WO2008033132A2

WO2008033132A2 - Modular building system

Info

Publication number: WO2008033132A2
Application number: PCT/US2006/035810
Authority: WO
Inventors: John Potter
Original assignee: John Potter
Priority date: 2006-09-14
Filing date: 2006-09-14
Publication date: 2008-03-20

Abstract

A modular prefabricated deck system which includes a plurality of rectangular flooring modules. Each module may include a plurality of laminations, such as a decorative upper element, and a lower support element for supporting the module upon the underlying joist structure of the deck. Additionally, the system includes a connector having spline and support portions for attaching the modules upon an underlying structure, such as a wood deck structure, upon installation.

Description

MODULAR BUILDING SYSTEM

TECHNICAL FIELD

[0001] This invention generally relates to a prefabricated modular building system finding particular utility in various building applications, including elevated deck structures, on-grade patio structures, and interior or exterior floor assemblies and wall assemblies.

BACKGROUND OF THE INVENTION

[0002] Known building elements and systems for patios, decks, and walls, and flooring have substantial limitations. Exterior patios, decks and wood platform structures have become commonplace additions to houses and other residential and commercial structures. A value of such structures is derived from an enlargement of the usable living space for entertainment, as well as an enhancement in the quality of outdoor activities such as relaxation. As a result, outdoor structures have become increasingly popular in residential home construction. Residential homes, as well as a variety of other buildings, often incorporate exterior decks into their design. Additionally, decks are commonly added onto existing structures.

[0003] Modular deck systems are also known. Typically, the modular systems include prefabricated wood panels for the deck flooring. Various types of prefabricated wood panels have been proposed. Usually the panels are constructed of individual boards secured together to form a modular panel. The prefabricated panel deck structures have included various approaches to securing the panels to an underlying support structure or sub-structure. One example is U.S. Patent No. 4,622,792 to Berts, which discloses a wood-based modular deck structure comprising a plurality of rectangular flooring platforms and cooperating rectangular frames defined by intersecting joist members.

[0004] Known tile or stone flooring systems for interior use also have substantial limitations. Typical tile or stone installation requires a substantial floor underlayment for rigidly supporting the tile to minimize cracking or other damage. The floor underlayment may include a plurality of plywood sheet elements secured to the joists. Alternatively, the floor underlayment may include a reinforced concrete panel product secured to the joist. Yet another approach to strengthening the floor underlayment may be a thick mortar bed having internal reinforcement. Each of these approaches to strengthening the floor for tile and stone installations includes limitations of increased costs and / or involved labor.

BRIEF SUMMARY OF THE INVENTION

[0005] The present invention provides a prefabricated modular building product having particular utility in a variety of building applications, including but not limited to elevated deck structures, interior and exterior floor assemblies, interior and exterior wall assemblies, and on-grade patio structures.

[0006] In one embodiment the present invention relates to a deck structure having improved deck surface aesthetic and durability. The deck structure according to one aspect of the present invention includes a plurality of prefabricated deck modules disposed upon an underlying support structure. The support structure may include a plurality of existing deck joists. The prefabricated deck modules may be manufactured from a variety of materials, such as concrete, natural stone, or polymer products. The deck modules may be disposed upon an existing deck joist structure during deck renovation or repair, or they may be utilized as a deck surface of a new deck. The deck modules are retained upon the deck structure by a plurality of connectors. The connectors restrain the deck modules from movement and provide an improved deck system in which the edges of the deck modules are uniformly spaced from the edges of adjacent deck modules. In one embodiment of the present invention, the connectors have an integrated spline portion and support portion. Desirably, a relatively seamless deck surface aesthetic may thus be achieved. The connectors may include flange sections for securing to the joists. The connector splines are adapted to be received into channels of adjacent deck modules. [0007] It is an object of the present invention to provide a modular deck flooring system which is easy to install, and which possesses numerous advantages over the prior art deck floors. A decrease in maintenance and a more aesthetically appealing deck surface is thus provided. In accordance with the invention, a deck system includes a plurality of individual prefabricated deck modules which are retained by a module support structure. The modules may be manufactured through a variety of approaches, materials, techniques, etc. Importantly, the modules include at least two structurally different elements, a first upper (deck) surface comprised of a low tensile strength material, such as natural stone or a concrete product, or tile, and a second lower surface comprised of a high tensile strength material. The first upper surface is coupled to the second lower surface through known materials securement means, including but not limited to adhesives and mechanical fasteners.

[0008] In one preferred form, the modules may be a cast concrete product, a synthetic polymer product, a natural stone product, or a combination thereof. In another preferred form, the modules include a lower composite material support layer, such as a plywood element or a high-strength composite element, and an upper natural stone facing layer. A lower element may be comprised of a high-strength composite material, such as glass-reinforced pultruded material. Alternative high-strength composite materials may be appreciated by those skilled in the present arts and the scope of the present invention is intended to cover such alternatives.

[0009] In another embodiment, the present invention provides an exterior or interior flooring system which is easy to install, and which possesses numerous advantages over prior floor technologies. The use of modular prefabricated building panels according to the present invention facilitates time and structural efficiency over the known floor systems.

[0010] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:

[0012] FIGURE 1 illustrates is a perspective view of a deck structure in accordance to the present invention.

[0013] FIGURE 2 is a top plan view of a portion of the deck structure of FIGURE 1 depicted during construction.

[0014] FIGURE 3 is an enlarged portion of FIGURE 2.

[0015] FIGURE 4 is a cross sectional view of a building panel.

[0016] FIGURE 5 is a top plan view of building panels, joists and connectors defining integrated spline and support portions.

[0017] FIGURE 6 is a side elevational view of a connector and building panels. [0018] FIGURE 7 is a detailed side elevational view of a portion of FIGURE 6 showing the spline portion and spacer element of a connector engaging adjacent building panels.

[0019] FIGURE 8 is a top plan view of a connector.

[0020] FIGURE 9 is a cross-sectional view of a connector taken along a centerline as indicated by section lines 9-9 in FIGURE 8.

[0021] FIGURE 10 is a cross-sectional view of a connector taken along a line between the centerline and the connector edge as indicated by section lines 10 — 10 in FIGURE 8.

[0022] FIGURE 11 is a detailed view of a connector and fastener of FIGURE 10.

[0023] FIGURE 12 is a side elevational view of a connector of FIGURE 8.

[0024] FIGURE 13 is another side elevational view of a connector of FIGURE 8.

[0025] FIGURE 14 is a detailed side elevational view of a portion of the connector of FIGURE 13.

[0026] FIGURE 15 is a bottom plan view of the connector of FIGURE 12.

DETAILED DESCRIPTION OF THE INVENTION

[0027] Deck structures typically include a support structure and a deck surface. One method of deck construction includes a number of vertical post anchored to the ground; horizontal beams supported above the ground by the vertical posts; a number of horizontal joints, parallel to and uniformly spaced apart from one another and anchored to the beams; and a floor surface of decking planks arranged horizontally and above and perpendicular to the joists. Deck construction typically utilizes common dimensional lumber and entails site construction of the deck of a size and configuration which is unique to a particular site. Limitations of the common lumber-based deck structures are well known. During construction, warped or misshapen lumber impedes quick application of the decking lumber to the support structure. Additionally, wood deck structures require periodic attention to maintain appearance and delay structural deterioration. For a variety of reasons, the availability of natural weather-resistant woods (redwood, cedar, teak, etc.) has become both limited and expensive. Chemically treated wood product may be utilized to delay natural fungal deterioration. Chemicals such as chromated copper arsenic (CCA) are used in the treatment process. Once incorporated into the deck structure, such chemically treated lumber may leach CCA or its derivatives into the surrounding environment. Maintenance of wood deck structures often includes periodic application of wood preservatives, stains, etc. In sum, known wood-based deck structures have substantial limitations.

[0028] Water entrapment between the deck surface and the support structure is often exacerbated by preventing or impeding the efficient run off of water, such as rain water. Deterioration of the wood deck structure often results from moisture trapped between the deck surface and the underlying support structure.

[0029] Also known are synthetic or synthetic/wood product combination lumber, such as TREX® brand polymer wood lumber manufactured by the TREX Corporation. Limitations of such lumber include the requisite slat-like aesthetic of the installed decking surface and the limited availability of color and texture combinations.

[0030] FIGURE 1 illustrates a house utilizing preferred embodiment of the present invention, including an interior floor structure 2, a wall structure 4, and an on- grade patio structure 6, and a deck structure 8. Each of these structures utilizes a modular building panel 10 as further described herein. In one preferred embodiment, the modular building panels 10 may be utilized within a deck structure 8. Referring to FIGURE 2, a deck structure 8 includes a plurality of modular building panels 10 disposed upon a deck substructure 12, including a plurality of joists 14 and associated framing elements 15. The deck substructure 12 can be a new or existing structure. Additional uses for the modular panels 10 include application in a substantially vertical orientation as a wall component, placement in an interior of a house or other structure to form an interior floor structure, and placement on-grade, for instance as a patio structure.

[0031] Referring to FIGURE 2, one application of the present invention is in an elevated deck structure 8. One embodiment of a deck structure 8 is illustrated wherein the deck panels 10 are connected to a plurality of joists 14 through a plurality of connectors 70. Each connector 70 defines panel support elements 74 and splines 72 adapted to cooperate to secure modular building panels 10 to deck structure 8, e.g., the joists 14. The panel support elements 74 and splines 72 are provided in substantially orthogonal relationship. In alternative embodiments, support elements 74 and splines 74 may be generally parallel.

[0032] FIGURE 2 illustrates a partially complete deck 8 wherein a portion of the deck surface has yet to be provided upon the joists 14. The deck panels 10 are preferably sized for placement on new or existing deck joist structure featuring regularly spaced joists 14. For common 16 inch-on-center deck joisting, a deck panel 10 according to the present invention is approximately 16 inches square. It is appreciated that alternative sized deck panels 10 may also be practicable. It should also be appreciated that alternative configurations (other than square or rectangular) may be also be practicable. For instance, diamond-shaped deck panels 10, etc., may be practicable. Additionally, while the panels 10 of FIGURE 2 are preferably 16 inch square products, other sizes or group of sizes are envisioned. For instance, the modular building panels 10 may have different sizes and shapes, including but not limited to square or rectangular elements. In this regard, an ashlar pattern of panels 10 may be formed using differently sized square and rectangular shaped modular panels 10. Additionally, alternative module 10 support approaches may also be practicable, such as discussed hereinafter. The deck 8 may further include one or more transparent panels, such as LEXAN panels, which are sized to cooperate with the support structure 18, 20, and which permit light to penetrate into the underside of the deck structure 8. Additionally or alternatively, the clear transparent panels may provide for light transmission of a light source beneath the deck structure 8 so as to provide lighting of the deck 8. [0033] FIGURE 3 is a detailed view of a portion of the deck structure of FIGURE 2 illustrating connectors 79 disposed between deck panels 10 and joists 14. The deck panels 10 are secured to the joists 14 by connectors 70, which in this embodiment to include panel support elements 74 and splines 72.

[0034] FIGURE 4 is a cross sectional view of deck panels 10. Deck panels 10 may be manufactured from a variety of known materials and processing techniques. For instance, deck panel 10 may be a unitary cast concrete-based module having an internal reinforcement, such as metal webbing or possibly polymer strips. In one preferred embodiment, panel 10 includes a veneer 30 secured to a support structure 32. Support structure is preferably a pultruded fiberglass reinforced structure. In other embodiments, support structure 32 may be a high strength composite structure including a high-strength tensile strength element such as fiberglass, KEVLAR®, graphite, or carbon fibers. Support structure 32 may alternatively include a high-strength composite element, a plywood-based material, a concrete-based reinforced product, a metal alloy, or a polymer, fiberglass, or other composite material product providing suitable structural characteristics. Veneer element 30 is secured to the support structure 32, such as via an adhesive or other known securement approaches. Together, veneer 30 and support structure 32 provide a high strength, low weight stone or other natural or concrete-based modular deck panel 10.

[0035] In other embodiments, veneer 30 of module panel 10 may be concrete product and decorated with known concrete finishing techniques to imitate a variety of natural stone products (for instance, BOMANITE® or other imprinted finishes, etc.). Alternatively, veneer 30 may be decorated with brick patterns (random, interlocking, ashlar, etc.). In yet another embodiment, veneer 30 may be decorated with indoor/outdoor carpet.

[0036] Deck panel 10 includes a natural stone facing or veneer element 30 secured to an underlying support structure 32. Stone veneer 30 may be selected from among a group of architectural stone materials such as granite, sandstone, etc. Stone veneer 30 includes beveled edges 54 to aid in visual alignment of the panels and reduce the tendency for chipping proximate the edges during handling and installation. Beveled edges 54 also improve the visual and structural aspects of panels 10 having veneer elements of different thickness, e.g., the veneer elements are aggressively textured material, such as some slates, etc. Stone veneer 30 may be secured to underlying support structure 32 with an adhesive, such as a two-part epoxy. Other adhesives or material joining techniques would also be appreciated by those skilled in the relevant arts. For example, mechanical fasteners may be used to couple veneer element 30 to the support structure 32.

[0037] Referring particularly to FIGURE 4, support structure 32 may be a pultruded fiberglass reinforced product having a substantially uniform cross section. The pultruded structure may include a plurality of ribs 34 for efficiently maintaining the structural strength of support structure 32 while allowing material reduction as compared to a panel structure having a uniform cross sectional area. Ribs 34 provide an additional benefit by defining a plurality of channels for water run-off from the top surface. Water, such as rain water, may pass between the joint areas of deck panels 10 and exit through the channels defined by ribs 34. A sealant, such as silicone, may be used in conjunction with elements of the deck structure to provide a relatively water-tight structure, an hence a relatively dry area beneath deck structure 8. For example, a silicon sealant may be applied between panels 10, deck structure 8 and connectors 70 to further direct water away from the deck underside. In use, ribs 34 of support structure 32 are placed perpendicular to joists 14 of deck 8. Each panel 10 defines channels 36 on opposite ends thereof, wherein each of the channels 36 are sized to receive a portion of a spline element 74 during deck assembly as described herein.

[0038] As shown in FIGURES 6 - 12, connectors 70 define a plurality of splines 72 and a plurality of panel support elements 74. Together panel support elements 74 and splines 72 cooperate to secure panels 10 to deck structure 8. As shown in FIGURE 5, splines 72 extend generally perpendicular to a joist 14 direction. Splines 72 are supported away from an upper surface of support element 74 by support 75. Laterally disposed portions of support element 74 may be considered flanges. [0039] As shown in FIGS. 6 - 12, connectors 70 include a plurality of apertures 76 for receiving fasteners 78 utilized to attached the connector to underlying joist 14. Apertures 76 include countersink features which permits the head of fasteners 78 to be at least partially received into connector 70. As illustrated in FIGS. 6-7, spline portions 72 engage channels 36 such as defined between elements 30 and 32 of building panels 10.

[0040] Connectors 70 include a plurality of spacer elements 80 which extend upwardly from surfaces of connector 70. Some spacer elements 80 extend from an upper surface of panel support element 74, while other space elements 80 extend upwardly from an upper surface of splines 72. During deck construction, spacer elements 80 maintain a minimum distance between adjacent pairs of building panels 10 as illustrated in FIGURES 5-7.

[0041] FIGURE 14 is a detailed partial view of connector 70 of FIGURE 13 showing a profile of groove 82 which extends generally along the length of connector 70, as further shown in FIGURE 15. Groove 82 functions as a drip edge or drip-forming structure to redirect water away from the interface between connector 70 and the top surface of underlying joist 14.

[0042] An application of the deck system will be described. Once a joist substructure has been provided, either as a new or existing construction, connectors 70 are secured to upper joist surfaces with fasteners, such as threaded fasteners 78. A row of starter connectors 70 may be secured adjacent the house structure to engage a first row of modular panels 10. Alternatively, the starter row can be secured along a deck edge away from the house structure. Connectors 70 may need to be shimmed and/or blocked to accommodate variations of the joist top surfaces. Connectors 70 may be cut or altered to provide an improved aesthetic, e.g., to prevent free edges of connectors 70 from extending past a joist 14 edge. A variety of threaded fasteners 78 may be utilized to secure the panel support elements 18 to the joists 14. For example, the threaded fasteners may include stainless steel flat head screws which are countersunk into the panel support elements 18. [0043] As a next step, the deck modules 10 are installed in a row, perpendicular to the joists 14. Deck panels 10 are placed upon panel support structures 72. Ribbing 34 on the back side of module 10 is aligned perpendicularly to joists 14, and as a result the front edges of deck modules 10 will reveal the spline receiving channels 36. Once the row of modules 10 has been placed, a second row of connectors is secured onto joists 14 with spline elements 74 engaging channels 36 of the first row of modules 10. The next row of deck modules 10 is then placed against the previous row of deck modules 10. The channels 36 of adjacent deck modules 10 are aligned to receive the secured spline 74 of the previously installed row of connectors 70. The process continues row-by-row until completion. Spacers 80 provide for uniform spacing between adjacent panels 10. As a result, each deck module 10 is supported by 4 connectors 70. Edge securement of the outer deck panels 10 may include threaded fasteners, or other known securement approaches. Additional edge treatment concepts may also be utilized to improve the overall deck aesthetic.

[0044] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

CLAIMSWhat is claimed is:

1. A deck structure comprising: an underlying deck structure including a plurality of joists; a plurality of modular building panels, each building panel including perimeter channels; and a plurality of connectors, each connector including spline portions engaging a pair of channels of an adjacent pair of building panels, and each connector including portions supporting corner regions of the adjacent pair of building panels away from the top face of said joist, together said spline portions and said support portion being secured to the joist by a plurality of threaded fasteners.

2. The deck structure of claim 1 wherein each of said plurality of building panels includes a first element being relatively inflexible and of a material selected from among the group consisting of: stone, mineral, tile, and concrete product, and further includes a second element of a fiber-reinforced composite material, said second element being disposed beneath the first element and coupled thereto, said second element supporting the building panel upon two of the plurality of joists.

3. The deck structure of claim 2 wherein the fiber-reinforced composite material includes a material selected from the group consisting of: KEVLAR fiber, carbon fiber, and fiber glass.

4. The deck structure of claim 3 wherein the composite material further includes a material selected from the group consisting of: epoxies, resins, and adhesives.

5. The deck structure of claim 2 wherein the second element includes a rib structure.

6. The deck structure of claim 1 wherein a length of each connector is less than 50% of the side length of said panels.

7. The deck structure of claim 1 wherein the spline portions extend outwardly generally from the centerline of an associated joist.

8. The deck structure of claim 1 wherein the spline portions extend outwardly generally perpendicular from the centerline of an associated joist.

9. The deck structure of claim 1 wherein each connector includes a plurality of spacers for maintaining a minimum distance between adjacent pairs of building panels.

10. The deck structure of claim 9 wherein at least one of the plurality of spacer extends upwardly away from a top surface of the spline portion.

11. An assembly for providing a deck surface on a deck structure having a plurality of generally parallel joists, said deck surface including a plurality of modular building panels, each of said plurality of building panels including a first element being relatively inflexible and of a material selected from among the group consisting of: stone, mineral, tile, and concrete product, and further including a second element of a fiber- reinforced composite material, said second element being disposed beneath the first element and coupled thereto, said second element supporting the building panel upon two of the plurality of joists, each of said building panels further including at least one channel, said assembly comprising a plurality of connectors each defining a spline portion and a support portion, said spline portion engaging a pair of channels of an adjacent pair of building panels, and together said spline portions and support portions being secured to the plurality of joists by threaded fasteners.

12. The assembly of claim 11 wherein each of the plurality of connectors includes at least one spacer which maintains a minimum distance between adjacent pairs of panels.

13. The assembly of claim 12 wherein at least one spacer extends from a top surface of the spline portion.