Modular Decking System Using Interlocking Cam Locks
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Solution Overview
Problem
Traditional decking systems, such as wood and concrete pavers, face issues like warping, rotting, maintenance requirements, health risks from chemicals, labor-intensive installation, and inability to be relocated or reconfigured easily, while existing modular systems lack intuitive assembly and accessory integration.
Innovation Solution
A modular, portable, and interlocking decking system composed of 100% post-consumer thermo-plastic waste, featuring three standard components: Pad, Pier, and Cam Lock, allowing for easy assembly and disassembly, with a custom hand tool for secure interlocking, and accommodating various accessories through a universal cam lock mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wood decking is used, then the structure provides natural appearance and structural strength, but it requires intensive maintenance and is susceptible to weather damage
Solution Approach 1:
The patent transforms wood decking into plastic decking by changing the material parameter from organic to synthetic. This parameter change eliminates susceptibility to rot, insects, and weather damage while maintaining structural integrity and appearance, thereby resolving the contradiction between reliability and maintenance requirements
Solution Approach 2:
The patent uses composite plastic materials that combine durability with aesthetic properties. The plastic decking material is engineered to mimic wood grain and appearance while providing superior resistance to environmental degradation, eliminating the need for chemical treatments and regular maintenance
2Reliability
If traditional concrete pavers are used, then the surface provides durability and stability, but the installation is labor-intensive and requires excavation
Solution Approach 1:
The patent divides the decking system into modular interlocking components that can be assembled without excavation. Each plank is a self-contained unit with integrated locking mechanisms, allowing rapid installation by simply connecting pieces together, thereby resolving the contradiction between durability and installation speed
Solution Approach 2:
The patent introduces an interlocking mechanism as an intermediary between decking planks. This mechanism provides the structural connection traditionally achieved through excavation and mortar, but enables rapid assembly by simply engaging the interlocking features, eliminating the need for labor-intensive installation
3Stability of the object's composition
If fixed decking structures are used, then the structure provides structural stability, but it cannot be relocated or reconfigured
Solution Approach 1:
The patent transforms the decking system from a fixed static structure to a dynamic reconfigurable system. The interlocking mechanism allows planks to be easily connected and disconnected, enabling the structure to be relocated or reconfigured while maintaining structural stability during use, thereby resolving the contradiction between stability and adaptability
4Reliability
If pressure treated lumber is used, then the wood provides enhanced durability, but the installation exposes workers to health risks from chemicals
Solution Approach 1:
The patent replaces expensive, chemically-treated permanent wood decking with affordable, chemically-free plastic decking. The plastic material inherently provides durability without requiring chemical treatments, eliminating health risks to installers and occupants while maintaining the desired longevity and performance
Data Source
AI summary
Components for use in the assembly and installation of a modular decking system, comprised of structural free floating piers which distributes loads of deck pad to ground, piers have a pad bearing surface and four uniformly placed receiver blocks which interlock with corresponding recesses at four pad corners, an interlocking cam passes through pad recesses at deck surface and locks to piers by rotating cam with custom designed tool.The system is designed to be assembled without permanent fasteners to allow for expansion, reconfiguration or relocation, or addition of traditional and contemporary deck accessories that engage and interlock with the piers, pads and cams. One ideal manufacturing method of one or any of the system components is compression molded post-consumer and/or industrial thermo-plastic waste.