Modular Decking Connector Hub for Tool-Free Rigid Assembly
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Solution Overview
Problem
Modular decking systems require skilled labor and tools for assembly, are susceptible to deflection under high loads, and have limited load-bearing capacity, making them unstable and difficult to align and connect.
Innovation Solution
A modular decking system with a connector comprising an elongate tube and a connection hub that allows horizontal supports to slide and engage without tools, distributing loads efficiently and enabling unskilled labor assembly, with increased rigidity and load capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional fastening means (clamp, bracket, socket, or pin connections) are used to connect vertical and horizontal supports, then the modular decking system can be assembled with structural connection, but skilled or trained personnel and appropriate tools are required for assembly
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (clamps, brackets, sockets, pins requiring tools) with a friction-based insertion system. The connector comprises an elongate tube inserted into the vertical support with horizontal supports that slide and engage through friction and geometric interlocking, eliminating the need for tools and skilled labor while maintaining structural connection.
2Strength
If traditional fastening means are used to connect vertical and horizontal supports, then connection can be achieved, but the load-bearing capacity at connection points is limited
Solution Approach 1:
The connector features a curved or arcuate engagement surface between the elongate tube and horizontal supports, creating a friction-based interlocking mechanism that distributes loads more effectively than rigid mechanical fasteners, thereby increasing load-bearing capacity while simplifying the connection structure.
Solution Approach 2:
The connector is pre-designed with specific geometric features and friction characteristics that enable self-locking and load distribution upon insertion, eliminating the need for additional fastening elements and pre-establishing high load-bearing capacity at the connection point.
3Length of stationary object
If scaffolding sub-structure is used to achieve desired stage height, then the modular decking system can reach required heights, but the system becomes susceptible to deflection under high loads
Solution Approach 1:
The curved engagement surfaces in the connector create friction-based mechanical interlocking that resists lateral forces and deflection more effectively than traditional rigid connections, maintaining structural stability at height without requiring additional bracing or support elements.
4Ease of operation
If the modular decking system uses traditional connection methods, then assembly can be achieved, but it becomes increasingly difficult to align and connect structures together under high loads
Solution Approach 1:
The connector utilizes friction as a key parameter, where the friction force between the elongate tube and horizontal supports provides both alignment tolerance during assembly and reliable load-bearing capacity under operational loads, eliminating the precision alignment requirements of traditional mechanical fastening systems.
Data Source
AI summary
A modular decking system comprising a decking panel, a plurality of vertical supports, at least two first horizontal supports, at least two second horizontal supports arranged perpendicular to the first horizontal supports, one or more third horizontal supports arranged between the first horizontal supports and parallel to the second horizontal supports, and a plurality of connectors for detachably coupling the first and second horizontal supports, is disclosed. The connectors include an elongate tube adapted for insertion into the vertical supports and a connection hub. The connection hub and the ends of the first and second horizontal supports include reciprocating formations to enable the respective ends of the first and second horizontal supports to slidingly engage with the connection hub.