Connector
The connector with a housing and projections simplifies lighting unit installation in composite decking by using existing panel recesses, providing a secure and flush attachment to the support structure, addressing installation challenges and thermal expansion.
Patent Information
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-09-13
- Publication Date
- 2026-03-18
AI Technical Summary
Installing lighting units in flooring, particularly with composite decking panels, often requires significant modifications or results in impractical protrusions, complicating the installation process.
A connector with a housing and projections that fits into pre-existing recesses of composite decking panels, allowing simultaneous secure attachment of lighting units and decking panels to a support structure, while maintaining a flush installation.
Simplifies lighting unit installation by leveraging existing decking panel features, ensuring a flush and secure connection without additional modifications, and accommodating thermal expansion.
Smart Images

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Abstract
Description
Field of the Invention The present invention relates to hardware for use with composite decking panels and particularly, although not exclusively, to hardware for installing lighting with composite decking panels. Background When constructing an area of decking, decking panels are laid on, and secured to, a support structure of joists. Decking panels are often secured to the support structure using a dedicated connector. Lighting units are frequently installed in and around buildings and built structures in order to provide functional or aesthetic lighting or lighting effects. Often, lighting units require a specific type of installation unit depending on the type of lighting unit being installed as well as where the lighting unit is being installed, for example, on a wall, in a ceiling or in a floor. Installing a lighting unit in a floor often presents a challenge as it either requires significant modifications to the flooring in order to accommodate the lighting unit or the lighting unit has to sit proud of the floor, which can be impractical. The present invention has been devised in light of the above considerations. Summary of the Invention According to a first aspect, there is provided a connector for attaching a lighting unit to a first composite decking panel, the connector comprising: a housing defining a channel for receiving the lighting unit; and a first projection protruding from the housing and away from the channel for receipt in a first recess of the first composite decking panel, wherein the first projection is spaced away from an upper edge of the housing. The invention provides a means of attaching a lighting unit to a composite decking panel leveraging a preexisting recess of the composite decking panel. As will be described in further detail below, the invention also provides a means of simultaneously securing the composite decking panel to a support structure and attaching the lighting unit to the composite decking panel using the connector. In other words, there is provided a connector for attaching a lighting unit to a composite decking panel by providing the lighting unit into a channel of the connector which comprises a projection adapted to extend into a recess of the composite decking panel. Put another way, there is provided a lighting installation connector adapted to secure a lighting unit to a composite decking panel. A composite decking panel is a type of flooring used in the construction of decking, for example in a garden or an outdoor area. A composite decking panel may be formed from a mixture of materials, such as a mixture of wood and plastic, or from a single material, such as wood or plastic. When constructing an area of decking, decking panels are laid on, and secured to, a support structure. The support structure may comprise one or more decking joists. The connector may be adapted to secure the first composite decking panel to a decking joist of the support structure. For example, securing the connector to the support structure when the first projection is received in the first recess may secure, or clamp, the first composite decking panel to the support structure. Composite decking panels are typically provided with a recess in a side wall of the composite decking panel, the width of the side wall of the composite decking defining a thickness of the composite decking panel. The recess typically extends along, or at least substantially along, a length of the composite decking panel. When composite decking panels are to be installed to construct an area of decking, adjacent composite decking panels are connected to each other by providing an attachment mechanism in the recess of one composite decking panel. The attachment mechanism is then also received in the recess of an adjacent composite decking panel in order to attach two composite decking panels together side by side. Once attached, the two composite decking panels will sit flush, or substantially flush, for example with a gap to provide drainage, side by side. The attachment mechanism is then secured to a support structure underlaying the area of decking. By providing a connector with a first projection spaced away from an upper edge of the housing, the connector may be Installed in an existing feature of a first composite decking panel without requiring further modification of the first composite decking panel or the connector. In this way, the attachment of a lighting unit to a first composite decking panel, or between a first composite decking panel and a second composite decking panel, is simplified by the connector. The channel may be an open cavity in the housing for receiving the lighting unit. The channel may be defined by first and second opposing side walls and a base. The side walls may each have a respective upper edge. The first projection may be a first transverse projection protruding from the first side wall. The first projection may be spaced from the upper edge of the first side wall. The first side wall of the housing may comprise a first inner surface, a first outer surface and a first upper edge. The second side wall of the housing may comprise a second inner surface, a second outer surface and a second upper edge. The second side wall may oppose the first side wall such that the second inner surface faces the first inner surface. The base may comprise a lower base surface facing away from the first upper edge and the second upper edge. The base may separate the first side wall and the second side wall. The first projection may protrude from the first outer surface of the first side wall for receipt in the first recess of the first composite decking panel. The lighting unit may be received loose within the channel. The lighting unit may be adhered, or otherwise attached, for example releasably attached, to one of the first inner surface, the second inner surface and an upper surface of the base. The lighting unit may be suspended within the cavity by a lighting unit supporting structure. When the first projection of the connector is provided in the first recess of the first composite decking panel and the first composite decking panel located on the supporting structure, a first portion of the composite decking, which may be a lower lip of the recess, may be provided between the first projection and the supporting structure. In particular, a lower projection surface of the first projection may abut an upper surface of the lower lip of the recess and a lower surface of the lower lip of the recess, opposite the upper surface of the lower lip, may abut a supporting surface of the support structure. The connector may be an elongate connector. In some examples, the housing comprises a longitudinal axis extending along a length of the channel (and so a length of the connector), wherein first projection protrudes in a transverse direction perpendicular to the longitudinal axis. A length of the connector, and so the housing and the channel, may be commensurate with a length of one or more composite decking panels. In some examples, the first projection comprises an elongate first projection extending along the housing in a longitudinal direction parallel to the longitudinal axis. Put another way, the first projection may extend along an axis parallel to the longitudinal axis of the housing in order to extend along a length of the channel in addition to protruding from the housing in a transverse direction perpendicular to the longitudinal axis. In some examples, the first projection comprises a plurality of first projections arranged along the housing in a longitudinal direction parallel to the longitudinal axis. The plurality of first projections may be arranged along the housing in a row of first projections. Each projection of the plurality of first projections may extend partially along the housing in a longitudinal direction parallel to the longitudinal axis. The first projection is dimensioned to be received within the first recess of the first composite decking panel. The first projection may be dimensioned to be received within the first recess of the first composite decking panel with a loose fit. The first projection may be dimensioned to be received within the first recess of the first composite decking panel with a snug fit. In some examples, the first projection protrudes from the housing, for example from the first outer surface of the first side wall, at a normal to the housing. The first projection may be angled with respect to the housing, for example with respect to the first outer surface of the first side wall, in order to cooperate with an angle of the first recess of the first composite decking panel with respect to the side wall of the composite decking panel. In some examples, the first projection protrudes from the housing, for example from the first outer surface of the first side wall, such that an angle between the first projection and the housing is an acute angle. In some examples, the connector further comprises a second projection protruding from the housing in a direction opposite to the first projection and away from the channel for receipt in a second recess of a second composite decking panel. The form and function of the second projection, and the interaction between the second projection and the second composite decking panel, may be analogous to the form and function of the first projection, and the interaction between the first projection and the first composite decking panel, as described herein. The second projection may be a second transverse projection protruding from the second side wall. The second projection may be spaced from the upper edge of the second side wall. As outlined above, when two composite decking panels are installed side by side when constructing a deking area, an attachment mechanism is usually provided to connect the composite decking panels to each other. By providing the connector with a first projection to be received in a first recess of a first composite decking panel and a second projection to be received in a second recess of a second composite decking panel, the connector may be adapted to perform the dual purpose of connecting two composite decking panels together side by side and securing the connecting two composite decking panels to a supporting structure, whilst also installing a lighting unit therebetween. Put another way, the connector may provide a means of joining two adjacent composite decking panels, securing the two adjacent composite decking panels to the supporting structure and installing a lighting unit between the two adjacent composite decking panels using the same, single component. Accordingly, the functionality of a conventional attachment mechanism may be replicated with the connector of the present disclosure with the additional functionality of providing a means of installing a lighting unit in a flooring formed of composite decking panels. In other words, the connector may provide a means for installing a lighting unit between two adjacent composite decking panels whilst also maintaining a secure mechanical connection between the adjacent composite decking panels and a supporting structure. The second projection may extend from the second outer surface of the second side wall for receipt in the second recess of the second composite decking panel. In some examples, the second projection extends from the housing, for example from the second outer surface of the second side wall, at a normal to the housing. The second projection may be angled with respect to the housing, for example the second outer surface of the second side wall, in order to cooperate with an angle of the second recess of the second composite decking panel with respect to the side wall of the second composite decking panel. In some examples, the second projection protrudes from the housing, for example from the second outer surface of the second side wall, such that an angle between the second projection and the housing is an acute angle. The first projection and the second projection may be angled the same with respect to the housing, for example with respect to the first outer surface of the first side wall and the second outer surface of the second side wall, respectively. The angle between the first projection and the housing, for example between the first projection the first outer surface of the first side wall, may be different from the angle between the second projection and the housing, for example between the second projection and the second outer surface of the second side wall. In some examples, the connector is formed from a metal. For example, the metal may be aluminium. It should be noted that the connector may be formed from any suitable metal, or any other suitable material, such as a plastic, for example a reinforced plastic. The connector may be dimensioned in order to be suitable for securing the first composite decking panel, and in some examples the second composite decking panel, to a supporting structure and for receiving the lighting unit. The first side wall, the second side wall and the base of the housing may have substantially the same thickness, for example a thickness of 2mm. The first side wall and the second side wall of the housing may be spaced apart by at least 4mm, for example by 6mm. The first side wall and the second side wall may have a height of at least 10mm, for example at least 15mm, for example 19mm. The channel defined by the housing, for example by the first inner surface of the first side wall, the second inner surface of the second side wall and the upper surface of the base, may have a 6mm by 17mm rectangular crosssection. In some examples, the first projection has a first thickness , for example extending in a direction parallel to the first outer surface and perpendicular to the longitudinal axis of the housing, and wherein the first thickness is at least 2mm, for example at least 4mm, for example 5mm. In some examples, the first projection protrudes from the housing, for example from the first outer surface, by at least 2mm, for example by at least 4mm. The first projection may have a square cross-section. The second projection may have the same dimensions as the first projection. For example, the second projection may have a second thickness, for example extending in a direction parallel to the second outer surface and perpendicular to the length of the channel, and wherein the second thickness is at least 2mm, for example at least 4mm, for example 5mm. In some examples, the second projection protrudes from the housing, for example from the second outer surface, by at least 2mm, for example by at least 4mm. In some examples, the first projection, for example an upper surface of the first projection, is spaced from an upper edge, for example the first upper edge along the first outer surface, by at least 2mm, for example by at least 4mm, for example by at least 6mm. The first projection, for example a lower surface of the first projection, may be spaced from a lower edge of the housing, for example the lower base surface along the first outer surface, by at least 2mm, for example by at least 4mm, for example by at least 6mm. In some examples, the first projection is spaced equally from the upper edge of the sound, for example the first upper edge of the first side wall, and the lower edge of the housing, for example the lower base surface of the base. The second projection may be aligned with the first projection. For example, the second projection, for example an upper surface of the second projection, may be spaced from an upper edge of the housing, for example the second upper edge along the second outer surface, by at least 2mm, for example by at least 4mm, for example by at least 6mm. The second projection, for example a lower surface of the second projection, may be spaced from a lower edge of the housing, for example the lower base surface along the second outer surface, by at least 2mm, for example by at least 4mm, for example by at least 6mm. In some examples, the second projection may be spaced equally from the upper edge of the housing, for example the second upper edge of the second side wall, and the lower edge of the housing, for example the lower base surface of the base. The dimensions of the connector may be adjusted according to the dimensions of the composite decking panels being used. In some examples, the connector further comprises a sealing unit for sealing the channel, the sealing unit comprising a sealing surface for contacting the upper edge of the housing, for example at least one of the first upper edge of the first side wall and the second upper edge of the second side wall. The sealing unit may seal the channel, such that the channel is bounded by the first inner surface, the second inner surface, the upper surface of the base and a lower surface of the sealing unit. The sealing surface, or at least a portion of the sealing surface, may contact the first upper edge and the second upper edge. The sealing surface may form part, or several non-continuous parts, of the lower surface of the sealing unit. The sealing unit may prevent matter, such as water, for example rainwater, or debris from entering the channel of the housing of the connector. The sealing unit may extend along a length of the channel. Put another way, the sealing unit may extend along an axis parallel to a longitudinal axis of the housing. The length of the sealing unit may be commensurate with the length of the connector, which in turn may be commensurate with a length of one or more composite decking panels. In some examples, the sealing unit comprises a first flange having a first top surface and a first portion of the sealing surface, opposite the first top surface, for contacting the first upper edge of the first side wall. The first flange may project from the sealing unit such that the first flange overlays, or substantially overlays, the first upper edge of the first side wall. In some examples, the sealing unit comprises a second flange having a second top surface and a second portion of the sealing surface, opposite the second top surface, for contacting the second upper edge of the second side wall. The second flange may project from the sealing unit such that the second flange overlays, or substantially overlays, the second upper edge of the second side wall. The first and second flanges may comprise first and second portions of the sealing surface, respectively. The first flange may be separated from the second flange by a remaining portion of the sealing unit. The first portion of the sealing surface and the second portion of the sealing surface may be separated from each other or non-continuous. The first portion of the sealing surface may be separated from the second portion of the sealing surface by a remaining portion of the sealing unit. The first flange, the second flange and the sealing unit may be formed from a unitary body. In some examples, the sealing unit further comprises an ancillary housing defining an ancillary channel for receiving the lighting unit, wherein the ancillary channel is adapted to be received in the channel of the connector with a friction fit. Put another way, the lighting unit may be received within the sealing unit, and in particular within the ancillary channel, which is then installed into the channel of the housing of the connector. In this way, the lighting unit may be held out of contact with the connector, thereby insulating the lighting unit from the surfaces of the connector, which may be formed of metal. In addition, the sealing unit may provide a barrier between the lighting unit and the connector when the lighting unit is being installed into the channel, thereby providing increased protection for the lighting unit and preventing, or mitigating, the risk of accidentally damaging the lighting unit on installation. The ancillary channel may be defined by first and second opposing ancillary side walls and an ancillary base. The first ancillary wall may comprise a first ancillary inner surface and a first ancillary outer surface. The second ancillary wall may comprise a second ancillary inner surface and a second ancillary outer surface. The second ancillary wall may oppose the first ancillary wall such that the second ancillary inner surface faces the first ancillary inner surface. The ancillary base may separate the first ancillary wall and the second ancillary wall. When the ancillary housing is received in the channel of the housing, the first ancillary outer surface may face the first inner surface and the second ancillary outer surface may face the second inner surface. In some examples, the sealing unit comprises one or more resiliently deformable projections provided on the housing and projecting away from the ancillary channel. For example, the one or more resiliently deformable projections may be provided on the first ancillary outer surface and / or the second ancillary outer surface for contacting the channel of the connector. In this way, the strength of the friction fit between the sealing unit and the connector, and in particular the channel of the housing, may be improved. The one or more resiliently deformable projections may be integral with the sealing unit, i.e., formed in the same unitary body with the sealing unit, or be attached to the housing, for example the first and / or second ancillary outer surface, of the sealing unit. In some examples, the sealing unit comprises an ancillary sealing member for sealing an opening of the ancillary channel, thereby enclosing the lighting unit within the ancillary channel. In this way, the lighting unit may be sealed from the environment within the sealing unit when the lighting unit is installed into the channel of the connector. The sealing member may prevent matter, such as water, for example rainwater, or debris from entering the ancillary channel and coming into contact with the lighting unit. In some examples, the ancillary sealing member comprises an ancillary sealing surface adapted to contact the first top surface of the first flange and the second top surface of the second flange. For example, the first flange of the sealing unit may be provided between a first upper edge of the first side wall of the housing and the ancillary sealing member and the second flange of the sealing unit may be provided between a second upper edge of the second side wall of the housing and the ancillary sealing member. In some examples, the ancillary sealing member has an ancillary top surface, wherein the ancillary top surface is a curved surface, for example a convex surface. In this way, matter, such as water, for example rainwater, may run off or fall away from the sealing member in order to prevent buildup or pooling over the connector, and in particular over the channel. In some examples, the ancillary sealing member is formed of silicone. The ancillary sealing member may be transparent or translucent. In some examples, the sealing unit is formed from a plastic. According to a second aspect there is provided a kit for attaching a lighting unit to a first composite decking panel, the kit comprising: a connector as described above; and a first composite decking panel comprising a first recess for receiving the first projection. In some examples, the kit further comprises a lighting unit. In some examples, the lighting unit comprises a light emitting diode, LED, and optionally wherein the lighting unit comprises an LED strip. In some examples, the kit further comprises an attachment member for securing the connector to a support structure, thereby securing the first composite decking panel to the support structure when the first projection is received in the first recess when the first projection is received in the first recess. For example, the attachment member may comprise a self-tapping screw that can pass through the base of the channel of the housing of the connector and Into the support structure. According to a third aspect, there is provided a system for attaching a lighting unit to a first composite decking panel, the system comprising: a first composite decking panel comprising a first recess; a connector comprising: a housing defining a channel for receiving the lighting unit; and a first projection protruding from the housing and away from the channel for receipt in a first recess of the first composite decking panel, wherein the first projection is spaced away from an upper edge of the housing, wherein the first projection is received in the first recess. The connector may comprise any of the features described above. In some examples, the system further comprises a lighting unit received in the channel. The lighting unit may comprise a light emitting diode, LED, and optionally an LED strip. In some examples, the system further comprises: a support structure for supporting the first composite decking panel; and an attachment member for securing the connector to the support structure such that the first composite decking panel is clamped between the first projection and the support structure. Accordingly, as the connector is secured to the support structure, the first projection may be brought into contact with an internal surface of the first recess in order to clamp the first composite decking panel to the support structure. In some examples, the connector is dimensioned such the connector is recessed with respect to an upper surface of the first composite decking panel, and optionally an upper surface of the second decking panel, for example by 2mm or more. In some examples, the sealing unit is dimensioned such that the sealing unit is recessed with respect to the upper surface of the first composite decking panel, and optionally an upper surface of the second decking panel, when the sealing unit is in contact with an upper edge of the housing, for example with at least one of the first upper edge of the first side wall and the second upper edge of the second side wall. The sealing unit may be recessed with respect to the upper surface of the first composite decking panel, and optionally an upper surface of the second decking panel, by 2mm or more. In this way, the connector and / or sealing unit may be recessed with respect to the upper surface, or walking surface where a person may walk, of the composite decking panel. Accordingly, the connector and / or sealing unit may be protected from additional stresses. In some examples, the first recess is larger than the first projection in at least one dimension to provide a first thermal expansion gap between the connector and the first composite decking panel and wherein the second recess is larger than the second projection in at least one dimension to provide a second thermal expansion gap between the connector and the second composite decking panel. Put another way, the first projection, and in some examples the second projection, of the connectors described above may be sized to fit loosely within the respective recess of the composite decking panels. The thermal expansion coefficient of the connector may be different to the thermal expansion coefficient of the composite decking panels. By providing a connector with projection(s) dimensioned to fit loosely within the recess(es) of the composite decking panel(s), the composite decking panel(s) and the connector may expand and contract, or shift slightly under stress such as a person walking over the composite decking panel(s), without the connector exerting additional stress on the composite decking panel(s). In this way, the lifespan of the system may be improved. In some examples, the system further comprises: a second composite decking panel comprising a second recess, and wherein the connector further comprises: a second projection protruding from the housing in a direction opposite to the first projection and away from the channel, wherein the second projection is received in the second recess. According to a fourth aspect, there is provided a method for securing a first composite decking panel to a support structure and installing a lighting unit into the first composite decking panel, the method comprising: locating the first composite decking panel on the support structure; inserting a first projection of a connector as described above into a first recess of the first composite decking panel; securing the base of the connector to the support structure using an attachment member; and inserting a lighting unit into the channel of the connector. The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided. Summary of the Figures Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which: Figure 1 shows a connector according to an aspect of the disclosure. Figures 2A and 2B show the connector of Figure 1 installed between two composite decking panels and securing the two composite decking panels to a support structure. Figure 3 shows a connector according to an aspect of the disclosure installed between two composite decking panels. Detailed Description of the Invention Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference. Figures 1,2A and 2B show a connector 100 for attaching a lighting unit 110 to a composite decking panel 120. In the specific examples shown in Figures 2A and 2B, the connector 100 is installed between a first composite decking panel 120 and a second composite decking panel 125 provided on the opposite side of the connector 100 to the first composite decking panel 120. In the example shown in Figure 1, the connector 100 comprises a housing 130 defining a channel 135 for receiving the lighting unit 110. The channel 135 is partially defined by a first side wall 140. The first side wall comprises a first inner surface 141, a first outer surface 142 and a first upper edge 144. The channel 135 is further partially defined by a second side wall 150. The second side wall comprises a second inner surface 151, a second outer surface 152 and a second upper edge 154. The second side wall 150 opposes the first side wall 140 such that the second inner surface 152 faces the first inner surface 142. The first side wall 140 is separated from the second side wall 150 by a base 160. The base 160 comprises a lower base surface 161 facing away from the first upper edge 144 and the second upper edge 154. In the example shown in Figure 1, the connector 100 is a unitary body formed from aluminium, for example by extrusion. The first side wall 140, the second side wall 150 and the base 160 have a thickness of 2mm. The first side wall 140 and the second side wall 150 are spaced apart by 6mm. The first side wall 140 and the second side wall 150 have a height of 19mm. The channel 135 defined by the first inner surface 141 of the first side wall 140, the second inner surface 151 of the second side wall 150 and the upper surface 162 of the base 160 has a 6mm by 17mm rectangular cross-section. The connector 100 comprises a first projection 143 protruding from the housing 130 and away from the channel 135, and in particular at a normal from the first outer surface 141 of the first side wall 140, for receipt in a first recess 121 of the first composite decking panel 120. In the example shown in Figure 1, the first projection 143 extends substantially in a longitudinal direction parallel to a longitudinal axis running the length of the housing 130. The first projection 143 protrudes in a transverse direction perpendicular to the longitudinal axis. The first projection 143 has a first thickness 146 extending in a direction parallel to the first outer surface 142 and perpendicular to the longitudinal axis of the housing 130. In the example shown in Figure 1, the first thickness is 5mm. In some examples, the first projection 143 protrudes from the first outer surface 142 by 5mm. The first projection 143 may therefore have a square cross-section. In the example shown in Figure 1, the first projection 143, and in particular the upper surface of the first projection 143, is spaced from the first upper edge 144 (i.e., the upper edge of the housing 130), along the first outer surface 142, by a distance 147 of 6mm and the first projection 143, and in particular the lower surface of the first projection 143, is spaced from the lower base surface 161 (i.e., the lower edge of the housing 130), along the first outer surface 142, by a distance 148 of 6mm. The connector 100 further comprises a second projection 153 protruding from the housing 130 and away from the channel 135, and in particular at a normal from the second outer surface 151 of the second side wall 150, for receipt in a second recess 126 of the second composite decking panel 125. The second projection 153 extends substantially in a longitudinal direction parallel to a longitudinal axis running the length of the housing 130. The second projection 153 protrudes in a transverse direction perpendicular to the longitudinal axis of the housing 130. In the example shown in Figure 1, the second projection 153 has the same dimensions as the first projection, i.e., the second projection 153 has a second thickness 156 of 5mm. In addition, the second projection 153 is aligned with the first projection 143, i.e., the second projection 153, and in particular the upper surface of the second projection 153, is spaced from the second upper edge 154 (i.e., the upper edge of the housing 130), along the second outer surface 152, by a distance 157 of 6mm and the second projection 153, and in particular the lower surface of the second projection 153, is spaced from the lower base surface 161 (i.e., the lower edge of the housing 130), along the second outer surface 152 by a distance 158 of 6mm. Figures 2A and 2B show the connector 100 of Figure 1 provided between a first composite decking panel 120 and a second composite decking panel 125, such that the first projection 143 is received in the first recess 121 and the second projection 153 is received in the second recess 126. In addition, Figures 2A and 2B show a support structure 170 for supporting the first composite decking panel 120, the second composite decking panel 125 and the connector 100. In the example shown in Figures 2A and 2B, the support structure 170 is a decking joist. In the example shown in Figure 2B, the connector 100 is secured to the support structure 170 by way of an attachment member 175, such as a self-tapping screw, which passes through the base 160 of the channel 135 and into the support structure 170. The action of securing the connector 100 to the support structure 170 with the attachment member 175 drives the connector 100 towards the supporting structure 170 such that the first projection 143 and the second projection 153 clamp the first composite decking panel 120 and the second composite decking panel 125, respectively, to the support structure 170. A plurality of attachment members 175 may be provided to secure the connector 100 at different points along the length of the connector 100, for example spaced along the longitudinal axis, to the underlying support structure 170. For example where the support structure 170 comprises a plurality of decking joists, the connector 100 may be secured to each decking joist that the connector 100 overlaps with by way of an attachment member 175. As shown in Figures 2A and 2B, the connector 100 is dimensioned such the connector 100 is recessed with respect to the upper surfaces of the first composite decking panel 120 and the second composite decking panel 125. In particular, the distance 147 between the first projection 143, and in particular the upper surface of the first projection 143, and the first upper edge 144 may be less than the height 122 of the first composite decking panel 120 above the first recess 121, for example by a difference of 2mm or more. As shown in Figure 2B, the first recess 121 is larger than the first projection 143, and the second recess 126 is larger than the second projection 153, in at least one dimension to provide a first thermal expansion gap 124 between the connector 100 and the first composite decking panel 120, and a second thermal expansion gap 128 between the connector 100 and the second composite decking panel 125. Figure 3 shows the connector 100 of Figure 1 installed between a first composite decking panel 120 and a second composite decking panel 125 provided on the opposite side of the connector 100 similarly to the example shown in Figures 2A and 2B. In the example shown in Figure 3, the connector 100 further comprises a sealing unit 200 for sealing the channel 135. The sealing unit 200 comprises a sealing surface having a first portion 201 for contacting the first upper edge 144 of the first side wall 140 and a second portion 202 for contacting the second upper edge 154 of the second side wall 150. The first portion 201 of the sealing surface is provided on a first flange 203 of the sealing unit 200. The second portion 202 of the sealing surface is provided on a second flange 204 of the sealing unit 200. The sealing unit 200 further comprises an ancillary housing 205 defining an ancillary channel 206 for receiving the lighting unit, which is an LED strip 111 in the example of Figure 3. The ancillary channel 206 is partially defined by a first ancillary wall 210 having a first ancillary inner surface 211 and a first ancillary outer surface 212. The ancillary channel 206 is further partially defined by a second ancillary wall 220 having a second ancillary inner surface 221 and a second ancillary outer surface 222. The second ancillary wall 220 opposes the first ancillary wall 210 such that the second ancillary inner surface 221 faces the first ancillary inner surface 211. The first ancillary wall 210 and the second ancillary wall 220 are separated by an ancillary base 230. The ancillary housing 205 is received in the channel 135 of the connector 100 with a friction fit such that the first ancillary outer surface 212 faces the first inner surface 141 and the second ancillary outer surface 222 faces the second inner surface 151. In the example shown in Figure 3, the sealing unit 200 comprises a first resiliently deformable projection 241 provided on the first ancillary outer surface 212 for contacting the first inner surface 141 and a second resiliently deformable projection 242 provided on the second ancillary outer surface 222 for contacting the second inner surface 151. The first resiliently deformable projection 241 and the second resiliently deformable projection 242 may be integrally formed with the sealing unit 200. The sealing unit 200 comprises an ancillary sealing member 250 for sealing the ancillary channel 206, thereby enclosing the LED strip 111 within the ancillary channel 206. The ancillary sealing member 250 comprises an ancillary sealing surface 251 adapted to contact the top surface of the first flange 203 and the top surface of the second flange 204. In the example shown in Figure 3, the ancillary sealing member 250 has a convex ancillary top surface 252. The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof. While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention. For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations. Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described. Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example + / -10%.
Claims
1. A connector for attaching a lighting unit to a first composite decking panel, the connector comprising: a housing defining a channel for receiving the lighting unit; anda first projection protruding from the housing and away from the channel for receipt in a first recess of the first composite decking panel,wherein the first projection is spaced away from an upper edge of the housing.
2. The connector as claimed in claim 1, wherein the housing comprises a longitudinal axis extending along a length of the channel, wherein first projection protrudes in a transverse direction perpendicular to the longitudinal axis.
3. The connector as claimed in claim 2, wherein the first projection comprises:an elongate first projection extending along the housing in a longitudinal direction parallel to the longitudinal axis; ora plurality of first projections arranged along the housing in a longitudinal direction parallel to the longitudinal axis.
4. The connector as claimed in any of claims 1 to 3, wherein the connector further comprises a second projection protruding from the housing in a direction opposite to the first projection and away from the channel for receipt in a second recess of a second composite decking panel.
5. The connector as claimed in any preceding claim, wherein the first projection has a first thickness, and wherein the first thickness is at least 2mm, for example at least 4mm, for example 5mm.
6. The connector as claimed in claim 5, wherein the first projection protrudes from the housing by at least 2mm, for example by at least 4mm.
7. The connector as claimed in any of claims 5 to 6, when dependent directly or indirectly on claim 4, wherein the second projection has the same dimensions as the first projection.
8. The connector as claimed in any preceding claim, wherein the first projection is spaced from a lower edge of the housing.
9. The connector as claimed in claim 8, wherein the first projection is spaced equally from the upper edge of the housing and the lower edge of the housing.
10. The connector as claimed in any of claims 8 to 9, when dependent directly or indirectly on claim 4, wherein the second projection is aligned with the first projection.
11. The connector as claimed in any of claims 1 to 10, wherein the connector further comprises a sealing unit for sealing the channel, the sealing unit comprising a sealing surface for contacting the upper edge of the housing.
12. The connector claimed in claim 11, wherein the sealing unit comprises an ancillary housing defining an ancillary channel for receiving the lighting unit, wherein the ancillary housing is adapted to be received in the channel of the housing with a friction fit.
13. The connector as claimed in claim 12, wherein the sealing unit comprises an ancillary sealing member for sealing an opening of the ancillary channel, thereby enclosing the lighting unit within the ancillary channel.
14. The connector as claimed in claim 13, wherein the ancillary sealing member has an ancillary top surface, wherein the ancillary top surface is a curved surface.
15. A kit for attaching a lighting unit to a first composite decking panel, the kit comprising: a connector as claimed in any of claims 1 to 14; anda first composite decking panel comprising a first recess for receiving the first projection.
16. The kit as claimed in claim 15, wherein the kit further comprises a lighting unit, and optionally wherein the lighting unit comprises an LED strip.
17. The kit as claimed in any of claims 16 to 17, wherein the kit further comprises an attachment member for securing the connector to a support structure, thereby securing the first composite decking panel to the support structure when the first projection is received in the first recess.
18. A system for attaching a lighting unit to a first composite decking panel, the system comprising:a first composite decking panel comprising a first recess;a connector comprising:a housing defining a channel for receiving the lighting unit; anda first projection protruding from the housing and away from the channel for receipt in a first recess of the first composite decking panel,wherein the first projection is spaced away from an upper edge of the housing, wherein the first projection is received in the first recess.
19. The system claimed in claim 18, wherein the system further comprises a lighting unit received in the channel.
20. The system as claimed in any of claims 18 to 19, wherein the system further comprises: a support structure for supporting the first composite decking panel; and an attachment member for securing the connector to the support structure such that the firstcomposite decking panel is clamped between the first projection and the support structure.
21. The system as claimed in any of claims 18 to 20, wherein the connector is dimensioned such the connector is recessed with respect to an upper surface of the first composite decking panel.
22. The system as claimed in claim 21, wherein the connector is recessed with respect to the upper surface of the first composite decking panel by 2mm or more.
23. The system as claimed in any of claims 18 to 22, wherein the first recess is larger than the first projection in at least one dimension to provide a first thermal expansion gap between the connector and the first composite decking panel.
24. The system as claimed in any of claims 18 to 23, wherein the system further comprises: a second composite decking panel comprising a second recess, and wherein the connector further comprises:a second projection protruding from the housing in a direction opposite to the first projection and away from the channel,wherein the second projection is received in the second recess.
25. A method for securing a first composite decking panel to a support structure and attaching a lighting unit to the first composite decking panel, the method comprising:inserting a first projection of a connector as claimed in any of claims 1 to 14 into a first recess of the first composite decking panel;locating the first composite decking panel on the support structure;securing the connector to the support structure using an attachment member; and inserting a lighting unit into the channel of the connector.
Citation Information
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