Deck Post Sleeve with Flanges for Square-Cut Assembly
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Solution Overview
Problem
The existing methods for joining box-frame-segments in deck construction, such as those using bevel cuts, are time-consuming and wasteful, and there is a need for a more efficient way to assemble and disassemble deck systems without requiring beveled edges.
Innovation Solution
The use of post sleeves with flanges that allow box-frame-segments to be joined with square cut edges, eliminating the need for bevel cuts, and enabling easier assembly and disassembly by positioning flanges within the segments and using fasteners for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bevel cuts are used to join box-frame-segments, then the joints can be formed, but the assembly process becomes time-consuming and material waste increases
Solution Approach 1:
The invention divides the connection system into separate components: a post sleeve that receives the post and flanges that attach to the box-frame-segments. This segmentation eliminates the need for complex bevel cuts on the box-frame-segments themselves, allowing them to be joined through simpler square cuts while maintaining joint integrity.
Solution Approach 2:
The post sleeve is pre-formed with a square opening that receives the post, and flanges are pre-attached to the box-frame-segments with square cuts. This preliminary preparation eliminates the need for time-consuming bevel cutting during assembly, as the components are designed to connect directly with square cuts.
2Manufacturing precision
If bevel cuts are used to join box-frame-segments, then the joints can be formed, but material waste increases
Solution Approach 1:
By separating the connection function into a post sleeve and flanges, the invention allows box-frame-segments to be cut with simple square cuts rather than requiring material removal for bevels. This segmentation preserves more of the original material while achieving the same joint formation capability.
Solution Approach 2:
Instead of modifying the box-frame-segments with bevel cuts to achieve proper joint formation, the invention inverts the approach by using a post sleeve with a square opening that accepts square-cut segments. This reversal eliminates material waste associated with bevel cutting while maintaining joint integrity.
3Ease of operation
If flanges are positioned within box-frame-segments and fasteners are used, then assembly and disassembly become easier, but the device complexity increases
Solution Approach 1:
The connection system is segmented into distinct components (post sleeve, flanges, fasteners) that can be independently manufactured and assembled. This segmentation allows for simpler individual parts that are easier to manufacture and assemble, even though the overall system has multiple components.
Solution Approach 2:
The flanges act as intermediary elements between the post sleeve and the box-frame-segments. These flanges provide attachment points for fasteners, creating a standardized interface that simplifies assembly and disassembly operations while managing the complexity through a clear hierarchical structure.
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 has 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.