Interlocking Composite Decking Joist and Beam Assembly
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Solution Overview
Problem
Current decking systems require conventional wood construction and complex fastening methods, making them labor-intensive and prone to maintenance issues, while lacking a fully maintenance-free solution for all components.
Innovation Solution
A decking system where all components, including deck boards, joists, and beams, are made of composite materials and interlock for secure assembly without additional fasteners, using specialized connectors and profiles for sliding engagement and interlocking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional wood construction joists and beams are used with mounting clips, nails, and screws, then the deck structure can be assembled, but the assembly process becomes labor-intensive and requires specialized tools
Solution Approach 1:
The patent combines the joist and beam into a single integrated composite component with interlocking features. The joist includes a top surface with a groove and bottom surface with a protrusion that mate with corresponding features on the beam, eliminating the need for separate mounting clips, nails, and screws. This merging of components directly resolves the technical contradiction by simplifying the fastening system while maintaining structural integrity.
Solution Approach 2:
The patent extracts and eliminates the complex fastening system (mounting clips, nails, screws) from the deck construction process. By designing the joist and beam with built-in interlocking features, the invention removes the need for additional fastening components, thereby reducing device complexity and labor requirements while achieving secure assembly.
2Ease of manufacture
If conventional wood construction materials are used, then the deck can be built, but ongoing maintenance such as painting and treatment is required
Solution Approach 1:
The patent employs composite materials for both the joist and beam components. The joist is made from a composite material comprising wood fibers and plastic, while the beam is made from a different composite material comprising recycled plastics. This use of composite materials eliminates the need for painting and treatment, reducing maintenance requirements while providing durability against rot and decay, thus resolving the technical contradiction.
3Strength
If additional fasteners are used to secure deck boards to joists, then the connection is secure, but the assembly process becomes more time-consuming and labor-intensive
Solution Approach 1:
The patent removes the need for additional fasteners by integrating connection features directly into the joist and beam structures. The groove-protrusion interlocking system provides secure connection without requiring nails, screws, or clips, thereby eliminating the time and labor associated with fastener installation while maintaining connection strength.
Solution Approach 2:
The joist and beam are designed with self-securing interlocking features where the groove in the joist top surface and the protrusion in the beam bottom surface automatically engage to provide a secure connection. This self-service mechanism eliminates the need for external fasteners and speeds up assembly, resolving the technical contradiction between connection strength and assembly speed.
4Reliability
If complex mounting clips and fasteners are used, then the deck components can be secured, but the assembly requires specialized labor and tools
Solution Approach 1:
The patent merges the structural components (joist and beam) with their fastening features into a single integrated system. The groove and protrusion features are built into the joist and beam themselves, eliminating the need for separate mounting clips and fasteners. This integration maintains structural stability while dramatically simplifying assembly, allowing DIY installation without specialized labor or tools.
Data Source
AI summary
A decking system comprises a ledger board for mounting on an upright supporting surface, a beam, a plurality of joists for spanning between the ledger board and the beam, and a plurality of deck boards for spanning across the joists in which all of the components can be mounted to one another by interlocking engagement of various connectors so that no additional fasteners are required for assembly. The components are formed of extruded and molded materials which do not require any maintenance. A railing system and a stair system are also provided which similarly connect by interlocking engagement of the components.