This invention relates to general deck construction. More particularly, it concerns a structure and a kit for building a modular structure having to support a plurality of flagstones to form a deck structure.
Decks, patios and terraces are all very popular structures among owners of houses or other types of lodging. These structures are typically adjoined to houses and are host to many activities, receptions, meetings and other social activities. One can sit down or lay down on patio furniture to relax or to discuss between friends. In fact, these structures are used very often during summer time and even year round. That is why it is important to have a solid structure that will last long and will be resistant to different climates. Since they can be very costly to build, it is also very important that these structures keep their original look as long as possible. Moreover, the look of the structure is also very important, as it will stand up for many years.
Traditionally, decks, terraces or raised patios are made all in wood, all in plastic or all in concrete. It is difficult to combine wood and concrete for forming a resistant, easy to assemble and nice looking patio. Building these prior art patios is not an easy task for someone who is not an expert in construction. Effectively, a deck structure is essentially composed of wooden framing members, like border, transverse and cross planks. The surface of the deck is also covered with wooden panels providing the flooring of the deck. These panels and the planks have to be cut according to predetermined dimensions to fit together. Planning the construction of the patio deck and building it are very time consuming. Furthermore, to complicate the matters, the different components needed to assemble the patio deck are often sold separately.
Almost the same issues arise for the construction of concrete decks. Moreover, frameworks have to be built before the pouring of the concrete itself. The size and shape of the frameworks have to be planned in advance and it is not an easy task to build them. After the concrete is poured, one has to wait until the concrete is hardened and cured before being able to use the deck for different activities. Moreover, the different components needed to assemble the deck can be very bulky, thus pretty difficult to be carried by car.
Also known in the art is U.S. Pat. No. 4,628,645 (ROMAN) disclosing a modular patio construction comprising a frame defining a plurality of cells adapted to receive a plurality of flagstones of fixed dimensions. The planks forming the frame have a ledge being L-shaped for supporting the flagstones within the cells. The cells are delimited by transverse and cross planks fixed within the frame. The frame, the cross and transverse planks together form a module. A number of modules can be assembled together side-by-side to form a patio construction.
However, a drawback to the modular patio construction of U.S. Pat. No. 4,628,645 is that since the ledges of the frame, cross and transverses planks are L-shaped, there is a risk of water accumulation in the comers of the ledges. During and after a rain shower, the water is not automatically drained by gravitational force from between the planks and the flagstones. This situation can result in structural damages to the module. Actually, the accumulation of water can weaken the strength of the ledge. The planks can even rot. The lifespan of the module is thus considerably reduced.
Another drawback is that constraints are applied to the corner of the ledges by the weight of the flagstones on these ledges. Again, these constraints can result in structural damages to the module.
Also known in the art are U.S. Pat. Nos. 3,504,472 (CLEMENT); 4,622,792 (BETTS); 4,628,645 (TAFELSKI); 4,999,964 (TAYLOR); 5,361,554 (BRYAN); 5,363,614 (FAULKNER); and 6,209,267 (DANTZER) which provide examples of modular structures for forming a patio deck.
A drawback of the modular patio constructions of the prior art is that they are often difficult to assemble and require that the user have good skills in construction, and more particularly in patio construction.
Thus, there is still presently a need for an easy way to build patio constructions that would simplify the process of building a deck.
An object of the present invention is to provide a modular deck structure that satisfies the above-mentioned need.
Accordingly, the present invention relates to a modular deck structure which comprises an open frame with interconnected crisscross framing members defining a plurality of polygonal cells. Each of the cells comprises a top, a bottom and an inner wall delimiting an opening. The inner wall comprises a sloping portion. The modular deck structure also comprises a plurality of flagstones with side edges. Each of the flagstones is sized and shaped to adjustably fit within a respective one of the cells. The sloping portion drains water out of the open frame to prevent water accumulation between the side edges of the flagstones and the inner walls.
The present invention also relates to a kit for assembling a modular deck structure. The kit comprises framing members being connectable to one another in order to form an open frame having a plurality of polygonal cells. Each of the cells comprises a top, a bottom and an inner wall delimiting an opening. The inner wall comprises a sloping portion. The kit also comprises a plurality of flagstones with side edges. Each of the flagstones is sized and shaped to adjustably fit within a respective one of the cells. The sloping portion drains water out of the open frame to prevent water accumulation between the side edges of the flagstones and the inner walls.
Preferably, both the previous modular deck structure and the kit for assembling the same also comprise conforming means for conforming the side edges of the flagstone to the sloping portion of the respective cell, thereby allowing each of the flagstones to sit properly on the sloping portion of the cell.
The present invention also relates to a modular deck structure which comprises an open frame with interconnected crisscross framing members defining a plurality of polygonal cells. Each of the cells comprises a top, a bottom and an inner wall delimiting an opening. The inner wall comprises a sloping portion. The modular deck structure also comprises a plurality of flagstones with side edges. Each of the flagstones is sized and shaped to adjustably fit within a respective one of the cells. The modular deck structure also comprises conforming means for conforming said side edges of the flagstone to the sloping portion of the respective cell, thereby allowing each of said flagstones to sit properly on said sloping portion of the cell. The sloping portion drains water out of the open frame to prevent water accumulation between the side edges of the flagstones and the inner walls.
Preferably, the deck further comprises vertical support posts connected to the module to support the same in a raised position.
Preferably, the deck is made with a plurality of modular deck structures interchangeable with each other, thereby providing a modular and easy-to-assemble patio construction. The modules may consist of prefabricated single piece structures. However, in accordance with a preferred aspect of the invention, the modules are made of interconnectable individual framing members.
A modular deck structure construction according to the invention makes it very easy and fast for any non handy person to build a nice looking deck made with flagstones. BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will become apparent upon reading the detailed description and upon referring to the drawings in which:
a is a schematic cross section view taken along line Va-Va in
b is a schematic cross section view taken along line Vb-Vb in
a to 8e are schematic side views of different variants of border planks according to the present invention, having different sloping portions.
a and 9b are schematic side views of two flagstones according to the present invention, having different side edges.
While the invention will be described in conjunction with example embodiments, it will be understood that it is not intended to limit the scope of the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included as defined by the appended claims.
In the following description, similar features in the drawings have been given similar reference numerals and in order to weight down the figures, some elements are not referred to in some figures if they were already identified in a precedent figure.
Referring to
In the illustrated case, the open frame 10 is made of treated wood, but other composite materials such as PVC, plastic, etc. can be used instead. The open frame 10 is composed of a number of prefabricated interconnectable individual planks. It is also possible to use a pre-cast module already provided with a number of cells 14, which requires little or no assembly. The pre-cast module is more difficult to carry by car than individual planks.
The module 2 has a square shape perimeter defined by four border planks 30 connected end to end. To facilitate the connection of the border planks 30 and secure them together, there are pre-drilled holes at their extremities to easily fit bolts. It is also possible to have no pre-drilled holes, but in this case, the user has to drill the holes and fit the bolts himself.
The module of the present invention is not limited to a square shape as depicted in
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In the second embodiment, as shown in
In the third embodiment, as shown in
Still according to the third embodiment, the device shown in
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Unlike the shim member 80 shown in
For better understanding, the inner wall 20 can be split in upper and lower sections. The lower section 84 is the surface of the inner wall 20 in contact with the shim member 80, while the upper section 86 is the surface of the inner wall 20 not in contact with the shim member 80. The upper section 86 conforms to the side edges 28 of the flagstones 24. The upper section can be vertical for conforming to the already available flagstones or it can be slanted to conform with the flagstone 24 (shown in
Referring to
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The step 8 does not have any cross planks 34, only three transverse planks 32 extending across the perimeter. Accordingly, in this case, the open frame is only composed of border 30 and transverse 32 planks.
Referring to
In the illustrated case, there are steps 8, as well as a layout of square 2 and triangular 5 modules forming the deck 4 having a trapezoidal shape. Different layouts can be made by interchanging modules 2, 5, 8 of place or by adding or removing some of the modules. Even years after the deck construction is finished, it is always possible to add modules. Furthermore, it is very easy to do so.
Different sizes and shapes of flagstones 24 can be used. For example, rectangular flagstones are used for the steps 8, while both square and triangular flagstones are used for the triangular 5 module.
Advantageously, an assembly kit having all the components needed for building a module is available. The framing members are pre-cut and have predetermined lengths to allow the construction of the open frame 10. Accordingly, there can be a kit for each different module. For example, there can be a kit for the triangular module 5, the square module 2, the rectangular module 8, etc. The flagstones are also part of the kit. For example, the kit for the triangular module 5 includes square and triangular flagstones. The kit for the narrow rectangular module 8, such as a step 8, includes narrow rectangular flagstones. The kit can be sold with already available flagstones 24 (as shown in
Once the user has bought the kit, for example, the square module 2, the necessary steps for assembling the module 2 are very easy. First, the user has to connect the four border planks 30 end to end with bolts to define the perimeter of the open frame 10. Once this is done, and that a square perimeter is formed, the user has to install the two transverse planks 32 within the perimeter so that they extend in parallel with respect to each other and that they are extending across the perimeter.
If the user has done everything right so far, the two transverse planks 32 slanted side edges 58 are now supported by the slanted inner edges of the border planks 30. The distance between the two transverse planks 32 is irrelevant at this stage. Actually, since the next step is to place the cross planks 34 within the perimeter to form the nine cells 14 of the module 2 and that in order for the cross planks 34 to tightly fit between the transverses planks 32, the user will have to adjust the distance between the transverse planks 32 manually until the cross planks 34 fit between the two. The user will have to do the same adjustment to fit the cross planks between the transverse planks 32 and the border planks 30. The nine cells 14 are now created and the cross planks 34 are supported by the slanted side edges of the transverse planks 32 and/or the border planks 30.
Once the open frame is assembled, if the user is not using any liners 78 or shim members 80, the flagstones 24 of the first and second embodiments can be easily fitted within the cells. If liners 78 or shim members 80 are used, they must be placed within the cells 14 and the flagstones 24 of the third and fourth embodiments have to be placed within the cell 14 and so that they are supported by the liners 78 or the shim members 80. The assembly of the module 2 is then completed and it can be installed on the supporting posts 6 if desired.
Although preferred embodiments of the present invention have been described in detail herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to these precise embodiments and that various changes and modifications may be effected therein without departing from the scope or spirit of the present invention.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/CA03/01751 | 11/13/2003 | WO | 5/13/2005 |
Number | Date | Country | |
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60425995 | Nov 2002 | US |