Modular, portable, interlocking decking system

• US 8,011,148 B2
• Filed: 06/16/2009
• Issued: 09/06/2011
• Est. Priority Date: 06/18/2008
• Status: Active Grant

• Current Assignee: UDECX, LLC
• Original Assignee: We Design Partners, LLC
• Inventors: Van Leeuwen, John M., Weaver, Michael P., Bertke, Patrick J.
• Primary Examiner(s): Glessner; Brian
• Assistant Examiner(s): FORD, GISELE D
• Application Number:
  US12/485,729
• Publication Number:
  US 20100257796A1
• Time in Patent Office: 812 Days
• Field of Search: 522/99, 522/63, 522/74, 524/80, 522/83, 522/84, 522/823, 522/821, 52/795, 527/450.5, 527/451.3, 527/471
• US Class Current: 52/263
• CPC Class Codes: E04F 11/1812 Details of anchoring to the wall or floor
• CPC Class Codes: E04F 15/02452 Details of junctions between the supporting structures and the panels or a panel-supporting framework
• CPC Class Codes: E04F 15/04 only of wood or with a top layer of wood, e.g. with wooden or metal connecting members rollable parquet E04F15/16
• CPC Class Codes: E04F 2015/02116 with fastening elements extending into the back side of the flooring elements
• CPC Class Codes: E04F 21/20 for laying flooring made of similar material to roads or pavements E01C ; arrangements for removing of previously fixed floor covering E04G23/00

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.

Claims

1. A modular, portable, interlocking decking system comprising:

a plurality of structural piers, each structural pier including a generally planar bearing plate having a bottom surface, each structural pier further including a top surface opposing the bottom surface of the bearing plate;

a plurality of generally hollow receiver blocks in the top surface of each structural pier, each receiver block including a slotted opening and a receiver block detent;

at least one generally rectangular surface pad, the surface pad comprising;

a generally planar, horizontal upper surface,

a lower portion, the lower portion including a generally hollow block receptacle at each corner of the surface pad, and

at least one fastener opening at each corner of the surface pad, the fastener opening extending from the upper surface to the block receptacle; and

a plurality of cam lock fasteners, the cam lock fasteners having a fastener detent configured to engage the receiver block detent,

wherein the bottom surface of the bearing plate of each structural pier rests upon a supporting surface and the block receptacles of the surface pad each engage a receiver block of a corresponding structural pier, the surface pad being detachably secured to the structural piers by inserting one of the cam lock fasteners into each fastener opening of the surface pad and into engagement with the slotted opening of a corresponding block receptacle, the receiver block detent engaging the fastener detent when the cam lock fasteners are placed into engagement with the slotted opening of a corresponding receiver block.

2. The decking system of claim 1 wherein the lower portion of the surface pad further includes structural ribs.

3. The decking system of claim 1 wherein the upper surface of the surface pad further includes weep holes for water drainage.

4. The decking system of claim 1 wherein the receiver block further includes a stop to limit rotation of the cam lock fastener when the cam lock fastener is in engagement with the receiver block.

5. The decking system of claim 1 wherein the cam lock fastener further includes a ramp cam portion.

6. The decking system of claim 1 wherein the structural piers further include at least one aperture extending through the bearing plate.

7. The decking system of claim 6, further comprising at least one anchor fastener, the anchor fastener extending through the aperture of the bearing plate and into the support surface to secure the structural pier to the support surface.

8. The decking system of claim 7 wherein the anchor fastener is a spike or a bolt.

9. The decking system of claim 1, further comprising at least one elongated perimeter skirt, the perimeter skirt including:

a generally horizontal skirt surface,

a generally vertical skirt face,

an interior portion delimited by the skirt surface and the skirt face, the interior portion including a generally hollow skirt block receptacle at opposing ends of the perimeter skirt, and

at least one skirt fastener opening at each end of the perimeter skirt, the skirt fastener opening extending from the skirt surface to the skirt block receptacle,

wherein the skirt block receptacles each engage a receiver block of a corresponding structural pier, the perimeter skirt being detachably secured to the structural piers by inserting one of the cam lock fasteners into each skirt fastener opening and into engagement with the slotted opening of a corresponding block receptacle.

10. The decking system of claim 1, further comprising a railing assembly, the railing assembly including:

a plurality of support blocks, the support blocks each having a generally hollow support block receptacle, a support block upper surface, at least one support block fastener opening extending from the support block upper surface to the support block receptacle, and a support block connector;

a support brace having a generally horizontal portion and a generally vertical portion, the horizontal and vertical portions each including a support brace connector;

a generally hollow, elongated support post, the support post having a plurality of post connectors; and

a railing assembly having at least one railing connector,

wherein the support block receptacles each engage a receiver block of a corresponding structural pier, the support blocks being detachably secured to the structural piers by inserting one of the cam lock fasteners into the support block fastener opening and into engagement with the slotted opening of a corresponding receiver block,

the support block connector being detachably coupled to the brace connector of the horizontal portion of the support brace to join the support brace to the support block,

the brace connector of the vertical portion of the support brace being detachably coupled to a first post connector to join the post to the support brace, and

the railing connector of the railing assembly being coupled to a second post connector to detachably join the railing assembly to the post.

11. The decking system of claim 10 wherein the support post further includes a post cap.

12. The decking system of claim 10, further including an extended cam lock fastener, the extended cam lock fastener extending through the post and the surface pad, into engagement with the slotted opening of a corresponding structural pier to detachably join the post and the surface pad to the structural pier.

13. The decking system of claim 1, further comprising a tool configured to rotatably urge the cam lock fasteners into engagement with the slotted opening of a corresponding block receptacle.

14. The decking system of claim 1, further comprising a pier extension block having an extension block top surface and an opposing extension block receptacle, the extension block top surface further including a plurality of generally hollow extension block receivers, each extension block receiver including a slotted opening,

the pier extension block being interposed between the surface pad and the structural pier,

the extension block receptacle engaging each of the receiver blocks of the structural pier, and

an extension block receiver block engaging the block receptacle of the surface pad,

the surface pad being detachably secured to the structural piers by inserting one of the cam lock fasteners into the fastener opening of the surface pad, through the extension block, and into engagement with the slotted opening of a block receptacle of a corresponding structural pier.

15. The decking system of claim 1, further comprising a step block having a step block top surface and an opposing step block receptacle, the step block top surface further including a generally hollow step block receiver having a slotted opening,

the step block being interposed between the surface pad and the structural pier,

the step block receptacle engaging a receiver block of the structural pier, and

the step block receiver engaging the block receptacle of the surface pad,

the surface pad being detachably secured to the structural piers by inserting one of the cam lock fasteners into the fastener opening of the surface pad, through the step block, and into engagement with the slotted opening of a block receptacle of a corresponding structural pier.

16. A modular, portable, interlocking decking system comprising:

a plurality of structural piers, each structural pier including a generally planar bearing plate having a bottom surface, each structural pier further including a top surface opposing the bottom surface of the bearing plate;

a plurality of generally hollow receiver blocks in the top surface of each structural pier, each receiver block including a slotted opening;

at least one generally rectangular surface pad, the surface pad comprising;

a generally planar, horizontal upper surface,

a lower portion, the lower portion including a generally hollow block receptacle at each corner of the surface pad, and

at least one fastener opening at each corner of the surface pad, the fastener opening extending from the upper surface to the block receptacle;

a plurality of cam lock fasteners;

at least one elongated perimeter skirt, the perimeter skirt including;

a generally horizontal skirt surface,

a generally vertical skirt face,

an interior portion delimited by the skirt surface and the skirt face, the interior portion including a generally hollow skirt block receptacle at opposing ends of the perimeter skirt, and

at least one skirt fastener opening at each end of the perimeter skirt, the skirt fastener opening extending from the skirt surface to the skirt block receptacle; and

a railing assembly, the railing assembly including;

a plurality of support blocks, the support blocks each having a generally hollow support block receptacle, a support block upper surface, at least one support block fastener opening extending from the support block upper surface to the support block receptacle, and a support block connector,

a support brace having a generally horizontal portion and a generally vertical portion, the horizontal and vertical portions each including a support brace connector,

a generally hollow, elongated support post, the support post having a plurality of post connectors, and

a railing assembly having at least one railing connector,

wherein the skirt block receptacles each engage a receiver block of a corresponding structural pier, the perimeter skirt being detachably secured to the structural piers by inserting one of the cam lock fasteners into each skirt fastener opening and into engagement with the slotted opening of a corresponding block receptacle,

wherein the bottom surface of the bearing plate of each structural pier rests upon a supporting surface and the block receptacles of the surface pad each engage a receiver block of a corresponding structural pier, the surface pad being detachably secured to the structural piers by inserting one of the cam lock fasteners into each fastener opening of the surface pad and into engagement with the slotted opening of a corresponding block receptacle, and

wherein the support block receptacles each engage a receiver block of a corresponding structural pier, the support blocks being detachably secured to the structural piers by inserting one of the cam lock fasteners into the support block fastener opening and into engagement with the slotted opening of a corresponding receiver block,

the support block connector being detachably coupled to the brace connector of the horizontal portion of the support brace to join the support brace to the support block,

the brace connector of the vertical portion of the support brace being detachably coupled to a first post connector to join the post to the support brace, and

the railing connector of the railing assembly being coupled to a second post connector to detachably join the railing assembly to the post.

17. The decking system of claim 16, wherein:

the receiver blocks further include a receiver block detent; and

the cam lock fasteners further include a fastener detent configured to engage the receiver block detent,

the receiver block detent engaging the fastener detent when the cam lock fasteners are urged into engagement with the slotted opening of a corresponding receiver block.

18. A method for installing a modular, portable, interlocking decking system comprising the steps of:

providing a plurality of structural piers, each structural pier including a generally planar bearing plate having a bottom surface, each structural pier also including a top surface opposing the bottom surface of the bearing plate, the structural piers further including a plurality of generally hollow receiver blocks in the top surface of each structural pier, each receiver block including a slotted opening and a receiver block detent;

providing at least one generally rectangular surface pad, the surface pad comprising;

a generally planar, horizontal upper surface;

a lower portion, the lower portion including a generally hollow block receptacle at each corner of the surface pad; and

at least one fastener opening at each corner of the surface pad, the fastener opening extending from the upper surface to the block receptacle;

providing a plurality of cam lock fasteners, the cam lock fasteners having a fastener detent configured to engage the receiver block detent;

resting the bottom surface of the bearing plate of each structural pier upon a supporting surface;

engaging each of the block receptacles of the surface pad with a receiver block of a corresponding structural pier; and

detachably securing the surface pad to the structural pier by inserting one of the cam lock fasteners into each fastener opening of the surface pad and into engagement with the slotted opening of a corresponding block receptacle, the receiver block detent engaging the fastener detent when the cam lock fasteners are placed into engagement with the slotted opening of a corresponding receiver block.