Modular Deck System with Roll-Lock Joist Connections
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Solution Overview
Problem
Existing deck systems are difficult to assemble, disassemble, and reassemble, making it cumbersome to move or store them, especially during periods of non-use such as winter.
Innovation Solution
A deck system comprising a perimeter box-frame with removably attached segments and joist assemblies that can be easily assembled and disassembled, featuring roll-lock tabs and spacers for secure attachment, allowing for efficient disassembly, transportation, and reassembly at different locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional deck systems are constructed with permanent connections, then structural strength and stability are improved, but ease of assembly and disassembly deteriorates
Solution Approach 1:
The deck system is divided into modular components including box frame segments, joist assemblies, and deck boards that can be independently assembled and disassembled. Each component maintains structural integrity through standardized connection interfaces while enabling easy reconfiguration.
Solution Approach 2:
Connection elements such as brackets, fasteners, and joining mechanisms serve as intermediaries between structural components. These intermediaries provide removable yet strong connections, allowing the deck to be assembled and disassembled without compromising structural strength during use.
2Reliability
If deck systems are designed for permanent installation, then reliability and stability are improved, but adaptability and ease of relocation deteriorates
Solution Approach 1:
The deck system transitions from a static permanent structure to a dynamic reconfigurable system. Components can be easily assembled, disassembled, and repositioned while maintaining reliable connections during each operational phase, enabling adaptation to different locations and uses.
Solution Approach 2:
The standardized modular components and universal connection interfaces allow the same deck system to be reliably installed in multiple locations and configurations. The system serves both as a stable permanent structure when assembled and as a portable structure that can be relocated as needed.
3Ease of operation
If complex connection mechanisms are used, then ease of assembly is improved, but device complexity increases
Solution Approach 1:
Complex connection mechanisms are extracted into separate standardized connection elements and fasteners that are independent from the main structural components. This allows the primary structural elements to remain simple while the connection functionality is handled by specialized, easily replaced components.
Data Source
AI summary
Deck systems, deck system components making up the deck systems, and methods of assembling and disassembling deck system components and the deck systems are described herein. A box-frame can be assembled from box-frame segments, angle clips, and fasteners. A box-frame can be supported by posts attached to the box-frame using post brackets and fasteners. Joist assemblies can be assembled using joist segments, joist spacers, and fasteners. Joist assemblies can be positioned within the box-frame. The joist assemblies can be secured to box-frame segments or another joist assembly using roll-lock tabs and roll-lock tab receivers and locking tabs and locking tab retainers that part of extrusions making up the box-frame segments, joist spacers, or joist segments. Deck boards can be secured to the joist assemblies using deck screws or deck clips. The post brackets can accommodate support posts below deck boards and railing posts extending above deck boards.