Hidden Deck Fastener

Abstract

A fastener used to attach adjacent, parallel boards to a transverse support structure such as in a deck, dock or similar structure. The fastener consists of two sides that are generally perpendicular to each other. One side is longer with respect to the other resulting in tabs extending out on opposite ends of the fastener. The short side of the fastener is attached to the underside of a board. The board is then turned upright and placed into position. One of the tabs is attached to the support structure. The other tab extends under, and is held down by, a previously installed board.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 60/901,493 filed on Feb. 14, 2007 and is hereby incorporated by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

REFERENCE TO SEQUENCE LISTING A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

[0003] Not Applicable

BACKGROUND OF THE INVENTION

[0004] The present invention relates to devices for fastening boards to supporting structures and more particularly to a fastener for securing adjoining boards to a common sub-structural element such as a joist.

[0005] Conventional decks typically include horizontal floors raised above the ground and supported by an underlying support structure. Decks are often attached to adjacent residential or commercial buildings. Deck boards are placed side by side during construction of a deck, and are typically arranged to cross the support structures, such as joints at an angle perpendicular to the longitudinal axis of the joist. Other structures utilizing similar flooring techniques include boat docks, ramps, stairs, landings, bridges, platforms and for structures for surrounding or enclosing swimming pools and hot tubs.

[0006] Typically, decks are constructed to withstand exposure to the elements and are often constructed from pressure treated wood or, more recently, plastic or composite material. Whether the deck boards, which form the flooring of the deck are comprised of wood, plastic, composite or other material, the support structure is typically formed of commonly available pressure treated lumber. The support structure is formed with joist and headers attached to posts. The deck boards are typically transversely fixed across the joist to the support structure, in a generally parallel relationship, by way of nails or screws, driven through the upper surface of the deck board into the joist below.

[0007] This manner of attaching deck boards to the support structure presents several disadvantages. If nails or screws are used, they typically cause discoloration of the surrounding wood surface over time. In addition, in driving the nail through the board, the surface of the board is often marred during hammering, causing unsightly dents and scratches to the top surface of the board. When using screws it is often necessary to drill a pilot hole to prevent the boards from splitting. This adds to the amount of time and labor that is needed to install the deck boards. Over time, nails and screws can work themselves loose from the board, projecting upward from the board's surface. Not only is this aesthetically unpleasing, it causes the deck board to loosen against the joist and also constitutes a safety hazard, particularly to individuals walking over the deck surface barefoot. In addition, both nails and screws are unsightly and detract from the appearance of the deck.

[0008] Therefore, it is desirable to have a fastening device which overcomes the shortcomings of the prior art fasteners and which attaches boards to the support structure with an unmarked upper surface.

[0009] U.S. Pat. No. 4,965,980 (Leavens) discloses an anchoring bracket for use in attaching substantially parallel boards to a generally transverse member or joist. While the deck bracket of Leaven has certain advantages over the prior art, it also has a number of disadvantages. Of these, the major disadvantage is that it requires the operator to have access to a region below the deck to enable the fasteners to be inserted upwardly through the holes in the angled portion and then driven into the deck boards. Moreover, the board spacer tabs are at fixed modular distances and cannot easily accommodate variations in the width of the deck boards. Also, this type of fastener requires two people to install the deck, one person above the deck and one person below. In addition, this type of fastener is easily visible from above the surface of the deck.

[0010] U.S. Pat. No. 5,027,573 (Commins) describes a fastener that requires driving metal prongs into the sides of the deck boards. While this method can hold down deck boards its disadvantages are obvious. When driving the prongs into the sides of the boards the boards can split or crack. The prongs will create openings in the boards that allow water to enter which can cause the boards to decay or crack. Also, this type of fastener does not allow the gap between adjacent boards to be adjusted based on choice of deck materials or personal preference. In addition, this type of fastener is easily visible from above the surface of the deck.

[0011] U.S. Pat. No. 4,844,651 (Partridge) describes a decking clip which attaches to the edge of a decking board and also on the under-surface thereof leaving an apertured lip projecting adjacent the lower surface of the board. These clips must be pre-attached to a deck board on both edges thereof with clips along one edge aligned with spaced joists and clips along the opposite edge misaligned with the joists. Boards are secured to the joists by engaging the misaligned lips under a board fixed to the joists and securing the opposite side of the board to the joists with fasteners extending through the apertured lips. Although effective for their purpose, these clips are expensive in that two rows of clips are required and otherwise are time consuming to attach. In addition, this type of fastener is easily visible from above the surface of the deck.

[0012] U.S. Pat. No. 6,851,884 (Eberle) describes a method of attachment that requires the cutting of a slot into the sides of the boards using a biscuit jointer or the like. The board is then held down with a small piece of plastic or metal that is screwed into the joist. This method of attachment has several disadvantages. Firstly, installation is a very labor intensive process. Secondly, the boards are held down by only a thin slice of material. This can result in failure of the attachment over time. Thirdly, the cut into the side of the deck board allows water to enter the board which can result in the decay or splitting of the board. Also, this type of fastener does not allow the gap between adjacent boards to be adjusted based on choice of deck materials or personal preference. In addition, this type of fastener is easily visible from above the surface of the deck.

[0013] U.S. Pat. No. 5,997,209 (Sachs) describes a fastener that requires the cutting of a slot into the sides of the boards using a biscuit jointer or the like. The board is then held down with a small piece of plastic or metal that is screwed into the joist. This method of attachment has several disadvantages. Firstly, installation is a very labor intensive process. Secondly, the boards are held down by only a thin slice of material. This can result in failure of the attachment over time. Thirdly, the cut into the side of the deck board allows water to enter the board which can result in the decay or splitting of the board. Also, this type of fastener does not allow the gap between adjacent boards to be adjusted based on choice of deck materials or personal preference. In addition, this type of fastener is easily visible from above the surface of the deck.

[0014] U.S. Pat. No. 6,416,269 (Martel) describes a fastener that requires driving metal prongs into the sides of the deck boards. While this method can hold down deck boards its disadvantages are obvious. When driving the prongs into the sides of the boards the boards can split or crack. The prongs will create openings in the boards that allow water to enter which can cause the boards to decay or crack. Also, this type of fastener does not allow the gap between adjacent boards to be adjusted based on choice of deck materials or personal preference. In addition, this type of fastener is easily visible from above the surface of the deck.

[0015] U.S. Pat. No. 6,810,633 (Harris Sr.) describes a fastener that requires the cutting of a slot into the sides of the boards using a biscuit jointer or the like. The board is then held down with a small piece of plastic or metal that is screwed into the joist. This method of attachment has several disadvantages. Firstly, installation is a very labor intensive process. Secondly, the boards are held down by only a thin slice of material. This can result in failure of the attachment over time. Thirdly, the cut into the side of the deck board allows water to enter the board which can result in the decay or splitting of the board. Also, this type of fastener does not allow the gap between adjacent boards to be adjusted based on choice of deck materials or personal preference. In addition, this type of fastener is easily visible from above the surface of the deck.

[0016] U.S. Pat. No. 5,775,048 (Orchard) describes a fastener that is attached first to the joists and then the deck boards are attached from underneath the deck by using toe nails or screws. This type of fastener requires access below the structure which is not always available. Also, this type of fastener requires two people to install the deck, one person above the deck and one person below. In addition, this type of fastener is easily visible from above the surface of the deck.

[0017] U.S. Pat. No. 6,299,400 (Tebo) describes a fastener that requires driving metal prongs into the side of the deck boards. While this method can hold down deck boards its disadvantages are obvious. When driving the prongs into the sides of the boards the boards can split or crack. The prongs will create openings in the boards that allow water to enter which can cause the boards to decay or crack. Also, this type of fastener does not allow the gap between adjacent boards to be adjusted based on choice of deck materials or personal preference. In addition, this type of fastener is easily visible from above the surface of the deck.

BRIEF SUMMARY OF THE INVENTION

[0018] It is an object of the present invention to provide a secure attachment of boards to transverse supporting members of a deck, dock, or other structure, without the use of visible fasteners.

[0019] It is yet another object of the present invention to eliminate the need to pre-drill or counter-sink screws to in order to attach the boards to the support structure.

[0020] It is also an object of the present invention to allow the boards to be installed while still allowing for an adjustable side gap between the boards.

[0021] It is also an object of the present invention to eliminate the need to penetrate either the sides, or the top, of the deck board.

[0022] It is also an object of the present invention to allow the boards to be installed from above the deck, or similar structure, by one person.

[0023] The board fastener of the present invention is attached first to the under-side of the board. The fastener has two protruding tabs that will extend outward from either side of the board. The board is then turned upright and placed into position with the proper side gap. When the board is installed, the rear tab of the fastener extends under, and is held down by, a previously installed board. The front tab is then attached to a joist using a screw, nail or staple. Whenever an obstruction may interfere with the attachment of the fastener (i.e. stringers, blocking, fascia boards, etc. . . . ) the fastener can be trimmed to enable attachment. The board fastener of the present invention allows one person to install all of the boards from above the surface of the structure without the fasteners being visible from above the surface of the structure.

[0024] It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto except insofar as such limitations are included in the following claims and allowable equivalents thereof.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0025] FIG. 1 is an isometric view of the fastener.

[0026] FIG. 2 is an isometric view of the fastener showing how it is attached to the underside of a board.

[0027] FIG. 3 illustrates how the fastener is used to attach the boards to the underlying support structure.

[0028] FIG. 4 illustrates the installation of a fastener that has been trimmed to allow for obstructions such as stringers, blocking, etc. . . .

DETAILED DESCRIPTION OF THE INVENTION

[0029] As shown in FIG. 1 the present invention is preferably comprised of a long side 1 joined perpendicularly to a short side 2. This results in two tabs 3, 4 that extend outward on either end. For the purpose of illustration, tab 3 will be considered the front tab and tab 4 will be considered the back tab. In actual use either tab can be considered the front tab with the other tab being the back tab. In most instances the fastener is attached to the board using a screw, nail or staple through penetrations 8 and 10. In most typical installations penetrations 5, 6 and 9 are not used. Penetration 7 is used in conjunction with a screw, nail or staple to attach the present invention to an underlying support structure as illustrated in FIG. 3.

[0030] As shown in FIG. 2 the fastener is attached to the underside of a board 11 using a screw, nail or staple (not shown) through penetrations 8 and 10 of the short side 2. The long side 1 extends perpendicularly to the board 11. Tabs 3 and 4 extend beyond the edges of the board

[0031] As shown in FIG. 3 the board 11 with the fastener attached is angled into proper position so that the back tab 4 will be located under a previously installed board 11. The side gap between the boards is set at the proper dimension. The front tab 3 is then attached to the support structure 12 with a screw, nail or staple (not shown) through penetration 7. The top edge 13 of the back tab 4 of each fastener is held down by a previously installed board 11.

[0032] As shown in FIG. 4 the fasteners can be trimmed to provide clearance for obstructions such as stringers, blocking, etc. A trimmed fastener is often used when installing the first and last boards. When trimmed, the short side 2 of the fastener is attached to a board 11 using penetrations 9 and 10. Penetration 6 is used to attach the long side 1 to the support structure. The front tab 3 is then attached to the support structure using penetration 7.

Claims

1. A fastening device for securing boards to a support structure, said fastening device comprising: a first side joined to a second side, said sides having a predetermined shape extending generally perpendicularly from a longitudinal axis of said fastening device at the juncture of said sides.

2. The fastening device of claim 1 wherein said first side has a plurality of penetrations.

3. The fastening device of claim 1 wherein said second side has a plurality of penetrations.

4. The fastening device of claim 1 wherein said sides have sufficient rigidity to resist deformation during fastening.

5. The fastening device of claim 1 wherein said fastening device is formed from corrosion resistant material.

6. A fastening device for securing boards to a support structure, said fastening device comprising: a first side joined to a second side, said sides having a predetermined shape extending generally perpendicularly from a longitudinal axis of said fastening device at the juncture of said sides, said first side being longer with respect to said second side and extending lengthwise beyond said second side at either end, resulting in two tabs, one on either end of said fastening device.

7. The fastening device of claim 6 where said tabs of said first side extend beyond the ends of said second side.

8. The fastening device of claim 6 where said tabs are comprised of a front tab and a back tab.

9. The fastening device of claim 6 wherein said back tab extends under a previously installed board.

10. The fastening device of claim 6 wherein said front tab is attached to said support structure.

11. A fastening device for securing boards to a support structure, said fastening device comprising: a first side joined to a second side, said sides having a predetermined shape extending generally perpendicularly from a longitudinal axis of said device at the juncture of said sides, said first side being longer than said second side, said first side extending lengthwise beyond ends of said second side.

12. The fastening device of claim 11 wherein said second side is attached to the under-side of a board.

13. The fastening device of claim 11 wherein said first side is attached to the said support structure.