Hollow profile decking system comprising plank and anchor using anchor flange construction

Abstract

A decking system, decking components and an installed deck for use on a support structure. The decking system comprises hollow profile planking units having anchor flanges on opposite edges that cooperate with an anchor structure to form a deck or platform. The flanges and the anchor units are shaped and configured to closely interact and form an installed platform structure. The planks comprise an extruded thermoplastic wood fiber composite having an internal structure sufficient to withstand installation, engineering forces placed on the installed platform, weathering and use. The anchor structures have a shape that conforms to the anchor flanges on the decking profiles to hold the deck in place.

We claim:  
     
         1 ) A system for the installation of a decking structure on a support, the system comprising: 
 (a) one or more hollow profile deck members, the members free from an installation slot, each member comprising a tread surface, a parallel opposite support surface and an anchor flange on opposite edges of the member; and    (b) one or more anchors that can cooperate with the profile flange in the installation of the profile on the support, the anchor comprising means to attach the anchor to the support using an anchor base portion, the anchor further comprising a vertical member extending from the base portion ending in a transverse portion, the transverse portion extending from the vertical portion forming an anchor flange that can interact with the profile flange in installing the member on the support.    
     
     
         2 ) The system of  claim 1  wherein the profile deck member comprises a hollow profile comprising a thermoplastic polymer-biofiber composite material.  
     
     
         3 ) The system of  claim 2  wherein the hollow profile comprises vertical support webs extending between the support surface and the tread surface, the webs horizontally spaced at a distance of about 2 centimeters or more between vertical support web structures.  
     
     
         4 ) The system of  claim 3  wherein adjacent support webs form an arch support structure within the hollow profile positioned such that the arch is compressed by a force normal to the tread surface of the plank.  
     
     
         5 ) The system of  claim 4  wherein the hollow profile contains two or more arch like supports within the profile.  
     
     
         6 ) The system of  claim 1  wherein the arch like support structure within the profile also forms a void space defined by the tread surface and the upper surface of the arch surface.  
     
     
         7 ) The system of  claim 6  wherein the profile also comprises a void space defined by the support surface and the bottom surface of the arch structure.  
     
     
         8 ) The system of  claim 1  wherein the anchor comprises a base, a vertical member extending from the base and a transverse member extending from the vertical member, the vertical member having an aperture for an attachment hardware, the aperture extending through the vertical member.  
     
     
         9 ) The system of  claim 8  wherein the anchor member comprises an extruded metallic unit having a length of greater than 2 centimeters with the base portion extending along the length of the extruded anchor and the anchor flange extending along the length of the extrusion.  
     
     
         10 ) The system of  claim 8  wherein the anchor member comprises an extruded thermoplastic unit having a length of greater than 2 centimeters with the base portion extending along the length of the extruded anchor and the anchor flange extending along the length of the extrusion.  
     
     
         11 ) The system of  claim 8  wherein the anchor has at least one integral screw fastener.  
     
     
         12 ) The system of  claim 8  wherein the anchor flange extends from the vertical portion of the anchor but departs from the horizontal by an angle of greater than about 5° to form an area that contacts a complementary area in the anchor flange of the deck member.  
     
     
         13 ) A plank, for deck or platform installation, comprising an extruded thermoplastic-biofiber hollow profile, the plank comprising a linear member having a tread surface and a parallel opposite support surface and parallel opposite edges, each edge comprising an anchor flange, said member comprising at least one internal arch support structure, wherein the plank has a compressive strength of at least 1500 pounds per square inch (10 megapascals) and a coefficient of thermal expansion of less than about 1.5×10 −5  inch per inch ° F.  
     
     
         14 ) The plank of  claim 13  wherein the anchor flanges are proximate the support surfaces.  
     
     
         15 ) The plank of  claim 13  wherein the thermoplastic comprises a polyolefin.  
     
     
         16 ) The plank of  claim 13  wherein the thermoplastic comprises a polyvinyl chloride.  
     
     
         17 ) The plank of  claim 13  wherein the biofiber comprises wood fiber.  
     
     
         18 ) The plank of  claim 13  wherein the plank comprises three or more arch support structures formed within said linear member.  
     
     
         19 ) The plank of  claim 13  wherein the anchor flange extends from the plank at an angle that departs from the horizontal by at least 5°.  
     
     
         20 ) The plank of  claim 13  wherein the plank has a width of at least 3 inches.  
     
     
         21 ) The plank of  claim 13  wherein the width of the plank is about 3 to about 18 inches.  
     
     
         22 ) The plank of  claim 13  further comprising a capstock layer.  
     
     
         23 ) The plank of  claim 22  wherein said capstock comprises an abrasion resistant coating.  
     
     
         24 ) The plank of  claim 23  wherein said abrasion resistant coating comprises acrylic polymer.  
     
     
         25 ) The plank of  claim 24  wherein said acrylic polymer is chemically cross-linked.  
     
     
         26 ) The plank of  claim 22  wherein said capstock comprises an anti-slip coating.  
     
     
         27 ) The plank of  claim 26  wherein said anti-slip coating is chemically crosslinked.  
     
     
         28 ) The plank of  claim 26  wherein said anti-slip coating comprises grit.  
     
     
         29 ) The plank of  claim 13  wherein said tread surface is cambered.  
     
     
         30 ) The plank of  claim 23 , wherein said camber has a slope of about 1 degree of arc, said slope being measured from plank center to plank edge.  
     
     
         31 ) An anchor structure that can be used to install a plank having a flange in a deck or platform, the anchor comprising a base and extending from the base a vertical member having an installation hardware aperture, and extending substantially horizontally from the vertical member, a transverse member, the transverse member positioned at an angle that departs from the horizontal by at least 5°.  
     
     
         32 ) The anchor of  claim 31  wherein said base member comprises an extended base member.  
     
     
         33 ) The anchor of  claim 31  wherein the aperture is configured to accept a screw fastener.  
     
     
         34 ) The anchor of  claim 33  wherein the aperture is further configured to retain a screw fastener.  
     
     
         35 ) A decking structure comprising: 
 (a) a support,    (b) one or more hollow profile deck members, the members free from an installation slot, each member comprising a tread surface, a parallel opposite support surface and an anchor flange on opposite edges of the member; and    (c) one or more anchors that can cooperate with the profile flange in the installation of the profile on the support, the anchor comprising means to attach the anchor to the support using an anchor base portion, the anchor further comprising a vertical member extending from the base portion ending in a transverse portion, the transverse portion extending from the vertical portion forming an anchor flange that can interact with the profile flange in installing the member on the support;    wherein said deck members are attached to said support by engaging said anchor flanges within the region partially enclosed by said anchor base, vertical, and transverse members and then attaching said anchor base members to said support via said attaching means and upon attachment to said support, longitudinal expansion and contraction of said deck members is not constrained by said anchors.    
     
     
         36 ) The structure of  claim 35  wherein said deck members are hollow planks further comprising an extruded thermoplastic-biofiber composite material, said plank including at least one internal arch support structure, wherein said plank has a compressive strength of at least 1500 pounds per square inch (10 megapascals) and a coefficient of thermal expansion of less than about 1.5×10 −5  inch per inch ° F.  
     
     
         37 ) The structure of  claim 36 , wherein said attachment means comprises screws.  
     
     
         38 ) The structure of  claim 36 , wherein said anchors substantially engage said anchor flanges the entire length of said planks.  
     
     
         39 ) The structure of  claim 36 , wherein said plank tread surface is cambered.  
     
     
         40 ) The structure of  claim 39 , wherein said camber has a slope greater than about 1 degree of arc, said slope being measured from plank center to plank edge.  
     
     
         41 ) The structure of  claim 36  wherein said anchor base and transverse members include two or more distinct widths whereby the spacing between planks can be varied to produce a variety of predetermined patterns.  
     
     
         42 ) The structure of  claim 36 , further comprising distinct end capping and edge capping trim members attached to the periphery of said structure.  
     
     
         43 ) The structure of  claim 36 , wherein said support comprises joists.  
     
     
         44 ) The structure of  claim 36 , wherein said planks include mortise-tenon joints.  
     
     
         45 ) The structure of  claim 36 , further comprising an underlayment of insect screen between said support and plank installation surfaces.  
     
     
         46 ) The structure of  claim 36 , further comprising one or more fasteners installed to fixedly attach said planks to said support structure whereby: 
 (a) longitudinal movement of said planks is constrained at the points of fixed attachment, and    (b) length changes induced by environmental fluctuations in temperature and humidity are partitioned into zones adjacent said points of fixed attachment.