Patent Publication Number: US-2004050009-A1

Title: Modular deck apparatus and method

Description:
TECHNICAL FIELD  
       [0001] Embodiments of the invention relate generally to decks for houses, residential dwellings, cottages and cabins. More particularly, the embodiments of the invention relate to a modular deck apparatus and method.  
       BACKGROUND INFORMATION  
       [0002] Many residences, cabins and cottages now have a deck attached directly to the house. A deck provides additional recreational space for enjoying the outdoors. Many decks provide space for grilling as well as for outdoor furniture used for relaxing. Others use a deck for sunbathing or other recreational purposes. Many decks are elevated above the ground and provide users with an elevated view of the real estate near the deck.  
       [0003] There are problems with associated with conventional decks. Most decks are “stick built.” In other words, the deck is built one board at a time. This is a time consuming process. Deck framing is typically built on site with pressure-treated lumber. Until recently, most treated wood contained arsenic. Arsenic has been determined to be harmful to humans. Thus, it is being phased out as a wood preservative. A treated lumber frame will last from 10-20 years. Then it will need to be replaced.  
       [0004] In most instances, a face plate is attached to the residence. The face plate is sealed against the elements, such as by placing a drip cap over the face plate. Initially, openings in the ground are made at very specific locations. The openings are also dug to a very specific depth to provide footings for the deck. The openings are filled with concrete and a connector is placed into the concrete. In some instances, upright posts are attached to the connectors in the concrete and cross members or stringers are placed onto the posts at a height substantially equal to the header on the side of the residence. In some instances, the connectors are not provided in the concrete and the upright merely sits atop the concrete. Joists are then attached to the header and the cross member. Specific joist hangers are used to attach the joists to the face plate and cross member. The joists are placed approximately 16 inches on center. This is a labor-intensive process. The weight of each joist makes it difficult to construct prefabricated, modular sections. Some modular wood systems have been developed, but they require many additional support posts and do not allow for the use of long decking planks due to the weight of the sections.  
       [0005] After the framing is complete, the decking is attached. The most common method for attaching the decking is from the top into the wood frame using nails or screws. Some manufacturers of non-wood decking have designed methods for attaching the decking from the topside without exposing any fastener heads. In addition, various steel hardware systems were recently developed to allow the decking to be attached from the underside by attaching it to the framing and then to the decking. Railings and stairs are attached last. One problem associated with attaching the decking material from the top of the deck to the joists is that nails or screws can then pop up at a later date. These pop ups can wreck havoc on users feet. The pop ups can also snag a paint brush or roller which is used to periodically stain or seal the deck.  
       [0006] Many of the decks are made from wood. Wood has a limited life span and also requires more maintenance than other materials in order to extend the life of the deck. For example, it is generally recommended that the homeowner stain and seal a deck every other year in order to extend the life of the deck. Staining and sealing the deck also renews the appearance of the deck since they are typically made of wood.  
       SUMMARY OF THE INVENTION  
       [0007] An apparatus for a deck includes a first upright post, a cross member attached to the first upright post, and an elongated modular joist unit, which includes at least two spaced joists, attached to the cross member. The apparatus for a deck can also include a second upright post. In this embodiment, the cross member is attached to the first upright post and the second upright post. Attached to the modular joist unit is a modular decking unit that includes a plurality of decking members. The modular joist unit includes a first end plate and a second endplate. In some embodiments one of the first endplate and the second endplate includes a curved surface. A deck unit is attached to the modular joist unit with a fastener. In some embodiments, the individual deck unit is attached to the modular joist unit, and then to the individual deck unit.  
       [0008] In some embodiments, the modular joist unit further includes a plurality of tabs adapted to receive fasteners. The fasteners pass through the tabs and then into a decking material that traverses the joists of the modular joist unit. In some embodiments, flanges are formed on each side of the modular joist. Slotted or oblong openings are placed in the flange to allow materials attached to the flange to move in the event there is a thermal coefficient of expansion mismatch. In some embodiments, the decking material comprises a modular decking unit that includes a plurality of individual planks.  
       [0009] The modular joist unit includes a first end plate and a second endplate. In some embodiments, one of the first endplate and the second endplate is adapted for attachment to a substantially vertical surface of an edifice. In some embodiments, one of the first endplate and the second endplate includes a locking mechanism for attachment to a substantially vertical surface of an edifice. In another embodiment, one of the first endplate and the second endplate has openings therein for receiving fasteners to attach substantially vertical surface of an edifice. In some embodiments, a second elongated modular joist unit is also attached to the cross member. The second elongated modular joist unit is attached to the first modular joist unit. In some embodiments, a weather proofing device is attached to one of the first end plate or the second end plate. The material of the elongated modular joist unit can be a non-wood material.  
       [0010] A method for assembling a deck includes attaching a first upright to a first anchor point, attaching a second upright to a second anchor point, attaching a cross beam to the first upright and the second upright, and connecting an elongated modular joist unit having at least two joists to the cross beam. The method can further include attaching the elongated modular joist unit to an edifice. Attaching the elongated modular joist unit to an edifice includes locking an end plate of the elongated modular joist unit to a face plate on an edifice. The method also includes attaching decking material to the modular joist unit, wherein the fasteners pass through a portion of the modular joist unit and into the decking material. In some embodiments, the decking material is a decking unit having at least two decking planks to the modular joist unit. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0011]FIG. 1 is a perspective view of a deck attached to a residential structure according to an embodiment of the invention.  
     [0012]FIG. 2 is a bottom perspective view of a deck which includes a cross member attached to an upright post according to an embodiment of this invention.  
     [0013]FIG. 3 is a bottom perspective view of a deck which includes a cross member attached to a first upright post and a second upright post according to an embodiment of this invention.  
     [0014]FIG. 4 is a perspective view of a modular joist unit according to an embodiment of this invention.  
     [0015]FIG. 5 is a perspective view of a plurality of modular joist units, one of which is triangular, which are connected to one another.  
     [0016]FIG. 6 is a perspective view modular joist unit according to an embodiment of this invention.  
     [0017]FIG. 7A is a perspective view of a portion of a joist of an embodiment of the modular joist arrangement.  
     [0018]FIG. 7B is another perspective view of a portion of a joist of an embodiment of the modular joist arrangement.  
     [0019]FIG. 8 is a perspective view of the perimeter of the modular joist unit according to an embodiment of the invention.  
     [0020]FIG. 9 is a perspective view of a modular joist unit according to an embodiment of the invention.  
     [0021]FIG. 10 is a perspective view of an end plate that abuts a face plate according to an embodiment of the invention.  
     [0022]FIG. 11 is a perspective view of a connecting plate for attaching an endplate of a modular joist unit to an edifice according to an embodiment of the invention.  
     [0023]FIG. 12 is a cross sectional view of the connecting plate along line  12 - 12  for attaching an endplate of a modular joist unit to an edifice according to an embodiment of the invention.  
     [0024]FIG. 13 is a perspective view of a free-standing deck according to an embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0025] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustrating specific embodiments in which the invention may be practiced. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of present inventions. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments of the invention is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.  
     [0026]FIG. 1 is a perspective view of a deck  100  attached to a residential structure  110  according to an embodiment of this invention. The deck  100  includes a first upright post  120  and a second upright post  122 . A cross member  124  is attached between the first upright post  120  and the second upright post  122 . The upright posts  120  and  122  are attached to anchor points  130  and  132 . Typically, the anchor points  130  and  132  are columns of concrete that are placed into the ground to a depth below the frost line. In other words, the anchor points  130  and  132  include the footings for the deck  100 . The deck includes one or more modular joist units  200 ,  202 ,  204 . The modular joist units  200 ,  202 ,  204  are attached to the cross member  124 . The modular joist units  200 ,  202 ,  204  are also attached to one another. Attached to the modular joist units  200 ,  202 ,  204  is decking material  150 . The decking material  150  can be in the form of individual planks or in the form of modular decking units which include at least two individual planks. The upright posts  120 ,  122  are connected to the anchor points  130 ,  132  by one of several methods. For example, the posts  120 ,  122  can be set into concrete associated with anchor points  130 ,  132 . In another embodiment, L-shaped bolts are placed into the wet concrete forming the anchor points  130 ,  132 . After the concrete associated with the anchor points  130 ,  132  has set, a U-shaped bracket can be placed or bolted onto a threaded end of the L-shaped bolt to hold the C-shaped bracket in place. The C-shaped bracket typically has openings therein so that the post  120 ,  122  can be bolted to the C-shaped bracket.  
     [0027]FIG. 2 is a bottom perspective view of a deck which includes a cross member attached to an upright post  220  according to an embodiment of this invention. A cross member  124  is attached to the upright post  220 . A first stiffening brace  222  and a second stiffening brace  224  are attached between the cross member  124  and the upright  220 . Elongated modular joist units  200 ,  202 ,  204  are attached to the cross member  124 . Each modular joist unit includes a first end plate and a second end plate. Rather than describing each of the modular joist units, one modular joist unit  200  will be described in detail with the understanding that the other two joist units  202 ,  204 , shown within FIG. 2, are similar to modular joist unit  200 . Modular joist unit  200  includes a first end plate  230  and a second end plate  232 . The end plate  232  is dimensioned so that it corresponds or fits over a face plate  140  which may be found on a resident&#39;s cottage or house.  
     [0028] As shown in FIG. 2, the height of the end plate  232  is greater than the height of the end plate  230  since the end plate  232  is dimensioned to fit over a standard face plate which is typically attached to a cottage or residence. In some embodiments, the end plate  232  and the end plate  230  would have substantially similar heights. In this other embodiment, the end plate  232  would attach to an existing face plate, such as  140 . The end plate  232  has a C-shaped cross section which fits directly over the face plate  140  of an edifice or building. The top portion of the end plate  232  is at an angle so that water associated with rain or melting snow will be deflected away from the residence to which it is attached. In other words, the end plate  232  includes a built-in flashing which will keep the elements away from the existing face plate on an edifice, such as a building, residence, cottage or cabin. The modular joist units attach to one another. In this particular embodiment, the face plate from an adjacent modular unit butts up against the end of a face plate from an adjoining modular unit. A sleeve or connecting plate can be used to attach the adjacent modular joist units  200 ,  202 ,  204 . Such a sleeve is shown as elements  240  and  242  in FIG. 2. Sleeve  240  connects the ends of the face plates associated with modular joist unit  200  and adjacent modular joist unit  202 . Sleeve  242  connects the ends of the face plate associated with modular unit  202  and the end plate of adjacent modular joist unit  204 . In another embodiment of the invention the endplate  230  is formed of tubular stock. Another tubular portion fits within the tubular stock to connect the modular joist unit  202  with an adjacent modular joist unit  204 . In the embodiment shown in FIG. 2, the joists of the modular joist units  200 ,  202 ,  204  are spaced away from one another. In other embodiments, the modular joist units are formed with joists on the perimeter of the modular joist unit and the modular joist units are connected to one another by bolting one modular joist unit to another modular joist unit thereby creating a doubling of the joists at the perimeter of the modular joist units. The modular joist units could also separated and an individual joist could be placed between the modular joist units to separate them. An additional endplate can be used to tie the joist units together. Regardless of the arrangement of the modular joist units, a decking material  150  is then attached between the modular decking units  200 ,  202 ,  204  to form the basic deck surface. As mentioned previously, the decking material may be individual planks of either wood or another artificial decking material. In another embodiment, the decking material may be a modular decking unit that includes at least two or more planks already attached to one another.  
     [0029]FIG. 3 is bottom perspective view of a deck which includes a cross member attached to a first upright post  120  and a second upright post  122 , and a third upright post  220 . The deck  300 , shown in FIG. 3, differs only slightly from the deck shown in FIG. 2. Rather than repeat the various aspects of the deck, only the differences will be discussed. The basic difference between deck  300 , shown in FIG. 3, and the deck shown in FIG. 2 is that the upright  220  has been supplemented with uprights  120  and  122 . This eliminates the need for the stiffening braces  222 ,  224 .  
     [0030]FIG. 14 is bottom perspective view of a deck which includes a first upright post  120  and a second upright post  122 , and a third upright post  220 . The deck  300 , shown in FIG. 14, differs only slightly from the deck shown in FIG. 2. Rather than repeat the various aspects of the deck, only the differences will be discussed. The basic difference between deck  300 , shown in FIG. 3, and the deck  1400  shown in FIG. 14 is that the uprights  120 ,  122  and  220  are attached to the separate modular joist units. This eliminates the need for the header or cross member  124 .  
     [0031]FIG. 4 is a perspective view of a modular joist unit  400  according to an embodiment of this invention. The modular joist unit  400  includes a first end plate  430  and a second end plate  432 . Attached to the end plates  430 ,  432  are individual joists  410 ,  412 ,  414  and  416 . In one embodiment, the modular joist unit  400  is made of a material other than wood, such as aluminum. The modular joist unit  400  can be comprised of fully welded aluminum shapes or fully welded aluminum joists. The joists can be made by various extruding, casting, forming, bending, rolling, cutting, punching, notching, drilling or other techniques. The finish on the aluminum can be anodized, painted, PVC coated, powder coated or milled. The finish can also be formed using other techniques. The advantage of using a material such as aluminum is that the modular joist unit  400  is sufficiently light to allow a person or persons to move the modular joist unit  400  into place onto a cross member  124 . A person or several persons can then attach the modular joist unit  400  to a face plate or over a face plate of a residence or edifice. The modular joist unit will allow for much more efficient construction since several joist units can be merely placed atop a cross member, such as  124  and to a face plate  140  on an edifice, to form the base to which the planking material  150  can be attached. Once anchors such as  130 ,  132  (shown in FIG. 1) are formed and the uprights and cross beam are in place, the modular joists and decking material can be used to quickly form the basic deck structure upon which the decking material  150  will be placed.  
     [0032]FIG. 5 is a perspective view of a plurality of modular joist units which can be attached together to form a deck having a desired shape. FIG. 5 shows a basic deck structure  500  without the decking material. The basic deck structure is comprised of a triangularly shaped modular joist unit  510  connected to a rectangular modular joist unit  520 . Both of these modular joist units  510 ,  520  are attached to the modular joist unit  400 . The base deck structure  500  is attached to a cross member  124  which is attached to uprights  120 ,  122 . FIG. 5 illustrates that the modular joist units can come in various shapes and sizes and can be attached to one another to form decks of various shapes.  
     [0033]FIG. 6 is a perspective view of another modular joist unit  610 . Modular joist unit  610  includes a curved end plate  630  and a straight end plate  632 . The modular joist unit  610  includes individual joist units  612 ,  614 ,  616 ,  618 . The modular joist unit  610  also may be made of material other than wood, such as aluminum. Modular unit  610  also shows that the modular units associated with a particular deck can include curves. Although the curve associated with end plate  630  is rather gradual, it is further contemplated that either more gradual or tighter curves having a smaller radius can also be used to form various deck modules which can be linked together to form a deck having a desired shape.  
     [0034]FIG. 7A is a perspective view of a portion of a joist associated with a modular joist unit  710 . The modular joist unit includes an end plate  732  and a first joist  712  and a second joist  714 . The joist  712  includes a set of tabs  720 ,  721  and  722 ,  723 . Each of the tabs  720 ,  721 ,  722 ,  723  includes an opening  730 ,  731 ,  733 ,  735 . The opening  730 ,  731 ,  732 ,  733  is large enough to allow the main shaft of a fastener to pass through the opening  730 ,  731 ,  733 ,  735 , but is small enough so that the upset end or enlarged end of a fastener will not pass through the opening  730 ,  731 ,  733 ,  735 . The opening is slotted or oblong to allow different rates of thermal expansion between the attached decking material (as shown in FIGS.  1 - 3 ) and the modular joist unit  710 . As a result, when a fastener is passed through the tab  720  and specifically through the opening  730  in tab  720 , the main portion or main body of the fastener passes through the opening and the head catches the tab. These tabs  720 ,  721 ,  723 ,  723  facilitate attaching the planking material from beneath the decking material. As a result, the fasteners used to attach the decking material from beneath will not be seen on the walking surface of the deck. This is more aesthetically pleasing to the eye. In addition, the decking material can be used as a weather shield for the fasteners so as to make the deck more maintenance free over the life of the deck.  
     [0035]FIG. 7B is a perspective view of a portion of a joist associated with a modular joist unit  710 . The modular joist unit includes an end plate  732  and a first joist  712  and a second joist  714 . The joist  712  includes a first flange  750  and a second flange  752 . Each of the flanges  750 ,  752 , includes a plurality of openings, such as  754 , therein. The openings  754  are large enough to allow the main shaft of a fastener to pass through the opening  754 , but are small enough so that the upset end or enlarged end of a fastener will not pass through the opening  754 . The opening is slotted or oblong to allow different rates of thermal expansion between the attached decking material (as shown in FIGS.  1 - 3 ) and the modular joist unit  710 .  
     [0036]FIG. 8 is a perspective view of a modular unit  810  according to yet another embodiment of the invention. In this particular embodiment of the invention, the modular joist unit  810  includes a surface  850  corresponding to the outside perimeter of the deck that will be formed using the modular joist unit  810 . A first bracket  860  and a second bracket  862  are spaced apart vertically from one another. The brackets  860 ,  862  are sized to receive a post  870  associated with a guard rail that will be attached or made on the outside perimeter of the deck when finished. The outside perimeter surface  850  has a second set of brackets  861 ,  863  which are spaced apart from the first set of brackets  860 ,  862 . The space between the sets of brackets  860 ,  862  and  861 ,  863  are set to comply with various regulation and building codes, as well as to look aesthetically pleasing to the deck owner. The sets of brackets  861 ,  863  and  860 ,  862  also allow for faster construction of the finished deck. In essence, deck posts, such as  870 , can be inserted into the bracket and further fastened to the modular joist unit  810  so that a guard rail may be more quickly constructed.  
     [0037]FIG. 9 shows a perspective view another embodiment of a modular joist unit  910 . The modular joist unit  910  includes brackets  960 ,  962  positioned on an inside surface  950  of an individual joist associated with the modular joist unit  910 . The individual joists that form the perimeter or outside perimeter of the deck are provided with sets of brackets  960 ,  962 . The sets of brackets are spaced about the perimeter and are dimensioned to receive deck posts  970 . Openings are made in the decking material having dimensions which are slightly bigger than the post. The decking posts  910  pass through the openings made in the decking material and into the brackets  960 ,  962 . Additional materials, such as a railing module  990 , can be placed between the posts  970  to form a guard rail. It should be noted that the railing module can be transparent, acrylic material. Furthermore, it is contemplated that the railing could be built up from separate materials in some embodiments.  
     [0038]FIG. 10 details the end plate  1032  which is used to abut up against a face plate of a cottage, residence or other edifice. The end plate  1032  includes openings  1040 ,  1041 ,  1042 ,  1043 ,  1044 ,  1045 ,  1046 ,  1047 . The openings are sized so that they receive the shafts of lag bolts and yet will not allow the head of a lag bolt to pass through the openings  1040 ,  1041 ,  1042 ,  1043 ,  1044 ,  1045 ,  1046 ,  1047 . In this way, lag bolts can be used to attach the end plate  1032  to a face plate  140  on an edifice. In other embodiments, there are different means for attaching the end plate  1032  to the face plate  140  of the edifice.  
     [0039]FIG. 11 is a perspective view of a connecting plate  1100  for connecting an end plate, such as  1032 , of a modular joist unit to an edifice, such as a house, cottage or cabin. The connector  1100  is essentially J shaped in cross section, as shown in FIG. 11, as well as FIG. 12.  
     [0040]FIG. 12 is a cross-sectional view of the connecting plate or connector  1100  along line  12 / 12 . The J-shaped connector includes openings  1102 ,  1103 ,  1104 . The openings are dimensioned to receive lag bolts or a similar connector which can be fastened or attached to a building or edifice. The J-shaped connector includes a base  1110 , a shortened leg  1112  and a connecting leg  1114 . The shortened leg  1112  which is used to hold the end plate  1032  in the channel formed by legs  1110 ,  1112  and  1114 . The shortened leg  1112  also includes openings or slots  1120 . One slot  1120  is shown in FIG. 11. In the finished product, there will be multiple slots which are spaced apart so as to receive the individual joists of a modular joist unit.  
     [0041]FIG. 13 is a perspective view of a free-standing deck  1300  according to another embodiment of this invention. The free-standing deck  1300  is made of a first deck module  1310 , a second deck module  1320  and a third deck module  1330 . The deck modules are placed directly upon a surface, such as the ground. The ground or surface is leveled or slightly sloped and prepared for receiving the deck  1300 . Once the ground or surface is prepared, deck modules  1310 ,  1320 ,  1330  are bolted or attached to one another to form a deck of a particular shape or desired shape. The modular joist units  1310 ,  1320 ,  1330  are formed of a material which will not corrode or rust, such as aluminum. Once attached to one another, a decking material can be placed upon the modular joist units  1310 ,  1320 ,  1330 . The decking material does not necessarily have to be a set or series of planks but can be another material so that the deck might have an appearance similar to a concrete patio. The deck  1300  which is formed, does not have any support structure other than the support from the ground or surface on which it sits. In some embodiments, the deck can be lowered into the ground or into the surface before a decking material is placed upon the deck.  
     [0042] Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art will appreciate that any arrangement calculated to achieve the same purpose can be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments of the invention. It is to be understood that the above description has been made in an illustrative fashion, and not a restrictive one. Combinations of the above embodiments, and other embodiments not specifically described herein will be apparent to those of skill in the art upon reviewing the above description. The scope of various embodiments of the invention includes any other applications in which the above structures and methods are used. Therefore, the scope of various embodiments of the invention should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.  
     [0043] It is emphasized that the Abstract is provided to comply with 37 C.F.R. § 1.72(b) requiring an Abstract that will allow the reader to quickly ascertain the nature and gist of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.  
     [0044] In the foregoing Description of Embodiments of the Invention, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Description of Embodiments of the Invention, with each claim standing on its own as a separate preferred embodiment.