Abstract:
A bracket for attaching a decking member to a supporting member comprises a main flange, a side flange extending approximately perpendicular to the main flange, at least one through hole defined in the side flange for receiving a fastener to attach the bracket to a side of a decking member and at least one protrusion extending from a lower side of the main flange and serving to contact the supporting member and to space the bracket and decking member above the supporting member. A method of securing a decking member to a supporting member is also described.

Description:
BACKGROUND 
       [0001]    Outdoor structures such as decks and other similar structures must withstand the elements without deteriorating before the end of their design life. Materials commonly used today include many different types of wood, composites and other non-wooden materials. Construction methods have changed because of new materials in some cases and also because of new safety requirements, to name just two reasons. As a result, the choices of hardware to secure decking members to supporting members fall short for many applications. 
       SUMMARY 
       [0002]    Described below are implementations of a new bracket for securing a decking member to a supporting member that provides for a robust connection, avoids the need to drive fasteners through a top surface of the decking material, can be quickly installed in various orientations and can be produced at a competitive price. 
         [0003]    In one implementation, a bracket for attaching a decking member to a supporting member comprises a main flange, a side flange extending approximately perpendicular to the main flange, at least one through hole defined in the side flange for receiving a fastener to attach the bracket to a side of a decking member and at least one protrusion extending from a lower side of the main flange and serving to contact the supporting member and to space the bracket and decking member above the supporting member. 
         [0004]    The main flange can comprise a widened portion having a lateral dimension wider than a side of the mounting member to which the bracket is configured for mounting. The main flange can be dimensioned to extend away from the side of the decking member when the bracket is installed. 
         [0005]    The at least one mounting opening in the main flange can be countersunk relative to an upper side of the bracket. The at least one protrusion can be aligned with the at least one mounting opening. The main flange can comprise four mounting openings. The at least one protrusion can comprise an annular shape. 
         [0006]    The at least one protrusion can comprise at least two protrusions spaced apart to support the decking member above the supporting member such that an space is defined between protrusions and between an upper surface of the supporting member and a lower surface of the decking member. 
         [0007]    The main flange can have a thickness of approximately 0.150 inch in an area comprising the at least one protrusion. 
         [0008]    The main flange can comprise at least one chamfered corner. Similarly, the side flange can comprise at least one chamfered corner. 
         [0009]    The bracket can be formed by a process in which a portion of material in a plane of the main flange is bent into the side flange. 
         [0010]    The main flange can comprise an attachment region having at least one mounting opening and a contiguous support region extending laterally away from the attachment region, and wherein the side flange extends from the support region. Alternatively, the main flange can be L-shaped. 
         [0011]    The side flange can extend at a position approximately midway along a longitudinal axis of the main flange. 
         [0012]    According to a method implementation, a method of securing a decking member to a supporting member with a bracket comprises providing a bracket having a main flange and a side flange extending approximately perpendicular to the main flange, at least one through hole in the side flange, at least one mounting opening in the main flange and at least one protrusion extending from the main flange. The method comprises positioning the side flange over a side surface of the decking member at a desired position, securing the side flange to the side surface with a fastener extending through the at least one through hole to thereby attach the bracket to the decking member, positioning the decking member with the attached bracket at a desired position relative to an underlying supporting member with the at least one protrusion contacting the supporting member to space the bracket and decking member above the supporting member and securing the main flange to an upper surface of the supporting member with a fastener extending through the at least one mounting opening. 
         [0013]    The method may further comprise spacing the decking member from a previously secured decking member. The side flange can have a thickness, and the thickness of the side flange can serve to provide a uniform spacer for a next decking member to be secured. 
         [0014]    In another method implementation, the at least one mounting opening in the main flange comprises at least two mounting openings that remain exposed after the side flange is secured. 
         [0015]    In another method implementation, the side flange is secured to the side surface of the decking member before the main flange is secured to the upper surface of the supporting member. 
         [0016]    The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  is a perspective view of an implementation of the bracket, showing a bracket body having a main flange and a side flange. 
           [0018]      FIG. 2  is a top plan view of the bracket of  FIG. 1 . 
           [0019]      FIGS. 3, 4, 5, 6 and 7  are rear elevation, front elevation, left side elevation, right side elevation and bottom plan views of the bracket of  FIG. 2 . 
           [0020]      FIG. 8  is a perspective view showing an implementation of the bracket as aligned relative to a typical supporting member or joist prior to installation. 
           [0021]      FIG. 9  is a perspective view showing two brackets installed on opposite edges of a decking member to secure it to alternating supporting members or joists in a typical mid-span application. 
           [0022]      FIG. 10  is a perspective view showing portions of first and second decking members each secured to a common joist with one bracket at a selected spacing between the first and second decking members. 
           [0023]      FIG. 11  is a side elevation view showing an end view of an installed decking member and portions of the adjacent decking members as they are held spaced above the supporting members by the brackets securing them. 
           [0024]      FIG. 12  is a top plan view of a section of a completed deck showing a series of decking members installed with brackets to multiple supporting members, with the decking members shown in transparent lines to show the brackets in more detail. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]      FIGS. 1-7  show an implementation of a bracket for securing a decking member. Although the bracket is described herein in terms of its function in securing a decking member, it can of course be used in other similar applications where two members need to be held in place relative to each other at desired positions. 
         [0026]    As best shown in the perspective view of  FIG. 1 , a bracket  10  has a body  12  in which a main flange  14  and a side flange  16  are defined. The side flange  16  is angled with respect to the main flange  14 . The main flange  14  and the side flange  16  are each generally planar. In the illustrated implementation, the side flange  16  is angled with respect to the main flange  14  by approximately 90°, but the flanges may be separated by other angles according to the specific application in which the bracket is being used. 
         [0027]    As shown, the main flange  14  has one or more mounting holes  18 , which may be arranged in any suitable pattern. For example, in the illustrated implementation (see, e.g.,  FIGS. 1, 2 and 7 ), there are four mounting holes  18  that are spaced longitudinally and laterally. Similarly, the side flange  16  can have one or more mounting holes  20 . In the illustrated implementation, there is a single mounting hole  20  in the side flange  16 , as best seen in  FIGS. 1, 3 and 5 . 
         [0028]    Optionally, the one or more mounting holes  18  may be counter sunk relative to the upper surface of the main flange  14  as seen in  FIGS. 1 and 2 . In this way, if screws, for example, are used to secure the main flange to a supporting member, the heads of the screws will be recessed or protrude only slightly above the upper surface of the main flange  14 . 
         [0029]    Further, the one or more of mounting holes  18  may be formed with mounting protrusions  24  protruding from a bottom side of the bracket  10 , as best seen in  FIGS. 3, 4, 5, 6 and 7 . The mounting protrusions  24  may be formed as a result of the counter sinking operation, or they may be provided for separately. The mounting protrusions  24  can have a generally annular shape. Advantageously, the mounting protrusions  24  can be used to space the remainder of the bracket  10  and the decking board to which it is secured above the surface of the supporting member by a gap H, as best shown in  FIG. 11 . It has been found that providing the gap H assists with preventing moisture from being entrained over the entire covered surface of the supporting member. In addition, providing the gap H helps reduce undesirable noises (including, e.g., squeaking) that can occur if broader areas of the decking members of some materials are in contact with the supporting members. 
         [0030]    The bracket  10  may be formed with one or more chamfered corners. In the illustrated implementation, there may be chamfered corners  22  on the main flange  14  and on the side flange  16  as shown. Of course, it would be possible to configure the bracket with fewer or more chamfered corners, or with corners that are rounded, square or of another shape, as would be appreciated by those of skill in the art. 
         [0031]    The main flange  14  can be described as having an attachment portion where the mounting holes  18  are located and an adjacent support region extending laterally away from the attachment region, and from where the side flange  16  extends. Stated differently, the main flange can be described as being L-shaped. 
         [0032]    Referring to  FIG. 2 , it can be seen that when viewed in a longitudinal direction A, the side flange  16  is positioned approximately midway between opposite ends of the main flange  14 . Referring to  FIG. 3 , a dimension S of the side flange  16  can be selected based on the thickness of the decking material or decking members. For example, if the decking material is 2″ by 6″ dimensional lumber (boards) or other 2″ boards, which have a finished thickness of 1½″, then the dimension S can be sized accordingly so as not to exceed the thickness of the decking members. For example, in one implementation, the dimension S may be about 1.25 inch with the mounting hole located at about 0.75 inch. In the same way, for decking material made of 5/4 lumber (having a finished thickness of 1 1/16″), a bracket having a side flange with a dimension S of about 0.725 inch and the mounting hole located at about 0.525 inch. 
         [0033]    As best shown in  FIG. 7 , the side flange  16  can have a lateral dimension of any selected length, such as a length B as shown in the illustrated implementation. Optionally, the side flange  16  can be separated from the attachment portion of the main flange by a gap G. 
         [0034]    The bracket  10  may be formed of any suitable material, e.g., galvanized sheet stock. According to one implementation, the bracket is made by stamping, and the side flange is formed as one piece with the main flange. In the illustrated implementation, the side flange and the main flange are made of  22  gauge material. In the illustrated implementation, the entire thickness of the main flange in the area of the mounting protrusions  24  is approximately 0.150 inches. 
         [0035]      FIG. 8  is a perspective view of a typical supporting member M 1 , such as a wooden joist, with the bracket  10  positioned on an upper side surface of the joist prior to being secured to the joist, such as with a fastener F, e.g., a screw.  FIG. 8  shows the screw F inserted through a second of the mounting holes  18 . In general, only one screw is necessary in most applications. If the second hole is not convenient, e.g., if the supporting member has an irregularity such as a knot directly below the second hole, then the screw can be driven into the supporting member through the first of the mounting holes  18  (not shown). 
         [0036]      FIG. 9  is a perspective view showing first, second and third joists M 2 , M 3  and M 4  that are spaced apart from each other (such as by, e.g., 16″ or 24″) and one decking member N 1  that is secured in place at one edge by a first bracket  110  connecting the decking member N 1  to the first joist M 2  and by a second bracket  112  connecting the decking member to the third joist M 4 . In addition, the opposite second edge of the decking member N 1  is secured by a third bracket  114  oriented opposite the first bracket  110  and also secured to the first joist M 2 , and by a fourth bracket  116  oriented opposite the second bracket  112  and also secured to the third joist M 4 . In some applications, it is possible to skip intermediate joists, such as the second joist M 3  as shown, particularly at mid-span locations. 
         [0037]    As can be seen in  FIG. 9 , each side flange  16  is secured to a side surface P of the decking member N using a fastener, e.g., a screw, driven through the mounting opening  20  in the side flange  16  to secure it to the decking member N 1 . Similarly, at least one fastener is driven through one of the mounting holes  18  in each main flange  14  to secure the brackets  110 ,  112  to the first joist M 2  and the third joist M 4 , respectively. 
         [0038]      FIG. 10  is another perspective view of the third joist M 4  and the installed decking board N 1  of  FIG. 9  shown at greater scale, and a second decking board N 2  shown in position relative to the first decking board N 1  and prior to its installation. As can be seen in  FIG. 10 , in the illustrated implementation approximately half of the main flange  14  extends below the decking member N 1  to which it is attached, and about half of the main flange extends away from the side of the decking member N 1  to expose two of the mounting holes  18 . Other proportions are also possible. 
         [0039]      FIG. 10  also shows that the fourth bracket  116  serves to help space adjacent decking boards by a uniform distance. In particular, the side flange  16  helps to space adjacent decking boards, such as the decking boards N 1  and N 2  as shown in  FIG. 10 . 
         [0040]      FIG. 11  shows an end view of an installed decking board N 4  relative to adjacent decking boards N 3  and N 5 , and a supporting member M 5 . As shown, the brackets  210  and  212 , and in particular their protrusions, serve to space the decking boards N 3 , N 4  and N 5  above the supporting member M 5 . In the area of the decking member N 4 , it can be seen that a gap H is defined between the lower surface of the decking member N 4  and the upper surface of the supporting member M 5 . By providing space between the decking boards and the supporting members, the brackets help to promote airflow between the decking boards and the supporting members, which helps to control moisture, condensation and mold. 
         [0041]      FIG. 12  is a top plan view of a section of a completed deck showing a series of decking members N 6 , N 7 , N 8 , N 9 , N 10  installed with brackets  210  to multiple supporting members M 6 , M 7  and M 8 , with the decking members shown in transparent lines to reveal the brackets and their connections. As also shown in Fig,  12 , at junctions where two brackets are used, the brackets are preferably oriented opposite to each other. 
         [0042]    In this example, each junction between one of the decking boards and one of the supporting members includes one or two of the brackets  210 . In contrast, as shown in  FIG. 9 , some applications allow for brackets to be used on alternating supporting members. Similarly, in some applications two brackets are used at every junction only at the ends of decking members, which would be their end connections to a supporting member. 
         [0043]    In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.