Abstract:
An anchor for installing a plank in a deck system includes a base portion, a plank-engaging portion and a fastener aperture. The plank-engaging portion has at least one protrusion. The fastener aperture has a longitudinal axis disposed at an oblique angle from vertical and extends through the base portion and plank-engaging portion. According to another aspect, a decking anchor has a generally key-hole shaped cross-section and a planar bottom surface.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to decking or fencing systems, and more particularly to an improved anchor fastener and anchoring system for decks or fences.  
       BACKGROUND  
       [0002]     In both new building constructions and renovation projects, there is an increasing demand in the residential, commercial and public building construction industries to provide private homes, businesses such as shops and restaurants, and public park facilities with deck structures. These structures typically comprise joists overlain with planks or floor boards and bound by a plurality of posts. Because of its natural beauty, comparatively low cost and abundant supply, wood has historically been the predominant material of choice in the construction of decks and similar structures, e.g., walkways, steps, and boat decks and piers. However, the lumber used in the construction of such structures requires considerable and costly maintenance to slow its inevitable deterioration caused by continual exposure to the sun, rain, snow and other natural elements. Moreover, wooden decks and related structures are subject to splintering which can be a hazard to individuals in bare feet. And, wooden structures are highly flammable.  
         [0003]     The traditional manner of attaching wooden decking planks to underlying joists is by nailing or screwing through the plank into the joist below. This attachment method presents a number of disadvantages. For example, nail or screw heads exposed on the top surface of the decking planks are aesthetically unappealing and may also present tripping, scratching or splintering hazards. Further, the nails may be pried upwards away from the joists by flexing of the deck planks caused by repeated foot traffic. Additionally, the use of nails or screws necessarily creates holes the decking planks which may cause the wood to split, and which may accelerate deterioration of the plank caused by weather or insects. Further disadvantages include increased difficulty of cleaning and/or painting the decking planks.  
         [0004]     Recently, decking systems using rigid plastics such as polyvinyl chloride (PVC), and plastic/fiber composites have become an increasingly popular alternative to wood in the construction of decks and similar structures. These decking systems have been designed with various securing mechanisms. According to some of these designs, the flooring planks are secured to fastener strips which in turn are secured to the joists. In others, the decking planks are secured directly to the joists via screws or similar fastening means.  
         [0005]     U.S. patent application Ser. No. 10/365,870 to Bruchu et al. discloses a decking system formed of extruded thermoplastic wood fiber composite having hollow profile deck planks which interact with decking anchors to form a platform structure. The deck planks have anchor flanges which cooperate with the anchor structure. The anchor structure has a shape that conforms to the anchor flanges to hold the planks in place. The anchor structure includes a vertical aperture into which a fastener is inserted to fix the anchor in place. This decking system requires a fairly complex design for the cooperating planks and anchor.  
         [0006]     U.S. Pat. No. 5,953,878 to Johnson discloses a decking system formed of extruded hollow polyvinyl or plastic planks having a plurality of slots on the side surfaces which overly the joists. The slots are engaged by mounting cleats which act to secure the planks to the joints and to each other. The cleats include a vertical slot through which a fastener is inserted to secure the cleat to the underlying frame. The cleat in slot arrangement allows for the different rates of thermal expansion and retraction of the plastic planks compared to the supporting wood frame.  
         [0007]     U.S. Pat. No. 5,660,016 to Erwin et al. discloses an extruded plastic decking plank and attachment system having planks formed of a rigid foam core and a resilient outer plastic shell. The attachment system includes hold down blocks which have a shape that cooperates with clamping portions on the planks to secure the planks to a support structure. The hold down blocks are secured to the support structure by a fastener which is inserted vertically through a top of the block.  
         [0008]     An improved low cost, easily installed decking structure and decking anchor is desired.  
       SUMMARY OF THE INVENTION  
       [0009]     According to one exemplary embodiment, an anchor for installing a plank in a deck system includes a base portion, a plank-engaging portion and a fastener aperture. The plank-engaging portion has at least one protrusion. The fastener aperture has a longitudinal axis which is inclined from vertical and extends through the base portion and plank-engaging portion.  
         [0010]     The anchors described herein may advantageously be used to secure planks to joists in decking systems. Unlike current decking systems having anchors with vertical fastener apertures, which require an installer to keep the anchor tight against the joist when installing the fastener, the angled aperture of the anchors described herein reduces or eliminates the need for a tight controlled positioning of the anchor.  
         [0011]     According to another aspect, a decking system includes a plurality of anchors and a plurality of planks. The anchors include a base portion, a plank-engaging portion, and at least one fastener aperture. The plank-engaging portion includes at least one protrusion. The fastener apertures have a longitudinal axis disposed obliquely from a vertical plane and which extend through the base portion and plank-engaging portion. The planks include a side wall having an anchor-engaging groove for cooperating with a corresponding protrusion of a corresponding anchor.  
         [0012]     According to a further aspect, a method of installing a deck system comprises providing a plank having an anchor-engaging groove, providing an anchor having a plank-engaging portion and a fastener aperture having a longitudinal axis which is disposed obliquely from a vertical plane, laying the plank on a decking joist, inserting the plank-engaging portion of the anchor into the anchor-engaging groove of the plank, and inserting a fastener through the fastener aperture and into the decking joist.  
         [0013]     According to another aspect, a decking system includes a plurality of decking planks, a plurality of anchors and a plurality of fasteners. The decking planks are disposed over supporting joists. Each of the decking planks have a first and second curvilinear side edge portion. The anchors have first and second side surfaces capable of frictionally mating between the first and second curvilinear side edge portion of adjacent ones of the decking planks. The fasteners are disposed through the anchors at an oblique angle from vertical for joining the decking planks to the supporting joists.  
         [0014]     According to another aspect, a decking anchor has a generally key-hole shaped cross-section and a planar bottom surface.  
         [0015]     According to another aspect, a system for anchoring adjacent planar members to a base member includes a plurality of anchors, a plurality of planar members and at least one base member. The plurality of anchors have a base portion, a planar member-engaging portion having at least one protrusion, and at least one fastener aperture with a longitudinal axis disposed obliquely from a vertical plane and extending through the base portion and planar member-engaging portion. The plurality of planar members include a side wall having an anchor-engaging groove for cooperating with a corresponding protrusion of a corresponding anchor. The anchors are fastened into the base member. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]      FIG. 1  is an end view of a partial decking system according to one exemplary embodiment.  
         [0017]      FIG. 2  is a top view of a partial decking system.  
         [0018]      FIG. 3A  is an isometric view of an exemplary anchor.  
         [0019]      FIG. 3B  is an isometric view of another exemplary anchor.  
         [0020]      FIG. 4  is a top isometric view of a decking plank of the decking system of  FIG. 1 .  
         [0021]      FIG. 5  is a top view of a partial decking system according to another exemplary embodiment.  
         [0022]      FIG. 6  is an isometric view of a further exemplary anchor.  
         [0023]      FIG. 7  is an isometric view of another exemplary anchor.  
         [0024]      FIG. 8  is an isometric view of another exemplary anchor.  
         [0025]      FIG. 9  is an isometric view of a partial decking system employing the anchor of  FIG. 8 .  
         [0026]      FIG. 10  is an elevational side view of a partial decking system employing another exemplary anchor.  
         [0027]      FIG. 11  is a front view of an exemplary partial fencing system.  
     
    
     DETAILED DESCRIPTION  
       [0028]     This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.  
         [0029]     Referring to  FIGS. 1 and 2 , an exemplary embodiment of a partial decking system  100  is shown including a plurality of anchors  10 , a plurality of planks  30 , a plurality of joists  40 , and a plurality of fasteners  50 .  
         [0030]     The anchors  10 , planks  30  and joists  40  of decking system  100  may be comprised of a variety of materials, including wood, metal, polymer, and composite materials. These articles may be cut, molded, drawn, injection-molded or extruded, for example. Preferably, the planks and anchors are comprised of a thermoplastic/fiber composite. The thermoplastics that can be used may include polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyacrylic materials, polyester materials and other common thermoplastics. More preferably, the anchors, planks and/or joists are comprised of an extruded vinyl/wood composite such as that employed in BOARDWALK® Composite decking and railing systems sold by CertainTeed Corporation of Valley Forge, Pa. The consolidation of vinyl and wood fibers into composite reinforcement may be made in-situ during in-line extrusion of the final end product extrudate, or, alternatively, prepared as a tape or rod and incorporated into an off-line extrusion of final product. The commingled fibers may also be pultruded, followed by overlay extrusion of a capstock polymer using a separate extruder, all in-line. In this case, the capstock polymer would preferably cover only the outside surface of the plank, anchor and/or joist. The capstock may be applied by coating or painting as well as coextruding. The polymer or composite articles, or the capstock overlaying the articles, may further include pigments, thermal stabilizers, impact modifiers, ultra-violet (UV) radiation screening agents and other performance and/or aesthetic enhancing additives.  
         [0031]     Referring to  FIGS. 1-3B , the anchor  10 ,  10 ′ comprises a base portion  12 , a plank-engaging portion  14 , at least one fastener aperture  16 ,  16 ′ and side walls  26 . A bottom surface  18  of the base portion  12  lies on the joist  40 . As best shown in  FIGS. 3A and 3B , the sides  24  of the plank-engaging portion  14  are preferably substantially semi-circular in shape, i.e., a cross-section of the plank-engaging portion  14  is circular or oval in shape. Side walls  26  of anchor  10  are substantially flat. The plank-engaging portion  14  includes two protrusions  20   a - b , each protrusion capable of engaging a corresponding anchor-engaging groove  38  on an adjacent plank  30 . The protrusions  20   a - b  are preferably shaped to substantially conform to the anchor-engaging grooves  38  of the planks  30 . The top of each protrusion  20   a - b  preferably includes a substantially planar section  22   a - b  which serves as the entry point for the fastener aperture  16 ,  16 ′. The planar section  22   a - b  allows the head of the fastener  50  to lie flush with the planar section  22   a - b.    
         [0032]     The anchor  10  can have a fastener aperture predrilled or premolded, or the fastener can form its own aperture when it is drilled or nailed, for example. The anchor  10  could also have one or more starter holes or notches for helping to start the fastener. The fastener aperture  16 ,  16 ′ is preferably pre-pierced in the anchor  10 ,  10 ′. It extends through the plank-engaging portion  14  and the base portion  12  at an oblique angle ø away from vertical. Preferably the angle ø is between about 5 and 60 degrees away from vertical. By placing the fastener aperture  16 ,  16 ′ at an angle away from vertical, the bottom surface  18  of the anchor  10 ,  10 ′ does not have to be held tight against the joist when installing the fastener as is typically the case with anchors having vertical fastener apertures.  
         [0033]     The anchor may include one fastener aperture  16 , as shown in  FIG. 3A , which begins at the planar section  22   a  of protrusion  20   a , or alternatively may also include a first and second fastener aperture  16 ′, as shown in  FIG. 3B , which begins at the planar section  22   b  of protrusion  20   b . The fastener apertures  16 ′ may overlap in the anchor  10 ′ or may be non-overlapping. The inclusion of a second fastener aperture allows the anchor  10 ′ to be placed adjacent to the plank in either of two orientations to anchor the plank to the joist, resulting in a less labor-intensive installation.  
         [0034]     Referring again to  FIGS. 2 and 3 A-B, in decking system  100 , there is preferably a separate anchor  10 ,  10 ′ on each joist  40  to anchor each plank  30 . Preferably, the anchor  10 ,  10 ′ of decking system  100  has a width W 1  less than the width W 2  of the joist  40 .  
         [0035]     Referring now to  FIG. 7 , another embodiment of an anchor  15  is shown. Anchor  15  includes a plank-engaging portion  17 , a base portion  19  and at least one fastener aperture  21   a - b . Unlike anchors  10 ,  10 ′ which have side walls  26  that are substantially flat, the entire plank-engaging portion  17  of anchor  15  is substantially spherical, spheroidal or ellipsoidal, and the base portion  19  has a bottom surface which is substantially circular (the anchor  15  resembles a doorknob). Preferably, a top of the plank-engaging portion  17  includes at least one, and preferably two, planar sections  23   a - b . The planar sections  23   a - b  are preferably the entry point for the fastener apertures  21   a - b  which extend through the plank-engaging portion  17  and base portion  19  at an oblique angle ø away from vertical. Preferably, the angle ø is between about 5 and 60 degrees away from vertical. Anchor  15  may have one fastener aperture, but preferably has two fastener apertures  21   a - b , which may be criss-crossed, overlapping or non-overlapping. The substantially spherical, spheroidal or ellipsoidal configuration of anchor  15  and presence of two fastener apertures allows an installer to place the anchor  15  in nearly any orientation against a plank and have a fastener aperture accessible for inserting a fastener.  
         [0036]     Advantageously, anchors  10 ,  10 ′,  15  are hidden or substantially hidden from view when installed in the decking system  100 . The anchors  10 ,  10 ′, and  15  also allow installation of the fasteners  50  from the top of the deck as opposed to the bottom, and therefore makes it easier to build decks which are near ground level. Also, unlike some decking systems having hidden fasteners which require special fasteners, standard fasteners, such as nails or deck screws may be used in decking system  100 .  
         [0037]     Referring to  FIGS. 1 and 4 , the planks  30  of decking system  100  include a top surface  32 , a bottom surface  34 , and two side walls  36   a - b . Each sidewall  36   a - b  includes an anchor-engaging groove  38 , which enables the planks  30  to be fastened to the joists  40  by means of the anchors  10 ,  10 ′,  15 . Preferably the anchor-engaging groove  38  extends the length of the plank  30  as shown in  FIG. 4 . Alternatively, each side wall  36   a - b  may include a plurality of anchor-engaging grooves located intermittently along the length of the plank  30  at locations where the plank  30  is to be anchored to the joists  40 . Preferably, the anchor-engaging groove  38  has a shape which conforms to the protrusions  20   a - b  of the anchor  10 ,  10 ′,  15 . Where the planks are comprised of a metal or a polymer or composite material, the anchor-engaging groove  38  is preferably formed in the plank during manufacture of the plank by molding, drawing or extrusion, depending on the material. Where the planks are comprised of lumber, the anchor-engaging grooves may be formed by a hand tool or a groove-forming machine. The decking system  100  may include one or more end planks (not shown) having only one side wall with an anchor-engaging groove and the other side wall having a flat surface.  
         [0038]     The planks  30  can be of any length or width, but preferably have a length and width equal to those of standard wood lumber. Where the planks are comprised of polymer or composite materials, the planks can be fabricated to include a simulated wood grain outer surface. Also, where the planks are comprised of polymer or composite materials, the planks may be substantially solid, partially solid, or hollow. Where the planks are hollow, they may include internal reinforcement braces. As stated above, the planks comprised of a polymer or composite material may include a capstock layer as an outer layer of the plank.  
         [0039]     Referring now to  FIGS. 5 and 6 , an alternative embodiment of a decking system  200  is shown including anchors  110 , planks  30  and joists  40 . The joists  40  and planks  30  are the same as described above with respect to decking system  100 , except that due to the nature of the anchor  110 , as described below, the planks of decking system  200  necessarily will contain an anchor-engaging groove which extends the length of the plank  30 .  
         [0040]     The anchors  110  of decking system  200  comprise a base portion  112 , a plank-engaging portion  114 , and a plurality of fastener apertures  116 . Unlike anchors  10 ,  10 ′,  15 , anchors  110  preferably extend substantially the length of the planks  30 . This configuration of the anchor advantageously provides extra support for the planks which is beneficial in demanding applications. (Alternatively, the anchors may have a length extending at least the distance between two joists.) A bottom surface  118  of the base portion  112  lies on the joist  40 . As best shown in  FIG. 6 , the sides  124  of the plank-engaging portion  114  are preferably substantially semi-circular in shape. The plank-engaging portion  114  includes two protrusions  120   a - b , each protrusion engaging a corresponding anchor-engaging groove  38  on an adjacent plank  30 . The protrusions  120   a - b  are preferably shaped to substantially conform to the anchor-engaging grooves  38  of the planks  30 . The top of each protrusion  120   a - b  preferably includes a substantially planar section  122   a - b  which serves as the entry point for the fastener aperture  116 . The planar section  122   a - b  allows the head of the fastener  50  to lie flush with the planar section  122   a - b .  
         [0041]     The fastener apertures  116  are preferably pre-pierced in the anchor  110 . They are preferably spaced intermittently along the length of the anchor  110  at locations where the anchor will intersect a joist  40 . The fastener apertures  116  extend through the plank-engaging portion  114  and the base portion  112  at an angle ø away from vertical. Preferably the angle ø is between about five and sixty degrees away from vertical. As stated above, by placing the fastener aperture  116  at an angle away from vertical, the bottom surface  118  of the anchor  110  does not have to be held tight against the joist when installing the fastener, as is typically the case with anchors having vertical fastener apertures.  
         [0042]     The anchor  110  may include a plurality of fastener apertures  116  having an entry point along only one protrusion as shown in  FIG. 6 , which begins at the planar section  122   a  of protrusion  120   a , or alternatively, the anchors  110  may include a second set of fastener apertures (not shown) which begin at the planar section  122   b  of protrusion  120   b . The fastener apertures may overlap in the anchor  110  or may be non-overlapping.  
         [0043]     As with anchors  10 ,  10 ′,  15 , anchor  110  is capable of being hidden or substantially hidden from view when installed in the decking system  200 .  
         [0044]     Referring to  FIGS. 8-9 , another embodiment of an anchor  310  and partial decking system  300  is shown. Anchor  310  includes a plank-engaging portion  314 , a base portion  312  and at least one fastener aperture  321 . The base portion  312  includes at least one end, and preferably two ends  316 ,  318 , which terminate inwardly from the respective ends  320 ,  322  of the plank-engaging portion  314  a distance sufficient to allow the respective end of the plank-engaging portion to engage and secure an adjacent plank  30 . A top of the plank-engaging portion  314  includes at least one, and preferably two, planar sections  323   a - b . The planar sections  323   a - b  are preferably the entry point for the fastener aperture  321  (or apertures) which extend through the plank-engaging portion  314  and base portion  312  at an oblique angle away from vertical. (The exit point for apertures may be completely enclosed by a bottom surface of the base portion as shown in  FIGS. 3A and 3B  or may extend at least partially through a side of the base portion as described below and shown in  FIG. 10 .) Preferably, the angle of the apertures  321  is between about 5 and 60 degrees away from vertical. Anchor  310  may have one fastener aperture  321  (as shown), but preferably has two fastener apertures, which may be criss-crossed, overlapping or non-overlapping.  
         [0045]     This anchor embodiment allows the single anchor  310  to be used to secure two planks that are perpendicular to one another, and therefore would be beneficial for employment in picture-framing deck planks (see  FIG. 10 ). The inclusion of two terminated base portion ends  316 ,  318  of anchor  310  and the presence of two fastener apertures  321  allows an installer to place the anchor  310  in either of two orientations against a plank while having a fastener aperture accessible for inserting a fastener and also an end capable of securing a perpendicular plank. The anchor  15  shown in  FIG. 7  may also be used in the decking system  300  to secure perpendicular decking planks.  
         [0046]     Referring to  FIG. 10 , another embodiment of an anchor  410  and decking system  400  is shown. Anchor  410  may have a size and shape similar to any of the anchors described herein, with the difference being that the exit point of the fastener aperture  412  is not entirely through the bottom surface  414  of the base portion  416  of anchor  410 , but rather extends at least partially through a side  418  of the base portion  416 . The purpose for this angle variation is to allow the fastener  50  to penetrate and directly secure the plank  30  to a joist. This embodiment may prevent the plank from moving due to expansion and contraction of the plank-forming material. Preferably, the fastener aperture  412  is at approximately between a 35-45° angle α away from vertical, and more preferably at approximately a 40° angle away from vertical. However, depending on the shape and width of the protrusions  420   a ,- b  of the anchor  410 , and also the distance of any gap between the protrusions and the anchor-engaging groove  38  of the plank  30 , the angle from vertical may vary to ensure that the fastener connects with a portion of the plank  30  when inserted through the fastener aperture  412 .  
         [0047]     Referring to  FIGS. 1, 2  and  5 , the decking systems  100 ,  200 ,  400  are installed by placing planks  30  perpendicularly across a plurality of spaced-apart joists  40 . To anchor the planks  30 , a bottom surface  18 ,  118 ,  414  of the base portion  12 ,  112 ,  416  of anchors  10 ,  10 ′, 15 ,  110 ,  410  are placed on joists  40  (in the embodiment shown in  FIG. 2 , preferably anchors  10  are placed on each joist  40 ) and a protrusion  20   a ,  120   a ,  420   a  of the anchors  10 ,  10 ′,  15 ,  110 ,  410  is placed adjacent the anchor-engaging groove  38  of the plank  30  so that the fastener aperture  16 ,  16 ′,  116 ,  412  of the anchor is accessible by an installer. A fastener  50  (or fasteners for anchor  110 ) is then inserted into the anchor  10 ,  10 ′,  15 ,  110 ,  410  via the fastener aperture  16 ,  16 ′,  116 ,  412  at an angle away from vertical as dictated by the angle of the fastener aperture. Tightening of the fastener  50  into the joist  40  will pull the anchor snugly into an anchoring position, preferably in firm contact with the anchor engaging groove  38  of the plank  30 . Referring to  FIGS. 2 and 4 , anchoring of one side wall  36   b  of the plank  30  may also push the plank into firmer engagement with a second set of anchors which have already been installed on an opposite edge  36   a  of the plank  30  and which have been seated into the anchor engaging groove  38  on the opposite edge  36   a . Once the anchors for one side wall  36   a  of a plank  30  have been fastened to the joist  40 , the anchor-engaging groove  38  of another plank  30  is placed against the protrusion  20   b ,  120   b ,  420   b  of the anchor  10 ,  10 ′,  15 ,  110  housing the entry point for the fastener aperture  16 ,  16 ′,  116 ,  412  (or is placed in sufficient enough proximity to the anchor-engaging groove  38  to facilitate anchoring of the plank  30 ). Depending on the desired appearance and the size and form of the anchor  10 ,  10 ′,  15 ,  110  the anchors may be entirely hidden from view, or a gap  60  of a desired width (preferably from 0-0.5 inch, and more preferably . 125  inch) may be left between the planks  30 .  
         [0048]     Although advantageously employed in decking systems, the anchors and planks described herein may also be beneficially employed in fencing systems to form a fence with a hidden fastening system. Such a system may eliminate unappealing visible nail or screw holes. Referring to  FIG. 11 , a partial fence  500  is shown including at least one rail  510 , a plurality of panels  520  and a plurality of anchors  530 . The anchors  530  may be any anchor described herein with respect to a decking system. The anchors are fastened to the rails  510  to secure adjacent panels  520  to the rails  510 .  
         [0049]     Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.