BRIEF DESCRIPTION OF THE FIGURES
Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which:
FIG. 1 is a partial perspective view of a decking system according to a preferred embodiment of the invention;
FIG. 2 is another partial perspective view of the decking system of FIG. 1;
FIG. 3 is another partial perspective view of the decking system of FIG. 1;
FIG. 4 is another partial perspective view of the decking system of FIG. 1;
FIG. 5 is another partial perspective view of the decking system of FIG. 1;
FIG. 6 is another partial perspective view of the decking system of FIG. 1;
FIG. 7 is another partial perspective view of the decking system of FIG. 1;
FIG. 8 is another partial perspective view of the decking system of FIG. 1;
FIG. 9 is another partial perspective view of the decking system of FIG. 1;
FIG. 10 is an environmental perspective view of the decking system of FIG. 1;
FIG. 11 is another partial perspective view of the decking system of FIG. 1;
FIG. 12 is another partial perspective view of the decking system of FIG. 1;
FIG. 13 is another partial perspective view of the decking system of FIG. 1;
FIG. 14 is a perspective view of a decking system according to another preferred embodiment of the invention;
FIG. 15 is a partial perspective view of the decking system of FIG. 13; and
FIG. 16 is a perspective view of a component of the decking system of FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now specifically to the drawings, an apparatus for use in forming a deck according to a preferred embodiment of the invention is illustrated in FIG. 1, and shown generally at reference numeral 10. The decking system 10 generally comprises a platform 12 and a cover piece 20. The platform 12 is preferably rectangular, and the cover piece 20 is positioned on a longitudinal edge 14 of the platform 12. The decking system 10 is particularly suited for building concrete decks, however, the decking system 10 can be used in conjunction with other suitable hardenable fill materials, such as grout, mortar, and various mixtures of water, sand, gravel crushed stones and/or other aggregates.
As shown in FIG. 1, the platform 12 is fluted such that it has alternating depressed sections 16 and elevated sections 18, thereby creating a pan with a series of troughs 17 that can receive concrete or other suitable hardening fill material. The platform 12 is preferably made of metal. The platform 12 is supported above the ground surface “G” by a support structure. The support structure can include beams (not shown) directly underneath the platform 12 supported by posts 50. The beams can be treated Parallam beams, treated wood two-by-tens or two-by-twelves, steel beams or other suitable structure. The posts can be metal tubes, treated wood four-by-fours or six-by-sixes, or other suitable structure.
The cover piece 20 is preferably made of metal, and has first, second and third sides 21, 22, 23, respectively. The first side 21 is sized to cover the longitudinal end 14 of the platform 12. The second side 22 extends outwardly from a base end 25 of the first side 21, and the third side 23 extends outwardly from the top end 26 of the first side 21. The second and third sides 22, 23, are preferably perpendicular to the first side 21, but can extend at other angles relative to the first side 21. Between the base end 25 and top end 26 of the first side 21, a plurality of flanges 28 extend outwardly from the first side 21. The flanges 28 are preferably perpendicular to the first side 21, but can be at other angles as well. The flanges 28 are shown in FIG. 1 to be positioned on the first side 21 about mid-way between the base end 25 and top end 26, however, the position of the flanges 28 on the first side 21 can vary depending on the depth of the troughs 17. The second side 22, third side 23 and flanges 28 all extend outwardly from the first side in the same direction.
The flanges 28 are positioned at a height on the first side 21 of the cover piece such that when the cover piece 20 is positioned on the longitudinal edge 14 of the platform 12, the second side 22 of the cover piece 20 is underneath and adjacent to the depressed sections 16 of the platform 12, and the flanges 28 are above and adjacent to the elevated sections 18 of the platform 12. As shown in FIG. 2, the cover piece 20 is placed onto the longitudinal edge 14 of the platform 12, and can be lightly hammered into position. Once in position, the cover piece 20 can be held in place on the longitudinal edge 14 of the platform 12 by the frictional engagement of the flanges 28 on the elevated sections 18 of the platform 12, and the second side 22 of the cover piece 20 with the depressed sections 16 of the platform 12, as shown in FIG. 3. The cover piece 20 is a self-bracing form that stays in place without outside bracing.
The flanges 18 are preferably formed by machine stamping rectangular openings 27, 27′ in the first side 21 of the cover piece 20, shown in FIG. 5, and bending the stamped out portion to an angle of approximately ninety degrees relative to the rest of the first side 21. Holes 29 can be formed in the flanges 28 to facilitate insertion of fasteners 39, such as screws, nails, pins or other fasteners, through the flanges 28 and into the elevated sections 18 of the platform 12 to securely attach the cover piece 20 to the platform 12, as shown in FIG. 4.
Depending on the total length of the longitudinal end 14 of the platform 12, additional cover pieces can be utilized. For example, FIG. 5 illustrates a second cover piece 20′ being positioned on the longitudinal end 14 of the platform 12 after the first cover piece 20. The second cover piece 20′ is identical in structure to the first cover piece 20, and therefore is not described in further detail. The first and second cover pieces 20, 20′ are joined together by a connector 30. The connector 30, which is similarly shaped as the cover pieces 20, 20′, is inserted between the first cover piece 20 and the platform 12, such that a part of the connector 30 is between the first cover piece 20 and the platform 12, as shown in FIGS. 6 and 7. The second cover piece 20′ is then positioned on the longitudinal end 14 of the platform 12 adjacent to the first cover piece 20, such that the second cover piece 20′ contacts the exposed portion of the connector 30. As such, the connector 30 resides between the junction of the first and second cover pieces 20, 20′ on one side, and the platform 12 on the other side, as shown in FIG. 8. The cover pieces 20, 20′ can then be securely connected by inserting fasteners 39 through the cover pieces 20, 20′ and into the connector 30, as shown in FIG. 9.
As shown in FIG. 10, side pieces 40, 40′ are mounted on the lateral edges 15, 15′, respectively, of the platform 12. The side pieces 40, 40′ are similar in structure to the cover pieces 20, 20′, except that they do not have flanges 28. As shown in FIG. 11, side piece 40 is positioned on lateral edge 15 of the platform 12, and mounted thereon with L-brackets 42. The other side piece 40′ is mounted on the other lateral edge 15′ of the platform 12 in similar fashion, and therefore is not shown in further detail. Side piece 40 is connected to the cover pieces 20 using corner brackets 44, as shown in FIGS. 3 and 12. Side piece 40′ is attached in a similar fashion, and therefore is not shown in further detail.
Maintaining the connectors 30, L-brackets 42 and corner brackets 44 inside of the cover pieces 20, 20′ and side pieces 40, 40′ provides an aesthetically pleasing appearance. In addition, a decorative piece (not shown) can be mounted on the cover pieces 20, 20′ and side pieces 40, 40′, and can be powder coated to allow for a black coating or other colors.
As shown in FIG. 10, the decking system 10 is preferably used in conjunction with an adjoining building structure, such as house “H”. The platform 12 includes a second longitudinal end 14′ opposite the first longitudinal end 14 and proximate the house “H”. As shown in FIG. 13, a plurality of threaded rods 19 are mounted at spaced apart intervals to the house “H” and extend approximately four to six inches onto the platform 12. As such, the exposed portions of the rods 19 are buried in the concrete when it is poured on the platform 12, thereby securely connecting the concrete to the house “H”. This secure connection is particularly important in the event of an earthquake or other similar natural disaster.
Once assembled, concrete or other hardening fill material can be poured onto the platform 12 and allowed to harden. Once the concrete has hardened, a variety of flooring materials can be laid on the concrete to provide a functional and aesthetically pleasing floor surface for the deck. A variety of flooring imprints, such as brick, stone or wooden imprints can be utilized.
An alternative embodiment of a decking system according to a preferred embodiment of the invention is illustrated in FIG. 14, and shown generally at reference numeral 100. The decking system 100 generally comprises a platform 112 and a cover piece 120, both of which are preferably metal. The platform 112 is fluted such that it has alternating depressed sections 116 and elevated sections 118, thereby creating a series of troughs 117 that can receive concrete, or other suitable fill material. Flanges 108 extend upwardly from the depressed and elevated sections 116, 118 of the platform 112, at an angle of approximately 90 degrees relative to the depressed and elevated sections 116, 118.
The cover piece 120 has first, second and third sides 121,122,123, respectively. The first side 121 is sized to cover the longitudinal end of the platform 112. The second side 122 extends perpendicularly from a base end 125 of the first side 121, and the third side 123 extends perpendicularly from the top end 126 of the first side 121.
The cover piece 120 is attached to the platform 112 by insertion of a fastener through holes 109 in the flanges 108 of the platform 112 and into the first side 121 of the cover piece 120. A removable strip 128 can be placed on the top surface of the third side 123 of the cover piece 120. The strip 128 protects the cover piece 120 from concrete while pouring. After the concrete has been poured, stamped and has been set up, the strip 128 is removed and discarded and a decorative “C” channel piece can be installed to the cover piece 120. Another benefit of the strip 125 is to create a recessed area for the decorative piece to fit. This allows for cleaning of the deck 100 without debris collecting on the edge of the deck 100 under the top edge of the recessed area. In addition, it provides a finished edge to the concrete and may be powder coated to match railings used on the deck 100.
In order to accommodate various sizes of platform 112, additional cover pieces can be utilized by use of a connector 130. As shown in FIG. 14, a second cover piece 120′ can be connected to the first cover piece 120 via connector 130. The connector 130 has the same general U-shape of the cover pieces 120, 120′. As shown in FIG. 15, the connector 130 has two C-channels 132, 132′ recessed in opposite sides of the connector 130 for receiving longitudinal edge portions of the cover pieces 120, 120′, respectively. A median section 134 of the connector 130 divides the C-channels 132, 132′. The C-channels 132, 132′ are shaped and sized such that the connector 130 frictionally engages the cover pieces 120, 120′. As such, the cover pieces 120, 120′ can be joined together by the connector 130, as shown in FIG. 14, and is held in place without the need for fasteners such as bolts or pins. In addition, the connector 130 hides the edges of the cover pieces 120, 120′.
A decking system and method of using same are described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.
Patent Application
20080066409
