Patent Publication Number: US-2022213701-A1

Title: A Connector For A Modular Decking System and A Modular Decking System Comprising The Same

Description:
TECHNICAL FIELD OF THE INVENTION 
     The present invention relates to a connector for a modular decking system, to a modular decking system comprising the connector and to a method of assembling a modular decking system using the connector. 
     BACKGROUND TO THE INVENTION 
     Modular decking systems are typically used in the construction of temporary or permanent structures such a stages for musicians, actors and other live performers. Modular decking systems generally comprise a plurality of vertical and horizontal supports which are arranged and connected at their respective ends to produce a frame that is capable of supporting a plurality of decking panels. The ends of the vertical and horizontal supports are typically connected by suitable fastening means, e.g. a clamp on bracket connection, a socket to bracket connection or a pin to bracket connection, meaning skilled or trained personnel are required to assemble such modular decking systems with appropriate tools. Moreover, the use of such fastening means to connect the vertical and horizontal supports limits the loads that can be applied at these connection points, which is undesirable. Most modular decking systems are often used in conjunction with a scaffolding sub-structure to achieve the desired stage height. However, a problem with known scaffolding systems is that they have a tendency to deflect when placed under high loads. This not only reduces the stability of the modular decking system, but also hinders the assembly of structures being built on the decking since it becomes increasingly difficult to align and connect the structures together. 
     It is an object of the embodiments of the present invention to provide a modular decking system that can be assembled without using tools and by installers with limited labour skills. 
     It is another object of embodiments of the present invention to provide a modular decking system that is less susceptible to deflection. 
     It is also an object of embodiments of the present invention to provide a modular decking system that is able to withstand greater loads. 
     SUMMARY OF THE INVENTION 
     According to a first aspect of the invention there is provided a modular decking system comprising:
         a decking panel;   a plurality of vertical supports;   at least two first horizontal supports;   at least two second horizontal supports arranged perpendicular to the first horizontal supports;   one or more third horizontal supports arranged between the first horizontal supports and parallel to the second horizontal supports, and   a plurality of connectors for detachably coupling the first and second horizontal supports, the connectors comprising an elongate tube adapted for insertion into the vertical supports and a connection hub, wherein the connection hub and the ends of the first and second horizontal supports comprise reciprocating formations to enable the respective ends of the first and second horizontal supports to slidingly engage with the connection hub.       

     The modular decking system according to the first aspect of the invention enables a stage or decked flooring system to be erected over a varied topographical ground condition &amp; substrate type, whilst maintaining complete structural integrity (irrespective of height) over side sway and support of both vertical &amp; lateral loading, whilst maintaining a flat horizontal working platform. Moreover, the design of the components and the way in which they are secured together permits the use of local unskilled labour with minimum supervision, meaning the modular decking system can be erected easily, quickly and at reduced cost relative to conventional decking systems. 
     The connection hub formations may be formed around the elongate tube. In some embodiments, the connection hub formations may be welded to the elongate tube. The connector may be adapted for insertion into a vertical support of a scaffolding sub-structure. In addition to connecting the first and second horizontal supports together, the connection hub is configured to gather loads from the first and second horizontal supports and distribute them to the ground in a very efficient manner. This in turn allows the system to achieve very high decking loads. 
     The connection hub may comprise a base plate and a top plate. The provision of the base plate and top plate increased the rigidity and overall strength of the connection hub. In use, the reciprocating ends of the first and second horizontal supports rest on and are supported by the base plate. The top plate and the base plate may be configured to fit around the elongate tube. 
     The elongate tube may extend through and protrude beyond the top plate. In particular, the elongate tube extends beyond an upper surface of the top plate. In use, decking boards, which have a cut-out corresponding to the size and shape of the vertical tube, are fitted and locked in position around the elongate tube protrusion. The decking boards have two functions, namely to provide a flat surface for the desired application and to provide force translation through the boards, which enables the decking system to withstand greater loads. Such an arrangement also helps to achieve squareness of the decking boards and rigidity across the floor. 
     The connection hub may comprise a plurality of braces/struts. The braces/struts may be spaced around the elongate tube. The braces/struts may extend between the underside of base plate and the elongate tube. The braces may be angled. In particular, the braces may be angled between 30° and 60°. In some embodiments the braces may be angled between 40° and 50°. For example, the braces may be angled at 45°. The braces allow the generated loads to be distributed away from the connection hub and into the decking structure which allows for loadings of up to 184 kN per connection hub, which is much higher than normal loadings (˜5 kN). The loads typically include dead loads, live loads, seismic loads and wind loads. 
     In addition to being insertable into a vertical support, the connection hub may be adapted to receive a vertical support which enables modular decking systems of increasing height to be built easily, quickly and with increased rigidity and strength. In some embodiments the vertical support may be a handrail stanchion. 
     The connection hub may comprise at least four formations for receiving reciprocating formations formed at the ends of the first and second horizontal supports. In some embodiments, the connection hub may comprise at least eight formations for reciprocating formations formed at the ends of the first and second horizontal supports. This enables decking beams to be installed at 45°, while allowing plan bars and braces to be attached to provide additional strength and rigidity to the decking structure. 
     The connection hub may comprise a female part and the ends of the first and second horizontal supports may each comprise a reciprocating male part for sliding engagement with the female part. In other embodiments the connection hub may comprise a male part and the ends of the first and second horizontal supports may each comprise a reciprocating female part for sliding engagement with the male part. 
     Irrespective of whether the male part is present at the ends of the horizontal supports or whether it projects radially outwards from the connection hub, the male part may have a circular cross-section, a diamond-shaped cross-section, a square-shaped cross-section or a rectangular-shaped cross-section when viewed in plan. The male part may be connected to the first and second horizontal supports or to the connection hub via a stem. The female part may have a substantially C-shaped cross-section when viewed in plan. 
     The male part or the female part of the connection hub may extend axially between the top plate and the base plate. 
     In some embodiments it may be desirable to erect a more permanent decking structure. Accordingly, the respective ends of the first and second horizontal supports may be secured to the connection hub by fastening means. The fastening means may comprise a bolted connection, in which case, the connection hub formations and the reciprocating formations located at the ends of the horizontal supports may comprise apertures for receiving the fastening means. 
     The first and third horizontal supports may each comprise means for fixing the third horizontal supports to the first horizontal supports. In particular, the first horizontal supports may be provided with U-shaped brackets which are adapted to receive a coupling part present at the ends of the third horizontal supports. In some embodiments, the end of the third horizontal supports may comprise an overhang portion from which the coupling part downwardly depends. The coupling part may be substantially J-shaped or hook-shaped. When a more permanent structure is desired, the U-shaped brackets may be provided with orifices and the ends of the third horizontal support may be provided with corresponding orifices which are configured to receive a bolt or other suitable fastening means therethrough, i.e. the orifices replace the overhang portions and J-shaped or hook-shaped coupling part. 
     A portion of each decking panel may be secured between the top plate of the connection hub and a decking panel retainer. In particular, each corner of the decking panel may be secured between the top plate and the decking panel retainer. The decking panel retainer may be circular. The decking panel retainer may additionally comprise a central hole or a cut out which allows a vertical support to be inserted into the connection hub. 
     A portion of each decking panel may be secured between a captivation details located on the top surface of the first horizontal support and a decking panel retainer. The captivation detail may have a substantially circular cross-section. The captivation detail may be positioned on the top surface of the first horizontal support between two U-shaped brackets. The captivation detail may be welded to the top surface of the first horizontal support. 
     Due to the increased loadings the modular decking system can withstand the modular decking is suitable for use as a structural building support. Accordingly, in some embodiments, the modular decking system may comprise a tower or column. The tower or column may be secured to two or more third horizontal supports. The third horizontal supports to which the tower or column are secured may be fixed to the first horizontal supports by a bolted connection. The modular decking system may therefore comprise third horizontal supports that are pinned/bolted to the first horizontal supports as well as third horizontal supports that comprise a coupling part that rotationally engages a bracket provided on the first horizontal support. 
     According to a second aspect of the invention there is provided a connector for a modular decking system, the connector comprising an elongate tube adapted for insertion into a vertical support and a connection hub that comprises formations that enables the connection hub to slidingly engage with reciprocating formations present at the ends of two or more horizontal supports. 
     The connector may be adapted for insertion into a vertical support of a scaffolding sub-structure. Advantageously the connector is insertable into a variety of scaffold systems selected from the group comprising Kwikstage, Cuplok, Scaffold Tube, Haki, Layher Ringlok, Alpac Ringlok, Futuro Ringlok, Metric Ringlok, Alround Ringlok, Turner+8 Co planer. 
     The connector may comprise a base plate on which the horizontal supports rest in use. The connection hub may be adapted to receive a vertical support member. The vertical support may comprise a handrail stanchion. 
     The connection hub may comprises a female part or a male part adapted for sliding interengagement with the respective ends of the horizontal supports. The male part or female part may extend axially between a top plate of the connection hub and the base plate. 
     The male part may have a circular cross-section, a diamond-shaped cross-section, a square-shaped cross-section or a rectangular-shaped cross-section when viewed in plan. The male part may be connected to the first and second horizontal supports or to the connection hub via a stem. The female part may have a substantially circular cross-section, a diamond-shaped cross-section, a square-shaped cross-section or a rectangular-shaped cross-section or C-shaped cross-section when viewed in plan. 
     The connection hub may comprise an aperture which is configured to receive a fastener for securing the connection hub and the respective ends of the horizontal supports together. The connection hub may comprise a plurality of apertures for receiving a corresponding number of fasteners. The fasteners may comprise a bolted connection, in which case the apertures are configured to receive an appropriately sized bolt which is retained in place by a nut. 
     According to a third aspect of the invention there is provided a method of assembling a modular decking system, the method comprising the steps of:
         providing a plurality of vertical supports;   inserting a connector into each vertical support, wherein each connector comprises an elongate tube adapted for insertion into the vertical support and a connection hub adapted to enable interconnection of a first horizontal support and a second horizontal support;   interconnecting the first horizontal support and the second horizontal support to the connection hub through sliding interengagement;   fixing one or more third horizontal supports between a pair of parallel first horizontal supports to define a support frame, and   securing one or more decking panels to the support frame.       

     The step of fixing the third horizontal support to the first horizontal support may comprise rotating the third or each third horizontal support relative to the first horizontal supports. 
     The method may comprise the additional step of securing the ends of the first and/or second horizontal supports to the connection hub using a bolted connection. 
     According to a fourth aspect of the invention there is provided a horizontal support adapted to rotationally engage with first horizontal supports of a modular decking system to secure the third horizontal support between the first horizontal supports. 
     The horizontal support according to the fourth aspect of the invention may incorporate any or all of the features described in relation to the modular decking system according to the first aspect of the invention and/or the method according to the third aspect of the invention. 
    
    
     
       DETAILED DESCRIPTION OF THE INVENTION 
       In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: 
         FIG. 1  shows an isometric view of a connector; 
         FIGS. 2A-2B  respectively show plan and elevation views of first horizontal support; 
         FIG. 3  shows a perspective view of the first horizontal support shown in  FIG. 2   
         FIGS. 4A-4D  show plan views of reciprocating formations for the connection hub and the first horizontal support; 
         FIGS. 5A-5C  respectively show plan, elevation and perspective views of a second horizontal support; 
         FIG. 6  shows an isometric view of a horizontal support retained in the connection hub; 
         FIG. 7  shows an elevation view of the third horizontal support; 
         FIG. 8  shows an end of the third horizontal support comprising an overhang portion and coupling part; 
         FIG. 9  shows an isometric view of a deck bay comprising modular decking system; 
         FIG. 10  shows an isometric view of the deck bay shown in  FIG. 9  with a handrail; 
         FIG. 11  shows an isomeric view of connector for use in a more permanent modular decking system involving fasteners; 
         FIGS. 12A-12B  respectively show elevation and perspective views of the first horizontal support for use in a more permanent decking system involving fasteners; 
         FIG. 13  shows an elevation view of a second horizontal support for use in a more permanent decking system involving fasteners. 
         FIG. 14  shows a method of securing a first horizontal support to the connection hub, and 
         FIG. 15  shows a method of securing a third horizontal support to a first horizontal support. 
     
    
    
     As shown in  FIG. 1  there is provided a connector  1  for a modular decking system. The connector  1  comprises an elongate tube  10  having a head portion and a tail portion. The head portion of the connector comprises a connection hub  11 . The connection hub comprises a top plate  12  and a base plate  13  which is supported by a plurality of braces/struts  14 . The braces/struts  14  are provided between the underside of the base plate and the vertical tube at an angle of 45°. The elongate tube  10  extends through and protrudes beyond the top plate  12 . The connection hub  11  also comprises a plurality of formations  15  which are arranged around the periphery of the elongate tube  10  and extend axially between the top plate  12  and the base plate  13 . As best shown in  FIG. 1  the top plate  12  is adapted to accommodate the formations  15  and comprises correspondingly shaped cut outs. Examples of connection hub formations are shown in  FIGS. 4A-4D . For instance, the connection hub formations may be substantially tubular (female part) substantially diamond-shaped (female part), rectangular (female part) or T-shaped (male part). 
     The connection hub formations  15  in this embodiment are configured to slidingly engage with reciprocating formations present at the ends of a first horizontal beam  20  and a second horizontal beam  30 . Exemplary reciprocating formations  21 ,  31  are shown in  FIGS. 4A-4D . In this embodiment the connection hub formation  15  comprises a hollow tube  17  with a gap  18  which extends axially from one end of the tube to the other. The reciprocating formation  21 ,  31  is in the form of a solid cylinder which it dimensioned to fit within the interior of the hollow tube  17 . The cylinder  21 ,  31  is connected to the first and second horizontal beams  20 ,  30  via a stem  22 ,  32  and the stem  22 ,  32  is configured to slide along the axial gap  18  formed in the wall of the hollow tube  17  until the base of the cylinder  21 ,  31  abuts the base plate  15  of the connection hub  11 . 
     As best shown in  FIGS. 2 and 3 , the first horizontal beam  20  comprises a circular captivation detail  23  for retaining a decking board in use. The captivation detail  23  is welded to the top surface of the first horizontal beam  20 . On either side of the first horizontal beam  20  there is provided a pair of spaced apart brackets  24 . Each bracket pair is substantially aligned with a respective captivation detail  23 . The brackets  24  are substantially U-shaped and comprise an aperture  25  in the bridging section spanning the two legs. 
       FIGS. 7 and 8  show a third horizontal beam  40 . Each end the third horizontal beam  40  comprises an overhang portion  41  which extends axially outwards from the third horizontal beam  40 . As best shown in  FIG. 8 , a J-shaped appendage  42  is attached to the underside of the overhang portion  41 . The J-shaped appendage  42  is configured for insertion into the bracket aperture  25 , and in use helps secure the third horizontal beam  40  to the first horizontal beam  20 . 
       FIG. 9  shows a deck bay  50  formed from the modular decking system. The deck bay  50  comprises a scaffolding sub-structure which includes four vertical tubes  51 . The lowermost end of each vertical tube is connected to a scaffold base plate  52  via a shank which extends upwardly from the centre of the base plate into the interior of the vertical tube  51 . Four horizontal tubes  53  are connected to the lower ends of the vertical tubes via couplers. The scaffolding sub-structure additionally comprises four cross-braces  54 . Each cross brace extends diagonally from a lower end of one vertical tube  51  to an upper end of and adjacent vertical tube  51 . 
     The tail end of the connector  1  is inserted into the upper end of vertical tube  51 . As best shown in  FIG. 9 , the first and second horizontal beams  20 ,  30  extend between the connectors  1 . The third horizontal beams  40  extend between the first horizontal beams  20 . As best shown in  FIG. 15 , to connect the first horizontal beam  20  to the connector  1 , one end of the first horizontal beam  20  is positioned above the connection hub  11 . Then the cylinder  21  is brought into alignment with the hollow tube  17  of the connection hub  11  while also ensuring that the stem  22  is suitably aligned with the gap  18 . Once aligned, the cylinder  21  is lowered into the hollow tube  17  until it abuts the base plate  13  of the connection hub  11 . This process is then repeated to secure the cylinder  21  at the opposite end of the first horizontal beam  20  within a hollow tube  17  of an adjacent connection hub  11 . The same process of sliding engagement is repeated to secure the second horizontal beams  20  between adjacent connection hubs  11 . Advantageously, securing the first and second beams  20 ,  30  to the connection hub  11  by sliding engagement avoids the need for pins, bolts and tools. 
     Next, the third horizontal beams  40  are secured between the first horizontal beams  20  ( FIG. 14 ). This is achieved by inserting the free end of the J-shaped appendage  42  into the aperture  25  formed in the U-shaped bracket  24 . In particular, the J-shaped appendage  42  is rotated into place as the third horizontal beam  40  is lowered into position. This not only secures the beams  20 ,  40  together, it also prevents the first horizontal beam  20  from rotating which gives it more strength and allows it to be of a lighter gauge. 
     As best shown in  FIG. 10 , the decking bay may comprise handrails  60 . If desired, handrail stanchions  61  are inserted into the head portion of the elongate tube  10  and horizontal handrail tubes  62  are arranged between and secured to the handrail stanchions by couplers. Decking panels  55  are then arranged to overlie the connection hub  11  and the captivation details  23  on the first horizontal beams  20 . If the decking bay  50  comprises handrail stanchions  61  then the decking panels  55  may be secured to the connection hub  11  using a decking panel clamp which is connected to the handrail stanchion  61 . In the absence of handrail stanchions  61 , the corners of the decking panel  55  may be secured to connection hub  11  using a decking panel retainer  56 . Decking panel retainers  56  are nevertheless used to secure the decking panels  56  to the top surface of the first horizontal beams  20  and as shown in  FIGS. 9 and 10  these overlie the captivation details  23 . 
     In alternative embodiments a more permanent modular decking system may be erected. Such systems may comprise the connector  100  shown in  FIG. 11  which comprises an elongate tube  110  adapted for insertion into a vertical support and a connection hub  120  having a base plate  121  and a top plate  122 . This connection hub  120  comprises formations  130  which are shaped to receive the ends of the first and second horizontal beams  140 ,  150  rather than a connection detail extending therefrom as in the previous embodiment described hereinabove. As shown in  FIG. 11-13 , the walls  131  of the formations  130  comprise holes  132  and the ends of the first and second horizontal beams  140 ,  150  also comprise holes  141 ,  151  which are arranged for receiving fastening means such as bolts. 
     In this embodiment, the second horizontal beams  150  extend between adjacent connection hubs  120  and between the first horizontal beams  140 , i.e. they replace the third horizontal beams  40 . To secure the second horizontal beams  150  between the first horizontal beams  140  each leg of the U-shaped bracket  142  is adapted to comprise holes  143  for receiving fastening means such as a bolt from a bolted connection. As best shown in  FIG. 12B , the U-shaped bracket  142  in this embodiment is also inverted relative to the U-shaped bracket  24  of the previously described embodiment. 
     To erect the more permanent modular decking system, the ends of the first and second horizontal beams  140 ,  150  are positioned above the connection hub  120 . They are then lowered until the ends contact the base plate  122  of the connection hub  120 . Bolts are then fed through the holes  132  formed into the walls  131  of the formations  130  and also through the holes  141 ,  151  formed in the first and second beams  140 ,  150  respectively. The bolts are retained in place using nuts. Second horizontal beams  150  are then lowered into the U-shaped brackets  142  and these are secured in place by feeding bolts through the holes  143  in the U-shaped brackets  142  and the second horizontal beams  151 . Nuts are again used to retain the bolts in place. Decking panels  55  are then secured in place in the same manner as described for the previous embodiment. 
     The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.