DECK BOARD FASTENERS AND METHODS

Abstract

A clip for attaching decking. The clip includes a bottom and a removable top insert. The bottom is made of a first material. The top is made of a second material. The first material of the bottom is different than the second material of the top. The clip has a generally T shape in a side view with a central bore passing through the top member and the bottom member to receive a screw or other fastening member, and a plurality of apertures through the top surface of the bottom member that engage the top member. The body of the bottom member has a transverse planar upper member and at least one perpendicularly positioned planar lower member or keel. The deck board fastener can also have a lip that projects upward from the upper surface of the transverse planar member. The lip can be positioned about an exterior edge of the transverse planar member or along the upper surface.

Claims

1. A decking clip comprising: a body having a transverse upper member with an upper surface and a lower surface and a perpendicular member extending from the lower surface of the body with a central bore therethrough and one or more clip anchor apertures positioned about the central bore; and a clip having an upper surface and a lower surface, a central aperture therethrough, and two or more anchors positioned along at least one edge of the clip and extending downward away from the lower surface of the clip.

2. The decking clip of claim 1, wherein the body is formed of a first material and the clip is formed of a second material.

3. The decking clip of claim 1, wherein the decking clip has a generally T-shaped side view.

4. The decking clip of claim 1, wherein the transverse upper member has a shape selected from biscuit, bowtie, rectangular, and oval.

5. The decking clip of claim 1, wherein a first axis of the transverse upper member is longer than a second perpendicular axis of the transverse upper member.

6. The decking clip of claim 1 further comprising one or more stabilizers extending from the upper surface of the transverse upper member which are substantially perpendicular to a plane formed by the perpendicular member.

7. The decking clip of claim 1 further comprising a second perpendicular member extending from the lower surface of the body.

8. The decking clip of claim 1 wherein the perpendicular member extending from the lower surface of the body has a uniform thickness.

9. The decking clip of claim 1 wherein the perpendicular member extending from the lower surface of the body has a first thickness at a first end and a second thickness at a second end.

10. The decking clip of claim 1 wherein the perpendicular member extending from the lower surface of the body has a rounded first end and a rounded second end.

11. The decking clip of claim 1 further comprising a tubular member extending from the lower surface of the body along the length of the perpendicular member.

12. The decking clip of claim 1 further comprising a guide member extending from the lower surface of the body adjacent the perpendicular member and the central aperture.

13. A method of assembling a deck structure, the method comprising: providing a joist member; providing a plurality of deck boards, each having laterally opposing side edges with a groove therein arranged to span across the joist member parallel and laterally adjacent to one another and transversely to the longitudinal direction of the joist member; providing a plurality of mounting clips, wherein each mounting clip comprises a body having a transverse upper member with an upper surface and a lower surface and a perpendicular member extending from the lower surface of the body with a central bore therethrough and one or more clip anchor apertures positioned about the central bore, and a clip having an upper surface and a lower surface, a central aperture therethrough, and two or more anchors positioned along at least one edge of the clip and extending downward away from the upper surface of the clip; positioning a portion of the transverse upper member in the groove in the board; and securing the deck clip to the joist by passing a fastening device through the clip aperture and the central aperture.

14. The method of claim 13, wherein the body of the decking clip is formed of a first material and the clip is formed of a second material.

15. The method of claim 13, wherein the decking clip has a generally T-shaped side view.

16. The method of claim 13, wherein the transverse upper member of the decking clip has a shape selected from biscuit, bowtie, rectangular, and oval.

17. The method of claim 13, wherein a first axis of the transverse upper member of the decking clip is longer than a second perpendicular axis of the transverse upper member of the decking clip.

18. The method of claim 13 wherein the decking clip further comprises one or more stabilizers extending from the upper surface of the transverse upper member which are substantially perpendicular to a plane formed by the perpendicular member.

19. The method of claim 13 wherein the decking clip further comprises a second perpendicular member extending from the lower surface of the body.

20. The method of claim 13 wherein the perpendicular member of the decking clip extending from the lower surface of the body has a uniform thickness.

21. The method of claim 13 wherein the perpendicular member of the decking clip extending from the lower surface of the body has a first thickness at a first end and a second thickness at a second end.

22. The method of claim 13 wherein the perpendicular member extending from the lower surface of the body has a rounded first end and a rounded second end.

23. The method of claim 13 the decking clip further comprises a tubular member extending from the lower surface of the body along the length of the perpendicular member.

24. The method of claim 13 the decking clip further comprises a guide member extending from the lower surface of the body adjacent the perpendicular member and the central aperture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:

[0024] FIGS. 1A-I illustrate a configuration for a deck board fastening device;

[0025] FIGS. 2A-E illustrate another configuration for a deck board fastening device;

[0026] FIGS. 3A-D illustrate another configuration for a deck board fastening device;

[0027] FIGS. 4A-D illustrate another configuration for a deck board fastening device;

[0028] FIGS. 5A-C illustrate a clip;

[0029] FIGS. 6A-B illustrate a deck board fastening device with an anchoring device; and

[0030] FIGS. 7A-B illustrate a deck board fastening device with an anchoring device.

DETAILED DESCRIPTION

[0031] FIGS. 1A-I illustrate a configuration for a deck board fastening device 100. The deck board fastening device 100 has a clip 110 and a deck board fastening device body 130. The clip 110 has a plate 112 with a planar upper surface 114 and a lower surface 116 and a clip aperture 118 positioned through the plate 112. Two or more clip anchors 120, 120′ can extend from the plate 112. The two or more clip anchors 120, 120′ can be integrally formed with the plate 112 such that one or more of the two or more anchors can be part of the clip 110 or can be formed such that the clip 110 operates as a single piece even where the one or more of the two or more clip anchors 120, 120′ are formed from a separate piece which is adhered to the plate 112. The one or more clip anchors 120, 120′ can have a notch 122 on one or both sides of each of the two or more clip anchors 120, 120′. The notch 122 is configured to secure the clip anchor 120 through an anchor receiving aperture 148 in the transverse upper member.

[0032] As an example, the planar upper surface 114 of the clip 110 can have a dimension of from 0.45 to 0.70 inches in a first dimension, 0.65 to 0.85 inches in a second dimension and a thickness of from 0.02 inches to 0.04 inches, more preferably about 0.51 inches in a first dimension, about 0.75 inches in a second dimension and a thickness of 0.03 inches. The clip aperture 118 in the plate 112 can have an oval shape which is 0.44 inches in a first dimension and 0.155 inches in a second dimension. The clip anchors 120, 120′ can extend laterally from the planar upper surface 114 before translating perpendicularly, or substantially perpendicularly, away from the planar upper surface 114. Thus, the width of the clip 110 at a location where an clip anchor 120 extends from both sides of the planar upper surface 114 can be from 0.55 inches to 0.65 inches, while the width of the clip 110 at a location where two anchors extend on either side can be for example, from 0.62 inches to 0.59 inches. The length of the clip anchor 120 from the top of the planar upper surface 114 can be from 0.10 inches to 0.20 inches, more preferably about 0.14 inches. The distance between a first clip anchor 120 and a second clip anchor 120′ on opposing sides of the planar upper surface 114 can be from 0.50 inches to 0.60 inches, more preferably about 0.51 inches. The distance between two clips on the same side of the planar upper surface 114 can be from 0.10 inch to 0.20 inch, more preferably about 0.156 inch.

[0033] In some configurations, the clip anchor 120 is a plate that fits within a recess on a transverse upper member 140. Two or more apertures can be provided to secure the clip anchor 120 to the transverse upper member 140, where, for example, a post extends from the upper surface of the transverse upper member 140.

[0034] Suitable materials for the plate include, but are not limited to metal, exterior grade metal, and stainless steel. However, other materials may be used without departing from the scope of the disclosure. Typically the hardness of the material comprising the clip 110 is greater than the hardness of the material comprising the deck board fastening device body 130.

[0035] The deck board fastening device body 130 can have a transverse upper member 140 and at least one perpendicularly positioned lower member 160, or keel, which extends perpendicularly from a lower surface 144 of the transverse upper member 140. The transverse upper member 140 has an upper surface 142 and a lower surface 144. The shape of the transverse upper member 140 can be biscuit-shaped with two curved opposing sides forming an arc from a top view. The arcs can have predetermined radii and arc lengths. The arced side can terminate at an end wall at either end. Two or more anchor receiving apertures 148, 148′ can be provided to receive the two or more clip anchors 120, 120′ from the clip 110. The anchors can pass completely through the two or more anchor receiving apertures 148, 148′, or be received into the aperture without passing through the entire transverse upper member 140.

[0036] The transverse upper member 140 can have a variety of shapes in a first plane including, for example, oval, biscuit, square, rectangular, or bowtie. As illustrated in FIG. 1, the transverse upper member 140 has a biscuit shape. A virtual centerline passes along a length of the transverse upper member 140.

[0037] A lip 150 can extend upward from the upper surface 142 of the transverse upper member 140. The lip 150 can be positioned at or near a side wall 146 of the transverse upper member 140 as illustrated, or on the upper surface 142 such that the lip 150 is positioned around a perimeter of a the plate 112 retaining area of the clip 110. Additionally, one or more stabilizers 152 can be provided along the transverse upper member 140 which are positioned perpendicular, or substantially perpendicular, to a plane formed by the perpendicularly positioned lower member 160 and a plane formed by the transverse upper member 140. The height of the lip 150 from the upper surface 142 of the transverse upper member 140 can correspond to the thickness of the plate 112 of the clip 110. Where the height of the lip 150 corresponds to the thickness of the plate 112, the upper surface of the lip 150 and the upper surface of the plate 112, when engaging the deck board fastening device body 130, would be positioned in the same plane. In other configurations, the height of the lip 150 from the upper surface 142 of the transverse upper member 140 can be greater or less than the thickness of the plate 112 of the clip 110 without departing from the scope of the disclosure. By correlating the height of the lip 150 to the thickness of the clip 110, during use the lip 150 will prevent the clip 110 from being damaged or inadvertently removed. A central aperture 143 corresponding at least partially to the clip aperture 118 passes through the transverse upper member 140.

[0038] The transverse upper member 140 of the deck board fastening device body 130 can have a first dimension of from 2.0 inches to 2.5 inches, a second dimension of 0.8 inches to 1.1 inches and a thickness of from 0.10 inches to 0.20 inches; more preferably a first dimension of about 2.3 inches, a second dimension of about 0.97 inches, and a thickness of about 0.15 inches. Two sides can be arced, terminating in an end having a length of from 0.90 inches to 1.10 inches, more preferably about 0.10 inches. The perpendicularly positioned lower member 160 can have a height of from the top of the transverse upper member 140 to the lower surface 163 of the perpendicularly positioned lower member 160 of from 0.35 inches to 0.45 inches, and more preferably about 0.40 inches.

[0039] As shown in FIGS. 1A-B the clip 110 is positioned above the deck board fastening device body 130 from an upper perspective view. FIG. 1C illustrates the deck board fastening device 100 with the clip 110 engaging the deck board fastening device body 130 with the clip anchor 120 passing through the anchor receiving aperture 148 so that the lower surface of the clip is adjacent the upper surface of the transverse upper member 140 of the deck board fastening device body 130.

[0040] FIG. 1D is a perspective view of a bottom surface of the deck board fastening device 100. The clip anchors 120 can be seen passing through an anchor receiving aperture 148. As will be appreciated by those skilled in the art, the anchor receiving aperture 148 need not pass entirely through the transverse upper member 140 of the deck board fastening device body 130, provided the anchor receiving aperture 148 is configured to engage the clip anchor 120 extending from the clip 110. Additionally, the perpendicularly positioned lower member 160 can have a guide member 162 which extends from the bottom surface of the deck board fastening device body 130 and engages the perpendicularly positioned lower member 160 on one end of the guide member 162. FIG. 1E is a side view of a deck board fastening device 100 showing the transverse upper member 140 and the perpendicularly positioned lower member 160.

[0041] FIG. 1F is a top plan view of a deck board fastening device 100 with the clip 110 engaging the deck board fastening device body 130. FIG. 1G is a cross-section of the deck board fastening device 100 shown in FIG. 1F along the lines G-G.

[0042] FIG. 111 is a cross-section of the deck board fastening device 100 shown in FIG. 1F along the lines H-H.

[0043] FIG. 1I is a cross-section of the deck board fastening device 100 shown in FIG. 1F along the lines I-I.

[0044] Suitable materials for the deck board fastening device body 130 include, but are not limited to plastic, polyvinylchloride (PVC), acrylic, polycarbonate, and composites thereof. However, other materials may be used without departing from the scope of the disclosure.

[0045] FIGS. 2A-E illustrate another configuration for a deck board fastening device 200. The clip 210 and deck board fastening device body 230 are configured similarly to the deck board fastening device 100 shown in FIG. 1. The perpendicularly positioned lower member 260, or keel, of the deck board fastening device 200 has one or more tubular ends 264, 266 extending from the lower surface 244 of the transverse upper member 240. The diameter across the tubular ends 264, 266 from the exterior surface is from 0.125 inches to 0.3125 inches, more preferably about 0.250 inches. The tubular ends 264, 266 can further be configured to define a hollowed tubular center 268 having a diameter between 0.06 inches and 0.08 inches, more preferably about 0.077 inches.

[0046] FIGS. 3A-D illustrate another configuration for a deck board fastening device 300. The clip 310 has a deck board fastening device body 330 with a transverse planar member 340. This configuration illustrates two perpendicularly positioned lower members 360, 360′, or keels, of the deck board fastening device 300 which extend from the lower surface 344 of the transverse upper member 340. The lower members can be rectangular in shape or have a stepped rectangular shape with a length and a height and a first width at a first end and a second width at a second end that is different than the first width. As illustrated, the first width is narrower at a first end near a center point of the transverse planar member 340 and the second width, greater than the first width, is wider at a second end that is an opposing second end of the lower member 360, 360′.

[0047] FIGS. 4A-D illustrate another configuration for a deck board fastening device 400. The clip 410 has a deck board fastening device body 430 with a transverse planar member 440. This configuration illustrates a perpendicularly positioned lower member 460, or keels, of the deck board fastening device 400 which extend from the lower surface 444 of the transverse upper member 440. The lower member 460 can have one or more tubular ends 464, 466 extending from the lower surface 444 of the transverse upper member 440 and forming part of the lower member 460. A central tubular member 465 can be provided with an aperture therethrough to receive an anchoring device through the transverse planar member 440 and clip 410. The tubular ends 464, 466 can further be configured to define a hollowed tubular center 468. The thickness of the tubular ends 464, 466 defining the hollowed tubular center 468 can vary. Changes in thickness can impact a compressibility of the tubular ends when the deck board fastening device is positioned between two deck boards.

[0048] FIGS. 5A-C illustrate a clip 510 for use in combination with the deck board fastening devices disclosed herein. The clip 510 is shown from a top view, perspective view and side view. The clip 510 has a plate 512 with a planar upper surface 514 and a lower surface 516 and a clip aperture 518 positioned through the plate 512. Two or more clip anchors 520, 520′ can extend from the plate 512. The two or more clip anchors 520, 520′ can be integrally formed with the plate 512 such that one or more of the two or more anchors can be part of the clip 510 or can be formed such that the clip 510 operates as a single piece even where the one or more of the two or more clip anchors 520, 520′ are formed from a separate piece which is adhered to the plate 512. The one or more clip anchors 520, 520′ can have a notch 522 on one or both sides of each of the two or more clip anchors 520, 520′. The notch 522 is configured to secure the clip anchor 520 to the fastening device.

[0049] FIGS. 6A-B illustrate a deck board fastening device 100 of FIG. 1 with an anchoring device 500 such as a screw. As illustrated the anchoring device 600 passes through the clip aperture 118 and the central aperture at an angle. As shown in FIG. 6B the anchoring device 600 passes across a surface of the guide member 162 which guides the angle at which the anchoring device 600 passes through the deck board fastening device 100 and into a joist (not shown).

[0050] FIGS. 7A-B illustrate a deck board fastening device 200 of FIG. 2 with an anchoring device 700. As illustrated the anchoring device 700 passes through the clip aperture 218 and the central aperture 243 at an angle. As shown in FIG. 7B the anchoring device 700 passes across a surface of the guide member 262 which guides the angle at which the anchoring device 700 passes through the deck board fastening device 200 and into a joist (not shown).

[0051] A suitable method for making the anchoring device described above, includes the steps of: placing a starting piece into a stamping machine; stamping one or more clips from the starting plate and forming the starting plate into a clip of either the configuration shown in FIG. 1 or FIG. 5. Additionally a plurality of suitable apertures are stamped into the one or more clips, wherein each aperture has a lower portion communicating with an upper portion. A central aperture is also stamped through the starting piece. Additionally, the apertures in the starting piece can be configured so that the through bore is wider at an upper surface diameter than the lower surface diameter. As will be appreciated by those of skill in the art, the order of stamping the starting pieces to form the clips can be, for example, to stamp the central aperture and the secondary apertures first and then stamp the overall shape of the plate; or stamp the plate first and then stamp the central aperture and secondary apertures through the plate.

[0052] The device body can be made by injecting an injectable material into an injection molding machine to form one or more anchoring devices.

[0053] Kits are also contemplated which include one or more anchoring devices. The one or more anchoring devices may be releasably connected such that the anchoring devices are separated during the installation process. Additionally fasteners may be provided as part of the kit. In some configurations, a fastener is positioned through each central aperture of a provided anchoring device.

[0054] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.