Note: Descriptions are shown in the official language in which they were submitted.
APPLICATION FOR A UNITED STATES PATENT
UNITED STATES PATENT AND TRADEMARK OFFICE
(Attorney Docket No. 13-782-US-CIP)
Title: Deck system and components thereof, and methods of
assembling and
disassembling deck systems and components
Inventor: Roger Winter
This is a divisional application of Canadian Patent Application No. 3,081,063,
which is a divisional
application of Canadian Patent Application No. 2,917,523, filed on 13th
January, 2016.
McDonnell Boehnen 1
Hulbert & Berghoff LIT
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Telephone (312) 913-0001
Date Recue/Date Received 2023-09-29
REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a continuation-in-part application of U.S. Patent
Application No.
14/517,408 filed on October 17, 2014. U.S. Patent Application No. 14/517, 408
is a continuation
application of U.S. Patent Application No. 13/973,757 filed August 22, 2013,
which issued as
U.S. Patent No. 8,863,466 on October 21, 2014. U.S. Patent Application No.
13/973,757 and
U.S. Patent Application No. 14/517,408 are incorporated by herein by
reference.
BACKGROUND
[0002] A deck is a structure typically built outdoors and typically connected
to a building. A
deck usually has a flat surface similar to a floor and can be built at a given
elevation above the
ground. A deck can support a load consisting of people, deck furniture, or
other items. The
supportable load can vary from deck to deck based on such items as the size
and type of material
used to build the deck.
OVERVIEW
[0003] Example embodiments pertaining to deck systems and components thereof,
as well as
example embodiments of assembling and dissembling deck systems and components
are
described herein. One or more of the example embodiments can provide for deck
system
components or deck systems that are easier to assemble, disassemble, and
reassemble than prior
decks. One or more of the example embodiments provide for disassembling an
assembled deck
system, moving the disassembled deck system from a first location to a second
location, such as
a storage building, and subsequently reassembling the deck system at the first
location, the
second location, or a third location. Disassembly of the deck system can occur
for storage of the
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components within the storage building during an expected time-frame when the
deck system
will not be used (such as winter time) or for some other reason.
100041 In one respect, an example embodiment can take the form of a deck
system comprising:
(i) a box-frame including a first box-frame-segment, a second box-frame-
segment, a third box-
frame-segment, and a fourth box-frame-segment, wherein each of the first box-
frame-segment,
the second box-frame-segment, the third box-frame-segment, and the fourth box-
frame-segment
includes a first top horizontal element, a locking tab slot adjacent to the
first top horizontal
element, a first base horizontal element, and a locking tab extending from and
above the first
base horizontal element, and (ii) a first joist assembly removably attached to
and within the box-
frame, wherein the first joist assembly includes a first box-frame-segment
attachment having a
first locking tab slot adapted for positioning over the locking tab of the
first box-frame-segment
and a first locking tab for positioning in the locking tab slot of the first
box-frame-segment, and
wherein the first joist assembly includes a second box-frame-segment
attachment having a
second locking tab slot adapted for positioning over the locking tab of the
second box-frame-
segment and a second locking tab for positioning in the locking tab slot of
the second box-frame-
segment.
100051 These as well as other aspects and advantages will become apparent to
those of
ordinary skill in the art by reading the following detailed description, with
reference where
appropriate to the accompanying drawings. Further, it should be understood
that the
embodiments described in this overview and elsewhere are intended to be
examples only and do
not necessarily limit the scope of the invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
100061 Example embodiments are described herein with reference to the
drawings. The items
shown in the figures are not or may not be to scale.
[0007] FIG. 1 shows components for assembling a perimeter box-frame of a deck
system in
accordance with one or more example embodiments.
[0008] FIG. 2 shows an assembled box-frame in accordance with one or more
example
embodiments.
[0009] FIG. 3 shows components of joist assemblies in accordance with one or
more example
embodiments.
[0010J FIG. 4 shows a deck system under construction in accordance with one or
more
example embodiments.
[0011] FIG. 5 shows details of the deck system shown in FIG. 4.
[0012] FIG. 6 shows another deck system in accordance with one or more example
embodiments.
100131 FIG. 7 shows another deck system in accordance with one or more example
embodiments.
[0014] FIG. 8 shows profiles of example extrusions in accordance with one or
more example
embodiments.
[00151 FIG. 9 shows a partial section view of a deck system and shows brackets
in accordance
with one or more example embodiments.
[0016] FIG. 10 shows a partial section view of a deck system and shows
brackets in
accordance with example embodiment(s).
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[0017] FIG. 11 shows partial section views shows in accordance with one or
more example
embodiments.
[0018] FIG. 12 shows various views of a deck-clip in accordance with one or
more example
embodiments.
[0019] FIG. 13 shows a partial section view of a deck system in accordance
with one or more
example embodiments.
[0020] FIG. 14, 15, 16, 17, 18, and 19 are large-scale views of portions of a
deck system
shown in FIG. 7.
[0021] FIG. 20 shows partial section views with respect to section lines shown
in FIG. 11.
[0022] FIG. 21 shows profiles of example extrusions in accordance with one or
more example
embodiments.
[0023] FIG. 22 shows components for assembling a deck system in accordance
with one or
more example embodiments.
[0024] FIG. 23 shows a profile of two extrusions connected together.
[0025] FIG. 24 is a flow chart showing steps for assembling and disassembling
a deck system.
[0026] FIG. 25 shows a box-frame and components thereof.
[0027] FIG. 26 shows example extrusions for box-frames, joists, and joist
assemblies.
[0028] FIG. 27 shows example deck-clips and deck board layout using the deck-
clips.
[0029] FIG. 28 shows an example deck-clip and deck board layout using the deck-
clip, and
example installation of a perimeter-trim-piece.
[0030] FIG. 29, 30, 31, 32, 33, and 34 show example post supports for an
example deck
system.
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[0031] FIG. 35 shows an example single extrusion joist and the joist and joist
spacers installed
into an example deck system.
[0032] FIG. 36 and 37 show components of a box-frame.
[0033] FIG. 38, 39, 40, and 41 show example joist assemblies.
[0034] FIG. 42 shows a joist assembly including a joist and an H-bar shim.
[0035] FIG. 43 shows a joist assembly including a ceiling gutter.
100361 FIG. 44 shows a joist assembly installed on a sloped surface.
[0037] FIG. 45 shows an example perimeter trim clip.
[0038] FIG. 46 shows an example deck-clip.
DETAILED DESCRIPTION
I. INTRODUCTION
10039] This description describes several example embodiments including
example
embodiments regarding deck systems and components thereof. The example deck
systems can
be used as a free-standing deck positioned on the ground or a deck attached to
a structure. As an
example, the deck attached to the structure can be attached to a wall or the
roof of the structure.
As another example, the deck can be placed or set on a roof or other
structure. The example
deck systems, or portions thereof, can be installed on land or in water. A
deck system having at
least a portion installed in water can be referred to as a pier. The example
deck systems, or
portions thereof, can be used as a bridge over a stream, a creek, a ditch, or
some other areas of
Earth. The example deck systems can be assembled and used at a recreational
vehicle (RV)
park. The example deck systems can be easily disassembled from one location,
moved to
another location, and reassembled at the other location.
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[0040] This description refers to extrusions. The extrusions can be produced
by extruding a
material through a die. Several of the example embodiments refer to the
extrusion material as
aluminum. The extrusions of the example embodiments can be a material other
than aluminum.
Extrusions used within the example deck systems can be cut from a stock length
extrusion. One
or more of the extrusions can be milled, mitered, punched, drilled, or
otherwise prepared to
receive one or more fasteners, anchors, or other deck system component.
[0041] The components, functions, and various views shown in the figures are
provided
merely as examples and are not intended to be limiting. Elements shown in the
various figures
having the same reference number can be the same or a similar element. Many of
the
components illustrated in the figures or described herein as being attached
can be attached using
any of a variety of fasteners. Some fasteners used to attach two or more
components can be a
part of the attachable component. The particular fasteners described herein
are provided as
examples only. A person having ordinary skill in the art will understand that
the fasteners used
to attach any two more components can have a different size, thread count, and
more or less
components (e.g., with or without a washer or nut).
[0042] The description identifies particular dimensions of various components.
The identified
dimensions are provided as examples only. A person having ordinary skill in
the art will
understand that a dimension of a component described as having a particular
dimension can be a
different dimension.
100431 In this description, the articles "a," "an," and "the" are used to
refer to elements of the
example embodiments. The intent of using those articles is that there is one
or more of the
elements. The intent of using the conjunction "or" within a described list of
at least two terms is
to indicate any of the listed terms or any combination of the listed terms.
The use of ordinal
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numbers such as "first," "second," "third" and so on is to distinguish
respective elements rather
than to denote a particular order of those elements.
[0044] The term "joist" in this description refers to a horizontal support. A
horizontal support
(i.e., a joist) can be used in construction of various structures such as, but
not limited to, a pier or
a deck (e.g., a deck attached to the side of a house or built on a rooftop). A
horizontal support
can be positioned within or as part of a structure such that the horizontal
support is parallel to the
Earth's horizon at which the structure is located or such that the horizontal
support is not parallel
to the Earth's horizon. In the latter case, the non-parallel placement may be
used so that rain that
falls upon boards positioned on the horizontal support will slide off of the
boards, or for some
other reason. A horizontal support can include or be referred to as a beam.
[0045] Various element names of the example deck systems are modified with the
term
"vertical" or "horizontal." Those element names are with respect to how the
components are
oriented in the drawings. A person skilled in the art will understand that an
element referred to
as a horizontal element may extend horizontally or substantially horizontally.
The person skilled
in the art will understand that an element referred to as a vertical element
may extend vertically
or substantially vertically. Any component referred to as a "vertical" element
can be referred to
as the element preceded by an ordinal number without the vertical descriptor
(e.g., a vertical
element can be referred to as a first element or a second element, etc.).
Similarly, any
component referred to as a "horizontal" element can be referred to as the
element preceded by an
ordinal number without the horizontal descriptor (e.g., a horizontal element
can be referred to as
a third element or a fourth element, etc.). A person skilled in the art will
also understand that
that the elements referred to as horizontal may be tilted such that the deck
system slopes. As an
example, a sloped deck system can be used as lean-to.
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11. EXAMPLE DECK SYSTEMS
A. BOX-FRAMES
[0046] FIG. 1 shows example components for assembling a perimeter box-frame
(or more
simply "box-frame" or alternatively, a "box-frame assembly") 100 usable within
the example
deck systems. As shown in FIG. 1, the box-frame components include box-frame-
segments 101,
102, 103, and 104, and angle clips 105. An area surround by a set of connected
box-frame-
segments can be referred to as a box-frame interior. For example, an area
surrounded by the
box-frame-segments 101, 102, 103, and 104 is a box-frame interior 112.
[0047] Each angle clip 105 can be arranged as an L-shaped clip having angle
clip segments
106 and 107 that extend from a joint or bend 108. Each angle clip segment 106
and 107 can
include at least one attachment hole, which can be a through-hole. Each
attachment hole within
angle clip segments 106 and 107 can correspond to a respective attachment hole
109 within the
box-frame-segments 101, 102, 103, and 104. As an example, angle clip 105 can
include four
attachment holes 109 for securing angle clip 105 to two box-frame-segments
using four number
ten by one inch (i.e., #10 x 1") flat head sheet metal screws, four lock
washers, and four nuts.
Angle clips 105 can be made from aluminum or another material. Angle clips
installed at
corners of a box-frame can be referred to as corner angle clips.
[0048] Each angle clip segment 106 and 107 can slide or otherwise be inserted
into a
respective box-frame-segment. Each box-frame-segment can include an angle clip
shelf 110 and
an angle clip slot 111 for guiding or supporting the angle clip 105 inserted
thereto.
[0049] Next, FIG. 36 and FIG. 37 show box-frame component views 121, 123, and
125. In
box-frame component view 121, the box-frame components are unattached, whereas
in box-
frame component views 123 and 125, the box-frame components are attached as
part of a box-
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frame. As an example, the box-frame with the components shown in box-frame
component
views 121, 123, and 125 can be the box-frame 100 shown in FIG. 1 or a
different box-frame.
100501 The box-frame component view 121 shows box-frame-segments 101A, 102A,
and
104A. The box-frame-segments 101A, 102A, and 104A are extrusions that can be
produced
from the same or similar extrusion die(s). Accordingly, any feature described
with respect to any
of the box-frame-segments 101A, 102A, and 104A can be applicable to the other
box-frame-
segments and any other box-frame-segment within a box-frame including the box-
frame-
segments 101A, 102A, and 104A.
100511 The box-frame-segments 101A, 102A, and 104A include a first vertical
element 139
and a second vertical element 129. Since the first vertical element 139 is
relatively farther from
an interior of an assembled box-frame and the second vertical element 129 is
relatively closer to
an interior of the assembled box-frame, the first vertical element 139 can be
referred to an outer
vertical element and the second vertical element 129 can be referred to as an
inner vertical
element. As shown in FIG. 36 and FIG. 37, the box-frame-segments 101A, 102A,
and 104A are
configured like the box-frame-segment 463 shown in FIG. 26. In an alternative
arrangement, the
box-frame-segments 101A, 102A, 104A and an box-frame-segment opposite the box-
frame-
segment 101A can be configured like the box-frame-segment 403 or the box-frame-
segment 487
shown in FIG. 26.
[0052] The outer vertical element 139 of each box-frame-segment 101A, 102A,
and 104A can
include attachment holes 109A that align with through-holes in an angle clip
105A. The inner
vertical element 129 of each box-frame-segment 101A, 102A, and 104A can
include attachment
holes 141 that align with a corresponding attachment hole 109A and a through-
hole in an angle
clip 105A. The box-frame component view 121 shows two instances of angle clips
105A. Each
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=
angle clip 105A includes angle clip segments 106A and 107A that extend from a
joint or bend
108A. The box-frame-segment 101A includes an angle clip shelf 110A to support
the angle clips
105A and an angle clip slot 111A into which the angle clips 105A can be
inserted.
100531 A fastener 113 can be positioned through an attachment hole 109A and a
through-hole
in an angle clip 105A. A washer 114 and a nut 115 can be attached to the
fastener 113 so as to
keep an angle clip 105A attached to a box-frame-segment. The fasteners 113,
the washers 114,
and the nuts 115 can be removed from the box-frame-segments 101A, 102A, and
104A and the
attachment clips 105A during disassembly of the box-frame. As an example, the
fasteners 113
can be #10 x 1" flat head sheet metal screws and the washers 114 can be lock
washers. Other
examples of the fasteners 113, 114 and 115 are possible.
[0054] The box-frame-segment 104A includes a locking-tab 167 that extends
upward from a
horizontal element 171. The horizontal element 171 extends from the outer
element 139 to the
locking-tab 167. A locking-tab slot 169 separates the interior vertical
element 129 and the
locking-tab 167. The box-frame-segment 104A includes a locking-tab 165 that
extends upward
from a horizontal element 657 that extends inwardly (towards a box-frame
interior) from the
interior vertical element 129. A locking-tab slot 163 is adjacent the locking-
tab 165. The box-
frame-segment 104A includes a perimeter-trip clip slot 659, a deck-clip slot
663, and splines 661
for receiving a deck-clip screw inserted through a deck-clip inserted into the
deck-clip slot 663.
[0055] Ends 116 of the box-frame-segments 101A, 102A, and 104A can be cut with
a bevel so
that two of the ends can abut one another to form a bevel or miter joint. Both
ends 116 of box-
frame-segments 101A are shown in box-frame component view 121, whereas only
one end 116
of box-frame-segments 102A and 104A are shown in box-frame component view 121.
FIG. 36
shows section views at intermediate points (opposite the displayed ends 116)
of the box-frame-
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segment 102A and 104A. The opposite ends of the box-frame-segments 102A and
104A can be
beveled for joining to a box-frame-segment opposite box-frame-segment 101A.
The box-frame-
segment opposite box-frame-segment 101A can be arranged like the box-frame-
segment 101A
and corresponds to the box-frame-segment 102 in the box-frame 100.
[0056] A component shown in any figure and designated by a reference number
followed by
the suffix "A" can be a component that is part of the box-frame 100 in place
of the component
with the similar reference number but without the suffix "A" in FIG. 1. For
example, box-frame-
segment 101A can take the place of box-frame-segment 101.
[0057] Turning to FIG. 37, the box-frame component view 123 shows the box-
frame-segment
101A attached to the box-frame-segment 102A and to the box-frame-segment 104A.
The box-
frame component view 123 also shows a box-frame-segment cover 199 prior to
installation onto
the box-frame-segment 101A. The box-frame-segment cover 199 includes a
vertical element
143 having a first surface 145 and a second surface on the opposing side, a
top horizontal
element 149, a top surface 147 of the top horizontal element 149, a locking-
tab 151, a locking-
tab 153, and an uplift-clip shelf 155. The box-frame-segment cover 199 is an
example of a box-
frame-attachment that is removably attachable to a box-frame-segment.
[0058] A locking-tab slot 157 is located between the locking-tab 153 and the
vertical element
143. The locking-tab slot 157 can be positioned over the locking-tab 167 when
the box-frame-
segment cover 199 is attached to the box-frame-segment 101A as shown in the
box-frame
component view 125. The locking-tab 151 can be positioned within the locking-
tab slot 163 and
the locking-tab 153 can be positioned within the locking-tab slot 169 when the
box-frame-
segment cover 199 is attached to the box-frame-segment 101A as shown in the
box-frame
component view 125. The box-frame-segment cover 199 covers the attachment
holes 141 of the
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box-frame-segment 101A and can reduce environmental exposure to fasteners
accessible via
those attachment holes. The ends 159 of the box-frame-segment cover 199 can be
cut with a
bevel for forming bevel or miter joints with joist elements (e.g., joist
spacers) having beveled or
mitered ends.
[0059] The heights and lengths of the extrusions used for the box-frame-
segments 101A,
102A, and 104A can be any of a variety of heights and lengths, although for
any particular box-
frame, the heights of the extrusions can be identical and the lengths of
opposing box-frame-
segments can be identical. As an example, the height of box-frame-segments
101A, 102A, and
104A can be 5.25 inches (0.13335 meters). As another example, a length of the
box-frame-
segment 101A can be 10 feet (3.048 meters) long, or 12 feet (3.6576 meters)
long, or some other
length. As yet another example, a length of the box-frame-segment 102A can be
14 feet (4.2672
meters) long, or 15 feet (4.572 meters) long, or some other length.
[0060] Next, FIG. 2 shows the box-frame 100 assembled and attached to support-
posts (or
more simply "posts") 10 on a first side 12 of the box-frame 100. Corner-post
brackets 8 and an
intermediate-post bracket 9 can be used for attaching the box-frame 100 to
posts 10. Other sides
13, 14, and 15 of the box-frame 100 are identified in FIG. 2. The box-frame-
segment 104 on
side 13 can include through-holes 11 for attaching the box-frame 100 to
another box-frame or to
a structure, such as a house or a mobile home. The box-frame-segments 101, 102
and 103 can
include through-holes arranged similar to through-holes 11, but those through-
holes are not
shown for clarity of FIG. 2.
[0061] Similar to the box-frame-segments 101A, 102A, and 104A, the lengths of
the box-
frame-segments 101, 102, 103, and 104 can be any length selected from a
plurality of lengths.
For a rectangular deck, lengths of opposing box-frame-segments are typically
identical. As an
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example, the length of the box-frame-segment 101 can be six foot, zero inches
(i.e., 6'- 0")
(1.8288 meters). As another example, the box-frame-segment 102 can be 10'- 0"
(3.048 meters).
Other example lengths for a box-frame-segment are also possible.
[0062] The box-frame-segments 101, 102, 103, and 104 can include or be
configured as any of
a variety of extrusions. Profiles of example extrusions 800 and 825 are shown
in FIG. 8, and
profiles of example extrusions 850 and 875 are shown in FIG. 21. For an
example deck system
comprising a single box-frame, the box-frame-segments 101, 102, 103, and 104
can be
configured like the extrusion 800 arranged with their flat vertical sides as
the outer edges of the
box-frame 100.
[0063] In FIG. 2 and in other figures described herein, the posts 10 are shown
as being
rectangular or rectangular prisms. The posts used with the example embodiments
do not have to
be rectangular. For instance, one or more posts used with the example
embodiments can be
cylindrical. Post brackets used with non-rectangular posts, such as
cylindrical posts, can have
non-rectangular shapes, such as cylindrical shapes, to accommodate the non-
rectangular posts.
[0064] A deck system can include two or more box-frames. For an example deck
system
comprising two or more box-frames configured like the box-frame 100, a box-
frame-segment
configured like the extrusion 800 from two separate box-frames can be bolted
together with their
flat vertical sides 801 abutting one another.
[0065] In FIG. 2, the corner-post brackets 8 and the intermediate-post bracket
9 are shown as
abutting an external surface of the box-frame-segment 101, 102, or 103. In an
alternative
arrangement, an upper portion of the corner-post brackets 8 and the
intermediate-post bracket 9
can be positioned within at least one of the box-frame-segments 101, 102, and
103 similar to
how corner post (or corner bracket) 971 and intermediate post (or intermediate
bracket) 977 are
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positioned within one or more of box-frame-segments 101A and 102A (as shown in
FIG. 29). In
this regard, the upper portion of the corner-post brackets 8 and the
intermediate-post bracket 9
can be positioned within a reinforcement guide to lock the corner-post
brackets 8 and the
intermediate-post bracket 9 into the one or more of box-frame-segments 101,
102, and 103.
[0066] FIG. 22 shows example components for a deck system using two or more
box-frame-
segments. In particular, FIG. 22 shows the box-frame-segment 100 and a box-
frame-segment
attachment 130 that when connected to another box-frame-segment, such as box-
frame-segment
100, fol ___ ins another box-frame, such as the box-frame of the deck system
705 shown in FIG. 7.
The box-frame-segment attachment 130 includes box-frame-segments 131, 132, and
133. For
these example embodiments, the box-frame-segments 101, 102, 103, 131, 132, and
133 can be
configured like the extrusion 800, and the box-frame-segment 104 can be
configured like the
extrusion 875. The box-frame-segment attachment 130 can include angle clips
105, two of
which can be used for attaching the box-frame-segment attachment 130 to the
box-frame 100.
B. JOISTS AND JOIST ASSEMBLIES
[0067] Next, FIG. 38 shows a joist assembly 173 and the components of the
joist assembly 173
prior to assembly of the joist assembly 173. The joist assembly 173 includes
three extrusions
that can be referred to as a joist spacer 175, a joist spacer 177, and a joist
segment 179. The joist
spacers 175 and 177 can be produced from the same or similar extrusion die(s)
and, therefore,
the joist spacers 175 and 177 can have identical features. The joist segment
179 can produced
from another extrusion die from which a joist segment 433 shown in FIG. 26 can
be produced.
[00681 The joist spacer 175 and the joist spacer 177 can include the features
of the box-frame-
segment attachment 405 shown in FIG. 26. Some of those features are identified
in FIG. 26. For
example, the joist spacer 177 includes the vertical element 455, the
horizontal element 437, the
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locking-tab 435, the uplift-clip shelf 479, the horizontal element 445, and
the locking-tab 443.
For attachment to the box-frame-segment 102A, the locking-tab 435 extends
downward from the
horizontal element 437 and the locking-tab 443 extends downward from the
horizontal element
445. A locking-tab slot 431 is formed by the vertical element 455, the
horizontal element 437,
and the locking-tab 435. A locking-tab slot 447 is formed by the vertical
element 455, the
horizontal element 445, and the locking-tab 443.
100691 The joist segment 179 includes a vertical element 197, a horizontal
element 203, a top
horizontal element 207, a horizontal element 211, a roll-lock tab 213, and a
roll-lock slot 209 for
positioning a roll-lock tab of a corresponding joist segment attachable to the
joist segment 179 to
form a joist. The horizontal element 203 extends from the vertical element 197
to a locking-tab
219. The locking-tab 219 can include a flange extending above the horizontal
element 203. A
joist assembly including the joist segment 179 can be formed by attaching the
joist segment 1037
shown in FIG. 26 to the joist segment 179.
100701 The joist segment 179 includes screw spline 201 (i.e., a lower screw
spline), and a
screw spline 697 (i.e., an upper screw spline). The joist spacers 175 and 177
can include
through-holes 665 for passing fasteners 191 and into the screw splines 201 and
697. As an
example, the fasteners 191 can include a flat head screw, such as any flat
head screw described
herein.
100711 Next, FIG. 39 shows components of a box-frame, such as the deck system
341 shown
in FIG. 25. In particular, FIG. 39 shows the box-frame-segment 101A, the box-
frame-segment
102A, the box-frame-segment 104A, the box-frame-segment cover 199 attached to
the box-
frame-segment 101A, and the joist assembly 173 attached to box-frame-segment
102A and the
box-frame-segment 104A. The locking tabs 435 of the joist spacers 175 and 177
are positioned
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within the locking-tab slots, formed in part by the locking tab 195, of the
box-frame-segments
104A and 102A, respectively. The locking tabs 443 of the joist spacers 175 and
177 are
positioned within the locking-tab slots, formed in part by the locking tab
595, of the box-frame-
segments 104A and 102A, respectively. As shown in FIG. 39, a joist assembly
can include one
joist or joist segment and two joist spacers. A three-piece joist assembly
(counting only the joist
spacer(s) and joist segment(s)) can be the first joist assembly installed
within a deck system
during its assembly and the last joist assembly removed from the deck system
during its
disassembly.
[0072] Next, FIG. 40 shows a joist assembly 501 and the components of the
joist assembly 501
prior to assembly of the joist assembly 501. The joist assembly 501 includes a
joist segment
503, a joist segment 505, a joist spacer 507, a joist spacer 509, and
fasteners 191. A four-piece
joist assembly (counting only the joist spacer(s) and joist segment(s)) can be
an intermediate joist
assembly installed within a deck system during its assembly and the last joist
assembly removed
from the deck system during its disassembly.
100731 The joist segment 503 can include the joist segment 433 shown in FIG.
26. The joist
segment 505 can include the joist segment 1037 shown in FIG. 26. Accordingly,
some of the
features of the joist segments 433 and 1037 are identified on the joist
segments 503 and 505.
[0074] The joist spacers 507 and 509 can each include the box-frame-segment
attachment 405
shown in FIG. 26. Accordingly, some of the features of the box-frame-segment
attachment 405
are identified on the joist spacers 507 and 509. Through-holes 665 can be
drilled through the
joist spacers 507 and 509 at locations corresponding to the screw spines 183
and 189 in the joist
segment 505 and at locations corresponding to the screw splines 201 and 697 in
the joist segment
503. Portions of the fasteners 191 can be passed through the through-holes 665
and threaded
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into the screw splines 183, 189, 201 and 697. The fasteners 191 can include
hex-head sheet
metal screws that are one inch long (i.e., #12 x 1" HH SMS) or some other
fastener.
[0075] The locking-tab 443 of the joist segments 507 and 509 can be positioned
within the
locking-tab slot 169 of the box-frame-segment 102A and 104A, respectively, and
the locking-tab
435 of the joist segments 507 and 509 can be positioned within the locking-tab
slot 163 of the
box-frame-segments 102A and 104A, respectively, when the joist assembly 501 is
positioned
within the deck system 341.
[0076] Next, FIG. 41 shows components of a box-frame, such as the deck system
341 shown
in FIG. 25. In particular, FIG. 41 shows the box-frame-segment 101A, the box-
frame-segment
102A, the box-frame-segment 104A, the box-frame-segment cover 199 attached to
the box-
frame-segment 101A, the joist assembly 173 attached to the box-frame-segment
102A and the
box-frame-segment 104A, and the joist assembly 501 attached to the box-frame-
segment 102A,
the box-frame-segment 104A, and the joist assembly 173. The locking tabs 435
of the joist
spacers 507 and 509 are positioned within the locking-tab slots, formed in
part by the locking tab
195, of the box-frame-segments 104A and 102A, respectively. The locking tabs
443 of the joist
spacers 507 and 509 are positioned within the locking-tab slots, formed in
part by the locking tab
595, of the box-frame-segments 104A and 102A, respectively.
100771 Next, FIG. 35 shows a joist assembly 265. The joist assembly 265
includes a joist
segment hanger 267, a joist segment 269, a joist segment hanger 271, and
fasteners 273. The
joist segment hangers 267 and 271 can include extrusions produced from the
same or similar
extrusion die(s) and, therefore, the joist segment hangers 267 and 271 can
have identical
features. The joist segment hangers 267 and 271 are examples of box-frame-
segment
attachments. The joist segment 269 can include a single extrusion produced
from another
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=
extrusion die. Through-holes 193 can be drilled through the joist segment
hangers 267 and 271
at positions that correspond to screw splines 1013, 1015, and 1019 in the
joist segment 269. As
an example, the fasteners 273 can include number twelve hex-head sheet metal
screws that are
one inch long (i.e., #12 x 1" HH SMS) or some other fastener.
[0078] The joist assembly 265 can attach to two distinct box-frame-segments of
a box-frame.
For example, as shown in FIG. 35, the joist assembly 265 can attach to the box-
frame-segment
102A and to the opposing box-frame-segment 104A. Other joist assemblies,
similar to the joist
assembly 265, can be attached to the box-frame-segments 102A and 104A. A joist
segment
spacer 297 can attach to the box-frame-segment 102A to separate the joist
assembly 265 from an
adjacent joist assembly attachable to the box-frame-segment 102A. The joist
segment spacer
297 can include an extrusion produced from the same or similar extrusion
die(s) from which the
joist segment hangers 267 and 271 are produced. Therefore, joist segment
hangers 267 and 271
can include the same features of the joist segment spacer 297, such as the
locking-tab slot 431
and the locking-tab 443. Joist segment spacers 599 and 601 can attach to the
box-frame-segment
104A to separate the joist assembly 265 from adjacent joist assemblies
attachable to the box-
frame-segment 104A.
[0079] As shown in FIG. 35, the joist segment spacer 297 includes a vertical
element 455, a
top horizontal element 437, a locking-tab 435, a horizontal element 445, a
locking-tab 443, and
an uplift-clip shelf 479. The vertical element 455 has a first side 299 and an
opposing side (not
shown in FIG. 35. The opposing side of the vertical element 455 can be flat
similar to how the
visible side of the joist segment hanger 271 appears flat in FIG. 35. The
vertical element 455,
the top horizontal element 437, and the locking-tab 435 form a locking-tab
slot 431. The vertical
element 455, the horizontal element 445, and the locking-tab 443 form a
locking-tab slot 447.
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Since the joist segment hangers 267 and 271 and the joist segment spacer 297
can be from the
same extrusion, the joist segment hangers 267 and 271 can have the same
features as the joist
segment spacer 297.
[0080] FIG. 35 shows a joist segment spacer 309 attached to the box-frame-
segment 102A.
The joist segment spacer 309 can be arranged like the joist segment spacer
297. The joist
assembly 265 is attachable to the box-frame-segment 102A adjacent to the joist
segment spacer
309. An uplift clip 307 can be inserted (e.g., slid) into a uplift-clip slot
formed by the joist
segment hanger 267. The uplift clip can be supported by an uplift-clip shelf
located on the joist
segment hanger 267.
[0081] The joist segment 269 includes a deck-clip slot 311. One or more deck-
clips 515 can
be inserted into the deck-clip slot 311. One or more of the deck-clips 515
inserted into the deck-
clip slot 311 can be slid within the deck-clip slot to reposition the deck-
clip slot 515 for desired
placement of deck boards on top of the joist segment 269. The joist segment
269 includes screw
splines 603 for retaining a deck-clip screw.
[0082] Next, FIG. 3 shows example components of additional joist assemblies
300 and 320
usable within an example deck system. The joist assemblies 300 and 320 are
shown
unassembled and assembled. The joist assemblies 300 and 320 are attachable to
and removable
from a box-frame, such as the box-frame 100. The joist assemblies 300 and 320
are attachable
within a box-frame interior, such as the box-frame interior 112.
[0083] The joist assembly components of joist assembly 300 include joist
segments 301, 303,
joist spacers 302, 304, and fasteners 305. The joist segment 301 can include
an aluminum
extrusion having a profile like the extrusion 800. The joist segment 303 can
include an
aluminum extrusion having a profile like the extrusion 825 or the extrusion
850. The joist
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spacers 302 and 304 can include aluminum extrusions having a profile like the
extrusion 850.
The fasteners 305 can include number twelve hex-head sheet metal screws that
are one inch long
(i.e., #12 x 1" HH SMS) or some other fastener.
[0084] The joist segments 301 and 303 can have a common length, such as 6'-
0," or some
other length. The joist spacers 302 and 304 can have a common length, such as
1' ¨2" (i.e., 14
inches), or some other length. The common length of the joist spacers 302 and
304 can depend
on a thickness of deck boards to be attached to the deck system. The common
length of joist the
segments 301 and 303 is typically a length that allows the joist segment 303
to be attached to the
box-frame-segment 101, the joist spacer 302 to be attached to the box-frame-
segment 104, and
the joist spacer 304 to be attached to the box-frame-segment 102, all within
the box-frame
interior 112 when assembled as the joist assembly 300.
[0085] The joist assembly components of the joist assembly 320 include the
joist segments
321, 323, the joist spacers 322, 324, and the fasteners 305. The joist segment
323 can include an
aluminum extrusion having a profile like the extrusion 825 or the extrusion
850. The joist
segment 321 and the joist spacers 322 and 324 can include aluminum extrusions
having a profile
like the extrusion 850.
[0086] The joist segments 321 and 323 can have a common length, such as 6'-
0," or some
other length. The joist spacers 322 and 324 can have a common length, such as
l' ¨ 2" (i.e., 14
inches), or some other length. The common length of the joist spacers 322 and
324 can depend
on a thickness of deck boards to be attached to the deck system. The common
length of the joist
segments 321 and 323 is typically a length that allows the joist segment 321
to be attached to the
box-frame-segment 103, the joist spacer 322 to be attached to the box-frame-
segment 104, and
the joist spacer 304 to be attached to the box-frame-segment 102, all within
the box-frame
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interior 112 when assembled as the joist assembly 320. The joist segment 323
can attach to
another joist assembly installed with the box-frame interior.
100871 Next, FIG. 4 shows an example deck system 400 under construction. Deck
system 400
includes the box-frame 100, the joist assembly 300 installed within the
interior 112 of the box-
frame 100, corner-post brackets 8, intermediate-post bracket 9, and posts 10.
FIG. 4 also shows
additional joist assemblies 402 and joist assembly 404 prior to installation
into the deck system
400. The joist assemblies 402 and 404 can be arranged like the joist assembly
300. The short
dashed lines within the box-frame 100 represent a location at which the joist
assembly 320 can
be installed into the deck system 400, typically after all other joist
assemblies to be installed into
the box-frame 100 have been installed.
[0088] In accordance with one or more example embodiments, a first installed
joist assembly
and all intermediate joist assemblies can be arranged like the joist assembly
300, and a last
installed joist assembly can be arranged like the joist assembly 320. The
intermediate joist
assemblies are installed between the joist assemblies 300 and 320. The
portions of two joist
segments that abut one another and the portion of a joist segment or joist
spacer that abuts a box-
frame-segment can have, in combination, a roll-lock tab and a roll-lock tab
receiver, as discussed
with respect to FIG. 8. The roll-lock tab is positioned within the roll-lock
tab receiver to secure
attachment of the abutting joist segments, joist spacers, or box-frame-
segments.
[0089] FIG. 4 shows a side view 450 in which joist assembly is installed
within the box-frame
interior 112 (without showing box-frame interior 112) and the joist assembly
402 is being
attached to the joist assembly 300 and to the box-frame interior 112. A roll-
lock tab receiver of
the joist assembly 300 receives a roll-lock tab of the joist assembly 402 and
then the joist
assembly 402 is rolled down (e.g., rotated downward) so that the roll-lock
tabs of the joist
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spacers of the joist assembly 402 enter into the roll-lock tab receivers of
the box-frame interior
112. Other joist assemblies, such as the joist assembly 404 can be similarly
installed within the
box-frame interior 112.
100901 Side 13 of the box-frame 100 can be attached to the example structure
discussed herein.
In an alternative arrangement, the box-frame 100 can include additional corner-
post brackets 8
and an intermediate-post bracket on the side 13. The posts 10 can include a
post made of wood,
aluminum, a composite material, or some other material. A wooden post can
include pressure
treated wood. The wood can be cedar, a hardwood, or some other wood. The posts
10 can be
referred to as four-by-four posts. The four-by-four posts may not have a four
inch width and
four inch depth. A bottom portion of the posts 10 can be placed upon concrete
footers or upon
brackets positioned on concrete footers within the ground below the deck
system 400. More than
one intermediate-post bracket and respective post 10 can be used on any given
side of an
example deck system.
[0091] In an alternative arrangement, the joist assembly 173 can be installed
within the deck
system 400 in place of the joist assembly 300, and the joist assembly 501 can
be installed within
the deck system 400 and to the joist assembly 300 in place of the joist
assemblies 402 and 404.
Accordingly, the joist assembly 501 can be rolled down into the deck system
400 in the manner
in which FIG. 4 shows the joist assembly 402 being rolled down into the deck
system 400. The
final joist assembly installed within the deck system 400 can include another
three-piece joist
assembly along with another box-frame-segment cover like box-frame-segment
cover 199.
[0092] Next, FIG. 5 shows additional details regarding the deck system 400.
The joist
assemblies 300, 402, 404, 406, 408, 410, and 320 are installed within the box-
frame 100. A
person having ordinary skill in the art will understand that a different
quantity of joist assemblies
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can be installed within box-frame. Corner-post brackets 8, intermediate-post
bracket 9, and posts
of deck system 400 are described elsewhere herein.
[0093] FIG. 5 shows dimensions 416 and 418 to provide perspective of the
example deck
systems. The dimension 416 can represent any of a variety of lengths, such as
a length between
center lines of the longitudinal joists of the joist assembly 300, a length
between ends of joist
segments of the joist assembly 300, or a length of a joist spacer of the joist
assembly 300. As an
example, the dimension 416 can be l'-2" (i.e., 14 inches), or some other
number of inches. A
dimension similar to dimension 416 can pertain to the other joist assemblies
of the deck system
400.
[0094] The dimension 418 can represent any of a variety of lengths, such as
the lengths of the
longitudinal joists within the joist assemblies 300, 402, 404, 406, 408, 410,
and 320 or a
longitudinal length of each of those joist assemblies including the joist
spacers. As an example,
the dimension 418 can be 6'-0" (i.e., 72 inches) or some other number of
inches.
C. DECK BOARDS
[0095] Next, FIG. 6 shows an example deck system 600. The deck system 600
includes the
box-frame 100 including the joist assemblies 300, 402, 404, 406, 408, 410, and
320. The deck
system 600 includes the posts 10, railing posts 60, corner-post brackets 62,
and intermediate-post
bracket 64. Four sides 66, 67, 68, 69 of the deck system 600 are identified in
FIG. 6. The deck
system 600 can include one or more additional intermediate-post brackets 9 or
62 along sides 66,
67, 68, or 69. The deck system 600 can include one or more additional corner-
post brackets 8 or
64 at corners of the box-frame 100.
[0096] The deck system 600 includes a plurality of deck-clips 5 and a
plurality of deck boards
6. A separate deck-clip 5 can be attached to each joist between each pair of
adjacent deck boards
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6. The deck-clips 5 can establish a substantially common spacing between each
adjacent pair of
deck boards 6. The spacing between the deck boards 6 can allow for water to
fall between the
deck boards 6 to reduce ponding of the water on the deck boards 6. The
substantially common
spacing can, for example, be within a range of one sixteenth of an inch (i.e.,
1/16") and one half
inch (i.e., 1/2"), inclusive.
[00971 The deck boards 6 extend perpendicular to the longitudinal portion of
the joist
assemblies 300, 402, 404, 406, 408, 410, and 320. A single deck board 6 can
extend completely
across box-frame 100. Alternatively, two or more deck boards 6 can be used to
extend across
box-frame 100 instead of one of the single deck boards that extend across box-
frame 100. A
deck board 6 extending across box-frame 100 can include a portion (e.g., a one
inch portion) that
extends beyond box-frame 100. The deck boards 6 can include a deck board made
of wood,
aluminum, polyvinyl chloride (PVC), a composite material, or some other
material. The wooden
boards can include pressure treated wood, cedar, a hardwood, or some other
wood.
[0098] The other deck systems described herein as having deck boards can
include the deck
boards 6. The deck boards can be oriented in orientations other than extending
perpendicular to
the longitudinal portion of a joist assembly. As an example, the deck boards 6
can be rotated a
number of degrees (e.g., 45 degrees) from the orientation in which the deck
boards extend
perpendicular to the longitudinal portion of the joists. The deck-clips 565 or
the deck-clips 605
can be used for positioning and attaching the deck boards 6 in those different
orientations.
100991 The box-frame 100, at side 66, can be attached to the example structure
discussed
herein. In an alternative arrangement, the box-frame 100 of can include
additional corner-post
brackets 62 and an intermediate-post bracket 64 on side 66. The posts 60,
similar to the posts 10,
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can include a post made of wood, aluminum, a composite material, or some other
material. The
posts 60, similar to the posts 10, can be referred to as four-by-four posts.
10100] The corner-post brackets 62 and the intermediate-post bracket 64
include a portion
extending above the box-frame 100. The posts 60 can be inserted into those
bracket portions and
attached to the corner-post brackets 62 and the intermediate-post bracket 64
using any of a
variety of fasteners. Horizontal railing components (not shown) can be
attached to the posts 60.
The horizontal railing components can include an upper horizontal railing
component and a
lower horizontal railing component. A plurality of spindles or balusters can
be attached to and
between the horizontal railing components.
101011 Next, FIG. 7 shows an example deck system 700 including deck systems
704 and 705.
The deck system 704 is positioned adjacent to a structure 702. The structure
702 can be
configured like the structures discussed herein. The deck system 704 is
removably attachable to
the structure 702. For purposes of this description, removably attachable
means a first element
(such as the deck system 704) can be attached to a second element (such as the
structure 702)
and the first element can be unattached from and removed away from the second
element. The
attachment and un-attachment of the first and second elements can be repeated
one or more
times.
101021 The deck system 704 includes joist assemblies 706, 708, 710, 712, and
714. One of the
joist assemblies 706 and 714 can be configured like the joist assembly 320 or
the joist assembly
173, while the other of those joist assemblies and the joist assemblies 708,
710, and 712 can be
configured like the joist assembly 300 or the joist assembly 501.
Alternatively, the deck system
704 can include joists like the joist 265 and joist spacers like the joist
spacers 297 and 309 in
place of one or more of the joist assemblies described with respect to the
deck system 704.
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[0103] The deck system 705 includes joist assemblies 716, 718, 720, 722, and
724. One of the
joist assemblies 716 and 724 can be configured like the joist assembly 320,
while the other of
those joist assemblies and the joist assemblies 718, 720, and 722 can be
configured like the joist
assembly 300.
[0104] A number of posts 10 can be used to support the deck system 700 above
the ground.
Each post 10 that supports the deck system 700 can be positioned within a
corner-post bracket
(such as corner-post bracket 9 or 64) or within an intermediate-post bracket
(such as
intermediate-post bracket 8 or 62).
[0105] FIG. 7 shows example locations within the deck system 700 at which
partial section
views 1100, 1150, 1300, 1301, and 1302, shown in FIG. 11 and FIG. 13 can be
taken. A partial
section view taken at line 1302 in FIG. 7 is not shown, but would look like
section view 1300 in
FIG. 7 without the following items: structure lines 702 and 1402, fasteners
1310 and 1312, and
shims 1306. FIG. 7 also shows portions 1400, 1500, 1600, 1700, 1800 and 1900
at which large-
scale views shown in FIG. 14 through FIG. 19 pertain.
[0106] Next, FIG. 25 shows components of a deck system 341 and deck system
features 1053
for an alternative arrangement of the deck system 341. The deck system 341
includes a box-
frame perimeter (also known as a "perimeter box-frame," or more simply as a
"box-frame," a
"deck perimeter", or a "deck-frame") 100A that includes box-frame-segments
101A, 102A,
103A, and 104A. Details corresponding to the box-frame-segments 101A, 102A,
and 104A are
shown in FIG. 36 and FIG. 37. The box-frame-segment 103A can be identical to
the box-frame-
segment 101A. The deck system 341 includes joists 343, 345, 347, 349, and 351.
[0107] In a first respect for the deck system 341, the joists 343, 345, 347,
349, and 351 can
each include a joist assembly like the joist assembly 265 shown in FIG. 35. A
joist segment
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hanger, like the joist segment hangers 267 and 271, can attach to the box-
frame-segments 102A
and 104A. Joist segment spacers, such as the joist spacer segment 297, can be
positioned on the
box-frame-segments 102A and 104A between each of the joists 343, 345, 347,
349, and 351, and
between the joist 343 and the box-frame-segment 101A, and between the joist
351 and the box-
frame-segment 103A. A box-frame-segment cover, like the box-frame-segment
cover 199, can
be attached to the box-frame-segment 101A and another can be attached to the
box-frame-
segment 103A.
101081 In a second respect for the deck system 341, the joist 343 can be part
of a joist assembly
like the joist assembly 173 shown in FIG. 38, and the joists 345, 347, 349,
and 351 can be part of
a joist assembly like the joist assembly 501 shown in FIG. 40.
101091 FIG. 25 shows the box-frame-segments 101A, 102A, and 103A are straight
box-frame-
segments. The box-frame attachments attached to each of the box-frame-segments
are straight
box-frame attachment. One or more of the box-frame-segments 101A, 102A, 103A,
and 104A
and the box-frame attachments attached thereto are straight box-frame
attachments. One or more
of the box-frame-segments and the corresponding box-frame attachment can be
curved. The
curve of a curved box-frame-segment may be such that a center point of box-
frame-segment is
furthest away from a box-frame-segment on the opposite side of the box-frame
perimeter. A
curved box-frame-segment and a curved box-frame attachment can include a
rolled extrusion.
The joists, joist segments, or joist assemblies that attach to a curved box-
frame-segment can be
miter cut for mounting flush to the curved box-frame-segment.
[0110] FIG. 25 illustrates a 90 deck-clip 515 installed in the joist 345, a
45 deck-clip 565
installed in the joist 347, and a 135 deck-clip 605 installed in the joist
349. The lines passing
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through the deck-clips 515, 565, and 605 represent an orientation of deck
boards that can be
attached to the deck system 341 by use of those deck-clips.
101111 The deck system 341 can be supported by an existing structure. For
instance, the box-
frame-segment 104A can be fastened to the structure. As another example, one
or more posts
can be positioned in or on the ground and attached to the deck system 341.
FIG. 25 shows
example posts (or brackets) 359, 361, 363, 365, 367, 369, 371, 373, and 375
that can be used to
support the deck system 341. One or more of the posts 359, 361, 363, 365, 367,
369, 371, 373,
and 375 can attach to the deck system 341 using a post bracket as described
herein or a different
type of post bracket or with a bracket integral to the post..
101121 The deck system features 1053 include a support beam 1061 extending
from a post (or
bracket) 1063 to a post (or bracket) 1071. The post (or bracket) 1063 and the
post (or bracket)
1071 can each include a 4 inch x 4 inch by 0.25 inch aluminum post. The joists
343, 345, 347,
349, and 351 extend to the box-frame-segment 102A or to a box-frame-segment
attachment
attached to the box-frame-segment 102A. FIG. 25 identifies detail areas 1051,
1055, 1057, and
1059 that pertain to the deck system features 1053. Details pertaining to
those detail areas are
shown in FIG. 31 to FIG. 34. The support beam 1061 and the posts supporting
the support beam
1061 allow for portions of the deck system 341 (i.e., portions of the box-
frame 101A, 102A,
103A and the joists 343, 345, 347, 349, and 351 to cantilever beyond the
support beam 1061.
D. DECK-CLIPS
10113] Next, FIG. 12 shows a deck-clip 5. FIG. 12 includes an isometric view
126 of the
deck-clip 5, a top view 127 of the deck-clip 5, and a side view 128 of the
deck-clip 5. The deck-
clip 5 includes a deck board retainer 512 including deck board retaining
surfaces 135 and 137 to
retain deck boards to the joist assemblies. The deck-clip 5 includes a base
514 and a vertical
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element 516 extending from the base 514 to the deck-clip retaining surfaces
135 and 137. The
deck-clip 5 can include a through-hole 120 in the base 514 for insertion of a
deck-clip screw 92.
The deck-clip 5 can be made of steel (e.g., stainless steel), aluminum,
plastic, or some other
material. Dimensions 122, 124 can be any of a variety of dimensions. The
dimension 122 can
depend upon a height (e.g., depth) of deck boards 6, or a height of a deck-
clip slot positioned
along a side of a deck board 6, used within a deck system. As an example, the
dimension 122
can equal 0.625 inches or some other dimension. As an example, the dimension
124, a thickness
of deck-clip 5, can equal 0.0625 inches or some other dimension. The size of
the deck-clip 5,
such as the depth and thickness dimensions, can vary per requirements of the
deck boards
installed onto the deck system. The deck-clip 5 is an example of a 90 deck-
clip. As an
example, the deck-clip 5, as well as any other deck-clip described herein, can
include a plastic
deck-clip, a metal deck-clip, or a deck-clip having a metal portion and a
plastic portion.
101141 The vertical element 516 includes a notched area 333. The notched area
333 includes a
first notch and a second notch accessible from opposing sides of the vertical
element 516. The
first notch and the second notch allow a portion of a respective tab (such as
tabs 329 and 331
shown in FIG. 26) of a deck component with a deck-clip slot (such as a joist,
joist segment, or
box-frame segment) to be positioned in between upper and lower portions of the
vertical element
516. In an alternative arrangement, the notched area 333 can begin at the base
514 such that the
lower portion of the vertical element 516 includes only the portion between
the first notch and
the second notch. Examples of a notched area 333 beginning at a base of a deck
clip are shown
in FIG. 27 and FIG. 28. Portions of the base 514 and the lower portion of the
vertical segment
516 can be positioned within recessed areas of a deck-clip slot (such as the
recessed areas 325
and 327 of the deck-clip slot shown in FIG. 26). The other portions of the
base 514 and the
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lower portion of the vertical segment 516 can be positioned between the
recessed areas of the
deck-clip slot.
101151 Next, FIG. 20 shows a partial section view 2002 with respect to section
lines 2000
shown in FIG. 11. The partial view 2002 shows deck-clips 5 secured to a joist
segment 1160
using fasteners 92. The deck-clips 5 provide for spacing for deck boards 6 and
for attachment of
deck boards 6 to joist segment 1160. FIG. 20 shows an alternative partial
section view 2006
showing a deck board 6 attached to an extrusion 2008, such as a joist segment,
using a deck
screw 2010. The deck screw 2010 provides an alternative manner for attaching
deck boards 6 to
a deck system. The deck screw 2010 can be inserted through a deck-clip slot
(such as the deck-
clip slot shown in FIG. 26) and into deck-screw splines (such as the deck-
screw splines 422
shown in FIG. 26).
101161 Next, FIG. 27 shows a deck-clip 515. FIG. 27 includes a top view 517 of
the deck-clip
515, a side view 519 of the deck-clip 515, a front view 521 of the deck-clip
515, an isometric
view 523 of the deck-clip 515, and installation view 525 of the deck-clip 515.
The deck-clip 515
can be referred to as a 90 deck-clip. The deck-clip 515 includes a base 529,
a vertical element
527, and a deck board retainer 535. The base 529 includes a through-hole 533
for insertion of a
deck-clip screw 92 into deck-screw splines (such as the deck-screw splines 422
shown in FIG.
26). The deck-clip screw 92 can keep the deck-clip 515 at a desired position
within a joist 537.
The vertical element 527 is perpendicular to the base 529 and to the deck
board retainer 535.
The base includes short edges 549 and 551 and long edges 553 and 555. The
vertical element
527 is parallel to the short edges 549 and 551. The deck board retainer 535
includes a notch 557
to allow the deck-clip screw 92 to be installed without tilting the deck-clip
screw 92.
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101171 The deck-clip 515 includes a notched area 333 within the vertical
element 527
beginning at the base 529. A height of a first notch and a second notch
accessible from opposing
sides of the vertical element 527 can be slightly greater than a height of
tabs (such as tabs 329
and 331 shown in FIG. 26) which will pass through the notched area 333. After
being installed
into a deck-clip slot, the portions of the base 529 that are wider than the
portion of the vertical
element 527 at the notched area 333 can prevent the deck-clip 515 from being
lifted upward out
of the deck-clip slot as that wider portion of the base 529 contacts or would
contact the lower
portion of the tabs 329 and 331 if upward movement of the deck-clip is
attempted. The deck-
screw 92 passing through the through-hole 533 and into deck-screw splines can
also prevent the
deck-clip 515 from being lifted upward out of the deck-clip slot.
[0118] As shown in the installation view 525, the deck-clip 515 is adapted to
provide spacing
between deck boards that are positioned perpendicular to the joist 537 in
which the deck-clip 515
is installed. The joist 537 includes a deck-clip slot 539. A milled-portion
541 of the of the joist
537 can include a portion of the joist 537 that is milled to allow the base
529 to be inserted into
the deck-clip slot 539. The milled-portion 541, and any other milled-portion,
for inserting a
deck-clip can be referred to as a "deck-clip insertion point." Once the deck-
clip 515 is slid
within the deck-clip slot 539 away from the milled portion 541, the joist 537
prevents the deck-
clip 515 from being lifted upward (e.g., vertically) out of the joist 537. The
partial deck
assembly shown in the installation view 525 includes the box-frame-segment
102A, a joist
spacer 543, a joist spacer 545, and fasteners 547. As an example the fasteners
547 can include
1.0 inch #12 hex head sheet metal screws. The box-frame segments, joist
segments, and other
joists can include a deck-clip insertion point similar to the milled portion
541 to allow for
insertion of a deck-clip into a deck-clip slot.
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[0119] FIG. 27 shows a deck-clip 565. FIG. 27 includes a top view 567 of the
deck-clip 565, a
side view 569 of the deck-clip 565, a front view 571 of the deck-clip 565, an
isometric view 573
of the deck-clip 565, and installation view 575 of the deck-clip 565. The deck-
clip 565 can be
referred to as a 45 deck-clip. The deck-clip 565 includes a base 579, a
vertical element 577, and
a deck board retainer 581. The base 579 includes a through-hole 583 for
insertion of a deck-clip
screw 92 into deck-screw splines (such as the deck-screw splines 422 shown in
FIG. 26). The
deck-clip screw 92 can keep the deck-clip 565 at a desired position within the
joist 537. The
vertical element 577 is perpendicular to the base 579 and to the deck board
retainer 581. The
base 579 includes short edges 585 and 587 and long edges 589 and 591. The
vertical element
577 is rotated 45 with respect to a corner of the base 579 formed by the
short edge 577 and the
long edge 591. The deck board retainer 581 includes a notch 593 to allow the
deck-clip screw 92
to be installed without tilting the deck-clip screw 92.
[0120] As shown in the installation view 575, the deck-clip 565 is adapted to
provide spacing
between deck boards that are positioned 45 from being perpendicular to the
joist 537 in which
the deck-clip 565 is installed. Once the deck-clip 565 is slid within the deck-
clip slot 539 away
from the milled portion 541, the joist 537 prevents the deck-clip 565 from
being lifted upward
out of the joist 537. The deck-clip 565 includes a notched area 333 within the
vertical element
577 beginning at the base 579. In an alternative arrangement for the deck-clip
565 and other
deck-clips having a notched area 333, the notched area 333 can be offset from
the base of the
deck-clip similar to how the notched area 333 of deck-clip 5 is offset from
the base 514 as shown
in FIG. 5.
[0121] Next, FIG. 28 shows a deck-clip 605. FIG. 28 includes a top view 607 of
the deck-clip
605, a side view 609 of the deck-clip 605, a front view 611 of the deck-clip
605, an isometric
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view 613 of the deck-clip 605, and installation view 615 of the deck-clip 605.
The deck-clip 605
can be referred to as a 135 deck-clip. The deck-clip 605 includes a base 619,
a vertical element
617, and a deck board retainer 621. The base 619 includes a through-hole 623
for insertion of a
deck-clip screw 92 into deck-screw splines (such as the deck-screw splines 422
shown in FIG.
26). The deck-clip screw 92 can keep the deck-clip 605 at a desired position
within the joist 537.
The vertical element 617 is perpendicular to the base 619 and to the deck
board retainer 621.
The base 619 includes short edges 625 and 627 and long edges 629 and 631. The
vertical
element 617 is rotated 45 with respect to a corner of the base 619 formed by
the short edge 627
and the long edge 629. The deck board retainer 621 includes a notch 633 to
allow the deck-clip
screw 92 to be installed without tilting the deck-clip screw 92.
101221 As shown in the installation view 615, the deck-clip 605 is adapted to
provide spacing
between deck boards that are positioned 45 from being perpendicular to the
joist 537 in which
the deck-clip 605 is installed, although the deck boards are oriented 90 from
the orientation of
the deck boards shown in the installation view 575. Once the deck-clip 605 is
slid within the
deck-clip slot 539 away from the milled portion 541, the joist 537 prevents
the deck-clip 605
from being lifted upward out of the joist 537. The deck-clip 605 includes a
notched area 333
within the vertical element 617 beginning at the base 619.
[0123] Next, FIG. 45 shows a perimeter-trim-piece 635. The perimeter-trim-
piece 635, like
any other perimeter-trim-piece described herein or shown in the figures, can
be inserted into a
perimeter-trim-piece slot, such as the perimeter-trim-piece slot 417 shown in
FIG. 26. The
perimeter-trim-piece 635 can be retained within the perimeter-trim-piece slot
417. The
perimeter-trim-piece 635, like other perimeter-trim-pieces, can be removed
from the perimeter-
trim-piece slot 417. Accordingly, the perimeter-trim-piece 635 can include a
removably
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retainable perimeter-trim-piece. The perimeter-trim-pieces, such as perimeter-
trim-piece 635,
can be used to keep one or more deck boards from sliding beyond an edge of a
box-frame-
segment and can be used to keep a portion of one or more deck boards from
being lifted upwards
from a box-frame-segment or joist.
101241 The perimeter-trim-piece 635 includes a vertical element 637, a
horizontal member
639, a horizontal base 641, an intermediate perimeter-trim-piece locking tab
643, and a distal
perimeter-trim-piece locking tab 645. The distal perimeter-trim-piece locking
tab 645 and then
the intermediate perimeter-trim-piece locking tab 643 can be positioned into
the perimeter-trim-
piece slot 417. The intermediate perimeter-trim-piece locking tab 643 includes
an upper surface
647, a lower surface 649, and an upright surface 651 that extends from the
lower surface 649 to
the horizontal base 641. The upright surface 651 can be positioned against a
vertical element of
a box-frame-segment that forms a perimeter-trim-piece slot. The horizontal
member 639 can be
positioned within a slot of one or more deck boards.
101251 Next, FIG. 28 illustrates insertion of a perimeter-trim-piece 655 into
a perimeter-trim-
piece slot of the box-frame-segment 102A. A box-frame-segment attachment 653
is attached to
the box-frame-segment 102A. As an example, the box-frame-segment attachment
653 can be a
joist, a joist spacer, or a joist assembly. The perimeter-trim-piece 655 can
include the same
features of the perimeter-trim-piece 635 shown in FIG. 45, but the perimeter-
trim-piece 635 may
not include the horizontal shelf 639. The perimeter-trim-piece 655 can include
barbs (e.g., sharp
points) protruding from the vertical element 637 for preventing or reducing
upright movement of
a deck board into which the barbs have been inserted. The barbs can be
positioned within a slot
of one or more deck boards to retain the deck board in position.
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[0126] As shown in FIG. 28, the distal perimeter-trim-piece locking tab 645
and the
intermediate perimeter-trim-piece locking tab 643 of the perimeter-trim-piece
655 are inserted
into the perimeter-trim-piece slot of the box-frame-segment 102A with the
vertical element 637
tilted from its vertical position and then the perimeter-trim-piece 655 is
rotated (counter-
clockwise with respect to FIG. 28) until the perimeter-trim-piece 655 snaps
into the perimeter-
trim-piece slot.
[0127] A perimeter-trim-piece installed into a perimeter-trim-piece slot may
include a single
perimeter-trim-piece. For example, for a box-frame-segment 12 feet long, the
perimeter-trim-
piece installed into a perimeter-trim-piece slot of that box-frame-segment may
be 12 feet long or
nearly 12 feet long. That perimeter-trim-piece may be nearly 12 feet long so
as to allow
perimeter-trim-pieces to be installed into box-frame-segments that attach to
the 12 foot long box-
frame-segment.
[0128] Next, FIG. 46 shows multiple views of a deck-clip 460. The deck-clip
460 can be a
metallic clip, such as a clip made of steel or aluminum. The various views of
the deck-clip 460
shown in FIG. 46 include section views 462, 464, and 466, a top view 468, a
front view 470, a
side view 472, and a material view 474 showing material used to form the deck-
clip 460. The
section view 462 corresponds to the section lines B-B shown in the front view
468. The section
view 464 corresponds to the section lines C-C shown in the front view 468. The
section view
466 corresponds to the section lines A-A shown in the front view 468.
[01291 The material view 474 shows bend lines 476 and 478 that indicate points
at which a
deck-clip material is bent to form the deck-clip 460. The material view 474
shows the deck-clip
material includes inner tabs 480 and 482, outer tabs 484 and 486, a lower base
portion 488, a
first intermediate portion 490, and a second intermediate portion 492. The
first intermediate
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portion is connected to and extends between the lower base portion 488 and the
second
intermediate portion 492. The first intermediate portion 490 can be referred
to as a notch.
[0130] Each of the inner tabs 480 and 482 and the outer tabs 484 and 486 can
include a pointed
end, such as the pointed end 494 of the outer tab 484. The points of the inner
tabs 480 and 482
can be positioned within a first deck board. The points of the outer tabs 484
and 486 can be
positioned within a second deck board. The inner tabs 480 and 482 can be
referred to as
proximal tabs as those tabs are closer to a center line that passes through
the lower base portion
488, the first intermediate portion 490, and the second intermediate portion
492, as shown in the
material view 474. The outer tabs 484 and 486 can be referred to as distal
tabs as those tabs are
further away from the aforementioned center line.
[01311 The deck-clip material shown in the material view 474 can be bent at
bend lines 476
and 478 to form the deck-clip 460 as shown in the other view of FIG. 46. As
such, the second
intermediate portion 492 can be perpendicular to the lower base portion 488
and to the inner tabs
480 and 482 and to the outer tabs 484 and 486. A through-hole 496 can be
provided in the lower
base portion 488 to allow a deck-clip screw, such as the deck-clip screw 92 to
pass through the
lower base portion 488 and into screw splines, such as the deck screw splines
422 shown in FIG.
26. Since deck screw splines can extend from end to end of a box-frame
segment, joist, or joist
segment, the example deck-clips described herein can be slid to a desired
location within the
box-frame segment, joist, or joist segment and screwed into the box-frame
segment, joist, or joist
segment at the desired location. While positioned within the deck-clip slot
away from a milled
portion at which the deck-clip was inserted into the deck-clip slot, the deck-
clip can be prevented
from being lifted upward (e.g., vertically) out of the box-frame segment,
joist, or joist segment.
Fastening the deck-clip 460 using a deck-clip screw 92 into a deck-clip slot
can secure the deck-
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clip sufficiently so that a deck board can be pushed in a direction towards
the deck-clip 460 such
that the points of the inner tabs 480 and 482 or the points of the outer tabs
484 and 486 pierce the
deck-board for securing the deck board to the box-frame segment, joist or
joist segment housing
the deck-clip 460.
[0132] The lower base portion 488 can have a width of 0.5 inches or some other
dimension
that allows the lower base portion 488 to be inserted into a milled-portion of
a joist or joist
segment, such as the milled-portion 541 shown in FIG. 27, and slid within the
deck-clip slot 539.
While in a deck-clip slot, away from a milled-portion that permits placement
of the deck-clip 460
into the deck-clip slot, the deck clip 460 can be restrained from being pulled
out of the deck-clip
slot due, in part to width of lower base portion 488. Furthermore, a dimension
of a distance from
the furthest edges of the outer tabs 484 and 486 can be 1.5 inches or some
other dimension.
Furthermore still, after the inner tabs 480 and 482 and the outer tabs 484 and
486 are bent at the
bend line 476, an end of a point of each of those tabs can be positioned
0.4375 inches or another
number of inches away from the second intermediate portion 492.
101331 As an alternative to inserting the lower base portion 488 into a milled
portion of a box-
frame segment, joist, or joist segment, the lower base portion 488 of the deck-
clip 460 can be
inserted into a deck-clip slot at any end of a box-frame segment, such as the
deck-clip slot 419
shown in FIG. 26, or the deck-clip slot at any end of a joist or joist
segment, such as the deck-
clip slot 683 shown in FIG. 26. The aforementioned ends of the box-frame
segment, joist, or
joist segment refer to the opposite ends of the box-frame segment, joist, or
joist segment,
longitudinally. The other deck-clips described herein can also be inserted
into deck-clip slots in
the foregoing manner or through a milled portion, such as the milled portion
541. Moreover,
multiple deck-clips can be inserted into a deck-clip slot at any end of a box-
frame segment, joist,
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or joist segment before the box-frame segment is attached to another box-frame
segment or
before the joist or joist segment in inserted into a box frame.
E. EXTRUSIONS
[0134] Next, FIG. 26 illustrates example extrusions for use within a box-
frame, a joist
assembly, or otherwise within a deck system. In particular, FIG. 26 shows a
box-frame-segment
assembly 401 including a box-frame-segment 403 and a box-frame-segment
attachment 405.
The box-frame-segment 403 can include an extrusion produced from a first
extrusion die and the
box-frame-segment attachment 405 can include an extrusion made from a second
extrusion die.
The features of those extrusions can be uniform over the entirety of the
respective extrusions
prior to performance of any milling, drilling or other operation to the
extrusions. The box-frame-
segments 101A, 102A, 103A, and 104A shown in FIG. 25 are examples of box-frame-
segments
that can include a profile like the box-frame-segment 403.
[0135] The box-frame-segment 403 includes a vertical element 407, a base
horizontal element
409, a top horizontal element 411, a top horizontal element 413, a top
horizontal element 415,
and a locking-tab 195. The box-frame-segment 403 includes a deck-clip slot 419
and deck screw
splines 422 accessible through the deck-clip slot 419 between the horizontal
element 413 and the
horizontal element 415. Adjacent to the horizontal element 415 is a locking-
tab slot 431 adapted
to accept a locking-tab 435 on the box-frame-segment attachment 405. The box-
frame-segment
403 includes a locking-tab 595 at an end of the horizontal element 409 adapted
to be positioned
within a locking-tab slot 447 on the box-frame-segment attachment 405.
[0136] A perimeter-trim-piece slot 417 is positioned between the horizontal
element 411 and
the horizontal element 413. The perimeter-trim-piece slot 417 includes a
vertical slot extending
from between the top horizontal elements 411 and 413 and a horizontal slot
extending from the
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vertical slot to beneath the horizontal element 413. As an example, the
vertical slot can be 0.125
inches and the horizontal slot can be 0.25 inches. A perimeter-trim-piece can
be inserted into the
perimeter-trim-piece slot 417 to cover edges of deck boards positioned upon a
deck system
including the box-frame-segment assembly 401.
101371 The box-frame-segment 403 can include a reinforcement shelf 421 to
support a
reinforcement element 423 within the box-frame-segment assembly 401. As shown
in FIG. 26,
an upper portion of the reinforcement element 423 can be positioned within a
reinforcement
guide 427 formed, in part, by and between the vertical element 407 and a
vertical element 425.
Any reinforcement element described herein can include an L-shaped piece of
aluminum or
some other metal. The L-shaped reinforcement element can include a vertical
portion that
extends from an upper surface 451 of the reinforcement shelf 421 to a position
within the
reinforcement guide 427. The reinforcement shelf 421 includes a lower surface
453. A box-
frame perimeter including the box-frame-segment 403 can be used without the
reinforcement
element 423. Placement of the reinforcement element 423 within the
reinforcement guide 427
and onto the reinforcement shelf 421 allows the reinforcement element 423 to
be locked into the
reinforcement guide 427. A reinforcement element locked into a reinforcement
guide can be
unlocked (e.g., removed) by applying sufficient forces to one or both of the
reinforcement
element and the box-frame-segment having the reinforcement guide.
101381 The box-frame-segment attachment 405 includes a vertical element 455, a
top
horizontal element 437 extending from the vertical element 455 to the locking-
tab 435. The box-
frame-segment attachment 405 includes a horizontal element 445 extending away
from the
vertical element 455 and the locking-tab 443 extending away from the
horizontal element 445 so
as to form the locking-tab slot 447. The box-frame-segment attachment 405
includes an uplift
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clip shelf 479 for supporting an uplift clip 449. Use of the uplift clip 449
can prevent removal of
the box-frame-segment attachment 405 from the box-frame-segment 403. Removal
of the uplift
clip 449 from a box-frame perimeter, such as the box-frame-segment assembly
401, allows for
the box-frame-segment attachment 405 to be removed from a box-frame-segment
403.
101391 FIG. 26 shows a box-frame-segment assembly 461 including a box-frame-
segment 463,
a box-frame-segment attachment 465, a reinforcement element 467, and an uplift
clip 469. The
box-frame-segment 463 is identical to the box-frame-segment 403 except that
the box-frame-
segment 463 includes a reinforcement fin 471. As shown in FIG. 26, the
reinforcement fin 471
extends from a vertical element 473 that includes one portion of the deck
screw spline 422 down
to the horizontal element 409. As an example, the reinforcement fin 471 can
have a thickness of
0.125 inches and a length of 4.125 inches. The box-frame-segment attachment
465 can be
identical to the box-frame-segment attachment 405. The uplift clip 469 can be
identical to the
uplift clip 449. In one respect, the reinforcement element 467 can be
identical to the
reinforcement element 423. In another respect, the reinforcement element 467
can have a
horizontal element that is shorter than the horizontal portion of the
reinforcement element 423
since the horizontal element of the reinforcement element 467 cannot extend
beyond the
reinforcement fin 471. The box-frame-segments 101A, 102A, 103A, and 104A shown
in FIG.
25 are examples of box-frame-segments that can a profile like the box-frame-
segment 463.
[0140] FIG. 26 shows a box-frame-segment assembly 485 including a box-frame-
segment 487,
a box-frame-segment attachment 489, a reinforcement element 491, an uplift
clip 493, and a
reinforcement fin 495. The box-frame-segment 487 includes an intelinediate
horizontal element
457, a vertical element 497, a vertical element 483, and a base horizontal
element 499. The
portion of the box-frame-segment 487 above the intermediated horizontal
element 457 includes
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the same features as the portion of the box-frame-segment assembly 461 above
the horizontal
element 409. The box-frame-segment assembly 485 includes a locking-tab 511
extending from
the horizontal element 457 and is adapted to be positioned within a locking-
tab slot 597 on the
box-frame-segment attachment 489. The vertical element 497 includes the
vertical element 407
of the box-frame-segment 403. The box-frame-segment 487 is a higher-profile
box-frame-
segment as compared to the box-frame-segments 403 and 463. The box-frame-
segment
attachment 489 can be identical to the box-frame-segment attachments 405 and
465. The uplift
clip 493 can be identical to the uplift clips 449 and 469. The reinforcement
element 491 can be
identical to the reinforcement element 467. The box-frame-segments 101A, 102A,
103A, and
104A shown in FIG. 25 are examples of box-frame-segments that can a profile
like the box-
frame-segment 487.
101411 FIG. 26 shows recessed areas 325, 327 and tabs 329, 331 of a deck-clip
slot within the
box-frame-segment 487. The recessed areas 325, 327 provide an area for a base
of a deck-clip
(or the base and a lower portion of a vertical element of the deck-clip) to be
positioned. The
recessed areas 325, 327 allow a deck-clip installed into the deck-clip slot to
be slid axially within
the deck-clip slot. The tabs 329, 331 correspond to notches of a notched area
333 of a deck-clip.
Portions of the tabs 329, 331 (at a location where the deck-clip is
positioned) can extend within
notches of the notched area 333 of a deck-clip. The tabs 329, 331 prevent an
installed deck-clip
from being lifted upward out of a deck-clip slot as portions of the base of
the deck-clip are
positioned below the tabs 329, 331.
[0142] Other deck-clip slots within the deck components shown in the figures
or described
herein, such as the deck-clip slot 419, can include recessed areas similar to
the recessed areas
325, 327, and can include tabs similar to tabs 329, 331. The description of
the recessed areas and
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tabs of the other deck-clips slots is therefore not repeated with the
description of the other deck-
clip slots.
101431 FIG. 26 also shows a joist assembly 699, a joist assembly 701, and a
joist 703. As
shown in FIG. 26, the joist assembly 699 includes a joist segment 1037 and a
joist segment 433.
The joist segment 1037 includes a vertical element 675, a base horizontal
element 669, a top
horizontal element 685, a top horizontal element 691, a locking tab 693
extending from the top
horizontal element 691, an inner vertical element 677, an inner vertical
element 681, an inner
horizontal element 679 connecting the inner vertical element 677 and the inner
vertical element
681. The locking tab 693, the top horizontal element 691, an inner vertical
element 689, and a
tab 695 form a roll-lock tab receiver 767 into which a roll-lock tab 213 on
the joist segment 433
can be positioned. The joist segment 1037 includes a vertical element 671
extending from the
base horizontal element 669 and a horizontal element 673 extending from the
vertical element
671. The vertical element 671 and the horizontal element 673 foini a tab
retainer for retaining a
locking tab 219 on the joist segment 433. The joist segment 1037 also includes
a screw spline
189 and a screw spline 183.
[0144] The joist segment 433 includes a vertical element 197, a base vertical
element 203, a
locking tab 219 located at an end of the base horizontal element 203. The
joist segment 433
includes a top horizontal element 207, an inner vertical element 439, an inner
horizontal element
211, and a roll-lock tab 213. The roll-lock tab 213, the inner horizontal
element 211 and the
inner vertical element 439 form a roll-lock tab receiver 209 into which the
roll-lock tab 213 can
be positioned. The joist segment 433 also includes a screw spline 201 and a
screw spline 697.
[0145] Assembly of the joist assembly 699 can include positioning the roll-
lock tab 213 into
the roll-lock tab receiver 767 and rotating one or more of the base horizontal
element 669 and the
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base horizontal element 203 towards one another until the locking tab 219
contacts and is
retained by the tab retainer formed by the vertical element 671 and the
horizontal element 673.
The assembly of the joist assembly can include positioning the locking tab 693
into the roll-lock
tab receiver 209.
[0146] As shown in FIG. 26, the joist assembly 701 includes a joist segment
707 and a joist
segment 355. The joist segment 707 includes the same features as the joist
segment 1037 and
includes a reinforcement fin 769 extending from the inner horizontal element
679 to the base
horizontal element 669. The joist segment 707, similar to the joist segment
1037, includes a
deck-clip slot 683 positioned between the top horizontal element 685 and the
top horizontal
element 691. The inner vertical element 677 and the inner vertical element 681
include splines
357 for retaining a deck-clip screw inserted into a deck-clip positioned
within the deck-clip slot
683. The joist segment 355 includes the same features as the joist segment
433. Assembling the
joist assembly 701 can occur in the same manner as assembling the joist
assembly 699.
[0147] As shown in FIG. 26, the joist 703 includes a vertical element 769, a
vertical element
773, a base horizontal element 771, a top horizontal element 1007, and a top
horizontal element
1009. The joist 703 includes a deck-clip slot 1023 positioned between the top
horizontal element
1007 and the top horizontal element 1009. The deck-clip slot 1023 provides
access to screw
splines 1025 formed on an inner vertical element 1029 and an inner vertical
element 1035. An
inner vertical element 1027 and the vertical element 769 and the top
horizontal element 1007
form a reinforcement guide for keeping a reinforcement element 1021 in
position on a
reinforcement shelf 1019. The joist 703 includes screw splines 1011, 1013, and
1015.
[0148] As shown in FIG. 26, the deck system components of the example deck
systems can
include tabs and tab slots on each or two components for locking the two
components together.
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As shown in FIG. 26 and other figures showing tabs and tab slots, a tab or an
element defining a
tab slot (e.g., the roll-lock tab receiver 209 or the locking-tab slot 431)
can be slanted (e.g., non-
perpendicular) with respect to an element from which the slanted element
extends. In particular,
the joist segments 355 and 433 each include a slanted element to form a roll-
lock tab receiver.
[0149] The tabs and tab slots on two components that lock together can include
tabs and tab
slots formed by perpendicular elements only. The box-frame segment assemblies
401, 461, and
485 are examples of deck system components that can include tabs and tab slots
formed by
perpendicular elements only. Alternatively, one or more of the box-frame
segment assemblies
401, 461, and 485 can include a tab or tab slot defined with at least one
slanted element. One or
more of the components described herein as being lockable or locked to another
component can
be unlockable or unlocked from the other component.
[0150] Next, FIG. 44 shows a side view of a joist assembly 771 positioned on a
surface 773.
As shown in FIG. 44, surface 773 is sloped with respect to a horizontal
reference 797.
Alternatively, the joist assembly 771 can be positioned on a surface that is
parallel to the
horizontal reference 797. The surface 773 can be a roof or a portion thereof
(e.g., roof shingles
or asphalt). The roof can be a top portion of a house or some other building.
As an example, the
roof can have a 6/12 pitch or some other pitch. For example embodiments that
pertain to
positioning the joist assembly 771 on a roof, the joist assembly 771 can be
referred to as a roof-
top joist.
[0151] The joist assembly 771 includes a joist 775 and H-bar shims 777, 779,
and 781. The
joist assembly can include a number of H-bar shims other than three, where the
number equals
one, two, or a number greater than three. The H-bar shims 777, 779, and 781
are attached to the
joist 775. In one respect, an H-bar shim can be removably attached to the
joist 775 using one or
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more fasteners. FIG. 44 shows fasteners 783, 785, and 787 for removably
attaching the H-bar
shims 777, 779, and 781, respectively, to the joist 775. The fasteners 783,
785, and 787 can
include a screw or some other type of fastener. In another respect, an H-bar
shim can be non-
removably attached to the joist 775 by welding the H-bar shim to the joist 775
or by another
process. An H-bar shim can be referred to as a support clip or an H-bar
support clip or by some
other term.
[0152] The joist assembly 775 can be one of several joist assemblies
positioned on the surface
773 as part of a structure, such as a roof-top deck. Each of those joist
assemblies can be installed
within a box-frame, such as one of the box-frames described in this
description.
[0153] FIG. 44 shows example dimensions 789, 791, 793, and 795. Dimension 795
represents
a dimension of an H-bar shim. As an example, the dimension 795 can be a
distance between
four inches (0.1016 meters) and eight inches (0.2032 meters) (e.g., six inches
(0.1524 meters)).
Other examples of dimension 795 are also possible. For two or more of H-bar
shims 777, 779,
and 781, the dimension 795 can be identical or may not be identical.
[0154] Dimension 791 represents a longitudinal dimension of the joist 775. As
an example,
the dimension 791 can be thirteen feet (i.e., 3.9624 meters). Other examples
of dimension 791
are also possible.
101551 Dimension 793 represents a distance between the closest surfaces of two
adjacent H-bar
shims on the same joist. As an example, the dimension 793 can be five feet and
six inches (i.e.,
1.9812 meters). In that way, the center lines of two adjacent H-bar shims with
the dimension
795 of six inches would be six feet (1.8288 meters) apart. Other examples of
dimension 793 are
also possible.
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[0156] Dimension 789 represents a height of an H-bar shim extending from a
bottom surface
799 of the joist 775 and the surface 773. For surface 773, dimension 789 at a
surface location
799, at a surface location 801, and at a surface location 803 are different
and can depend on the
pitch of the surface 773. As an example, the dimension 789 for the H-bar shim
777 at the
surface location 801 can be three feet (i.e., 0.9144 meters), the dimension
789 for the H-bar shim
779 at the surface location 803 can be two feet (i.e., 0.6096 meters), and the
dimension 789 for
the H-bar shim 781 at the surface location 805 can be 1 foot (i.e., 0.3048
meters). Other
examples of the dimension 789 for H-bar shims 777, 779, and 781 are also
possible.
[0157] In an alternative arrangement, the joist 775 can be oriented in an
arrangement in which
the joist 775 is perpendicular to the arrangement of the joist 775 as shown in
FIG. 44 and in
which the joist 775 is above the surface location 803 but is not above the
surface locations 801
and 805. A second joist can extend parallel to the joist 775 and above the
surface location 801
and a third location can extend parallel to the joist 775 and above the
surface location 805. In
this alternative arrangement, a joist assembly including the joist 775 can
include multiple H-bar
shims that are a common first height, a joist assembly including the second
joist can include
multiple H-bar shims that are a common second height greater than the first
height, and a joist
assembly including the third joist can include multiple H-bar shims that are a
common third
height less than the first height.
[0158] Next, FIG. 42 shows a section view of a joist assembly 725 including a
joist 727 and an
H-bar shim 729. The H-bar shim 729 includes a horizontal element 731, a
vertical element 733,
and a vertical element 735. A thickness of the horizontal element 731, the
vertical element 733
and the vertical element 735 can be a uniform thickness such as 0.125 inches
(0.003175 meters).
Different examples of the uniform thickness are also possible. In an
alternative arrangement, the
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horizontal and vertical elements of the H-bar shim 729 may not have a uniform
thickness. The
joist assembly 775 shown in FIG. 44 can be arranged like the joist assembly
725.
101591 The vertical element 733 includes a bottom surface 715 and a top
surface 713. The
vertical element 735 includes a bottom surface 717 and a top surface 711. The
top surfaces 711
and 713 can be formed by milling (e.g., cutting) portions of the vertical
elements 735 and 733,
respectively, above the horizontal element 731. Milling the vertical elements
735 and 733 can be
performed to allow the joist 727 to be level or substantially level when
positioned on a pitched
roof or other inclined surface.
101601 The H-bar shim 729 can have various dimensions, some of which are shown
in FIG. 42.
A dimension 719 represents a dimension from the bottom surfaces 715 and 717 to
a bottom
surface of the horizontal element 731. The dimension 719 may be identical for
each H-bar shim
installed within a joist (e.g., H-bar shims 777, 779, and 781 shown in FIG.
44). A dimension 721
represents a dimension from an upper surface of the horizontal element 731 to
the top surfaces
711 and 713. A dimension 723 represents a dimension from the bottom surfaces
715 and 717 to
the top surfaces 711 and 713. The dimensions 721 and 723 may be different for
each H-bar shim
installed within a joist (e.g., H-bar shims 777, 779, and 781).
101611 The joist 727 a top horizontal element 749, a top horizontal element
751, a horizontal
element 757, an outer vertical element 753, an outer vertical element 755, an
inner vertical
element 759, an inner vertical element 761, an inner vertical element 763, an
inner vertical
element 765, a screw spline 737, and a screw spline 739. The top horizontal
elements 749 and
751 can be separated to form a narrow portion of a deck-clip slot 745. The
inner vertical
elements 759 and 763 can be recessed from edges of the top horizontal elements
749 and 751 so
as to form a wider portion of the deck-clip slot 745. The inner vertical
elements 761 and 765 can
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be separated at a distance to form a deck screw spline 747 for retaining deck
screws driven into
the deck screw spline 747.
[0162] Through-holes can be drilled through the outer vertical elements 753
and 755 and the
vertical elements 733 and 735. Fasteners 741 can be inserted through those
through-holes to
releasably attach the joist 727 to the H-bar shim 729.
[0163] An angle clip 552 can be positioned within a recessed area of the joist
727 formed
between tabs 556 and 558. The angle clip 552 can be removably fastened to the
joist 727 by a
fastener 564 extending into the screw spline 739. The angle clip 552 can be
removable fastened
to an attachment element 572 by a fastener (not shown) positioned within
attachment hole 568.
As an example, the attachment element 572 can include a joist spacer or brace
positioned
between the joist 727 and another joist within a box-frame perimeter. That
other joist can be
configured like the joist 727.
101641 An angle clip 554 can be positioned within a recessed area of the joist
727 formed
between tabs 560 and 562. The angle clip 554 can be removably fastened to the
joist 727 by a
fastener 566 extending into the screw spline 737. The angle clip 554 can be
removable fastened
to an attachment element 574 by a fastener (not shown) positioned within
attachment hole 570.
As an example, the attachment element 574 can include a joist spacer or brace
positioned
between the joist 727 and another joist within a box-frame perimeter. That
other joist can be
configured like the joist 727. In another arrangement, the attachment elements
572 and 574 can
include a single element such as a box-frame segment (e.g., box frame segment
104A). The
fastener 564 and the fastener positioned within the attachment hole 568 can
include any of the
fasteners described herein or another fastener. The fasteners 564 and 566 and
the fasteners
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positioned within the attachment holes 568 and 570 can include any of the
fasteners described
herein or another fastener.
101651 Next, FIG. 43 shows a joist assembly 845 with a ceiling gutter 829. The
joist assembly
includes a joist segment 847 and a joist segment 849. The joist segment 847
includes the ceiling
gutter 829, a vertical element 851, a top horizontal element 853, a top
horizontal element 855, a
horizontal element 857, a locking tab vertical member 859, a locking tab
horizontal member 861,
an inner vertical element 897, an inner vertical element 899, an inner
vertical element 911, an
inner vertical element 913, a vertical element 893, an inner horizontal
element 915, an inner
horizontal element 919, an inner horizontal element 823, a horizontal element
895, and screw
splines 863 and 865. The vertical element 893, the top horizontal element 855,
the inner vertical
element 913, and the horizontal element 895 form a roll-lock tab receiver 921
adapted for
receiving a roll-lock tab of a joist segment, such as joist segment 849.
[0166] The joist segment 849 includes a vertical element 931, a top horizontal
element 933, an
inner vertical element 935, an inner horizontal element 937, a roll-lock tab
939, a screw spline
941, a screw spline 943, a bottom horizontal element 945, and a locking tab
947.
[0167] The ceiling gutter includes a horizontal element 869 and a vertical
element 867
extending from the horizontal element 857 to the horizontal element 869. A
vertical element 871
extends away from the horizontal element 869 towards, but stopping short, of
the horizontal
element 857. A vertical element 873 is similarly situated on the opposite side
of the horizontal
element 869.
[0168] A gasket gap protrusion including a gasket gap 923 extends inward from
the vertical
element 871 towards the vertical element 867. Similarly, a gasket gap
protrusion including a
gasket gap 925 extends inward from the vertical element 873 towards the
vertical element 867.
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A ceiling panel gap 929 is formed between the bottom horizontal element 945
and the gasket gap
protrusion including the gasket gap 925. A ceiling panel gap 927 is formed
between the
horizontal element 857 and the gasket gap protrusion including the gasket gap
923. As an
example, the ceiling panel gaps 927 and 929 can include a gap between 0.0625
inches and 0.25
inches. A rubber gasket or otherwise can be inserted into the gasket gaps 923
and 925. The
gasket can include a wedge gasket. A ceiling panel can be inserted into each
of the ceiling panel
gaps 927 and 929 and into ceiling gaps of a ceiling gutter on an adjacent
joist assembly or box-
frame-segment. After a ceiling panel is inserted into the ceiling panel gaps,
a spacer, such as a
W-shaped spacer, can be inserted in between the vertical element 867 and the
installed ceiling
panel.
101691 The features of the ceiling gutter 829 extending from the horizontal
element 857 can be
included with a different joist or joist segment described herein. For
example, the features
extending from the horizontal element 857 can extend from the base horizontal
element 669 of
the joist segment 1073 and the joist segment 707 (as the joist segment 707
includes the features
of the joist segment 1073) (shown in FIG. 26). As another example, the
features extending from
the horizontal element 857 can extend from the base horizontal element 771 of
the joist 703
shown in FIG. 26.
101701 Next, FIG. 8 shows profiles of example extrusions 800 and 825 of
various components
of the example deck systems. The extrusion 800 includes vertical surfaces 801
and 802,
horizontal surfaces 803, 804 and 806, a locking tab 805, an angle-clip shelf
110, an angle-clip
slot 111, a roll-lock-tab receiver 809, and a roll-lock tab 810. Each of those
elements of the
extrusion 800 can extend along an entire length of the extrusion 800 or a
component having a
profile like the extrusion 800.
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=
[0171] The horizontal surface 804 is at a top side of the extrusion 800. The
horizontal surface
803 is at a bottom side of the extrusion 800. The angle-clip shelf 110 or the
angle-clip slot 111
can be configured for guiding an angle-clip, such as the angle-clip 105,
within deck assembly
components or extrusions having a profile like the extrusion 800. An angle
clip 105 can be
positioned within the angle-clip slot 111 or outside of and below the angle-
clip slot 111.
[0172] The extrusion 825 includes the vertical surfaces 826 and 827, the
horizontal surfaces
828, 829, 830, 833 and 838, long roll-lock tabs 834 and 840, screw splines (or
self-tapping
raceways) 831 and 832, a threaded screw slot 835, a roll-lock-tab receiver
836, a deck-clip slot
837, a locking tab edge 841, and a locking tab retainer 839. Each of those
elements of the
extrusion 825 can extend along an entire length of the extrusion 825 or a
component having a
profile like the extrusion 825.
[0173] The horizontal surfaces 829 and 830 are at a top side of the extrusion
825. The
horizontal surface 828 is at a bottom side of the extrusion 825. Deck-clips,
such as deck-clips 5,
can be inserted into the deck-clip slot 837. A fastener placed through deck-
clip 5 and into
threaded screw slot 835 can fasten the deck-clip 5 to the extrusion 825 or a
component having a
profile like the extrusion 825.
[0174] Next, FIG. 21 shows profiles of example the extrusions 850 and 875 used
for various
components of the example deck systems. The extrusion 850 comprises the same
elements as
the extrusion 825 except that the extrusion 850 includes short roll-lock tab
843 instead of long
roll-lock tab 834. The extrusion 825 and the extrusion 850 can be formed from
separate and
different extrusion dies. Alternatively, the extrusion 850 can be formed by
milling the extrusion
825 to modify the long roll-lock tab 834 to be a short roll-lock tab 843. As
an example, the long
roll-lock tabs 834 or 840 can be or about twice as long (i.e., 2X), three
times as long (i.e., 3X),
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four times as long (i.e., 4X) or five times as long (i.e., 5X) as the short
roll-lock tab 843. As
another example, the long roll-lock tabs 834 or 840 can be within a range of
1.1 (i.e., 1.1X) to 5
times (i.e., 35X) longer than the short roll-lock tab 843. As yet another
example, the short roll-
lock tab 843 can be 1/8 inches long and the long roll-lock tabs 834 or 840 can
be 3/8 to 1/2
inches long. The length of the short roll-lock tab 843 can be a length that
allows a joist assembly
including a joist spacer or segment having a profile like the extrusion 850 to
be snapped into an
end of a box-frame assembly and secured within the box-frame assembly, yet
allow for
subsequent removal of that joist assembly from the box-frame assembly.
101751 The extrusion 875 includes horizontal surfaces 876 and 879, vertical
surfaces 877 and
878 of a vertical riser 891 extending between the horizontal surfaces 876 and
879, angle clip
shelves 886 and 887, angle clip slots 884 and 885, locking tabs 888 and 889,
roll-lock tab
receivers 880 and 881, and roll-lock tabs 882 and 883. Each of those elements
of the extrusion
875 can extend along an entire length of the extrusion 875 or a component
having a profile like
the extrusion 875. The horizontal surface 879 is at a top of the extrusion
875. The horizontal
surface 876 is at a bottom of the extrusion 875.
[0176] Next, FIG. 23 shows a profile 2300 of the extrusion 800 and the
extrusion 825
connected to one another. Connecting the extrusions 800 and 825 to one another
can include
bringing the locking tab 805 into contact with the locking tab retainer 839,
and then rotating one
or more of the extrusions until the roll-lock tab 810 is positioned within the
roll-lock-tab receiver
836 and the roll-lock tab 833 is positioned within the roll-lock-tab receiver
809. The long toll-
lock tab 834 can provide for a more secured connection of the extrusions 800
and 825.
Alternatively, the roll-lock tab 810 can be positioned within the roll-lock-
tab receiver 836 and
the roll-lock tab 833 can be positioned within the roll-lock-tab receiver 809
and then one or more
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of the extrusions can be rotated until locking tab 805 contact and attaches to
the locking tab
retainer 839.
F. POST BRACKETS
[0177] Next, FIG. 9 shows a partial section view 900 of a portion of a box-
frame assembly
attached to a post 10, and a deck board 6 attached to the box-frame assembly
using a deck-clip 5
and a deck-clip screw 92. The deck screw 92, if used, can include a 0.75 inch
long No. 10 sheet
metal screw with a Phillips head, and a 24 threads per inch rating. Other
examples of the deck-
clip screw 92 are also possible. The box-frame assembly can be configured like
box-frame
assembly 100 or the box-frame assembly of the deck system 341.
[0178] The section view 900 shows the post 10 positioned within and attached
to an
intermediate-post bracket 9 using fasteners 903. The fasteners 903 can include
a flat-head
fastener, such as a flat-head screw. Dimensions 905, 906, and 907 are provided
to provide
perspective with respect to the intermediate-post bracket 9. The dimensions
905 and 907 can
represent a thickness of elements and the dimension 906 can represent a length
of an opening
within the intermediate-post bracket 9. As an example, the dimensions 905 and
907 can be three
sixteenths of an inch (i.e., 3/16") or some other number of inches. As another
example, the
dimension 906 can be three and nine sixteenths inches (i.e., 3 - 9/16") or
some other number of
inches.
101791 FIG. 9 shows a joist or box-frame-segment 917 comprising an extrusion
908 configured
like the extrusion 800 and an extrusion 909 configured like the extrusion 825.
The extrusions
908 and 909 can attach together similar to the manner in which the extrusions
800 and 825 are
attached as described with respect to FIG. 23. FIG. 9 shows an angle clip 105
attached to the
extrusion 908 using fasteners 901. The fasteners 901 can include number 10 by
1 inch (i.e., #10
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x 1") flat head screws with a lock washer and nut. FIG. 9 shows fasteners 305
within screw
splines, such as screw splines 831 and 832 shown in FIG. 8. The fasteners 305
can be positioned
within screw splines of one or more extrusions, such as the extrusions of a
joist spacer and into a
joist segment.
101801 FIG. 9 shows details of the intermediate-post bracket 9, which is shown
in several other
figures as well. The intermediate-post bracket 9 comprises a long side 938,
short sides 934 and
936, another short side (not shown) opposite short side 934 and between the
long side 938 and
the short side 936, and a post-opening 950. The long side 938 includes
attachment holes 940,
942, 944. The short side 934 includes attachment hole 946. The short side 936
includes
attachment hole 948. The short side opposite short side 934 can include an
attachment hole at a
position similar to attachment hole 946. The short sides 934 and 936 can have
a height
dimension 954 of 2 inches or some other number of inches. The long side 938
can have a height
dimension 952 of 4 inches or some other number of inches above the upper
surface of the short
sides 934, 936.
101811 A portion of a post, such as the post 10, can be inserted into a post-
opening 950.
Fasteners, such as the fasteners 903, can be inserted into holes 944, 946, and
948 and an
attachment hole on short side opposite the short side 934 to secure the corner-
post bracket 9 to
the post 10. A box-frame-segment, such as box-frame-segment 102, positioned
above post-
opening 950 can be attached to the corner-post bracket 9 using fasteners, such
as the fasteners
901, placed into attachment holes 940 and 942.
[01821 FIG. 9 also shows details of corner-post bracket 8, which is shown in
several other
figures described herein. The corner-post bracket 8 comprises long sides 910
and 912, short
sides 914 and 916, a post-opening 928, attachment holes 918, 920 and 922 on
long side 912,
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attachment hole 924 on short side 914, and attachment hole 926 on short side
916. The long side
910 can include attachment holes in arrangement similar to the attachment
holes on the long side
912. The short sides 914 and 916 can have a height dimension 930 of 2 inches
or some other
number of inches. The long sides 910 and 912 can have a height dimension 932
of 4 inches or
some other number of inches above the upper surface of the short sides 914 and
916.
[0183] A portion of a post, such as the post 10, can be inserted into the post-
opening 928. The
fasteners, such as the fasteners 903, can be inserted into the attachment
holes 922, 924 and 926
and an attachment hole on the long side 910 to secure the corner-post bracket
8 to the post 10.
Two box-frame-segments, such as the box-frame-segments 101 and 102, positioned
above the
post-opening 928 can be attached to the corner-post bracket 8 using fasteners,
such as the
fasteners 901, placed into the attachment holes 918 and 920 or similarly
positioned attachment
holes within the long side 910.
[0184] Next, FIG. 10 shows a partial section view 1000 of a portion of a box-
frame assembly
attached to a post 10 and a deck board 6. The box-frame assembly can be
configured like the
box-frame 100.
[0185] Section view 1000 shows the post 10 positioned within and attached to
the
intermediate-post bracket 62 using the fasteners 903. Dimensions 1004, 1006,
1008, and 1010
are provided to provide perspective with respect to the intermediate-post
bracket 62. The
dimensions 1004 and 1008 can represent a thickness of elements and the
dimension 1006 can
represent a length of an opening within the intermediate-post bracket 62. The
dimension 1010
can represent a length (e.g., a height) of a short element of the intermediate-
post bracket 62. The
dimensions 1004 and 1008 can be three sixteenths of an inch (i.e., 3/16") or
some other number
of inches. The dimension 1006 can be three and nine sixteenths inches (i.e., 3
9/16") or some
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other number of inches. The dimension 1010 can be two inches (i.e., 2") or
some other number
of inches.
[0186] FIG. 10 shows a joist or box-frame-segment 1017 comprising an extrusion
1016
configured like the extrusion 800 and an extrusion 1018 configured like the
extrusion 825.
Extrusions 1016 and 1018 can attach to together similar to the manner in which
the extrusions
800 and 825 are attached as described with respect to FIG. 23. FIG. 10 shows
fasteners 305
within screw splines, such as the screw splines 831 and 832 of a joist spacer
and into a joist
segment.
[0187] The intermediate-post bracket 62 includes a portion that abuts joist or
box-frame-
segment 1017 and a portion above joist or box-frame-segment 1017. A post 60
can be
positioned within support ring 1012 and above a support bracket 1014 attached
to box-frame-
segment 1017 using one or more deck screws 92. The support ring 1012 can
include attachment
holes 1030, 1048, 1056, and 1058. The support ring 1012 and the support
bracket 1014 can be
made of aluminum or another material. The support bracket 1014 can be
configured as an L-
bracket that includes attachment holes 1031 and 1033. One or more fasteners
903 can attach the
intermediate-post bracket 62 and the support ring 1012 to the post 60. One or
more fasteners 903
can attach the support ring 1012 and the support bracket 1014 to the post 60.
[0188] FIG. 10 shows details of the intermediate-post bracket 62, which is
shown in several
other figures as well. The intermediate-post bracket 62 comprises a long side
1038, short sides
1040 and 1046, another short side (not shown) opposite short side 1040 and
between long side
1038 and short side 1046, and a post-opening 1050. The long side 1038 includes
attachment
holes 1032, 1034, and 1036, and another attachment hole in line with the
attachment hole 1030
of the support ring 1012. The short side 1040 includes the attachment hole
1042. The short side
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1046 includes the attachment hole 1044. The short side opposite the short side
1040 can include
an attachment hole at a position similar to attachment hole 1042. The short
sides 1040 and 1046
can have a height dimension 1010, as previously discussed. The long side 1038
can have a
height dimension 1061 equal to eight inches or some other number of inches.
The support ring
1012 can have a height dimension 1060 equal to two inches or some other number
of inches.
The dimension 1062 can represent a space between the short side 1040 and the
support ring
1014. The dimension 1062 can equal four inches or some other number of inches.
[0189] A portion of a post, such as the post 10, can be inserted into the post-
opening 1050.
The fasteners, such as fasteners 903, can be inserted into the holes 1036,
1042, 1044, and an
attachment hole on the short side opposite the short side 1040 to secure the
intermediate-post
bracket 62 to the post 10. A joist or box-frame-segment 1017, positioned above
the post-opening
1050 can be attached to the intermediate-post bracket 62 using fasteners, such
as fasteners 901,
placed into the attachment holes 1032 and 1034.
[0190] FIG. 10 also shows details of the corner-post bracket 64, which is
shown in several
other figures described herein. The corner-post bracket 64 comprises long
sides 1078 and 1096,
short sides 1080 and 1086, and a post-opening 1081. The long side 1078
includes attachment
holes 1072, 1074, and 1076, and another attachment hole in line with
attachment hole 1070 of
support ring 1094. The short side 1080 includes an attachment hole 1082. The
short side 1086
includes an attachment hole 1084. The long side 1096 can include attachment
hole 1098 and
other attachment holes arranged like the attachment holes on the long side
1078. The short sides
1080 and 1086 can have a height dimension 1099 equal to two or some other
number of inches.
The long sides 1078 and 1096 can have a height dimension 1093 of eight or some
other number
of inches. The support ring 1094 can have a height dimension 1095 equal to two
or some other
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number of inches. Dimension 1097 can represent a space between short side 1080
and support
ring 1094. Dimension 1097 can equal four or some other number of inches.
[0191] A portion of a post 10 can be positioned within the post-opening 1081.
Fasteners, such
as fasteners 903, can be inserted into the attachment holes 1076, 1082, 1084,
and an attachment
hole on the long side 1096 to secure the corner-post bracket 62 to the post
10. A joist or box-
frame-segment 1017, positioned above post-opening 1081 and below support ring
1096, can be
attached to the corner-post bracket 62 using the fasteners 903 placed into the
attachment holes
1072, 1074 and similarly positioned holes on the long side 1096.
[0192] The intermediate-post bracket 64 includes a portion that abuts joist or
box-frame-
segment 1017 and a portion above joist or box-frame-segment 1017. A post 60
can be
positioned within the support ring 1092. The support ring 1092 can include
attachment holes
1070, 1088, 1092, and an attachment hole in line with the attachment hole
1096. The support
ring 1092 can be made of aluminum or another material. One or more fasteners
903 can attach
the intermediate-post bracket 62 and the support ring 1092 to the post 60.
[0193] Next, FIG. 29 shows details of a corner post (or corner bracket) 959
attached to a
structure 953. As an example, the corner post (or corner bracket) 959 can
include a 4 inch x 4
inch by 0.25 inch aluminum post or a bracket within which a 4 inch x 4 inch
post can be inserted.
Any 4 inch x 4 inch dimensions referred to herein can be replaced by a 6 inch
x 6 inch dimension
or some other dimension. The height of the corner post (or corner bracket) 959
in post form, as
with any other post described herein can depend, in part, upon an elevation
above the ground at
which a deck is being installed. The height of the corner post (or corner
bracket) 959 in bracket
form can be a fixed height for all instances and the height of posts installed
into the brackets can
be varied to provide the desired deck height. The corner post (or comer
bracket) 959 is attached
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"
to the box-frame-segment 104A and to the box-frame-segment 101A using
fasteners 957 (e.g., 'A
- 20 x 1.5 inch long flathead sheet metal screws with nut and lock washer). As
shown in FIG. 29
and other figures, the box-frame-segment 104A is attached to the structure 953
using a fastener
1310 and may be separated from the structure 953 by one or more shims 1306.
The box-frame-
segment cover 199 and the joist spacer 175 are attached to box-frame-segments
101A and 104A,
respectively, below the deck boards 961 and 963, which are separated by a 90
deck-clip 515.
101941 FIG. 29 shows details of an intermediate post (or intermediate bracket)
949 (i.e., a post
or bracket not in a corner of a deck system). The intermediate post (or
intermediate bracket) 949
can include a 4 inch x 4 inch by 0.25 inch aluminum post. The intermediate
post (or
intermediate bracket) is centered with respect to a joist 951 and is adjacent
to the structure 953.
The intermediate post (or intermediate bracket) 949 is attached to the box-
frame-segment 104A
using fastener(s) 957. The joist 951 can include any of the joists, joist
segment, joist spacers, or
joist assemblies described herein as attaching to the box-frame-segment 104A.
The deck boards
961 and 963 are separated by another instance of a 90 deck-clip 515.
101951 FIG. 29 shows details of a corner post (or corner bracket) 971. The
corner post (or
corner bracket) 971 can include a 4 inch x 4 inch by 0.25 inch aluminum post.
The corner post
or bracket (or corner bracket) 971, like other posts, can include four sides,
such as sides 253,
255, 259, and 261. The corner post (or corner bracket) 971 is attached to the
box-frame-segment
101A and to the box-frame-segment 102A using fasteners 957. Since the box-
frame-segments
101A and 102A are not directly attached to the structure 953, the corner post
(or corner bracket)
971 can be referred to as an independent corner post. The box-frame-segment
cover 199 and the
joist spacer 177 are attached to box-frame-segments 101A and 102A,
respectively, below the
deck boards 973 and 975, which are separated by another instance of a 90 deck-
clip 515.
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101961 FIG. 29 shows details of an intermediate post (or intermediate bracket)
977. The
intermediate post (or intermediate bracket) 977 can include a 4 inch x 4 inch
by 0.25 inch
aluminum post. The intermediate post (or intermediate bracket) 977 is centered
with respect to a
joist 979. The intermediate post (or intermediate bracket) 977 is attached to
the box-frame-
segment 102A using a fastener(s) 957. Since the box-frame-segment 102A is not
directly
attached to the structure 953, the intermediate post (or intermediate bracket)
977 can be referred
to as an independent intermediate post. The joist 979 can include any of the
joists, joist segment,
joist spacers, or joist assemblies described herein as attaching to the box-
frame-segment 102A.
The deck boards 973 and 975 are separated by another instance of a 90 deck-
clip 515.
101971 The lower portion of FIG. 29 shows aspects of some of the deck
components shown in
FIG. 29. In particular, the lower left portion of FIG. 29 shows a sectional
view of the comer post
(or corner bracket) 971, the box-frame-segment 102A, and the joist spacer 177.
The comer post
(or corner bracket) 971 includes a bearing area 989 at which a load of the box-
frame-segment
102A, the joist spacer 177, and the joist spacer 199 contacts the comer post
(or corner bracket)
971.
(0198] In one respect, the comer post (or comer bracket) 971 can include a
single partial side
that is concealed by the box-frame-segments to which the comer post (or corner
bracket) 971 is
attached. A bottom portion 993 of the box-frame-segment 102A and a portion of
the
reinforcement shelf 421 (not shown) at location 263 can be milled to allow an
upper part of the
side 253 of the comer post (or corner bracket) 971 to be positioned within the
box-frame-
segment 102A. In this way, an upper part of the side 253 of the comer post (or
corner bracket)
971 is concealed within the box-frame-segment 102A.
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[0199] In another respect, the corner post (or corner bracket) 971 can include
multiple partial
sides that are concealed by the box-frame-segments to which the corner post
(or corner bracket)
971 is attached (e.g., the upper part of the side 253 can be concealed by the
box-frame-segment
102A and an upper part of the side 251 can be concealed by the box-frame-
segment 101A. The
box-frame-segment 101A can be milled at a bottom portion of the box-frame-
segment 101A
similar to the bottom portion 993, and at a portion of the reinforcement shelf
421 of the box-
frame-segment 101A to allow the upper part of the side 251 to be positioned
within the box-
frame-segment 101A.
[0200] A top portion of the upper part of the side of a post (or post bracket)
inserted into a box-
frame-segment can be inserted into a reinforcement guide, such as the
reinforcement guide 427,
of a box-frame-segment. The reinforcement guide can have a width slightly
larger than a width
of the side of the post such that the side of the post can effectively lock
into the reinforcement
guide. The side of a post (or post bracket, or reinforcement element or corner
angle clip) locked
into a reinforcement guide can be unlocked (e.g., removed) by applying
sufficient forces to one
or both of the post and the box-frame-segment having the reinforcement guide.
Top portions of
one or more sides of other posts (or post bracket, or reinforcement element or
corner angle clip)
described herein or used in an example deck system can also be locked into and
unlocked from a
reinforcement guide of a box-frame-segment. Attachment holes 141 are milled
within the
reinforcement fin 995 to allow for positioning the fasteners 957 that are used
to attach the box-
frame-segment 102A to the corner post (or corner bracket) 971.
[0201] The lower right portion of FIG. 29 shows other aspects of some of the
deck components
shown in FIG. 29. In particular, FIG. 29 shows the corner post (or comer
bracket) 959, the box-
frame-segment 101A, and the fasteners 957. A bottom portion 997 of the box-
frame-segment
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101A is milled to allow an upper wall section of the corner post (or corner
bracket) 959 to be
positioned within the box-frame-segment 101A. The upper wall section of the
corner post (or
corner bracket) 959 is releasably attached to the box-frame-segment 101A using
the fasteners
957.
[0202] Next, the top of FIG. 30 shows details of the intermediate post (or
intermediate bracket)
363 of the deck system 341 shown in FIG. 25. The intermediate post (or
intermediate bracket)
363 is offset with respect to the joists 347 and 349 and is adjacent to the
structure 953. The
inteimediate post (or inteiniediate bracket) 363 can include a 4 inch x 4 inch
by 0.25 inch
aluminum post. The intermediate post (or intermediate bracket) 363 is attached
to the box-
frame-segment 104A using the fastener(s) 957. FIG. 30 shows the deck boards
961 and 963
separated by a gap 967. The gap 967 can exist because of the placement of 90
deck-clips 515
rather than the deck-clips 565 and 605 shown in FIG. 25. A joist spacer, such
as the joist spacer
509 shown in FIG. 40, can attach to the box-frame-segment 104A in proximity to
the
intermediate post (or intermediate bracket) 363. That joist spacer can include
an extrusion like
the box-frame-segment attachment 405 shown in FIG. 26.
[0203] Next, the center of FIG. 30 shows details of an intermediate post (or
intermediate
bracket) 981. The intermediate post (or intermediate bracket) 981 is not shown
in the deck
system 341 of FIG. 25, but can be installed within the deck system 341 in
between two joists
such as joists 347 and 349. Installing the intermediate post (or intermediate
bracket) 981 in
between the joists 347 and 349 may permit for omitting the post (or bracket)
369 shown in FIG.
25. The intermediate post (or intermediate bracket) 981 can include a 4 inch x
4 inch by 0.25
inch aluminum post. The intermediate post (or intemiediate bracket) 981 can
attach to the box-
frame-segment 102A using the fastener(s) 957. Since the box-frame-segment 102A
is not
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directly attached to the structure 953, the intermediate post (or intermediate
bracket) 981 can be
referred to as an independent intermediate post. The deck boards 973 and 975
are attached to the
deck system 341 in proximity to the intermediate post (or intermediate
bracket) 981. The deck
boards 973 and 975 are separated by a gap 983 that can exist because of the
placement of 90
deck-clips 515. A joist spacer, such as the joist spacer 507 shown in FIG. 40,
can attach to the
box-frame-segment 102A in proximity to the intermediate post (or intermediate
bracket) 981.
That joist spacer can include an extrusion like the box-frame-segment
attachment 405 shown in
FIG. 26.
[0204] Next, the lower left portion of FIG. 30 shows aspects of some of the
deck components
shown in upper right portion of FIG. 29. In particular, the lower left portion
of FIG. 30 shows
the intermediate post (or intermediate bracket) 949, the box-frame-segment
104A, and the joist
951. The joist 951 includes the joist segment 1037 and the joist segment 433.
A bottom portion
989 of the box-frame-segment 104A can be milled to allow an upper portion of
three wall
sections of the intermediate post (or intermediate bracket) 949 to be
positioned within the box-
frame-segment 104A. A bottom portion of the joist spacers 509 attached to the
box-frame-
segment 104A can also be milled to allow an upper portion 1043 of a respective
wall section of
the intermediate post (or intermediate bracket) 949 to be positioned within
the joist spacers 509.
The milling of the joist spacers 509 and the box-frame-segment 104A allow for
the upper
portions of the intermediate post (or intermediate bracket) 949 to be
concealed.
[0205] Next, the lower right portion of FIG. 30 shows aspects of some of the
deck components
shown in the upper portion of FIG. 30. In particular, the lower right portion
of FIG. 30 shows
the intermediate post (or intermediate bracket) 363 and the box-frame-segment
104A. A bottom
portion 1001 of the box-frame-segment 104A can be milled to allow an upper
portion of three
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wall sections of the intermediate post (or intermediate bracket) 363 to be
positioned within the
box-frame-segment 104A. A bottom portion of the joist spacer 509 attached to
the box-frame-
segment 104A can also be milled to allow an upper portion 1043 of a respective
wall section of
the intermediate post (or intermediate bracket) 363 to be positioned within
the joist spacer 509.
[02061 Next, the upper portion of FIG. 31 shows details in the detail area
1049 of the deck
system 341 shown in FIG. 25. The detail area 1049 shows the box-frame-segment
104A attaches
to the structure 953 using a fastener 1310 and are separated by a shim 1306.
The corner of the
deck system 341 shown in the detail area 1049 includes a corner angle clip
105A where two box-
frame-segments 104A and 103A abut one another. The corner angle clip can be
used with the
box-frame-segments 103A and 104A. The corner angle clip 105A can include or be
formed
from a 4 inch by 4 inch by 0.25 inch by 4 inch piece of aluminum. The corner
angle clip 105A
can attach to the box-frame-segments 103A and 104A using the fasteners 957.
The deck boards
961 and 963 are separated by another instance of a 90 deck-clip 515. A box-
frame-segment
attachment 1047 is attached to the box-frame-segment 104A. A box-frame-segment
attachment
1043 is attached to the box-frame-segment 103A. The box-frame-segment
attachments 1043 and
1047 can include an extrusion having the features of the box-frame-segment
attachment 405.
One or more of the box-frame-segment attachments 1043 and 1047 can be part of
a joist
assembly including the joist 351 shown in FIG. 25.
102071 Next, the center portion of FIG. 31 shows details in the detail area
1051 of the deck
system features 1053 shown in FIG. 25. The detail area 1051 shows the box-
frame-segment
102A and the box-frame-segment 103A and the comer angle clip 105A located
where two box-
frame-segments 102A and 103A abut one another. The corner angle clip can be
used with the
box-frame-segments 103A and 104A. The corner angle clip 105A can include or be
formed
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from a 4 inch by 4 inch by 0.25 inch by 4 inch piece of aluminum. The corner
angle clip 105A
can attach to the box-frame-segments l 02A and 103A using the fasteners 957.
The deck boards
973 and 975 are separated by another instance of a 90 deck-clip 515. A box-
frame-segment
attachment 1045 is attached to the box-frame-segment 102A. A box-frame-segment
attachment
1043 is attached to the box-frame-segment 103A. The box-frame-segment
attachments 1043 and
1045 can include an extrusion having the features of the box-frame-segment
attachment 405.
One or more of the box-frame-segment attachments 1043 and 1045 can be part of
a joist
assembly including the joist 351 shown in FIG. 25.
[0208] Next, the lower left portion of FIG. 31 shows aspects of some of the
deck components
shown in the detail area 1049 of FIG. 31. In particular, the lower left
portion of FIG. 31 shows
an elevation view of the corner angle clip 105A, the box-frame-segment 104A,
and the fasteners
957.
[0209] Next, the lower right portion of FIG. 31 shows aspects of some of the
deck components
shown in the detail area 1051 of FIG. 31. In particular, the lower right
portion of FIG. 31 shows
an elevation view of the corner angle clip 105A, the box-frame-segment 102A,
the box-frame-
segment attachments 1043 and 1045, and the fasteners 957. A top part of the
corner-clip angle
105A can be inserted into the reinforcement guide 427 of the box-frame-segment
102A and
another top part 249 of the corner angle clip 105A can be inserted into the
reinforcement guide
427 of the box frame segment 103A. That insertion and placement onto the
reinforcement shelf
421 can allow for the corner angle clip 105A to be locked into a box-frame-
segment. Corner
angle clips 105A inserted into other box-frame-segments having a reinforcement
guide can also
be locked into and unlocked from a reinforcement guide of those other box-
frame-segments.
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102101 Turning to Fla 32, the upper portion of FIG. 32 shows details in the
detail area 1055
of the deck system features 1053 shown in FIG. 25. The detail area 1055 shows
a post (or
bracket) 1063 attached to the box-frame-segment 101A by the fastener(s) 957
and attached to the
support beam 1061 and the angle clip 105A by fastener(s) 1073, such as 1/4 -
20 x 1.5 inch Philips
head sheet metal screw(s). The post (or bracket) 1063 and the box-frame-
segment 101A can
provide support for deck boards 1065, 1067, and 1069 separated by deck board
gaps 788
provided for by use of the deck-clips 515. The support beam 1061 can include
extrusions having
the features of the box-frame-segment assembly 485 shown in FIG. 26 or can
include features of
a common aluminum shape. The angle clip 105A can be attached to the support
beam 1061
using fastener(s) 957. The support beam 1061 can provide support for the box-
frame-segment
cover 199 attached to the box-frame-segment 101A. Portions of the box-frame-
segment 101A
and the box-frame-segment cover 199 can be milled to allow upper portions of
the post (or
bracket) 1063 to be positioned within and concealed by the box-frame-segment
101A and the
box-frame-segment cover 199.
102111 The lower left portion of FIG. 32 shows an elevation view of elements
shown in the
detail area 1055. In particular, the lower left portion of FIG. 32 shows a
cross section view of
the post (or bracket) 1063, the support beam 1061, the angle clip 105A
positioned within the
support beam 1061, the fasteners 957 that attach the post (or bracket) 1063 to
the box-frame-
segment 101A, and the deck board 1067.
[0212] The lower right portion of FIG. 32 shows another elevation view of
elements shown in
the detail area 1055. In particular, the lower right portion of FIG. 32 shows
the post (or bracket)
1063, the support beam 1061, the angle clip 105A, the box-frame-segment 101A
and the box-
frame-segment attachment 199, and the deck board 1069.
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102131 Turning to FIG. 33, the upper portion of FIG. 33 shows details in the
detail area 1057
of the deck system features 1053 shown in FIG. 25. The detail area 1057 shows
the joist 347, the
support beam 1061, a joist bracket 1075, and a joist bracket 1077. The joist
brackets 1075 and
1077 are attached to the joist 347 and to the support beam 1061 by fasteners
1079. As an
example, the fasteners 1079 can include Phillips head sheet metal screws. The
joist brackets
1075 and 1077 can include a 4 inch x 4 inch x 0.1875 inch x 2 inch clip angle
made of aluminum
or another metal. Other example dimensions of the joist brackets 1075 and 1077
are also
possible. The deck boards 1065, 1067 and 1069 can be positioned on the joist
347 and separated
by the use of the deck-clips 515.
102141 The lower left portion of FIG. 33 shows additional aspects of some of
the deck
components shown in the detail area 1057 by way of an elevation view. In
particular, this
elevation view shows the support beam 1061, the joist 347, the joist bracket
1075, the joist
bracket 1077, the fasteners 1079, the deck board 1067, and a deck-clip 515.
102151 The lower right portion of FIG. 33 shows additional aspects of some of
the deck
components shown in the detail area 1057 by way of another elevation view. In
particular, this
elevation view shows the support beam 1061, the joist 347, the joist bracket
1075, the fasteners
1079, and the deck board 1067.
102161 Turning to FIG. 34, the upper portion of FIG. 34 shows details in the
detail area 1059
of the deck system features 1053 shown in FIG. 25. The detail area 1059 shows
the joist 349, the
support beam 1061, a post (or bracket) 1083, a joist bracket 1087, and a joist
bracket 1089. The
joist brackets 1087 and 1089 are attached to the joist 349 and to the support
beam 1061 by
fasteners 1079. The joist brackets 1087 and 1089 can be configured like the
joist brackets 1075
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and 1077 shown in FIG. 33. The deck boards 1065, 1067 and 1069 can be
positioned on the joist
349 and separated by the use of the deck-clips 515.
[0217] The lower left portion of FIG. 34 shows additional aspects of some of
the deck
components shown in the detail area 1059 by way of an elevation view. In
particular, this
elevation view shows the support beam 1061, the joist 349, the joist bracket
1087, the joist
bracket 1089, the fasteners 1079, the deck board 1067, a deck-clip 515, the
post (or bracket)
1083, and fasteners 957 used to attach the post (or bracket) 1083 to the
support beam 1061. An
area 1085 of the support beam 1061 can be milled to allow an upper portion of
the post (or
bracket) 1083 to be positioned within and concealed by the support beam 1061.
[0218] The lower right portion of FIG. 34 shows additional aspects of some of
the deck
components shown in the detail area 1059 by way of another elevation view. In
particular, this
elevation view shows the support beam 1061, the joist 349, the joist bracket
1087, the fasteners
1079, the deck board 1067, the post (or bracket) 1083, the area 1085 of the
post (or bracket)
1083 is milled to allow the upper portion of the post (or bracket) 1083 to be
positioned within the
support beam 1061. The fasteners 957 are used to attach the post (or bracket)
1083 to the
support beam 1061.
G. ADDITIONAL DECK SYSTEM DETAILS
[0219] Next, FIG. 11 shows a partial section view 1100 through various
portions of the deck
system 704 shown in FIG. 7. The section view 1100 shows a perimeter joist 1102
of the deck
system 704 having a lower surface 1103 and alternative lower surfaces 1104,
1105, and 1106
such that the perimeter joist 1102 can be formed with extrusions of different
heights. The
extrusions having longer heights can be used for longer spans of the perimeter
joist 1102.
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[0220] The perimeter joist 1102 can be formed by attaching an extrusion 1108
to an extrusion
1109. The extrusion 1108 can be configured like the extrusion 800. The
extrusion 1108 can be a
box-frame-segment of the box-frame 100. The extrusion 1108 can be configured
like the
extrusion 825 or the extrusion 850. The extrusion 1108 can be a joist segment
of a joist
assembly, such as the joist assembly 300 or the joist assembly 320. A deck
board 6 is attached to
the perimeter joist 1102 using the deck-clip 5 and a deck-clip screw 92. That
deck board, deck-
clip, and deck-clip screw are not shown in FIG. 7.
[0221] An angle clip 105 attaches to the perimeter joist 1102 and to a joist
spacer 1110 of the
box-frame of deck system 704. The fasteners 903 can fasten the angle clip 105
to the perimeter
joist 1102. In FIG. 11, the fasteners 305 can be positioned within screw
splines, such as the
screw splines 831 and 832 described with respect to FIG. 8. The fasteners 305
can be positioned
within screw splines of one or more extrusions, such as the extrusions of a
joist segment and into
a joist spacer.
[0222] A dimension 1157 pertains to the section view 1100 and to another
section view 1150
shown in FIG. 11. The dimension 1157 represents a height of the perimeter
joist 1102. The
dimension 1157 can equal four or another number of inches. The dimension 1107
represents an
example width of the perimeter joist 1102. The dimension 1107 can equal 1.75
(i.e., 1 3/4) inches
or another number of inches.
[0223] The section view 1150 is another partial section view through the deck
system 704
shown in FIG. 7. The section view 1150 shows details of a multi-joist segment
1151 formed by
joist segments 1159 and 1160. The joist segment 1159 is configured like the
extrusion 800 and
is part of the joist assembly 710. The joist segment 1160 is configured like
the extrusion 825 and
is part of the joist assembly 712. The section view 1150 shows a lower surface
1152 of the
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multi-joist segment 1151 and alternative lower surfaces 1153, 1154, and 1155
of the multi-joist
segment 1151. Extrusions having longer heights can be used for longer spans of
the multi-joist
segment 1151.
102241 A deck board 6 is attached to the multi-joist segment 1151 using the
deck-clip 5 and a
deck-clip screw 92. That deck board, deck-clip, and deck-clip screw are not
shown in FIG. 7.
The multi-joist segment 1151 is attached to the joist spacers 1161 and 1162 of
respective joist
assemblies. The dimension 1156 represents an example width of the multi-joist
segment 1151.
The dimension 1156 can equal 1.75 (i.e., 1 3/4) inches or another number of
inches. A reinforcing
angle 1158 can be used within the multi-joist segment 1151.
102251 Next, FIG. 13 a partial section view 1300 through a portion of the deck
system 704 and
a portion of the joist assembly 708 shown in FIG. 7. FIG. 13 shows the joist
spacer 1308 and a
joist segment 1318 of the joist assembly 708, and the box-frame-segment 1404
of box-frame 100
of the deck system 704. The box-frame-segment 1404 is configured like the
extrusion 800. The
joist spacer 1308 is configured like the extrusion 850. The joist segment 1318
can be configured
like the extrusion 800, the extrusion 825, or the extrusion 850.
102261 The joist spacer 1308 and the box-frame-segment 1404 can attach
securely together at
an attachment point 1316 using the locking tab of the box-frame-segment 1404
and the locking
tab retainer of the joist spacer 1308, and using the roll-lock tab and roll-
lock tab receivers of the
box-frame-segment 1404 and the joist spacer 1308. Fasteners 902 can attach the
joist spacer
130810 the joist segment 1318.
102271 FIG. 13 shows the box-frame-segment 1404 is attached to the structure
702 using
fasteners 1310 and 1312. The fastener 1310 can include a lag screw used
without fastener 1312.
Shims 1306 are positioned between the box-frame-segment 1404 and the external
line of the
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structure 702. The shims 1306 can include through-holes to allow the fastener
1310 to pass
through the shims 1306. Alternatively, the shims 1306 can be positioned
adjacent to the fastener
1310. The fastener 1312 can include a nut that abuts an internal line 1402
representing, for
example, a wall of the structure 702.
[0228] FIG. 13 shows a deck-clip 5 and a deck-clip screw 92 positioned within
the joist spacer
1308. FIG. 13 shows a deck board 6 attachable to the deck system 700, and the
attached box-
frame-segment 1404 and the joist spacer 1308 having a lower surface 1302 or
alternative lower
surfaces 1303, 1304, and 1305. The alternative lower surfaces provide for
longer spans of the
box-frame-segment 1404 and the joist spacer 1308 or for increased loading of
the deck system
700. A dimension 1307 represents an example width of the attached box-frame-
segment 1404
and the joist spacer 1308. The dimension 1307 can equal two inches or another
dimension.
[0229] FIG. 13 also shows a partial section view 1301 for a portion of the
deck systems 704
and 705 shown in FIG. 7. The partial section view 1301 shows the joist spacers
1320 and 1324,
configured like the extrusion 800, and the box-frame-segment 1322, configured
like the
extrusion 875. The box-frame-segment 104 of the box-frame 100 can include the
box-frame-
segment 1322. The joist spacer 1320 can be a joist spacer of the joist
assembly 710. The joist
spacer 1324 can be a joist spacer of the joist assembly 720. The partial
section view 1301 shows
attachment points 1326 and 1328 of the locking tabs of the box-frame-segment
1322 to the
locking tab retainers of the joist spacers 1320 and 1324. The partial section
view 1301 also
shows retaining points 1330 and 1332 of roll-lock tabs of the joist spacers
1320 and 1324 within
roll-lock tab receivers of the box-frame-segment 1322.
[0230] Next, FIG. 14 is a large-scale plan view of a portion 1400 of the deck
system 700
shown in FIG. 7. FIG. 14 shows that portion of the deck system 700 attached to
the structure
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702 using the fasteners 1310 and 1312. The shims 1306 are positioned between a
box-frame-
segment 1404 and an external line of the structure 702. The fasteners 1310 and
1312 and the
shims 1306 can be positioned in other positions of the structure 702 and the
box-frame-segment
1404. For example, the fastener 1310 can be positioned such that a center line
running length-
wise of the fastener 1310 is coaxially with an interface point at which joist
segments 1410 and
1412 abut one another, or at another position.
102311 A box-frame-segment 1404 can be configured like the extrusion 800 and
can be
attached to a joist spacer 1406 of the joist assembly 712, and to a joist
spacer 1408 of the joist
assembly 714. The extrusions 1406 and 1408 can be configured like the
extrusion 850. The joist
assembly 712 includes a joist segment 1410 configured like the extrusion 800.
The joist
assembly 714 includes a joist segment 1412 configured like the extrusion 825.
The joist spacer
1406 and the joist segment 1410 attach to one another using one or more
fasteners 902 installed
into screw splines of joist segment 1410. The joist spacer 1408 and the joist
segment 1412 attach
to one another using one or more fasteners 902 installed into screw splines of
the joist segment
1412.
[0232] FIG. 14 shows deck-clips 5 and deck-clip screws 92 positioned within
the joist segment
1412. FIG. 14 also shows positions of edges 6A of the deck boards 6 attachable
to the deck
system 700.
[0233] =Next, FIG. 15 is a large-scale plan view of a portion 1500 of the deck
system 700
shown in FIG. 7. FIG. 15 shows that portion of the deck system 700 attached to
the structure
702 using the fasteners 1310 and 1312. The shims 1306 are positioned between a
box-frame-
segment 1404 of the box-frame 100 of the deck system 700 and an external line
of the structure
702. The shims 1306 can include through-holes to allow the fastener 1310 to
pass through the
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shims 1306. Alternatively, the shims 1306 can be positioned adjacent to the
fastener 1310. The
fastener 1312 can abut internal line 1402 of the structure 702.
102341 The box-frame-segment 1404 can be configured like the extrusion 800 and
can be
attached to a joist spacer 1408 of the joist assembly 714. Portions of a box-
frame-segments that
abut one another can be mitered as shown at miter joint 1510. The joist spacer
1408 can be
configured like the extrusion 850. The joist assembly 714 includes a joist
segment 1508
configured like the extrusion 825 or the extrusion 850. The box-frame of the
deck system 700
includes a box-frame-segment 1504 configured like the extrusion 800. The box-
frame-segments
1404 and 1504 can attach to one another using angle clip 105, and angle clip
105 can attach to
the box-frame-segments 1404 and 1504 using one or more fasteners 903 installed
into screw
splines of box-frame-segments 1404 and 1504. The deck-clips 5 and the deck-
clip screws 92 can
be positioned within the joist segment 1508. The joist spacer 1408 and the
joist segment 1508
can be attached together using one or more fasteners 305. FIG. 15 also shows
positions of the
deck boards 6 attachable to the deck system 700.
102351 Next, FIG. 16 is a large-scale view of a portion 1600 of deck system
700 shown in FIG.
7. Portion 1600 includes extrusions of joist assemblies 712, 714, 722, and 724
shown in FIG. 7.
102361 The joist assembly 712 includes joist segment 1410, and a joist spacer
1602 configured
like the extrusion 850. The joist segments 1410 and 1602 can attach to one
another using one or
more fasteners 902.
[02371 The joist assembly 714 includes a joist spacer 1604 configured like the
extrusion 850
and the joist segment 1412. The extrusions 1604 and 1412 can attach to one
another using one
or more fasteners 902. The joist assembly 714 can be the last joist assembly
installed into deck
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system 700 during assembly and the first joist assembly removed from the deck
system 700
during disassembly of the deck system 700.
102381 The joist assembly 722 includes a joist spacer 1608 configured like the
extrusion 850,
and a joist segment 1614 configured like the extrusion 800. The joist spacer
1608 and the joist
segment 1614 can attach to one another using one or more fasteners 902.
[0239] The joist assembly 724 includes a joist spacer 1610 configured like the
extrusion 850,
and a joist segment 1616 configured like the extrusion 850. The joist spacer
1610 and the joist
segment 1616 can attach to one another using one or more fasteners 902. The
joist assembly 724
can be the last joist assembly installed into the deck system 705 during
assembly and the first
joist assembly removed from the deck system 705 during disassembly of the deck
system 705.
[0240] In accordance with an example embodiment, roll-lock tabs of the joist
spacers 1602 and
1604 can be positioned within a roll-lock tab receiver of a box-frame-segment
of the deck system
700, and roll-lock tabs of the joist spacers 1608 and 1610 can be positioned
within a roll-lock tab
receiver of a box-frame-segment of the deck system 705. Each of those box-
frame-segments can
be configured like the extrusion 800 and can be attached to one another using
fasteners 902 or
another type of fastener. The locking tabs of the box-frame-segments and the
locking tab
retainers of the joist spacers 1602, 1604, 1608, and 1610 are used for
attachment of those joist
spacers to the box-frame-segment.
[0241] In accordance with one or more example embodiments, such as embodiments
discussed
with respect to FIG. 23, the roll-lock tabs of the joist spacers 1602, 1604,
1608, and 1610 can be
positioned with one of two roll-lock tab receivers within a box-frame-segment
configured like
the extrusion 875. The box-frame-segment configured like the extrusion 875 can
be a box-
frame-segment of a box-frame within the deck system 704 or 705. The locking
tabs of the box-
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frame-segment and the locking tab retainers of the joist spacers 1602, 1604,
1608, and 1610 are
used for attachment of those joist spacers.
[0242] Deck-clips 5 and deck-clip screws 92 can be positioned within joist
segments 1412 and
1616. FIG. 16 also shows positions of edges 6A of deck boards 6 attachable to
deck systems 704
or 705.
[0243] Next, FIG. 17 is a large-scale view of a portion 1700 of the deck
system 700 shown in
FIG. 7. Portion 1700 includes elements of the joist assemblies 714 and 724,
and box-frame-
segments 1504 and 1704, of the box-frames of deck systems 704 and 705,
respectively. The
box-frame-segment 1704, similar to box-frame 1504, can be configured like the
extrusion 800.
[0244] The joist assembly 714 includes a joist spacer 1604 configured like the
extrusion 850,
and joist segment 1508 configured like the extrusion 825 or the extrusion 850.
The joist spacer
1604 and the joist segment 1508 can attach to one another using one or more
fasteners 902. The
joist assembly 714 can be the last joist assembly installed into the deck
system 704 during
assembly and the first joist assembly removed from the deck system 704 during
disassembly of
the deck system 704.
[0245] The joist assembly 724 includes a joist spacer 1610 configured like the
extrusion 850,
and a joist segment 1702 configured like the extrusion 825 or the extrusion
850. The joist spacer
1610 and the joist segment 1702 can attach to one another using one or more
fasteners 902. The
joist assembly 724 can be the last joist assembly installed into the deck
system 705 during
assembly and the first joist assembly removed from the deck system 705 during
disassembly of
the deck system 705.
[0246] Angle clips 105 can be inserted into the box-frame-segments 1504 and
1704 for
attaching to box-frame-segments configured like the extrusion 800.
Alternatively, an angle clip
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105 can be inserted into box-frame-segments 1504 and 1704 and into a box-frame-
segment
configured like the extrusion 875. The deck-clips 5 and the deck-clip screws
92 are positioned
within the joist segments 1508 and 1702. FIG. 17 also shows positions of the
deck boards 6
attachable to the deck system 700.
102471 Next, FIG. 18 is a large-scale view of a portion 1800 of the deck
system 700 shown in
FIG. 7. Portion 1800 includes elements of the joist assemblies 722 and 724.
[0248] The joist assembly 722 includes a joist spacer 1806 configured like the
extrusion 800
and a joist segment 1614 configured like the extrusion 800. The joist spacer
1806 and the joist
segment 1614 can attach to one another using one or more fasteners 902.
[0249] The joist assembly 724 includes a joist spacer 1808 configured like the
extrusion 850
and a joist segment 1616 configured like the extrusion 850. The joist spacer
1808 and the joist
segment 1616 can attach to one another using one or more fasteners 902. The
joist assembly 724
can be the last joist assembly installed into the deck system 705 during
assembly and the first
joist assembly removed from the deck system 705 during disassembly of the deck
system 705.
[0250] In accordance with one or more example embodiment, roll-lock tabs of
joist spacers
1806 and 1808 can be positioned within a roll-lock tab receiver of a box-frame-
segment 1810 of
the deck system 705. The box-frame-segment 1810 can be configured like the
extrusion 800.
The locking tab of the box-frame-segment 1810 and the locking tab retainers of
joist spacers
1806 and 1808 are used for attachment of joist spacers 1806 and 1808 to the
box-frame-segment
1810.
[0251] An intermediate-post bracket 9 attached to the post 10 using the
fasteners 903 is shown
in FIG. 18. The inteimediate-post bracket 9 can be attached to the box-frame-
segment 1810
using one or more fasteners 903 or another type of fastener. In an alternative
embodiment, the
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intermediate-post bracket 9 shown in FIG. 18 can be replaced with an
intermediate-post bracket
64 and the support ring 1012 to accommodate a railing post and railing
attachable to the deck
system 700. The deck-clips 5 and the deck-clip screws 92 are positioned within
the joist
segment 1616. FIG. 18 shows positions of edges 6A of the deck boards 6
attachable to the deck
system 700.
[0252] Next, FIG. 19 is a large-scale view of a portion 1900 of the deck
system 700 shown in
FIG. 7. Portion 1900 includes elements of the joist assembly 724 and the box-
frame-segments
1704 and 1810 of box-frames of the deck system 705. The box-frame-segments
1704 and 1810
can be configured like the extrusion 800. The box-frame-segments 1704 and 1810
can attach to
one another using angle clip 105, and angle clip 105 can attach to the box-
frame-segments 1704
and 1810 using one or more fasteners 903 installed into screw splines of box-
frame-segments
1704 and 1810.
[0253] The joist assembly 724 includes the joist spacer 1804 configured like
the extrusion 850,
and the joist segment 1702 configured like the extrusion 825 or the extrusion
850. The joist
assembly 724 can be the last joist assembly installed into the deck system 705
during assembly
and the first joist assembly removed from the deck system 705 during
disassembly of the deck
system 705.
[0254] A corner-post bracket 8 attached to the post 10 using the fasteners 903
is shown in FIG.
19. The corner-post bracket 8 can be attached to the box-frame-segments 1704
and 1810 using
one or more fasteners 903 or another type of fastener. In an alternative
embodiment, the corner-
post bracket 9 shown in FIG. 19 can be replaced with a corner-post bracket 62
and support ring
1094 to accommodate a railing post and railing attachable to the deck system
700. A deck-clip 5
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and deck-clip screw 92 are positioned within the extrusion 1702. FIG. 19 shows
positions of
deck boards 6 attachable to the deck system 700.
III. ASSEMBLY AND DISASSEMBLY OF DECK SYSTEM
[0255] FIG. 24 is a flow chart showing example set of steps 2400 that can be
carried out to
assemble and disassemble a deck system in accordance with one or more example
embodiments.
One or more of the steps (shown in blocks numbered with even numbers between
2402 and
2428, inclusive) or portions of the steps of the set 2400 are not required for
each and every
example embodiment. The steps shown in the set 2400 can be carried out in
various
arrangements, and one or more of the steps can be repeated.
[0256] Block 2402 includes assembling perimeter box-frame. Assembling the box-
frame can
include inserting angle clips (e.g., corner angle clips) into box-frame-
segments. Each angle clip
can be inserted into two box-frame-segments to form a rectangular box-frame.
Fasteners can be
inserted into the angle clips and box-frame-segments to more securely attach
two box-frame-
segments together.
[0257] Next, block 2404 includes attaching perimeter box-frame to structure.
Attaching the
box-frame can include drilling holes within one or more box-frame-segments and
into the
structure. Shims can be placed between the structure and the box-frame to
provide spacing, as
necessary, between the structure and the deck system being attached to the
structure. Fasteners
310 and 312 can be inserted into holes within the box-frame and the structure
for attachment of
the box-frame and the structure.
[0258] Next, block 2406 includes attaching the perimeter box-frame to post and
post bracket.
A support post can be positioned upon a footing, such as a concrete footing. A
post bracket,
such as corner-post bracket or an intermediate-post bracket, can be attached
to the support post
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using fasteners, such as fasteners 903. The post bracket can be attached to a
box-frame-segment
of the box-frame using fasteners, such as fasteners 903.
[0259] Next, block 2408 includes assembling joist assemblies. In one respect,
assembling the
joist assemblies can include attaching two joist spacers to two joist
segments. The joist spacers,
for example, can be configured like the extrusion 850, or the box-frame-
segment attachment 405,
465, or 489. The joist segments, for example, can be configured like the
extrusion 800 and the
extrusion 825, or the joist segments 433 and 1037, or the joist segments 707
and 355. The
fasteners 305 can be used to attach a joist spacer to a joist segment.
[0260] If the quantity of joist assemblies of a set of joist assemblies 300
and 320 to be
assembled for a deck system equals N (where N is greater than or equal to 2),
then N-1 joist
assemblies can be configured like the joist assembly 300, and one joist
assembly can be
configured like the joist assembly 320. The N-1 joist assemblies can be the
first joist assemblies
to be installed into the box-frame and the joist assembly 320 can be installed
after each of the
joist assemblies 300 is installed into the box-frame.
[0261] If the quantity of joist assemblies of a set of joist assemblies 173
and 501 to be
assembled for a deck system equals N (where N is greater than or equal to 3),
then N-2 joists can
be configured like the joist assembly 501, and two three-piece joist
assemblies can be configured
like the joist assembly 173. The three-piece joist assemblies can be the first
and last joist
assemblies installed in the box-frame. Box-frame-segment covers 199 can be
attached to the
box-frame along with the three-piece joist assemblies, as shown in FIG. 39.
The N-2 joist
assemblies 501 can be installed into the box-frame after the first joist
assembly 173 is installed
and prior to installation of the last joist assembly 173.
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[0262] Next, block 2410 includes installing joist assemblies into the
perimeter box-frame.
Installing the joist assemblies can include, starting at one side of the box-
frame, installing each
joist assembly configured like the joist assembly 300 until the remaining
space in the interior of
the box-frame and at the opposite side of the box-frame, and then installing
the joist assembly
configured like the joist assembly 320 into the remaining space. Installing
each joist assembly
until the installing the last joist assembly can include roll-lock tabs being
positioned into roll-
lock tab receivers at the attachment points of three box-frame-segments and
two joist spacers and
a joist segment of a joist assembly or at the attachment points of two box-
frame-segments and a
joist segment of a previously-installed joist assembly and two joist spacers
and a joist segment of
a joist assembly. Installing the last joist assembly can include roll-lock
tabs being positioned
into roll-lock tab receivers at the attachment points of three box-frame-
segments and a joist
segment of a previously-installed joist assembly, and two joist segments and
two joist spacers of
the joist assembly.
[0263] Next, block 2412 includes attaching deck-clips and deck boards to the
joist assemblies.
Attaching the deck-clips can include inserting the deck-clips 5 into the deck-
clip slots 837 within
a joist segment configured like the extrusion 825 or the extrusion 850, and
securing the inserted
deck-clip 5 using a deck-clip screw 92. A plurality of each deck board can be
retained, at least in
part, by deck board retaining surfaces 135 and 137 of a plurality of deck-
clips. Additionally or
alternatively, deck boards can be attached to the joist assemblies using the
deck screws 2010.
[0264] Next, block 2414 includes attaching railing to post bracket. Attaching
the railing can
include attaching a railing post 60 within a corner-post bracket 64 or within
an intermediate-post
bracket 62 and within a support ring 1012 or 1094 using fasteners 903. A
support bracket 1014
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can be attached to a support post 10 and the railing post 60 using fasteners
903. Any of a variety
of railing components can be attached to and between two railing posts 60.
102651 Next, block 2410 includes removing the railing from the post bracket.
Removing the
railing from the post bracket can include removing any components attached to
and between two
railing posts, removing fasteners attaching the railing post 60 to post
brackets, support ring, and
support brackets and then removing the railing post from the brackets and from
the deck system.
[0266] Next, block 2418 includes removing deck-clips and deck boards from the
joist
assemblies. Removing the deck-clips and deck boards can including removing any
deck screws
that attach the deck boards to the joist assemblies. Removing the deck boards
can include sliding
the each deck board away from the deck board retaining surfaces that are
retaining the deck
board. Removing the deck-clips can include removing the deck-clip screws 92
that retain the
deck-clip to the joist assemblies.
102671 Next, block 2420 includes removing joist assemblies from the perimeter
box-frame.
Removing the joist assemblies can include removing the joist assemblies in a
reverse order in
which the joist assemblies were installed into the box-frame. In other words,
the joist assemblies
can be removed using a last-in-first-out procedure.
102681 Next, block 2422 includes disassembling joist assemblies. Disassembling
the joist
assemblies can include removing fasteners placed into a joist spacer and joist
segment pair, and
then separating the joist spacer from the joist segment.
102691 Next, block 2424 includes removing post and post bracket from perimeter
box-frame.
Removing the box-frame from the post and post bracket can include removing the
fasteners that
attach the post and post bracket to a box-frame-segment. The post bracket can
be removed from
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the post. In accordance with some example embodiments, the post can be removed
from the
footer.
102701 Next, block 2426 includes removing perimeter box-frame from structure.
Removing
the box-frame can include removing fasteners 310 and 312 and shims used to
attach the box-
frame and the structure.
102711 Next, block 2428 includes disassembling perimeter box-frame.
Disassembling the box-
frame can include removing any fasteners that secure two box-frame-segments.
Disassembling
the box-frame can include removing angle clips (e.g., corner angle clips) from
the box-frame-
segments.
IV. CONCLUSION
[0272] Example embodiments have been described above. Those skilled in the art
will
understand that changes and modifications can be made to the described
embodiments without
departing from the true scope and spirit of the present invention, which is
defined by the claims.
Any reference within a claim to an item in a figure is for ease of reference
and does not
necessarily limit the scope of the claim.
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