Modular decking planks

Abstract

A decking system for placement on a subassembly having at least two spaced apart joists. A plurality of elongated tubular elements for placement in lateral interlocking engagement with each other transversely of and spanning the distance between the joists. Each of said plurality of elements having a top portion, a bottom portion, and first and second side walls connecting said top and bottom portions. The top portion extends laterally beyond the first side wall and has formed thereon a downwardly extending longitudinal flange. The bottom portion extends laterally beyond the second side wall and has formed thereon an upwardly extending longitudinal wall defining an upwardly opening channel adjacent the second side wall adapted to receive therein a watertight relation the downwardly extending longitudinal flange. The bottom portion having formed therein a plurality of apertures intermediate the second side wall and the upwardly extending longitudinal wall, adapted for the insertion of fasteners therethrough for engagement with the joists.

Description

FIELD OF THE INVENTION[0001]The present invention relates generally to construction materials and more particularly to materials used for indoor and outdoor decking. In even greater particularity the present invention relates to the use of prefabricated decking planks and in still greater particularity to decking planks made from extruded materials. The invention is applicable, for example, in the construction of boat docks, piers, decks, patios, walkways, pontoon boat floors, and the like.BACKGROUND OF THE INVENTION[0002]Extruded polyvinyl building and construction materials are increasing in popularity due to their light weight, which greatly simplifies shipping, handling and installation, and also due to their durability in adverse weather conditions, which greatly increases their service life. Polyvinyl materials do not need to be periodically painted or preserved, which greatly lowers maintenance costs, and modern ultraviolet inhibitors prevent UV breakdown of polyvinyl materia...

AI Technical Summary

Benefits of technology

[0012]It is an object of the invention to provide a modular, one-piece plastic construction element which may be readily assembled together with a number of like elements to form a decking or other structure.

[0013]It is another object of the invention to provide a modular decking plank that is relatively inexpensive to manufacture.

Problems solved by technology

Because nails or screws driven directly through the plastic are likely to cause stress risers and / or cracking, the hollow extruded members require special mounting brackets or cleats in order to secure the members to the supporting frame or structure.

Such prior art systems have a number of drawbacks, including relatively high material costs and relatively long installation time, and on many such systems it is difficult to properly align the holes in the deck members with the preinstalled clips.

Moreover, if the pre-installed clips are not mounted properly the decking members may move or “wander” slightly, giving the deck an unsightly and unprofessional appearance.

Unlike the invention, such two-piece designs generally require substantial time and effort to assemble.

Another drawback with prior art methods is that polyvinyl, like all construction materials, flexes slightly under load.

On conventional wood decks such flexing is almost completely unnoticeable.

However, on plastic or polyvinyl decks such flexing often creates an unnerving and unpleasant squeak or creaking sound.

For many reasons, most consumers consider such speaking and creaking a very undesirable attribute.

Further, known polyvinyl decking has a tendency to deform along reinforcement lines, thus creating unsightly rows along the plank.

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