Abstract:
Components for use in the assembly and installation of a modular decking system, comprised of structural free floating piers which distributes loads of deck pad to ground, piers have a pad bearing surface and four uniformly placed receiver blocks which interlock with corresponding recesses at four pad corners, an interlocking cam passes through pad recesses at deck surface and locks to piers by rotating cam with custom designed tool. 
     The system is designed to be assembled without permanent fasteners to allow for expansion, reconfiguration or relocation, or addition of traditional and contemporary deck accessories that engage and interlock with the piers, pads and cams. One ideal manufacturing method of one or any of the system components is compression molded post-consumer and/or industrial thermo-plastic waste.

Description:
This application claims priority to U.S. provisional patent application No. 61/132,214, filed Jun. 18, 2008. 
    
    
     FIELD 
     The present invention relates to decking, platform, walkway, and or stage systems which incorporate non-traditional construction methods, typically used in the assembly of traditional pressure treated decks, composite decks, cement or stone patio pavers and any surface constructed to enhance outdoor and/or indoor living needs and use. The present invention particularly is a modular, portable and interlocking decking system that is predominately and ideally comprised of 100% post-consumer and/or industrial thermo-plastic waste that can easily be assembled, disassembled, stored, or transported for relocation or reconfiguration. 
     BACKGROUND 
     It is common for homes and other structures to be enhanced with the addition of outdoor living spaces often constructed of wood, framed with either a wood or composite surface, poured in place concrete patios or brick pavers placed over a compacted aggregate base. 
     The first of the aforementioned construction methods, particularly wood, are subject to weather causing the structure to warp, splinter or rot. Maintenance is required to protect the structure 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. Commonly, installation requires a specialized skill set and is labor intensive requiring footings to be dug below the specified frost line. Additionally, pressure treated lumber is treated with chemicals exposing the installer to health risks. Lumber is also susceptible to deterioration by mildew, mold, and insects and is subject to staining. The deck is considered to be a fixed structure; therefore it cannot be relocated and only removable in a more-or-less destructive fashion. 
     Second, there are drawbacks to pour in place patios and various paver systems. Particularly, each method requires labor-intensive excavation and can become stained. Concrete pavers are subject to cracking due to settling. 
     Numerous designs of decking systems have been developed to address the issues associated with wood framed decks, concrete patios and pavers. 
     U.S. Pat. No. 5,848,501 is in reference to a modular portable stage and floor system using a small number of standardized modular components to construct a temporary platform. Modular and vertical supports can be detachably coupled together in a slidably interlocked manner using a universal connector mechanism in to a support frame structure for supporting a plurality of modular deck panels. By using a small number of supports and a universal connector mechanism that is similar for all structural interconnections required to build the support frame structure, the modular portable stage and floor system is strong and stable, yet easily transported, assembled and disassembled. 
     U.S. Pat. No. 4,691,484 is in reference to a portable deck system of any size and shape that can be packaged and shipped in a collapsible configuration in motor homes, trailers and the like for quick assembly. 
     U.S. Pat. No. 4,622,792 is in reference to a modular deck structure comprised of a plurality of rectangular flooring platforms. 
     U.S. Pat. No. 6,209,267 B1 is in reference to a modular decking system with finished planks for mounting on outside edges of the frames to finish the base of the deck, a railing assembly includes posts for mounting, and rectangular fence panels which are connected to the posts, mainly by sliding the panels into longitudinally extending grooves in the post. 
     U.S. Pat. No. 6,128,880 is in reference to a modular decking system that allows the user to install decking over areas containing buried services such as cables or piping. The system is readily removable by an owner in a non-destructive manner so that it can be easily reinstalled. 
     U.S. Pat. No. 6,804,923 B1 is in reference to a modular prefabricated deck system which includes a plurality of rectangular flooring modules. Each module may include a plurality of laminations, such as a decorative upper element, and a lower support element for supporting the module. Each module may include interlocking structure for engaging adjacent modules upon installation. 
     U.S. Pat. No. 7,140,156 is in reference to materials for use in installing a deck including a plurality of decking tiles, each of the tiles having an outside corner angle with a hole at a predetermined location with respect to the corner and a plurality of decking tile connectors. Fasteners upstanding in the quadrants at locations align with the holes in the tiles. 
     U.S. Pat. No. 5,163,967 is in reference to a concrete pier block having an upwardly opening recess forming an anchor seat for building elements. The recess opens out the side so that building elements can be laid horizontally therein. 
     U.S. Pat. No. 5,758,467 is in reference to a modular construction member for the construction of decking, flooring, roofing, and the like, including a mateable connector formed integrally with the construction member for connecting successive deck members to form a deck assembly. 
     U.S. Pat. No. 6,061,991 is in reference to a deck system that provides an easy to install deck by using unique columns, rails and planks. The rails enable quick assembly. 
     SUMMARY 
     It is an object of the present invention to provide a portable, modular and interlocking decking system that can be assembled and disassembled for reconfiguration, relocation and expansion. The general ease-of-use of the system and simple interlocking component design allows for the decking system to be installed in a matter of time that is significantly less than the installation of a traditional pressure treated lumber deck, composite material deck or other concrete/brick patio surface. The system is comprised of three standard components—Pad, Pier and Cam Lock—each of which interlocks together using a custom designed hand tool that is provided with the purchase of the system. The Pad serves as the deck&#39;s surface, the Piers support the Pads at each corner, and each Pad is secured in place by a Cam Lock that locks with Pier(s) below. The assembly process is intuitive; four piers will be set to support one pad. Once the pad is resting on the bearing plate of the support pier, the cam lock is then secured into place. The modularity of the system allows for a simple and easy assembly process, which allows for multiple configurations. The universal, interlocking design of the system allows for the addition of the following accessory components, consisting of, but not limited to, railings, storage bins, light fixtures, gazebos, planters, benches, tables and other accessories that will utilize the same surface pad corner recesses and cam lock system to engage and secure with a support pier. 
     The free-floating foundation is based on individual load bearing piers resting on grade or level surface and is considered a temporary structure, allowing the system to be utilized by more than just homeowners. Renters, condominium owners and secondary residences, such as cottages or trailers, will benefit from the interlocking and modular system, ideally being able to relocate, reconfigure, expand the system or store the system if desired. 
     The system components are designed to be easily packaged on and within the dimensions of standardized palettes traditionally used for shipping and storage purposes. 
     A support pier has four receiver blocks that support the surface pads and can, if desired, be secured to the ground via spikes that pass through a hole within the support pier base. A receiver block is a protrusion molded atop the pier, that accepts the cam lock, the locking mechanism that ultimately secures the system together. Each pier having four receiver blocks allows for engagement with the corner recess holes of one, two, three or four surface pads based on varying configurations. A cam lock passes through the surface pad recess at each corner to lock with the support pier by means of rotating it vertically 90 degrees in a clockwise fashion with detents providing tactile feedback and locking the cam once the turn is complete. The support piers are designed to maximize bearing support and distribute dead and/or live load weight to the ground. 
     A surface pad is designed to be easily and manually transported for easy and quick placement on the support piers. Once locked together via the cam lock engagement with support piers, the pads bear on load bearing plates within the support piers and are connected by means of the receiver blocks. Each pad has structural support webbing on its underside to distribute the live and dead load weights to the support piers. Each pad has drainage or weep holes passing through its top surface to shed and disperse water. 
     When a surface pad is resting on the bearing plate of a support pier and a receiver block is in the bottom surface pad recesses, a cam lock will be used to lock the system in place. When a cam lock is placed through the top surface pad corner recess, the hand tool is used to turn the cam lock 90 degrees in a clockwise fashion. The cam lock mechanism is designed to give the user tactile feedback once the cam lock is turned the full 90 degrees and locked in place. 
     Pier extension block rest atop and engages a structural pier as a means to keep deck surface level when installed on sloped grades. 
     Similarly, a step block rest atop and engages a structural pier as a means to elevate a portion, or portions of deck pads to create a multi-level surface within one assembly. 
     A perimeter skirting module utilizes the same method of attachment by means of a cam lock engaging a structural pier and designed to conceal support piers below deck surface. 
     A railing system may be added to the installed deck by means of a support block secured to a structural pier. A lateral brace is attached to the support block by means of sliding a molded “t” rail into and through the “t” rail slot within the support block and vertical post is then secured to lateral brace by means of similar “t” rail/“t” rail slot method of installation. 
     Currently developed and/or future accessories and their individual components will engage the piers and pads and utilize the same or similar method(s) of locking components or modules together with the use of a cam lock fastener. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A fuller understanding of the nature and objects of the present invention will become apparent upon consideration of the following detailed description, taken in connection with the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of an overall system illustrating the interaction of modular components in a state of assembly and or disassembly; 
         FIG. 2  is a top isometric view of a support pier according to an embodiment of the invention; 
         FIG. 3  is a bottom isometric view of a support pier according to an embodiment of the invention; 
         FIG. 4  is a top isometric view of a support pier illustrating a spike and through hole for securing the support pier to the ground, grade, or surface below; 
         FIG. 5  is a top isometric view of a support pier secured to grade or surface below; 
         FIG. 6  is top isometric view of a support pier about to engage an anchor bolt secured within a fixed footer or foundation and securing hardware. 
         FIG. 7  is a top isometric view of a support pier showing a washer and nut securing the structural pier to the anchor bolt; 
         FIG. 8  is a top isometric view of a surface pad according to an embodiment of the invention; 
         FIG. 9  is a bottom isometric view of a surface pad according to an embodiment of the invention; 
         FIG. 10  is a top view of a surface pad; 
         FIG. 11  is a section view of the surface pad of  FIG. 10 ; 
         FIG. 12  is a top isometric view of a surface pad aligning with a structural pier; 
         FIG. 13  is a top isometric view of a surface pad bottom recess fitting onto a receiver block of a support pier 
         FIG. 14  is a detail isometric view illustrating a surface pad corner that can be secured to a support pier at any one of four possible points of engagement; 
         FIG. 15  is a detail isometric view illustrating a surface pad corner that can be secured to a support pier at any one of four possible points of engagement; 
         FIG. 16  is a detail isometric view illustrating a surface pad corner that can be secured to a support pier at any one of four possible points of engagement; 
         FIG. 17  is a top isometric view of a surface pad secured to a corresponding number of support piers according to an embodiment of the invention; 
         FIG. 18  is a top isometric view of adjacent pads and piers assembled to form a surface shape according to another embodiment of the invention; 
         FIG. 19  is a top isometric view of the cam lock according to an embodiment of the invention; 
         FIG. 20  is a bottom isometric view of the cam lock according to an embodiment of the invention; 
         FIG. 21  is a top isometric view illustrating a surface pad resting on a support pier with a cam lock aligned for placement; 
         FIG. 22  is a top isometric view showing a surface pad secured to a support pier via means of a cam lock in place; 
         FIG. 23  is a top isometric view of a cam lock and a hand tool according to an embodiment of the invention; 
         FIG. 24  is a top view of a hand tool in position to rotate a cam lock; 
         FIG. 25  is a top view of a hand tool rotating a cam lock 90 degrees in a clockwise fashion; 
         FIG. 26  is a top view of a surface pad, structural pier, and cam lock; 
         FIG. 27  is a section view of the surface pad of  FIG. 26 , support pier, and cam lock engagement; 
         FIG. 28  is a top isometric view of successively installed piers, pads, and cam locks; 
         FIG. 29  is a top isometric view of a pier extension block aligned with a structural pier; 
         FIG. 30  is a top isometric view of a pier extension blocked engaging a structural pier; 
         FIG. 31  is an elevation view illustrating the use of a pier extension on sloped grade; 
         FIG. 32  is a top isometric view of a step block aligned with a structural pier; 
         FIG. 33  is a top isometric view a step block engaging a structural pier; 
         FIG. 34  is an elevation view illustrating the use of a step block to create multi-level surfaces; 
         FIG. 35  is a top isometric view of a module of perimeter skirting and disclosing certain aspects of an embodiment of the present invention; 
         FIG. 36  is a bottom isometric view of a perimeter skirting module according to an embodiment of the invention; 
         FIG. 37  is a top isometric view of a perimeter skirting module aligned with surface pad and support piers; 
         FIG. 38  is a top isometric view of perimeter skirting module engaging support pier; 
         FIG. 39  is a top isometric view of a support block according to an embodiment of the invention; 
         FIG. 40  is a bottom isometric view of a support block according to an embodiment of the invention; 
         FIG. 41  a top isometric view of a lateral support brace according to an embodiment of the invention; 
         FIG. 42  is a bottom isometric view of a lateral support brace according to an embodiment of the invention; 
         FIG. 43  is a top isometric view of a support block engaging a support pier and a cam lock aligned for installation, and a lateral support brace aligned to engage with support block; 
         FIG. 44  is a top isometric view of an extruded railing post and defining embodiments; 
         FIG. 45  is a top view of the railing post according to an embodiment of the invention; 
         FIG. 46  is a top isometric view of an extruded railing post aligned to engage a lateral support brace; 
         FIG. 47  is a top isometric view of a railing module according to an embodiment of the invention; 
         FIG. 48  is a detail isometric view of a railing module according to an embodiment of the invention; 
         FIG. 49  is a top view of a railing module according to an embodiment of the invention; 
         FIG. 50  is a top isometric view of a railing module aligned for engagement with railing posts; 
         FIG. 51  is a top isometric view of a post cap according to an embodiment of the invention; 
         FIG. 52  is a bottom isometric view of a post cap according to an embodiment of the invention; 
         FIG. 53  is a top isometric view of an extended cam lock fastener according to an embodiment of the invention; 
         FIG. 54  is a detail isometric view of the extended cam lock according to an embodiment of the invention; 
         FIG. 55  is a detail isometric view of the extended cam lock according to an embodiment of the invention; 
         FIG. 56  is a top isometric view of an extended cam lock fastener aligned with a post cap and railing post for engagement with surface pad and pier below; 
         FIG. 57  is a top isometric view of multi directional railing modules sharing a common railing post; and 
         FIG. 58  illustrates components packaged or shipped on standardized pallets. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, in  FIG. 1  there is shown a modular, interlocking decking system  1000  showing the basic assembly or disassembly of the core system components embodying the present invention. As hereinafter described, the decking system is modular, therefore expandable and reconfigurable and can be assembled and disassembled as desired. 
       FIG. 1  illustrates a perspective view of the basic assembly and or disassembly of the core system components. Load bearing deck surface pad  10  rests upon and is supported by structural pier  1  and cam lock fastener  20  passes through load bearing deck surface pad  10  and engages structural pier  1  rotated 90 degrees securing all components in place. Perimeter skirting  70  is attached to structural pier  1  and secured by means of cam lock fastener  20 . Support block  80  rests upon structural pier  1  and is secured by means of cam lock fastener  20 . Lateral support brace  90  engages with support block  80  by means of molded interlocking component on lateral support brace  90  through molded receiver element on support block  80 . 
     Extruded vertical post  100  engages molded interlocking component on lateral support brace  90  and molded receiver element on extruded post  100 . Railing module  200  engages extruded vertical post  100  by means of “T” member and “T” slot. Post cap  300  aligns with top opening of extruded vertical post  100  and is secured in place with extended cam lock fastener  400 . Step block  60  rests upon structural pier  1  providing a bearing surface for surface pad  10 . Load-bearing deck surface pad  10  is secured to step block  60  by means of a cam lock fastener  20 . Similarly, pier extension block  50  receives load bearing deck surface pad  10  and is secured in place by cam lock fastener  20 . 
       FIG. 2  illustrates structural pier  1  comprised of four uniformly placed receiver blocks  5  and molded into the receiver block top surface  5  to a male detent  3  and cam slot  4  and load bearing elevated surface plate  6 . Structural support pier  1  can be secured to the grade or a substructure via through hole  7  on bearing plate  8  resting on grade shown in  FIG. 3 . Fastener  501  shown in  FIG. 4  aligns with hole  7 .  FIG. 5  shows structural support pier  1  being anchored to the ground by means of fastener  501  passing through the hole  7  until it engages with top surface  9  of bearing plate. An anchor bolt  504  capped with optional washer  503  and secured by optional nut  502  shown in  FIG. 6  secures fastener  501 . When washer  503  makes contact with top surface  9  of bearing plate as shown in  FIG. 7 , structural pier  1  is secured to grade or below surface. 
     As shown in  FIG. 8 , surface pad  10  includes, at each corner, four uniformly placed through holes  11 . Weep holes  12  provide for drainage of pad surface  13  to distribute water away from the system. Structural ribs  17  distribute dead and live surface loads. As shown in  FIG. 9 , receiver block receptacle  15  receives the receiver block  5  of structural pier  1 . As shown in section in  FIG. 11 , molded shoulder  18  in through hole  11  on surface pad  10  to receive alignment collar  26 . 
     As shown in  FIG. 12 , surface pad  10  aligns and engages with receiver block  5 , which is part of structural pier  1 . Once aligned,  FIG. 13  shows surface pad  10  engaged with structural pier  1 . As shown in  FIG. 14 ,  FIG. 15 , and  FIG. 16 , a corner surface pad  10 , can engage with receiver blocks on structural pier  1  in four possible configurations. A surface pad  10  engages with structural pier one at each corner, as shown in  FIG. 17 . Further illustrating the assembly process,  FIG. 18  expands upon  FIG. 17  by placing surface pad  10  adjacent to surface pad  10  on structural piers  1 . 
     As shown in  FIG. 19 , cam lock fastener  20  has receiver slots  21  on cam lock surface  22  that engage with the hand tool to secure the cam lock fastener  20  in place. Additional elements of the cam lock fastener  20  are the structural support ribs  23  and ramped cam component  25 . As shown in  FIG. 20 , female détente  27  engages with receiver block male détente  3  of structural pier  1 . Female détente  27  is molded into alignment collar  24  and engages with male détente  3  of receiver block  5  of structural pier  1 . The cam lock fastener  20  passes through hole  11  engaging with surface pad  10  to secure with structural pier  1 , as shown in  FIG. 21 .  FIG. 22  shows cam lock fastener  20  fully engaged with surface pad  10  and structural pier  1 . 
     As shown in  FIG. 23 , custom hand tool  30  engages with cam lock fastener  20  receiver slots  21  via molded driver blades  31 . The custom hand tool  30  is used to rotate cam lock fastener  20  ninety degrees in a clockwise fashion until female detent aligns with male detent and provides tactile feedback, to secure surface pad  10  to structural pier  1 , as shown in  FIG. 25 . 
     As shown in section detail in  FIG. 27 , cam lock fastener  20  engages with receiver block  5  of structural pier  1 . Molded stop  40  prevents the cam lock fastener  20  from being rotated more than ninety degrees. 
     As shown in  FIG. 29  and  FIG. 30 , pier extension block  50  includes receiver blocks  5 , and engages with top bearing plate  6 . The pier extension block  50  engages with receiver blocks  5  of structural pier  1 . The pier extension block  50  is utilized when the system is installed over a sloped grade. As shown in  FIG. 31 , pier extension block  50  is utilized to address the shown sloped grade  55 , by engaging with structural pier  1  and surface pad  10 . Similar to the pier extension block, as shown in  FIG. 32  and  FIG. 33 , a step block  60  engages with receiver block  5  to allow for multiple planes of the decking system.  FIG. 34  further illustrates step block  60  engaging with structural pier  1  and surface pads  10 , providing multiple surface levels. Structural pier  1  is installed over a grade  65 . 
     As shown in  FIG. 35  and  FIG. 36 , perimeter skirting  70  includes recess hole  11 , load bearing surface  15  and engaging surface  14 . As shown in  FIG. 37  and 
       FIG. 38 , perimeter skirting  70  engages with structural pier  1 , butting up against outer side wall of surface pad  10 . Perimeter skirting  70  is secured to structural pier  1  by means of aforementioned cam lock fastener  20 . 
     The system includes a multitude of accessory components that engage with the aforementioned receiver blocks  5 . As shown in  FIG. 39 , a railing module component engages with a support block  80 , including a molded “T”-slot  81  and a through hole  11  as shown in  FIG. 39 . As shown in  FIG. 41  and  FIG. 42 , a lateral support brace  90 , including a molded “T” fastener  91  and  92  which engage with aforementioned “T” slot  81  of the support block  80 . As shown in  FIG. 43 , support block  80  aligns and engages with structural pier  1 , then cam lock fastener  20  is engaged with structural support pier  1 . Once cam lock fastener  20  is secured, lateral support brace  90  engages with support block  80  by means of aforementioned “T” fastener  91  and t-slot  81 . 
     As shown in  FIG. 44  and  FIG. 45 , the support block  80  is engaged with structural pier  1 . Additionally, support brace  90  is engaged with support block  80 . Next, an extruded vertical post  100  includes a “T” slot receiver channel  101  and a cylindrical receptacle cavity  102 . Extruded receiver block  103  receives alignment boss  301  of post cap  300 . The extruded vertical post  100  aligns and engages with lateral support brace  90  by means of LT″ fastener  92 . As shown in  FIG. 47  and  FIG. 48 , railing module  200  includes “T” fastener  201  to engage with aforementioned support brace  90 . Railing module  200  aligns and engages with extruded vertical posts  100 , as shown in  FIG. 50 . As shown in  FIG. 51  and  FIG. 52 , post cap  300  is molded with through hole  11  and alignment boss  301 , designed to engage with aforementioned extruded vertical post  100 . Completing the railing module, as shown in  FIG. 53 , an extended cam lock fastener  400 , including molded structural ribbing  401 , aforementioned receiver slots  21  and ramp cam component  25 , is used to pass through post cap  300  and engage with structural pier  1 . As shown in  FIG. 56 , the extended cam lock fastener  400  aligns with post cap  300 , passing through hole  11  and the cylindrical receptacle cavity  102  of extruded vertical post  100 , securing railing system components to surface pad  10  and structural pier  1 . 
     As shown in  FIG. 57 , extruded vertical post  100  is used to complete and turn the decking system corner, adjoining perpendicular railing modules  200 . 
     As shown in  FIG. 58 , the entire decking system is designed and sized to fit within standardized shipping palettes  505 . 
     Since certain changes may be made in the foregoing disclosure without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description and depicted in the accompanying drawings be construed in an illustrative and not in a limiting case.