Static structures (e.g. – buildings) – Machine or implement – Tiling
Reexamination Certificate
1999-05-04
2001-05-01
Redman, Jerry (Department: 3634)
Static structures (e.g., buildings)
Machine or implement
Tiling
C052S745210, C052S747100, C052SDIG001, C156S527000
Reexamination Certificate
active
06223496
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates in general to a method and apparatus for installing planks for decking material and more particularly, to a set of specialty tools and method of use for installation, placement and setting of flexible planking material for decks. The apparatus of the present invention represents a unique, lightweight, and portable tool set and method of use for installation of said flexible top decking material.
A vinyl deck construction system which includes a sandwich of a bottom and top plank portion is currently available from Heritage Vinyl Products of Macon, Miss. The vinyl deck plank construction comprises a bottom structural plank member which is placed and secured onto a deck frame and a top flexible plank decking material which is placed, pressed, and snapped into place on said bottom decking. This unique deck material form and style which is provided by Heritage Vinyl Products is known as the “Teck Deck” system. It provides a vinyl deck surface which is comprised of a series of planks which are formed from said bottom and top plank decking materials. The top plank snaps onto a set of ears of the bottom plank via the action of a groove within said top plank when the ears on said bottom plank are compressed. No claim is made to the decking materials which are proprietary to Heritage Vinyl Products.
The current method of snapping said top plank onto said bottom plank requires the installer to use a large mallet or hammer. The installer currently places the top planking and decking material onto the bottom plank and proceeds to hammer the top plank into place in order to compress the ears of said bottom plank into the groove of the top plank. This method is extremely time consuming, difficult to perform, and further risks damage to the top and bottom planking material.
The art of the present invention allows for the installation of said top plank onto said bottom plank via the action of a set of specialty installation tools and without the use of mallets or hammers. That is, the apparatus of the present art represents a set of specialty tools which are capable of snapping the top and bottom planks together via the action of a set of specially designed rollers and guides. By the using the special apparatus of the current art, a method has been developed which allows for installation of the top and bottom planking materials while the installer simply walks or crawls behind and pushes the specialty tool apparatus. This method of installation eliminates the risk of damage to the top and bottom decking planks and also provides for a quick and easy installation of said top plank onto said bottom plank.
Accordingly, it is an object of the present invention to provide a method and apparatus for installing a flexible top plank decking material onto a bottom plank decking material, especially for the Teck Deck series of decking materials and any decking materials which are substantially similar, without the use of mallets or hammers.
Another object of the present invention is to provide a method and apparatus for installing a flexible top plank decking material onto a bottom plank decking material which is quick and easy to use without damaging said decking materials and which is substantially capable of use by an installer working from a standing or crawling position.
A further object of the present invention is to provide an apparatus for installing a flexible top plank decking material onto a bottom plank decking material which is portable.
SUMMARY OF THE INVENTION
To accomplish the foregoing and other objects of this invention there is provided a method and apparatus for installing flexible decking planks. The apparatus comprises two roller systems which are described separately but used in conjunction with one another in order to perform the installation method described herein. The first roller system is defined as the plank top installation tool and the second roller system is defined as the plank top end installation tool. The plank top installation tool is used to place and secure substantially all of the flexible plank top onto the bottom plank, whereas the plank top end installation tool is used to place and secure the ends of the plank top. The method of placing said plank top onto said plank bottom first requires use of the plank top installation tool to secure and place most of the plank top and then use of the plank top end installation tool to secure and place the ends of said plank top.
The preferred embodiment of the plank top installation tool comprises a roller and face plate yoke, a face plate, a front roller guide, a pressure roller, a front roller guide axle, a pressure roller axle, and a handle. The face plate is of substantially flat form with ears extending upward to provide a pivoting attachment to the yoke via the front roller guide axle. The yoke acts as the central housing upon which all parts attach directly or indirectly. The bottommost portion of the face plate comprises one or more alignment grooves for proper alignment with and onto the ears of the bottom plank. The face plate along with the front roller guide is attached via the front roller guide axle. The front roller guide acts to guide and align the flexible top plank material under the pressure roller via the one or more roller grooves contained on the front roller guide. The pressure roller is mounted rearward of the front roller guide and serves to press the top plank onto the bottom plank after being fed over the front roller guide. The pressure roller is held in place with the pressure roller axle. The handle attaches to the yoke in order to provide a means by which pressure may be applied to the top plank material through the pressure roller and while the user is in a standing position. The alignment grooves in the face plate further serves to hold the frontmost portion of the plank top installation tool onto the ears of the bottom plank in order to provide a moment arm force onto the pressure roller without raising the face plate from its contact and connection with the bottom plank.
The preferred embodiment of the top plank end installation tool comprises a front pressure roller and a rear roller, a right side plate with one or more guide ears, a left side plate with one or more guide ears, a force application front handle, a force application rear handle, a front spacer bushing, and a rear spacer bushing. In a preferred embodiment, said bushings are held in place by fasteners such as bolts which penetrate both the right side plate and the left side plate and serve as axles. Alternative embodiments may incorporate pins or dowels in place of said bolts. Said front roller is mounted onto said front spacer bushing and said rear roller is mounted onto said rear spacer bushing in such a relation that each are allowed to roll on said bushings. Each of said rollers are slightly shorter in length than the bushing onto which they are mounted in order to ensure free rolling of said rollers. The placement of each of said rollers is such that said guide ears extend below the surface of said rollers and serve to guide the top plank end installation tool on the flexible top plank. Said rollers place a user supplied force on said top plank in order to push said top plank onto said bottom plank and press or snap it into place. It is important to note that although the rollers are mounted on bushings in a preferred embodiment, alternative embodiments may incorporate rollers which simply bear upon the fasteners or bolts which hold them and the side plates together.
In operation of the plank top installation tool, the user first places, aligns and secures the bottommost portion of the face plate containing the alignment grooves onto the interfacing portion of the bottom plank containing the bottom plank ears. Thereafter, the user threads a flexible top plank over the front roller guide and under the pressure roller. With the top plank threaded, the user the presses downward with the handle and begins walking in a forward direction. As the user walks, the top p
Klug Kevin L.
Lev Bruce A.
Redman Jerry
LandOfFree
Method and apparatus for plank top installation for a deck does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Method and apparatus for plank top installation for a deck, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method and apparatus for plank top installation for a deck will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2518169