Abstract:
A deck planking assembly system, comprised of two independent extrusions, to construct outdoor decks, docks and like structures. The top member includes a horizontal walking surface with multiple downwardly projecting vertical legs for locking devices and two additional projections for outer side walls. The second member of the device includes an elongated support formed from a rigid extrusion of metal, plastic or composite material, having a horizontal mounting surface which is affixed to a joist system. This contains multiple upwardly extending vertical legs at different lengths to create a crowned walking surface. Each vertical leg supports a horizontal extension terminating into an engaging locking method and an intermediate support means for the top member.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    Priority is claimed from U.S. Provisional Patent Application No. 60/352,760 filed Jan. 28, 2002 entitled “ARTIFICIAL DECKING MATERIAL AND METHOD FOR USE,” which is incorporated herein by reference in its entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to outdoor decks, and more particularly, to man-made decking material or planks that can be used on new or renovated outdoor decks.  
         BACKGROUND OF THE INVENTION  
         [0003]    Conventional decks are usually made of wood and consist of individual planks nailed or screwed into underlying wood joists. A typical deck comprises the use of nominal 2 inch by 6 inch planks having a dressed dimension of 1½ inches by 5½ inches secured to underlying joists spaced, for instance, on 16 inch centers. Other deck designs may utilize nominal 2 inch by 4 inch and 2 inch by 8 inch wood planks secured to the supporting joists. Such wood planks are subject to warping, rotting, splintering, splitting and require continual maintenance such as by staining or coating with protective sealants. In addition, such wood planks are subject to being cored by carpenter ants, wasps and other insects.  
           [0004]    To address these concerns, man-made materials have been developed to address some or most of the above mentioned problems. For example, metal planking alone, while resistant to weathering if properly painted, is undesirable as a decking material because of its tendency to get extremely hot from exposure to the sun. While plastic plank members have been proposed such as shown in U.S. Pat. No. 5,009,045 which solve a number of the problems with wood and metal planks, they have a tendency to soften under high temperatures reached under a hot sun, thereby causing significant warping, which is both unattractive and may offer a tripping hazard.  
           [0005]    The present invention serves to solve the ongoing problem associated with man-made materials by combining the benefits of a strong weather-resistant lower support member, with an attractive weather-resistant upper thermoplastic surface member.  
         SUMMARY OF THE INVENTION  
         [0006]    The decking system of the present invention comprises a lower member that serves as a structural support for the surface member that serves as the walking surface of the deck. The lower member is comprised of a base with a series of vertical struts. The lower members are attached to the decking joists by means such as screws, bolts, or nails. Each surface member has a clip arrangement that interlocks with a corresponding vertical strut of the lower member. Subsequently, the surface member is either slid longitudinally over the lower member such that the clips of the surface member grasp the vertical struts of the lower member, or the surface member is simply pressed downward such that the clips of the surface member expand and then contract around the struts of the lower member, thereby interconnecting the surface member to the lower member.  
           [0007]    In addition, the present invention offers the benefit of easy and relatively inexpensive replacement of the surface member. More specifically, should the surface member of one or more planks become damaged due to an event such as a grilling mishap, the surface member of the affected planks are simply slipped off, with a new surface member quickly installed. This feature also lends itself to modifying the appearance of the decking surface in the event that the deck owner desires a different color or textured surface. In this case, the surface members are simply slipped off the entire deck, with substitute surface members installed, and with no screwing or nailing required. Accordingly, the present invention offers multiple advantages over a wood deck, and further offers a significant improvement over artificial decking due to its ease of installation and its performance after installation. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0008]    [0008]FIG. 1 is an exploded perspective view of the decking system;  
         [0009]    [0009]FIG. 2 is a cross-sectional view of the lower member of the decking system;  
         [0010]    [0010]FIG. 3 is a cross-sectional view of the surface member of the decking system;  
         [0011]    [0011]FIG. 4 is a cross-sectional view of the assembled decking system; and  
         [0012]    [0012]FIG. 5 is a cross-sectional view of the assembled decking system where webbing is used between certain biased clips. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0013]    The present invention is a two-member system comprising a structural base and a overlying surfacing layer. The two-member system may be installed on either newly constructed decks or renovated decks. The first member, or lower member, comprises a structural support member that is directly attached to the upper surface of the decking joists. The second member, or surface member, is interconnected to the lower member and serves as the walking surface of the deck.  
         [0014]    In newly constructed decks, the foundation and structural members, including joists, are first constructed to provide the structural support for deck planking. Alternately, in the case of a deck renovation, the worn or otherwise undesirable existing deck surfacing is removed for replacement, thereby exposing the underlying joists. In either case, the two-member deck planking system of the present invention is attached to the upper surface of the structural joists.  
         [0015]    As previously noted, the lower member of the present invention is directly attached to the top of the exposed structural joists. The lower member is preferably made of a man-made material that offers good weather-resistant properties, and is structurally capable of acting as a support for the surface member. Preferably, the lower member is metal, plastic, or a composite material. More preferably, the lower member is made of aluminum. Aluminum offers the benefit of being relatively strong while being relatively light weight.  
         [0016]    The lower member is preferably manufactured in widths that correspond to typical wood products. More particularly, in a preferred embodiment, the lower member is manufactured in about a 5½ width to correspond to a typical wood dressed dimension of 5½ inches, as is the typical dressed dimension width of a nominal 2 inch by 6 inch wooden plank. Alternately, the lower member may be manufactured in other desirable widths, such as widths that correspond to standard 2 inch by 4 inch planking. One of the benefits of the present invention is the ability to manufacture the materials in an assortment of attractive and custom widths.  
         [0017]    Preferably, the lower member is produced in lengths that provide for ease of construction at the installation site. Accordingly, in a preferred embodiment, the planks are produced in lengths that are dimensionally consistent with the particular deck under construction. The lower member may be manufactured in an extrusion process, whereby custom lengths of planking may be produced. This has the benefit of minimizing the number of exposed ends within the central area of the deck. For example, custom lengths of a desired size maybe extruded such that one plank spans the entire length of the deck, thereby eliminating the existence of multiple planks to span the length of the deck.  
         [0018]    The lower member is preferably oriented such that the long axis of the lower member is approximately perpendicular to the orientation of the underlying joists. The lower member is then attached to the joists by an appropriate securing means, such as by nailing, or by screwing the lower member into the joists.  
         [0019]    Referring now to FIG. 1, decking system  10  is depicted in an exploded perspective view. Decking system  10  includes both lower member  12  and surface member  14 . FIG. 2 depicts lower member  12 . FIGS.  3  depicts surface member  14 . Referring now to FIG. 2, in a preferred embodiment, lower member  12  is comprised of a base  16 , side struts  20   a  and  20   b , and two pairs of T-shaped vertical struts  30   a ,  30   b , and  40   a ,  40   b . Base  16  extends along the entire width of lower member  12 . A side strut  20   a ,  20   b  is positioned at each extreme end or side. Side struts  20   a ,  20   b  extend from the base  16  vertically and are generally L-shaped. The L-shaped side struts  20   a ,  20   b  include vertical portions  22   a ,  22   b  and a lateral portions  24   a ,  24   b . Lateral portions  24   a ,  24   b  are positioned at the top of vertical portions  22   a ,  22   b  of side struts  20   a ,  20   b . Lateral portions  24   a ,  24   b  extend toward the center of lower member  12 .  
         [0020]    The two pairs of T-shaped vertical struts  30   a ,  30   b , and  40   a ,  40   b  are placed interiorly of side struts  20   a ,  20   b . The outside most T-shaped vertical struts  30   a ,  30   b , those nearest side struts  20   a ,  20   b , include a vertical portion  32   a ,  32   b , and top portions  34   a ,  34   b . Interior to T-shaped vertical struts  30   a ,  30   b , are T-shaped vertical struts  40   a ,  40   b . T-shaped vertical struts  40   a ,  40   b  include vertical portions  42   a ,  42   b  and top portions  44   a ,  44   b.    
         [0021]    Lower member  12  is preferably manufactured in an extrusion process, whereby a continuous length of the lower member  12  is produced. In addition, as a result of this manufacturing process, no weld points exist. More specifically, no weld points exist between side struts  20   a ,  20   b  and base  16 , nor between T-shaped vertical struts  30   a ,  30   b , and  40   a ,  40   b  and base  16 , nor between vertical portions  22   a ,  22   b  and lateral portions  24   a ,  24   b , nor between vertical portions  32   a ,  32   b  and  42   a ,  42   b  and top portions  34   a ,  34   b  and  44   a ,  44   b.    
         [0022]    Although the top surface of the lower member  12  and surface member  14  may be flat, the present invention preferably incorporates a slope for assisting with drainage of surface water. Thus, in still a further aspect of the invention, as can be seen from FIG. 2, T-shaped vertical struts  40   a ,  40   b  are taller than T-shaped vertical struts  30   a ,  30   b . More particularly, vertical portions  42   a ,  42   b  of T-shaped vertical struts  40   a ,  40   b  are longer than vertical portions  32   a ,  32   b  of T-shaped vertical struts  30   a ,  30   b . Furthermore, vertical portions  32   a ,  32   b  of T-shaped struts  30   a ,  30   b  are longer than vertical portions  22   a ,  22   b  of side struts  20   a ,  20   b . The top surface  26   a  of side strut  20   a , top surface  36   a  of T-shaped vertical strut  30   a , and top surface  46   a  of T-shaped vertical strut  40   a  are aligned to provide a downward side slope toward the direction of side strut  20   a . Similarly, on the other side of the plank, top surface  26   b  of side strut  20   b , top surface  36   b  of T-shaped vertical strut  30   b , and top surface  46   b  of T-shaped vertical strut  40   b  are aligned to provide a downward side slope toward the direction of side strut  20   b . By way of example and not limitation, for a 5½ inch wide plank, the total height between the bottom of base  16  and the top of L-shaped side struts  20   a ,  20   b  may be between about 0.40 to 0.60 inches, and more preferably between about 0.45 and 0.55 inches, and more preferably yet, about 0.50 inches. In addition, the total height between the bottom of base  16  and the top of T-shaped vertical struts  30   a ,  30   b  maybe between about 0.45 to 0.65 inches, and more preferably between about 0.50 and 0.60 inches, and more preferably yet, about 0.55 inches. The total height between the bottom of base  16  and the top of T-shaped vertical struts  40   a ,  40   b  may be between about 0.50 to 0.70 inches, and more preferably between about 0.55 and 0.65 inches, and more preferably yet, about 0.575 inches. Accordingly, for a 5½ inch wide plank, the struts are manufactured to provide between about {fraction (0/1000)} to {fraction (300/1000)} inch slope, and more preferably between about {fraction (50/1000)} to {fraction (100/1000)} inch slope, and more preferably yet, about {fraction (75/1000)} of an inch slope or crown from the side to the center-most T-shaped strut of the plank. Of course, the amount of crowning can be adjusted to accommodate the width of planks desired. The particular dimensions can also be modified as desired for each of the struts.  
         [0023]    The above described extrusion manufacturing process lends itself to the relatively precise production of the various strut structures and heights previously described. Accordingly, following connection of overlying surface member  14 , the top of surface member  14  mirrors the influence of the length of the side struts  20   a ,  20   b  and T-shaped vertical struts  30   a ,  30   b , and  40   a ,  40   b . As a result, the top surface of surface member  14  is slightly sloped to provide improved surface drainage off of each individual decking plank.  
         [0024]    As noted above, upon installation, surface member  14  overlies lower member  12 . Surface member  14  is preferably manufactured using a flexible material that lends itself to forming a relatively snug fit over lower member  12 . More preferably, surface member  14  is constructed of a material having some resilient characteristics, so that its structural components “grasp” or frictionally resist movement after placement over the underlying lower member  12 . Accordingly, in a preferred embodiment, surface member  14  is constructed of a plastic material. Still more preferably, the surface member is manufactured of polyethylene material in an extrusion process, whereby relatively tight manufacturing tolerances are possible, such that surface member  14  frictionally grasps side struts  20   a ,  20   b , and T-shaped vertical struts  30   a ,  30   b  and  40   a ,  40   b  of lower member  12 . The use of a plastic material also offers the added benefit of providing a relatively maintenance free surface that does not absorb moisture, and which does not readily stain or become unsightly. In addition, the use of plastic in the surface member  14  allows the appearance of the surface member to be custom manufactured. Thus, another aspect of the invention involves that method or process of providing variation of color and overall surface appearance. For example, various color tan and brown resins may be used to produce a material with a wood appearance. In addition, supplemental pellets with higher melting points and different colors may be added in the mix during the manufacturing process to render a streaked appearance that is indicative of natural wood-grain textures. Alternately, bright colors could be used, for example, red, yellow or orange colored plastic could be used at locations where it is desirable to warn pedestrians of a potential hazard, such as a step, or for trademark logos.  
         [0025]    Prior art designs rely on interlocking close tolerance extensions to secure the two members together. These designs do not compensate for the potential extreme temperature variations, and corresponding expansion and contraction problems at the decking surface. The present invention incorporates several locking extensions, or clips, which are unique compared to prior art. The clips are designed to flex together, and expand when pressed into the lower member  12 . This flexibility lessens the requirement for maintaining and controlling close tolerances for securing the assembly of the two members. Also, as previously noted, the lower member  12  of the present invention is preferably fabricated from a rigid material, such as aluminum. This assists with addressing expansion/contraction problems that may be observed if both members of the decking system  10  were constructed of thermoplastics.  
         [0026]    Referring now to FIG. 3, surface member  14  includes top surface  50  that extends the entire width of surface member  14 . Top surface  50  possesses an upper wearing surface  52  and a bottom surface  54 . As shown in FIG. 3, upper wearing surface  52  may include longitudinal texturing to aid in traction. Alternately, upper wearing surface  52  may include side-slope texturing to aid in dissipating surface moisture. Of course, surface texturing may be purely random or may be patterned in decorative styles. In addition, texturing offers the added benefit of dissipating heat from exposure to the sun. That is, the texturing provides an increased surface area for heat to dissipate. Furthermore, the surface member  14  is in contact with the struts of the lower member  12 , which provides further heat dissipating potential to the decking system, because heat is transferred from the surface member  14  directly to the lower member  12 , where heat can dissipate to the surrounding atmosphere via the struts  20   a ,  20   b ,  30   a ,  30   b , and  40   a ,  40   b , as well as the base  16 .  
         [0027]    Surface member  14  includes side panels  60   a ,  60   b . Side panels  60   a ,  60   b  fit over the outer exterior of side struts  20   a ,  20   b . Therefore, upon installation, the entire upper exposed surface of lower member  12  is covered by surface member  14 , including the sides of lower member  12 . This feature lends itself to an attractive appearance upon completion of the plank installation, because the aluminum appearance of lower member  12  is no longer visible. Furthermore, since surface member  14  completely covers the lower member  12 , the attachment devices such as screws that are driven through the lower member  12  into the underlying joists are completely hidden.  
         [0028]    Surface member  14  also includes a number of biased side clips attached to its bottom surface  54 . More particularly, biased side clip  28   a ′ is positioned on the bottom surface  54  of surface member  14  to correspond to the location of the interior side  29   a ′ of lateral portion  24   a  of L-shaped side strut  20   a . The shape of the biased side clips is preferably convex on the side of the strut to which it acts. For example, biased side clip  28   a ′ is convex relative to interior side  29   a ′ of lateral portion  24   a  of side strut  20   a . Similarly, on the other side of the plank, biased side clip  28   b ′ is convex relative to interior side  29   b ′ of lateral portion  24   b  of side strut  20   b.    
         [0029]    For each T-shaped vertical strut  30   a ,  30   b  and  40   a ,  40   b  there are preferably two biased side clips. For example, biased side clips  38   a ,  38   a ′ grasp T-shaped vertical strut  30   a . More specifically, biased side clip  38   a  grasps the exterior side  39   a  of top portion  34   a  of T-shaped vertical side strut  30   a . As described above, the convex side of biased side clip  38   a  is closest to the strut it is grasping, that is, T-shaped vertical strut  30   a . Biased side clip  38   a ′ grasps the interior side  39   a ′ of top portion  34   a  of T-shaped vertical strut  30   a . From FIG. 4, it can be seen that top portion  34   a  of T-shaped vertical strut  30   a  fits between biased side clips  38   a ,  38   a′.    
         [0030]    In a similar manner to that previously described, biased side clips  38   b ,  38   b ′ grasp T-shaped vertical strut  30   b ; biased side clips  48   a ,  48   a ′ grasp T-shaped vertical strut  40   a ; and finally, biased side clips  48   b ,  48   b ′ grasp T-shaped vertical strut  40   b . As illustrated in FIG. 4, utilizing the biased side clips in conjunction with the struts, surface member  14  interlocks with lower member  12 . The biased clip mechanism for interlocking the surface member to the lower member  12  enables the surface member  14  to freely slide along the lower member  12  to allow for thermal expansion and contraction that occurs as a result of heating and cooling the plastic of the surface member  14 . This reduces the occurrences of warping of the surface member  14 , which is both a visual distraction and a potential tripping hazard. In addition, the use of clips along the entire width of the plank ensures that the surface member  14  is soundly attached to the lower member  12 , thereby eliminating the sensation of unsecured or loose portions of the surface member  14  when crossed by a person walking on the surface member  14 .  
         [0031]    End pieces or caps of plastic covering that match the appearance of the surface member  14  may be installed to provide a finished appearance to the ends of the planks that exist at the edge of the deck. Preferably, the end pieces would simply snap over the end of each plank.  
         [0032]    The above text describes a preferred embodiment for a plank having a width of about 5½ inches. However, a narrower or wider width plank may also be produced using a fewer number or greater number of struts, as may be appropriate for the desired plank width. For example, if a narrow plank is desired, a plank could be produced with a set of side struts  20   a ,  20   b , and only one T-shaped vertical strut located in the center of the plank. Alternately, a plank could be manufactured using side struts  20 ,  20   b  and two, three, four (as previously described), five, or any number of T-shaped vertical struts. Accordingly, in a preferred method of manufacture, use of fewer or greater numbers of struts than those earlier described would simply entail extruding the lower member with the desired number of T-shaped vertical struts distributed relatively evenly between side struts  20   a ,  20   b , so as to provide a relatively even support for surface member  14 . Furthermore, the production of surface member  14  will necessarily require modification so as to provide corresponding biased side clips at appropriate locations so as to grasp the various struts of lower member  12 .  
         [0033]    Referring now to FIG. 5, in a separate aspect of the invention, webbing  70  can be provided between the biased clips of the surface member  14  to prevent the biased clips from undergoing excessive movement during installation. Webbing  70  may be provided between only two biased clips, or it may be provided between a plurality of biased clips. As an example where four T-shaped vertical struts are used, webbing  70  is preferably located between biased clips  28   a ′ and  38   a ,  38   a ′ and  48   a ,  48   a ′ and  48   b ′,  48   b  and  38   b ′, and  39   b  and  28   b ′. Webbing  70  may be a solid structure along the entire length of the surface member  14 , or it may take the form of intermittent structural members that are placed at various distances along the length of the surface member  14 .  
         [0034]    While the above description and the drawings disclose and illustrate numerous alternative embodiments, one should understand, of course, that the invention is not limited to these embodiments. Those skilled in the art to which the invention pertains may make other modifications and other embodiments employing the principles of this invention, particularly upon considering the foregoing teachings. Therefore, by the appended claims, the applicant intends to cover any modifications and other embodiments as incorporate those features which constitute the essential features of this invention.