US20070204784A1

US20070204784A1 - Portable Deck

Info

Publication number: US20070204784A1
Application number: US11/681,846
Authority: US
Inventors: Robert Schmid; Louis A. Maccarella
Original assignee: Porta Deck LLC
Current assignee: PORTA-DECK LLC; Porta Deck LLC
Priority date: 2006-03-03
Filing date: 2007-03-05
Publication date: 2007-09-06

Abstract

A portable deck includes a plurality of legs that have a slot on each side face. An adjustable foot is removably attached to each leg to account for uneven ground surfaces on which the portable deck may be place. At least two braces and at least two rails are generally disposed between the plurality of legs to form a generally rectangular frame. The rails and braces are removably disposed in the slots of the legs. A plurality of planks are removably mounted to and supported by the rails to form a top surface of the portable deck. The portable deck provides a firm, level surface on which to place outdoor accessories.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Patent Application No. 60/778,850, filed Mar. 3, 2006 and entitled “Portable Deck”, the entire subject matter of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

This invention generally relates to decks and, more particularly, to a portable deck which is relatively easy to assemble and disassemble and is relatively easily transportable.
The recreational vehicle (RV) industry is a large, thriving industry. Typically, the purchase of an RV is but the first step in the hobby/lifestyle. People who purchase RVs typically purchase several accessories for use therewith in order to make the RV experience more pleasurable. Frequently included among these accessories are outdoor amenities such as outdoor furniture, outdoor grills, and the like. The use of such outdoor accessories often depends on the terrain of the campsite or parking location in which the RV is located. If the ground is not level or is slightly infirm (soggy from recent rainfall, for instance), the use of such outdoor accessories is difficult, if not impossible. Therefore, in at least such circumstances, a firm, relatively level surface on which to place outdoor accessories is desirable. It is also desirable for such a surface to be able to be assembled and disassembled easily for ease of use. Also, it is desirable for such a surface to be compactly stored, as space within an RV is typically relatively limited.

BRIEF SUMMARY OF THE INVENTION

Briefly stated, a preferred embodiment of the present invention is directed to a portable deck that includes a plurality of legs that have a slot on each side face. An adjustable foot is removably attached to each leg to account for uneven ground surfaces on which the portable deck may be place. At least two braces and at least two rails are generally disposed between the plurality of legs to form a generally rectangular frame. The rails and braces are removably disposed in the slots of the legs. A plurality of planks are removably mounted to and supported by the rails to form a top surface of the portable deck. The portable deck provides a firm, level surface on which to place outdoor accessories.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of a preferred embodiment of the invention will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings an embodiment which is presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.

In the drawings:

FIG. 1 is a top perspective photographic view of an assembled portable deck in accordance with a preferred embodiment of the present invention;

FIG. 2 is a top perspective photographic view of the portable deck of FIG. 1 having two planks removed therefrom and displayed on top of the portable deck;

FIG. 3 is a top perspective photographic view of the portable deck of FIG. 1 having all of the planks removed and having an optional double rail shown therewith;

FIG. 4 is a top perspective photographic view of the portable deck of FIG. 1 having the optional double rail of FIG. 3 engaged therewith in place of a single rail;

FIG. 5 is an end view of a brace of the portable deck of FIG. 1;

FIG. 6 is an end view of a single rail of the portable deck of FIG. 1;

FIG. 7 is an end view of a double rail of the portable deck of FIG. 3;

FIG. 8 is an end view of a plank of the portable deck of FIG. 1;

FIGS. 9 a and 9 b are bottom side perspective photographic views of a disassembled leg and insert, respectively, of the portable deck of FIG. 1;

FIGS. 10 a and 10 b are top side perspective photographic views of the disassembled leg and insert, respectively, of FIG. 9;

FIGS. 11 a, 11 b, and 11 a are a top plan view, a side elevational view, and a bottom plan view, respectively, of an alternate leg similar to the leg of FIG. 9;

FIGS. 12 a, 12 b, and 12 c are a top plan view, a side elevational view, and a bottom plan view, respectively, of an alternate insert similar to the insert of FIG. 9;

FIG. 13 is a top side perspective photographic view of the leg and insert of FIG. 9, the leg and insert being partially assembled;

FIG. 14 is a bottom side perspective photographic view of the leg and insert of FIG. 9, the leg and insert being fully assembled;

FIG. 15 is a top side perspective photographic view of the insert of FIG. 9 partially inserted within a single rail of FIG. 1;

FIG. 16 is a top side perspective photographic view of the assembled leg and insert of FIG. 14 with the insert fully inserted within the single rail of FIG. 15;

FIG. 17 is a top side perspective photographic view of a foot of the portable deck of FIG. 1;

FIG. 18 is a top perspective photographic view of the foot of FIG. 17 engaged with the leg of FIG. 9; and

FIG. 19 is a top side perspective photographic view of the portable deck of FIG. 1 disassembled and configured in a bundle for storage.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used in the following description for convenience only, and is not limiting. The words “right,” “left,” “upper,” and “lower” designate directions in the drawings to which reference is made. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
Referring to the drawings in detail, wherein like numerals indicate like elements throughout, there is shown in FIGS. 1-19 a preferred embodiment of a portable deck, indicated generally at 10, in accordance with the present invention. The portable deck 10 is intended to be relatively easily assembled and relatively easily disassembled and reconfigurable into a relatively compact bundle 10′ for transport and/or storage thereof.
Referring to FIGS. 1-4, the portable deck 10, when fully assembled (FIG. 1), provides a relatively flat, relatively sturdy top surface. The portable deck 10 is preferably a four foot by four foot square structure when assembled, although it should be evident to one of ordinary skill in the art that the portable deck 10 can be of any size or any shape, provided the portable deck 10 is still capable of functioning as described herein.
A basic configuration of the portable deck 10, as shown in FIG. 1, includes four legs 40, with one leg 40 disposed at each corner of the portable deck 10. As discussed in more detail below, each leg 40 preferably has an adjustable foot 50 engaged therewith. The feet 50 of the portable deck 10 can be adjusted in the height direction in order to account for uneven ground surfaces (not shown) on which the portable deck 10 may be placed.
Referring now to FIGS. 1-3, the basic configuration of the portable deck 10 further includes at least two braces 14 and two single rails 20 that are generally disposed between the legs 40 to form a generally rectangular, and preferably square, frame 11. As will be described in greater detail below, the single rails 20 are preferably oppositely disposed from one another to form two sides of the frame 11 and the braces 14 are oppositely disposed from one another to form the other two sides of the frame 11. Preferably, at least the single rails 20 include flanges 20 a extending outwardly from a side thereof so that, when the frame 11 is assembled, the flanges 20 a extend inwardly toward one another. The flanges 20 a preferably function to support a plurality of planks 12 therebetween to form the top surface of the portable deck 10.
Referring to FIGS. 3 and 4, alternatively, at least one of the single rails 20 can be replaced with a double rail 30 to expand the portable deck 10 from the basic four foot by four foot configuration to an alternate, four foot by eight foot configuration (not shown). Although a complete alternate configuration is not shown explicitly, it should be evident to one of ordinary skill in the art from the attached figures that such an alternate configuration would essentially comprise two basic configuration portable decks 10 linked by a common double rail 30 and two common middle legs 40. It should be further evident to one of ordinary skill in the art that more than two basic configuration portable decks 10 can be combined using more than one double rail 30 to create further alternate configurations of various sizes and shapes.
It is further contemplated that, instead of or in addition to using a double rail 30 to expand the basic configuration portable deck 10, two additional single rails 20 can be engaged with two adjacent legs 40 of the portable deck 10, together with an additional brace 14 and two additional legs 40 to form an alternate, four foot by eight foot configuration (not shown) essentially comprising two basic configuration portable decks 10 linked by a common brace 14 and two common middle legs 40. It is still further contemplated that one of the braces 14 of the basic configuration portable deck 10 can be replaced with an additional single rail 20 having the flange 20 a of the single rail 20 extending outwardly away from the center of an alternate configuration portable deck (not shown). In this way, the alternate configuration portable deck includes three single rails 20 and one brace 14. Two additional braces 14 can then be engaged to the legs 40 of the alternate configuration portable deck on either side of the additional single rail 20 and in line with the original single rails 20 of the alternate configuration portable deck. Two additional legs 40 can then be attached to free ends of the braces 14 with an additional, fourth single rail 20 disposed therebetween, opposite the third single rail 20, with the flange 20 a of the fourth single rail 20 extending inwardly toward the third single rail 20. Planks 12 can then be placed on the flanges 20 a of the third and fourth single rails 20, generally oriented at ninety degrees to the planks 12 of the alternate configuration portable deck (i.e., the original basic configuration portable deck 10 with one of the braces 14 replaced with the third single rail 20). In this way, another alternate, four foot by eight foot configuration (not shown) can be formed without the need to use a double rail 30 to do so. It should be evident to one of ordinary skill in the art that either of the above-described alternate, four foot by eight foot configurations can be further expanded in like manner to form portable decks larger than four feet by eight feet in various shapes, including, but not limited to, rectangular, square-shaped, L-shaped, U-shaped, plus-shaped, and cross-shaped.
The double rail 30 is generally similar to the single rail 20, differing in that the double rail 30 includes two flanges 30 a, one flange 30 a extending outwardly from each opposing side of the double rail 30, rather than just a single flange, as is portrayed with respect to the single rail 20. In this way, at least one of the single rails 20 can be replaced with the double rail 30, as shown in FIG. 4, in order to provide a surface (i.e., the second flange 30 a) extending outwardly from an expandable frame 11′, so that, if additional braces 14, legs 40, and single rail 20 are engaged thereto, additional planks 12 can be supported thereby to create the alternate configuration four foot by eight foot portable deck.
Referring to FIGS. 2, 3, and 5, each brace 14 is preferably an elongate box-shaped beam, preferably having a rectangular cross section when viewed from an end thereof. The braces 14 generally function to support and space the other two sides of the frame 11, 11′ made up by the single rails 20 and/or double rails 30. The braces 14 preferably have at least partially hollow interiors 14 a.
Referring to FIGS. 2, 3, and 6, the single rail 20 is preferably generally similar to the brace 14 except that it includes the flange 20 a extending outwardly from a side thereof. That is, the single rail 20 is preferably an elongate box-shaped beam with a preferably generally hollow interior 20 b. The single rails 20 function primarily to support the plurality of planks 12 therebetween on the flanges 20 a thereof, while, at the same time, also spacing the other two sides of the frame 11, 11′ made up by the braces 14.
Referring to FIGS. 3, 4, and 7, the double rail 30 is preferably generally similar to the single rail 20, except that it includes two flanges 30 a, one flange 30 a extending outwardly from each side thereof, rather than just one side thereof, as with the single rail 20. That is, the double rail 30 is preferably an elongate box-shaped beam having a preferably generally hollow interior 30 b. The double rail 30 functions to allow assembly of the expandable frame 11 in that the double rail 30 is capable of supporting planks 12 on either side thereof. The double rail 30 further functions to space the other two sides of the frame 11′ made up by the braces 14.
Referring to FIGS. 1, 2, and 8, the planks 12 are generally elongate, preferably open-bottom beams, which are preferably E-shaped in cross section when viewed from either end. Each plank 12 preferably includes a segmented bottom surface 12 a and a flat, generally continuous top surface 12 b. The top surface 12 b preferably includes a plurality of ridges or treads 12 c extending upwardly therefrom and running the length of the plank 12 to enhance grip thereon, thereby decreasing the likelihood of a person, object, animal, etc. slipping on the top surface of the portable deck 10.
Referring to FIGS. 9-12, each of the legs 40 is generally a rectangular parallelepiped having four generally T-shaped slots 40 a (when viewed from a top end of the leg 40) formed therein, preferably one slot 40 a in each side face of the leg 40. Preferably, the slots 40 a are open at the top end of the leg 40. The leg 40 preferably includes a threaded bottom hole 40 b in a bottom end thereof and a threaded top hole 40 c in the top end thereof.
The slots 40 a of the legs 40 are configured to removably engage inserts 42. Specifically, the inserts 42 preferably each include a complementarily-shaped tongue 42 c disposed on an end thereof. That is, each tongue 42 c is generally T-shaped and sized to be selectively placed within any one of the slots 40 a of the leg 40 through the open top end of the desired slot 40 a. It is preferred that each insert 42 further includes a block-like insert portion 42 a at an end opposite the tongue 42 c and a rectangular end flange 42 b extending outwardly from the insert portion 42 a and disposed between the insert portion 42 a and the tongue 42 c. While the tongue 42 c of the insert 42 shown in FIGS. 9 and 10 extends along substantially the entire height of the insert 42, it is noted that the tongue 42 c, and, in turn, the slots 40 a of the legs 40, need not be that long and can, instead, extend along only a portion of the height of the insert 42 (and the slots 40 a a complementary distance along the legs 40), as shown in the alternate legs 40 and inserts 42 of FIGS. 11 and 12, respectively.
Referring to FIGS. 13-16, the insert 42 is shown in various stages of engagement with the leg 40 and the single rail 20. As described above, the tongue 42 c of the insert 42 slides within a selected one of the slots 40 a of the leg 40 (FIGS. 13, 14, and 16). The insert portion 42 a of the insert 42 engages within an end of the single rail 20, and, although not shown in FIGS. 13-16, other inserts 42 similarly engage within the other end of the single rail 20, as well as each of the ends of the braces 14 and double rails 30, as can be seen in FIGS. 1-4.
Referring still to FIGS. 13-16, the insert portion 42 a is placed within the interior 20 b of the single rail 20 preferably so that the end flange 42 b abuts the end of the single rail 20 (FIG. 16). It is preferred that the insert portion 42 a be retained within the end of the single rail 20 in a conventional manner, such as, but not limited to, a force fit, an adhesive, and/or a fastener, such as a bolt, screw, rivet, or some other suitable generally conventional fastener. With inserts 42 engaged within both ends of the single rail 20, the single rail 20 is then able to be engaged with a leg 40 at either end to allow assembly of the portable deck 10.
Referring now to FIGS. 1-4 and 18, once the desired number of braces 14, single rails 20, and/or double rails 30 are engaged with the desired number of legs 40, caps 44 can be engaged with the tops of each of the legs 40 in order to retain the corresponding tongues 42 c within the slots 40 a of the leg 40. Preferably, each cap 44 is generally rectangular or, more specifically, square-shaped, when viewed from above, and functions to essentially obstruct or close off the open ends of the slots 40 a at the top end of each of the legs 40. Preferably, a fastener 46 is used to selectively retain the cap 44 in engagement with the top of the leg 40. The fastener 46 is preferably a screw, although it is within the spirit and scope of the present invention that another type of fastener be used, such as a bolt, for instance.
Referring to FIGS. 17 and 18, each foot 50 includes a generally square-shaped plate 51 with a threaded rod 52 extending upwardly from a top surface thereof. Preferably, the threaded rod 52 is attached to the plate 51 in a conventional manner. For instance, it is contemplated that the threaded rod 52 be welded to the plate 51 directly or that a nut be welded to the plate 51 with the threaded rod 51 being threadably engageable with the nut. Alternatively, the plate 51 can have a threaded hole (not shown) disposed therethrough with which the threaded rod 51 is threadably engageable. It is further alternatively contemplated that the plate 51 have a through hole (not shown) disposed therein through which the threaded rod 52 (in the form of a bolt) can be placed. A nut can then be threaded down the threaded rod 52 so that it is snug with the top of the plate 51, thereby engaging the threaded rod 52 with the plate 51 by sandwiching the plate 51 between the nut and a head of the threaded rod 52. It is noted that the above-described manners of attachment are merely exemplary and that additional manners of attaching the treaded rod 52 to the plate 51 are also contemplated by the present invention.
The threaded rod 52 preferably threadably engages the bottom hole 40 b of the leg 40 and can be used to adjust the height of the leg 40 by rotating the foot 50 with respect to the leg 40. That is, the foot 50 can be rotated in a counterclockwise direction (when viewed from underneath) in order to threadably engage less of the threaded rod 52 within the bottom hole 40 b, thereby increasing the overall height of the leg 40, or, alternatively, the foot 50 can be rotated in a clockwise direction (when viewed from underneath) to threadably engage more of the threaded rod 52 within the bottom hole 40 b, thereby decreasing the overall height of the leg 40.
Referring to FIG. 19, the above-described components of the portable deck 10, when disassembled, can preferably be stacked in a compact manner and lashed together using tethers 60 to form a bundle 10′. The tethers 60 are preferably conventional and preferably include adjustable nylon straps 62, the ends of which are releasably engageable using clips 64. The clips 64 are preferably generally conventional plastic spring clips, although it is within the spirit and scope of the present invention that any suitable clips or retaining members be used. Alternatively, it should be evident that the clips 64 could be eliminated altogether and the ends of the straps 62 tied together to constrain the bundle 10′. Moreover, while it is preferred that nylon straps 62 are used, it is not intended to be limiting. As such, any type of strap, rope, cord, chain, etc. could be used to lash the bundle 10′ together.
Preferably, each of the above-described components of the portable deck 10 are formed out of aluminum. While this is preferred, it is contemplated that the components be made of a different, suitable material. As such, it is within the spirit and scope of the present invention that the components of the portable deck 10 be made from another metal, such as steel, or a polymeric material, such as plastic. Additionally, it is contemplated that some of the components of the portable deck 10 be made of a material different from other components of the portable deck 10. For instance, the braces 14, single rails 20, double rails 30, legs 40, and feet 50 could be made from aluminum and the planks 12 could be made from a polymeric material. This is but one permutation of materials of components and is not intended to be limiting. As such, it should be evident to one of ordinary skill in the art that numerous materials permutations are possible for the present invention, all of which are contemplated herein.
In use, the bundle 10′ is removed from a storage location and placed in a suitable location for assembly of the portable deck 10. The clips 64 are unlatched and the components of the portable deck 10 are removed from the tethers 60. If not already attached, the feet 50 are attached to their corresponding legs 40. The tongues 42 c of the inserts 42 in each of the braces 14, single rails 20, and/or double rails 30 are then placed within the appropriate slots 40 a of the appropriate legs 40 to prepare the frame 11, 11′ of the portable deck 10. Once the frame 11, 11′ is satisfactorily assembled, the caps 44 are engaged with each of the tops of the legs 40 to retain the braces 14, single rails 20, and/or double rails 30 in engagement with their corresponding legs 40. The planks 12 are then placed into the frame 11, 11′ so that portions of the bottom surfaces 12 a of each of the planks 12 abut portions of the flanges 20 a, 30 a of the single and/or double rails 20, 30, thereby forming the top surface of the portable deck 10. At this point, if the top surface of the portable deck 10 is not sufficiently level or if any of the feet 50 are not sufficiently supporting the portable deck 10 on the surface or are otherwise out of contact with the surface on which the portable deck 10 is placed, one, some, or all of the feet 50 can be rotated in the appropriate direction to adjust the overall height of the leg(s) 40 in order to adequately adjust the stability and/or pitch of the portable deck 10. Once assembled in this manner, the portable deck 10 can be used to support outdoor accessories (not shown), people (not shown), or anything else the user may wish to place on top of the portable deck 10.
When the portable deck 10 is no longer desired to be used, it can be disassembled by essentially reversing the above steps. The components of the portable deck 10 can then be restacked in a compact manner and lashed together using the tethers 60 to form the bundle 10′. The bundle 10′ can then be carried back and placed into its storage location for future use.
In this way, the portable deck 10 provides a portable, relatively easily-stored surface that can be relatively easily assembled and disassembled. When disassembled, the portable deck 10 is configurable into a bundle 10′, which is relatively compact for ease of storage. When assembled, the portable deck 10 provides for a relatively sturdy, flat surface on which outdoor accessories, people, and anything else can be supported. The portable deck 10 is especially useful to provide a relatively flat, firm surface for placement on an otherwise infirm (for instance, soggy) surface or a slightly pitched or uneven surface.
It will be appreciated by those skilled in the art that changes could be made to the embodiment described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but it is intended to cover modifications within the spirit and scope of the present invention.

Claims

1. A portable deck for use with a recreational vehicle, comprising:

a plurality of legs removably attached to an adjustable foot to account for uneven ground surfaces on which said portable deck may be placed, each leg of said plurality of legs having a slot on each side face of said leg;

at least two braces and at least two rails generally disposed between said plurality of legs to form a generally rectangular frame, said rails and braces being removably disposed in said slots of said legs; and

a plurality of planks removably mounted to and supported by said rails to form a top surface of said portable deck, wherein said portable deck provides a firm, level surface on which to place outdoor accessories.

2. The portable deck of claim 1, wherein each adjustable foot includes a generally square-shaped plate and a rod, said rod extending upwardly from a top surface of said plate.

3. The portable deck of claim 2, wherein each rod threadingly engages a bottom hole of each leg, each foot is rotated to either increase or decrease a height of said portable deck.

4. The portable deck of claim 1, wherein said rails include at least one flange, said planks being supported by said flanges.

5. The portable deck of claim 4, wherein at least one of said rails include at least two flanges extending outwardly from each opposing side of said rail, said at least two flanges of said at least one of said rails allow alternate configurations or various sizes and shapes of said frame.

6. The portable deck of claim 1, wherein said braces and rails are hollow and have an opening at each end.

7. The portable deck of claim 1, further comprising inserts removably engaged at a first end with one of said legs and removably engaged at a second end with one of side braces or rails.

8. The portable deck of claim 7, wherein said first end of each insert includes a tongue extending from a flange and said second end of each insert includes an insert portion, each tongue engages a slot of said plurality of legs and each insert portion engages an interior of one of said at least two rails when said portable deck is assembled.

9. The portable deck of claim 1, wherein each of said plurality of legs includes a threaded bottom hole and a threaded top hole, one of said adjustable foot engages said bottom hole and a cap engages said top hole when said portable deck is assembled.

10. The portable deck of claim 1, wherein said at least two rails are oppositely disposed from one another to form two sides of said frame and said at least two braces are oppositely disposed from one another to form the other two sides of said frame when said portable deck is assembled.