US20100180532A1 - Deck plank fastener - Google Patents
Deck plank fastener Download PDFInfo
- Publication number
- US20100180532A1 US20100180532A1 US12/355,123 US35512309A US2010180532A1 US 20100180532 A1 US20100180532 A1 US 20100180532A1 US 35512309 A US35512309 A US 35512309A US 2010180532 A1 US2010180532 A1 US 2010180532A1
- Authority
- US
- United States
- Prior art keywords
- plank
- fasteners
- joists
- fastener
- deck
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F21/00—Implements for finishing work on buildings
- E04F21/18—Implements for finishing work on buildings for setting wall or ceiling slabs or plates
- E04F21/1838—Implements for finishing work on buildings for setting wall or ceiling slabs or plates for setting a plurality of similar elements
- E04F21/1844—Implements for finishing work on buildings for setting wall or ceiling slabs or plates for setting a plurality of similar elements by applying them one by one
- E04F21/1855—Implements for finishing work on buildings for setting wall or ceiling slabs or plates for setting a plurality of similar elements by applying them one by one of elongated elements, e.g. sidings
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F21/00—Implements for finishing work on buildings
- E04F21/0076—Implements for finishing work on buildings for marking and cutting tiles
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02044—Separate elements for fastening to an underlayer
- E04F2015/0205—Separate elements for fastening to an underlayer with load-supporting elongated furring elements between the flooring elements and the underlayer
- E04F2015/02066—Separate elements for fastening to an underlayer with load-supporting elongated furring elements between the flooring elements and the underlayer with additional fastening elements between furring elements and flooring elements
- E04F2015/02072—Separate elements for fastening to an underlayer with load-supporting elongated furring elements between the flooring elements and the underlayer with additional fastening elements between furring elements and flooring elements the additional fastening elements extending into the back side of the flooring elements
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/05—Separate connectors or inserts, e.g. pegs, pins, keys or strips
- E04F2201/0511—Strips or bars, e.g. nailing strips
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T403/00—Joints and connections
- Y10T403/46—Rod end to transverse side of member
Definitions
- the invention relates to deck plank fastener for securing a deck plank to a joist and for supporting deck planks relative to one another. More particularly, the invention relates to a hidden deck plank fastener that is not visible, does not protrude from the deck surface, and is secured against the under-side of the planks.
- the simplest deck plank fastening system consists of a plurality of securing or anchoring elements, such as nails or screws, driven downward through the top of a plank, such as a wood or composite board, and into the top surface of a supporting beam, such as a joist or ledger board.
- a plank such as a wood or composite board
- a supporting beam such as a joist or ledger board
- Deck planks installed using the simplest system of the preceding paragraph must be carefully aligned to achieve a desirable aesthetic as well as functional result, for example, secure attachment and uniform spacing or parallelism without large gaps. Also, the insertion of the nails or screws must be performed carefully to ensure proper penetration of the joist, which will be concealed from view by the overlying wood board at the time of insertion, in order to achieve optimal attachment. This process is time consuming and requires some skill.
- the anchoring element's penetration of the upper surface of the plank leaves the plank with a pock-marked appearance and prone to rot and weather damage, which severely decreases the longevity of the deck.
- the nail or screws may work loose and protrude from the upper surface of the planks, which poses a risk of injury to users of the deck. Penetration of the top of the plank decreases the integrity of the plank and thus the deck as a whole, and increases the risk of injury.
- an improved deck plank fastening system includes fasteners that attach to a side surface of the plank and a top surface of the joist using nails or screws.
- Such designs facilitate uniform spacing or parallelism of planks by providing tabs or vertically oriented flanges that engage adjacent planks.
- the tabs facilitate installation by locating the points of penetration at more readily visible and accessible positions.
- the fasteners improve the longevity of the resulting deck by repositioning the point of penetration to the side of the plank, which is less prone to weathering.
- the tabs reduce the risk of injury to the user of the deck by hiding the nails or screws below the surface.
- the fasteners improve the aesthetic appeal of the deck.
- the object of the present invention is, therefore, to provide an improved deck plank fastener, which, among other desirable attributes, significantly reduces or overcomes the above-mentioned deficiencies of prior deck plank fasteners.
- the present invention provides a hidden deck plank fastener, a decking system, and methods for assembling a decking structure.
- a first aspect of the present invention is a hidden deck plank fastener for securing a deck plank to a joist.
- the fastener comprises a substantially flat body having a top surface, a first end, a second end and two opposing lateral edges.
- the fastener further comprises a first hole in the first end, and a second hole the second end.
- the fastener further comprises two tabs extending upward away from the body at an angle to the top surface from two opposing positions located along the opposing lateral edges.
- a second aspect of the present invention is a decking system using the hidden deck plank fastener of the first aspect of the present invention.
- the decking system comprises a plurality of joists arranged in a planar array at spaced intervals.
- the decking system further comprises a plurality of planks in spaced and side-by-side relationship on the joists, each plank having a near and a far edge, the near and far edges of adjacent planks being parallel to one another and confronting one another.
- the decking system further comprises a plurality of hidden fasteners securing the planks to the joists, each of a first set of the hidden fasteners connecting the bottom of a plank at the near edge to the top of a joist, and each of a second set of the hidden fasteners connecting to the bottom of a plank at a far edge projecting under the near edge of the adjacent plank.
- a third aspect of the present invention is a method for assembling a decking structure using the hidden deck plank fastener of the first aspect of the present invention.
- the first step of the method comprises providing a base formed by an array of spaced-apart joists, each joist having an upper surface lying in a common plane with the other joists.
- the second step comprises affixing a first plank to the plurality of joists in a desired position to serve as a reference plank.
- the third step comprises positioning a second plank with a bottom surface of the second plank facing upward.
- the fourth step comprises attaching each of a first plurality of fasteners to the bottom of the second plank at a far edge of the second plank and at positions corresponding to the underlying joists.
- the fifth step comprises attaching each of a second plurality of fasteners to the bottom of the second plank at a near edge of the second plank and at positions offset from the underlying joists.
- the sixth step comprises turning the second plank over so that the bottom surface of the second plank and the fasteners face downward.
- the seventh step comprises then positioning the second plank in the desired position side-by-side with the reference plank with each of the first plurality of fasteners overlying a joist, and each of the second plurality of fasteners projecting under an adjacent edge of the reference plank.
- the eighth step comprises securing each of the first plurality of fasteners to a corresponding joist.
- the method includes installing a plurality of additional planks to the decking structure by repeating the third and subsequent steps with the second plank as the reference plank and the additional plank as the second plank.
- a fourth aspect of the present invention is a method for assembling a decking structure having planks angled at a predetermined angle, such as 45 degrees, to the joists using the hidden deck plank fastener of the first aspect of the present invention.
- the first step of the method comprises providing a base formed by an array of spaced-apart joists, each joist having an upper surface lying in a common plane with the other joists.
- the second step comprises affixing a first plank to a corner of the plurality of joists in a desired position and at the predetermined angle to the joists to serve as a reference plank.
- the third step comprises positioning a second plank on the joists side-by-side with the reference plank and in a position corresponding substantially to the desired position of the second plank in the decking structure with a top surface of the second plank facing upward.
- the fourth step comprises marking the bottom surface of the second plank along each joist with a marking line extending across the plank from the near edge to the far edge, each marking line being positioned to correspond substantially with the edge of the joist nearest the reference plank.
- the fifth step comprises attaching each of a first plurality of fasteners to the bottom surface of the second plank along the far edge at a position such that one of the plurality of marking lines is visible through a first hole of the first plurality of fasteners.
- the sixth step comprises attaching each of a second plurality of fasteners to the bottom surface of the second plank along the near edge at positions such that each marking line is visible through a first hole of the second plurality of fasteners.
- the seventh step comprises positioning the second plank in the desired position side-by-side with the reference plank with each of the second fasteners projecting under the adjacent edge of the reference plank.
- the eighth step comprises securing each of the plurality of the first plurality of fasteners to a joist.
- the method includes installing a plurality of additional planks to the decking structure by repeating the third and subsequent steps with the second plank as the reference plank and the additional plank as the second plank.
- FIG. 1 illustrates a perspective view of a deck plank fastener embodying the present invention in one embodiment
- FIG. 2 illustrates a top plan view of the deck plank fastener in FIG. 1 ;
- FIG. 3 illustrates a cross-sectional side view of the deck plank fastener in FIG. 1 , viewed along the section line 3 - 3 of FIG. 2 ;
- FIG. 4 illustrates an end view of the deck plank fastener in FIG. 1 ;
- FIG. 5 illustrates a decking structure using the deck plank fasteners
- FIG. 6 shows the installing of a fastener at one edge of an inverted plank according to the present invention
- FIG. 7 shows the installing of another fastener at the opposite edge of an inverted plank according to the present invention
- FIG. 8 shows the inverted plank with fasteners at each edge in preparation for installation with a previously installed plank according to the present invention
- FIG. 9 shows the detail of positioning a plank right side up with a previously installed plank according to the present invention.
- FIG. 10 shows the securing of a plank right side up in the desired position relative to a previously installed plank according to the present invention
- FIG. 11 shows a first step of assembling the decking structure, wherein the deck planks are to be installed in a 45 degree angular orientation according to the present invention
- FIG. 12 shows an initial plank inverted with fasteners secured at one edge in the 45 degree angular orientation installation according to the present invention
- FIG. 13 shows the initial plank installed right side up in the 45 degree angular orientation installation according to the present invention
- FIGS. 14A and 14B show the marking of a second plank for fastener locations in the 45 degree angular orientation installation according to the present invention
- FIG. 15 shows multiple fasteners attached to each edge of an inverted plank in the 45 degree angular orientation installation according to the present invention.
- FIG. 16 shows the positioning of a plank with fasteners right side up adjacent a previously installed plank in the 45 degree angular orientation installation according to the present invention.
- the deck plank fastener 1 has a body 2 , which is preferably stamped in finished form from a sheet of stainless steel in a metal forming press.
- the body 2 is generally rectangular as shown in the plan view of FIG. 2 .
- the body 2 is a substantially planar member having a top surface 3 and a bottom surface 4 .
- the body 2 also has a first end 5 , a second end 6 and two pairs of opposing lateral edges including long edges 11 and short edges 12 .
- First end 5 and second end 6 correspond to the ends of the body 2 that abut the short edges 12 .
- first end 5 , second end 6 , long edges 11 and short edges 12 do not necessarily indicate structural distinctions in all embodiments.
- the deck plank fastener 1 also has a first hole 8 formed at a substantially central position of the first end 5 of the body 2 , and a second hole 9 formed at a substantially central position of the second end 6 of the body 2 .
- the first hole 8 and the second hole 9 are sized to receive an anchoring element, such as a wood screw 24 as shown in FIG. 3 .
- the deck plank fastener 1 also has two tabs 10 which are integral with the long edges 11 of the body 2 and extend upward at an angle to the top surface 3 .
- the width of tabs 10 is set to establish plank-to-plank spacing in the resulting deck structure.
- the tabs 10 may be positioned either closer toward the first end 5 or the second end 6 of the body 2 .
- the width and lateral placement of the tabs 10 is only limited by the distance between and relative positions of the first hole 8 and second hole 9 .
- the tabs 10 may be formed using a number of techniques but, preferably, are formed in the metal forming press contemporaneously with the forming of the body 2 .
- the body 2 is formed to include a plurality of ribbed contours, such as impressed reinforcement contours 13 .
- the contours 13 serve many functions including, for example, reinforcing the structure of the body 2 , promoting traction between the fastener 1 and the planks or joists, and providing body thickness for a deeper first hole 8 and second hole 9 .
- the first hole 8 and second hole 9 are circumscribed by a pair of conical recesses 18 , 19 , respectively, for engaging with screws 24 .
- the conical recess 18 which surrounds the first hole 8 , is tapered inwardly from the bottom surface 4 to the top surface 3 and, hence, is larger at the bottom and smaller at the top as the first hole 8 approaches the top surface 3 .
- the taper of the conical recess 18 engages a screw 24 that is inserted from the bottom side of the body 2 through the first hole 8 and into a plank that abuts the top surface 3 of the body 2 .
- conical recess 19 which surrounds second hole 9 , is tapered inwardly from the top surface 3 to the bottom surface 4 and, hence, is larger at the top and smaller at the bottom as the second hole 9 approaches the bottom surface 4 .
- the taper of conical recess 19 engages a screw 24 that is inserted from the top side of the body 2 through the second hole 9 and into a joist that abuts the bottom surface 4 of the body 2 .
- a cross-sectional view of the fastener 1 shows the undulating height of the contours 13 and the holes 8 , 9 with conical recesses 18 , 19 along the longitudinal centerline of the body 2 .
- the anchoring elements are screws 24 , such as wood screws having conical-shaped head portions, as shown in FIG. 3 .
- the screws 24 or other anchoring elements may be of many shapes and sizes and that the first hole 8 with conical recess 18 and second hole 9 with conical recess 19 may be shaped and sized to receive the anchoring elements.
- the deck plank fastener 1 also comprises wings 16 , which are integral with the edges 11 , 12 of the body 2 and are bent downward toward the bottom surface 4 .
- wings 16 are discontinuous around portions of the edges 11 , 12 of the body 2 from which the tabs 10 extend.
- the length of the wings 16 along the edge of the body 2 may be varied, but, preferably, the length is maximized such that a wing 16 extends along the entire edge of body 2 except from where the upward tabs 10 extend.
- the wings 16 are also discontinuous around the corners of the body 2 , for example, around corner carve-outs 15 .
- the wings 16 may also be continuous around the corners by being formed into a rounded or angular corner.
- wings 16 may be formed by many techniques, but, preferably, are formed in the metal forming press contemporaneously with the forming of the body 2 . Preferably, the wings 16 are bent at a smaller angle toward the bottom surface 4 than the tabs 10 are bent toward the top surface 3 .
- the wings 16 serve many functions including, for example, reinforcing the structure of the body 2 , promoting traction between the fastener 1 and planks or joists, and facilitating the sliding of the protruding fastener 1 attached to a plank under the exposed edge of a previously installed plank.
- the present invention provides a decking structure 20 that is constructed using the hidden fasteners of FIGS. 1-4 .
- the decking structure 20 comprises a base structure formed by horizontal support beams, including joists 21 and ledger boards 22 .
- the joists 21 are connected at opposite ends of the ledger boards 22 and at evenly spaced intervals. Together, the joists 21 and ledger boards 22 form a substantially horizontal plane that serves as a support surface for the planks 23 .
- a first plank 23 a is attached to one side of the decking structure 20 .
- the first plank 23 a is affixed to the joists 21 and ledger board 22 along one edge of the base structure such that second plank 23 b can be attached in parallel across the entirety of the working surface created by the joists 21 .
- a plank has a near and a far edge, wherein the near edge faces the viewer in FIG. 5 and exposed joists of the base structure, and the far edge face away from the viewer in FIG. 5 and toward the installed planks.
- a first plank 23 a is shown in an installed position in the decking structure on top of the ledger board 22 and the mating ends of the joists 21 .
- the first plank 23 a may be attached to the decking structure 20 by any known means.
- the first plank 23 a is attached using a set of the hidden fasteners la, which are secured to the top of the ledger board 22 along the facing edge at positions offset from the joists 21 using screws 24 or other anchoring elements.
- fasteners 1 a are attached with the tabs 10 facing downward and butted against the ledger board 22 .
- Additional screws 24 are used to connect the hidden fasteners 1 a with the bottom of the first plank 23 a in its desired position and are installed from below the plank 23 a.
- another set of hidden fasteners 1 b is attached along the near edge in the same manner as explained hereafter in connection with hidden fastener 1 c and plank 23 c, as shown in FIG. 6 .
- the fasteners 1 b are located at positions corresponding to the underlying joists 21 so that the first plank 23 a can be secured to the joists 21 by inserting screws 24 or other anchoring elements downward into the joists 21 from above the plank.
- planks 23 are also attached to the joists 21 using hidden fasteners 1 .
- the planks 23 may be cut to length before placement or after being secured to the joists 21 .
- plank 23 c is the next plank to be installed in the decking structure 20 adjacent to the near edge of plank 23 b.
- the plank 23 c is initially inverted and placed on the joists in the desired final position lengthwise with the bottom surface of the plank 23 c facing upward.
- the hidden fastener 1 c is attached to the near edge of the plank 23 c above each underlying joist 21 with the tabs 10 butted up against the edge of the plank 23 c, the bottom surface 4 facing upward and the free end 6 of the hidden fastener 1 c projecting outward from the edge.
- the first end 5 of the hidden fasteners 1 c is secured to the plank 23 c by inserting a screw 24 or other anchoring element through the first hole 8 of the first hidden fastener 1 c and driving the screw 24 into the plank 23 c with a drill D or screw driver.
- another set of hidden fasteners 1 d is attached to the bottom surface 4 of the inverted plank 23 c along the far edge at positions offset by a minimal distance A from the underlying joists 21 and the hidden fasteners 1 c.
- a first end 5 of the hidden fastener 1 d is attached to the plank 23 c by inserting a screw 24 through the first hole of the hidden fastener 1 d and driving the screw 24 into the plank 23 c with a drill D or screw driver.
- the tabs 10 of the hidden fastener 1 d are butted up against the edge of the plank 23 c and the free end 6 of the hidden fastener 1 d projects outwards from the edge.
- FIG. 8 illustrates the inverted plank 23 c after the first and second sets of hidden fasteners 1 c, 1 d are attached to opposite edges.
- the inverted plank 23 c is shown on the deck structure with previously installed planks 23 a and 23 b.
- the plank 23 c With the hidden fasteners 1 c, 1 d attached to the bottom surface of the plank 23 , the plank 23 c is turned over into an upright position so that the top surface of the plank 23 c faces upward and the hidden fasteners 1 c, 1 d are facing downward.
- the righted plank 23 c is then positioned for attachment to the joists 21 in approximately the proper position relative to the plank 23 b that was previously installed and serves as a reference.
- the final positioning of the plank 23 c relative to the plank 23 b is accomplished as shown in FIG. 9 by, first, sliding the projecting second ends 6 of the hidden fasteners 1 d, which are positioned on a far edge (as viewed in FIG. 5 ) of the plank 23 c, under the near edge of the reference plank 23 b.
- plank 23 c is slid in the direction of the arrow B toward the reference plank 23 b in the plane of the working surface created by the joists 21 so that the fasteners 1 d slide under the plank 23 b until tabs 10 of the hidden fasteners 1 c of the reference plank 23 b engage with far edge of the plank 23 c, and tabs 10 of the hidden fasteners 1 d of the plank 23 c engage with the near edge of the reference plank 23 b in the desired final position of the plank 23 c.
- the tabs 10 thus establish a uniform spacing between the adjacent planks 23 b, 23 c.
- the hidden fasteners 1 c are secured to the joists 21 with screws 24 and a drill D, or other anchoring means.
- the turning over step and the positioning step may be merged into a single motion, for instance, by simultaneously rotating the plank 23 c proximate to the reference plank 23 b, thereby causing the protruding end 6 of the fasteners 1 d to pivot under the reference plank 23 b rather than slide, and pressing the plank 23 c toward the reference plank 23 b so that the plank 1 c is firmly held in the desired position.
- the far edge of the second plank 23 c faces (or “confronts”) the near edge of the reference plank 23 b, creating the desired aesthetic of the decking structure.
- Additional planks 23 are installed in the decking structure 20 by repeating the fastener attachments and plank installing steps until the entire working surface of the decking structure 20 is complete.
- FIGS. 11-16 a method for assembling a decking structure having planks angled at a predetermined angle to the joists and utilizing the hidden fasteners 1 is shown.
- this method will be described in relation to a decking structuring having planks angled at 45 degrees to the joists, however, it should be appreciated that the method is also applicable to other predetermined angle designs.
- the base structure comprises horizontal support beams, including the parallel joists 21 connected at their ends with transverse ledger boards 22 to establish a support surface for the planks.
- an initial hidden fastener 1 e is affixed to the top surface at the junction of the outermost joist 21 and the ledger board 22 .
- the initial hidden fastener 1 e is preferably affixed such that the bottom surface 4 of the initial hidden fastener 1 e faces upward and the tabs 10 are aligned with the inside edge of the outermost joist 21 or the ledger board 22 .
- the initial hidden fastener 1 e is secured by inserting a screw 24 downward through the first hole 8 into the joist 21 or the ledger board 22 .
- FIGS. 12-13 show the method of attaching a first plank 23 d to the base.
- the first plank 23 d is shaped like an isosceles right triangle.
- the first plank 23 d may be cut from a larger plank before or after the first plank is secured to the base.
- a decking structure having planks angled relative to the joists at an angle other than 45 degrees would use a first plank of another shape (i.e. not an isosceles right triangle).
- a decking structure having planks angled at 30 degrees relative to the joists would use a first plank of a 30-60 degree right triangle.
- the plank 23 d has a textured or otherwise designated upper surface
- the plank is inverted with the upper surface facing downward.
- the plank may be located on the outermost joist 21 a and the ledger board 22 to facilitate placement of the fasteners 1 f and 1 g.
- the hidden fastener 1 f of the first plank 23 d is secured by a screw 24 along the hypotenuse edge of the plank 23 d at a position such that the first hidden fastener 1 f is a predetermined distance from the apex of the adjacent 45 degree angle.
- the predetermined distance is set so that the projecting second end 6 of the hidden fastener 1 f overlies the joist 21 or ledger board 22 when the plank 23 d is installed in the upright position, as shown, for example, in FIG. 13 .
- the second hidden fastener 1 g of the first plank 23 d is secured by a screw 24 along the hypotenuse edge of the first plank 23 d at a predetermined distance from the apex of the adjacent 45 degree angle in the same fashion. In each case, the fasteners are secured with the tabs 10 abutting the hypotenuse edge.
- first plank 23 d overhangs the outermost joist 21 and ledger board 22 may be adjusted by altering the placement of the hidden fasteners 1 f and 1 g along the hypotenuse edge of the first plank 23 d.
- a doubler (not shown) may be required at the corner for the first plank 23 d.
- a doubler is attached to the inside of the outermost joist 21 or the ledger board 22 facing toward the array of joists 21 and extending from the intersection of the outermost joist 21 and the ledger board 22 a sufficient distance to provide fastening points for the fasteners connected to the first plank 23 d. If a doubler is used, the initial hidden fastener 1 e may be affixed to the doubler rather than the outermost joist 21 or the ledger board 22 .
- the first plank 23 d is turned upright so that the top surface of the first plank 23 d faces upward.
- the first plank 23 d is aligned relative to the outermost joist 21 and ledger board 22 so that the securing holes 9 of the hidden fasteners 1 f and 1 g are positioned centrally over the outermost joist 21 and ledger board 22 .
- the apex of the right angle of the triangle-shaped first plank 23 d points away from the array of joists 21
- the two sides of the triangle-shaped first plank 23 d are parallel to the outermost joist 21 and ledger board 22 respectively
- the hypotenuse of the triangle-shaped first plank 23 d runs at 45 degrees to the outermost joist 21 and ledger board 22 .
- the first plank 23 d is secured to the outermost joist 21 and ledger board 22 by inserting screws 24 downward through the second holes 9 of the hidden fasteners 1 f, 1 g of the first plank 23 d into the outermost joist 21 and ledger board 22 , respectively.
- the outermost joist 21 is secured to the first plank 23 d by inserting a screw 24 upward through the second hole 9 of the initial hidden fastener 1 e into the first plank 23 d.
- the first plank serves the function of a reference plank for the adjacent planks.
- FIGS. 14A , 14 B, 15 and 16 show the installation of a second 45 degree plank 23 f on the base structure after several other planks 23 e have been installed utilizing the hidden fasteners.
- FIG. 14A shows the second plank 23 f positioned with a top surface of the plank 23 f facing upward in a position corresponding to a desired final position of the plank 23 f on the decking structure spaced from the previously installed plank (see FIG. 16 ) by the tabs 10 of the fastener 1 b.
- the plank 23 f may be cut to size and shape before or, if permitted, after installation.
- An exposed near edge of the second plank 23 f is marked with a marking utensil 25 at marking positions 26 corresponding to the intersections of the edge of the plank 23 f and the far side of each joist 21 .
- Each intersection of the plank 23 f edge with the joists 21 is marked.
- the plank 23 f is then turned over so that the bottom surface of the plank 23 f faces upward, as shown in FIG. 14B , and marking lines 27 are extended from the marking positions 26 across the bottom of plank 23 f at a 45 degree angle to the plank 23 f.
- the marking lines 27 thus correspond to the far side of the intersecting joists 21 and could also be drawn from below using the joists themselves as a guide.
- the marking line 27 would be at 60 degrees to the lengthwise axis of the second plank 23 f. In each case, only one intersection per joist is marked, and the marking line 27 could also be drawn with the use of a 60 degree triangle.
- plank 23 f may be marked with marking positions 26 and/or marking lines 27 without being placed on the surface of the joists 21 and/or having marking positions 26 marked.
- marking positions 26 and/or marking lines 27 may be measured and mark marking positions 26 and/or marking lines 27 along the bottom surface of the plank 23 f based on the known positions of, distance between, and orientation of the joists 21 .
- FIG. 15 shows how the hidden fasteners 1 h, 1 i are secured to the plank 23 f after it has been marked.
- a first set of hidden fastener 1 h is butted against an edge of the plank 23 f and the marking line 27 visible through and centered within the first hole 8 of the hidden fastener 1 h.
- the hidden fastener 1 h is secured to the second plank 23 f by inserting a screw 24 downward through the first hole 8 into the second plank 23 f.
- a second set of hidden fastener 1 i is affixed to the plank 23 f in the same manner along the opposing edge at each marking line 27 .
- plank 23 f is shown top side up after the hidden fasteners 1 h are secured at various positions corresponding to the intersections with each joist 21 .
- plank 23 f is ready to be positioned and affixed to the joists 21 adjacent a previously installed plank 23 e.
- plank 23 f is aligned relative to the previously installed plank 23 e, which serves as a reference together with its secured fasteners 1 j.
- the protruding ends 6 of the hidden fasteners 1 h are slid under the adjacent edge (i.e. near edge) of the reference plank 23 e.
- plank 23 f is pressed against the adjacent edge of the reference plank 23 e until the tabs 10 of the fasteners 1 h, 1 j abut the adjacent edges of the planks 23 e, 23 f when the planks are in their desired final position.
- the hidden fasteners 1 i at the near edge of the plank 23 f can then be secured to the joists 21 by inserting screws 24 downward through the second hole 9 of the hidden fastener 1 g into the joist 21 .
- planks are installed in the decking structure in the same manner as plank 23 f until the entire surface of the decking structure 20 is complete.
- the hidden fasteners can be stamped in a number of shapes with or without ribbed contours.
- the projecting ends of the hidden fasteners which are slid under a previous attached plank can be secured with screws from below after installation, or be left unsecured. This one secured edge of a plank holds down the adjacent edge of the adjacent plank. Accordingly, the invention has been described in several preferred embodiments by way of illustration rather than limitation.
Abstract
Description
- The invention relates to deck plank fastener for securing a deck plank to a joist and for supporting deck planks relative to one another. More particularly, the invention relates to a hidden deck plank fastener that is not visible, does not protrude from the deck surface, and is secured against the under-side of the planks.
- The simplest deck plank fastening system consists of a plurality of securing or anchoring elements, such as nails or screws, driven downward through the top of a plank, such as a wood or composite board, and into the top surface of a supporting beam, such as a joist or ledger board. Although the concept is simple, professional quality installation using this approach requires a high degree of precision, significant time expenditure, and sometimes leads to a flawed result.
- Deck planks installed using the simplest system of the preceding paragraph must be carefully aligned to achieve a desirable aesthetic as well as functional result, for example, secure attachment and uniform spacing or parallelism without large gaps. Also, the insertion of the nails or screws must be performed carefully to ensure proper penetration of the joist, which will be concealed from view by the overlying wood board at the time of insertion, in order to achieve optimal attachment. This process is time consuming and requires some skill.
- Even if the installation is performed properly, the anchoring element's penetration of the upper surface of the plank leaves the plank with a pock-marked appearance and prone to rot and weather damage, which severely decreases the longevity of the deck. In addition, the nail or screws may work loose and protrude from the upper surface of the planks, which poses a risk of injury to users of the deck. Penetration of the top of the plank decreases the integrity of the plank and thus the deck as a whole, and increases the risk of injury.
- These and other problems have spurred on numerous advancements in the field. For instance, an improved deck plank fastening system includes fasteners that attach to a side surface of the plank and a top surface of the joist using nails or screws. Such designs facilitate uniform spacing or parallelism of planks by providing tabs or vertically oriented flanges that engage adjacent planks. The tabs facilitate installation by locating the points of penetration at more readily visible and accessible positions. The fasteners improve the longevity of the resulting deck by repositioning the point of penetration to the side of the plank, which is less prone to weathering. In addition, the tabs reduce the risk of injury to the user of the deck by hiding the nails or screws below the surface. Also, the fasteners improve the aesthetic appeal of the deck.
- Many other improvements and permutations have been conceived in this field, including: replacing the use of nails or screws with sharp prongs or teeth that penetrate or bite into the deck planks to provide attachment; and increasing the angle of insertion (relative to the vertical) of the nail or screw into the joist to facilitate insertion. Such improvements have specific advantages in specific circumstances, but have not foreclosed innovation in the field.
- The object of the present invention is, therefore, to provide an improved deck plank fastener, which, among other desirable attributes, significantly reduces or overcomes the above-mentioned deficiencies of prior deck plank fasteners.
- Accordingly, the present invention provides a hidden deck plank fastener, a decking system, and methods for assembling a decking structure.
- A first aspect of the present invention is a hidden deck plank fastener for securing a deck plank to a joist. The fastener comprises a substantially flat body having a top surface, a first end, a second end and two opposing lateral edges. The fastener further comprises a first hole in the first end, and a second hole the second end. The fastener further comprises two tabs extending upward away from the body at an angle to the top surface from two opposing positions located along the opposing lateral edges.
- A second aspect of the present invention is a decking system using the hidden deck plank fastener of the first aspect of the present invention. The decking system comprises a plurality of joists arranged in a planar array at spaced intervals. The decking system further comprises a plurality of planks in spaced and side-by-side relationship on the joists, each plank having a near and a far edge, the near and far edges of adjacent planks being parallel to one another and confronting one another. The decking system further comprises a plurality of hidden fasteners securing the planks to the joists, each of a first set of the hidden fasteners connecting the bottom of a plank at the near edge to the top of a joist, and each of a second set of the hidden fasteners connecting to the bottom of a plank at a far edge projecting under the near edge of the adjacent plank.
- A third aspect of the present invention is a method for assembling a decking structure using the hidden deck plank fastener of the first aspect of the present invention. The first step of the method comprises providing a base formed by an array of spaced-apart joists, each joist having an upper surface lying in a common plane with the other joists. The second step comprises affixing a first plank to the plurality of joists in a desired position to serve as a reference plank. The third step comprises positioning a second plank with a bottom surface of the second plank facing upward. The fourth step comprises attaching each of a first plurality of fasteners to the bottom of the second plank at a far edge of the second plank and at positions corresponding to the underlying joists. The fifth step comprises attaching each of a second plurality of fasteners to the bottom of the second plank at a near edge of the second plank and at positions offset from the underlying joists. The sixth step comprises turning the second plank over so that the bottom surface of the second plank and the fasteners face downward. The seventh step comprises then positioning the second plank in the desired position side-by-side with the reference plank with each of the first plurality of fasteners overlying a joist, and each of the second plurality of fasteners projecting under an adjacent edge of the reference plank. The eighth step comprises securing each of the first plurality of fasteners to a corresponding joist. Lastly, the method includes installing a plurality of additional planks to the decking structure by repeating the third and subsequent steps with the second plank as the reference plank and the additional plank as the second plank.
- A fourth aspect of the present invention is a method for assembling a decking structure having planks angled at a predetermined angle, such as 45 degrees, to the joists using the hidden deck plank fastener of the first aspect of the present invention. The first step of the method comprises providing a base formed by an array of spaced-apart joists, each joist having an upper surface lying in a common plane with the other joists. The second step comprises affixing a first plank to a corner of the plurality of joists in a desired position and at the predetermined angle to the joists to serve as a reference plank. The third step comprises positioning a second plank on the joists side-by-side with the reference plank and in a position corresponding substantially to the desired position of the second plank in the decking structure with a top surface of the second plank facing upward. The fourth step comprises marking the bottom surface of the second plank along each joist with a marking line extending across the plank from the near edge to the far edge, each marking line being positioned to correspond substantially with the edge of the joist nearest the reference plank. The fifth step comprises attaching each of a first plurality of fasteners to the bottom surface of the second plank along the far edge at a position such that one of the plurality of marking lines is visible through a first hole of the first plurality of fasteners. The sixth step comprises attaching each of a second plurality of fasteners to the bottom surface of the second plank along the near edge at positions such that each marking line is visible through a first hole of the second plurality of fasteners. The seventh step comprises positioning the second plank in the desired position side-by-side with the reference plank with each of the second fasteners projecting under the adjacent edge of the reference plank. The eighth step comprises securing each of the plurality of the first plurality of fasteners to a joist. Lastly, the method includes installing a plurality of additional planks to the decking structure by repeating the third and subsequent steps with the second plank as the reference plank and the additional plank as the second plank.
-
FIG. 1 illustrates a perspective view of a deck plank fastener embodying the present invention in one embodiment; -
FIG. 2 illustrates a top plan view of the deck plank fastener inFIG. 1 ; -
FIG. 3 illustrates a cross-sectional side view of the deck plank fastener inFIG. 1 , viewed along the section line 3-3 ofFIG. 2 ; -
FIG. 4 illustrates an end view of the deck plank fastener inFIG. 1 ; -
FIG. 5 illustrates a decking structure using the deck plank fasteners; -
FIG. 6 shows the installing of a fastener at one edge of an inverted plank according to the present invention; -
FIG. 7 shows the installing of another fastener at the opposite edge of an inverted plank according to the present invention; -
FIG. 8 shows the inverted plank with fasteners at each edge in preparation for installation with a previously installed plank according to the present invention; -
FIG. 9 shows the detail of positioning a plank right side up with a previously installed plank according to the present invention; -
FIG. 10 shows the securing of a plank right side up in the desired position relative to a previously installed plank according to the present invention; -
FIG. 11 shows a first step of assembling the decking structure, wherein the deck planks are to be installed in a 45 degree angular orientation according to the present invention; -
FIG. 12 shows an initial plank inverted with fasteners secured at one edge in the 45 degree angular orientation installation according to the present invention; -
FIG. 13 shows the initial plank installed right side up in the 45 degree angular orientation installation according to the present invention; -
FIGS. 14A and 14B show the marking of a second plank for fastener locations in the 45 degree angular orientation installation according to the present invention; -
FIG. 15 shows multiple fasteners attached to each edge of an inverted plank in the 45 degree angular orientation installation according to the present invention; and -
FIG. 16 shows the positioning of a plank with fasteners right side up adjacent a previously installed plank in the 45 degree angular orientation installation according to the present invention. - Referring to
FIGS. 1-4 , a first embodiment of the hiddendeck plank fastener 1 is shown. Thedeck plank fastener 1 has abody 2, which is preferably stamped in finished form from a sheet of stainless steel in a metal forming press. Thebody 2 is generally rectangular as shown in the plan view ofFIG. 2 . Thebody 2 is a substantially planar member having atop surface 3 and abottom surface 4. Thebody 2 also has afirst end 5, asecond end 6 and two pairs of opposing lateral edges including long edges 11 andshort edges 12.First end 5 andsecond end 6 correspond to the ends of thebody 2 that abut the short edges 12. - It should be appreciated that a symmetrical or asymmetrical
deck plank fastener 1 is possible, and thus the designations offirst end 5,second end 6, long edges 11 andshort edges 12 do not necessarily indicate structural distinctions in all embodiments. - The
deck plank fastener 1 also has afirst hole 8 formed at a substantially central position of thefirst end 5 of thebody 2, and asecond hole 9 formed at a substantially central position of thesecond end 6 of thebody 2. Thefirst hole 8 and thesecond hole 9 are sized to receive an anchoring element, such as awood screw 24 as shown inFIG. 3 . - The
deck plank fastener 1 also has twotabs 10 which are integral with thelong edges 11 of thebody 2 and extend upward at an angle to thetop surface 3. The width oftabs 10 is set to establish plank-to-plank spacing in the resulting deck structure. Thetabs 10 may be positioned either closer toward thefirst end 5 or thesecond end 6 of thebody 2. Generally, the width and lateral placement of thetabs 10 is only limited by the distance between and relative positions of thefirst hole 8 andsecond hole 9. Thetabs 10 may be formed using a number of techniques but, preferably, are formed in the metal forming press contemporaneously with the forming of thebody 2. - The
body 2 is formed to include a plurality of ribbed contours, such asimpressed reinforcement contours 13. Thecontours 13 serve many functions including, for example, reinforcing the structure of thebody 2, promoting traction between thefastener 1 and the planks or joists, and providing body thickness for a deeperfirst hole 8 andsecond hole 9. - The
first hole 8 andsecond hole 9 are circumscribed by a pair ofconical recesses screws 24. Theconical recess 18, which surrounds thefirst hole 8, is tapered inwardly from thebottom surface 4 to thetop surface 3 and, hence, is larger at the bottom and smaller at the top as thefirst hole 8 approaches thetop surface 3. The taper of theconical recess 18 engages ascrew 24 that is inserted from the bottom side of thebody 2 through thefirst hole 8 and into a plank that abuts thetop surface 3 of thebody 2. Whereas theconical recess 19, which surroundssecond hole 9, is tapered inwardly from thetop surface 3 to thebottom surface 4 and, hence, is larger at the top and smaller at the bottom as thesecond hole 9 approaches thebottom surface 4. The taper ofconical recess 19 engages ascrew 24 that is inserted from the top side of thebody 2 through thesecond hole 9 and into a joist that abuts thebottom surface 4 of thebody 2. Referring toFIG. 3 , a cross-sectional view of thefastener 1 shows the undulating height of thecontours 13 and theholes conical recesses body 2. - Preferably, the anchoring elements are
screws 24, such as wood screws having conical-shaped head portions, as shown inFIG. 3 . It should be appreciated that thescrews 24 or other anchoring elements may be of many shapes and sizes and that thefirst hole 8 withconical recess 18 andsecond hole 9 withconical recess 19 may be shaped and sized to receive the anchoring elements. - Referring to
FIGS. 1-4 , thedeck plank fastener 1 also compriseswings 16, which are integral with theedges body 2 and are bent downward toward thebottom surface 4. Preferably,wings 16 are discontinuous around portions of theedges body 2 from which thetabs 10 extend. The length of thewings 16 along the edge of thebody 2 may be varied, but, preferably, the length is maximized such that awing 16 extends along the entire edge ofbody 2 except from where theupward tabs 10 extend. Preferably, thewings 16 are also discontinuous around the corners of thebody 2, for example, around corner carve-outs 15. However, thewings 16 may also be continuous around the corners by being formed into a rounded or angular corner. Like thetabs 10,wings 16 may be formed by many techniques, but, preferably, are formed in the metal forming press contemporaneously with the forming of thebody 2. Preferably, thewings 16 are bent at a smaller angle toward thebottom surface 4 than thetabs 10 are bent toward thetop surface 3. Thewings 16 serve many functions including, for example, reinforcing the structure of thebody 2, promoting traction between thefastener 1 and planks or joists, and facilitating the sliding of the protrudingfastener 1 attached to a plank under the exposed edge of a previously installed plank. - Referring to
FIG. 5 , the present invention provides adecking structure 20 that is constructed using the hidden fasteners ofFIGS. 1-4 . Thedecking structure 20 comprises a base structure formed by horizontal support beams, includingjoists 21 andledger boards 22. Thejoists 21 are connected at opposite ends of theledger boards 22 and at evenly spaced intervals. Together, thejoists 21 andledger boards 22 form a substantially horizontal plane that serves as a support surface for the planks 23. - A
first plank 23 a is attached to one side of thedecking structure 20. Preferably, thefirst plank 23 a is affixed to thejoists 21 andledger board 22 along one edge of the base structure such thatsecond plank 23 b can be attached in parallel across the entirety of the working surface created by thejoists 21. For discussion purposes, a plank has a near and a far edge, wherein the near edge faces the viewer inFIG. 5 and exposed joists of the base structure, and the far edge face away from the viewer inFIG. 5 and toward the installed planks. - For illustrative purposes, in
FIG. 5 , afirst plank 23 a is shown in an installed position in the decking structure on top of theledger board 22 and the mating ends of thejoists 21. Thefirst plank 23 a may be attached to thedecking structure 20 by any known means. Preferably, thefirst plank 23 a is attached using a set of the hidden fasteners la, which are secured to the top of theledger board 22 along the facing edge at positions offset from thejoists 21 usingscrews 24 or other anchoring elements. Preferably tofasteners 1 a are attached with thetabs 10 facing downward and butted against theledger board 22.Additional screws 24 are used to connect thehidden fasteners 1 a with the bottom of thefirst plank 23 a in its desired position and are installed from below theplank 23 a. Before installation of thefirst plank 23 a, another set ofhidden fasteners 1 b is attached along the near edge in the same manner as explained hereafter in connection with hiddenfastener 1 c andplank 23 c, as shown inFIG. 6 . Thefasteners 1 b are located at positions corresponding to theunderlying joists 21 so that thefirst plank 23 a can be secured to thejoists 21 by insertingscrews 24 or other anchoring elements downward into thejoists 21 from above the plank. - The second and subsequent planks 23 are also attached to the
joists 21 usinghidden fasteners 1. The planks 23 may be cut to length before placement or after being secured to thejoists 21. For the purposes of illustration and description, it will be assumed thatseveral planks FIG. 5 , and thatplank 23 c is the next plank to be installed in thedecking structure 20 adjacent to the near edge ofplank 23 b. - As shown in
FIG. 6 , to facilitate the securing of thehidden fasteners 1 c to the near edge of theplank 23 c, theplank 23 c is initially inverted and placed on the joists in the desired final position lengthwise with the bottom surface of theplank 23 c facing upward. - With the
plank 23 c inverted in the desired position, thehidden fastener 1 c is attached to the near edge of theplank 23 c above eachunderlying joist 21 with thetabs 10 butted up against the edge of theplank 23 c, thebottom surface 4 facing upward and thefree end 6 of the hiddenfastener 1 c projecting outward from the edge. Thefirst end 5 of thehidden fasteners 1 c is secured to theplank 23 c by inserting ascrew 24 or other anchoring element through thefirst hole 8 of the firsthidden fastener 1 c and driving thescrew 24 into theplank 23 c with a drill D or screw driver. - As shown in
FIG. 7 , another set ofhidden fasteners 1 d is attached to thebottom surface 4 of theinverted plank 23 c along the far edge at positions offset by a minimal distance A from theunderlying joists 21 and thehidden fasteners 1 c. Afirst end 5 of the hiddenfastener 1 d is attached to theplank 23 c by inserting ascrew 24 through the first hole of the hiddenfastener 1 d and driving thescrew 24 into theplank 23 c with a drill D or screw driver. Again, thetabs 10 of the hiddenfastener 1 d are butted up against the edge of theplank 23 c and thefree end 6 of the hiddenfastener 1 d projects outwards from the edge. -
FIG. 8 illustrates theinverted plank 23 c after the first and second sets ofhidden fasteners inverted plank 23 c is shown on the deck structure with previously installedplanks - With the hidden
fasteners plank 23 c is turned over into an upright position so that the top surface of theplank 23 c faces upward and thehidden fasteners - As shown in
FIG. 9 , the rightedplank 23 c is then positioned for attachment to thejoists 21 in approximately the proper position relative to theplank 23 b that was previously installed and serves as a reference. - The final positioning of the
plank 23 c relative to theplank 23 b is accomplished as shown inFIG. 9 by, first, sliding the projecting second ends 6 of thehidden fasteners 1 d, which are positioned on a far edge (as viewed inFIG. 5 ) of theplank 23 c, under the near edge of thereference plank 23 b. Theplank 23 c is slid in the direction of the arrow B toward thereference plank 23 b in the plane of the working surface created by thejoists 21 so that thefasteners 1 d slide under theplank 23 b untiltabs 10 of thehidden fasteners 1 c of thereference plank 23 b engage with far edge of theplank 23 c, andtabs 10 of thehidden fasteners 1 d of theplank 23 c engage with the near edge of thereference plank 23 b in the desired final position of theplank 23 c. Thetabs 10 thus establish a uniform spacing between theadjacent planks - Referring to
FIG. 10 , after positioning thesecond plank 23 c in its final, desired position, with thehidden fasteners 1 d projecting under the near edge of thereference plank 23 b and with the exposedsecond end 6 of thehidden fasteners 1 c overlying thejoists 21, thehidden fasteners 1 c are secured to thejoists 21 withscrews 24 and a drill D, or other anchoring means. - It should be appreciated that the turning over step and the positioning step may be merged into a single motion, for instance, by simultaneously rotating the
plank 23 c proximate to thereference plank 23 b, thereby causing theprotruding end 6 of thefasteners 1 d to pivot under thereference plank 23 b rather than slide, and pressing theplank 23 c toward thereference plank 23 b so that theplank 1 c is firmly held in the desired position. In either arrangement, the far edge of thesecond plank 23 c faces (or “confronts”) the near edge of thereference plank 23 b, creating the desired aesthetic of the decking structure. - Additional planks 23 are installed in the
decking structure 20 by repeating the fastener attachments and plank installing steps until the entire working surface of thedecking structure 20 is complete. - Referring to
FIGS. 11-16 , a method for assembling a decking structure having planks angled at a predetermined angle to the joists and utilizing thehidden fasteners 1 is shown. For exemplary purposes, this method will be described in relation to a decking structuring having planks angled at 45 degrees to the joists, however, it should be appreciated that the method is also applicable to other predetermined angle designs. - A base structure is provided using known techniques and methods as mentioned above. In general, the base structure comprises horizontal support beams, including the
parallel joists 21 connected at their ends withtransverse ledger boards 22 to establish a support surface for the planks. - Referring to
FIG. 11 , an initialhidden fastener 1 e is affixed to the top surface at the junction of theoutermost joist 21 and theledger board 22. The initialhidden fastener 1 e is preferably affixed such that thebottom surface 4 of the initialhidden fastener 1 e faces upward and thetabs 10 are aligned with the inside edge of theoutermost joist 21 or theledger board 22. The initialhidden fastener 1 e is secured by inserting ascrew 24 downward through thefirst hole 8 into thejoist 21 or theledger board 22. -
FIGS. 12-13 show the method of attaching afirst plank 23 d to the base. In a 45-degree angled decking structure, thefirst plank 23 d is shaped like an isosceles right triangle. Thefirst plank 23 d may be cut from a larger plank before or after the first plank is secured to the base. - It should be appreciated that a decking structure having planks angled relative to the joists at an angle other than 45 degrees would use a first plank of another shape (i.e. not an isosceles right triangle). For instance, a decking structure having planks angled at 30 degrees relative to the joists would use a first plank of a 30-60 degree right triangle.
- Referring to
FIG. 12 , if thefirst plank 23 d has a textured or otherwise designated upper surface, the plank is inverted with the upper surface facing downward. If desired, the plank may be located on theoutermost joist 21 a and theledger board 22 to facilitate placement of thefasteners - The
hidden fastener 1 f of thefirst plank 23 d is secured by ascrew 24 along the hypotenuse edge of theplank 23 d at a position such that the firsthidden fastener 1 f is a predetermined distance from the apex of the adjacent 45 degree angle. The predetermined distance is set so that the projectingsecond end 6 of the hiddenfastener 1 f overlies thejoist 21 orledger board 22 when theplank 23 d is installed in the upright position, as shown, for example, inFIG. 13 . The secondhidden fastener 1 g of thefirst plank 23 d is secured by ascrew 24 along the hypotenuse edge of thefirst plank 23 d at a predetermined distance from the apex of the adjacent 45 degree angle in the same fashion. In each case, the fasteners are secured with thetabs 10 abutting the hypotenuse edge. - It should be appreciated that the amount that
first plank 23 d overhangs theoutermost joist 21 andledger board 22 may be adjusted by altering the placement of thehidden fasteners first plank 23 d. In addition, to create a deck wherein the planks 23 are flush with the edge of thejoists 21 andledger board 22, a doubler (not shown) may be required at the corner for thefirst plank 23 d. In general, a doubler is attached to the inside of theoutermost joist 21 or theledger board 22 facing toward the array ofjoists 21 and extending from the intersection of theoutermost joist 21 and the ledger board 22 a sufficient distance to provide fastening points for the fasteners connected to thefirst plank 23 d. If a doubler is used, the initialhidden fastener 1 e may be affixed to the doubler rather than theoutermost joist 21 or theledger board 22. - Referring to
FIG. 13 , thefirst plank 23 d is turned upright so that the top surface of thefirst plank 23 d faces upward. Next, thefirst plank 23 d is aligned relative to theoutermost joist 21 andledger board 22 so that the securingholes 9 of thehidden fasteners outermost joist 21 andledger board 22. For example, in a deck structure assembled with planks at 45 degrees to thejoists 21, the apex of the right angle of the triangle-shapedfirst plank 23 d points away from the array ofjoists 21, the two sides of the triangle-shapedfirst plank 23 d are parallel to theoutermost joist 21 andledger board 22 respectively, and the hypotenuse of the triangle-shapedfirst plank 23 d runs at 45 degrees to theoutermost joist 21 andledger board 22. - After placement, the
first plank 23 d is secured to theoutermost joist 21 andledger board 22 by insertingscrews 24 downward through thesecond holes 9 of thehidden fasteners first plank 23 d into theoutermost joist 21 andledger board 22, respectively. Finally, theoutermost joist 21 is secured to thefirst plank 23 d by inserting ascrew 24 upward through thesecond hole 9 of the initialhidden fastener 1 e into thefirst plank 23 d. - Once installed, the first plank serves the function of a reference plank for the adjacent planks.
-
FIGS. 14A , 14B, 15 and 16 show the installation of a second 45degree plank 23 f on the base structure after severalother planks 23 e have been installed utilizing the hidden fasteners. In particular,FIG. 14A shows thesecond plank 23 f positioned with a top surface of theplank 23 f facing upward in a position corresponding to a desired final position of theplank 23 f on the decking structure spaced from the previously installed plank (seeFIG. 16 ) by thetabs 10 of thefastener 1 b. Theplank 23 f may be cut to size and shape before or, if permitted, after installation. - An exposed near edge of the
second plank 23 f is marked with a markingutensil 25 at markingpositions 26 corresponding to the intersections of the edge of theplank 23 f and the far side of eachjoist 21. Each intersection of theplank 23 f edge with thejoists 21 is marked. - The
plank 23 f is then turned over so that the bottom surface of theplank 23 f faces upward, as shown inFIG. 14B , and markinglines 27 are extended from the markingpositions 26 across the bottom ofplank 23 f at a 45 degree angle to theplank 23 f. The marking lines 27 thus correspond to the far side of the intersectingjoists 21 and could also be drawn from below using the joists themselves as a guide. For example, in a decking structure having planks angled at 60 degrees to thejoists 21, the markingline 27 would be at 60 degrees to the lengthwise axis of thesecond plank 23 f. In each case, only one intersection per joist is marked, and the markingline 27 could also be drawn with the use of a 60 degree triangle. - It should be appreciated that the
plank 23 f may be marked with markingpositions 26 and/or markinglines 27 without being placed on the surface of thejoists 21 and/or having markingpositions 26 marked. One skilled in the art could measure and mark markingpositions 26 and/or markinglines 27 along the bottom surface of theplank 23 f based on the known positions of, distance between, and orientation of thejoists 21. -
FIG. 15 shows how thehidden fasteners plank 23 f after it has been marked. A first set of hiddenfastener 1 h is butted against an edge of theplank 23 f and the markingline 27 visible through and centered within thefirst hole 8 of the hiddenfastener 1 h. After thehidden fastener 1 h is properly aligned, thehidden fastener 1 h is secured to thesecond plank 23 f by inserting ascrew 24 downward through thefirst hole 8 into thesecond plank 23 f. As shown, a second set of hiddenfastener 1 i is affixed to theplank 23 f in the same manner along the opposing edge at each markingline 27. - Referring to
FIG. 16 , theplank 23 f is shown top side up after thehidden fasteners 1 h are secured at various positions corresponding to the intersections with eachjoist 21. - The
plank 23 f is ready to be positioned and affixed to thejoists 21 adjacent a previously installedplank 23 e. - The
plank 23 f is aligned relative to the previously installedplank 23 e, which serves as a reference together with itssecured fasteners 1 j. First, the protruding ends 6 of thehidden fasteners 1 h are slid under the adjacent edge (i.e. near edge) of thereference plank 23 e. Next,plank 23 f is pressed against the adjacent edge of thereference plank 23 e until thetabs 10 of thefasteners planks hidden fasteners 1 i at the near edge of theplank 23 f can then be secured to thejoists 21 by insertingscrews 24 downward through thesecond hole 9 of the hiddenfastener 1 g into thejoist 21. - Additional planks are installed in the decking structure in the same manner as
plank 23 f until the entire surface of thedecking structure 20 is complete. - It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the broader aspects of the present invention. For example, the hidden fasteners can be stamped in a number of shapes with or without ribbed contours. The projecting ends of the hidden fasteners which are slid under a previous attached plank can be secured with screws from below after installation, or be left unsecured. This one secured edge of a plank holds down the adjacent edge of the adjacent plank. Accordingly, the invention has been described in several preferred embodiments by way of illustration rather than limitation.
Claims (21)
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US12/355,123 US20100180532A1 (en) | 2009-01-16 | 2009-01-16 | Deck plank fastener |
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US12/355,123 US20100180532A1 (en) | 2009-01-16 | 2009-01-16 | Deck plank fastener |
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US20100180532A1 true US20100180532A1 (en) | 2010-07-22 |
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US12/355,123 Abandoned US20100180532A1 (en) | 2009-01-16 | 2009-01-16 | Deck plank fastener |
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US20100186338A1 (en) * | 2007-07-02 | 2010-07-29 | Ecoform Pty Ltd | Abutment for a Modular Decking System |
EP2754770A1 (en) * | 2013-01-15 | 2014-07-16 | Placoplatre | Construction panel for installation on a framework |
USD792757S1 (en) | 2016-06-20 | 2017-07-25 | Simpson Strong-Tie Company Inc. | Deck board fastener |
USD795049S1 (en) | 2016-06-20 | 2017-08-22 | Simpson Strong-Tie Company Inc. | Deck board fastener |
USD796306S1 (en) | 2016-06-20 | 2017-09-05 | Simpson Strong-Tie Company Inc. | Deck board fastener |
USD796305S1 (en) | 2016-06-20 | 2017-09-05 | Simpson Strong-Tie Company Inc. | Deck board fastener |
US10113306B2 (en) | 2016-06-20 | 2018-10-30 | Simpson Strong-Tie Company Inc. | Deck board fasteners |
US20230243161A1 (en) * | 2020-09-07 | 2023-08-03 | Gihong Kim | Bracket for connecting wooden decks, and wooden deck coupling structure using same |
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US7621089B2 (en) * | 1999-07-02 | 2009-11-24 | John Potter | Prefabricated modular building component and method of use |
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US4296580A (en) * | 1978-09-29 | 1981-10-27 | Weinar Roger N | Wall constructed from panels held in position with the aid of concealed fasteners and concealable fasteners for use in assembling such wall |
US4255914A (en) * | 1978-10-23 | 1981-03-17 | Automated Building Components, Inc. | Clip for securing planar members |
US4448007A (en) * | 1981-04-22 | 1984-05-15 | Adams George C | Wall panel fastener |
US4498272A (en) * | 1982-05-20 | 1985-02-12 | Rollform, Incorporated | Panel fastener |
US4777778A (en) * | 1986-01-27 | 1988-10-18 | Etudes G.P. Realisations | Fastener for fixing wall-covering material to a batten |
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US20070056243A1 (en) * | 2005-08-19 | 2007-03-15 | Riccitelli Martin G | Hidden deck fastener system |
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Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100186338A1 (en) * | 2007-07-02 | 2010-07-29 | Ecoform Pty Ltd | Abutment for a Modular Decking System |
US9096975B2 (en) * | 2007-07-02 | 2015-08-04 | Ecoform Pty Ltd | Abutment for a modular decking system |
EP2754770A1 (en) * | 2013-01-15 | 2014-07-16 | Placoplatre | Construction panel for installation on a framework |
WO2014111428A1 (en) * | 2013-01-15 | 2014-07-24 | Placoplatre | Construction panel for installation on a framework |
US9803370B2 (en) | 2013-01-15 | 2017-10-31 | Placoplatre | Construction panel for installation on a framework |
USD796306S1 (en) | 2016-06-20 | 2017-09-05 | Simpson Strong-Tie Company Inc. | Deck board fastener |
USD795049S1 (en) | 2016-06-20 | 2017-08-22 | Simpson Strong-Tie Company Inc. | Deck board fastener |
USD796305S1 (en) | 2016-06-20 | 2017-09-05 | Simpson Strong-Tie Company Inc. | Deck board fastener |
USD792757S1 (en) | 2016-06-20 | 2017-07-25 | Simpson Strong-Tie Company Inc. | Deck board fastener |
US10113306B2 (en) | 2016-06-20 | 2018-10-30 | Simpson Strong-Tie Company Inc. | Deck board fasteners |
US10309099B2 (en) * | 2016-06-20 | 2019-06-04 | Simpson Strong-Tie Company Inc. | Deck board fastener methods |
US20230243161A1 (en) * | 2020-09-07 | 2023-08-03 | Gihong Kim | Bracket for connecting wooden decks, and wooden deck coupling structure using same |
US11859391B2 (en) * | 2020-09-07 | 2024-01-02 | Gihong Kim | Bracket for connecting wooden decks, and wooden deck coupling structure using same |
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