REVERSIBLE DECK PLANK
20240247499 ยท 2024-07-25
Inventors
Cpc classification
E04F2015/0205
FIXED CONSTRUCTIONS
International classification
Abstract
Embodiments described herein are directed to a reversible deck system. The deck system is described as reversible because it may be installed onto the deck structure in two different orientations. In a first orientation, a walking surface is facing upward. The walking surface is substantially solid (e.g., without gaps) and forms a final finished surface of a deck. In a second orientation, the walking surface is facing downward. In the downward facing orientation, a joist structure onto which deck boards may be installed is facing upward. The reversible deck system includes four major structural members, including a wide deck plank, a narrow deck plank, a tongue edge cap, and a groove edge cap. In an aspect, the major structural members may be formed through an aluminum extrusion process.
Claims
1. A reversible plank comprising: an elongated body having a length, a width, and a thickness, wherein the elongated body includes by a tongue-side portion running the length of the elongated body opposite a groove-side portion running the length of the elongated body, an upper side of the elongated body forming a rectangular walking surface; a first leg extending downward along the length of the elongated body from the tongue-side portion, the first leg having a first end connected to a lower side of the elongated body and a second end; a tongue extending substantially perpendicularly from the first leg along the length of the first leg in a direction away from the tongue-side portion of the elongated body, an upper surface of the tongue being substantially parallel to the rectangular walking surface; and a second leg extending downward along the length of the elongated body from the groove-side portion, the second leg having an upper end connected to a lower side of the elongated body and a joist connection structure connected to a lower end of the second leg, the joist connection structure being substantially parallel to the rectangular walking surface.
2. The reversible plank of claim 1, wherein the first leg is substantially perpendicular to the elongated body.
3. The reversible plank of claim 1, wherein an upward facing surface of the tongue is lower than a downward facing surface of the elongated body.
4. The reversible plank of claim 1, further comprising a rib extending from the top side of the joist connection structure substantially perpendicular to the joist connection structure and substantially parallel to the second leg.
5. The reversible plank of claim 4, wherein the rib includes an upper terminal end at a height that is substantially equal to the lower side of the elongated body.
6. The reversible plank of claim 4, wherein a majority of the joist connection structure extends away from the groove-side portion of the elongated body.
7. The reversible plank of claim 1, wherein the second leg forms a groove by including a horizontal portion between a first vertical portion and a second vertical portion, wherein the first vertical portion is connected to the lower side of the elongated body and the second vertical portion is connected to the joist connection structure.
8. The reversible plank of claim 7, wherein a length of the horizontal portion is substantially equal to a length of the tongue, such that a terminal end of a separate tongue on a separate reversible plank would be substantially adjacent to a groove-side facing wall of the first vertical portion when the tongue on the separate reversible plank is installed in the groove.
9. A groove-side end cap comprising: an elongated body having a length, a width, and a thickness, wherein the elongated body includes by a tongue-side portion running the length of the elongated body opposite a finished edge running the length of the elongated body, an upper side of the elongated body forming a rectangular walking surface; a first leg extending downward along the length of the elongated body from the tongue-side portion, the first leg having a first end connected to a lower side of the elongated body and a second end; a tongue extending substantially perpendicularly from the first leg along the length of the first leg in a direction away from the tongue-side portion of the elongated body, an upper surface of the tongue being substantially parallel to the rectangular walking surface; and the finished edge extending downward along the length of the elongated body from a side opposite the tongue-side portion.
10. The reversible plank of claim 9, wherein the first leg is substantially perpendicular to the elongated body.
11. The reversible plank of claim 9, wherein an upward facing surface of the tongue is lower than a downward facing surface of the elongated body.
12. The reversible plank of claim 9, wherein the finished edge is substantially perpendicular to the elongated body.
13. The reversible plank of claim 9, wherein the finished edge is substantially perpendicular to the elongated body.
14. A tongue-side end cap comprising: an elongated body having a length, a width, and a thickness, wherein the elongated body includes by a finished-edge-side portion running the length of the elongated body opposite a groove-side portion running the length of the elongated body, an upper side of the elongated body forming a rectangular walking surface; a finished edge extending downward along the length of the elongated body from the finished-edge-side portion; and a leg extending downward along the length of the elongated body from the groove-side portion, the leg having an upper end connected to a lower side of the elongated body and a joist connection structure connected to a lower end of the leg, the joist connection structure being substantially parallel to the rectangular walking surface.
15. The tongue-side end cap of claim 14, further comprising a rib extending from the top side of the joist connection structure substantially perpendicular to the joist connection structure and substantially parallel to the leg.
16. The tongue-side end cap of claim 15, wherein the rib includes an upper terminal end at a height that is substantially equal to the lower side of the elongated body.
17. The tongue-side end cap of claim 15, wherein a majority of the joist connection structure extends away from the groove-side portion of the elongated body.
18. The tongue-side end cap of claim 14, wherein the leg forms a groove by including a horizontal portion between a first vertical portion and a second vertical portion, wherein the first vertical portion is connected to the lower side of the elongated body and the second vertical portion is connected to the joist connection structure.
19. A deck assembly comprising: a first reversible deck plank connected to a deck joist by a connector passing through a first structure in the first reversible deck plank; a second reversible deck plank connected to the deck joist by a screw passing through a second structure in the second reversible deck plank, wherein the second reversible deck plank includes a first tongue that is fit into a first groove on the first reversible deck plank; a tongue-side end cap, wherein the tongue-side end cap includes a second groove that receives into a second tongue on the first reversible deck plank; and a groove-side end cap, wherein the groove-side end cap includes a third tongue that is fit into a third groove on the second reversible deck plank.
20. The deck assembly of claim 19, wherein the first reversible deck plank includes an elongated body with an upward facing rectangular walking surface and the first structure is a joist connection structure that is different from the elongated body and is connected to the elongated body by a leg extending downward from the elongated body.
21. The deck assembly of claim 19, wherein the first reversible deck plank includes an upward facing joist connection structure and the first structure is an elongated body with a downward facing walking surface, wherein the elongated body is different from a joist connection structure and is connected to the elongated body by a leg extending downward from the joist connection structure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Illustrative embodiments are described in detail below with reference to the attached drawing figures, wherein:
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DETAILED DESCRIPTION
Overview
[0017] Embodiments described herein are directed to a reversible deck system. The reversible deck system may be installed on a deck structure. The deck system is described as reversible because it may be installed onto the deck structure in two different orientations. In a first orientation, a walking surface is facing upward. The walking surface is substantially solid (e.g., without gaps) and forms a final finished surface of a deck. The final finished surface is a surface people walk on and objects (e.g., tables and chairs) rest on. In a second orientation, the walking surface is facing downward. In the downward facing orientation, a joist structure onto which deck boards (e.g., wood or composite) may be installed is facing upward. The deck boards may be installed perpendicular to the joists.
[0018] The reversible deck system includes four major structural members, including a wide deck plank, a narrow deck plank, a tongue edge cap, and a groove edge cap. The deck assembly may be formed by joining a plurality of wide deck planks and narrow deck planks to form a deck surface with desired dimensions. A tongue side cap forms one edge of the deck assembly, while a groove edge cap forms the other edge. In an aspect, the major structural members may be formed through an aluminum extrusion process. The major structural members may be attached to a deck structure using screws, adhesive, bolts, and or other suitable connection technologies.
[0019] Turning now to
[0020] The wide deck plank 100 is shown with a walking surface 102 facing upward and a joist connection structure 142 facing downward. The walking surface 102 may serve as a final exposed surface for a deck assembly on which people walk and objects (e.g., tables and chairs) are supported. Alternatively, the wide deck plank 100 may be installed with the joist connection structure 142 facing upward. In this orientation, deck boards may be installed on top of the joist connection structure 142. The deck boards could be installed with an orientation that is substantially perpendicular to the length of the joist connection structure 142.
[0021] A first edge of the wide deck plank 100 includes an elongated groove 140, which may extend along the entire end of the wide deck plank 100. The first edge may be described herein as the groove edge. The elongated groove 140 may have a U-shaped cross section. A second edge of the wide deck plank 100, opposite of the grove edge, includes a tongue 110, which may extend along the entire end of the wide deck plank 100. The second edge may be described herein as the tongue edge. The tongue 110 is located approximately a thickness of the walking surface 102 below the walking surface 102. This location of the tongue 110 defines an upper outside surface 106, and a lower outside surface 108 of a tongue-edge flange 112 that extends vertically from the wide deck plank 100 in a direction substantially perpendicular to the walking surface 102. A deck assembly may be formed, in part, by inserting a tongue from an adjacent reversible deck plank (not shown) or other component into the groove 140 of the wide deck plank 100.
[0022] A first rib 114 and a second rib 116 descend generally vertically from the planar walking surface 102. These ribs may rest on a flange or other portion of an interlocking member, such as narrow reversible deck plank 200, groove-side end cap 300, and/or tongue-side end cap 400. These ribs may extend across the entire length of the wide deck plank 100 from one of its ends to the other.
[0023] The wide deck plank 100 includes a joist section 118, which extends downward from a leg 124 attached to a lower edge of the groove 140. The joist section 118 includes a joist connection structure 142, which may attach to a deck structure (not shown). The joist connection structure 142 is below and substantially parallel to the walking surface 102. The joist connection structure 142 extends the length of the wide deck plank 100. An upper-leg flange 120 extends perpendicularly from the leg 124 toward the tongue edge side of the wide deck plank 100. A lower-leg flange 122 extends perpendicularly from the leg 124 toward the tongue edge side of the wide deck plank 100.
[0024] The joist section 118 includes a rib 126 extending in an upward orientation that is substantially parallel to the leg 124 and perpendicular to the joist connection structure 142. An upper-rib flange 130 extends perpendicularly from the rib 126 toward the groove edge side of the wide deck plank 100. A lower-rib flange 132 extends perpendicularly from the rib 126 toward the groove edge side of the wide deck plank 100. When joined with a second plank, the bottom of the rib 114 may rest on the top surface of an upper-rib flange 130 of the second plank (not shown). In an aspect, the top surface 128 of the rib 126 is the approximately the same distance from the top-facing surface 134 of the joist connection structure 142 as the bottom edge of the groove 129. The joist connection structure 142 includes a fastener groove 133 through which screws, or other fasteners, may be driven.
[0025] Turning now to
[0026] The narrow deck plank 200 is shown with a walking surface 202 facing upward and a joist connection structure 242 facing downward. The walking surface 202 may serve as a final exposed surface for a deck assembly on which people walk and objects (e.g., tables and chairs) are supported. The narrow deck plank 200 may be installed with the joist connection structure 242 facing upward. In this orientation, deck boards may be installed on top of the joist connection structure 242. The deck boards could be installed with an orientation that is substantially perpendicular to the length of the joist connection structure 242.
[0027] A first edge of the narrow deck plank 200 includes an elongated groove 240, which may extend along the entire end of the narrow deck plank 200. The first edge may be described herein as the groove edge. The elongated groove 240 may have a U-shaped cross section. A second edge of the narrow deck plank 200, opposite of the grove edge, includes a tongue 210, which may extend along the entire end of the narrow deck plank 200. The second edge may be described herein as the tongue edge. The tongue 210 is located approximately a thickness of the walking surface 202 below the walking surface 202. This location of the tongue 210 defines an upper outside surface 206, and a lower outside surface 208 of a tongue-edge flange 212 that extends vertically from the narrow deck plank 200 in a direction substantially perpendicular to the walking surface 202. A deck assembly may be formed, in part, by inserting a tongue from an adjacent reversible deck plank (not shown) or other component into the groove 240 of the narrow deck plank 200.
[0028] A first rib 214 and a second rib 216 descend generally vertically from the planar walking surface 202. These ribs may rest on a flange or other portion of an interlocking member, such as wide reversible deck plank 100, groove-side end cap 300, and/or tongue-side end cap 400. These ribs may extend across the entire length of the narrow deck plank 200 from one of its ends to the other.
[0029] The narrow deck plank 200 includes a joist section 218, which extends downward from a leg 224 attached to a lower edge of the groove 240. The joist section 218 includes a joist connection structure 242, which may attach to a deck structure (not shown). The joist connection structure 242 is below and substantially parallel to the walking surface 202. The joist connection structure 242 extends the length of the narrow deck plank 200. An upper-leg flange 220 extends perpendicularly from the leg 224 toward the tongue edge side of the narrow deck plank 200. A lower-leg flange 222 extends perpendicularly from the leg 224 toward the tongue edge side of the narrow deck plank 200.
[0030] The joist section 228 includes a rib 226 extending in an upward orientation that is substantially parallel to the leg 224 and perpendicular to the joist connection structure 242. An upper-rib flange 230 extends perpendicularly from the rib 226 toward the groove edge side of the narrow deck plank 200. A lower-rib flange 232 extends perpendicularly from the rib 226 toward the groove edge side of the narrow deck plank 200. When joined with a second plank, the bottom of the rib 214 may rest on the top surface of an upper-flange 230 of the second plank (not shown). In an aspect, the top surface 228 of the rib 226 is the approximately the same distance from the top-facing surface 234 of the joist connection structure 242 as the bottom edge of the groove 229. The joist connection structure 242 includes a fastener groove 233 through which screws, or other fasteners, may be driven.
[0031] Turning now to
[0032] The groove-side end cap 300 includes a top 304, the top surface of which may form part of the walking surface of the deck assembly when installed in the orientation shown in
[0033] Turning now to
[0034] The tongue-side end cap 400 includes a joist section 418, which extends downward from a leg 420 attached to a lower-back side of the groove 430. The joist section 418 includes a joist connection structure 442, which may attach to a deck structure (not shown). The joist connection structure 442 is below and substantially parallel to the walking surface 416. The joist connection structure 442 extends the length of the tongue-side end cap 400. An upper-leg flange 422 extends perpendicularly from the leg 420 to form the lower end of the groove 430.
[0035] The joist section 418 includes a rib 406 extending in an upward orientation that is substantially perpendicular to the joist connection structure 402. An upper-rib flange 410 extends perpendicularly from the rib 406. A lower-rib flange 412 extends perpendicularly from the rib 406 toward the groove edge side of the tongue-side end cap 400.
[0036] Turning now to
[0037] If the deck is supported by the ground, as might be typically found in a backyard deck, then the next step is to dig holes for the footings, which are concrete bases that support the deck's weight. The footings are typically made of concrete and are placed below the frost line to prevent shifting during freeze-thaw cycles. Posts, which are vertical supports, are then attached to the footings using post anchors.
[0038] Beams and joists may comprise the main support structure for the deck. The reversible decking described herein may be attached to beams and joists. Beams are horizontal supports that are attached to the posts and/or main structure. In aspects, the beams may be supported by cables (such as in the case of a balcony attached to an apartment building) or other structural members. The beams carry the weight of the deck and transfer it to the footings, posts, and/or other structural members. Joists are attached to the beams and provide a surface to which the decking boards are attached. Joist hangers, which are metal brackets, may be used to secure the joists to the beams. The decking forms the surface of the deck. Decking boards are attached to the joists using deck screws, hidden fasteners, or other methods. The reversible decking may include marks indicating where screws should be used to secure the deck plank to the joists or other structural members.
[0039] Turning now to
[0040] Turning now to
[0041] Upon exiting the die, the extruded aluminum is quickly cooled with fans or water. This rapid cooling hardens the aluminum. The speed of the cooling process may be controlled to maintain the desired properties of the aluminum. After cooling, the extruded aluminum is moved to a stretcher, for straightening and work hardening. The hardened extrusions are brought to the saw table and cut according to the required lengths. The final step is aging, during which the aluminum is baked in an aging oven, which speeds up the hardening process. Additional complexities may be created during this process by adding a variety of fabrication techniques and finishes, such as anodizing or painting.
[0042] Turning now to
[0043] Turning now to
[0044] Turning now to
[0045] While operations are depicted in the drawings in a particular order, such operations are not required to be performed in the particular order shown or in sequential order, and all illustrated operations are not required to be performed. Actions described herein can be performed in a different order.
[0046] Having now described some illustrative implementations, it is apparent that the foregoing is illustrative and not limiting, having been presented by way of example. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, those acts and those elements may be combined in other ways to accomplish the same objectives. Acts, elements and features discussed in connection with one implementation are not intended to be excluded from a similar role in other implementations or implementations.
[0047] The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of including comprising having containing involving characterized by characterized in that and variations thereof herein, is meant to encompass the items listed thereafter, equivalents thereof, and additional items, as well as alternate implementations consisting of the items listed thereafter exclusively. In one implementation, the systems and methods described herein consist of one, each combination of more than one, or all of the described elements, acts, or components.
[0048] Any references to implementations or elements or acts of the systems and methods herein referred to in the singular may also embrace implementations including a plurality of these elements, and any references in plural to any implementation or element or act herein may also embrace implementations including only a single element. References in the singular or plural form are not intended to limit the presently disclosed systems or methods, their components, acts, or elements to single or plural configurations. References to any act or element being based on any information, act or element may include implementations where the act or element is based at least in part on any information, act, or element.
[0049] Any implementation disclosed herein may be combined with any other implementation or embodiment, and references to an implementation, some implementations, one implementation or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described in connection with the implementation may be included in at least one implementation or embodiment. Such terms as used herein are not necessarily all referring to the same implementation. Any implementation may be combined with any other implementation, inclusively or exclusively, in any manner consistent with the aspects and implementations disclosed herein.
[0050] References to or may be construed as inclusive so that any terms described using or may indicate any of a single, more than one, and all of the described terms. References to at least one of a conjunctive list of terms may be construed as an inclusive OR to indicate any of a single, more than one, and all of the described terms. For example, a reference to at least one of A and B can include only A, only B, as well as both A and B. Such references used in conjunction with comprising or other open terminology can include additional items.
[0051] Where technical features in the drawings, detailed description or any claim are followed by reference signs, the reference signs have been included to increase the intelligibility of the drawings, detailed description, and claims. Accordingly, neither the reference signs nor their absence have any limiting effect on the scope of any claim elements.
[0052] Modifications of described elements and acts such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations can occur without materially departing from the teachings and advantages of the subject matter disclosed herein. For example, elements shown as integrally formed can be constructed of multiple parts or elements, the position of elements can be reversed or otherwise varied, and the nature or number of discrete elements or positions can be altered or varied. Other substitutions, modifications, changes and omissions can also be made in the design, operating conditions and arrangement of the disclosed elements and operations without departing from the scope of the present disclosure. For example, the fluid lines or fittings described can be configured for use in various other components including, but not limited to, plumbing systems or other piping systems. Further relative parallel, perpendicular, vertical or other positioning or orientation descriptions include variations within +/?10% or +/?10 degrees of pure vertical, parallel or perpendicular positioning. References to approximately, substantially or other terms of degree include variations of +/?10% from the given measurement, unit, or range unless explicitly indicated otherwise. Coupled elements can be electrically, mechanically, or physically coupled with one another directly or with intervening elements. Scope of the systems and methods described herein is thus indicated by the appended claims, rather than the foregoing description, and changes that come within the meaning and range of equivalency of the claims are embraced therein.
[0053] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.