Deck Post Sleeve with Flanges for Square-Cut Frame Assembly
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Solution Overview
Problem
The existing methods for assembling deck components, particularly those using box-frame-segments, require bevel cuts which are time-consuming and wasteful, and often result in unsightly visible fasteners when attaching guard rails.
Innovation Solution
The use of post sleeves with flanges that allow box-frame-segments to be joined without bevel cuts, utilizing square-cut edges and attachment holes for secure fastening, thereby simplifying the assembly process and hiding fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bevel cuts are used to join box-frame-segments, then the segments can be connected to form miter joints, but the assembly process becomes time-consuming and material waste increases
Solution Approach 1:
The invention divides the connection system into separate components: angle clips with attachment holes and box-frame-segments with square cuts. This segmentation eliminates the need for complex bevel cuts on the frame segments themselves, simplifying their manufacturing while maintaining joint functionality through the modular angle clip connectors
Solution Approach 2:
The angle clips are pre-formed with attachment holes and L-shaped geometry before installation. This preliminary preparation allows for quick connection to the square-cut box-frame-segments without requiring on-site bevel cutting, thereby reducing assembly time and eliminating material waste from improper cuts
2Ease of manufacture
If bevel cuts are used to join box-frame-segments, then miter joints can be formed, but material waste increases due to cutting errors
Solution Approach 1:
The connection function is segmented into the angle clip component which contains the attachment holes, separating it from the box-frame-segments. This allows the frame segments to be simple square-cut pieces without complex bevels, eliminating material waste from erroneous bevel cutting while the angle clips handle the connection geometry
Solution Approach 2:
The angle clips serve as disposable connection elements that absorb the complexity of the joint formation. Rather than wasting expensive box-frame-segment material on incorrect bevel cuts, the system uses relatively inexpensive angle clips that can be easily replaced if installation errors occur
3Reliability
If visible fasteners are used to attach vertical posts to deck frame, then the attachment is secure, but the appearance becomes unsightly
Solution Approach 1:
The invention extracts the fastener attachment function from the visible exterior of the deck structure. Fasteners are installed through angle clips that connect to the deck frame from below or through hidden pathways, removing the unsightly visual element while preserving the structural attachment security through the same fastener mechanism
Solution Approach 2:
The angle clip acts as an intermediary component between the vertical post and the deck frame. It provides attachment holes for secure fastening while its L-shaped design allows it to be positioned in locations that hide the fasteners from view, thus mediating between the conflicting requirements of secure attachment and aesthetic appearance
Data Source
AI summary
Deck components comprising a post sleeve and flanges extending away from side walls of the post sleeve are described. The post sleeve includes a rectangular cross section. Interior flanges can comprise attachment holes for affixing the interior flanges to box-frame-segments having square-cut edges. Box-frame-segments and box-frame-segment attachments with square-cut edges can abut the exterior surface of a post sleeve side wall. Use of the post sleeve can reduce or eliminate the need to produce beveled joints box-frame-segments and box-frame-segment attachments. Post sleeves can comprise a post sleeve extension extending above box-frame-segments that attach to the flanges of the post sleeve. The post sleeve and post sleeve extension can comprise a single metal extrusion. Alternatively, the post sleeve extension can be attached to the post sleeve. In one example, a post sleeve extender is placed into a post sleeve and the post sleeve extension is placed onto the post sleeve extender.