Deck system and components thereof, and methods of assembling and disassembling deck systems and components
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E04B-001/18
E04C-003/02
E04F-015/02
출원번호
US-0973757
(2013-08-22)
등록번호
US-8863466
(2014-10-21)
발명자
/ 주소
Winter, Roger
출원인 / 주소
Winter, Roger
대리인 / 주소
McDonnell Boehnen Hulbert & Berghoff LLP
인용정보
피인용 횟수 :
4인용 특허 :
28
초록▼
Deck systems, deck system components making up the deck systems, and methods of assembling and disassembling deck system components and the deck systems are described herein. A box-frame can be assembled from box-frame segments, angle clips, and fasteners. A box-frame can be supported by posts attac
Deck systems, deck system components making up the deck systems, and methods of assembling and disassembling deck system components and the deck systems are described herein. A box-frame can be assembled from box-frame segments, angle clips, and fasteners. A box-frame can be supported by posts attached to the box-frame using post brackets and fasteners. Joist assemblies can be assembled using joist segments, joist spacers, and fasteners. Joist assemblies can be positioned within the box-frame. The joist assemblies can be secured to box-frame segments or another joist assembly using roll-lock tabs and roll-lock tab receivers and locking tabs and locking tab retainers that part of extrusions making up the box-frame segments, joist spacers, or joist segments. Deck boards can be secured to the joist assemblies using deck screws or deck clips. The post brackets can accommodate support posts below deck boards and railing posts extending above deck boards.
대표청구항▼
1. A deck system comprising: a first perimeter box-frame comprising a first box-frame segment (BFS), a second BFS, a third BFS, and a fourth BFS, wherein the first BFS is removably attached to the second BFS and to the third BFS, wherein the second BFS is removably attached to the first BFS and to t
1. A deck system comprising: a first perimeter box-frame comprising a first box-frame segment (BFS), a second BFS, a third BFS, and a fourth BFS, wherein the first BFS is removably attached to the second BFS and to the third BFS, wherein the second BFS is removably attached to the first BFS and to the fourth BFS, wherein the third BFS is removably attached to the first BFS and to the fourth BFS, and wherein the fourth BFS is removably attached to the second BFS and to the third BFS; andone or more joist assemblies removably attached to and within the perimeter box-frame, wherein each joist assembly comprises two joist segments and two joist spacers between the two joist segments,wherein each of the first BFS, the second BFS, the third BFS, and the fourth BFS includes a roll-lock tab receiver configured for receiving a roll-lock tab,wherein a first joist spacer of each joist assembly comprises a roll-lock tab configured for positioning within the roll-lock tab receiver of the second BFS, andwherein a second joist spacer of each joist assembly comprises a roll-lock tab configured for positioning within the roll-lock tab receiver of fourth BFS. 2. The deck system of claim 1, wherein the first joist spacer of each joist assembly does not include a roll-lock tab positioned beneath the roll-lock tab receiver of the second BFS when the roll-lock tab of the first joist spacer is positioned within the roll-lock tab receiver of the second BFS, andwherein the second joist spacer of each joist assembly does not include a roll-lock tab positioned beneath the roll-lock tab receiver of the fourth BFS when the roll-lock tab of the second joist spacer is positioned within the roll-lock tab receiver of the fourth BFS. 3. The deck system of claim 2, wherein a first joist segment of a first joist assembly comprises a roll-lock tab configured for positioning within the roll-lock tab receiver of first BFS, andwherein a second joist segment of the first joist assembly comprises a roll-lock tab receiver configured for receiving a roll-lock tab of a first joist segment of a second joist assembly. 4. The deck system of claim 3, wherein the second joist segment includes a deck clip slot configured for receiving one or more deck clips to provide spacing between deck boards. 5. The deck system of claim 4, wherein each of the one or more deck clips is secured to the second joist segment by a respective deck clip screw,wherein the one or more deck clips retain a deck board to a joist assembly, andwherein the deck board conceals each deck clip screw securing the one or more deck clips. 6. The deck system of claim 4, wherein each deck clip of the one or more deck clips includes a first portion, a second portion, and a third portion,wherein the second portion extends from an edge of the first portion to a center portion of the third portion and includes a slot on each of two edges extending from the first portion to the third portion,wherein the second portion and the third portion form a T-shaped segment of the deck clip and the first portion and the second portion form an L-shaped segment of the deck clip,wherein the first portion and the third portion are parallel to each other and perpendicular to the second portion, andwherein the first portion includes a through-hole for insertion of a deck-clip screw. 7. The deck system of claim 6, wherein two of the deck boards, adjacent to one another, each include a slot for positioning a part of the third portion of a deck clip used to attach the two adjacent deck boards to a joist segment,wherein each of the two deck boards include a slot on an opposite side of the deck boards, andwherein the slots on the opposite sides of the deck board are for positioning a part of the third portion of two other deck clips to further attach the two deck boards to the joist segment. 8. The deck system of claim 4, wherein the one or more deck clips can be attached to the joist segment with or without securing the one or more deck clips to the joist segment with a deck clip screw. 9. The deck system of claim 4, wherein the second joist segment includes a threaded screw slot accessible through the deck clip slot,wherein the deck clip slot and the threaded screw slot extend an entire length of the second joist segment, andwherein each of the one or more deck clips is retained to the second joist segment by a deck-clip screw positioned into the threaded screw slot. 10. The deck system of claim 2, wherein each of the first BFS, the second BFS, the third BFS, and the fourth BFS includes a locking tab for attachment of the first BFS, the second BFS, the third BFS, and the fourth BFS to a respective locking tab retainer on the two joist segments and the two joist spacers. 11. The deck system of claim 1, further comprising: a second perimeter box-frame comprising a fifth BFS, a sixth BFS, and a seventh BFS,wherein the sixth BFS is removably attached to the fifth BFS and to the seventh BFS,wherein the fifth BFS is removably attached to the fourth BFS,wherein the seventh BFS is removably attached to the fourth BFS, andwherein the fourth BFS comprises a vertical riser, a first roll-lock tab receiver on a first side of the vertical riser, and a second roll-lock tab receiver on a second side of the vertical riser. 12. The deck system of claim 1, further comprising: a second perimeter box-frame comprising a fifth BFS, a sixth BFS, a seventh BFS, and an eighth BFS,wherein the fourth BFS and the fifth BFS each comprise a flat surface and a roll-lock tab receiver,wherein the flat surfaces of the fourth BFS and the fifth BFS abut each other,wherein the roll-lock tab receiver of the fourth BFS is within an interior of the first perimeter box-frame, andwherein the roll-lock tab receiver of the fifth BFS is within an interior of the second perimeter box frame. 13. The deck system of claim 1, further comprising: at least one corner-post bracket removably attached to the first perimeter box-frame,wherein each corner-post bracket comprises four wall segments for surrounding a portion of four sides of a post, andwherein each corner-post bracket comprises two wall extension segments including attachment holes for attaching the corner-post bracket to two of the first BFS, the second BFS, the third BFS, and the fourth BFS. 14. The deck system of claim 13, further comprising: a support ring adapted for receiving a portion of a railing post,wherein the two wall extension segments include portions that extend above the two of the first BFS, the second BFS, the third BFS, and the fourth BFS attached to the corner-post bracket,wherein the portions of the two wall extension segments can be positioned within the support ring, andwherein the support ring, the corner-post bracket are removably attached to the railing post. 15. The deck system of claim 1, further comprising: at least one intermediate-post bracket removably attached to the first perimeter box-frame,wherein each intermediate-post bracket comprises four wall segments for surrounding a portion of four sides of a post, andwherein each intermediate-post bracket comprises a wall extension segment including an attachment hole for attaching the intermediate-post bracket to one of the first BFS, the second BFS, the third BFS, and the fourth BFS. 16. The deck system of claim 15, further comprising: a support ring adapted for receiving a portion of a railing post,wherein the wall extension segment include a portion that extends above the one of the first BFS, the second BFS, the third BFS, and the fourth BFS attached to the intermediate-post bracket,wherein the portion of the wall extension segment can be positioned within the support ring, andwherein the support ring, the intermediate-post bracket are removably attached to the railing post. 17. The deck system of claim 1, further comprising: a plurality of angle clips, wherein each angle clip provides for attaching two of the first BFS, the second BFS, the third BFS, and the fourth BFS together. 18. The deck system of claim 17, wherein each angle clip includes at least one attachment hole that corresponds to an attachment hole in each of the two of the first BFS, the second BFS, the third BFS, and the fourth BFS to be attached to the angle clip. 19. The deck system of claim 1, wherein the first joist spacer of each joist assembly includes a roll-lock tab that (i) is positioned beneath the roll-lock tab receiver of the second BFS when the roll-lock tab of the first joist spacer is positioned within the roll-lock tab receiver of the second BFS, and (ii) has a length that allows the joist assembly to be attached to and removed from the first perimeter box-frame, andwherein the second joist spacer of each joist assembly includes a roll-lock tab that (i) is positioned beneath the roll-lock tab receiver of the fourth BFS when the roll-lock tab of the second joist spacer is positioned within the roll-lock tab receiver of the fourth BFS, and (ii) has a length that allows the joist assembly to be attached to and removed from the first perimeter box-frame. 20. The deck system of claim 1, wherein at least one of the first BFS and the second BFS includes a through-hole for attaching the at least one of the first BFS and the second BFS to a structure, andwherein an end of a fastener inserted into the through-hole within the first BFS is concealed by a first joist segment attached to the first BFS or an end of a fastener inserted into the through-hole within the second BFS is concealed by the first joist spacer. 21. The deck system of claim 1, wherein at least one of the first BFS, the second BFS, the third BFS, and the fourth BFS includes an extrusion having an angle-clip shelf and angle-clip slot that extend along an entire length of the extrusion, andwherein the angle-clip shelf supports at least one of an angle-clip and a reinforcing angle positioned on the angle-clip shelf, andwherein the at least one of the angle-clip and the reinforcing angle positioned on the angle-clip shelf ends just below the angle-clip slot or extends into the angle-clip slot. 22. The deck system of claim 1, wherein each of the two joist segments and the two joist spacers include an extrusion,wherein each of the extrusions includes two screw splines that extend along an entire length of the extrusion, andwherein a fastener can be inserted into the a screw spline of a joist segment and a corresponding screw spline of a joist spacer to attach that joist segment to that joist spacer. 23. A method comprising: assembling a first perimeter box-frame comprising a first box-frame segment (BFS), a second BFS, a third BFS, and a fourth BFS, wherein the first BFS is removably attached to the second BFS and to the third BFS, wherein the second BFS is removably attached to the first BFS and to the fourth BFS, wherein the third BFS is removably attached to the first BFS and to the fourth BFS, and wherein the fourth BFS is removably attached to the second BFS and to the third BFS,and wherein each of the first BFS, the second BFS, the third BFS, and the fourth BFS includes a roll-lock tab receiver configured for receiving a roll-lock tab,assembling a plurality of joist assemblies, wherein each joist assembly comprises a first joist spacer having a roll-lock tab for positioning within the roll-lock tab receiver of the second BFS, a second joist spacer having a roll-lock tab for positioning within the roll-lock tab receiver of fourth BFS, a first joist segment, and a second joist segment, wherein the first joist spacer attaches to a first end of the first joist segment and a first end of the second joist segment, and wherein the second joist spacer attaches to a second end of the first joist segment and a second end of the second joist segment; andattaching the plurality of joist assemblies within the perimeter box frame. 24. The method of claim 23, further comprising: attaching a corner-post bracket to a first support post and to the first box-frame segment; andattaching an intermediate post bracket to a second support post and to the first box-frame segment. 25. The method of claim 24, further comprising: attaching two sides of the corner-post bracket to a first support ring and to a first railing post; andattaching a side of the intermediate-post bracket to a second support ring and a second railing post. 26. The method of claim 23, further comprising: assembling a second perimeter box-frame comprising a fifth BFS, a sixth BFS, a seventh BFS, and an eighth BFS,wherein the fourth BFS and the fifth BFS each comprise a flat surface and a roll-lock tab receiver,wherein the flat surfaces of the fourth BFS and the fifth BFS abut each other,wherein the roll-lock tab receiver of the fourth BFS is within an interior of the first perimeter box-frame, andwherein the roll-lock tab receiver of the fifth BFS is within an interior of the second perimeter box frame. 27. The method of claim 23, further comprising: assembling a second perimeter box-frame comprising a fifth BFS, a sixth BFS, and a seventh BFS,wherein the sixth BFS is removably attached to the fifth BFS and to the seventh BFS,wherein the fifth BFS is removably attached to the fourth BFS,wherein the seventh BFS is removably attached to the fourth BFS, andwherein the fourth BFS comprises a vertical riser, a first roll-lock tab receiver on a first side of the vertical riser, and a second roll-lock tab receiver on a second side of the vertical riser. 28. The method of claim 23, wherein assembling the first perimeter box-frame comprises: inserting a respective portion of a first angle clip into the first BFS and into the second BFS;inserting a respective portion of a second angle clip into the first BFS and into the third BFS;inserting a respective portion of a third angle clip into the second BFS and into the fourth BFS; andinserting a respective portion of a fourth angle clip into the third BFS and into the fourth BFS. 29. The method of claim 23, further comprising: removing any deck boards attached to any of the joist assemblies;removing each joist assembly from the first perimeter box-frame;disassembling the first perimeter box-frame such that the none of the first BFS, the second BFS, the third BFS, and the fourth BFS is attached to each other. 30. The method of claim 29, further comprising: dissembling each joist assembly such that none of the first joist spacer, the second joist spacer, the first joist segment, and the fourth joist segment of that joist assembly is attached to each other. 31. The method of claim 13, wherein the first joist segment of each joist assembly, except for a final-installed joist assembly, includes a roll-lock tab for positioning within a roll-lock tab receiver of the first BFS or within a roll-lock tab receiver of a joist segment of a joist assembly previously attached within the perimeter box frame;wherein the first joist segment of the final-installed joist segment includes a roll-lock tab for positioning within a roll-lock tab receiver of a joist segment of a joist assembly previously attached within the perimeter box frame and a roll-lock tab for positioning within a roll-lock tab receiver of the fourth BFS, andwherein attaching each joist assembly, except for the final-installed joist assembly, includes positioning the roll-lock tab of the first joist segment within the roll-lock tab receiver of the first BFS or within the roll-lock tab receiver of a joist segment of a joist assembly previously attached within the perimeter box frame and rolling the joist assembly downward so that a locking tab of the first BFS or of the joist segment of the joist assembly previously attached within the perimeter box frame contacts a locking tab retainer of the first joist segment of the joist assembly being attached.
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