank while also acting as a flashing for the deck joist. The receiver includes a plurality of retainers that provide automatic spacing for the deck planks. For example, once the receiver is in place the deck planks are simply pressed or snapped on to the receiver. The decking planks are adapted to shed water and resist the accumulation of water, ice or snow by incorporating a design that includes a convex plank top surface, a point for a continuous drop, and a void in the plank edge to allow for proper water drainage. Once installed if a single deck plank needs to be removed for whatever reason the planks can simply be slid off the end and reinstalled. 
         [0009]    In an embodiment, the system includes a receiver and plank, wherein the receiver includes a receiver body including a receiver top surface and an receiver bottom surface. The receiver further includes a retainer extending from the receiver top surface, wherein the retainer has a retainer first end and a retainer second end, wherein the retainer first end extends from the retainer interior surface. The retainer second end may be conical shaped. In yet another example, the retainer is integrally formed with the receiver. 
         [0010]    The plank includes a plank body including a plank top surface, plank bottom surface, and two plank edges. The plank may be a deck board. In an example, the plank top surface is convex. The plank further includes a set of arms extending perpendicular from the plank bottom surface, wherein each arm includes an arm first end and an arm second end, wherein the arm first end extends from the plank bottom surface, wherein the arm second end includes a tab extending parallel to the plank body. The retainer first end is configured to receive the tabs of the set of arms. When the tabs of the arms are engaged with the retainer of the receiver, the arms maintain a space between the receiver top surface and the plank bottom surface. The tab may include a tab end that is tapered. 
         [0011]    The receiver may include a plurality of retainers periodically spaced along a length of the receiver. The retainer first end includes a retainer groove on each side of the retainer for receiving the tabs of a set of arms. 
         [0012]    In an example, each plank edge includes an arm extending from the interior surface of the plank body, wherein the arm second end includes a tab extending parallel to the plank of the body. In addition, the arm second end may include a point to enable a continuous drip from the plank. 
         [0013]    The system may further include at least one fastener configured to connect the receiver to a deck joist, wherein at least a portion of the fastener resides in a portion of the space between the receiver top surface and the plank bottom surface. 
         [0014]    In another embodiment, the system includes a receiver, a plank, and a deck board. The receiver includes a receiver body including a receiver top surface and a receiver bottom surface. The receiver further includes a retainer extending from the receiver top surface, wherein the retainer has a retainer first end and a retainer second end, wherein the retainer first end extends from the receiver top surface. In an example, the retainer is integrally formed with the receiver. 
         [0015]    The plank includes a plank top surface, plank bottom surface, and two plank edges. The plank further includes a set of arms extending perpendicular from the plank bottom surface, wherein each arm includes an arm first end and an arm second end. The arm first end extends from the plank bottom surface, wherein the arm second end includes a tab extending parallel to the plank body. 
         [0016]    The deck board includes a deck board body including a board bottom surface, a board top surface, and board ends, wherein the deck board body is configured to mate with the plank body. In an example, when the deck board body mates with the plank body, the deck board body conceals the plank from view. The deck board ends may include a board groove for receiving the plank edges. In another example, the deck board ends include a point to enable a continuous drip from the deck boards. 
         [0017]    The retainer first end is configured to receive the tabs of the set of arms. When the tabs of the arms are engaged with the retainer of the receiver, the arms maintain a space between the receiver top surface and the plank bottom surface. 
         [0018]    The system may include at least one fastener configured to connect the receiver to a deck joist, wherein at least a portion of the fastener resides in a portion of the space between the receiver top surface and the plank bottom surface. 
         [0019]    An objective of the invention is to provide a solution to the complicated and cumbersome installation of current deck products, including providing a solution to spacing of the deck planks. 
         [0020]    Another objective is to provide weather protection to the deck joists and to resist degradation and other issues due to seasonal expansion and contraction, as well as a means of concealing the installation fasteners. 
         [0021]    An advantage of the present system is that it simplifies a decking installation process by providing a system that inherently provides equal spacing for the deck planks. 
         [0022]    A further advantage of the present system is that it conceals the installation fasteners, making it more aesthetically pleasing while providing protection to the installation fasteners from the environmental elements. 
         [0023]    Another advantage of the invention is that it provides improved water control and does not allow moisture to accumulate anywhere in or on the system. 
         [0024]    Yet another advantage is that the positioning of the installation screws is directly below the decking board, thus they are concealed and out of sight and are also out of direct exposure to weather. 
         [0025]    A further advantage of the invention is that the use of materials and designs that resist degradation due to seasonal expansion and contraction. 
         [0026]    Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements. 
           [0028]      FIG. 1  is a front cross-sectional view of an embodiment of the system in combination with a deck joist. 
           [0029]      FIG. 2  is a side cross-sectional view of an embodiment of the system disclosed herein including a plank installed onto the receiver. 
           [0030]      FIG. 3  is a side cross-sectional view of an example of a plank disclosed herein. 
           [0031]      FIG. 4  is a side cross-sectional view of an embodiment of the system disclosed herein including a deck board installed on a plank, which is installed on a receiver. 
           [0032]      FIG. 5  is a side cross-sectional view of an embodiment of a plank disclosed herein. 
           [0033]      FIG. 6  is a side cross-sectional view of an embodiment of a deck board disclosed herein. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0034]    As shown in  FIGS. 1-2 , the present disclosure provides a decking system  10  that includes a receiver  12  and plank  14  that may removeably attach to each other. For example, the plank  14  may snap, slide, or otherwise temporarily lock into the receiver  12 . 
         [0035]      FIG. 2  depicts the receiver  12  including a generally linear receiver body  16  including a receiver top surface  18  and a receiver bottom surface  20 . The receiver  12  further includes a retainer  22  extending from the receiver top surface  18 . The retainer  22  may be integrally formed with the receiver  12 , or a separate entity that is otherwise attached to the receiver  12 . As shown in  FIG. 2 , the receiver  12  may include a plurality of retainers  22 . The retainers  22  may be spaced periodically such that the position of the retainers  22  on the receiver  12  enables a user to attach planks  14 , such as deck boards, that will automatically be aligned. In other words, the spacing of the retainers  22  prevents users from having to measure and align the deck boards themselves, a frustrating and cumbersome process. 
         [0036]    The retainer  22  has a retainer first end  24  and a retainer second end  26 , wherein the retainer first end  24  extends from the receiver top surface  18 . The retainer  22  may have any suitable shape. In an example, the retainer second end  26  may be conical shaped. Although, it is contemplated that the shape of the retainer second end  26  may be spherical, square, or rectangular, among other shapes. 
         [0037]    The plank  14  includes a generally linear plank body  28  including an plank top surface  30 , plank bottom surface  32 , and two plank edges  34 . In an example, the plank  14  is a deck board. The plank  14  and receiver  12  may be independently made from any of a number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, among others. 
         [0038]    The plank top surface  30  may be convex such that rain and water run off the plank edges  34 . The plank  14  also includes a set of arms  36  extending perpendicular from the plank bottom surface  32 , wherein each set of arms  36  includes two arms  38 . Each arm  38  includes an arm first end  40  and an arm second end  42 , wherein the arm first end  40  extends from the plank bottom surface  32 . 
         [0039]    As shown in  FIG. 3 , the arm second end  42  includes a tab  44  extending parallel to the plank body  28 . Within a set of arms  36 , the two tabs  44  of separate arms  38  may be pointed towards each other. The tab  44  may include a tab end  54  that is tapered. The tapered shape of the tab end  54  may facilitate a user in snapping the plank  14  into place around the retainer  22 . Of course, it is contemplated the tab end  54  may be any suitable shape for facilitating temporarily locking the tab  44  around the retainer groove  48 . For example, the tab end  54  may be round. 
         [0040]    The retainer first end  24  is configured to receive the tabs  44  of the set of arms  36 . For example, the retainer first end  24  may include a retainer groove  48  on each side of the retainer  22  for receiving the tabs  44  of a set of arms  36 . 
         [0041]    When the tabs  44  of the arms  38  are engaged with the retainer  22  of the receiver  12 , the arms  38  maintain a space  46  between the receiver top surface  18  and the plank bottom surface  32 . In an example, the system  10  may further include at least one fastener  52  configured to connect the receiver  12  to a deck joist. The fastener  52  may be any suitable fastener  52  that connects the receiver to structure, such as a deck joist. For example, the fastener  52  may be a screw, nail, clamp, staple, latch, pin, or anchor, among others. 
         [0042]    As shown in  FIG. 2 , at least a portion of the fastener  52  resides in a portion of the space  46  between the receiver top surface  18  and the plank bottom surface  20 . For example, when the fastener  52  is a screw, the head of the screw may reside in the space  46  between the receiver top surface  18  and the plank bottom surface  32 . 
         [0043]    As shown in  FIG. 3 , each plank edge  34  may include an arm  38  extending from the plank bottom surface  32 , wherein the arm second end  42  includes a tab  44  extending parallel to the plank body  28 . In addition, the arm second end  42  may include a point  50  to enable a continuous drip from the plank  14 . For example, the point  50  may be located on a corner between the arm  38  and the tab  44 . As shown in  FIG. 3 , the plank edge  34  may include a corner between the arm  38  and the tab  44 , wherein a portion of the corner is a void  68  to allow water drainage from the plank edges  34 . 
         [0044]    In another embodiment, the system  10  includes a receiver  12 , a plank  14 , and a deck board  56 . Similarly to the receiver  12  and plank  14 , the deck board  56  may be made from any of a number of different materials including, but not limited to, aluminum, polyvinyl chloride (PVC), and polypropylene, among others. As shown in  FIG. 4 , the plank  14  removeably attaches to the retainers  22  of the receiver  12 . In addition, the deck board  56  removeably attaches to the plank  14 , such that the deck board  56  conceals the plank  14  from view. 
         [0045]    As shown in  FIG. 6 , the deck board  56  may include a deck board body  58  including a board bottom surface  62 , a board top surface  60 , and board ends  64 . The deck board body  58  is configured to mate with the plank  14 . For example, the deck board ends  64  may include a board groove  66  for receiving the plank edges  34 . 
         [0046]    In contrast to the example in  FIG. 3 , the example of the plank  14  in  FIG. 5  does not include arms  38  extending from the plank edges  34 . As a result, the plank edges  34  may be positioned within the board grooves  66  of the deck board  58 . The plank edges  34  may be snapped, slid, or otherwise removeably attached to the deck board  58 . 
         [0047]    In another example, the deck board ends  64  include a point  50  to enable a continuous drip from the deck boards  56 . As shown in  FIG. 6 , the deck board ends  34  may include a corner that includes the point  50 . The corner may further include a void  68  that allows for proper drainage of the water. 
         [0048]    It should be noted that various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. For example, various embodiments of the method and portable electronic device may be provided based on various combinations of the features and functions from the subject matter provided herein.

Technology Classification (CPC): 4