Abstract:
A portable, modular, interlocking decking system or apparatus that can be assembled and disassembled for resizing, transport, relocation and expansion. The decking comprises a plurality of panels shaped and dimensioned to interlock with other panels via fastener, the fastener comprising an axially rotatable locking mechanism which have detents in some embodiments.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention relates to a modular decking system that can be assembled and disassembled for reconfiguration, relocation, and expansion; and more particularly relates to a modular decking system comprised of panels that assemble to form a deck, anchors that uniformly bear the weight from the panels, and fastening components that rotatably lock the panels to the anchors and to the surface to restrict lateral movement therebetween. 
     Description of the Related Art 
     Installation of permanent decking requires a specialized skill set and is labor intensive, sometimes requiring footings to be dug or other construction. Traditional decks are often constructed to be a fixed in place and cannot be relocated and can only be removed or relocated through destructive means. Although modular decking kits having attachable members are known in the art, they are often fabricated from wooden members which may warp, splinter, or rot. Most modular decking comprises rectangular decking members affixed together on a subgrade, joists, beams or framing to form a larger deck. These members are not easily secured, transported and detached. Maintenance may be required to protect wooden decking from the elements and seal the surface from moisture. Variations in temperature and humidity cause them to expand and contract, which loosens the metal connection hardware. Lumber used in constructing traditional decking is also susceptible to deterioration by mildew, mold, and infestation. 
     In many instances, modular decking is not efficient or easily assembled in the construction of a decking. What is needed in the art is a multipurpose, lightweight decking, which does can be easily assembled, disassembled and transported; and which is suitable to withstand inclement weather, harsh environments, heavy foot traffic, and is resilient when exposed to harsh cleaning chemicals. This modular decking should also provide lateral support, comfort, and reduction of fatigue during walking or standing by users of the tile. 
     It is therefore desirable that a multi-configurable modular decking system be provided which overcomes these difficulties. 
     SUMMARY OF THE INVENTION 
     From the foregoing discussion, it should be apparent that a need exists for a modular decking system having unique and multi-configurable panels, anchors, locking components. 
     Beneficially, such a system would overcome many of the difficulties of the prior art by providing a modular decking system comprised of panels that assemble to form a deck, anchors that uniformly bear the weight from the panels while anchored into a ground or wall surface, and fasteners that rotatably lock the panels to the anchors to restrict lateral movement therebetween. The system leverages the weight of the panels, frictional forces, and fastening components to restrict lateral movement between the panels, the anchor, and a surface. 
     The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available apparatii and methods. Accordingly, the present invention has been developed to provide a modular decking apparatus that assembles to form a deck, the deck being disassemblable and portable, the decking system comprising: a plurality of hexagonal panels having a planar top surface, each panel defining six recesses circumscribing the top surface at evenly-spaced intervals, wherein each recess is shaped as a circular sector, each recess for receiving a fastener; wherein each panel further defines a plurality of apertures on the top surface; the panel further comprising an anchor affixed to a bottom surface of the panel, the anchor comprising: a plurality of fastener receptacles, each fastener receptacle having a foot for engaging a ground surface which protrudes downwardly, each fastener receptacle circumscribing an outside edge of the anchor at evenly-spaced intervals, each fastener receptacle disposed beneath a recess; a plurality of reinforced ribs disposed beneath the bottom surface, the plurality of reinforced ribs configured to enhance structural integrity of the panel; each fastener receptacle comprising an upwardly-protruding locking protrusion for engaging a fastener, the locking protrusion defining at least one locking hole; and a plurality of fasteners, each fastener for interconnecting a plurality of panels, each fastener locking over locking protrusions on separate panels. 
     The apparatus of claim  1 , wherein each fastener comprises a cylindrical base configured to abut a fastener receptacle, the at least one fastener further comprising a cap configured to overlay the base, the cap defining at least one cap hole, wherein the at least one cap hole is configured to align with the at least one locking hole of the locking protrusion from the fastener receptacle for at least partially fastening the at the at least one anchor to the at least one panel. 
     The plurality of apertures in the at least one panel may be drainage holes for liquid accumulating on the top surface. In some embodiments, the top surface of the anchor engages and contour a bottom surface of the panel. 
     The panel and anchor may be formed as an integrated piece. The plurality of reinforced ribs may comprise perpendicularly crossing beams. The base may comprise a plurality of detents configured to frictionally engage the locking protrusion of the fastener receptacle. 
     The cap may be substantially circular in some embodiments. The at least one cap hole may have a hexagonal shape. 
     The apparatus may further comprise at least one cap fastener configured to pass through the at least one cap hole and the at least one locking hole. 
     The at least one cap fastener is a bolt in some embodiments. The at least one cap fastener may comprise a cap fastener hole configured to receive an Allen wrench. The cap may define a plurality of teardrop-shaped locking hole. 
     These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1  is a top perspective view of a panel in accordance with the present invention; 
         FIG. 2  is a top perspective view of a panel mated with an anchor in accordance with the present invention; 
         FIG. 3  is a bottom perspective view of a panel in accordance with the present invention; 
         FIG. 4  is a top perspective view of a fastener locking the panel to the anchor in accordance with the present invention; 
         FIG. 5  is a top perspective view of a fastener having a base and a cap in accordance with the present invention; 
         FIG. 6  is a top perspective view of a cap for a fastener in accordance with the present invention; 
         FIGS. 7A and 7B  are side perspective views of a cap fastener and an Allen screw in accordance with the present invention; 
         FIG. 8  is a top perspective view of a self-locking fastener with a self-locking cap removed from a self-locking base in accordance with the present invention; and 
         FIG. 9  is a top perspective view of a self-locking cap in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. 
     As referenced in  FIGS. 1-9 , a modular decking system  100  comprises at least one panel  102  that assembles to form a deck; at least one anchor  114  that mates with the panel  102  to uniformly bear the dead and/or live load weight from the panel  102  while anchored into a ground or wall surface; and at least one fastener  132  that rotatably locks the panel  102  to the anchor  114  to restrict lateral movement therebetween. 
     The anchors  114  position at a panel periphery  108  on each panel  102 . The generally peripheral positioning of the anchors  114  and interconnections allow for a more uniform weight distribution of a load on the decking. Additionally, the fastener  132  creates a lock through frictional forces while also providing tactile feedback to indicate when the panel  102  and the anchor  114  are locked into place. The fastener  132  also requires minimal special tools or skillset to lock or remove. 
     In some embodiments, the system  100  comprises at least one panel  102  and at least one anchor  114  that have substantially the same contour shape. The substantially same contour shape enables for intuitive and facilitated mating therebetween. The panel  102  and the anchor  114  interlock together at the panel periphery  108  and at an anchor periphery  122  through at least one fastener  132 . The fastener  132  uses a rotatable locking mechanism having a plurality of detents  140 . The detents  140  create frictional forces against the anchor and the panel to form a snug fit therebetween. The detents  140  also create tactile feedback during rotation of the fastener  130  to indicate when the locking is complete. 
     The fastener  132  has at least one cap hole  138  that can be aligned with at least one locking hole  130  in the anchor  114 . Once aligned, at least one cap fastener  152  can pass through the holes  130 ,  138  to further secure the lock. In this manner, the interlocking connections are doubly secured while still maintaining their simplicity to form the interlocking interaction between panels  102  and anchors  114 . 
     In some embodiments, the at least one panel  102  forms a substantial portion of the deck&#39;s surface. The at least one anchor  114  uniformly supports the dead and/or live load weight from the panel  102 . The points of interconnection where the fasteners  132  lock the panels  102  and anchors  114  occur at the panel recessions  110   a - 110   f  and the anchor recessions  124   a - 124   f . Because the interconnections with the anchor  114  occur at the peripheries  108 ,  122 , the load on the decking is more uniformly distributed. 
     Additionally, each panel  102  is secured in place to the anchor  114  by at least one fastener  132  that engages the anchor  114  at a plurality of anchor recessions  124   a - 124   f  on the anchor periphery  122 . The fasteners  132  rotatably lock the panel  102  to the anchor  114  through frictional engagement, detents  140  that snap together and provide tactile feedback, and additional fastening components that pass through at least one locking hole  130  at the anchor recessions  124   a - 124   f  and at least one cap hole  138  at the fastener  132 . In one embodiment, six anchors  114  support a single panel  102  and any number of adjacent panels  102 . The use of six anchors  114  and six correlating fasteners  132  is consistent with the hexagonal shape of the panel  102 . However, in other embodiments, any number of anchors  114  and fasteners  132  may be used. 
     As referenced in  FIG. 1 , the system  100  comprises at least one panel  102 . The panel  102  is configured to interlock with additional panels  102  to form the decking. In some embodiments, the decking may include a floor decking, a wall, a patio, a pier, or a boat deck. The panel  102  is defined by a panel bottom surface  104  and a panel top surface  106 . The panel  102  may have a generally flat, hexagonal shape. Though in other embodiments, other shapes for the panel  102  may include, without limitation, a pentagonal, cube, triangle, and rectangle shape. Suitable materials for the panel  102  may include, without limitation, composite lumber, polymeric resins, polyvinyl chloride, virgin polyvinyl chloride, virgin/reclaimed polyvinyl chloride mixtures, compression molded rubber, rigid polymers, hard wood, soft wood, and a combination of wood fiber, plastic, and binding agents. 
     The panel  102  is further defined by a panel periphery  108  having a plurality of panel recessions  110   a - 110   f . The panel recessions  110   a - 110   f  may form a substantially half-circle shape at evenly-spaced sections of the periphery of the panel  102 . The at least one panel  102  also includes a plurality of apertures  112   a - 112   c  that are efficacious for enabling water, ice, or debris to pass through. One example of the apertures  112   a - 112   c  includes drainage or weep holes passing through the panel  102  serve to shed and disperse water from the deck. The plurality of apertures  112   a - 112   c  can take any number of shapes, and may be pre-molded, pre-drilled, or otherwise pre-made with the panel  102 . 
     Turning now to  FIG. 2 , the system  100  is shown to include at least one anchor  114 . The anchor  114  is defined by an anchor top surface  116 , an anchor bottom surface  118 , and a cavity (not shown). In some embodiments, the anchor  114  is configured to have substantially the same contour shape as the panel  102 , whereby the panel  102  mates with the anchor  114 . The anchor  114  receives the panel  102  at the anchor top surface  116 , thereby engaging the panel bottom surface  104 . An anchor periphery  122  aligns flush against a panel periphery  108  when the panel  102  and anchor  114  engage. The panel  102  may be secured, via adhesive, molded attachment, or other means, to the anchor  114 , concealing all of its fastening components and substantially all of the panel bottom surface  104  and the anchor top surface  116 . 
     The anchor  114  is designed to support the panel  102 , maximizing support for the panel  102  and uniformly distributing dead and/or live load weight onto a ground or wall surface. Because the anchor  114  attaches to the panel periphery  108 , specifically at the plurality of panel recessions  110   a - 110   f , the weight on the decking is uniformly distributed. Furthermore, since six anchors  114  may be used, the weight is further distributed, since it is known that the larger the number of supports, the more uniform is the weight distribution. 
     The anchor  114  fastens to a ground or wall surface at the anchor bottom surface  118 . In some embodiments, the anchor  114  rests on a grade or level surface and is considered a temporary structure, allowing the system  100  to be utilized by more than just building component. 
     As illustrated in  FIG. 3 , the anchor  114  forms a cavity that enables it to be portable and lightweight. To further reinforce the anchor  114  without significantly increasing its weight, the cavity in the anchor  114  is filled with a reticulated structure, such as a plurality of reinforced ribs  120 . The plurality of reinforced ribs  120  are configured to enhance the structural integrity of the anchor  114 . The ribs  120  serve to further distribute the live and dead load weight from the panel  102  to the anchors  114 . The ribs  120  may include a crosslinking series of barriers that fill the cavity. The crosslinking configuration serves to resist lateral and compressive forces that tend to destabilize the anchor  114 . 
     Those skilled in the art, in light of the present teachings, will recognize that by creating structural integrity in the cavity of the anchor  114  through ribs  120 , rather than filling the cavity with a solid material, the weight of the anchor  114  is reduced while still maintaining strength and stability. Additionally, the reinforced ribs  120  establish an exact, consistently-spaced gap between adjacent panels  102 , allowing for water drainage and air circulation. 
     The anchor  114  is further defined by a plurality of anchor recessions  124   a - 124   f  at the anchor periphery  122 . The anchor recessions  124   a - 124   f  have substantially the same contour shape as the panel recessions  110   a - 110   f , thereby enabling a flush surface with the panel periphery  108  while the panel  102  and the anchor  114  are engaged. 
     Each anchor recession  124   a - 124   f  has a fastener receptacle  126  that integrates therein. The fastener receptacle  126  forms a substantially wing shaped extension to the anchor recessions  124   a - 124   f . Due to this unique wing shaped configuration, the fastener receptacle  126  provides a locking surface for the various fastening components to engage. The fastener receptacle  126  forms a stable surface for receiving fastening components. Thus, frictional engagement works with the detents  140  in the fastening components to lock the fastener  132  into the fastener receptacle  126 . 
     In one embodiment, the fastener receptacle  126  includes a locking protrusion  128  that extends perpendicularly from the fastener receptacle  126 . The locking protrusion  128  provides yet another locking mechanism to secure the fastener  132  to the fastener receptacle  126 . At least one locking hole  130  is disposed to cross transversely across the locking protrusion  128 . The locking hole  130  enables passage of fastening components that help secure the panel  102  to the anchor  114 . 
     Each fastener receptacle  126  extends transversely across the anchor  114 . The fastener receptacle  126  is disposed to extend beyond the anchor bottom surface  118 . In this manner, the fastener receptacle  126  forms an extension that orients perpendicularly to the anchor  114 . The fastener can be used to penetrate the ground or wall surface for anchoring. For example, six fastener receptacles  126  on the anchor periphery  122  penetrate the ground surface until the anchor  114  is level and stable relative to the ground surface. However in other embodiments, the fastener receptacle  126  may attach to the ground or wall surface through other means, including, without limitation, screws, nails, magnets, ropes, and adhesives. 
     It is significant to note that the panel  102  and the anchor  114  have a lightweight construction, being made of lightweight plastic or another composite material, with each panel  102  and each anchor  114  manufactured as individual single pieces. One possible form of manufacturing may include injection molding, although compression molding or any other suitable technique for molding polymeric resin may also be used. Additionally, during fabrication, the panel  102  and the anchor  114  may be reinforced by pulling reinforced fibers through the resin. 
     Turning now to  FIG. 4 , the system  100  further comprises at least one fastener  132  that is configured to rotatably fasten against the fastener receptacle  126  at the anchor recessions  124   a - 124   f  and the panel recessions  110   a - 110   f . The fasteners  132  serve to restrict lateral movement between the panel  102  and the anchor  114 . The fastener  132  also works with the fastener receptacle  126  for anchoring to the ground or wall surface. In one embodiment, six fasteners  132  engage six fastener receptacles  136 . 
       FIG. 5  illustrates a perspective close-up view of the fastener  132 . The fastener  132  comprises a base  136  having an elongated shape that is configured to at least partially pass through the fastener receptacle  126 . The base  136  has a plurality of detents  140  configured on the outer surface of the base  136  to provide tactile feedback for when the fastener  132  is rotatably locked to the fastener receptacle  126 . The fastener  132  utilizes frictional engagement and the detents  140  to form a snug fit with the fastener receptacle  126 . In this manner, the panel  102  and the anchors  114  are securely held into place with minimal tools or skillsets needed. 
     Each fastener  132  passes through the panel recessions  110   a - 110   f  and the anchor recession  124   a - 124   f , locking into place with the fastener receptacle  126  by means of a vertical 360° rotation. In one embodiment, detents  140  in the fastener  132  engage depressions in the fastener receptacle  126 . The detents  140  provide tactile feedback once the turn is complete and the fastener  132  is locked into place. In one embodiment, the system  100  utilizes six fasteners  132  to engage six fastener receptacles  126 . Additional fastening components may be used to further secure the fastener  132  to the anchor  114  and the panel  102 . 
     As shown in  FIG. 6 , the fastener  132  comprises a cap  136  that is disposed to overlay the base  136 . The cap  136  comprising at least one cap hole  138 . The cap hole  138  may have a variety of shapes, including, without limitation, circles, tear drops, hexagons, pentagons, and cubes. For example,  FIG. 6  illustrates a central hexagonal-shaped cap hole  138  concentric to outer circular and smaller hexagonal holes. The at least one cap hole  138  is configured to align with the locking hole  130  of the protrusion  128  from the fastener receptacle  126 . 
     Once the cap hole  138  aligns with the locking hole  130  in the locking protrusion  128 , then at least one cap fastener  152  ( FIG. 7A ), such as a screw, bolt, nail, and nut, can pass through the aligned cap hole  138  and the locking hole  130  to fasten the anchor  114  to both the panel  102  and the ground or wall surface.  FIG. 7B  illustrates an Allen screw  154 , which is an alternative embodiment of the cap fastener  152 . The cap fastener  152  comprises a cap fastener hole  156  that provides a grip for a wrench to rotatably fasten the cap fastener  152  or the Allen screw  154 . It is significant to note that while having small structural differences, both types of cap fasteners  152 ,  154  enable rotatable tightening and loosening of the cap  136  relative to the base  136 , and also fasten the fastener  132  to the fastener receptacle  126 . 
       FIGS. 8 and 9  illustrate an alternative embodiment of a self-locking fastener  142  having a self-locking base  158  with an internal clip  144  to attach a self-locking cap  150 . The clip  144  is disposed inside the self-locking base  158 . As the self-locking cap  150  is rotated, the clip  144  clamps down on a teardrop cap hole  148  on the self-locking cap  150  through a clip slot  160 . The self-locking base  158  comprises a teardrop locking hole  146  that aligns with the teardrop cap hole  148 . Once aligned, the self-locking fastener  142  can be made to attach the fastener receptacle  126  with the cap fastener  152 . It is significant to note however, that the self-locking fastener  142 , though having slightly different mechanisms, operates in substantially the same manner as the fastener  132  discussed above. 
     In some embodiments, the system  100  utilizes components that are precut and assembled with minimal tools or skillset. The system  100  is efficacious for constructing a solid, yet easily detachable and portable surfaces, for a deck, floor, wall, ceiling, or roof. Those skilled in the art will recognize that the modular, portable capacity of the system  100  provides numerous solutions to decking. 
     For example, renters, condominium owners, and secondary residences, such as cottages or trailers, can benefit from the interlocking and modular decking system  100 . These users are ideally able to relocate, reconfigure, expand, or store the system  100 , as needed. Additionally, the components of the system  100  are designed to be easily packaged on and within the dimensions of standardized palettes traditionally used for shipping and storage purposes. 
     Additionally, the universal, interlocking design of the system  100  allows for the addition of accessory components, consisting of, but not limited to: stairways, umbrellas, benches, tables, railings, storage bins, light fixtures, gazebos, planters, and other accessories. The accessories can be supported on the same anchors  114  that support the panel  102 . 
     During installation of a deck utilizing the system  100 , the area where the installation will take place is preferably level. Where minor discrepancies occur, the length of the fastener receptacles  126  on the anchor recessions  124   a - 124   f  can be increased or decreased, as needed. The fastener receptacles  126  from the anchors  114  may then penetrate the ground surface of the designated deck area for preparation to receive the panels  102 . The panel  102  is then attached to the anchors  114  at the panel periphery  108  using the fastener  132  to hold the panels  102  in place against the anchor  114 . The fasteners  132  are inserted into the fastener receptacles  126  of the anchor recessions  124   a - 124   f  and rotated up to 360°. A plurality of detents  140  in the base  136  of the fastener  132  provide tactile feedback once the locking rotation is complete and the fastener  132  locked into place. 
     Additional fastening components, such as screws or bolts, are passed through the locking hole  130  and cap hole  138  to enhance the attachment. Additional anchors  114  may be placed on the ground to receive additional panels  102 . This installation process continues until the desired dimensions of the deck have been completed. The system  100  may be disassembled through simple removal of the fasteners  132 , without requiring excessive force or breakage of the panels  102  or anchors  114 . 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.