U.S. patent application number 12/132110 was filed with the patent office on 2009-11-19 for panelling system primarily for decking.
Invention is credited to Kelly Gibson, Len Hoard.
Application Number | 20090282771 12/132110 |
Document ID | / |
Family ID | 39671611 |
Filed Date | 2009-11-19 |
United States Patent
Application |
20090282771 |
Kind Code |
A1 |
Gibson; Kelly ; et
al. |
November 19, 2009 |
PANELLING SYSTEM PRIMARILY FOR DECKING
Abstract
A panelling system for decks has a series of panels each formed
from main strips arranged side edge to side edge and cut to a
common length with a groove along each side. A plurality of
fasteners extend into facing grooves to hold the strips together
and also have a hole to be screwed to a support. At two of the four
sides of the main panel are attached divider strips formed also
from the same deck planks and fastened together using the same
fasteners in the grooves to form a common panel member for
transportation and installation. The panels are laid on top of
strapping carried at right angles to supporting joists so that the
ends of the main planks are supported by two parallel strapping
pieces with an additional one in the center. The fasteners also
project beyond the panel edge to connect the panels together.
Inventors: |
Gibson; Kelly; (Keewatin,
CA) ; Hoard; Len; (Winnipeg, CA) |
Correspondence
Address: |
ADE & COMPANY INC.
2157 Henderson Highway
WINNIPEG
MB
R2G1P9
CA
|
Family ID: |
39671611 |
Appl. No.: |
12/132110 |
Filed: |
June 3, 2008 |
Current U.S.
Class: |
52/592.1 ;
52/589.1 |
Current CPC
Class: |
E04F 15/02 20130101;
E04F 2201/05 20130101; E04F 15/04 20130101 |
Class at
Publication: |
52/592.1 ;
52/589.1 |
International
Class: |
E04B 5/43 20060101
E04B005/43 |
Foreign Application Data
Date |
Code |
Application Number |
May 14, 2008 |
CA |
2628801 |
Claims
1. A panelling system comprising: a plurality of deck panel members
for locating on a supporting structure generally edge to edge in an
array to at least partly cover the supporting surface; each deck
panel member having a front surface for defining an exposed surface
of the panelling system, a rear surface for engaging the supporting
structure and four side edges; each deck panel member comprising a
plurality of strips arranged side edge to side edge to form a panel
body with the side edges adjacent but spaced from one another; a
side edge of each strip which faces a corresponding side edge of a
next adjacent strip having a groove therealong recessed into the
side edge so that the grooves of two of the strips face one another
at the side edges; the side edges of the strips being connected by
at least one fastener member which includes two end portions each
inserted into a respective one of the grooves and a bridging
portion holding the side edges at a predetermined spacing; each end
portion having an attachment into the groove of the respective
strip with the attachment arranged to hold the strips fastened
together as a common panel member separate from the supporting
structure during transportation and installation.
2. The panelling system according to claim 1 wherein each end
portion comprises a flat plate portion inserted into the groove and
extending partly along the groove.
3. The panelling system according to claim 1 wherein each end
portion butts against a bottom of the groove.
4. The panelling system according to claim 1 wherein there is
provided on the bridging portion a shoulder for engaging the end
face of one of the strips for holding the strip at a predetermined
location.
5. The panelling system according to claim 1 wherein the bridging
portion is recessed from the front and rear surfaces.
6. The panelling system according to claim 1 wherein the attachment
of the end portions to the groove is effected by insert members
engaged through the strip and across the groove.
7. The panelling system according to claim 1 wherein the attachment
of an end portion to the respective groove is effected by barb
members on the end portion engaging side walls of the groove.
8. The panelling system according to claim 7 wherein the end
portion includes first barb members extending parallel to the
bridging portion and second barb members extending at right angles
to the bridging portion so as to hold the end portion in the groove
against movement relative to the groove in two directions.
9. The panelling system according to any one of claims 1 wherein
the bridging portion includes a hole for receiving a fastening
screw engaging from the fastener member to the supporting structure
to hold the panel on the supporting structure.
10. The panelling system according to claim 1 wherein two parallel
ones of the strips with a space therebetween have ends thereof
which face a corresponding side edge of a next adjacent strip with
a space therebetween; the side edge of said next adjacent strip
having a groove therealong recessed into the side edge; the side
edges of each of said two parallel ones of the strips having a
groove therealong recessed into the side edge such that the grooves
of two facing side edges of the two parallel strips are facing
grooves; and at least one fastener member connecting the ends of
the two parallel strips to the next adjacent strip, which fastener
member includes two end portions with one end portion inserted into
the groove of the next adjacent strip and one end portion inserted
into the facing grooves of the two parallel strips with a part of
the end portion bridging the space between the two parallel end
strips.
11. The panelling system according to claim 1 wherein there are a
plurality of the fastener members each arranged to connect at least
two of the strips together and wherein at least some of the
fastener members have portions thereof extending beyond the panel
member for engaging and fastening to a next adjacent panel
member.
12. The panelling system according to claim 1 wherein each panel
has a plurality of main strips defining a panel portion having four
sides including a first pair of parallel sides and a second pair of
parallel sides, a first dividing strip along one of the first
parallel sides and a second dividing strip along an opposed one of
the first parallel sides.
13. The panelling system according to claim 12 wherein each of the
main strips has along at least one side thereof three of the
fastener members with one at each end and one in the center.
14. The panelling system according to claim 12 wherein there are
provided some panels where the main strips are parallel to the
dividing strips and some panels where the main strips are at right
angles to the dividing strips.
15. The panelling system according to claim 12 wherein each of the
dividing strips of each panel member includes a portion projecting
beyond the main strips of the respective panel member such that,
when four of the panel members are assembled into the system with
the main strips of one panel member at right angles to the main
strips of each next adjacent panel and with one of the dividing
strips between the main strips of each panel member and the next so
as to form a rectangular area at a junction between corners of the
main strips of the four of the panels; the rectangular area defined
at the junction between said four of the panels is filled by said
portion of said at least one dividing strip.
16. The panelling system according to claim 12 wherein the
supporting structure comprises a plurality of parallel joists and
strapping pieces over the joists at right angles to the joists and
wherein each of the main strips lies at right angles to the
strapping pieces and is supported at each end by a respective one
of two end strapping pieces.
17. The panelling system according to claim 16 wherein there is
provided an additional strapping piece in the center between the
end strapping pieces.
18. The panelling system according to claim 16 wherein the dividing
strips bridge an end strapping piece of one panel and an end
strapping piece of a next adjacent panel.
19. The panelling system according to claim 16 wherein all the main
strips of all the panels extend in same direction.
20. A panelling system comprising: a plurality of panel members for
locating on a supporting structure generally edge to edge in an
array to at least partly cover the supporting surface; each panel
member having a front surface for defining an exposed surface of
the panelling system, a rear surface for engaging the supporting
structure and four side edges; each panel member comprising a
plurality of strips arranged side edge to side edge to form a panel
body with the side edges adjacent but spaced from one another;
wherein there are a plurality of fastener members each arranged to
connect at least two of the strips together; and wherein at least
some of the fastener members have portions thereof extending beyond
the panel member for engaging and fastening to a next adjacent
panel member.
21. The panelling system according to claim 20 wherein the fastener
members include a hole for screw fastening of the fastener member
to the supporting structure.
22. The panelling system according to claim 20 wherein each panel
has a plurality of main strips defining a panel portion having four
sides including a first pair of parallel sides and a second pair of
parallel sides, a first dividing strip along one of the first
parallel sides and a second dividing strip along an opposed one of
the first parallel sides.
23. The panelling system according to claim 22 wherein each of the
main strips has along at least one side thereof three of the
fastener members with one at each end and one in the center.
24. The panelling system according to claim 22 wherein there are
provided some panels where the main strips are parallel to the
dividing strips and some panels where the main strips are at right
angles to the dividing strips.
25. A panelling system comprising: a plurality of panel members for
locating on a supporting structure generally edge to edge in an
array to at least partly cover the supporting surface; each panel
member having a front surface for defining an exposed surface of
the panelling system, a rear surface for engaging the supporting
structure and four side edges; each panel member comprising a
plurality of strips arranged side edge to side edge to form a panel
body with the side edges adjacent but spaced from one another;
wherein each panel has a plurality of main strips defining a panel
portion having four sides including a first pair of parallel sides
and a second pair of parallel sides, a first dividing strip along
one of the first parallel sides and a second dividing strip along
an opposed one of the first parallel sides; wherein the supporting
structure comprises a plurality of parallel joists and strapping
pieces over the joists at right angles to the joists; and wherein
each of the main strips lies at right angles to the strapping
pieces and is supported at each end by a respective one of two end
strapping pieces.
26. The panelling system according to claim 25 wherein there are
provided some panels where the main strips are parallel to the
dividing strips and some panels where the main strips are at right
angles to the dividing strips.
27. The panelling system according to claim 25 wherein there is
provided an additional strapping piece in the center between the
end strapping pieces.
28. The panelling system according to claim 25 wherein the dividing
strips bridge an end strapping piece of one panel and an end
strapping piece of a next adjacent panel.
29. The panelling system according to claim 25 wherein all the main
strips of all the panels extend in same direction.
Description
[0001] This invention relates to a panelling system defined by a
plurality of inter-engaging panels. The system is primarily
designed for decking. The system is primarily designed for use with
panels formed of wood or wood composite material but other
materials can be used either to form the entire panel or a part of
the panel.
BACKGROUND OF THE INVENTION
[0002] Various techniques have been proposed for the manufacture of
wood decking. Conventionally wood decking is formed side by side
planks which are laid over a sub-frame typically of parallel joists
and arranged with spaces between the side edges for expansion and
drainage. This construction is time consuming and relatively
inaccurate so that gaps can be uneven leading to an unattractive
appearance.
[0003] In published US Patent Application 2006/0076394 published
Apr. 13, 2006 and in corresponding Canadian Application Serial No:
2,525,516 originally published Mar. 4, 2005 of Kelly Gibson, one of
the inventors herein, is disclosed a panelling system primarily for
flooring which is formed from a plurality of wood floor panel
members defined by a rectangular panel formed of wood and along two
opposed side edges a decorative dividing strip extending along the
length of the side edge and having a top surface of the strip lying
in a common plane with the upper surface of the panel with the
other opposed side edges of the panel being exposed for butting
directly against a next adjacent panel. The dividing strips project
beyond an end of the side edge and are cut at 45 degrees to form a
pointed portion having an apex at a position mid way through the
thickness of the dividing strip such that four dividing strips,
when the panels are laid on the floor, meet at the junction between
four of the panels with the apexes in contact at a center of the
rectangular area at the junction. This arrangement as disclosed was
proposed for use with rectangular panels of solid wood or for deck
strips and as such was not suitable for high quality interior
flooring. The disclosure of this published application is
incorporated herein by reference.
[0004] Recently decking planks formed from wood composite materials
have become available where the planks have grooves along the side
edges and are fastened to the joists of the sub-frame and held at
required spacing by fasteners in the form approximately shown in
U.S. Design Pat. No. 427,050 (Bryan) issued Jun. 27, 2000. These
are in the form of a square insert plate which inserts into the
facing grooves of two of the planks with a leg between the planks
which extends down toward the sub-frame with a hole in the leg so
that the leg can be screwed down onto a joist. The decking is
supplied as a series of planks which are cut and assembled on site
with a collection of the fasteners which are inserted on site and
screwed into position.
SUMMARY OF THE INVENTION
[0005] It is one object of the invention to provide a panelling
system primarily for decking.
[0006] According to one aspect of the invention there is provided a
panelling system comprising:
[0007] a plurality of deck panel members for locating on a
supporting structure generally edge to edge in an array to at least
partly cover the supporting surface;
[0008] each deck panel member having a front surface for defining
an exposed surface of the panelling system, a rear surface for
engaging the supporting structure and four side edges;
[0009] each deck panel member comprising a plurality of strips
arranged side edge to side edge to form a panel body with the side
edges adjacent but spaced from one another;
[0010] a side edge of each strip which faces a corresponding side
edge of a next adjacent strip having a groove therealong recessed
into the side edge so that the grooves of two of the strips face
one another at the side edges;
[0011] the side edges of the strips being connected by at least one
fastener member which includes two end portions each inserted into
a respective one of the grooves and a bridging portion holding the
side edges at a predetermined spacing;
[0012] each end portion having an attachment into the groove of the
respective strip with the attachment arranged to hold the strips
fastened together as a common panel member separate from the
supporting structure during transportation and installation.
[0013] Preferably each end portion comprises a flat plate portion
inserted into the groove and extending partly along the groove.
[0014] In one arrangement of this fastener, each end portion butts
against a bottom of the groove.
[0015] In another arrangement of this fastener, there is provided
on the bridging portion a shoulder for engaging the end face of one
of the strips for holding the strip at a predetermined
location.
[0016] Preferably the bridging portion is recessed from the front
and rear surfaces so that the panel can be used either way up
without the bridging portion forming an unsightly member at the
surface.
[0017] In one arrangement of this fastener, the attachment of the
end portions to the groove is effected by insert members or pins
engaged through the strip and across the groove.
[0018] In another arrangement of this fastener, the attachment of
an end portion to the respective groove is effected by barb members
on the end portion engaging side walls of the groove.
[0019] Preferably in this arrangement the end portion includes
first barb members extending parallel to the bridging portion and
second barb members extending at right angles to the bridging
portion so as to hold the end portion in the groove against
movement relative to the groove in two directions.
[0020] Preferably the bridging portion includes a hole for
receiving a fastening screw engaging from the fastener member to
the supporting structure to hold the panel on the supporting
structure.
[0021] Preferably two parallel ones of the strips with a space
therebetween have ends thereof which face a corresponding side edge
of a next adjacent strip with a space therebetween; the side edge
of said next adjacent strip having a groove therealong recessed
into the side edge; the side edges of each of said two parallel
ones of the strips having a groove therealong recessed into the
side edge such that the grooves of two facing side edges of the two
parallel strips are facing grooves; and at least one fastener
member connecting the ends of the two parallel strips to the next
adjacent strip, which fastener member includes two end portions
with one end portion inserted into the groove of the next adjacent
strip and one end portion inserted into the facing grooves of the
two parallel strips with a part of the end portion bridging the
space between the two parallel end strips.
[0022] Preferably there are a plurality of the fastener members
each arranged to connect at least two of the strips together and
wherein at least some of the fastener members have portions thereof
extending beyond the panel member for engaging and fastening to a
next adjacent panel member.
[0023] Preferably each panel has a plurality of main strips
defining a panel portion having four sides including a first pair
of parallel sides and a second pair of parallel sides, a first
dividing strip along one of the first parallel sides and a second
dividing strip along an opposed one of the first parallel sides.
However other panel constructions can be used.
[0024] In this arrangement, preferably each of the main strips has
along at least one side thereof three of the fastener members with
one at each end and one in the center.
[0025] In this arrangement, preferably there are provided some
panels where the main strips are parallel to the dividing strips
and some panels where the main strips are at right angles to the
dividing strips.
[0026] In this arrangement, preferably each of the dividing strips
of each panel member includes a portion projecting beyond the main
strips of the respective panel member such that, when four of the
panel members are assembled into the system with the main strips of
one panel member at right angles to the main strips of each next
adjacent panel and with one of the dividing strips between the main
strips of each panel member and the next so as to form a
rectangular area at a junction between corners of the main strips
of the four of the panels; the rectangular area defined at the
junction between said four of the panels is filled by said portion
of said at least one dividing strip.
[0027] In this arrangement, preferably the supporting structure
comprises a plurality of parallel joists and strapping pieces over
the joists at right angles to the joists and wherein each of the
main strips lies at right angles to the strapping pieces and is
supported at each end by a respective one of two end strapping
pieces.
[0028] Preferably there is provided an additional strapping piece
in the center between the end strapping pieces.
[0029] Preferably the dividing strips bridge an end strapping piece
of one panel and an end strapping piece of a next adjacent
panel.
[0030] Preferably all the main strips of all the panels extend in
same direction.
[0031] According to a second aspect of the invention there is
provide a panelling system comprising:
[0032] a plurality of panel members for locating on a supporting
structure generally edge to edge in an array to at least partly
cover the supporting surface;
[0033] each panel member having a front surface for defining an
exposed surface of the panelling system, a rear surface for
engaging the supporting structure and four side edges;
[0034] each panel member comprising a plurality of strips arranged
side edge to side edge to form a panel body with the side edges
adjacent but spaced from one another;
[0035] wherein there are a plurality of fastener members each
arranged to connect at least two of the strips together;
[0036] and wherein at least some of the fastener members have
portions thereof extending beyond the panel member for engaging and
fastening to a next adjacent panel member.
[0037] According to a third aspect of the invention there is
provide a panelling system comprising:
[0038] a plurality of panel members for locating on a supporting
structure generally edge to edge in an array to at least partly
cover the supporting surface;
[0039] each panel member having a front surface for defining an
exposed surface of the panelling system, a rear surface for
engaging the supporting structure and four side edges;
[0040] each panel member comprising a plurality of strips arranged
side edge to side edge to form a panel body with the side edges
adjacent but spaced from one another;
[0041] wherein each panel has a plurality of main strips defining a
panel portion having four sides including a first pair of parallel
sides and a second pair of parallel sides, a first dividing strip
along one of the first parallel sides and a second dividing strip
along an opposed one of the first parallel sides;
[0042] wherein the supporting structure comprises a plurality of
parallel joists and strapping pieces over the joists at right
angles to the joists;
[0043] and wherein each of the main strips lies at right angles to
the strapping pieces and is supported at each end by a respective
one of two end strapping pieces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] One embodiment of the invention will now be described in
conjunction with the accompanying drawings in which:
[0045] FIG. 1 is a plan view of a first panel of a flooring system
according to the present invention.
[0046] FIG. 2 is a plan view of a second panel of the flooring
system according to the present invention.
[0047] FIG. 3 is a cross sectional view through a junction between
two boards of the panel of FIG. 1 showing two different embodiments
of fasteners therebetween and the connection to the support
structure
[0048] FIG. 4 is a plan view of a series of such panels assembled
with a support structure to form part of the flooring system.
[0049] FIG. 5 is an isometric view of one of the fasteners of FIG.
3.
[0050] FIG. 6 is a top plan view of the fastener of FIG. 5.
[0051] FIG. 7 is a top plan view on an enlarged scale showing the
connection between strips using the fastener of FIG. 5.
[0052] In the drawings like characters of reference indicate
corresponding parts in the different figures.
DETAILED DESCRIPTION
[0053] Reference is made to the above published application of
Gibson which shows and describes the details of the panels with the
dividing strips and the interconnection between the four corners of
the panels at the dividing strips.
[0054] The arrangement described herein and shown generally in FIG.
4 comprises a floor system defined by a series of panel members,
four of which are shown at 10 through 13. Each of the panel
members, as best visible in FIG. 3, has a top surface 16 defining a
floor surface on which the user walks and providing an attractive
appearance as described hereinafter. Each of the panel members
includes a bottom surface 17 for sitting on a support
structure.
[0055] The arrangement as shown is primarily for decking and hence
is supported on a support structure defined by joists 17A, 17B
forming a frame and by strapping rails 17C applied on top of the
joists. The joists are commonly 2.times.8 or 2.times.10 lumber
standing vertically with cross joists 17A and end joists 17B at
right angles. The strapping is 2.times.4 or 2.times.6 lumber
applied across the joists 17A at right angles thereto and laid flat
so as to provide support for the panels 10 to 13 etc and
particularly the ends of the boards of the panels as described
hereinafter.
[0056] Each of the panel members is formed from a plurality of side
by side main strips 10A to 10E which are connected together side by
side to form an initial panel portion 14. The number, length and
width of the strips can vary in accordance with requirements to
manufacture a panel of a required size. The main panel has four
side edges so that for example the panel 10 has side edges 20 and
21 which form a first pair of opposed side edges and side edges 22
and 23 which form a second pair of opposed side edges.
[0057] The main strips are formed from deck boards which are
commonly available and can be formed from many different wood
varieties or from a wood/resin composite material or wholly from
plastics. Typically the boards are 1.times.6 which, when the panels
are placed into location, are laid flat side by side over the
strapping 17C. Each board has a groove 19 recessed horizontally
from each of the vertical side edges 18.
[0058] In order to form these boards into a flooring system having
an attractive appearance, each base panel formed by the side by
side boards has attached two dividing strips which are attached to
opposite side edges of the panel. Thus for example the panel 10 in
FIG. 1 has two dividing strips 30 and 31 attached along the side
edges 20 and 21. The panel 11 in FIG. 2 has two dividing strips 30A
and 31A attached along the side edges 22 and 23. The dividing
strips are formed from a board similar in appearance to the boards
forming the panel but are arranged at right angles to the boards so
as to provide an attractive appearance in the floor when completed
and laid.
[0059] Each dividing strip has a depth equal to the thickness of
the boards so that a bottom surface of the dividing strip is
coincident with the plane of the bottom surface 17 and similarly a
top surface of the dividing strip is coincident with the plane of
the top surface 16. The dividing strips are preferably formed from
the same boards as the main strips 10A to 10E so as to have the
same dimensions and the same appearance.
[0060] The panel 11 has the dividing strips indicated at 30A and
31A which are arranged parallel to the main boards 10A to 10E
rather than at right angles thereto as in panel 10. In this way the
panel portion 14 is in the same orientation relative to the panel
portion 14 of the panel 10. However the dividing strips 30A and 31A
are carried by the panel portion 14 of the panel 11 on the sides 22
and 23 of the panel portion. In this way the side edges of the
panel 10 which include the dividing strips 30 and 31 engage
respectively the side edge 21 and 22 of the panel portion 14 of the
panel 11 which are free from the dividing strips. Similarly the
dividing strips 30A and 31A butt the next adjacent panel not
numbered.
[0061] The panel 11 also has bare edges 23A butting the dividing
strips 30 and 31 and its dividing strip 30A butts the edge 23B of
the panel 12. In this way it will be appreciated that the whole
floor can be laid by rotating the panels back and forth through
1800 and laying them each to the next with the side edges butting.
In this way between each panel and the next adjacent panel is one
dividing strip thus separating the panels by the thickness of the
dividing strip while allowing the bare edge of the strip to butt
against the outside surface of the dividing strip.
[0062] Each of the dividing strips extends along the full length of
the respective side edge of the panel and also extends beyond the
end of the side edge into a pointed portion 50. This arrangement is
described in more detail in the above prior application of Gibson.
In general the pointed portion 50 is cut to form two side edges 52
and 53 converging to an apex 54. The ends 52 and 53 are cut at
45.degree. relative to the sides of the dividing strip so that they
are 900 to each other forming a right angle triangle converging to
the apex 54 which lies on a centre line of the dividing strips
30A.
[0063] Each of the strips 10A through 10E is of an equal common
width and is formed from conventional floor planking so each strip
has a groove 19 on each side.
[0064] The divider strips are formed from a material of the same
width and same construction as the strips forming the panel. Thus
each divider strip itself has a groove 19 along each side. The
divider strips are formed from a common source of the same material
and generally therefore have the same width of the strips 10A
through 10E and can be taken from the same supply. The divider
strips may not be visually distinct from the main strips. However
visually distinct divider strips can be used to generate a
pattern.
[0065] Thus in FIG. 2, there is shown a flooring pattern formed
from two separate types of panels where one of the types is as
shown in FIG. 1 where the divider strips are at right angles to the
main strips and a second of the types is shown in FIG. 2 where the
divider strips are parallel to the main strips. As shown in FIG. 4
this forms a pattern where all the main strips are oriented in a
common direction and the divider strips form a series of rows
across and parallel to the main strips. It will be appreciated that
the combination of such panels can be used to create many different
panelling effects and patterns.
[0066] In all of the panels, the dividing strips include the
pointed portions 50 as previously described projecting beyond an
edge of the panel body. Thus the dividing strips of the panel
members are arranged with the portions 50 of the dividing strips of
each panel member projecting beyond the main strips of the
respective panel member such that, when four of the panel members
are assembled into the system with the main strips of one panel
member at right angles to the main strips of each next adjacent
panel and with one of the dividing strips between the main strips
of each panel member and the next so as to form a rectangular area
at a junction between corners of the main strips of the four of the
panels; the rectangular area defined at the junction between said
four of the panels is filled by said portion of said at least one
dividing strip.
[0067] A fastener arrangement for connecting each strip to the next
adjacent strip is shown in FIGS. 3 and 5 to 7. In each case the
divider strips and the main strips are fastened together using the
fastener members 60 to form a common panel member for
transportation and installation.
[0068] The fastener members 60 in the form of joining plates are
used to connect the main strips of the panels and the divider
strips of the panels to the main strips. Sufficient numbers of
plates can be used to ensure a structurally stable product.
[0069] The strips including the main strips and the divider strips
are fastened together using the fastening members 60. Each main
strip 10A to 10E has three of the fastening members 60 located at
spaced positions along its length. Thus at each end of a main strip
is located two of the fastening members 60 and an additional
fastening member 60 is located at the center of each main strip.
Each main strip is fastened to its next adjacent main strip by the
fastener members 60 which bridge the space between the main strip
and the next adjacent element which can be another main strip or it
can be one of the dividing strips or it can be a component of a
next adjacent panel.
[0070] It will be appreciated that the panels are intended to form
decking and decking conventionally has spaces between the boards or
strips forming the decking. In order to achieve this effect in the
panels, each main strip is separated from its next adjacent main
strip by a space which can typically be 1/4 inch. In addition the
end of each main board is separated from the next adjacent element
by a similar space. In FIG. 1 the end of each main board is
fastened to the inside edge or inner side of the divider strip. In
FIG. 2, the ends of the main strips are exposed for connection
during assembly of the structure to the divider strip of a next
adjacent panel.
[0071] In addition to the spaces between the main strips and the
divider strips there are also spaces formed between the side edges
52 and 53 of the points and the respective side edges of the next
adjacent points 50. This provides an assembly in which the spaces
are provided throughout the structure which matches the arrangement
of conventional decking structures.
[0072] The structure of the fasteners 60 is shown initially in FIG.
3. In FIG. 3 for convenience of illustration there are two types of
fasteners shown including a first fastener 61 and a second fastener
type 62. The fastener 62 is shown in more detail in FIGS. 5, 6 and
7.
[0073] The fastener 62 comprises a generally planar body 63 with a
central bridging portion 64 to be located between the two strips
and two insert portions 65 and 66 arranged to be inserted into the
two facing grooves 19 of two adjacent strips. Each insert portion
65, 66 is generally rectangular so as to be inserted into the
respective groove along a part of the length of the groove and to a
position closely adjacent to but slightly spaced from the base 19A
of the groove. Each insert portion therefore includes a top surface
67 and a bottom surface 68 for engaging respectively the top
surface 19B of the groove and the bottom surface 19C of the groove.
The intention is that the insert portion acts as a tight engagement
fit within the groove. In order to enable the insert portion to be
inserted into the groove, it is tapered from the top surface 67
downwardly to a front nose 69 and also upwardly from the bottom
surface 68. In addition the insert portion includes side walls 70
and 71 and again the nose 69 is tapered inwardly at 72 and 73 so
that the nose is tapered in both directions allowing ready insert
of the insert portion into the mouth of the groove from which
position it can be inserted by pressure into the groove as a tight
fit.
[0074] In this embodiment the central bridging portion 64 has a
thickness that is greater than the insert portions 65 and 66 so as
to define shoulders 73 on each side of the bridging portion 64 at
both the top surface 67 and the bottom surface 68. It will be
appreciated therefore that with the insert portion driven into the
groove, the shoulder 73 will engage the edge surface 18 of the
strip to be attached. Thus the four shoulders of the bridging
portion 64 engage the side edges 18 of two of the strips and hold
those strips at a predetermined spacing defined by the width of the
bridging portion 64.
[0075] In order to maintain the insert portion 65 and 66 within its
respective groove, the upper and lower surfaces are formed with
barbs 74 and 75. In the embodiment shown there are three barbs 74
extending across the insert portion parallel to the bridging
portion 64. These of course are shaped to prevent the insert
portion from being pulled back out of the groove after insertion
into the groove. Thus they are shaped with a wedging action on one
side and a sharp edge on the other side in a conventional manner of
such a barb. In the embodiment shown there are three such barbs on
the top and bottom surface of each of the insert portions 65 and
66.
[0076] In order to prevent movement of the insert portion along the
groove, there are additional barbs 75 provided which extend at
right angles to the bridging portion 64. These barbs are located at
the side surfaces 70 and 71 and project upwardly from the upper and
lower surfaces to a height approximately equal to those of the
barbs 74. It will be appreciated therefore that pressure of the
insert portion into the groove will cause the barbs to bite into
the material at the top and bottom surfaces of the groove to resist
or prevent movement of the insert portion in both directions out of
the groove and longitudinally along the groove.
[0077] It will be appreciated that the location and arrangement of
the barbs can vary with the intention that they be designed simply
for ready insertion of the insert portion into the groove and to
provide the resistance to movement in both directions.
[0078] Additional engagement of the bars with the surfaces of the
groove can be obtained by pressing the material of the strip along
the sides of the strip so as to compress the strip at the groove
tending to compress the strip onto the insert portion by distorting
the material of the insert portion slightly to obtain greater
bighting effect.
[0079] The bridging portion 64 has a height from the top and bottom
surfaces of the insert portion which is less than the distance
between the groove and the top and bottom surfaces of the strip.
Thus as best shown in FIG. 3, the top and bottom surfaces 78 and 79
of the bridging portion 64 are recessed from the respective
surfaces 16 and 17 of the strips. Thus when assembled, the
fasteners are not visible at the surface and are only visible by
looking down into the respective space so that the appearance is
acceptable as the fastening component of the structure rather than
as an unattractive element at the surface.
[0080] The bridging portion 64 has a central hole 80 which passes
through the bridging portion from the top surface to the bottom
surface to allow a screw 81 to be inserted to engage through the
fastener into the supporting strapping 17C. Thus the fasteners act
to both hold the strips side by side and also to provide a
fastening system for attaching the panel to the support structure
when the panel is located in place.
[0081] As shown in FIGS. 1 and 2, the fasteners 60 are arranged
between each main strip and the next adjacent main strip and
between the main strips and the dividing strips. Thus in FIG. 1 the
fasteners are located into the space between two of the main strips
at the ends of the main strips and these fasteners are available
for connection to the dividing strip either of the same panel or
the next adjacent panel. In addition where the edge of the panel is
available for engagement with the next adjacent panel, the
fasteners are the edge are located in place and are available for
engagement with the next adjacent panel.
[0082] The fasteners of the panel therefore provide firstly the
function of holding the panel assembled as an individually
transportable unit prior to installation and also they provide the
connection from one panel to the next as the panels are assembled
and thirdly they also provide the arrangement for fastening the
panels to the support structure during the installation or after
the installation is completed.
[0083] The use of three fasteners along each main strip provides
sufficient fastening strength to allow the panels to be carried and
moved from place to place both for storage and transportation. It
will be appreciated that the panels of FIG. 1 are more stable in
that the divider strips are at right angles to the main strips and
therefore prevent bending of the structure. The arrangement of FIG.
2 is less stable since the structure can bend about transverse axes
but the fastening arrangements described provide sufficient
strength to enable the transportation and assembly of the panels of
both types.
[0084] Turning now to FIG. 7, a first fastener 62A is shown which
is arranged to connect between the side edge 18 of a main strip 10A
and the side edge 18 of a second strip 10B. In addition the ends of
those main strips 10A and 10B also fasten to the dividing strip 30.
Thus will be appreciated that the fastener 62 is inserted into the
groove 18 of the dividing strip 30 so that the barbs 75 and 74
engage into the groove 18 to hold the fastener against movement out
of the groove and movement along the groove.
[0085] The other insert portion of the fastener is inserted into
the groove 19 of the side of each of the main strips 10A and 10B.
There is no groove at the end of the strips and hence the width of
the fastener 62 across the ends is arranged so that it is less than
the spacing between the bases of the grooves 19 of the boards 10A
and 10B. The barbs 74 prevent the strips 10A and 10B being moved
longitudinally away from the fastener. The barbs 75 prevent the
strips 10A and 10B being moved apart. The shoulders on the bridging
portion 64 act to hold the space between the ends of the main
strips and the dividing strip. In the embodiment shown there is no
shoulders on the fastener between the main strip 10A and the main
strip 10B. However the engagement of the barbs can be sufficient to
hold the main strips in place.
[0086] As an alternative arrangement there may be provided a raised
shoulder in a bridging section between the edge 18 of the main
strip 10A and the edge 18 of the main strip 10B. This will form the
bridging section 64 into a T shape with a portion extending along
into the space between the edges 18 of the strips 10A and 10B.
[0087] A further fastener indicated at 62B is located between the
opposite side edge 18 of the main strip 10A and the dividing strip
30 at a position adjacent the point 50 and its side surface 52.
This fastening member 62B is generally of the same shape and
construction as the fastener member 62A and acts to engage into
groove 19 of the dividing strip 30 and also into the groove 19 of
the outer side edge of the main strip 10A. The remaining part of
the fastener projects outwardly beyond the edge of the panel for
engagement with the dividing strip 32A of the next adjacent panel
11. Thus the portion 85 of the fastener 62B normally projects
outwardly from the edge 18 of the main strip 10A and from the
surface 52 of dividing strip 30. In this embodiment the fastener
62B has no shoulders acting to locate the spacing between the
various components. However it will be appreciated that a separate
fastening element can be manufactured which is shaped with h the
generally Y-shaped spaces between the two dividing strips 30 and
32A and the edges of the main strip 10A.
[0088] Thus the fasteners may be manufactured in a manner which
allows all of the fastener members to be of the same shape or three
different types of fastener member can be manufactured for each of
the three different locations on the panels. Thus for example the
bridging portion can be T-shaped for the fastening member 62A, can
be Y-shaped for the member 62B and can be simply a central flat
strip for the fastening members located in the center of the main
strips.
[0089] A second simpler form of fastener member 61 is shown also in
FIG. 3 and this is in the form of simply a flat square plate
without any raised bridging portion and without any barbs. In this
arrangement the flat square plate is inserted into the grooves 19
until the edges of the flat square plate engage the base of the
grooves. Thus the spacing between the edges 18 is maintained fixed
by the fact that the plate has a width greater than the depth of
the two grooves.
[0090] It will be appreciated that this arrangement can be used in
any of the various locations of the panel. However in the absence
of any barbs it is necessary to hold the plate in place and in this
embodiment this is effected by a pair of pins 90 engaged through
the plate on either side of the junction so that each strip is
fastened to the plate by two such pins.
[0091] An arrangement is also possible which uses barbs 74 and 75
of connector 62 but uses the engagement with the bottom of the
groove to accurately maintain the spacing between the connected
strips as in connector 61.
[0092] As shown n FIG. 4, the supporting structure comprises a
plurality of parallel joists 17A and strapping pieces 17C over the
joists at right angles to the joists. Each of the main strips 10A
to 10E lies at right angles to the strapping pieces 17C and is
supported at each end by a respective one of two end strapping
pieces 17E and 17F on which the end lies. The screws 81 in the
holes 80 of the fasteners 62 at the ends of the main strips thus
can engage into the strapping pieces 17E and 17F respectively.
There is provided also an additional strapping piece 17G in the
center between the end strapping pieces.
[0093] The dividing strips 30 bridge an end strapping piece 17E of
one panel and an end strapping piece 17F of a next adjacent panel.
In this arrangement it is necessary that all the main strips of all
the panels extend in same direction since these are carried on the
strapping pieces extending across the full extent of the deck.
[0094] This arrangement allows an increased spacing between joists
from 16 inches to 24 inches in view of the additional of the
strapping relative to conventional systems.
[0095] The panels are stable element of the order of 24 inches in
width which thus can be stored as a stack on a conventional pallet
which is a much more stable system of transportation and storage
than the conventional long boards.
[0096] Since various modifications can be made in my invention as
herein above described, and many apparently widely different
embodiments of same made within the spirit and scope of the claims
without department from such spirit and scope, it is intended that
all matter contained in the accompanying specification shall be
interpreted as illustrative only and not in a limiting sense.
* * * * *