Abstract
A deck clip system, in which a deck clip or series of deck clips are provide for rapid deployment of deck boarding on joists. The deck clips have a base element and engaging elements. The base element can be affixed to a joist and the engaging elements extend from the base vertically to engage planks or deck boarding. The planks may have recesses configured to receive the engaging elements. The clips may be arranged or disposed into a strip for even faster deployment.
Claims
1. A clip for use in the installation of deck boards comprising: a base generally in the configuration of a prism and having a major plane and a major axis; a plurality of verticals, each vertical of said plurality of verticals comprising a proximal end and an opposing distal end with an elongated body generally in the configuration of a prism extending therebetween, said each vertical being attached to said major plane of said base at said proximal end such that said major plane of said each vertical is generally perpendicular to said major plane of said base, where said major planes of said each vertical are generally parallel; and at least one vertical of said plurality of verticals comprising a retaining element disposed at said distal end, said retaining element protruding outward from a lateral side of said at least one vertical.
2. The clip of claim 1, wherein said at least one vertical comprises at least two verticals.
3. The clip of claim 2, wherein a first vertical of said at least two verticals and a second vertical of said at least two verticals are connected to said base at opposing sides of said base.
4. The clip of claim 3, wherein said clip is made of a material having sufficient ductility that said first vertical and said second vertical may be temporarily pinched together without breaking said clip.
5. The clip of claim 4, wherein said clip is manufactured via sheet metal fabrication.
6. The clip of claim 5, wherein said base has a generally H-shaped cross section comprising two pairs of legs having a crossbar extending therebetween, wherein a major axis of said crossbar is generally perpendicular to a major axis of each of said pairs of legs and said first vertical and said second vertical are attached to said base at opposing sides of said crossbar.
7. The clip of claim 6, wherein said retaining element is generally in the configuration of an irregular trapezoid comprising: a base connected to said at least one vertical; a top side angled downward toward said base; an opposing bottom side generally parallel to said major plane of said base; and a hook disposed at an end of said bottom side distal said at least one vertical, said hook pointing downward towards said base.
8. The clip of claim 7, further comprising an aperture extending from a top side to an opposing bottom side of said base, said aperture sized and shaped for receiving a fastener.
9. The clip of claim 8, wherein each leg in said two pairs of legs has a proximal end at said crossbar and an opposing distal end with a leg body extending therebetween, said leg body disposed at a downward angle from said base such that said distal ends of said legs are not coplaner with said base.
10. The clip of claim 9, wherein said distal ends of said legs in said two pairs of legs are coplanar with each other.
11. The clip of claim 5, wherein at least two verticals comprises four verticals, a first two verticals of said four verticals attached to said base at a first side, and a second two verticals of said four verticals attached to said base at a second side opposite said first side.
12. The clip of claim 11, wherein said first two verticals are disposed proximal to a minor axis of said base and said second two verticals are disposed distal to said minor axis.
13. The clip of claim 12, wherein said retaining element is generally in the configuration of an inverted J.
14. The clip of claim 13, further comprising an aperture extending from a top side to an opposing bottom side of said base, said aperture sized and shaped for receiving a fastener.
15. The clip of claim 5, wherein said verticals comprise spring arms disposed at opposing ends of said major axis of said base, each of said spring arms having an engagement hook at a distal end thereof.
16. A clip strip comprising a plurality of clips of claim 5.
17. The clip strip of claim 16, further comprising a base element generally in the configuration of an elongated prism sized and shaped to be placed on a deck joist.
18. The clip strip of claim 17, further comprising a spacer element generally in the configuration of an elongated prism and having a plurality of apertures sized and shaped for passage of said verticals and retaining elements.
19. The clip strip of claim 18, wherein each of said plurality of clips is disposed at each aperture, and said verticals and retaining elements of each said clip pass through said aperture and are oriented such that said retaining elements of adjacent clips in said clip strip extend towards each other.
20. The clip strip of claim 19, wherein said clip strip is disposed in a rolled configuration.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is an isometric elevation view of a deck clip according to the present disclosure.
[0028] FIG. 2 is a top elevation view of the deck clip of FIG. 1.
[0029] FIG. 3 is an isometric elevation view of an alternative deck clip according to the present disclosure.
[0030] FIG. 4 is a reverse isometric elevation view of the alternative deck clip of FIG. 3.
[0031] FIG. 5 is a top elevation view of the deck clip of FIG. 3.
[0032] FIG. 6 provides rolled, exploded, and assembled views of a clip strip using the deck clips of FIGS. 1-5.
[0033] FIG. 7 is an isometric elevation view of decking being installed using the clip strip of FIG. 6.
[0034] FIG. 8 is a side elevation view of decking being installed using the clip strip of FIG. 6.
[0035] FIG. 9 provides isometric and elevation views of an alternative deck clip according to the present disclosure.
[0036] FIG. 10 is an isometric elevation view of an alternative deck clip according to the present disclosure.
[0037] FIG. 11 depicts embodiments of individual clips for use with the deck installation system according to the present disclosure.
[0038] FIG. 12 depicts a deck installation using the clip strip of the present disclosure with an illumination element.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0039] The following detailed description and disclosure illustrates by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the disclosed systems and methods, and describes several embodiments, adaptations, variations, alternatives and uses of the disclosed systems and methods. As various changes could be made in the above constructions without departing from the scope of the disclosures, it is intended that all matter contained in the description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0040] FIG. 1 depicts an embodiment of a deck clip according to the present disclosure. The depicted deck clip (101) comprises a base (103) with two attached verticals (109), each of the verticals (109) having a pair of opposing retaining elements (111). The depicted base (103) is a generally H-shaped element having a pair of opposing legs (107) connected by a crossbar (105). The legs (107) provide stability and an attaching point for installing a plurality of deck clips (101) into a clip strip (601) as described elsewhere herein. As can be seen in FIG. 2, the crossbar (105) may comprise an aperture (115) sized and shaped to receive a fastener for affixing a clip strip (601) comprised of one or more of the deck clips (101) to a joist, as described elsewhere herein.
[0041] In the depicted embodiment of FIG. 1 and FIG. 2, the major axis of the crossbar (105) is generally orthogonal to the major axis of each of the legs (107), but in an alternative embodiment, the crossbar (105) may be attached to one or more of the legs (107) at a non-orthogonal angle. In the depicted embodiment of FIG. 1 and FIG. 2, the major axis of the crossbar (105) is attached to each of the legs (107) at about the same corresponding location on each leg (107), but in an alternative embodiment, the crossbar (105) may be attached to one of the legs (107) at a different location from the other. In the depicted embodiment of FIG. 1, the legs (107) are about the same length, but in an alternative embodiment, the legs (107) may be longer on one side of the crossbar (105) than the other, or may be about the same length on each side of the crossbar (105). Similarly, in an alternative embodiment, only one leg (107) may be longer than the other, and on one or both sides of the crossbar (105). In the depicted embodiment of FIG. 1 and FIG. 2, the major axes of the legs (107) are generally parallel to each other, but in an alternative embodiment, the legs (107) may not be parallel. The particular arrangement and configuration of the legs (107) will generally depend on the manner in which the deck clips (101) are manufactured and cut, and the manner in which the deck clips (101) will be assembled into a clip strip (601).
[0042] As seen in FIG. 1, a pair of opposing verticals (109) are attached to the base (103). In the depicted embodiment, these verticals (109) are attached at opposing top and bottom sides of the crossbar (105), and extend most of the length of the crossbar (105) between the legs (107), with small cutouts to accommodate the manufacturing process, as described elsewhere herein. The depicted verticals (109) are generally elongated, flat rectangular prisms having retaining elements attached thereto, as described elsewhere herein. The depicted verticals (109) are connected to the base (103) so that the major plane of each vertical (109) is generally perpendicular to the major plane of the base, resulting in the major planes of the verticals (109) being generally parallel to each other. The depicted verticals (109) may be monolithically constructed with the base, but are not so rigidly constructed as to be incapable of flexing. That is, the verticals (109), with sufficient pressure, can be pinched or squeezed together, moving them out of parallel. As described elsewhere herein, this feature facilitates installing.
[0043] In the depicted embodiment of FIG. 1 and FIG. 2, the major planes of the verticals (109) crossbar (105) are generally orthogonal to the major plane of the base (103), but in an alternative embodiment, one or more of the verticals (109) may be non-perpendicular. In the depicted embodiment of FIG. 1 and FIG. 2, the major planes of the verticals (109) crossbar (105) are generally parallel to each other, but in an alternative embodiment, the verticals (109) may be non-parallel. In the depicted embodiment of FIG. 1 and FIG. 2, the verticals (109) generally extend most of the width of the crossbar (105), but in an alternative embodiment, one or more of the verticals (109) may extend only part of the width of the crossbar (105). In the depicted embodiment of FIG. 1 and FIG. 2, the verticals (109) are generally in the configuration of elongated rectangular prisms with cutaways to facilitate material flexing and bending, but in an alternative embodiment, other shapes or configurations may be used, or portions of the rectangular prism may be omitted or cut out. The particular arrangement and configuration of the verticals (109) will generally depend on the manner in which the deck clips (101) are manufactured and cut, and the manner in which the deck clips (101) will be assembled into a clip strip (601).
[0044] In the depicted embodiments, each of the verticals (109) comprises a pair of opposing retaining elements (111). The depicted retaining elements (111) are disposed at the top side of the vertical (109), opposite the base (103), and protrude outwardly from opposing lateral sides of the verticals (109) in a direction opposite the base (103), causing the retaining elements (111) of the two verticals (109) to project in opposing directions. The depicted retaining elements (111) are generally in the configuration of an irregular trapezoidal prism, where the base of the trapezoid is connected to the vertical (109), a first side (113) of the trapezoid is angled downward, and the opposing second side of the trapezoid is roughly perpendicular to the base of the trapezoid. The first side (113) is oriented upwards, providing a sliding surface for installing plans, as described elsewhere herein. In the depicted embodiments, the second (bottom) side of the trapezoid comprises a hook (117). The depicted hook (117) points downward, which helps to retain and hold planks in place, as described elsewhere herein.
[0045] In the depicted embodiment of FIG. 1 and FIG. 2, the major planes of the retaining elements (111) are parallel to each other, and generally orthogonal to the major planes of the verticals (109), but in an alternative embodiment, one or more of the retaining elements (111) may be non-parallel with one or more others, and/or non-perpendicular to the vertical (109). In the depicted embodiment of FIG. 1 and FIG. 2, the retaining elements (111) are generally the size, shape, and configuration, but in an alternative embodiment, one or more of the retaining elements (111) may have a different size, shape, or configuration from the others. In the depicted embodiment of FIG. 1 and FIG. 2, the verticals (109) each have the same number of retaining elements (111), but in an alternative embodiment, one or more verticals (109) may have more or fewer than two retaining elements (111), and/or the number of retaining elements (111) may differ.
[0046] FIG. 3, FIG. 4, and FIG. 5 depict an alternative embodiment of the deck clip (101A) in which one vertical (109B) does not have retaining elements, but the other vertical (109A) does. This embodiment, known as a starter clip, may be disposed at one end of a clip strip to retain the first (or last) plank in an installation. This may result in a more attractive installation, allow for finishing carpentry, and prevent the hooks (117) or retaining elements (111) from protruding and causing damage, injury, or increasing the spacing between a decking board and the ribbon decking board (705).
[0047] One or more of the deck clips (101) and (101A) may be assembled into a clip strip (601) as shown in the exemplary embodiment of FIG. 6. The depicted clip strip (601) comprises a base element (603) and a spacer element (605). The depicted base element (601) is generally in the configuration of an elongated prism sized and shaped to be placed on a decking joist or beam. The depicted base element (603) is made of a compressible material, such as a foam. The spacer element is also generally in the configuration elongated prism, and comprises a plurality of apertures sized and shaped so that the verticals (109) and retaining elements (111) of a plurality of clips (101) and (101A) may pass through the apertures. The apertures are spaced at a predetermined distance about the width of the planks with which the system will be used. To assemble the clip strip (601), a plurality of clips (101) and (101A) are passed through the apertures and oriented so that the retaining elements (111) of adjacent clips (101) and (101A) extend towards each. The base element (103) is then installed on the bottom of the spacer element (605) to hold the clips (101) and (101A) in place. The assembled clip strip (601) may be rolled for easy storage, packaging, shipment, distribution, and deployment. An embodiment of a rolled clip strip (601) is also shown in FIG. 6. In an embodiment, the base element (103) may comprise a pair of opposing snap-on legs (607) sized and shaped to snap onto a decking joist (707), as shown in FIG. 7.
[0048] FIG. 7 depicts a method for installing and using the clip strip (601). In the depicted embodiment, the deck frame (701) is assembled. As will be familiar to a person of ordinary skill in the art, the direction of the framing joists (707) is perpendicular to that of the decking surface or planks (803), which are installed across multiple joists (707) for stability. One or more clip strips (601) are placed and installed on top of each deck joist (707). The clip strips (601) will generally have a starter clip (101A) at one end, followed by a sequence of regular clips (101). The clip strip (601) is installed by placing the end having the starter clip (101A) abutting the deck ribbon board (705). The spacing of the spacer element (605) then sets the proper spacing for all deck boards (803). The clip strips (601) may be cut to length if a shorter length is needed. This may be done, for example, by severing the spacer element (605) using a cutting tool commonly available at a construction site, such as a saw, scissors, knife, and so forth. The clip strip (601) may be installed by snapping it onto the joist (707), or by use of a fastener, such as hardware. In the depicted embodiment, hardware will be used in a later step, and the snap-on functionality of the legs (607) is sufficient to hold the clip strip (601) in place until the hardware is installed. Alternatively if legs (607) are not a part of the system, the base (603) could use an adhesive to temporarily hold the clip strips (601) to the joists (707) until the fasteners (805) may be affixed to secure the system (601) in place. Also, location holes (608), or mounting holes (608), may be present in the spacer strip (605) for installing such a fastener, and a fastener may be inserted through the location holes (608) to affix the strip to the joist. The fastener may be any suitable fastener for the material type and installation environment. In an embodiment, the clip strip (601) may be outfitted with other elements, such as lighting elements, heating elements, associated wiring for such elements, and/or mount points for other elements.
[0049] Once the clip strips (601) are installed, the deck planking (803) may be placed. The clips (101) and (101A) are designed for use with hidden fastener decking (803). Such decking comprises planks which have lateral channels (801) or recesses (801) disposed lengthwise on the planks (803) and sized and shaped to receive some or all of a retaining element (111). The decking (803) is installed by lowering the decking (803) between two adjacent clips (101) and (101A) until the retaining elements (111) snap into the recesses (801). As shown in FIG. 8, the flexibility of the verticals (109) and the sloped shape of the top side (113) of the retaining elements (111) facilitates passage of the decking (803), until the recess (801) is adjacent the retaining elements (111), which then snap into place in the recess (801). The hook (117) may also catch and hold material within the recess (801) to further secure the decking (803) and inhibit unwanted movement. That is, once the fastener (805) is installed, the hooks (117) can engage to apply downward retention, which reduces unwanted movement in the boards, and adds structural strength to inhibit upward movement, such as from uplift stress, which could lead to board disengagement.
[0050] Finally, a fastener (805) may be used to affix the clips (101) and (101A) to the joist by driving the fastener through the aperture (115). Where a piece of decking (803) is used or needed which does not have a recess, a starter clip (101A) may be used, as shown in FIG. 8.
[0051] The deck clips (101) can generally be made from sheet metal on a press. The design may be press cut from a single sheet of material and the verticals (109) and retaining elements (111) can be bent into final position. As seen in the figures, rounded cutaways are present near the rotation points of the material to accommodate this bending and reduce material damage or breakage. The particular dimensions and shapes of the various elements of the deck clips (101) may vary based on this manufacturing process. For example, it is desirable to minimize material waste, and the flat layout of the deck clip (101) may select element sizes and shapes to maximize cost-effective use of raw materials, or to accommodate the limitations or requirements of presses or other manufacturing equipment.
[0052] The particular dimensions and configuration of the clips (101) and (101A) may vary from embodiment to embodiment depending on the decking (803) with which the clips (101) and (101A) will be used. For example, as can be seen in the FIGs, the height of the verticals (109) will be sufficient to cause the bottom of the retaining elements (111) to reach the recesses (801) when the bottom of the decking (803) is adjacent the joists (707). This should preferably be a snug fit that allows only minimal perceptible vertical movement of the decking (803) off the joists (707), in accordance with prevailing construction standards, practices, and conventions for decking (803). Likewise, it should be noted that the distance between the verticals (109) (i.e., in the depicted embodiments, the height of the crossbar (105) portion of the base (103)) is effectively the amount of spacing between planks (803). The amount of this spacing may vary depending on various factors, such as the needs of the particular deck project, minimum or maximum spacing requirements under applicable building or construction codes or other laws, or under prevailing standards or conventions to allow (among other things) sufficient thermal expansion and contraction and to minimize the risk of injury to people or animals atop the decking (803), and on the thickness and dimensions of the decking (803) with which the clip strip (601) will be used, as well as purely aesthetic considerations. This system also facilitates the removal of deck boards (803), such as a board is damaged, or if access is needed beneath the deck surface. In this case, the user would remove the fastener (805) and the decking (803) may then be pried out by moving the verticals (109) from a perpendicular orientation to that of an inward tilting position so individual deck boards (803) can be accessed.
[0053] By way of example and not limitation, FIG. 9 depicts an alternative embodiment of a deck clip (101B) for use in a clip strip (601) as described herein. In the depicted embodiment of FIG. 9, the clip (101B) comprises a generally rectangular base (103) having four verticals (109) extending therefrom, two on each of the long sides of the base (103). The verticals (109) also have retaining elements (111) formed by bending the vertical to reverse direction and proceed in a downward angle to form the general configuration of an inverted J-shape (e.g., giving the general impression of a candy cane, or shepherd's crook), and terminating in a hook (117) for engagement. As shown in FIG. 9, the two outermost verticals (109) face one direction, and the two innermost verticals (109) face the opposite direction. Though not shown, an embodiment of this configuration could have one set of verticals (109) with no retaining elements (111) as described elsewhere herein for use as a starter clip. This embodiment has various advantages, including that the verticals (109) are not disposed back-to-back of each other, which facilitates a narrower gap between deck boards (803) because the verticals (109) do not flex into another opposing vertical. Further, because there are two verticals (109) per deck board (803) in this configuration, the installation has increased engagement with the groove (801) over the length of the board. This may be particularly useful where a plurality of deck boards (803) are abutted to each other (e.g., end-to-end), as it facilitates easier and stronger engagement with the hooks (117).
[0054] By way of example and not limitation, FIG. 10 depicts an alternative embodiment of a deck clip (101C) for use in a clip strip (601) as described herein. In the depicted embodiment of FIG. 10, the clip (101C) is similar in configuration to the clips (101) and (101A) of FIGS. 1-5, except that the legs (107) are not straight, rectangular prisms, but rather have an angled portion between the crossbar (105) and the tips of the legs (107), giving the legs (107) a bowed or arched appearance. This feature may be used to facilitate installation. As also shown in FIG. 10, this feature causes the elevation of the retaining elements (111) to be slightly higher than in a similar dimensioned embodiment with flat legs (107). When the decking (803) is installed and the retaining elements (111) snap into the recesses (801), the fastener (805) can be driven to attach the clip (101C) to the joist (707). The force of this installation will pull the base (103) to the joist (707), flattening the angle in the legs (107) and causing the retaining elements (111), already disposed within the recesses (801), to descend, creating more friction between the retaining elements (111) and the decking (803). The hooks (117) may dig or bite further into the material of the recesses (801), providing a more secure installation such that comprises a generally rectangular base (103) having four verticals (109) extending therefrom, two on each of the long sides of the base (103). The verticals (109) also have retaining elements (111) formed by bending the vertical to reverse direction and proceed in a downward angle, giving the general impression of a candy cane or shepherd's crook, and terminating in a hook (117) for engagement. As shown in FIG. 9, the two outermost verticals (109) face one direction, and the two innermost verticals (109) face the opposite direction. Though not shown, an embodiment of this configuration could have one set of verticals (109) with no retaining elements (111) as described elsewhere herein for use as a starter clip.
[0055] FIG. 11 depicts a further alternative embodiment in which the clip (101C) is an individual board clip comprised of opposing spring arms (109C) with engagement hooks (117C) at a distal end. In the depicted embodiment, the clips (101C) are attached to a joist using a joist mount (201) which causes the clips (101C) to be disposed offset from the joist, not disposed atop the joist, which allows for longer spring arms (109C). By staggering the installation on opposing sides of the joist as shown in FIG. 11, the clips (101C) are not adjacent to each other and the operation of the spring arms (109C) does not interfere with each other. In this embodiment, a deck board may be placed between two clips (101C) and the engagement hooks (117C) extend into the deck board groove to engage the deck board and hold it in place. As seen in FIG. 11, the joist mount (201) has corresponding interlocking structures on opposing ends to ensure proper spacing.
[0056] FIG. 12 depicts an embodiment in which a clip strip has an illuminating element, allowing the clip strips to be lit and for light to project through the gap between deck boards. Alternatively, or additionally, the clip strip may comprise a heating element or other decorative or functional element, and the associated wiring to operate such elements. By way of example and not limitation, the clip strips may be operably connected to a controller with a wireless transmitter which can connect to a network to communicate with a computer to allow remote control of the features via, for example, a remote, or a device application, or which can directly communicate via a wireless protocol, such as BlueTooth.
[0057] Throughout this disclosure, geometric terms may be used to characterize, among other things, sizes, shapes, dimensions, angles, distances, and relationships. These terms may be used with qualifiers such as generally, about, and approximately. One of ordinary skill in the art will understand that, in the context of this disclosure, these terms are used to describe a recognizable attempt to conform a device or component to the qualified term. By way of example and not limitation, components described as being generally coplanar will be recognized by one of ordinary skill in the art to not be actually coplanar in a strict geometric sense because a plane is a purely geometric construct that does not actually exist and no component is truly planer, nor are two components ever truly coplanar. Variations from geometric descriptions are unavoidable due to, among other things, manufacturing tolerances resulting in shape variations, defects, imperfections, non-uniform thermal expansion, natural wear, minor variations that are nevertheless recognizable as the qualified term, and other deformations. One of ordinary skill in the art will understand how to apply geometric terms, whether or not qualified by relative terms such as generally, about, and approximately, to describe a reasonable range of variations from the literal geometric term in view of these and other considerations appropriate to the context. Additionally, the use of the conjunctive and disjunctive should not necessarily be construed as limiting, and the conjunctive may include the disjunctive, and vice versa.
[0058] While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.
